Ford Ranger Maintaince And Repair Manual page 292

Upper intake manifold torque sequence on the 2.3L and 2.5L engine
19. Engage the four electrical connectors to the injectors.
20. Install the engine oil dipstick, then connect the fuel return and supply lines to the fuel supply
manifold.
The following procedures are for installing the upper intake manifold.
2. Make sure the gasket surfaces of the upper and lower intake manifolds are clean. Place a gasket on the
lower intake manifold assembly, then place the upper intake manifold in position.
3. Install the retaining bolts and tighten in sequence to 15−3 ft. lbs.
4. Connect the EGR tube to the EGR valve and tighten it to 18 ft. lbs.
5. Connect the coolant bypass line and tighten the clamp. Connect the PCV system hose to the fitting on
the underside of the upper intake manifold.
6. If removed, install the vacuum tee on the upper intake manifold. Use Teflon® tape on the threads and
tighten to 12−18 ft. lbs. Reconnect the vacuum lines to the tee, the EGR valve and the fuel pressure
regulator and canister purge line as necessary.
7. Hold the accelerator cable bracket in position on the upper intake manifold and install the retaining
bolt. Tighten the bolt to 10−15 ft. lbs.
8. Install the accelerator cable to the bracket.
9. Position a new gasket on the fuel charging assembly air throttle body mounting flange. Install the air
throttle body to the fuel charging assembly. Install two retaining nuts and two bolts and tighten to
15−6 ft. lbs.
10. Connect the accelerator and speed control cable (if equipped), then install the throttle linkage shield.
11. Reconnect any electrical harness plugs which were removed.
12. Connect the air intake hose, air bypass hose and crankcase ventilation hose.
13. Reconnect the negative battery cable. Refill the cooling system to specifications and pressurize the
fuel system by turning the ignition switch on and off (without starting the engine) at least six times.
Leaving the ignition on for at least five seconds each time.
14. Start the engine and let it idle while checking for fuel, coolant and vacuum leaks. Correct as
necessary. Road test the vehicle for proper operation.
2.9L Engine
1. Disconnect battery negative cable.
2. Remove air cleaner air intake duct from throttle body.
3. Disconnect throttle cable and bracket assembly.
4. Disconnect EGR tube at EGR valve.
5. Label and disconnect all vacuum hoses from fittings on upper intake manifold.
6. Detach the electrical connections at throttle body, EGR pressure sensor, intake manifold upper and
lower and distributor. Also disconnect fuel injector subharness from main EEC harness.
7. Remove upper intake manifold (plenum) assembly.
REMOVAL & INSTALLATION
HOW TO USE THIS BOOK
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