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Installation (3.0L 4V - 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. Position NEW gaskets in upper intake manifold. Position upper intake manifold and install the 8 bolts and tighten in proper sequence. See Fig 7. See TORQUE SPECIFICATIONS .
  2. Install EVR valve and bolts. Tighten bolts to specification. See TORQUE SPECIFICATIONS . Connect EVR vacuum line and electrical connector. See Fig 6.
  3. Install EGR valve, bolts and nuts. Tighten bolts and nuts to specification. See TORQUE SPECIFICATIONS . Connect EGR vacuum line. See Fig 5.
  4. Connect the following to the upper intake manifold:
    • EVAP vacuum hose.
    • Positive Crankcase Ventilation (PCV) vacuum hose.
    • EGR vacuum supply hose.
    • EGR Vacuum Regulator (EVR) valve vacuum supply hose.
  5. Connect engine wiring harness to throttle body stud. See Fig 4. Connect TP sensor and IAC valve harness connectors. See Fig 3.
  6. Connect throttle cable and cruise control cable. See Fig 2. Install accelerator cable splash shield and pin-type retainers. See Fig 1. Install cleaner outlet tube, tighten clamps and install hoses. Connect negative battery cable.
Fig 1: Removing & Installing Accelerator Cable Splash Shield (3.0L 4V Shown; 3.0L 2V Is Similar)
G00241931Courtesy of FORD MOTOR CO.
Fig 2: Removing & Installing Throttle Cables (3.0L 4V)
G00241932Courtesy of FORD MOTOR CO.
Fig 3: Removing & Installing Throttle Position Sensor & Idle Air Control Valve Connectors (3.0L 4V)
G00241933Courtesy of FORD MOTOR CO.
Fig 4: Removing & Installing Engine Harness At Throttle Body Stud (3.0L 4V)
G00241934Courtesy of FORD MOTOR CO.
Fig 5: Removing & Installing EGR Valve (3.0L 4V)
G00152645Courtesy of FORD MOTOR CO.
Fig 6: Removing & Installing EGR Vacuum Regulator Valve (3.0L 4V)
G00241935Courtesy of FORD MOTOR CO.
Fig 7: Upper Intake Manifold Tightening Sequence (3.0L 4V)
G00009350Courtesy of FORD MOTOR CO.
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