Ford 1997 Aerostar Workshop Manual page 2

1997 Aerostar/Ranger
14. Clean upper intake manifold and mating surfaces.
Installation
1. NOTE: Use Silicone Gasket and Sealant F6AZ-19562-AA or equivalent meeting Ford
specification WSE-M4G323-A6.
Apply sealant and install the left valve cover and a new gasket. Tighten the bolts to 14 Nm (10 lb-ft).
2. NOTE: Use Silicone Gasket and Sealant F6AZ-19562-AA or equivalent meeting Ford
specification WSE-M4G323-A6.
Apply sealant and install the right valve cover and a new gasket. Tighten the bolts to 14 Nm (10 lb-ft).
3. Route the left side spark plug wires and connect the wires to the locators on the valve cover and to
the spark plugs.
4. NOTE: Tighten the bolts in sequence in two steps.
Remove the tape from the lower intake manifold and install a new gasket. Install upper intake
manifold, and the three bolts and the three stud bolts. Tighten the bolts in two steps. Tighten to 20
Nm (14 (lb-ft) then tighten to 25 Nm (18 lb-ft). Route and connect the PCV valve and hose.
5. Connect the brake booster vacuum, EGR valve and the engine vacuum harness to the upper intake
manifold.
6. Install the coil and bracket assembly to the upper intake manifold. Install the coil bracket brace to the
bracket and exhaust manifold. Tighten the retainers to 18 Nm (13 lb-ft).
7. Connect the wiring connectors to the coil connector, radio noise suppressor, EVR vacuum and
electrical connectors, left side spark plug wires to the coil and right side spark plug wires to the spark
plugs.
8. Connect the right side valve cover harness locators. Connect the heater control vacuum hose source
to the engine vacuum harness. Connect the IAT harness locator to the generator bracket.
9. Install the EGR valve tube. Tighten the tube nut to 20 Nm (15 lb-ft). Tighten the bolt to 16 Nm (11 lb-
ft). Connect the DPFE vacuum hoses and electrical connector.
10. Connect the throttle cable (09A758A) and speed control cable (9A825) to the throttle body and
locator. Install the bracket with cables attached to the throttle body. Tighten the bolts to 10 Nm (89 lb-
in).
11. Connect the canister purge hose to the valve and the locator to the accelerator control bracket. Install
the accelerator control splash shield.
12. Connect the wiring connectors to the TPS and IAC and the 42-pin connector to the bracket at the rear
of the intake manifold.
13. Install the outlet tube and tighten the clamps securely. Connect the crankcase ventilation hose to the
air cleaner outlet tube. Connect the wiring connectors to the MAF sensor, IAT sensor, and the
harness locator to the outlet tube.
14. NOTE: When the battery has been disconnected and reconnected, some abnormal drive
symptoms may occur while the powertrain control module (PCM) (12A650) relearns its
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2011-04-27