Part 1 of 2
Intake Manifold-5.4LRemoval
1. Disconnect the battery ground cable.
2. Remove the interior engine cover.
3. Disconnect the fuel hose spring lock couplings.
4. Drain the cooling system.
5. Position the engine air cleaner (ACL).
1. Remove the four bolts.
2. Loosen the clamp.
3. Position the ACL to gain access to the mass airflow (MAF) sensor electrical connector.
6. Disconnect the MAF sensor electrical connector and remove the ACL.
7. Disconnect the two hoses.
8. Loosen the clamp and remove the air cleaner outlet pipe.
9. Remove the accelerator cable snow shield.
10. Disconnect the throttle body controls.
1. Disconnect the accelerator cable.
2. Disconnect the speed control actuator cable.
3. Remove the throttle return spring.
11. Compress and slide the hose clamp and disconnect the upper radiator hose.
12. Disconnect the coolant hose.
13. Disconnect the coolant hose.
14. Disconnect the throttle position (TP) sensor.
1. Disconnect the TP sensor electrical connector.
2. Detach the harness routing clip.
15. Disconnect the differential pressure feedback exhaust gas recirculation (EGR) system.
1. Disconnect the electrical connector.
2. Disconnect the two hoses.
16. Remove the differential pressure feedback EGR system bracket.
17. Remove the bolt and the bracket.
18. Remove the bolts and the generator upper support bracket.
19. Remove the bolt retaining the transmission fluid filler tube support bracket.
20. Remove the bolts and position the accelerator cable bracket and cables aside.
21. If equipped, disconnect the auxiliary heater hoses and position aside.
22. Disconnect and remove the idle air control (IAC) valve fresh air hose.
23. Disconnect the evaporative emission canister purge valve hose and vacuum hose.
24. Remove the two evaporative emission canister purge valve nuts and position the valve aside.
25. Disconnect the fuel pressure sensor vacuum hose and the electrical connector.
26. Disconnect the EGR vacuum regulator solenoid connections.
27. Disconnect the EGR valve vacuum hose.
28. Disconnect the IAC valve electrical connector.
29. Disconnect the brake booster and main engine vacuum harness and position aside.
30. Disconnect the differential pressure feedback EGR sensor hoses from the EGR valve.
31. Remove the exhaust manifold-to-EGR valve tube.
^ Disconnect the upper fitting.
^ Disconnect the lower fitting and remove the tube.
32. Remove the four bolts, and the throttle body and adapter as an assembly.
^ Discard the throttle body adapter gasket.
33. Disconnect and remove the positive crankcase ventilation hose.
34. NOTE: LH is shown, RH is similar.
Disconnect the eight ignition coil electrical connectors.
35. NOTE: LH is shown, RH is similar.
Disconnect the eight fuel injector electrical connectors.
36. Remove the eight bolts and the eight ignition coils.
37. Remove the bolts, the thermostat housing and the thermostat.
^ Disconnect the O-ring seal.
38. Remove the nine bolts retaining the intake manifold.
39. Remove the intake manifold.
^ Discard the intake manifold gaskets.
40. Inspect the throttle body, the intake manifold, and their sealing surfaces for damage.