The following was copied from the 05 Ford Service Manual
Removal
WARNING: Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in personal injury.
WARNING: Fuel in the fuel system remains under high pressure even when the engine is not running. Before servicing or disconnecting any of the fuel lines or fuel system components, the fuel system pressure must be relieved to prevent accidental spraying of fuel, causing personal injury or a fire hazard.
Disconnect the fuel supply spring lock coupling from the fuel rail. For additional information, refer to Section 310-00 .
Drain the cooling system. For additional information, refer to Section 303-03 .
Remove the generator. For additional information, refer to Section 414-02 .
Remove the air cleaner. For additional information, refer to Section 303-12 .
Disconnect the upper radiator hose from the thermostat housing.
Disconnect the heater coolant hose from the coolant bypass tube.
Disconnect the evaporative emissions system (EVAP) tube quick connect coupling from the intake manifold. For additional information, refer to Section 310-00 .
Disconnect the quick connect couplings and remove the positive crankcase ventilation (PCV) tube. For additional information, refer to Section 310-00 .
Disconnect the fuel rail pressure and temperature sensor electrical connector and vacuum connector.
Disconnect the 8 fuel injector electrical connectors.
Disconnect the 4 LH ignition coil electrical connectors.
Disconnect the throttle position (TP) sensor and electronic acceleration control electrical connectors.
Disconnect the LH radio ignition interference capacitor electrical connector.
Disconnect the camshaft position (CMP) sensor electrical connector.
Disconnect the variable camshaft timing (VCT) solenoid electrical connector.
Disconnect the engine oil pressure (EOP) sensor electrical connector.
Disconnect the LH heated exhaust gas oxygen sensor (H02S) electrical connector and detach the electrical connector retainer.
Disconnect the heated PCV intake fitting electrical connector.
Disconnect the brake booster vacuum hose from the intake manifold vacuum tube.
Disconnect the LH engine wiring harness retainers from the LH valve cover studs and position aside.
Remove the 10 intake manifold bolts
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.
Remove the 3 bolts, the coolant bypass tube and discard the gaskets.
Clean and inspect the sealing surfaces with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
Position the intake manifold assembly forward to gain access to the remaining electrical connectors.
Disconnect the charge motion control valve (CMCV) electrical connector.
Disconnect the manifold vacuum tube from the valve cover stud and the support bracket.
Disconnect the cylinder head temperature (CHT) sensor jumper harness electrical connector.
Disconnect the LH and RH knock sensor (KS) electrical connectors.
Remove the nut and disconnect the engine wiring harness retainer from the CMCV stud.
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.
Remove the intake manifold and discard the gaskets.
Inspect and clean the sealing surfaces with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
Installation
NOTE: Electrical and vacuum harnesses must not restrict movement of the CMCV control rods at rear of the intake manifold. Use extreme care on installation of the intake manifold to prevent any pinching of electrical and vacuum harnesses.
Using new intake manifold gaskets, position the intake manifold.
Using new gaskets, position the coolant crossover and install the 3 bolts
Tighten to 10 Nm (89 lb-in).
Install the intake manifold bolts and tighten in 2 stages, in the sequence shown.
Stage 1: Tighten to 2 Nm (18 lb-in).
Stage 2: Tighten to 10 Nm (89 lb-in).
Connect the engine wiring harness retainer to the CMCV stud and install the nut.
Tighten to 10 Nm (89 lb-in).
Connect the CMCV electrical connector.
Connect the CHT sensor jumper harness electrical connector.
Connect the LH and RH KS electrical connectors.
Connect the manifold vacuum tube to the support bracket and the valve cover stud.
Connect the brake booster vacuum hose to the intake manifold vacuum tube.
Connect the heated PCV intake fitting electrical connector.
Connect the LH H02S electrical connector and attach the wiring harness retainer.
Connect the EOP sensor electrical connector.
Connect the VCT solenoid electrical connector.
Connector the CMP sensor electrical connector.
Connect the LH radio ignition capacitor electrical connector.
Connect the TP sensor and electronic acceleration control electrical connectors.
Connect the 8 fuel injector electrical connectors.
Connect the 4 LH ignition coil electrical connectors.
Connect the fuel rail pressure and temperature sensor electrical connector and vacuum connector.
Connect the fuel supply spring lock coupling to the fuel rail. For additional information, refer to Section 310-00 .
Position the PCV tube and connect the quick connect couplings. For additional information, refer to Section 310-00 .
Position the EVAP tube and connect the quick connect coupling to the intake manifold. For additional information, refer to Section 310-00 .
Connect the heater coolant hose to the coolant bypass.
Connect the upper radiator hose to the thermostat housing.
Install the generator. For additional information, refer to Section 414-02 .
Install the air cleaner. For additional information, refer to Section 303-12 .
Fill and bleed the engine cooling system. For additional information, refer to Section 303-03 .
