Ford Expedition 2004 Workshop Manual
Intake manifold — 4.6l
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- Owner's manual (344 pages) ,
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- Owner's manual (353 pages)
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2004 Expedition/Navigator Workshop Manual
SECTION 303-01A: Engine — 4.6L and 5.4L
IN-VEHICLE REPAIR
Intake Manifold — 4.6L
Printable View (1287 KB)
Removal
WARNING: Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related components. Highly flammable mixtures are always
present and can be ignited. Failure to follow these instructions may result in personal injury.
1. Disconnect the battery ground cable. For additional information, refer to
2. Remove the air cleaner outlet pipe. For additional information, refer to
3. Drain the engine cooling system. For additional information, refer to
4. Compress the hose clamp and disconnect the upper radiator hose.
5. Remove the three bolts and the appearance cover mounting bracket.
6. Disconnect the throttle body cam.
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 bracket and cables aside.
8. Disconnect the main vacuum harness.
9. Disconnect the fuel pulse damper vacuum hose.
http://www.fordtechservice.dealerconnection.com/pubs/content/~WS4J/~MUS~LEN/20/S...
Section
414-01.
Section
303-12.
Section
303-03.
2004 Expedition/Navigator Workshop Manual
Procedure revision date: 06/23/2003
11/3/2009
12
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Summary of Contents for Ford Expedition 2004
- Page 1 2004 Expedition/Navigator Workshop Manual SECTION 303-01A: Engine — 4.6L and 5.4L 2004 Expedition/Navigator Workshop Manual IN-VEHICLE REPAIR Procedure revision date: 06/23/2003 Intake Manifold — 4.6L Printable View (1287 KB) Removal WARNING: Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related components. Highly flammable mixtures are always present and can be ignited.
- Page 2 2004 Expedition/Navigator Workshop Manual 10. Disconnect the climate control vacuum hose. 11. Remove the idle air control (IAC) fresh air hose and disconnect the differential pressure feedback exhaust gas recirculation (EGR) sensor electrical connector. 12. Disconnect the EGR vacuum regulator solenoid connections. 13.
- Page 3 2004 Expedition/Navigator Workshop Manual 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.
- Page 4 2004 Expedition/Navigator Workshop Manual 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 adapter for damage.
- Page 5 2004 Expedition/Navigator Workshop Manual 29. Loosen the generator lower mounting bolts. 30. Disconnect the harness routing clip. 31. Remove the bolts and position the generator aside. 32. Remove the bolts, water thermostat housing and thermostat. Discard the O-ring seal. 33. Remove the nine bolts. http://www.fordtechservice.dealerconnection.com/pubs/content/~WS4J/~MUS~LEN/20/S...
- Page 6 2004 Expedition/Navigator Workshop Manual 34. Remove the intake manifold assembly. 1. Lift the intake manifold. 2. Disconnect the intake manifold tuning valve connector. 3. Remove the intake manifold and discard the gaskets. Inspect the intake manifold assembly for damage. Installation CAUTION: Do not use metal scrapers, power abrasive discs or any abrasive means to clean the sealing surfaces.
- Page 7 2004 Expedition/Navigator Workshop Manual 5. NOTE: The thermostat housing bolts are tightened in sequence with the intake manifold bolts. Install the thermostat housing and loosely install the bolts. 6. Tighten the 11 bolts in two stages in the sequence shown. Stage 1: tighten to 2 Nm (18 lb-in).
- Page 8 2004 Expedition/Navigator Workshop Manual 10. Rotate the belt tensioner clockwise and install the drive belt. Refer to the decal on the radiator upper air deflector for belt routing. 11. Connect the eight fuel injector electrical connectors. 12. Install and connect eight ignition coils. For additional information, refer to Section 303-07A.
- Page 9 2004 Expedition/Navigator Workshop Manual 18. Connect the heater hose and heated throttle body hose. 19. Install the exhaust manifold to EGR valve tube. Hand-tighten the fittings. Tighten the upper fitting. Tighten the lower fitting. 20. Connect the differential pressure feedback EGR sensor vacuum hoses to the EGR tube. 21.
- Page 10 2004 Expedition/Navigator Workshop Manual 23. Connect the evaporative emission canister purge valve hose and the EGR valve vacuum hose. 24. Connect the TP sensor and IAC electrical connectors. 25. Connect the EGR vacuum regulator solenoid connections. 26. Install the IAC fresh air hose and connect the differential pressure feedback EGR sensor electrical connector. 27.
- Page 11 2004 Expedition/Navigator Workshop Manual 29. Connect the main vacuum harness. 30. Install the accelerator cable bracket and the bolts. 31. Connect the throttle body cam. 1. Connect the accelerator cable. 2. Connect the speed control actuator cable. 3. Install the throttle return spring. 32.
- Page 12 2004 Expedition/Navigator Workshop Manual http://www.fordtechservice.dealerconnection.com/pubs/content/~WS4J/~MUS~LEN/20/S... 11/3/2009...
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Questions and answers
Iac valve wiring harness connection instructions
For a 2004 Ford Expedition, the IAC (Idle Air Control) valve wiring harness connection instructions are:
1. Connect the IAC electrical connector.
2. Install the IAC fresh air hose.
This answer is automatically generated