OEM 2004 Ford Expedition Intake Manifold

2004 Ford Expedition Intake Manifold Parts Q&A

• Q: How to service the intake manifold on a 4.6L engine on 2004 Ford Expedition?

  A: You should start the intake manifold service of a 4.6L engine by disconnecting the battery cable ground and removing the air cleaner outlet pipe. Upper radiator hose requires a compressed hose clamp before you drain engine fluid and remove it. The service requires three bolt removal for the appearance cover mounting bracket followed by disconnection of the throttle body cam and accelerator cable and speed control actuator cable and accelerator return spring. Start by detaching the main vacuum harness following the removal of its bolts and then disconnect the fuel pulse damper vacuum hose along with the climate control vacuum hose and Idle Air Control (IAC) fresh air hose and differential pressure feedback Exhaust Gas Recirculation (EGR) sensor electrical connector. The service technician disconnects the EGR vacuum regulator solenoid's connections as well as IAC and Throttle Position sensor electrical wires and the EGR valve vacuum tube and the evaporative emission canister purge valve hose. The brake booster vacuum tube nut deserves removal, while the differential pressure feedback EGR sensor vacuum hoses should be disconnected from the EGR tube. Also, the technician should separate the fuel hose spring lock coupling from the system. The technician disconnects heater hose together with heated throttle body hose and Positive Crankcase Ventilation (PCV) hose. Remove the four studs that allow the throttle body adapter to advance forward and detach the heated throttle body hose and remove the throttle body adapter by throwing away the gasket while checking for any damage. The process starts with power steering removal through disconnecting the upper bracket and removing eight ignition coils followed by eight fuel injectors and then rotating the belt tensioner to allow the drive belt removal from the generator pulley before disconnection of the harness routing clip and generator mounting bolts for position aside removal. Take out the intake manifold assembly by removing all nine bolts and letting it rise while separating the intake manifold tuning valve connector before discarding the gaskets. The installation process involves cleaning all sealing surfaces with a plastic scraper followed by new intake manifold gaskets positioning after which install nine bolts on the upper intake manifold without tightness. Install the water thermostat with new O-ring while attaching the intake manifold tuning valve electrical connector then loosely place thermostat housing bolts and tighten them in two steps starting at 2 Nm up to 25 Nm. The generator must be in position where you can tighten the lower mounting bolts followed by the upper mounting bracket bolts and the harness routing clip installation. The installation of drive belts requires a clockwise movement of belt tensioners after you complete the connection of fuel injector wires and ignite coil installations. The first task involves attaching the fuel hose spring lock coupling and then installing the upper mounting bracket for the power steering reservoir. Finally, position the throttle body adapter roughly and connect the heated throttle body hose. You must use a new gasket when installing the throttle body adapter and tighten its bolts in two steps starting at 90 Nm (80 inch lbs.) before going 90° farther. Install the exhaust manifold to EGR valve tube while performing initial force on the fittings until securing the upper and lower connections. The EGR tube requires connection of differential pressure feedback EGR sensor vacuum hoses and reinstallation of brake booster vacuum tube with bracket followed by nut installation. First put the vacuum harness into general placement and proceed by connecting the evaporative emission canister purge valve vacuum hose followed by the EGR valve vacuum hose. Correctly wire the TP sensor with the IAC electrical connectors and differential pressure feedback EGR sensor and install each piece using the EGR vacuum regulator solenoid, IAC fresh air hose, EGR vacuum hose, climate control vacuum hose and fuel pulse damper vacuum hose. Reinstall the main vacuum harness while also fitting the accelerator cable bracket with bolts and linking the throttle body cam and both accelerator cable and speed control actuator cable and throttle return spring. To complete the installation place the appearance cover mounting bracket by using three bolts while also linking the upper radiator hose with proper clamping followed by air cleaner outlet pipe installation and grounding down the battery before filling and bleeding the engine cooling system.