Removal & Installation (4.0L)
WARNING: This page is about a different car, the 2002 Ford Ranger. However, it is still accessible from the selected car via links, so may be relevant.
- Disconnect battery ground cable. Remove bolts and shield. Remove air cleaner outlet pipe. Detach Mass Air Flow (MAF) sensor harness connector. Loosen clamps and remove pipe. Disconnect Idle Air Control (IAC) valve and Throttle Position (TP) sensor electrical connectors. Disconnect Exhaust Gas Recirculation (EGR) valve vacuum hose.
- Detach accelerator and speed control cables from throttle body. Detach accelerator and speed control cables from bracket, and position cables aside. Remove exhaust manifold-to-EGR valve tube. Disconnect EGR valve vacuum regulator electrical connector and vacuum hoses. Loosen clamp and disconnect brake booster vacuum hose.
- Mark spark plug wire locations and disconnect spark plug wires from coil. Remove spark plug wire routing clip push pin and position spark plug wires aside. Remove wiring harness bracket retainer, then position wiring harness aside. Remove accelerator cable routing clip push pin and wiring harness push pin.
- Remove bolt and position coil and bracket aside. Disconnect vacuum hoses. Disconnect PCM electrical connector. Disconnect ground wires and position wiring harness aside. Detach electrical connector retainer. Remove intake manifold bolts and slightly lift intake manifold. Remove heated PCV hose retainers and remove heated PCV fitting. Remove intake manifold.
- Ensure gasket mating surfaces are clean and flat. Install NEW intake manifold gasket. Install intake manifold. To complete installation, reverse removal procedure. Tighten bolts to specification. See TORQUE SPECIFICATIONS .