Intake Manifold, Upper - Ford Aerostar 1997 Workshop Manual

1997 Aerostar/Ranger
Section 03-01C: Engine, 4.0L V-6
IN-VEHICLE SERVICE

Intake Manifold, Upper

Removal
NOTE: The procedure for removal and installation of the upper intake manifold (9424) has been
changed. After removing the ignition coil and bracket assembly, the EGR valve (EGR valve) (9D475),
the intake manifold to EGR valve tube, and the EGR transducer vacuum lines must be removed.
Refer to Section 03-08
NOTE: The intake manifold is a four-piece assembly consisting of the upper intake manifold, the
throttle body (9E926), the fuel injection supply manifold (9D280) and the lower intake manifold. For
servicing of the throttle body and fuel injection supply manifold, refer to
WARNING: RESIDUAL PRESSURE REMAINS IN FUEL SYSTEM AFTER ENGINE IS SHUT OFF.
THIS COULD RESULT IN INJURY OR FIRE WHEN FUEL LINES ARE DISCONNECTED. DISCONNECT
INERTIA FUEL SHUTOFF SWITCH AND CRANK ENGINE UNTIL FUEL IN LINES IS USED UP. REFER
TO SECTION 03-04C.
1. Disconnect the battery ground cable (14301) at the battery.
2. Disconnect the intake air temperature (IAT) electrical connector and crankcase ventilation hose from
air cleaner outlet tube.
3. Loosen clamps and remove air cleaner outlet tube from vehicle.
4. Remove the accelerator control splash shield and disconnect the throttle cable, and if equipped,
speed control cable from the upper intake.
5. Disconnect vacuum hoses from the brake booster and upper intake.
6. Disconnect the exhaust feed hoses from the differential pressure feedback EGR (DPFE) sensor.
7. Disconnect the PCV ventilation hose from the upper intake manifold.
8. Disconnect the electrical connectors from the DPFE, idle air control (IAC), throttle position (TP)
sensor and EGR transducer.
9. Remove the anti-lock electronic control module. Refer to procedure in
10. Remove floor mount cup holder and remove the interior engine access cover.
11. Disconnect heater hose locating bracket and unbolt transmission filler tube and position aside.
12. Disconnect spark plug wires from the ignition coil pack and disconnect fuel charging wiring from
ignition coil pack.
13. Remove the retaining nut on the engine oil level indicator dipstick tube and remove tube.
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1997 Aerostar, Ranger Workshop Manual
Section 03-04C
Section 06-09A
Page 1 of 4
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2011-04-27