Intake Manifold, Upper: Removal
WARNING: This page does not describe the selected car, but rather 8 other vehicles, including the 1996 Ford Pickup, 1996 Ford Econoline, 1996 Ford Club Wagon, 1996 Ford Cab & Chassis, and 1995 Ford Pickup. However, it is still accessible from the selected car via links, so may be relevant.
- Disconnect the electrical connectors at the following locations: * EGR external pressure valve * throttle position sensor (TP sensor) * idle air control valve (IAC valve) * EGR transducer
- Disconnect the following vacuum connections: * vacuum line at the EGR external pressure valve * evaporative emission (EVAP) system lines to the throttle body and evaporative emission canister purge valve (EVAP canister purge valve) * vacuum lines to the upper intake manifold vacuum outlet fitting and cap vacuum tree (labeling the hose locations with tape is recommended to aid installation)
- Tag EGR transducer hoses. Remove two screws, EGR transducer and bracket. Disconnect hoses. Disconnect the PCV hose from the fitting, located on the underside of the upper intake manifold
- Remove the accelerator control splash shield, and disconnect the accelerator cable and speed control actuator cable. Position the cable away from the engine. Disconnect the air cleaner outlet tube from the throttle body.
- Disconnect the EGR valve to exhaust manifold tube from the EGR external pressure valve and the rear exhaust manifold . Remove the EGR valve to exhaust manifold tube from the engine. Remove the screw and washer assembly attaching the intake manifold support (9J444) to the upper intake manifold.
- Remove the seven studs that retain the upper intake manifold. Remove the upper intake manifold and throttle body from the lower intake manifold.
CAUTION:
When disconnecting throttle cable from ball stud, use a screwdriver or similar tool close to the ball stud to pry off. Removing by hand may damage the cable.