Upper Intake Manifold

REMOVAL
1. Disconnect the battery ground cable.





2. Remove the air cleaner outlet tube.
- Disconnect the IAT sensor electrical connector.
- Loosen the two air cleaner outlet tube clamps and remove the air cleaner outlet tube.
- Remove the PCV hose from the air cleaner outlet tube.





3. Disconnect the idle air control electrical connector.





4. Remove the bolt and the accelerator control splash shield.





5. Disconnect the Throttle Position (TP) sensor electrical connector.





6. Disconnect the accelerator cable from the throttle linkage.





7. Remove the nut.





8. Remove the other nut.





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





10. Remove the accelerator cable bracket.
1 Remove the nut.
2 Remove the accelerator cable bracket.





11. Disconnect the EGR valve vacuum connector.





12. Disconnect the fuel pressure regulator vacuum connection.





13. Disconnect the two pressure transducer hoses.





14. Disconnect the upper EGR valve-to-exhaust manifold tube fitting.





15. Disconnect the following connections:
- the engine vacuum regulator (EVR) electrical connector
- the engine vacuum regulator (EVR) vacuum connector





16. Disconnect the EGR backpressure transducer electrical connector.
17. Remove the ignition coil bracket.





18. Disconnect the accelerator cable from the upper intake manifold retaining clips.





19. Remove the screws and the intake cover plate.





20. To prevent distortion, remove the bolts in the sequence shown.





21. Disconnect the two vacuum connections from the front of the intake manifold and the two PCV heater hoses.
- Remove the upper intake manifold and discard the old gasket.





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





24. Disconnect the Positive Crankcase Ventilation (PCV) hose, and the two PCV heater hoses.

INSTALLATION
1. Clean and inspect all surfaces, install new seals and gaskets.

NOTE: Use Metal Surface Cleaner F4AZ-19A536-RA or equivalent meeting Ford specification WSE-M5B392-A and a suitable plastic or wooden scraper to clean the upper and lower intake manifold gasket surfaces.





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 crankcase ventilation tube.
5. Connect the vacuum supply line to the brake booster at the LH rear upper intake connection.





6. Tighten the bolts in the sequence shown.





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





8. Install the accelerator cable bracket.
1 Position the accelerator cable bracket.
2 Install the bolt.





9. Install the nut.





10. Install the other 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 valve vacuum connector.





16. Connect the fuel pressure regulator vacuum connector.





17. Connect the upper EGR valve-to-exhaust manifold tube connection.





18. Connect the EGR backpressure transducer electrical connection.





19. Connect the TP sensor electrical connector.





20. Connect the IAC electrical connector.





21. Install the accelerator control splash shield and bolt.





22. Install the air cleaner outlet tube.
- Connect the IAT sensor electrical connector.
- Position the air cleaner outlet tube and tighten the clamps.
- Connect the PCV hose to the air cleaner outlet tube.