The Ford 4.0 liter six-cylinder engine was equipped with a one-piece intake plenum. Once the throttle body combines air and fuel into a combustible mixture, the mixture is then directed to the plenum. The plenum then divides the mixture and distributes it to each of the engine's six cylinders. If the plenum is damaged, air can leak into the plenum and damage the engine due to a lack of fuel. In some cases the plenum can be repaired, but replacement may be the only viable option. In either case, the plenum must first be removed.
Remove the plastic weather shield that covers the top of the throttle body by removing its fasteners with a socket wrench and lifting the shield off of the throttle body.
Loosen the air cleaner duct's clamp with a screwdriver and pull the duct off of the front of the throttle body.
Remove the bolts that secure the throttle cable's bracket to the intake manifold with a socket wrench.
Pull the electrical connections off of the intake plenum and off of the intake manifold.
Compress the clamps that secure the vacuum lines to the manifold and pull the lines clear of the manifold.
Remove the intake plenum's six retaining bolts with a socket wrench and lift the plenum off of the engine.
