Upper Intake Manifold

REMOVAL





1. Disconnect the battery ground cable.





2. On early models, remove the air cleaner outlet tube.
a. Disconnect the intake air temperature (IAT) sensor electrical connector.
b. Loosen the two air cleaner outlet tube clamps and remove the air cleaner outlet tube.





3. On late models, remove the air cleaner outlet tube.
a. Disconnect the IAT sensor electrical connector.
b. Loosen the two air cleaner outlet tube clamps and remove the air cleaner outlet tube.





4. Disconnect the crankshaft ventilation hose from the throttle body.





5. Disconnect the idle air control electrical connector.





6. Remove the snow shield bolt and the snow shield.





7. On early models, disconnect the throttle position (TP) sensor electrical connector.





8. On late models, disconnect the throttle position (TP) sensor electrical connector.





9. Disconnect the accelerator cable from the throttle linkage.





10. Remove the accelerator cable bracket nut.





11. Remove the accelerator cable bracket nut.





12. Remove the accelerator and cruise control cables from the retaining clip.





13. Remove the accelerator cable bracket.
a. Remove the nut.
b. Remove the accelerator cable bracket.





14. Disconnect the EGR electrical connector





15. On early models, disconnect the EGR vacuum connector.





16. On late models, disconnect the EGR vacuum connector.





17. Disconnect the fuel pressure regulator vacuum connection.





18. On late models, disconnect the two pressure transducer hoses.





19. On late models, disconnect the upper EGR tube fitting.





20. Disconnect the following connections:
a. The engine vacuum regulator (EVR) electrical connector.
b. The engine vacuum regulator (EVR) vacuum connector.





21. On late models equipped with the DPFE system, disconnect the EGR backpressure transducer electrical connector.
22. Remove the ignition coils bracket.





23. Disconnect the accelerator cables from the upper intake manifold retaining clips.





24. Remove the two intake cover plate screws and the intake cover plate.





25. Remove the six upper intake manifold bolts in the sequence shown.





26. Disconnect the two vacuum connections from the front of the intake manifold.
^ Remove the upper intake manifold and discard the old gasket.





27. Disconnect the Vapor Management Valve (VMV) purge line.
28. Disconnect the brake booster vacuum supply line at the LH rear upper intake connection.





29. Disconnect the positive crankcase ventilation (PCV) hose.

INSTALLATION
1. Clean and inspect all surfaces, install new seals and gaskets.
^ Use Metal Surface Cleaner F4AZ-19A536-RA or equivalent meeting Ford specification WSE-MSB392-A and a suitable plastic or wooden scraper to clean file upper and lower intake manifold gasket surfaces.

NOTE: Before installing the upper intake manifold, the EGR exhaust port must be clean and free of obstructions. Use combustion chamber cleaner and a suitable wire brush to remove carbon buildup from the EGR passages in the upper and lower intake manifolds and cylinder head.





2. Position the upper intake manifold and gasket and start the bolts.





3. Connect the upper intake vacuum connection and the VMV purge line.





4. Connect the PCV hose.
5. Connect the vacuum supply line to the brake booster at the LH rear upper intake connection.





6. Tighten the six upper intake manifold bolts in the sequence shown.





7. Install the upper intake manifold cover plate and tighten the two screws.





8. Install the accelerator cable bracket.
a. Position the accelerator cable bracket.
b. Install the bolt.





9. Install the accelerator cable bracket nut.





10. Install the accelerator cable bracket nut.





11. Connect the accelerator cable to the throttle linkage.





12. Position the accelerator and cruise control cables into the retaining clip.
13. Install the ignition coils and the ignition coil bracket.





14. Connect the following connections:
^ The engine vacuum regulator (EVR) electrical connector.
^ The engine vacuum regulator (EVR) vacuum connector.





15. Connect the EGR vacuum connector.





16. Connect the fuel pressure regulator vacuum connector.





17. Connect the EGR electrical connector.





18. If equipped with the DPFE system, connect the EGR vacuum connector.





19. Connect the upper EGR tube connection.





20. On late models equipped with the DPFE system, connect the EGR backpressure transducer electrical connection.





21. On early models, connect the throttle position (TP) sensor electrical connector.





22. On late models, connect the TP sensor electrical connector.





23. Connect the IAC electrical connector.





24. Install the snow shield and bolt.





25. Connect the positive crankshaft ventilation hose to the throttle body.





26. On early models, install the air cleaner outlet tube.
a. Connect the intake air temperature (IAT) sensor electrical connector.
b. Position the air cleaner outlet tube and tighten the clamps.





27. On late models, install the air cleaner outlet tube.
a. Connect the IAT sensor electrical connector.
b. Position the air cleaner outlet tube and tighten the clamps.





28. Connect the battery ground cable.

NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy.