Do I have to remove ALL Spark Plugs/Coil Packs to remove the Intake Manifold?

[intelisevil]

2003 5.4

The previous owner apparently cross-threaded the bolt on the cylinder 4 coil pack. The bolt is completely rounded off.

Will I be able to remove the intake manifold without removing that coil pack and spark plug?

Thanks in Advance,

 

[stamp11127]

I'd try to extract the broken bolt with a screw extractor or left handed drill bit before removing parts.

 

[1955moose]

Is it just rounded off at the head? Or is it broken off? If it's just rounded off, you should be able to get a small pair of locking vice grips on the bolt head to remove it. Then again it depends on what's in the way, that is the bolt and coil buried way down in the hole of no return.

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[Hamfisted]

Do you have a copy of the Ford shop manual ? The coil fasteners actually screw into the intake manifold. If that's the only coil still attached you can most likely pull it out with the intake manifold and work on the fastener once it's out of the vehicle. Are you replacing the intake manifold ?

Here's a helpful video that the Ford Tech made :


If you need the Ford shop manual you can download it here : https://spaces.hightail.com/space/hoVVsN5P2A
The 2V intake removal section starts at page 865 ....



-Mike

 

[JExpedition07]

On my 3 valve my shop replaced a coil and lost the fastener so they jammed some random bolt in the hole crooked. I found out when I went to change my plugs and boots when I realized the head was completely different.....then it sheered off. I paid another shop to extract after I tried and they could not, had to fabricate a bracket off of the intake manifold to hold the coil down. Sometimes it ain’t easy to extract depending on the situation.

 

[intelisevil]

Yes you can remove the intake manifold with cylinder 4 coil pack still bolted to it!!!

For those of you not looking at a map, that's the passenger side one sitting in the back seat . . . I didn't see any way I could have used vice grips on it until it was out of the vehicle.

Since I didn't have the correct size wrench to remove the EGR tube, I just unbolted the the EGR valve from the throttle body assembly (already had the gasket). This caused some slight problems as I removed the intake manifold but it worked out.

When I'm working on bolts I can't see, I always get the socket with extension firmly on the bolt head then put the ratchet on the extension. When I got to the last intake manifold bolt on the back of the passenger side I found it wasn't even finger tight. Hopefully that will be the source of my coolant leak.

At least it's going to be a piece of cake to replace the spark plugs with the intake manifold off.

 

[Trainmaster]

Thanks for getting back to us. That note will be a help to others down the road.

I always buy cars used, several years old. Over the course of the first year or so I discover every job that has been done since the thing was built by the shoddy work and crappy aftermarket parts left behind. Lots of people just don't care about their work.

 

[1955moose]

Should be a law that hacks aren't allowed to sell a vehicle that they worked on. Punishment would be the old owner pays for everything they broke, or screwed up. Wouldn't that teach em to do it right, or leave it alone. Fines and repairs would double for shops that screwed up. Sure would make buying a used car more pleasant.

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