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Installation (3.0L 2V - Upper)

WARNING: This page is about a different car, the 2003 Mercury Sable and 2003 Ford Taurus. However, it is still accessible from the selected car via links, so may be relevant.
  1. Clean all sealing surfaces. Inspect upper intake manifold gaskets. Install NEW gaskets as necessary. See Fig 11. Install upper intake manifold. Tighten bolts in 2 stages in the proper sequence. See Fig 12. First, hand tighten bolts, then tighten to specification. See TORQUE SPECIFICATIONS .
  2. Connect spark plug wire retainer and radio interference capacitor electrical connector. See Fig 10. Connect wiring harness retaining clip.
  3. Connect vacuum hose to upper intake manifold. Connect vacuum regulator solenoid vacuum and electrical connections. See Fig 9.
  4. Connect EGR tube and vacuum hose to EGR valve. See Fig 8. Tighten EGR tube fitting to specification. See TORQUE SPECIFICATIONS . Connect PCV tube to upper intake manifold. See Fig 7.
  5. Install upper intake manifold support bracket. See Fig 6. Tighten bolts to specification. See TORQUE SPECIFICATIONS . Connect wiring harness to intake manifold support bracket. See Fig 5.
  6. Connect IAC valve and TP sensor electrical connectors. See Fig 4. Connect EVAP return tube and vacuum hose. See Fig 3.
  7. Install accelerator cable bracket and bolts. See Fig 2 Tighten bolts to specification. See TORQUE SPECIFICATIONS . Connect accelerator cable, speed control actuator cable and throttle return spring to throttle body. See Fig 1.
  8. Install accelerator cable shield. See Figure. Install air cleaner assembly and air cleaner outlet tube. Connect negative battery cable.
Fig 1: Removing & Installing Throttle Cables (3.0L 2V)
G00241936Courtesy of FORD MOTOR CO.
Fig 2: Removing & Installing Accelerator Cable Bracket (3.0L 2V)
G00241937Courtesy of FORD MOTOR CO.
Fig 3: Removing & Installing EVAP Return Tube & Vacuum Hose (3.0L 2V)
G00241938Courtesy of FORD MOTOR CO.
Fig 4: Removing & Installing Idle Air Control Valve & Throttle Position Sensor Connectors (3.0L 2V)
G00241939Courtesy of FORD MOTOR CO.
Fig 5: Removing & Installing Engine Harness At Manifold Bracket (3.0L 2V)
G00241940Courtesy of FORD MOTOR CO.
Fig 6: Removing & Installing Manifold Support Bracket (3.0L 2V)
G00241941Courtesy of FORD MOTOR CO.
Fig 7: Removing & Installing PCV Valve At Intake Manifold (3.0L 2V)
G00241942Courtesy of FORD MOTOR CO.
Fig 8: Removing & Installing EGR Tube & Vacuum Hose (3.0L 2V)
G00241943Courtesy of FORD MOTOR CO.
Fig 9: Removing Vacuum Solenoid Connector & Vacuum Lines (3.0L 2V)
G00241944Courtesy of FORD MOTOR CO.
Fig 10: Removing & Installing Spark Plug Wire Retainer & Radio Interference Capacitor (3.0L 2V)
G00241945Courtesy of FORD MOTOR CO.
Fig 11: Installing Intake Manifold Gaskets (3.0L 2V)
G00241946Courtesy of FORD MOTOR CO.
Fig 12: Upper Intake Manifold Tightening Sequence (3.0L 2V)
G00241947Courtesy of FORD MOTOR CO.
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