Intake Manifold Removal on Ford 4.6 Engine?

Intake Manifold

REMOVAL & INSTALLATION

4.6L Engine
VIN H DOHC Engine
Lower

Fig. Lower intake manifold and related parts-4.6L DOHC engine

1. Before servicing the vehicle, please familiarize yourself with safety procedures.
2. Remove the upper intake manifold.
3. Disconnect the spring lock couplings.
4. Remove the cooling fan.
5. Remove the accessory drive belt tensioner.
6. Remove the accessory drive belt.
7. Remove the wire harness retainer.
8. Remove the alternator.
9. Remove the alternator bracket studs.
10. Remove the upper coolant hose.
11. Remove the coolant bypass hose.
12. Remove the thermostat housing coolant hose.
13. Remove the engine coolant temperature (ECT) sensor electrical connector.
14. Remove the coolant crossover tube.
15. Remove the vacuum hose.
16. Remove the engine harness retainers.
17. Remove the fuel rail pressure (FRP) sensor electrical connector.
18. Remove the intake manifold runner control (IMRC) motor electrical connector.
19. Remove the fuel injector connectors.
20. Remove the lower intake manifold bolts.
21. Remove the lower intake manifold assembly.
22. Remove the intake manifold gaskets.

To install:

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

   Hand-start all fasteners.
   
   
   
   
   

   

   Fig. Lower intake manifold torque sequence-4.6L DOHC engine
2. Tighten all fasteners in the sequence shown in the illustration to 89 inch lbs. (10 Nm).

1. Before servicing the vehicle, refer to the -Precautions- section.
2. Remove the upper intake manifold.
3. Disconnect the spring lock couplings.
4. Remove the cooling fan.
5. Remove the accessory drive belt tensioner.
6. Remove the accessory drive belt.
7. Remove the wire harness retainer.
8. Remove the alternator.
9. Remove the alternator bracket studs.
10. Remove the upper coolant hose.
11. Remove the coolant bypass hose.
12. Remove the thermostat housing coolant hose.
13. Remove the engine coolant temperature (ECT) sensor electrical connector.
14. Remove the coolant crossover tube.
15. Remove the vacuum hose.
16. Remove the engine harness retainers.
17. Remove the fuel rail pressure (FRP) sensor electrical connector.
18. Remove the intake manifold runner control (IMRC) motor electrical connector.
19. Remove the fuel injector connectors.
20. Remove the lower intake manifold bolts.
21. Remove the lower intake manifold assembly.
22. Remove the intake manifold gaskets.
    
    
    

    

    Fig. Lower intake manifold and related parts-4.6L DOHC engine
23. Installation is the reverse of the removal procedure, noting the following:
    
    NOTE

    Hand-start all fasteners.
    
    
    1. Tighten all fasteners in the sequence shown in the illustration to 89 inch lbs. (10 Nm).
       
       
       

       

       Fig. Lower intake manifold torque sequence-2005 4.6L (VIN H) DOHC engine

Upper

Fig. Upper intake manifold and related parts-4.6L DOHC engine

1. Before servicing the vehicle, please familiarize yourself with safety procedures.
2. Disconnect the battery ground cable.
3. Drain the cooling system.
4. Remove the air cleaner outlet pipe.
5. Remove the exhaust gas recirculation (EGR) system module.
6. Remove the positive crankcase ventilation (PCV) valve hose.
7. Remove the brake booster vacuum hose.
8. Remove the evaporative emissions (EVAP) hose.
9. Remove the coolant hose clamp.
10. Remove the PCV coolant hose.
11. Remove the coolant hose clamp.
12. Remove the PCV coolant hose.
13. Remove the accelerator cable.
14. Remove the speed control cable.
15. Remove the accelerator cable return spring.
16. Remove the accelerator cable pin-type retainer.
17. Remove the accelerator cable bracket.
18. Remove the idle air control (IAC) valve electrical connector.
19. Remove the throttle position (TP) sensor electrical connector.
20. Remove the fuel rail shield.
21. Remove the radio capacitor.
22. Remove the upper intake manifold bolts.
23. Remove the upper intake manifold studs.
    
    
    

    

    Fig. Upper intake manifold bolt torque sequence-4.6L DOHC engine
24. Remove the upper intake manifold.

To install:

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

   Locations 5 and 9 use studs.
2. Tighten the bolts and studs in the sequence shown to 89 inch lbs. (10 Nm).

1. Before servicing the vehicle, refer to the -Precautions- section.
2. Disconnect the battery ground cable.
3. Drain the cooling system.
4. Remove the air cleaner outlet pipe.
5. Remove the exhaust gas recirculation (EGR) system module.
6. Remove the positive crankcase ventilation (PCV) valve hose.
7. Remove the brake booster vacuum hose.
8. Remove the evaporative emissions (EVAP) hose.
9. Remove the coolant hose clamp.
10. Remove the PCV coolant hose.
11. Remove the coolant hose clamp.
12. Remove the PCV coolant hose.
13. Remove the accelerator cable.
14. Remove the speed control cable.
15. Remove the accelerator cable return spring.
16. Remove the accelerator cable pin-type retainer.
17. Remove the accelerator cable bracket.
18. Remove the idle air control (IAC) valve electrical connector.
19. Remove the throttle position (TP) sensor electrical connector.
20. Remove the fuel rail shield.
21. Remove the radio capacitor.
22. Remove the upper intake manifold bolts.
23. Remove the upper intake manifold studs.
    
