Upper Intake Manifold: Removal

WARNING: This page is about a different car, the 2024 Ford Transit-350 HD, 2024 Ford Transit-350, 2024 Ford Transit-250, and 2024 Ford Transit-150. However, it is still accessible from the selected car via links, so may be relevant.

NOTE: If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions can result in engine damage.

Remove the air cleaner outlet pipe. Refer to: Air Cleaner Outlet Pipe .
- Follow directions to release the quick release coupling type 5. Disconnect the brake vacuum hose from the upper intake manifold. Refer to: QUICK RELEASE COUPLING
- Remove the bolt and position the brake vacuum tubes aside.
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Position the crankcase vent tube away from the intake manifold.

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- Follow directions to release the quick release coupling type 17. Disconnect the EVAP canister purge valve tube quick connect coupling from the intake manifold. Refer to: QUICK RELEASE COUPLING
- Detach the EVAP canister purge valve tube retainers.
- Detach the EVAP canister purge valve and position aside.
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- NOTE: When disconnecting the throttle body electrical connector disengage the red locking tab on the throttle body electrical connector by sliding it to the rear of the throttle body electrical connector, away from the throttle body. Squeeze the throttle body electrical connector while removing.
  
  Disconnect the throttle body electrical connector and detach the wire harness retainer.
- Remove the upper intake manifold support bracket bolt.
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Follow directions to release the quick release coupling type 3. Disconnect the PCV tube quick connect coupling from the intake manifold and position aside. Refer to: QUICK RELEASE COUPLING

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Disconnect the MAPT sensor electrical connector and wiring harness retainers.

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Remove the following items:
1. Remove the differential pressure feedback EGR valve sensor. Refer to: Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Sensor .
2. Remove the EGR valve outlet tube. Refer to: Exhaust Gas Recirculation (EGR) Outlet Tube .
Remove the bolts and the upper intake manifold.

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- Visually inspect the upper intake manifold gaskets for nicks, cuts and abrasions. If these conditions are not present, the gaskets may be re-used.
- Clean and inspect all of the sealing surfaces of the upper and lower intake manifold.

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