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Home >> Lincoln >> 2002 >> Navigator RWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 850 (Engine - 5.4L (3V) - F250-F550 Super Duty) >> In-Vehicle Repair >> Intake Manifold >> Removal

Intake Manifold: Removal

WARNING: This page is about a different car, the 2005 Ford Pickup and 2005 Ford Cab & Chassis. 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 spring lock coupling from the fuel rail. For additional information, refer to SPRING LOCK COUPLINGS .
  2. Drain the cooling system. For additional information, refer to DRAINING .
  3. Remove the generator. For additional information, refer to GENERATOR -- GASOLINE ENGINES .
  4. Remove the air cleaner. For additional information, refer to AIR CLEANER ELEMENT -- 5.4L (3V) .
  5. Disconnect the upper radiator hose from the thermostat housing.
  6. Disconnect the heater coolant hose from the coolant bypass tube.
  7. Disconnect the evaporative emissions system (EVAP) tube from the intake manifold. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION - GASOLINE AND DIESEL .
  8. Disconnect the quick connect couplings and remove the positive crankcase ventilation (PCV) tube. For additional information, refer to QUICK CONNECT COUPLING .
  9. Disconnect the fuel rail pressure and temperature sensor electrical connector and vacuum connector.
  10. Disconnect the 8 fuel injector electrical connector
  11. Disconnect the 4 LH ignition coil electrical connectors.
    Fig 1: Identifying LH Ignition Coil Electrical Connectors
    G03919844Courtesy of FORD MOTOR CO.
  12. Disconnect the throttle position (TP) sensor and electronic acceleration control electrical connectors.
  13. Disconnect the heated PCV intake fitting electrical connector.
    Fig 2: Disconnecting Heated PCV Intake Fitting Electrical Connector
    G03919845Courtesy of FORD MOTOR CO.
  14. Disconnect the engine oil pressure (EOP) sensor electrical connector.
    Fig 3: Locating Engine Oil Pressure (EOP) Sensor Electrical Connector
    G03919846Courtesy of FORD MOTOR CO.
  15. Disconnect the LH camshaft position (CMP) sensor electrical connector.
    Fig 4: Identifying LH CMP Sensor Electrical Connector
    G03919847Courtesy of FORD MOTOR CO.
  16. Disconnect the LH variable camshaft timing (VCT) solenoid electrical connector.
  17. Disconnect the LH radio ignition interference capacitor electrical connector.
  18. Disconnect the wiring harness retainers from the LH valve cover studs and position the harness aside.
  19. Disconnect the brake booster vacuum hose from the intake manifold vacuum tube.
  20. Remove the 10 intake manifold bolts.
    21. 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.
  21. 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.
  22. Disconnect the charge motion control valve (CMCV) electrical connector.
  23. Disconnect the intake manifold vacuum tube from the valve cover stud and the support bracket.
  24. Position the intake manifold assembly forward and disconnect the cylinder head temperature (CHT) sensor jumper harness electrical connector.
    Fig 5: Disconnecting Cylinder Head Temperature Sensor Jumper Harness Electrical Connector
    G03919848Courtesy of FORD MOTOR CO.
  25. Disconnect the LH and RH knock sensor (KS) electrical connectors.
    Fig 6: Disconnecting LH And RH Knock Sensor (KS) Electrical Connectors
    G03919849Courtesy of FORD MOTOR CO.
  26. Remove the nut and disconnect the engine wiring harness retainer from the CMCV stud.
  27. Disconnect the RH heated exhaust gas oxygen sensor (H02S) electrical connector and detach the electrical connector retainer.
    Fig 7: Locating RH HO2S Electrical Connector Retainer At Coolant Tube Support Bracket
    G03919850Courtesy of FORD MOTOR CO.
    28. 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.
  28. Remove the intake manifold and discard the gaskets.
    • Clean and inspect the sealing surfaces with metal surface prep and silicone gasket remover. Follow the directions on the packaging.
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