Intake Manifold: Removal
WARNING: This page is about a different variant/trim than selected.
- With the vehicle in NEUTRAL, position it on a hoist. Refer to: Jacking and Lifting - Overview .
- Disconnect the battery ground cable. Refer to: Battery Disconnect and Connect - Vehicles With: Dual Batteries .
- Drain the engine cooling system. Refer to: Engine Cooling System Draining, Vacuum Filling and Bleeding .
- Remove the coolant hose from the engine appearance cover. Disconnect the heater hose and position aside. Use the General Equipment: Hose Clamp Remover/Installer
- Remove the oil filler cap and remove the engine appearance cover. Install the oil filler cap.
- Disconnect the fuel tubes and position aside. Refer to: Quick Release Coupling
.
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NOTE: Vehicle with rear climate control shown, others similar.
Disconnect the retainers and the coolant hose. Remove the bolt and position aside the coolant hose. Use the General Equipment: Hose Clamp Remover/Installer
- Disconnect the retainers and position aside the transmission vent tube.
- Disconnect the electrical connectors and the wire harness retainer. Disconnect the glow plug connector from the bracket.
- Remove the bolts for the fuel rail.
- Disconnect the fuel tubes at the fuel injection pump. Disconnect the retaining clip and position aside. Refer to: Quick Release Coupling
.
- Remove the bolt and position aside the brake booster tube bracket.
- Disconnect the electrical connectors and the wire retainer. Remove the 2 bolts.
- Disconnect the EGRT sensor electrical connector and the wire retainer.
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NOTE: During the removal of the EGRT sensor, the threaded bushing must be held with a wrench to prevent damage to the connecting EGR tube.NOTE: Lubricate the EGRT sensor threads with penetrating and lock lubricant to assist in removal of the EGRT sensor.
Remove the EGRT sensor.
Material: Motorcraft® Penetrating and Lock Lubricant / XL-1
- Remove the throttle body. Refer to: Throttle Body .
- Remove the EGR valve bolts. Discard the gasket.
- Remove the mixer tube nuts at the EGR valve.
- Remove the mixer tube bolts at the intake manifold.
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NOTE: During removal of the intake manifold, the mixer tube will have to be removed from the intake manifold before it can be removed from the vehicle.
Remove the bolts and the intake manifold. Remove the mixer tube from the vehicle.
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NOTE: The O-ring seal is to be reused unless damaged.
Remove and discard the gasket. Inspect the O-ring.
- Visually inspect the intake manifold gaskets for nicks, cuts and abrasions. If these conditions are not present, the gaskets may be reused.