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Removal & Installation (3.0L - Upper)

WARNING: This page is about a different car, the 2002 Lincoln LS. However, it is still accessible from the selected car via links, so may be relevant.
  1. Disconnect negative battery cable. Drain engine cooling system. See COOLING SYSTEM DRAINING  under COOLING SYSTEM. Remove engine appearance cover. Remove air cleaner outlet tube. Disconnect Throttle Position (TP) sensor and Idle Air Control (IAC) valve connectors.
  2. Disconnect accelerator cable and speed control actuator cable from throttle body lever. Remove accelerator cable bracket from throttle body and move aside. Disconnect coolant, EVAP vapor purge valve and Positive Crankcase Ventilation (PCV) hoses from throttle body. Disconnect exhaust manifold-to-EGR tube and vacuum hose at EGR valve.
    3. NOTE: Cowl vent screen must be removed to remove upper intake manifold.
  3. Remove 2 windshield wiper pivot arm nut covers and nuts. Remove 2 wiper pivot arms. Remove left and right side cowl vent screen extension panels. Disconnect windshield washer nozzle hoses from engine main wiring harness at lower right side of engine compartment.
    4. NOTE: Cowl vent screen pin-type retainers are reusable.
  4. Remove 9 pin-type retainers and remove cowl vent screen. Remove 7 bolts and remove strut support brace. See Figure. Remove vacuum hoses from mounting bracket. Remove bracket and position accelerator and speed control cables aside. Disconnect IMTV harness connector. Remove 2 bolts retaining IMTV and remove IMTV.
  5. Disconnect Differential Pressure Feedback EGR (DPFEGR) connector. Remove stud and nut retaining DPFE and position aside. Remove nut and bolts retaining fuel pressure sensor shield and remove shield. Disconnect vacuum hose at rear of upper intake manifold. Disconnect Intake Manifold Tuning Valve (IMTV) connector.
  6. Disconnect connector and vacuum hose from EGR vacuum regulator valve. Remove 2 bolts from upper intake support bracket. Remove intake manifold bolts in reverse order of tightening sequence. See Fig 1. Remove upper intake manifold and discard upper intake manifold gaskets.
  7. To install, reverse removal procedure. Tighten upper intake manifold bolts in sequence and to specification. See Fig 1. See TORQUE SPECIFICATIONS .
Fig 1: Upper Intake Manifold Tightening Sequence (3.0L)
G00009349Courtesy of FORD MOTOR CO.
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