Ford Aerostar 1997 Workshop Manual page 16

1997 Aerostar/Ranger
14. Remove the EGR tube retaining bolts and release EGR tube from upper intake.
15. Disconnect the mass air flow (MAF) sensor electrical connector.
16. Disconnect the bulkhead wiring harness, remove pushpin locators and position wiring harness aside.
17. Remove the three bulk head bracket bolts and remove bracket.
18. Remove the two EGR transducer retaining bolts and remove transducer from the upper intake
manifold.
19. Remove the six nuts securing the upper intake manifold and remove the upper intake manifold.
20. Remove and discard upper intake manifold gaskets.
Installation
1. Replace intake manifold gaskets and install the upper intake manifold.
2. Tighten the upper manifold nuts to 20-25 Nm (15-18 lb-ft) using intake the center-out sequence.
3. Install EGR transducer on upper intake manifold with the retaining two bolts.
4. Fit bulkhead wiring harness bracket and install the three retaining bolts.
5. Connect the bulkhead wiring harness, install pushpin locators and position wiring.
6. Connect the MAF sensor electrical connector.
7. Install the EGR tube into upper intake manifold and tighten retaining bolts.
8. Install the engine oil level indicator dipstick tube and tighten the retaining nut.
9. Connect spark plug wires on ignition coil pack and connect fuel charging wiring to ignition coil pack.
10. Install transmission filler tube and connect heater hose locating bracket.
11. Install interior engine access cover and floor mount cup holder.
12. Install the anti-lock electronic control module; refer to procedure in
13. Connect electrical connections at the DPFE, IAC, TP sensor and EGR transducer.
14. Connect vacuum hose at the brake booster and the PCV ventilation hose at the upper intake
manifold.
15. Connect the exhaust feed hoses to the DPFE.
16. Install the throttle cable, and if equipped, the speed control cable on to the upper intake.
17. Install the accelerator control splash shield to the throttle body.
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Section 06-09A .
2011-04-27