How to replace Intake Manifold on 2005 Ford explorer?

Intake Manifold

Removal & Installation

4.0L Engine
VIN E Engine

1. Before servicing the vehicle, refer to the Precautions section.
2. Remove or disconnect the following:
   
   
   Negative battery cable

   Air cleaner-to-intake tube

   Accelerator splash shield

   Accelerator and, if equipped with cruise control, speed control cables from the throttle control cam

   Accelerator cable retaining bracket from the upper intake manifold

   Label and disengage all vacuum and electrical connections on the intake manifold.

   Upper intake manifold attaching bolts

   Lift up on the manifold and remove both fuel Vapor Management Valve (VMV) hoses

   Intake manifold and discard the gasket

To install:

NOTE

Ford does not specify a sequence for either upper or lower intake manifolds, but it is recommended that you start tightening in the middle and work your way out to the ends. Repeat the tightening sequence several times until the bolts will no longer turn at the specified torque.

1. Install the lower intake manifold. Torque the bolts to 10 ft. lbs. (13 Nm) for 2000, and 13 ft. lbs. (18 Nm) for 2001.
2. Position the upper manifold on the lower manifold.
3. Install or connect the following:
   
   
   Attach both VMV hoses to the manifold

   Upper manifold attaching bolts. Torque the bolts to 62 inch lbs. (7 Nm).

   Attach any vacuum and electrical connections that were removed

   Accelerator cable bracket to the intake and the cable (or cables if equipped with cruise control) to the throttle cam

   Accelerator splash shield

   Air cleaner-to-intake supply tube

   Negative battery cable
4. Start the vehicle and check for leaks, repair if necessary.

1. Before servicing the vehicle, please familiarize yourself with safety procedures.
2. Remove or disconnect the following:
   
   
   Negative battery cable

   Splash shield

   Air cleaner outlet pipe

   Accelerator and speed control cables from the throttle body

   Accelerator cable and the speed control cable from the bracket. Position the cables away from the intake manifold.

   All the vacuum hoses

   KS electrical connector

   IAC valve electrical connector

   TP sensor electrical connector

   EGR transducer electrical connector

   Wiring anchor

   EGR tube from the EGR valve

   Wiring harness pin-type retainer

   Spark plug wires

   Intake manifold retainers, then slightly reposition the manifold to access the EGR vacuum regulator (EVR) solenoid.

   EVR solenoid vacuum and electrical connections

   Intake manifold

   To install, reverse the removal procedure. Torque the bolts to 89 inch lbs. (10 Nm). There is no particular sequence.

Fig. Parts to be removed prior to intake manifold removal-2003-05 4.0L SOHC engine

Fig. Intake manifold removal-2003-05 4.0L SOHC engine

1. Before servicing the vehicle, please familiarize yourself with safety procedures.
2. Disconnect the battery ground cable.
3. Remove the air cleaner outlet pipe.
4. Remove the positive crankcase ventilation (PCV) tube
5. Remove the brake booster vacuum supply hose
6. Remove the engine main vacuum harness-to-intake manifold fitting
7. Remove the evaporative emissions (EVAP) return tube
8. Remove the EVAP tube pin-type retainer
9. Remove the exhaust gas recirculation (EGR) system module electrical connector
10. Remove the wiring harness pin-type retainer
11. Remove the engine main vacuum harness-to-EGR system module fitting
12. Remove the EGR tube fitting
13. Remove the throttle position (TP) sensor electrical connector
14. Remove the electronic throttle body electrical connector
15. Remove the electronic throttle body-to-intake manifold bolt
16. Remove the intake manifold mounting bolts
17. Remove the intake manifold
18. Remove the intake manifold gaskets

To install:

1. Installation is the reverse of the removal procedure.
   
   CAUTION

   Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools can cause scratches and gouges which can make leak paths.
2. Clean the sealing surfaces, inspect the gaskets and install new gaskets if necessary. There is no special torque sequence.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
2. Remove or disconnect the following:
   
   
   Negative battery cable

   Splash shield

   Air cleaner outlet pipe

   Accelerator and speed control cables from the throttle body

   Accelerator cable and the speed control cable from the bracket. Position the cables away from the intake manifold.

