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Upper Intake Manifold: Removal

WARNING: This page is about a different car, the 2006 Mercury Montego, 2006 Ford Freestyle, and 2006 Ford Five Hundred. However, it is still accessible from the selected car via links, so may be relevant.

    All vehicles 

  1. Drain the cooling system. For additional information, refer to DRAINING .
  2. Disconnect the battery ground cable. For additional information, refer to REMOVAL AND INSTALLATION .
  3. Remove the air cleaner outlet pipe. For additional information, refer to REMOVAL AND INSTALLATION .
  4. Remove the 4 transaxle roll restrictor cross brace bolts.
  5. Remove the bolt and the transaxle roll restrictor cross brace.
  6. Disconnect the evaporative emissions (EVAP) canister purge valve tube from the upper intake manifold and detach the retainer.
  7. Disconnect the positive crankcase ventilation (PCV), brake booster and vacuum harness tubes from the upper intake manifold.
  8. Detach the fuel tube retainer from the upper intake manifold.
  9. Disconnect the exhaust gas recirculation (EGR) system module electrical connector and vacuum tube.
  10. Detach the vacuum tube from the upper intake manifold vacuum tube retainer.
  11. Disconnect the EGR system module tube from the EGR system module.

    12. Early build 

  12. Disconnect and plug the throttle body and PCV coolant hoses.

    13. Late build 

  13. Disconnect and plug the 2 PCV coolant hoses.

    14. All vehicles 

  14. Disconnect the throttle body electrical connector.
  15. If equipped, remove and discard the 4 upper-to-lower intake manifold screws.
  16. Remove the 8 bolts and the upper intake manifold.
    • Remove and discard the gaskets.
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