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Home >> Ford >> 2002 >> Crown Victoria Base, 4.6 9 >> Repair and Diagnosis (Single Page) >> Engine Mechanical >> Mechanical >> Engine - 4.6L >> In-Vehicle Repair >> Intake Manifold - Natural Gas Engines >> Removal

Intake Manifold - Natural Gas Engines: Removal

  1. Remove the wiper arm and pivot shaft. For additional information, refer to MOUNTING ARM AND PIVOT SHAFT .
  2. Remove the air cleaner outlet tube.
  3. Disconnect the fuel line. For additional information, refer to FUEL SYSTEMS .
  4. Disconnect the fuel charging wiring electrical connectors from the eight ignition coils and the eight fuel injectors.
    Fig 1: Identifying Fuel Charging Wiring Electrical Connectors - Natural Gas
    G01941136Courtesy of FORD MOTOR CO.
  5. Disconnect the fuel charging wiring electrical connector from the fuel pressure sensor.
    Fig 2: Identifying Fuel Pressure Sensor Fuel Charging Electrical Connector
    G01941137Courtesy of FORD MOTOR CO.
  6. Disconnect the fuel charging wiring electrical connector from the fuel temperature sensor.
    Fig 3: Identifying Fuel Temperature Sensor Fuel Charging Electrical Connector
    G01941138Courtesy of FORD MOTOR CO.
  7. Disconnect the fuel charging wiring electrical connector from the engine coolant temperature sensor.
    Fig 4: Identifying Engine Coolant Temperature Sensor Fuel Charging Electrical Connector
    G01941139Courtesy of FORD MOTOR CO.
  8. Separate the isolation valve wiring lead from the upper generator support bracket and disconnect.
    Fig 5: Identifying Isolation Valve Wiring Lead & Upper Generator Support Bracket
    G01941140Courtesy of FORD MOTOR CO.
  9. Disconnect the generator battery cable.
    Fig 6: Identifying Generator Battery Cable
    G01941141Courtesy of FORD MOTOR CO.
  10. Remove the power distribution box access cover.
    Fig 7: Identifying Power Distribution Box Access Cover
    G01941142Courtesy of FORD MOTOR CO.
  11. Remove the nut and the wiring.
    Fig 8: Identifying Power Distribution Cable Nut
    G01941143Courtesy of FORD MOTOR CO.
  12. Disconnect the fuel charging wiring electrical connectors at the inner fender splash shield.
    Fig 9: Identifying Fuel Charging Electrical Connectors
    G01941144Courtesy of FORD MOTOR CO.
  13. Disconnect the fuel charging wiring electrical connector from the A/C pressure transducer.
    Fig 10: Identifying A/C Pressure Transducer Fuel Charging Electrical Connector
    G01941145Courtesy of FORD MOTOR CO.
  14. Disconnect the fuel charging wiring electrical connector from the cylinder head temperature sensor jumper.
    Fig 11: Identifying Cylinder Head Temperature Sensor Jumper & Fuel Charging Wiring Electrical Connector
    G01941146Courtesy of FORD MOTOR CO.
  15. Disconnect the fuel charging wiring electrical connector from the camshaft position sensor.
    Fig 12: Identifying Camshaft Position Sensor Fuel Charging Electrical Connector
    G01941147Courtesy of FORD MOTOR CO.
  16. Disconnect the fuel charging wiring electrical connector from the generator.
    Fig 13: Identifying Generator Fuel Charging Electrical Connector
    G01941148Courtesy of FORD MOTOR CO.
  17. Disconnect the fuel charging wiring electrical connector from the throttle position sensor.
    Fig 14: Identifying Throttle Position Sensor Fuel Charging Electrical Connector
    G01941149Courtesy of FORD MOTOR CO.
  18. Disconnect the fuel charging wiring from the radio ignition interference capacitor.
    Fig 15: Identifying Fuel Charging Wiring & Radio Ignition Interference Capacitor
    G01941150Courtesy of FORD MOTOR CO.
  19. Disconnect the fuel charging wiring from the exhaust gas recirculation (EGR) vacuum regulator solenoid.
    Fig 16: Identifying Exhaust Gas Recirculation (EGR) Vacuum Regulator Solenoid Fuel Charging Wiring
    G01941151Courtesy of FORD MOTOR CO.
  20. Disconnect the differential pressure feedback exhaust gas recirculation EGR system electrical connector.
    Fig 17: Identifying Differential Pressure Feedback Exhaust Gas Recirculation EGR System Electrical Connector
    G01941152Courtesy of FORD MOTOR CO.
