IN-VEHICLE REPAIR. Upper Intake Manifold

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1 Engine 3.9L and 4.2L IN-VEHICLE REPAIR Upper Intake Manifold Special Tool(s) Remover, Spark Plug Wire (T74P-6666-A) Material Item Silicone Brake Caliper Grease and Dielectric Compound D7AZ-19A331-A (Motorcraft XG-3) or equivalent Specification ESE-M1C171-A CAUTION: During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces, that enters the oil passages, coolant passages or the oil pan can cause engine failure. 1. With the vehicle in neutral, position it on a hoist. For additional information, refer to Section Disconnect the battery ground cable. For additional information, refer to Section Partially drain the cooling system. 4. Remove the wiper motor and pivot assembly. For additional information, refer to Section Remove the engine air cleaner outlet tube. For additional information, refer to Section Copyright 2003, Ford Motor Company Last updated: 07/31/2003

2 Engine 3.9L and 4.2L IN-VEHICLE REPAIR 6. Remove the parts in the order indicated in the following illustrations and tables. 1 9A758 Accelerator cable 2 9A825 Speed control cable 3 9E894 Spring 4 N S190 Cable bracket stud bolt (2 req d) Cable bracket (position aside) 6 9G271 Evaporative (EVAP) emission return tube 7 Clamp (part of 2A047) 8 2A047 Brake booster vacuum hose

3 Engine 3.9L and 4.2L IN-VEHICLE REPAIR 9 Exhaust gas recirculation 13 12B637 EGR system module electrical (EGR) system connector module-to-exhaust manifold 14 12B637 Idle air control (IAC) tube lower fitting (part of electrical connector 9D477) 15 12B637 Throttle position (TP) sensor 10 EGR system electrical connector (part of module-to-exhaust manifold 12B637) tube upper fitting (part of 9D477) Positive crankcase ventilation (PCV) hose 11 9D477 EGR system module-to-exhaust manifold LH spark plug wire assembly tube (with retainers) 12 9E498 EGR system module vacuum Installation Note connector 18 9E498 Upper intake manifold 21 Upper intake manifold bolt (8 vacuum tube connector req d) (Part of 9424) 19 Coolant inlet hose (part of Installation Note 18663) Upper intake manifold 20 Coolant outlet hose (part of 18663) Upper intake manifold gasket (6 req d) 7. To install, reverse the removal procedure.

4 Engine 3.9L and 4.2L IN-VEHICLE REPAIR 8. Fill and bleed the cooling system. For additional information, refer to Section Item 4: Cable Bracket Stud Bolt Removal Note 1. Remove the engine harness retainer from the stud bolt. Item 17: LH Spark Plug Wire Assembly 1. CAUTION: Spark plug wires must be connected correctly. Mark the spark plug wires before removing them. CAUTION: It is important to twist the spark plug wire boots while pulling upward to avoid possible damage to the spark plug wires. With a twisting motion, use the special tool to pull the spark plug wires from the spark plugs and the ignition coil. 2. Disconnect the two engine harness pin type retainers. 2. Remove the pin-type retainers and the spark plug wires as an assembly. Item 21: Upper Intake Manifold Bolt Installation Note 1. Tighten the upper intake manifold bolts in two stages in the sequence shown. Tighten the bolts to 6 Nm (53 lb-in). Tighten the bolts to 10 Nm (89 lb-in). Item 22: Upper Intake Manifold Removal Note 1. Disconnect the four engine harness pin type retainers.

5 Engine 3.9L and 4.2L IN-VEHICLE REPAIR Item 17: Spark Plug Wire Installation Note 1. CAUTION: Make sure the spark plug boots are positioned so the spark plug wires do not contact the exhaust manifold. Apply dielectric grease to the inside of the spark plug wire boots before attaching to the spark plugs and ignition coil.

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