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Intake Manifold: Removal

WARNING: This page is about a different car, the 2010 Ford Pickup, 2010 Ford F550 Super Duty, 2010 Ford F450 Super Duty, 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. Disconnect the fuel supply spring lock coupling from the fuel rail. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION - GASOLINE AND DIESEL .
  2. Drain the cooling system. For additional information, refer to ENGINE COOLING .
  3. Remove the generator. For additional information, refer to CHARGING SYSTEM .
  4. Remove the Air Cleaner (ACL) outlet pipe. For additional information, refer to INTAKE AIR DISTRIBUTION & FILTERING .
  5. Disconnect the upper radiator hose from the thermostat housing.
  6. Disconnect the heater coolant hose and PCV coolant hose from the engine coolant crossover assembly.
  7. Disconnect the Intake Manifold Runner Control (IMRC) actuator electrical connector.
  8. Disconnect the fuel rail pressure and temperature sensor electrical connector and vacuum connector.
  9. Disconnect the 10 fuel injector electrical connectors.
  10. Disconnect the PCV tube quick connect coupling from the intake manifold. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION - GASOLINE AND DIESEL .
  11. Disconnect the Evaporative Emission (EVAP) tube quick connect coupling from the intake manifold. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION - GASOLINE AND DIESEL .
  12. Disconnect the quick connect coupling and remove the crankcase ventilation tube. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION - GASOLINE AND DIESEL .
  13. Disconnect the wiring harness and vacuum harness retainers from the rear of the intake manifold.
  14. Disconnect the engine vacuum hose connections from the rear of the intake manifold and position aside.
  15. Disconnect the 2 heated PCV coolant hoses from the intake manifold.
  16. Disconnect the Throttle Position (TP) sensor and Electronic Throttle Control (ETC) electrical connectors.
  17. Disconnect the engine wiring harness position retainers from the intake manifold.
  18. Remove the 12 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 2 gaskets.
    • Clean and inspect the sealing surfaces with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
    20. 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.
  20. Remove the intake manifold and discard the 10 gaskets.
    • Clean and inspect the sealing surfaces with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
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