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Intake Manifold: Removal

WARNING: This page is about a different car, the 2010 Ford Pickup and 2010 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.
WARNING: Do not smoke, carry lighted tobacco or have an 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 serious personal injury.
WARNING: Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury.
  1. Drain the cooling system. For additional information, refer to ENGINE COOLING .
  2. Remove the generator. For additional information, refer to CHARGING SYSTEM .
  3. Disconnect the fuel supply spring lock coupling from the fuel rail. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION - GASOLINE AND DIESEL .
  4. Disconnect the upper radiator hose from the thermostat housing.
  5. Disconnect the heater coolant hose from the engine coolant crossover manifold assembly.
  6. Disconnect the quick connect coupling from the intake manifold and position aside the Evaporative Emission (EVAP) system tube. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION - GASOLINE AND DIESEL .
  7. Disconnect the quick connect couplings and remove the PCV tube. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION - GASOLINE AND DIESEL .
  8. Disconnect the quick connect coupling and position the crank case vent tube aside. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION - GASOLINE AND DIESEL .
  9. Remove the 4 bolts and the Air Cleaner (ACL) outlet pipe-to-Throttle Body (TB) adapter.
  10. Disconnect the fuel rail pressure and temperature sensor electrical connector and vacuum connector.
  11. Disconnect the 8 fuel injector electrical connectors.
    12. NOTE: RH shown in illustration, LH similar.
    Fig 1: Locating Ignition Coil Electrical Connectors
    G06772559Courtesy of FORD MOTOR CO.
  12. Disconnect the 8 ignition coil electrical connectors.
  13. Disconnect the Throttle Position (TP) sensor and Electronic Throttle Control (ETC) electrical connectors.
  14. Disconnect the LH Variable Camshaft Timing (VCT) solenoid electrical connector.
  15. Disconnect the LH radio ignition interference capacitor electrical connector.
  16. Disconnect the wiring harness retainers from the LH valve cover studs and position the harness aside.
  17. Disconnect the brake booster vacuum hose from the intake manifold vacuum tube.
  18. Remove the 10 intake manifold bolts.
    19. NOTE: 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.
  19. Remove the 3 bolts, the engine coolant crossover manifold assembly and discard the gaskets.
    • Clean and inspect the sealing surfaces with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
  20. Disconnect the intake manifold vacuum tube from the valve cover stud and the support bracket.
  21. Disconnect the engine wiring harness retainer from the rear of the intake manifold.
    22. NOTE: 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.
  22. Remove the intake manifold and intake manifold vacuum tube as an assembly. Discard the intake manifold 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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