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Home >> Mercury >> 2009 >> Mariner Base, 2.5 7, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 79 (Engine Mechanical - 5.4L (4V)) >> In-Vehicle Servicing >> Intake Manifold >> Removal

Intake Manifold: Removal

WARNING: This page is about a different car, the 2009 Ford Mustang. 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.
NOTE: During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces that enters the oil passages, coolant passages or the oil pan, can cause engine failure.
  1. Release the fuel system pressure. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION .
  2. Drain the engine cooling system. For additional information, refer to ENGINE COOLING .
  3. Drain the Supercharger (SC) cooling system. For additional information, refer to SUPERCHARGER COOLING .
  4. Remove the 4 nuts and the strut tower cross brace.
    5. Fig 1: Locating Strut Tower Cross Brace & Nuts
    GF0000372Courtesy of FORD MOTOR CO.
  5. Remove the Air Cleaner (ACL) outlet pipe. For additional information, refer to INTAKE AIR DISTRIBUTION AND FILTERING .
  6. Disconnect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  7. Remove the EGR tube. For additional information, refer to ENGINE EMISSION CONTROL .
  8. Disconnect the Throttle Position (TP) sensor electrical connector.
  9. Remove the 4 bolts and position the Throttle Body (TB) and spacer assembly aside.
  10. Disconnect the Intake Air Temperature 2 (IAT2) sensor electrical connector.
  11. Disconnect the fuel supply tube. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION .
  12. Disconnect the 4 LH fuel injector electrical connectors.
  13. Remove the 2 bolts and the wiring harness retainer from the rear of the intake manifold.
  14. Detach the 2 wiring harness pin-type retainers from the rear of the intake manifold.
  15. Disconnect the fuel rail pressure and temperature sensor electrical connector.
  16. Disconnect the 4 RH fuel injector electrical connectors.
  17. Disconnect the EGR system module electrical connector.
  18. Disconnect the crankcase ventilation tube from the RH side of the SC.
  19. Disconnect the SC bubbler hose from the rear of the SC.
  20. Rotate the SC drive belt tensioner clockwise and remove the drive belt from the SC drive pulley.
    21. Fig 2: Rotating SC Belt Tensioner Clockwise & Remove SC Belt Off SC
    GF0046329Courtesy of FORD MOTOR CO.
  21. Disconnect the 2 upper radiator hoses and the 2 coolant vent hoses from the intake manifold.
  22. Disconnect the 2 coolant hoses from the Charge Air Cooler (CAC).
  23. Disconnect the heater hose located below the rear of the intake manifold.
  24. Remove the 14 bolts and the intake manifold assembly.
    • Discard the gaskets.
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