LEMON Manuals: Even more car manuals for everyone
Home >> Ford >> 2009 >> Flex Limited, FWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 697 (Engine - 5.4L (3V) - F-150 & Mark LT) >> In-Vehicle Servicing >> Intake Manifold >> Removal

Intake Manifold: Removal

WARNING: This page is about a different car, the 2007 Lincoln Mark LT and 2007 Ford Pickup. However, it is still accessible from the selected car via links, so may be relevant.
WARNING: Do not smoke or carry lighted tobacco or 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 personal injury.
WARNING: Fuel in the fuel system remains under high pressure even when the engine is not running. Before servicing or disconnecting any of the fuel lines or fuel system components, the fuel system pressure must be relieved to prevent accidental spraying of fuel, causing personal injury or a fire hazard.
  1. Disconnect the fuel supply tube spring lock coupling. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION article.
  2. Drain the cooling system. For additional information, refer to ENGINE COOLING article.
  3. Remove the generator. For additional information, refer to GENERATOR AND REGULATOR article.
  4. Remove the air cleaner. For additional information, refer to INTAKE AIR DISTRIBUTION AND FILTERING article.
  5. Disconnect the upper radiator hose from the thermostat housing.
  6. Disconnect the heater coolant hose from the coolant bypass tube.
  7. Disconnect the quick connect coupling and remove the evaporative emissions (EVAP) tube from the intake manifold. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION article.
  8. Disconnect the fuel rail pressure and temperature sensor electrical connector and vacuum connector.
  9. Disconnect the 8 fuel injector electrical connectors.
  10. Disconnect the 4 LH ignition coil electrical connectors.
    Fig 1: Disconnecting LH Ignition Coil Electrical Connectors
    GF0002730Courtesy of FORD MOTOR CO.
  11. Disconnect the throttle position (TP) sensor and electronic throttle control electrical connectors.
  12. Disconnect the heated PCV element electrical connector.
    Fig 2: Disconnecting Heated PCV Element Electrical Connector
    GF0002731Courtesy of FORD MOTOR CO.
  13. Disconnect the engine oil pressure (EOP) sensor electrical connector.
    Fig 3: Identifying Engine Oil Pressure (EOP) Sensor Electrical Connector
    G03919846Courtesy of FORD MOTOR CO.
  14. Disconnect the LH camshaft position (CMP) sensor electrical connector.
    Fig 4: Identifying LH CMP Sensor Electrical Connector
    G03919847Courtesy of FORD MOTOR CO.
  15. Disconnect the LH variable camshaft timing (VCT) solenoid electrical connector.
  16. Disconnect the LH radio ignition interference capacitor electrical connector.
  17. Disconnect the wiring harness retainers from the LH valve cover studs and position the harness aside.
  18. Disconnect the brake booster vacuum hose from the intake manifold vacuum tube.
  19. Remove the 10 intake manifold bolts.
    20. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.
  20. Remove the 3 bolts, the coolant bypass tube and discard the gaskets.
    • Clean and inspect the sealing surfaces with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
  21. Disconnect the charge motion control valve (CMCV) electrical connector.
  22. Disconnect the intake manifold vacuum tube from the valve cover stud and the support bracket.
  23. Position the intake manifold assembly forward and disconnect the cylinder head temperature (CHT) sensor jumper harness electrical connector.
    Fig 5: Disconnecting Cylinder Head Temperature (CHT) Sensor Jumper Harness Electrical Connector
    GF0002732Courtesy of FORD MOTOR CO.
  24. Disconnect the LH and RH knock sensor (KS) electrical connectors.
    Fig 6: Disconnecting LH And RH Knock Sensor Electrical Connectors
    GF0002733Courtesy of FORD MOTOR CO.
  25. Remove the nut and disconnect the engine wiring harness retainer from the CMCV stud.
  26. Disconnect the RH heated exhaust gas oxygen sensor (HO2S) electrical connector and detach the electrical connector retainer.
    Fig 7: Locating Electrical Connector Retainer At Coolant Tube Support Bracket
    G03919850Courtesy of FORD MOTOR CO.
    27. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.
  27. Remove the intake manifold and discard the gaskets.
    • Clean and inspect the sealing surfaces with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
scientia non olet · About LEMON Manuals