  21. Disconnect the fuel charging wiring from the idle air control valve.
    Fig 18: Identifying Idle Air Control Valve Fuel Charging Wiring
    G01941153Courtesy of FORD MOTOR CO.
  22. Disconnect the throttle cable and the speed control actuator cable from the throttle body.
    Fig 19: Identifying Throttle Cable & Speed Control Actuator Cable
    G01941154Courtesy of FORD MOTOR CO.
  23. Remove the bolts and position the cables and bracket out of the way.
    Fig 20: Identifying Throttle Cable & Speed Control Actuator Cable Bracket Bolts
    G01941155Courtesy of FORD MOTOR CO.
  24. Remove the bolts and position the fuel charging wiring out of the way.
    Fig 21: Identifying Fuel Charging Wiring Bolts
    G01941156Courtesy of FORD MOTOR CO.
  25. Disconnect the hoses from the differential pressure feedback EGR system.
    Fig 22: Identifying Differential Pressure Feedback EGR Hoses
    G01941157Courtesy of FORD MOTOR CO.
  26. Disconnect the vacuum hose from the (EGR) valve.
    Fig 23: Identifying EGR Valve Vacuum Hose
    G01941158Courtesy of FORD MOTOR CO.
  27. Disconnect the main chassis vacuum supply hose from the throttle body adapter.
    Fig 24: Identifying Throttle Body Adapter Main Chassis Vacuum Supply Hose
    G01941159Courtesy of FORD MOTOR CO.
  28. Disconnect the crankcase ventilation tube at two locations and remove from the vehicle.
    Fig 25: Identifying Crankcase Ventilation Tube
    G01941160Courtesy of FORD MOTOR CO.
  29. Disconnect the vacuum hose from the throttle body adapter.
    Fig 26: Identifying Throttle Body Adapter Vacuum Hose
    G01941161Courtesy of FORD MOTOR CO.
  30. Disconnect the vacuum hoses from the EGR vacuum regulator solenoid.
    Fig 27: Identifying EGR Vacuum Regulator Solenoid Vacuum Hoses
    G01941162Courtesy of FORD MOTOR CO.
  31. Disconnect the EGR tube from the EGR valve.
    Fig 28: Identifying EGR Tube - Natural Gas
    G01941163Courtesy of FORD MOTOR CO.
  32. Remove the bolts from the isolation valve.
    Fig 29: Identifying Isolation Valve Bolts
    G01941164Courtesy of FORD MOTOR CO.
  33. Remove the four bolts.
    Fig 30: Identifying Fuel Injection Supply Manifold Bolts
    G01941165Courtesy of FORD MOTOR CO.
  34. Remove the fuel injection supply manifold and the fuel injectors as an assembly.
    Fig 31: Identifying Fuel Injection Supply Manifold
    G01941166Courtesy of FORD MOTOR CO.
  35. Disconnect the heater water hose from the intake manifold.
    Fig 32: Identifying Intake Manifold Heater Water Hose
    G01941167Courtesy of FORD MOTOR CO.
  36. Disconnect the upper radiator hose from the water outlet adapter.
    Fig 33: Identifying Upper Radiator Hose & Water Outlet Adapter
    G01941168Courtesy of FORD MOTOR CO.
  37. Remove the bolts and the eight ignition coils.
    Fig 34: Identifying Ignition Coil Bolts
    G01941169Courtesy of FORD MOTOR CO.
  38. Remove the bolts and the generator support bracket.
    Fig 35: Identifying Generator Support Bracket Bolts
    G01941170Courtesy of FORD MOTOR CO.
  39. Remove the bolts and the water outlet adapter.
    Fig 36: Identifying Water Outlet Adapter Bolts
    G01941171Courtesy of FORD MOTOR CO.
  40. Remove the water thermostat and the O-ring.
    Fig 37: Identifying Water Thermostat
    G01941172Courtesy of FORD MOTOR CO.
  41. Remove the bolts.
    Fig 38: Identifying Intake Manifold Bolts
    G01941173Courtesy of FORD MOTOR CO.
  42. Remove the intake manifold.
    Fig 39: Identifying Intake Manifold
    G01941174Courtesy of FORD MOTOR CO.
  43. Remove the intake manifold gaskets.
    Fig 40: Identifying Intake Manifold Gaskets
    G01941175Courtesy of FORD MOTOR CO.
  44. Clean the sealing surfaces.
    Fig 41: Identifying Intake Manifold Sealing Surfaces
    G01941176Courtesy of FORD MOTOR CO.
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