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Intake Manifold: Removal

WARNING: This page is about a different car, the 2008 Ford Pickup and 2008 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. Disconnect the fuel supply spring lock coupling from the fuel rail. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION - GASOLINE AND DIESEL article.
  2. Drain the cooling system. For additional information, refer to ENGINE COOLING article.
  3. Remove the generator. For additional information, refer to GENERATOR AND REGULATOR article.
  4. Remove the air cleaner outlet pipe. For additional information, refer to INTAKE AIR DISTRIBUTION AND FILTERING article.
  5. Disconnect the upper radiator hose from the thermostat housing.
  6. Disconnect the heater coolant hose from the engine coolant crossover manifold assembly.
  7. Disconnect the evaporative emissions (EVAP) system tube from the intake manifold and position aside. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION - GASOLINE AND DIESEL article.
  8. Disconnect the quick connect couplings and remove the PCV tube. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION - GASOLINE AND DIESEL article.
  9. Remove the 4 bolts and the air cleaner 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. Disconnect the throttle position (TP) sensor and electronic acceleration control electrical connectors.
  13. Disconnect the heated PCV intake fitting electrical connector.
  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. 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.
  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 Motorcraft Metal Surface Prep. Follow the directions on the packaging.
  20. Disconnect the charge motion control valve (CMCV) electrical connector.
  21. Disconnect the RH heated exhaust gas oxygen sensor (HO2S) electrical connector and detach the electrical connector retainers.
    22. Fig 1: Locating Electrical Connector Retainer At Coolant Tube Support Bracket
    G03919850Courtesy of FORD MOTOR CO.
  22. Disconnect the intake manifold vacuum tube from the valve cover stud and the support bracket.
  23. Position the intake manifold assembly forward and disconnect the cylinder head temperature (CHT) sensor jumper harness electrical connector.
  24. Disconnect the LH and RH knock sensor (KS) electrical connectors.
  25. Remove the nut and disconnect the engine wiring harness retainer from the CMCV stud.
    26. 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.
  26. Remove the intake manifold and discard the gaskets.
    • Clean and inspect the sealing surfaces with Motorcraft Metal Surface Prep and Silicone Gasket Remover. Follow the directions on the packaging.
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