Intake Manifold

Removal & Installation

CAUTION
Do not use solvent of any type when cleaning the gasket surfaces on the intake manifold and the throttle body assembly, as damage to the gasket surfaces and throttle body assembly may result. Use care in cleaning the gasket surfaces on the intake manifold and the throttle body assembly, as sharp tools may damage the gasket surfaces.

To Remove:

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
2. Disconnect the negative battery cable.
3. Remove the bolts and the shield.
4. Remove the air cleaner outlet pipe by disconnecting the tube, detaching the mass airflow (MAF) sensor wiring pin-type retainer, loosening the clamps, and removing the pipe.
5. Disconnect the idle air control (IAC) valve, throttle position (TP) sensor, and the TP sensor wiring pin-type retainer.
6. Disconnect the MAF sensor wiring pin-type retainer.
7. Disconnect the accelerator and speed control cables.
8. Disconnect the exhaust gas recirculation (EGR) valve vacuum hose and tube fitting.
9. Disconnect the EGR vacuum regulator solenoid valve electrical connector and vacuum hose.
10. Disconnect the hose.
11. Loosen the clamp and disconnect the brake booster vacuum hose.

    CAUTION
    It is important to twist the spark plug wire boots while pulling upward to avoid damaging the spark plug wire.

    NOTE: Spark plug wires must be connected to the correct ignition coil terminal. Mark the spark plug wire locations before removing them.

12. Disconnect the right-hand spark plug wires from the coil. Remove the spark plug wire routing clip pin-type retainer and position the wires aside.
13. Remove the wiring harness bracket retainer, then position the wiring harness aside.
14. Remove the accelerator cable routing clip pin-type retainer and the wiring harness pin-type retainer.
15. Remove the bolts and position the coil and bracket off to the side.
16. Disconnect the vacuum hoses.
17. Remove the nut.
18. Disconnect the powertrain control module (PCM).
19. Remove the retainer and position the ground wires off to the side.
20. Detach the electrical connector retainer.
21. Remove the intake manifold bolts and lift up the intake manifold.
22. Remove the heated positive crankcase ventilation (PCV) hose retainers and remove the heated PCV fitting.
23. Remove the intake manifold.

To Install:

NOTE: Ford does not specify a torque sequence for the intake manifold. It is recommended that you start tightening in the middle and work your way out to the ends. Tighten the bolts in increments up to the final torque specification. Ensure that the bolts will no longer turn at the specified torque.

1. Lower the intake manifold on the engine and connect the heated PCV hose and fittings.
2. Ensure that the intake manifold is properly aligned on the engine. Install the eight intake manifold bolts.  
   • Torque the bolts to 89 in-lb (10 Nm).
3. Connect the heated PCV hose retainers and the heated PCV fitting.
   • Torque to 71 in-lb (8 Nm).
4. Connect the electrical connector retainer.
5. Connect the PCM.
6. Connect the vacuum hoses.
7. Reattach the accelerator cable routing clip pin-type retainer and the wiring harness pin-type retainer.
8. Install the wiring harness bracket retainer.
9. Connect the right-hand spark plug wires to the coil. Connect the spark plug wire routing clip pin-type retainer.
10. Connect the brake booster vacuum hose.
11. Connect the EGR vacuum regulator solenoid valve electrical connector and vacuum hose.
12. Connect the exhaust gas recirculation (EGR) valve vacuum hose and tube fitting.
13. Connect the accelerator and speed control cables.
14. Connect the MAF sensor wiring pin-type retainer.
15. Connect the idle air control (IAC) valve, throttle position (TP) sensor, and the TP sensor wiring pin-type retainer.
16. Connect the air cleaner outlet pipe.
17. Install the shield and bolts.
18. Connect the negative battery cable.
19. Start the vehicle and check for leaks, repair if necessary.