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Home >> Ford >> 2009 >> Flex Limited, FWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 875 (Engine - 4.0L (SOHC)) >> In-Vehicle Servicing >> Intake Manifold >> Removal And Installation

Removal And Installation

WARNING: This page is about a different car, the 2007 Ford Ranger. However, it is still accessible from the selected car via links, so may be relevant.
  1. Remove the air cleaner outlet pipe. For additional information, refer to INTAKE AIR DISTRIBUTION AND FILTERING article.
  2. Disconnect the accelerator cable from the throttle body (TB).
  3. If equipped, disconnect the speed control actuator cable from the TB.
  4. Disconnect the throttle position (TP) sensor electrical connector.
  5. Detach the wiring harness retainer.
  6. Disconnect the idle air control motor electrical connector.
  7. Disconnect the EGR valve vacuum hose connector.
  8. Disconnect the exhaust manifold-to-EGR valve tube from the EGR valve.
    • To install, tighten to 34 Nm (25 lb-ft).
  9. Disconnect the evaporative emissions (EVAP) purge valve-to-intake manifold hose from the intake manifold.
  10. Disconnect the EGR vacuum regulator solenoid electrical connector.
  11. Disconnect the EGR vacuum regulator solenoid vacuum connector.
  12. Disconnect the brake booster vacuum hose from the intake manifold.
    13. CAUTION: It is important to twist the spark plug wire boots while pulling upward to avoid possible damage to the spark plug wire.
    NOTE: Spark plug wires must be connected to the correct ignition coil terminal. Mark the spark plug wire locations before removing them.
  13. Disconnect the RH spark plug wires from the ignition coil.
  14. Detach the RH spark plug wire retainer from the intake manifold and position the spark plug wires aside.
  15. Disconnect the ignition coil electrical connector.
  16. Detach the wiring harness retainer from the ignition coil bracket.
  17. Detach the accelerator cable retainer from the ignition coil bracket.
  18. Disconnect the radio interference capacitor electrical connector.
  19. Remove the 4 bolts and position the ignition coil and bracket aside.
    • To install, tighten the lower rear bolt to 28 Nm (21 lb-ft).
    • To install, tighten the lower front bolt to 23 Nm (17 lb-ft).
    • To install, tighten the 2 upper bolts to 8 Nm (71 lb-in).
  20. Disconnect the vacuum harness main vacuum connector from the intake manifold.
  21. Remove the wiring harness-to-cowl bracket nut.
  22. Disconnect the 3 PCM electrical connectors.
  23. Remove the wiring harness ground wire stud bolt and position the wiring harness aside.
    • To install, tighten to 10 Nm (89 lb-in).
  24. Detach the knock sensor electrical connector from the intake manifold.
  25. Loosen the bolts and lift up the intake manifold.
    • To install, tighten to 10 Nm (89 lb-in).
  26. Remove the heated PCV fitting bolts and detach the heated PCV fitting from the intake manifold.
    • To install, tighten to 8 Nm (71 lb-in).
  27. Remove the intake manifold.
  28. Inspect the intake manifold gaskets. Install new gaskets if necessary.
  29. To install, reverse the removal procedure.
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