Upper

Removal

1. Disconnect the battery ground cable.
2. Remove the air cleaner outlet tube.





3. Remove the accelerator cable snow shield.





4. Disconnect the accelerator cable from the speed control actuator cable (if equipped) and position aside.





5. Loosen the bolt and slide the engine control wiring connector off the bracket.





6. Note: Spark plug wires must be connected to the correct ignition coil terminal. Mark spark plug wires before removing them.

Disconnect the spark plug wires from the ignition coil.





7. Disconnect the ignition coil and the radio ignition interference capacitor electrical connectors.





8. Disconnect the throttle position (TP) sensor electrical connector.





9. Disconnect the electrical connectors:
- idle air control (IAC) solenoid
- EGR transducer
- EGR solenoid





10. Disconnect the vacuum connections:
- EGR solenoid
- EGR valve





11. Disconnect the brake booster vacuum hose, the positive crankcase ventilation (PCV) hose, and the vacuum hose.





12. Disconnect the hoses from the EGR backpressure transducer.





13. Disconnect the canister purge line from the throttle body.





14. Remove the nuts.





15. Remove the fuel line bracket.





16. Remove the upper intake manifold and the gasket.
17. Inspect and install new gaskets, if necessary.

Installation





1. Note: Before installing the upper intake manifold, the EGR port must be clean and free of obstruction. Remove carbon buildup from the EGR passages. Inspect and install new seals.

Position the upper intake manifold.





2. Position the fuel line bracket.





3. Install the nuts.
- Tighten the nuts in the sequence shown.





4. Connect the canister purge line from the throttle body.





5. Connect the hoses to the EGR backpressure transducer.





6. Connect the brake vacuum booster hose, the positive crankcase ventilation (PCV) hose and the vacuum hose.





7. Connect the vacuum connections:
- EGR valve
- EGR solenoid





8. Connect the electrical connectors:
- EGR solenoid
- EGR transducer
- idle air control (IAC) solenoid





9. Connect the throttle position (TP) sensor electrical connector.





10. Connect the ignition coil and the radio ignition interference capacitor electrical connectors.





11. CAUTION: Correct installation of the spark plug wires is critical to vehicle operation. If one spark plug wire is not correctly installed on the spark plug or ignition coil, both spark plugs connected to that segment of the ignition coil may not fire under load.

Note: Wipe the spark plug wires with a clean, damp cloth prior to inspection.

Note: When a spark plug wire is removed for any reason from a spark plug or ignition coil, or a new spark plug wire is installed, Silicone Brake Caliper Grease and Dielectric Compound D7AZ-19A331-A or equivalent meeting Ford specification ESE-M1C171-A must be applied to the spark plug wire boot prior to installation.

Connect the spark plug wires to the ignition coil.





12. Slide the engine sensor control wiring connector on the bracket and tighten the bolt.





13. Connect the accelerator cable to the speed control actuator cable (if equipped).





14. Install the accelerator cable snow shield.
15. Install the air cleaner outlet tube.
16. Connect the battery ground cable.