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Intake Manifold: Removal

WARNING: Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited, resulting in possible personal injury.
WARNING: Fuel in the fuel system remains under high pressure even when the engine is not running. Before repairing or disconnecting any of the fuel system components, the fuel system pressure must be relieved to prevent accidental spraying of fuel, causing personal injury or a fire hazard.
  1. Release the fuel system pressure. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION .
  2. Drain the cooling system. For additional information, refer to ENGINE COOLING .
  3. Disconnect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  4. Remove the air cleaner outlet pipe. For additional information, refer to INTAKE AIR DISTRIBUTION & FILTERING .
  5. Remove the cowl panel grille. For additional information, refer to FRONT END BODY PANELS .
  6. Disconnect the fuel supply tube spring lock coupling from the fuel rail. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION .
  7. Remove the 6 bolts and the cross-vehicle brace.
  8. Disconnect the throttle position (TP) sensor electrical connector.
  9. Disconnect the fuel pressure sensor electrical connector and vacuum hose.
  10. Disconnect the throttle body electrical connector.
  11. Disconnect the evaporative emissions (EVAP) hose from the intake manifold.
  12. Disconnect the fuel rail temperature sensor electrical connector.
  13. Disconnect the exhaust gas recirculation (EGR) system module electrical connector and the vacuum harness from the EGR system module.
  14. Disconnect the EGR system module-to-exhaust manifold tube from the EGR system module.
  15. Remove the crankcase ventilation tube.
  16. Disconnect the vacuum supply tube.
    Fig 1: Identifying Vacuum Supply Hose/Tube
    G03996268Courtesy of FORD MOTOR CO.
  17. Detach the vacuum harness retainers from the LH engine appearance cover bracket.
  18. Detach the engine wiring harness from the engine appearance cover brackets.
  19. Remove the 4 nuts and the 2 engine appearance cover brackets.
  20. Disconnect the 8 fuel injectors and the radio interference ignition capacitor electrical connectors.
    Fig 2: Locating Fuel Injector And Radio Interference Capacitor Electrical Connectors
    G03996269Courtesy of FORD MOTOR CO.
  21. Remove the 2 nuts and the engine wiring harness retainer.
    Fig 3: Identifying Engine Wiring Harness Retainer And Nuts
    G03996270Courtesy of FORD MOTOR CO.
  22. Remove the nut and the radio interference ignition capacitor.
  23. Disconnect the 2 throttle body coolant tubes.
    24. NOTE: The throttle body and adapter are shown removed for clarity. It is not necessary to remove the throttle body and adapter to remove the intake manifold.
    Fig 4: Identifying Bolts Loosening/Tightening Sequence
    G03996271Courtesy of FORD MOTOR CO.
  24. Remove the 7 bolts and 3 studs in the sequence shown.
  25. Remove the intake manifold and discard the gaskets.
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