Lower Intake Manifold: Removal

NOTE: During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces that enters the oil passages, coolant passages or the oil pan, can cause engine failure.

With the vehicle in NEUTRAL, position it on a hoist. REFER to JACKING AND LIFTING for lifting points.
Release the fuel system pressure. REFER to FUEL SYSTEM PRESSURE RELEASE .
Disconnect the battery ground cable. REFER to BATTERY DISCONNECT .
Drain the cooling system. REFER to COOLING SYSTEM DRAINING, FILLING AND BLEEDING - 3.5L TI-VCT .
Remove the upper intake manifold. REFER to Upper Intake Manifold .
Disconnect the 6 fuel injector electrical connectors.

Fig 1: Locating Fuel Injector Electrical Connectors
Courtesy of FORD MOTOR CO.
Disconnect the fuel supply tube-to-fuel rail quick connect coupling. REFER to QUICK CONNECT COUPLING . Position fuel supply tube aside.
- Remove the bolt from the fuel supply tube-to-rail bracket.
Fig 2: Locating Fuel Rail Quick Connect Coupling
Courtesy of FORD MOTOR CO.
Remove the 2 thermostat housing-to-lower intake manifold bolts.

Fig 3: Locating Thermostat Housing-To-Lower Intake Manifold Bolts
Courtesy of FORD MOTOR CO.
Remove the 10 bolts and the lower intake manifold.
- Remove and discard the intake manifold and thermostat housing gaskets.
- Clean and inspect all sealing surfaces.
Fig 4: Locating Lower Intake Manifold Bolts
Courtesy of FORD MOTOR CO.