Upper

Upper Intake Manifold Removal

1. Remove air cleaner outlet tube (9B659).
2. Disconnect accelerator cable (9A758) at throttle body (9E926). Disconnect speed control actuator (9A825), if equipped.
3. Remove retaining bolts from accelerator cable bracket (9723) and position cables aside.
4. Disconnect vacuum lines from fuel pressure regulator (9C968) and intake manifold (9424).
5. Disconnect necessary electrical connectors.
6. Remove drive belt (8620).

Crankcase Ventilation Tube:

7. Disconnect crankcase ventilation hoses (6853) located on upper intake manifold.
8. Remove generator mounting brace. Remove bolt retaining upper intake manifold support bracket to upper intake manifold.
9. If required, remove throttle body retaining nuts and remove throttle body.
10. If required, remove the EGR valve (EGR valve) (9D475) from the upper intake manifold.
11. Remove the retaining nut and remove wiring retainer bracket located at the LH front of the intake manifold and set aside with ignition wires.

Upper Intake Torque & Sequence:

12. Remove intake manifold upper gasket retaining bolts and stud bolts and intake manifold.
13. Remove intake manifold upper gasket (9H486).

Upper Intake Manifold Installation

1. Position new intake manifold upper gasket and upper intake manifold on top of lower intake manifold.

Note: Use locating pins to secure position of intake manifold upper gasket between upper and lower intake manifolds.

Note: When the upper intake manifold is removed, always use a new intake manifold upper gasket upon reassembly.

2. Install bolts and stud bolts in original locations.
Tighten in numerical sequence in three steps:
- 10 Nm (8 ft. lbs.)
- 20 Nm (15 ft. lbs.)
- 32 Nm (24 ft. lbs.)

Note: Apply a light coat of Pipe Sealant with Teflon� D8AZ-19554-A or equivalent meeting Ford specifications WSK-M2G350-AZ and ESR-M18P7-A to retaining bolts and stud bolt threads prior to installation.

3. If removed, install EGR valve on intake manifold.
Tighten retaining nuts to 20-30 Nm (15-22 ft. lbs.).
Install upper intake manifold support bracket bolt.
Tighten bolt to 20-30 Nm (15-22 ft. lbs.).






4. If removed, install throttle body and retaining nuts.
Tighten nuts in a cross-tightening sequence to 20-30 Nm (15-22 ft. lbs.).

Fuel Injection Supply Manifold:

5. Connect rear crankcase ventilation hoses at positive crankcase ventilation valve (PCV valve) (6A666) and upper intake manifold.
6. Install generator mounting brace.
Tighten retaining nut and bolt to 30-40 Nm (22-30 ft. lbs.).
7. Install drive belt.
8. Connect necessary electrical connectors.
9. Connect necessary vacuum hoses.
10. Position accelerator cable bracket.
Install and tighten retaining bolts to 20-30 Nm (15-22 ft. lbs.).
11. Connect speed control actuator to throttle body, if equipped.
12. Connect accelerator cable to throttle body.
13. Check and, if necessary, adjust engine idle speed.
Adjust speed control.
14. Install engine air cleaner (ACL) (9600) and air cleaner outlet tube.