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Intake Manifold: Removal

WARNING: This page is about a different variant/trim than selected.

WARNING: Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related components. Highly flammable mixtures are always present and can be ignited, resulting in possible personal injury.

WARNING: Fuel in the fuel system remains under high pressure even when the engine is not running.

Disconnect the battery ground cable (14301). Refer to BATTERY, MOUNTING AND CABLES .
Drain the coolant system. Refer to ENGINE COOLING .
Remove the air cleaner outlet tube.
Compress and slide the hose clamp and disconnect the water outlet hose.

Fig 1: Compressing And Sliding Hose Clamp And Disconnecting Water Outlet Hose
Courtesy of FORD MOTOR CO.
Remove the accelerator cable splash shield.

Fig 2: Removing Accelerator Cable Splash Shield
Courtesy of FORD MOTOR CO.
Relieve the fuel system pressure. Refer to REMOVAL & INSTALLATION .
Disconnect the accelerator and speed control cables and remove the return spring.

Fig 3: Disconnecting Accelerator And Speed Control Cables And Removing Return Spring
Courtesy of FORD MOTOR CO.
Position the accelerator cable bracket aside.
- Remove the bolts.
- Position the bracket and cables aside.
Fig 4: Positioning Accelerator Cable Bracket Aside
Courtesy of FORD MOTOR CO.
Disconnect the PCV vacuum and coolant hoses.

Fig 5: Disconnecting PCV Vacuum And Coolant Hoses
Courtesy of FORD MOTOR CO.
Disconnect the vacuum lines:
- brake booster
- engine sensor control wiring harness
Fig 6: Disconnecting Vacuum Lines
Courtesy of FORD MOTOR CO.
Remove the bolt (RH) and position the radio interference capacitor aside.

Fig 7: Removing Bolt (RH) And Positioning Radio Interference Capacitor Aside
Courtesy of FORD MOTOR CO.
Disconnect the vacuum line.

Fig 8: Disconnecting Vacuum Line
Courtesy of FORD MOTOR CO.
Disconnect the five RH fuel injector electrical connectors and five ignition coil electrical connectors.

Fig 9: Disconnecting Five RH Fuel Injector Electrical Connectors And Five Ignition Coil Electrical Connectors
Courtesy of FORD MOTOR CO.
Disconnect the idle air control motor electrical connector and the bypass hose.

Fig 10: Disconnecting Idle Air Control Motor Electrical Connector And Bypass Hose
Courtesy of FORD MOTOR CO.
Disconnect the heater hose.

Fig 11: Disconnecting Heater Hose
Courtesy of FORD MOTOR CO.
If equipped, disconnect the EGR transducer and disconnect the throttle position sensor connectors.

Fig 12: Disconnecting EGR Transducer And Disconnecting Throttle Position Sensor Connectors
Courtesy of FORD MOTOR CO.
If equipped, disconnect the EGR transducer vacuum lines.

Fig 13: Disconnecting EGR Transducer Vacuum Lines
Courtesy of FORD MOTOR CO.
If equipped, remove the EGR transducer bracket.

Fig 14: Removing EGR Transducer Bracket
Courtesy of FORD MOTOR CO.
If equipped, position the EGR valve to exhaust manifold tube aside.
- Disconnect the upper fitting.
- Loosen the lower fitting.
- Position the tube aside.
Fig 15: Positioning EGR Valve To Exhaust Manifold Tube Aside
Courtesy of FORD MOTOR CO.
If equipped, disconnect the EGR valve vacuum line.

Fig 16: Disconnecting EGR Valve Vacuum Line
Courtesy of FORD MOTOR CO.

NOTE: The EGR valve is shown removed for clarity.

Fig 17: Disconnecting EVR Solenoid Electrical And Vacuum Harness

G01544545

Courtesy of FORD MOTOR CO.

If equipped, disconnect the EVR solenoid electrical and vacuum harness.

NOTE: The idle air control valve is shown removed for clarity.

Fig 18: Removing Throttle Body Adapter

G01544546

Courtesy of FORD MOTOR CO.

Remove the throttle body adapter.
- Remove the four bolts.
- Remove the throttle body adapter.
- Remove the throttle body adapter gasket.
If equipped, remove the EVR bracket.
- Remove the bolts.
- Remove the bracket.
Fig 19: Removing EVR Bracket
Courtesy of FORD MOTOR CO.
Disconnect the five LH fuel injector electrical connectors and ignition coil connectors.

Fig 20: Disconnecting Five LH Fuel Injector Electrical Connectors And Ignition Coil Connectors
Courtesy of FORD MOTOR CO.
Disconnect the water temperature indicator sender unit electrical connectors.

Fig 21: Disconnecting Water Temperature Indicator Sender Unit Electrical Connectors
Courtesy of FORD MOTOR CO.
Remove the generator (GEN) (10300). Refer to GENERATORS & REGULATORS .
Remove the ignition coils.
- Remove the 10 bolts.
- Remove the 10 ignition coils.
Fig 22: Removing Ignition Coils
Courtesy of FORD MOTOR CO.
Disconnect the fuel injection supply manifold.
- Disconnect the fuel lines.
- Disconnect the vacuum connector from the fuel pressure regulator.
Remove the bolt and position the capacitor aside.

Fig 23: Removing Bolt And Positioning Capacitor Aside
Courtesy of FORD MOTOR CO.
Disconnect the cylinder head temperature sensor.

Fig 24: Disconnecting Cylinder Head Temperature Sensor
Courtesy of FORD MOTOR CO.
Remove the water thermostat and housing.
Remove the bolts, the upper intake manifold and the intake manifold gaskets (9439). Discard the intake manifold gaskets.

Fig 25: Removing Bolts, Upper Intake Manifold And Intake Manifold Gaskets
Courtesy of FORD MOTOR CO.
If necessary, remove the fuel injection supply manifold.
- Remove the four bolts.
- Remove the fuel injection supply manifold.
Fig 26: Removing Fuel Injection Supply Manifold
Courtesy of FORD MOTOR CO.
Separate the upper and lower intake manifolds (9424).
- Remove the 10 bolts.
Fig 27: Separating Upper And Lower Intake Manifolds
Courtesy of FORD MOTOR CO.

CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the aluminum retainer plate. These tools cause scratches and gouges, which make leak paths.

Clean all mating surfaces.