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Intake Manifold-Lower: Removal

  1. Remove the upper intake manifold. For additional information, refer to INTAKE MANIFOLD-UPPER .
  2. Disconnect the fuel lines. For additional information, refer to REMOVAL, OVERHAUL & INSTALLATION - BLACKWOOD, EXPEDITION, F150 PICKUP & NAVIGATOR - GASOLINE .
  3. Disconnect the engine water bypass hose (8597).
    Fig 1: Disconnecting Engine Water Bypass Hose (8597)
    G03570311Courtesy of FORD MOTOR CO.
  4. Disconnect the electrical connector from the water temperature indicator sender (10884).
    Fig 2: Disconnecting Electrical Connector From Water Temperature Indicator Sender (10884)
    G03570312Courtesy of FORD MOTOR CO.
  5. Disconnect the upper radiator hose (8260), the heater water inlet hose and the heated positive crankcase ventilation (PCV) water heated fitting inlet hose.
    Fig 3: Disconnecting Upper Radiator Hose (8260)
    G03570313Courtesy of FORD MOTOR CO.
  6. Remove the four bolts and the upper generator support bracket (10153).
    Fig 4: Removing Upper Generator Support Bracket (10153) Bolts
    G03570314Courtesy of FORD MOTOR CO.
  7. Disconnect the eight fuel injectors (9F593).
    Fig 5: Disconnecting Eight Fuel Injectors (9F593)
    G03570315Courtesy of FORD MOTOR CO.
  8. Disconnect the vacuum line from the fuel injector pressure regulator (9C968) and position out of the way.
    Fig 6: Disconnecting Vacuum Line From Fuel Injector Pressure Regulator (9C968)
    G03570316Courtesy of FORD MOTOR CO.
  9. Disconnect the wire harness pin-type retainer.
    Fig 7: Disconnecting Wire Harness Pin-Type Retainer
    G03570317Courtesy of FORD MOTOR CO.
  10. Remove the bolts and lower intake manifold (9424).
    • Discard the lower intake retaining bolts.
      Fig 8: Removing Lower Intake Manifold (9424) Bolts
      G03570318Courtesy of FORD MOTOR CO.
  11. Remove the bolts and the radio ignition interference capacitors (18801).
    Fig 9: Removing Radio Ignition Interference Capacitors (18801) Bolts
    G03570319Courtesy of FORD MOTOR CO.
  12. Remove and inspect the gaskets, install new gaskets if necessary.
    Fig 10: Identifying Gasket
    G03570320Courtesy of FORD MOTOR CO.
    13. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.
    Fig 11: Cleaning Sealing Surfaces
    G03570321Courtesy of FORD MOTOR CO.
  13. Clean the sealing surfaces.
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