Ported Intake Manifold Install (and Removal) - Submitted by FordFasteRR Tools and Materials Needed: Basic mechanic socket set Jack and two jackstands Estimated Time: 2 hours. Before you begin be sure to disconnect the battery. Have a few bottles of water (or beer) to drink. 1. Remove the air intake pipes & associated vacume lines. 2. Remove the injector harness from the injectors. 3. Remove the map sensor harness. 4. Remove the idle air bypass valve harness & the TPS sensor harness. 5. Remove the pcv hoses (there are two of them on the back of the valve cover, one goes directly to the intake manifold next to the map sensor, the other went to the intake pipe). 6. Remove the throttle linkage cable & cruise control linkage cable* (*if applcable). Set them aside and out of the way. 7. Remove the four nuts holding the TB in place, pull the TB & Gasket off and set it aside. 8. Remove the Brake Booster Vacuum Hose & both of the TB coolant hoses. (This would be a good time to do the TB Coolant bypass mod, just re-route one hose back to the return nipple.) 9. Unscrew the fuel tank vapor valve bracket, & remove vacume line (you will find this valve just below the brake booster hose). Leave it dangling there, do not remove its harness. 10. Remove the 2 bolts holding the fuel rail in place. 11. Carefully pull the fuel rail out of the manifold, set it aside (on the drivers side). If you want, you can wrap it in a towel to keep the injectors from getting dirty, & keep an eye on the black o-rings, you dont want to lose them. 12. Remove the firewall ground wire from the back of the manifold. 13. Remove the wire-harness clip that is just below the ground wire, it holds a wire loom to the manifold, you will need to zip tie this back on later if you break the clip. 14. Jack up the car, insert jacksstands using all known safety measures & procedures. 15. Get under the car and remove the two LOWER bolts holding the black steel manifold brackets. 16. Reach up and try your best to remove the TOP two bolts holding the steel brackets (this is almost impossible to do because of the small space, but I managed to get one of them off when I did this mod, but I dont recall which one... anyway, just do it). 17. While you are still down there, use your socket wrench extension to reach the manifold nut that is hidden above the air conditioner compressor (that's the only nut that is tricky). 18. Remove the remaining lower manifold nuts. 19. Get back on the top of the engine and remove the remaining top manifold nuts. 20. Carefully pry the manifold free of the head, and remove it straight upwards and out of the engine bay. Check for any remaining wires or vacume lines that may be left... remove as necessary. 21. Remove all of the brackets and sensors from the manifold & attach them to the new Ported manifold. 22. If your gaskets broke, install new ones, you can buy a gasket set from the dealer for $25. It will include gaskets for the IAC valve, TB & manifold, there is no gasket for the MAP. If you are carefull during the removal process, you can easily reuse your stock gaskets. 23. You will not need to re-install the manifold brackets, you can discard them & save weight. 24. Re-install EVERYTHING in the same order that you removed them. 25. Do not over-torque the manifold bolts. just tighten them down snug and tight, but not TOO tight. (Reccomended settings for most of the parts of this install are 17-13 ft. lb.) 26. I was able to re-install the manifold without getting back under the car. You will most likely encounter trouble getting the nut between the IM & A/C compressor, but with a little TLC you can get it on there... I've done it a bunch of times with no trouble at all. Click here to discuss this Do It Yourself Guide.

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