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Home >> Ford >> 2005 >> Freestar Base >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> Engine >> In-Vehicle Repair >> Upper Intake Manifold >> Removal
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Upper Intake Manifold: Removal

Fig 1: Identifying Upper Intake Manifold Components (1 Of 2)
G04003887Courtesy of FORD MOTOR CO.
Fig 2: Identifying Upper Intake Manifold Components (2 Of 2)
G04003888Courtesy of FORD MOTOR CO.
CAUTION: 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. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING & LIFTING .
  2. Disconnect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  3. Partially drain the cooling system.
  4. Remove the wiper motor and pivot assembly. For additional information, refer to WIPERS AND WASHERS .
  5. Remove the engine air cleaner outlet tube. For additional information, refer to INTAKE AIR DISTRIBUTION & FILTERING .
  6. Disconnect the accelerator cable from the throttle body.
  7. Disconnect the throttle return spring from the accelerator cable bracket.
  8. Disconnect the speed control cable from the throttle body.
  9. Remove the engine harness retainer from the accelerator cable bracket stud bolt.
  10. Remove the 2 cable bracket stud bolts and position aside the cable bracket.
  11. Disconnect the EVAP emission return tube from the intake manifold.
  12. Disconnect the brake booster vacuum hose clamp and the brake booster vacuum hose from the intake manifold.
  13. Disconnect the upper and lower EGR system module tube fittings and remove the tube.
  14. Disconnect the EGR system module vacuum connector.
  15. Disconnect the EGR system module electrical connector.
  16. Disconnect the IAC electrical connector.
  17. Disconnect the TP sensor electrical connector.
  18. Disconnect the crankcase vent hose from the intake manifold.
    19. CAUTION: Spark plug wires must be connected correctly. Mark the spark plug wires before removing them.
    CAUTION: It is important to twist the spark plug wire boots while pulling upward to avoid possible damage to the spark plug wires.
    Fig 3: Pulling LH Spark Plug Wires From Spark Plugs
    G04003889Courtesy of FORD MOTOR CO.
  19. With a twisting motion, use the special tool to pull the LH spark plug wires from the spark plugs and the ignition coil.
  20. Remove the LH pin-type retainers and the spark plug wires as an assembly.
  21. Disconnect the upper intake manifold vacuum tube connector.
  22. Disconnect the coolant inlet hose clamp and the coolant hose from the intake manifold.
  23. Disconnect the coolant outlet hose clamp and the coolant hose from the intake manifold.
  24. Remove the 8 upper intake manifold bolts.
  25. Disconnect the 4 engine harness pin-type retainers.
    Fig 4: Disconnecting Engine Harness Pin-Type Retainers (1 Of 2)
    G04003890Courtesy of FORD MOTOR CO.
  26. Disconnect the 2 engine harness pin-type retainers.
    Fig 5: Disconnecting Engine Harness Pin-Type Retainers (2 Of 2)
    G04003891Courtesy of FORD MOTOR CO.
  27. Remove the intake manifold and discard the intake manifold gaskets)
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