    
    

    

    Fig. Upper intake manifold and related parts-4.6L DOHC engine
24. Remove the upper intake manifold.
25. Installation is the reverse of the removal procedure. Tighten the bolts and studs in the sequence shown to 89 inch lbs. (10 Nm).
    
    NOTE

    Locations 5 and 9 use studs.
    
    
    
    
    

    

    Fig. Upper intake manifold bolt torque sequence-4.6L DOHC engine

VIN W SOHC Engine

Fig. Intake manifold and related parts-4.6L SOHC engine

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

   Throttle body

   Ignition coils

   Fuel injection supply manifold

   Upper radiator hose and the heater hose

   Alternator

   Accelerator cable bracket

   Throttle body adapter

   Thermostat housing

   Intake manifold bolts

   Intake manifold. Tilt the manifold to slide it out from underneath the exhaust gas recirculation (EGR) tube.

   To install, reverse the removal procedure. Tighten retaining bolts is sequence shown.
   
   

   

   

   Fig. Tighten the manifold bolts in the sequence shown-4.6L SOHC Engine

1. Before servicing the vehicle, refer to the -Precautions- section.
2. Relieve the fuel system pressure.
3. Drain the cooling system.
4. Remove or disconnect the following:
   
   
   Negative battery cable

   Air cleaner outlet pipe

   EGR tube

   Alternator

   Fuel tube spring lock coupling

   Upper radiator hose from the thermostat housing

   Brake booster vacuum tube bracket bolt and disconnect the tube from the throttle body adapter; position the tube aside

   Heater hose from the intake manifold

   Crankcase breather tube

   Heater control vacuum hose fitting

   Vacuum tube from the throttle body adapter

   EGR system module and fuel pressure sensor vacuum fittings

   PCV valve tube

   Thermostat housing cover, the O-ring seal and the thermostat

   Electronic throttle body and throttle position (TP) sensor electrical connectors

   Fuel pressure sensor electrical connector

   EVAP tube from the throttle body adapter

   Heated PCV coolant inlet hose

   Heated PCV coolant outlet hose

   Coolant outlet hose anchor from the fuel rail stud

   EGR system module electrical connector

   Ground wire connection

   RH fuel injector, coil pack electrical connectors and the wiring harness retainers

   LH fuel injector and coil pack electrical connectors and the fuel charging wiring harness retainers

   Wire harness locators and the knock sensor (KS) electrical connector from the back of the intake manifold

   All 8 ignition coils

   Intake manifold bolts and intake manifold
   
   

   

   

   Fig. External hoses and related parts for intake manifold removal-2005 4.6L (VIN W) engine (1 of 3)

   
   
   

   

   

   Fig. External related parts for intake manifold removal-2005 4.6L engine (VIN W) (2 of 3)

   
   
   

   

   

   Fig. Intake manifold removal-2005 4.6L engine (VIN W) (3 of 3)

To install:

1. Clean all mating surfaces.
2. Position the intake manifold and new gasket.
3. Tighten the intake manifold bolts, in sequence shown, to 18 ft. lbs. (25 Nm).
   
   
   

   

   Fig. Intake manifold bolt tightening sequence-4.6L (VIN W) SOHC engine
4. Apply dielectric compound to the inside of the coil boots, then install all 8 ignition coils and the bolts.
5. Install or connect the following:
   
   
   Wire harness locators and the KS electrical connector to the back of the intake manifold

   LH fuel injector and coil pack electrical connectors and the fuel charging wiring harness retainers

   RH fuel injector, coil pack electrical connectors and the wiring harness retainers

   Ground wire

   EGR system module electrical connector

   Coolant outlet hose anchor to the fuel rail stud

   Heated PCV coolant outlet hose and position the clamp

   Heated PCV coolant inlet hose and position the clamp

   EVAP hose to the throttle body adapter

   Fuel pressure sensor electrical connector

   TP sensor and the electronic throttle body electrical connectors

   Thermostat, with a new O-ring; tighten housing bolts to 18 ft. lbs. (25 Nm)

   PCV valve tube

   Vacuum harness and connect the fuel pressure sensor and EGR system module vacuum fittings

   Vacuum tube to the throttle body adapter

   Heater control vacuum hose fitting

   Crankcase breather tube and connect it to the valve cover

   Heater hose and position the clamp

   Brake booster vacuum tube and connect it to the throttle body adapter, install the vacuum tube bracket bolt

   Upper radiator hose to the thermostat housing

   Fuel tube spring lock coupling

   Alternator

   EGR tube

   Air cleaner outlet pipe

   Battery ground cable
6. Refill and bleed the engine cooling system.

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