Removal & Installation (Upper)
WARNING: This page is about a different car, the 2002 Mercury Villager. However, it is still accessible from the selected car via links, so may be relevant.
- Disconnect negative battery cable. Drain cooling system. See COOLING SYSTEM DRAINING under COOLING SYSTEMS. Remove air cleaner outlet tube. Disconnect Manifold Absolute Pressure/Barometric (MAP/BARO) sensor, Throttle Position (TP) sensor, TP switch and idle speed control valve connectors. Disconnect MAP/BARO solenoid. Disconnect and plug front throttle body coolant hose.
- Disconnect EVAP vacuum hose. Disconnect fuel regulator vacuum hose. Disconnect spark plug wire retainers, then remove spark plug wire boots, and position aside. Disconnect vacuum reservoir vacuum hose. Disconnect speed control and accelerator cables, and position cables aside. Disconnect brake booster check valve vacuum hose.
- Disconnect EGR modulator tube. Disconnect EGR tube from EGR valve. Disconnect fuel lines bracket from EGR adapter plate. Unclip and disconnect MAP/BARO vacuum hoses. Disconnect EGR adapter plate from bracket. Remove PCV breather tube bracket bolts. Disconnect PCV breather hose.
- Disconnect EGR temperature sensor and EVAP purge solenoid connectors. Remove upper intake manifold bolts. From underside of manifold, disconnect coolant and vacuum hoses. Release clamps and disconnect vacuum hoses from manifold. Remove upper intake manifold. Remove manifold gaskets.
- To install, reverse removal procedure. Ensure gasket surfaces are clean before using a NEW upper intake manifold gasket. Install and tighten bolts to specification. See TORQUE SPECIFICATIONS . Fill and bleed cooling system. See COOLING SYSTEM FILLING & BLEEDING under COOLING SYSTEMS.