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Home >> Ford >> 2006 >> Focus ZX5 SE, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 1121 (Engine - 4.6L And 5.4L) >> In-Vehicle Servicing >> Intake Manifold - 4.6L >> Removal

Intake Manifold - 4.6L: Removal

WARNING: This page is about a different car, the 2008 Ford RV Cutaway, 2008 Ford Econoline, 2008 Ford E450 Super Duty, and 2008 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.
WARNING: Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.
WARNING: Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury.
  1. Remove the engine cover. For additional information, refer to INTERIOR TRIM AND ORNAMENTATION article.
  2. Disconnect the fuel supply tube spring lock coupling. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION - GASOLINE AND DIESEL article.
  3. Disconnect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES article.
  4. Drain the cooling system. For additional information, refer to ENGINE COOLING article.
  5. Disconnect the quick connect couplings and remove the PCV tube. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION - GASOLINE AND DIESEL article.
  6. Remove the throttle body (TB). For additional information, refer to FUEL CHARGING AND CONTROLS - 4.6L (2V) AND 5.4L (2V) article.
  7. Remove the 8 ignition coils. For additional information, refer to ENGINE IGNITION - 4.6L (2V) AND 5.4L (2V) article.
  8. Disconnect the upper radiator hose.
  9. If equipped, disconnect the auxiliary heater hoses and position them aside. For additional information, refer to CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS article.
    10. Fig 1: Identifying Auxiliary Heater Hoses
    G03885101Courtesy of FORD MOTOR CO.
  10. Disconnect the heater coolant hose.
    11. Fig 2: Heater Coolant Hose & Clamp
    GF0011595Courtesy of FORD MOTOR CO.
  11. Rotate the tensioner clockwise and remove the accessory drive belt from the generator pulley.
    12. Fig 3: Rotating Tensioner Clockwise
    GF0000336Courtesy of FORD MOTOR CO.
  12. Disconnect the generator wiring harness retainer.
    13. Fig 4: Generator Wiring Harness Retainer
    GF0011596Courtesy of FORD MOTOR CO.
  13. Remove the 3 bolts and the generator support bracket.
  14. Remove the transmission fluid level indicator and tube bolt.
    • To install, tighten to 28 Nm (21 lb-ft).
    15. Fig 5: Transmission Fluid Level Indicator Tube & Bolt
    GF0011597Courtesy of FORD MOTOR CO.
  15. Remove the nut and position the transmission fluid level indicator and tube aside.
    • To install, tighten to 10 Nm (89 lb-in).
    16. Fig 6: Transmission Fluid Level Indicator Tube & Bolt
    GF0011598Courtesy of FORD MOTOR CO.
  16. Disconnect the vacuum harness connector.
    17. Fig 7: Vacuum Harness Connector
    GF0011599Courtesy of FORD MOTOR CO.
  17. Disconnect the crankcase vent tube quick connect coupling from the LH valve cover. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION - GASOLINE AND DIESEL article.
  18. Disconnect the EGR system module electrical connector.
  19. Disconnect the EGR system module vacuum hose connector.
  20. Disconnect the upper and lower fittings and remove the exhaust manifold-to-EGR system module tube.
  21. Remove the 2 bolts and the EGR system module.
    • Discard the EGR system module gasket.
  22. Disconnect the fuel pressure and temperature sensor electrical connector.
  23. Disconnect the evaporative emissions (EVAP) system vapor tube quick connect coupling from the intake manifold. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION - GASOLINE AND DIESEL article.
  24. Disconnect the PCV coolant hose from the TB adapter.
  25. Disconnect the vacuum harness connector from the intake manifold.
  26. Disconnect the 8 fuel injector electrical connectors.
  27. Disconnect the wiring harness retainer from the rear of the RH cylinder head.
    28. Fig 8: Wiring Harness Retainer
    GF0011600Courtesy of FORD MOTOR CO.
  28. Disconnect the coolant hose from the heater outlet tube.
    29. Fig 9: Heater Outlet Tube Coolant Hose & Clamp
    GF0011601Courtesy of FORD MOTOR CO.
  29. Remove the stud bolt and position the heater outlet tube aside.
    30. Fig 10: Heater Outlet Tube & Stud Bolt
    GF0011602Courtesy of FORD MOTOR CO.
  30. Disconnect the 2 electrical connector position retainers from the support bracket and position the wiring harness onto the transmission.
    31. Fig 11: Electrical Connector Position Retainers
    GF0011603Courtesy of FORD MOTOR CO.
  31. Remove the 2 bolts, thermostat housing and thermostat.
    • Discard the O-ring seal.
  32. Remove the 9 intake manifold bolts.
  33. Remove the intake manifold and discard the intake manifold gaskets.
    • Inspect the intake manifold assembly for damage.
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