To remove the intake manifold, first relieve the fuel system pressure and disconnect the cable from the negative battery terminal. Remove the air intake duct and air filter housing, then drain the cooling system for all models except 5.0L. Disconnect the electrical connectors from the throttle body and fuel injectors, label and disconnect the brake booster vacuum line along with any other vacuum lines connected to the intake manifold. For models excluding 5.0L, remove the drivebelt, alternator, and alternator mounting bracket. If equipped with an electrically heated PCV valve, disconnect its electrical connector. Disconnect the crankcase ventilation hose from the valve cover and intake manifold, as well as the electrical connector and EVAP purge line from the EVAP canister purge valve, and the fuel supply line from the fuel rail. For 4.6L engines, remove the ignition coils, disconnect the upper radiator hose, and remove the thermostat housing and thermostat. Disconnect the EGR module electrical connector and the heater coolant hose, then disconnect the knock sensor electrical connector and detach the knock sensor connector retainer. For 3-valve engines, remove the fuel rail and injectors, and for 2004 and 2005 models, disconnect the electrical connector from the IMT valve. For 5.4L engines, disconnect the upper radiator hose and engine oil pressure sensor, and disconnect the electrical connectors from the left side CMP sensor and VCT solenoid. Disconnect the brake booster vacuum hose and loosen the intake manifold bolts in 1/4-turn increments until they can be removed by hand. Unbolt and remove the coolant crossover assembly, then disconnect the electrical connector from the CHT sensor and the two knock sensors. For 5.0L and 6.2L engines, remove the throttle body, detach the electrical harness, and remove the ignition coils, alternator, and thermostat housing. Disconnect the EVAP tube and PCV hose, then remove the fuel injector insulators and disconnect the purge valve electrical connector. Finally, remove the intake manifold bolts and the intake manifold with the fuel rail still attached, ensuring to break any gasket seal carefully without damaging the surfaces. Clean all traces of gasket material from the sealing surfaces, avoiding abrasive tools, and cover open engine areas to prevent debris entry. For installation, transfer components to the new manifold, install gaskets ensuring proper alignment, set the manifold in place, tighten the bolts following the recommended sequence, and refill the cooling system before starting the engine to check for leaks.
Posted by FordPartsGiant Specialist 