   All the vacuum hoses

   KS electrical connector

   IAC valve electrical connector

   TP sensor electrical connector

   EGR transducer electrical connector

   Wiring anchor

   EGR tube from the EGR valve

   Wiring harness pin-type retainer

   Spark plug wires

   Intake manifold retainers, then slightly reposition the manifold to access the EGR vacuum regulator (EVR) solenoid.

   EVR solenoid vacuum and electrical connections

   Intake manifold

   To install, reverse the removal procedure. Torque the bolts to 89 inch lbs. (10 Nm). There is no particular sequence.

1. Before servicing the vehicle, refer to the -Precautions- section.
2. Disconnect the battery ground cable.
3. Remove the air cleaner outlet pipe.
4. Remove the positive crankcase ventilation (PCV) tube
5. Remove the brake booster vacuum supply hose
6. Remove the engine main vacuum harness-to-intake manifold fitting
7. Remove the evaporative emissions (EVAP) return tube
8. Remove the EVAP tube pin-type retainer
9. Remove the exhaust gas recirculation (EGR) system module electrical connector
10. Remove the wiring harness pin-type retainer
11. Remove the engine main vacuum harness-to-EGR system module fitting
12. Remove the EGR tube fitting
13. Remove the throttle position (TP) sensor electrical connector
14. Remove the electronic throttle body electrical connector
15. Remove the electronic throttle body-to-intake manifold bolt
16. Remove the intake manifold mounting bolts
17. Remove the intake manifold
18. Remove the intake manifold gaskets
    
    
    

    

    Fig. Parts to be removed prior to intake manifold removal-2005 4.0L SOHC engine
    
    
    
    

    

    Fig. Intake manifold removal-2005 4.0L SOHC engine

To install:

1. Installation is the reverse of the removal procedure.
   
   CAUTION

   Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools can cause scratches and gouges which can make leak paths.
2. Clean the sealing surfaces, inspect the gaskets and install new gaskets if necessary. There is no special torque sequence.

1. Before servicing the vehicle, refer to the -Precautions- section.
2. Remove or disconnect the following:
   
   
   Battery ground cable

   Engine cover

   Air cleaner outlet pipe

   Accelerator and speed control cables

   Idle air control valve and TP sensor electrical connectors

   TP sensor wiring routing clip

   EGR vacuum hose and EGR tube from EGR valve

   EGR vacuum regulator solenoid connections

   Fuel vapor hose

   Brake booster vacuum hose

   Spark plug wires (mark locations prior to removal)

   Accelerator cable routing clip and wiring harness

   Ignition coil bracket lower, then upper, bolts; position coil aside

   Remaining vacuum hoses from intake manifold (mark for installation locations)

   Wiring harness retaining nut at bulkhead

   PCM connector

   Ground wires from body connections

   Knock sensor connector

   Intake manifold bolts, and lift up manifold

   Heated PCV hose retainers and PCV fitting
3. Remove intake manifold

To install:

1. Clean the mating surfaces.
2. Position the intake manifold, while installing the PCV fitting and hose retainers.
3. With intake manifold fully in place, tighten the bolts to 89 inch lbs. (10 Nm).
4. Install or connect the following:
   
   
   Knock sensor connector

   Ground wires to body connections

   PCM connector

   Wiring harness retaining nut at bulkhead

   Vacuum hoses to intake manifold

   Ignition coil bracket lower, then upper, bolts

   Accelerator cable routing clip and wiring harness

   Spark plug wires

   Brake booster vacuum hose

   Fuel vapor hose

   EGR vacuum regulator solenoid connections

   EGR vacuum hose and EGR tube to EGR valve

   TP sensor wiring routing clip

   Idle air control valve and TP sensor electrical connectors

   Accelerator and speed control cables

   Air cleaner outlet pipe

   Engine cover
5. Connect the battery ground cable.

-------