Removal & Installation
WARNING: This page is about a different car, the 2002 Mercury Grand Marquis, 2002 Lincoln Town Car, and 2002 Ford Crown Victoria. However, it is still accessible from the selected car via links, so may be relevant.
- Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE . Disconnect negative battery cable. Disconnect fuel supply line. See FUEL LINE CONNECTOR . Drain the engine cooling system. Remove the wiper mounting arm and pivot shaft. Remove the drive belt. Raise and support vehicle.
- Disconnect crankshaft position sensor harness connector. Disconnect pin-type retainer from A/C compressor bracket. Disconnect A/C compressor harness connector. Remove oil filter. Disconnect oil pressure sensor harness connector and power steering pressure switch harness connector. Remove the right side catalytic converter assembly. Disconnect EGR tube from exhaust manifold. Lower the vehicle. Disconnect differential pressure feedback EGR system harness connector. Disconnect ignition coil harness connectors. Disconnect from fuel injector harness connectors.
- Disconnect the accelerator cable, speed control actuator cable and throttle return spring. Remove the cables from EGR tube heat shield and position out of the way. Remove the bolts and EGR tube heat shield. Disconnect the evaporative emissions return tube, main chassis vacuum supply hose, and EGR valve vacuum supply hose. Disconnect PCV tube assembly and remove. Disconnect EGR vacuum regulator solenoid harness connector. Disconnect vacuum line from the EVAP canister purge valve. Disconnect generator cable, harness connector and harness pin-type retainer. Remove bolts and generator mounting bracket.
- Remove upper radiator hose. Disconnect idle air control valve and throttle position sensor harness connectors. Disconnect heater water hose. Disconnect EGR tube nut from EGR valve. Separate fuel charging wiring harness pin-type retainer from the crash bracket. Disconnect LH heated oxygen sensor and the transmission harness connectors from wiring bracket. Remove the wiring bracket. Disconnect wiring connector from bracket.
- Remove bolts and throttle body. Remove cables from crash bracket. Remove bolt and stud. Remove crash bracket. Disconnect vacuum lines and remove vacuum harness. Remove ground connector from right rear stud. Remove generator harness pin-type retainer from the left front stud. Remove four studs and fuel injection supply manifold with fuel injectors as an assembly. Remove ignition coils. Remove water outlet adapter. Disconnect cooling sensor harness connector. Remove thermostat. Remove fuel charging wiring position retainer from rear of intake manifold. Remove bolts and intake manifold. Remove intake manifold gaskets. Clean the sealing surfaces.
- Install NEW intake manifold gaskets. Install the intake manifold and hand-tighten bolts. Install water thermostat. Install water outlet adapter and loosely install bolts. Tighten bolts in sequence. See Fig 1. To complete installation, reverse removal procedure. Check the engine oil. Fill the engine cooling system.