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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 - 5.4L >> Removal

Intake Manifold - 5.4L: 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. Remove the throttle body (TB) spacer. For additional information, refer to FUEL CHARGING AND CONTROLS - 4.6L (2V) AND 5.4L (2V) article.
  6. Compress and slide the hose clamp and disconnect the upper radiator hose.
  7. Disconnect the coolant hose.
    8. Fig 1: Locating Heater Coolant Hose
    G03885093Courtesy of FORD MOTOR CO.
  8. Remove the 3 bolts and the generator upper support bracket.
  9. Remove the transmission fluid indicator and tube support bracket bolt.
    10. Fig 2: Identifying Tube Support Bracket Bolt
    G03887936Courtesy of FORD MOTOR CO.
  10. Remove the nut and position the transmission fluid indicator and tube aside.
    11. Fig 3: Identifying Transmission Fluid Indicator Tube Retaining Nut
    G03885597Courtesy of FORD MOTOR CO.
  11. Disconnect the evaporative emissions (EVAP) tube quick connect coupling from the LH valve cover. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION - GASOLINE AND DIESEL article.
  12. If equipped, disconnect the auxiliary heater hoses and position aside. For additional information, refer to CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS article.
    13. Fig 4: Identifying Auxiliary Heater Hoses
    G03885101Courtesy of FORD MOTOR CO.
  13. Disconnect the quick connect couplings and remove the PCV tube. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION - GASOLINE AND DIESEL article.
  14. Disconnect the fuel rail pressure and temperature sensor vacuum hose and the electrical connector.
    15. Fig 5: Fuel Rail Pressure & Temperature Sensor Vacuum Hose & Electrical Connector
    GF0011607Courtesy of FORD MOTOR CO.
    NOTE: LH shown, RH similar.
  15. Disconnect the 8 ignition coil electrical connectors.
    16. Fig 6: Identifying Ignition Coil Electrical Connectors
    G03885104Courtesy of FORD MOTOR CO.
    NOTE: LH shown, RH similar.
  16. Disconnect the 8 fuel injector electrical connectors.
    17. Fig 7: Fuel Injector Electrical Connectors
    G03885105Courtesy of FORD MOTOR CO.
  17. Remove the 8 bolts and the 8 ignition coils.
  18. Remove the 2 bolts, the thermostat housing and the thermostat.
    • Discard the O-ring seal.
  19. Remove the 9 bolts, the intake manifold assembly and discard the intake manifold gaskets.
    20. Fig 8: Intake Manifold Assembly & Gaskets
    GF0011608Courtesy of FORD MOTOR CO.
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