Upper Intake Manifold

Upper Intake Manifold








Removal and Installation
1. Disconnect the battery ground cable.

2. WARNING: Never remove the pressure relief cap under any conditions while the engine is operating. Failure to follow these instructions could result in damage to the cooling system or engine or personal injury. To avoid having scalding hot coolant or steam blow out of the cooling system or reservoir, use extreme care when removing the pressure relief cap from a hot cooling system or reservoir. Wait until the engine has cooled, then wrap a thick cloth around the pressure relief cap and turn it slowly until the pressure begins to release. Step back while the pressure is released from the cooling system. When certain all pressure has been released, remove the pressure cap (still with a cloth).

CAUTION: The coolant must be recovered in a suitable, clean container for reuse. If the coolant is contaminated, it must be recycled or disposed of correctly.

CAUTION: Vehicle cooling systems are filled with Motorcraft Premium Gold Engine Coolant VC-7-A (in California and Oregon, VC-7-13, in Canada VC-7-C) or equivalent meeting Ford specification WSS-M97B51-A1yellow color) or equivalent. Always fill the cooling system with the same coolant that is present in the system. Do not mix coolant types.

Wrap a thick cloth around the coolant pressure relief cap on the degas bottle. Slowly turn the cap counterclockwise (left) until the pressure begins to release.
^ Step back while the pressure releases.
3. Remove the air cleaner outlet pipe.
4. Remove the exhaust gas recirculation (EGR) system module.
5. Disconnect the positive crankcase ventilation (PCV) hose from the intake manifold.
6. Disconnect the brake booster vacuum hose from he intake manifold.
7. Disconnect the evaporative emissions (EVAP) hose from the upper intake and position aside.
8. Disconnect the vacuum harness connector from he intake manifold.
9. Disconnect the coolant hoses from the intake manifold.
^ Plug the coolant hoses.
10. Disconnect the accelerator cable and the speed control cable (if equipped) from the throttle body linkage.
^ Remove the accelerator cable return spring.
11. Remove the 2 bolts and position aside the accelerator cable and bracket.
^ Disconnect the accelerator cable pin-type retainer.
12. Disconnect the idle air control (IAC) electrical connector.
13. Disconnect the throttle position (TP) sensor electrical connector.
14. Remove the 2 fuel rail shield nuts and the shield.
^ To install, tighten to 10 Nm (89 inch lbs.).
15. Remove the radio capacitor nut and the radio capacitor.
^ To install, tighten to 10 Nm (89 inch lbs.).

16. NOTE: Locations 3, 5 and 9 use studs.





Remove the upper intake manifold bolts and studs.
^ To install, tighten to 10 Nm (89 inch lbs.) in the sequence shown.
17. Remove the upper intake manifold.
^ Clean and inspect the gasket. Install new if necessary.
18. To install, reverse the removal procedure.