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Upper Intake Manifold: Removal

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 AND LIFTING .
  2. Disconnect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  3. Drain the cooling system. For additional information, refer to ENGINE COOLING .
  4. Remove the cowl panel grille. For additional information, refer to FRONT END BODY PANELS .
  5. Disconnect the windshield wiper motor electrical connector.
    Fig 1: Locating Windshield Wiper Motor Electrical Connector
    G04004018Courtesy of FORD MOTOR CO.
  6. Remove the bolts and the cowl top panel.
    Fig 2: Locating Cowl Top Panel Bolts
    G04004019Courtesy of FORD MOTOR CO.
  7. Remove the engine air cleaner outlet pipe. For additional information, refer to INTAKE AIR DISTRIBUTION AND FILTERING .
  8. Disconnect the accelerator cable from the throttle body.
  9. Disconnect the throttle return spring from the accelerator cable bracket.
  10. Disconnect the speed control cable from the throttle body.
  11. Detach the engine harness retainers from the accelerator cable bracket stud bolt and the throttle position (TP) sensor stud bolt.
  12. Remove the 2 cable bracket stud bolts and position aside the cable bracket.
  13. Disconnect the evaporative emission (EVAP) return tube from the intake manifold.
  14. Disconnect the brake booster vacuum hose from the intake manifold.
  15. Disconnect the upper and lower exhaust gas recirculation (EGR) system module tube fittings and remove the tube.
  16. Disconnect the EGR system module vacuum connector.
  17. Disconnect the EGR system module electrical connector.
  18. Disconnect the idle air control (IAC) valve electrical connector.
  19. Disconnect the TP sensor electrical connector.
  20. Disconnect the crankcase vent hose from the intake manifold.
    21. 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 Spark Plug Wire Off Spark Plug
    G03948432Courtesy of FORD MOTOR CO.
  21. With a twisting motion, use the special tool to pull the LH spark plug wires from the spark plugs and the ignition coil.
  22. Remove the LH pin-type retainers and the spark plug wires as an assembly.
  23. Disconnect the upper intake manifold vacuum tube connector.
  24. Disconnect the coolant inlet hose clamp and the coolant hose from the intake manifold.
  25. Disconnect the coolant outlet hose clamp and the coolant hose from the intake manifold.
  26. Remove the 8 upper intake manifold bolts.
  27. Disconnect the 4 engine harness pin-type retainers.
    Fig 4: Locating Engine Harness Pin-Type Retainers
    G04660270Courtesy of FORD MOTOR CO.
  28. Disconnect the 2 engine harness pin-type retainers.
    Fig 5: Locating Engine Harness Pin-Type Retainers
    G04660271Courtesy of FORD MOTOR CO.
  29. Remove the intake manifold and discard the intake manifold gaskets.
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