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Intake Manifold: Removal

WARNING: This page is about a different car, the 2005 Lincoln Town Car. However, it is still accessible from the selected car via links, so may be relevant.
  1. Disconnect the fuel tube spring lock coupling. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION .
  2. Disconnect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  3. Drain the engine cooling system. For additional information, refer to ENGINE COOLING .
  4. Remove the air cleaner outlet pipe resonator assembly. For additional information, refer to INTAKE AIR DISTRIBUTION AND FILTERING .
  5. Remove the wiper mounting arm and pivot shaft. For additional information, refer to WIPERS AND WASHERS .
  6. Remove the RH cowl extension.
    1. Remove the pin-type retainers.
    2. Remove the nuts.
    3. Remove the bolts.
    4. Remove the extension.
    Fig 1: Removing RH Cowl Extension
    G04001832Courtesy of FORD MOTOR CO.
  7. Remove the LH cowl extension.
    1. Disconnect the electrical connector.
    2. Remove the bolts.
    3. Remove the extension.
    Fig 2: Removing LH Cowl Extension
    G04001833Courtesy of FORD MOTOR CO.
  8. Disconnect the fuel charging wiring electrical connectors from the eight ignition coils.
    Fig 3: Disconnecting Fuel Charging Wiring Electrical Connectors From Eight Ignition Coils
    G03881457Courtesy of FORD MOTOR CO.
  9. Disconnect the fuel charging wiring electrical connectors from the eight fuel injectors.
    Fig 4: Disconnecting Fuel Charging Wiring Electrical Connectors From Fuel Injectors
    G04001835Courtesy of FORD MOTOR CO.
  10. Remove the bolts and the exhaust gas recirculation (EGR) system module tube heat shield.
    Fig 5: Removing Exhaust Gas Recirculation System Module Tube Heat Shield
    G03881459Courtesy of FORD MOTOR CO.
  11. Disconnect the electrical connector and the vacuum hoses.
    Fig 6: Disconnecting Electrical Connector
    G04001837Courtesy of FORD MOTOR CO.
  12. Disconnect the evaporative emissions (EVAP) canister purge valve emissions tubes.
    Fig 7: Disconnecting Evaporative Emissions Canister Purge Valve Emissions Tubes
    G04001838Courtesy of FORD MOTOR CO.
  13. Disconnect the generator electrical connector.
    Fig 8: Disconnecting Generator Electrical Connector
    G04001875Courtesy of FORD MOTOR CO.
  14. Remove the bolts and the generator mounting bracket.
    Fig 9: Removing Generator Mounting Bracket Bolts
    G04002089Courtesy of FORD MOTOR CO.
  15. Disconnect the upper radiator hose.
    Fig 10: Disconnecting Upper Radiator Hose
    G04001841Courtesy of FORD MOTOR CO.
  16. Disconnect the throttle control and the throttle position (TP) sensor electrical connector.
    Fig 11: Locating Electrical Connectors
    G03881492Courtesy of FORD MOTOR CO.
  17. Disconnect the heater hose.
    Fig 12: Disconnecting Heater Hose
    G04001843Courtesy of FORD MOTOR CO.
  18. Disconnect the EGR system module tube nut from the EGR system module.
    Fig 13: Disconnecting EGR System Module Tube Nut From EGR System Module
    G04001844Courtesy of FORD MOTOR CO.
  19. Remove the nut at the exhaust manifold and remove the EGR tube.
    Fig 14: Removing EGR Tube
    G04001845Courtesy of FORD MOTOR CO.
  20. Separate the fuel charging wiring pin-type retainer from the crash bracket.
    Fig 15: Removing Fuel Charging Wiring Pin-Type Retainer From Crash Bracket
    G04001846Courtesy of FORD MOTOR CO.
  21. Remove the crash bracket bolt and prevent the bolt from contacting the cylinder head with a rubber band or tie strap.
    Fig 16: Preventing Bolt From Contacting Cylinder Head With Rubber Band Or Tie Strap
    G04001847Courtesy of FORD MOTOR CO.
  22. Remove the stud.
    Fig 17: Removing Stud
    G04001848Courtesy of FORD MOTOR CO.
  23. Disconnect the fuel pressure and temperature sensor electrical connector and the vacuum hose.
    Fig 18: Disconnecting Fuel Pressure And Temperature Sensor Electrical Connector And Vacuum Hose
    G04001849Courtesy of FORD MOTOR CO.
  24. Remove the generator harness position retainer from the LH front stud.
    Fig 19: Removing Generator Harness Position Retainer From LH Front Stud
    G04001850Courtesy of FORD MOTOR CO.
  25. Remove the fuel charging wiring pin-type retainer from the rear of the manifold.
    Fig 20: Removing Fuel Charging Wiring Pin-Type Retainer From Rear Of Manifold
    G04001851Courtesy of FORD MOTOR CO.
  26. Disconnect the ground wire connector from the RH rear stud.
    Fig 21: Disconnecting Ground Wire Connector From RH Rear Stud
    G04001852Courtesy of FORD MOTOR CO.
  27. Disconnect the coolant temperature sensor electrical connector.
    Fig 22: Disconnecting Coolant Temperature Sensor Electrical Connector
    G04001853Courtesy of FORD MOTOR CO.
  28. Remove the bolts and the eight ignition coils.
    Fig 23: Removing Ignition Coils
    G03881477Courtesy of FORD MOTOR CO.
  29. Remove the bolts and the coolant outlet adapter.
    Fig 24: Removing Coolant Outlet Adapter Bolts
    G04002104Courtesy of FORD MOTOR CO.
  30. Remove the thermostat and discard the O-ring.
    Fig 25: Removing Thermostat
    G04002392Courtesy of FORD MOTOR CO.
  31. Remove the bolts and the intake manifold.
    Fig 26: Removing Intake Manifold Bolts
    G04001857Courtesy of FORD MOTOR CO.
  32. Remove and discard the intake manifold gaskets.
    Fig 27: Removing Intake Manifold Gaskets
    G03881839Courtesy of FORD MOTOR CO.
  33. Clean the sealing surfaces.
Fig 28: Cleaning Sealing Surfaces
G04001859Courtesy of FORD MOTOR CO.
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