Removal And Installation

All vehicles 

1. With vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING AND LIFTING article.
2. Disconnect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES article.
3. Remove the air cleaner outlet pipe. For additional information, refer to INTAKE AIR DISTRIBUTION AND FILTERING - 2.3L article.
4. Remove the bolt, 2 nuts and the generator air inlet duct.
   • To install, tighten to 6 Nm (53 lb-in).
Fig 1: Locating Generator Air Inlet Duct, Bolt And Nuts
Courtesy of FORD MOTOR CO.
5. Depress the locking ring and disconnect the brake booster vacuum supply tube from the intake manifold.
Fig 2: Locating Locking Ring And Brake Booster Vacuum Supply Tube
Courtesy of FORD MOTOR CO.
6. Disconnect the Evaporative Emission (EVAP) tube from the intake manifold.
7. Disconnect the 2 swirl control valve electrical connectors.
8. Detach the 2 wiring harness pin-type retainers and remove the fuel rail insulator.
Fig 3: Locating Fuel Rail Insulator Retainers
Courtesy of FORD MOTOR CO.
9. Detach the electrical connector pin-type retainer.
Fig 4: Locating Electrical Connector Pin-Type Retainer
Courtesy of FORD MOTOR CO.
10. If equipped, remove the 7 screws and the underbody cover.
Fig 5: Locating Splash Shield Bolts
Courtesy of FORD MOTOR CO.

Vehicles equipped with manual transaxle 

11. Remove the 2 bolts and position the clutch slave cylinder aside.
    • To install, tighten to 22 Nm (16 lb-ft).

Vehicles with Secondary Air Injection (AIR) 

12. Disconnect the Secondary Air Injection (AIR) pump electrical connector.
13. Remove the 3 bolts and position the AIR pump aside.
    • To install, tighten to 30 Nm (22 lb-ft).
14. Disconnect the vacuum hose from the intake manifold.

All vehicles 

15. Detach the radiator hose retaining clip from the intake manifold.
16. Remove the intake manifold lower bolt.
    • To install, tighten to 18 Nm (159 lb-in).
Fig 6: Locating Intake Manifold Lower Bolt
Courtesy of FORD MOTOR CO.
17. Disconnect the Manifold Absolute Pressure (MAP) sensor electrical connector.
18. Disconnect the Intake Manifold Runner Control (IMRC) actuator electrical connector.
19. Disconnect the Engine Oil Pressure (EOP) switch electrical connector.
    • Detach the wiring harness pin-type retainer and position the wiring harness aside.
20. Remove the nut and the S-terminal wire from the starter.
    • To install, tighten to 12 Nm (106 lb-in).
21. Disconnect the Throttle Body (TB) electrical connector.
NOTE: Discard the TB gasket.
22. Remove the 4 bolts and position the TB aside.
    • To install, tighten to 10 Nm (89 lb-in).
23. Detach the 2 pin-type retainers from the intake manifold.
Fig 7: Locating Pin-Type Retainers
Courtesy of FORD MOTOR CO.
NOTE: There are 2 different size bolts used. Mark the location of the bolts to make sure they are installed in their original locations.
24. Remove the 7 bolts and position the intake manifold aside to access the crankcase vent hose clamp and the EGR tube.
    • To install, tighten to 18 Nm (159 lb-in).
25. Release the clamp and disconnect the crankcase vent hose.
26. Detach the Knock Sensor (KS) electrical connector pin-type retainer.
27. Remove the EGR tube.
    • To install, tighten to 55 Nm (41 lb-ft).
28. Remove the intake manifold and discard the gaskets.
    • To install, tighten to 18 Nm (159 lb-in).
29. To install, reverse the removal procedure.
    • Install new TB and intake manifold gaskets.