Ford Expedition 2004, Navigator 2004 Workshop Manual
SECTION 303-01A: E ngine — 4.6L and 5.4L 2004 Expedition/Navig ator Workshop Manual
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2004 Expedition/Navigator Workshop Manual
11/3/2009
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IN-VEHICLE REPAIR
Procedure revision date: 06/23/2003
Intake Manifold — 4.6L
Removal
WARNING: Do not smoke or carry lighted tobacco or open fl ame of any type when working on or near any fuel-related co mponents. Highly flammable mixtures are always
present and can be ignited. Failure to follow these instructions may result in personal inju ry.
1. Disconnect the battery ground cable. For additional information, refer to Section 414-01.
2. Remove the air cleaner outlet pipe. For additional information, refer to Section 303-12.
3. Drain the engine cooling system . For additional information, ref er to Section 303-03.
4. Compress the hose clamp and disconnect the upper radiator hose.
5. Remove the three bolts and the appearance cover mounting bracket.
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6. Disconnect the throttle body c am.
1. Disconnect the accelerator cable.
2. Disconnect the speed control actuator cable.
3. Remove the accelerator return spring.
7. Remove the accelerator cable bracket bolts and position the bra cket and cables aside.
8. Disconnect the main vacuum harness.
9. Disconnect the fuel pulse damper vacuum hose.
12
2004 Expedition/Navigator Workshop Manual
11/3/2009
http://www.fordtechservice.dealerconnection.com/pubs/content/~WS4J/~MUS~LEN/20/S
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10. Disconnect the climate control vacuum hose.
11. Remove the idle air control (IAC) fresh air hose and disconne ct the differential pressure feedba ck exhaust gas recirculation (EGR) sensor electrical connector.
12. Disconnect the EGR vacuum regulator solenoid connections.
13. Disconnect the IAC and throt tle position (TP) sensor electrica l connectors.
14. Disconnect the EGR valve v acuum hose and the evaporative emission canister purge valve hose and position them aside.
15. Disconnect the evaporative emission canister purge valve vacu um hose and remove the vacuu m harness.
12
2004 Expedition/Navigator Workshop Manual
11/3/2009
http://www.fordtechservice.dealerconnection.com/pubs/content/~WS4J/~MUS~LEN/20/S
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16. Remove the nut and disconnect the brake booster vacuum tube. Position the bracket and tube aside.
17. Position the crankcase ventilation hose aside.
18. Disconnect the differential pressure feedback EGR sensor vacuum hoses from the EGR tube .
19. Position the exhaust manifo ld to EGR valve tube aside.
Disconnect the upper fitting.
Loosen the lower fitting.
Position the tube aside.
20. Disconnect the fuel hose sp ring lock coupling. For additional information, refer to Section 310-00.
21. Disconnect the heater hose and the heated throttle body ho se.
12
2004 Expedition/Navigator Workshop Manual
11/3/2009
http://www.fordtechservice.dealerconnection.com/pubs/content/~WS4J/~MUS~LEN/20/S
...
22. Disconnect the positive crankcase ventilation (PCV) hose.
23. Remove the four bolts and move the throttle body adapter forward slightly.
24. Disconnect the heated throttle body hose and remove the throttle body adapter.
Discard the throttle body adapter-to-intake manifold gasket.
Inspect the throttle body and ad apter for damage.
25. Remove the power steering reservoir upper mounting bracke t.
26. Disconnect and remove the eight ignition coils. For additional information, refer to Section 30 3-07A.
27. Disconnect the eight fuel injectors.
28. Rotate the belt tensioner clo ckwise and detach the drive belt from the generator pulley.
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