Upper

REMOVAL
1. Remove air cleaner outlet tube (9B659). Refer to Powertrain Management.
2. Disconnect accelerator cable (9A758) at throttle body (9E926). Disconnect speed control actuator cable (9A825) (if equipped).
3. Remove retaining bolts from accelerator cable bracket (9723) and position cables aside.
4. Disconnect vacuum lines at upper intake manifold (9424).
5. Disconnect necessary electrical connectors.
6. Disconnect crankcase ventilation tube (6758) at the upper intake manifold and at positive crankcase ventilation valve (PCV valve)(6A666).
7. Remove throttle body if necessary. Refer to Powertrain Management.
8. Remove the EGR valve (9D475) from the upper intake manifold. Refer to Powertrain Management.
9. Remove the nut and bolt retaining engine support and wiring retainer bracket located at the LH front of the intake manifold and set aside with ignition wires.
10. Remove upper intake manifold retaining bolts/studs.
11. Remove upper intake manifold and intake manifold upper gasket (9H486).

INSTALLATION

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

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

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

NOTE:
Apply a light coat of Pipe Sealant with Teflon(R) D8AZ-19554-A or equivalent meeting Ford specification WSK-M2G350-A2 and ESR-M18P7-A to retaining bolts and stud bolt threads prior to installation.

2. Install bolts and stud bolts in original locations. Tighten in sequence shown in three steps:
Step 1 ... 10 Nm (7.5 ft. lbs.).
Step 1 ... 20 Nm (15 ft. lbs.).
Step 1 ... 32 Nm (23 ft. lbs.).
3. Install engine support and wiring bracket and retaining nut and bolt to LH front of the upper intake manifold. Tighten bolt to 20-30 Nm (15-22 ft. lbs.). Tighten nut to 8-11 Nm (71-97 inch lbs.).
4. Install the EGR valve.
5. Install throttle body and new throttle body gasket (TB gasket)(9E936) if removed. Cross-tighten retaining nuts to 20-30 Nm (15-22 ft. lbs.).
6. Connect crankcase ventilation tube to positive crankcase ventilation valve on the upper intake manifold.
7. Connect necessary fuel charging wiring connectors.
8. Connect necessary vacuum hoses.
9. Position accelerator cable bracket. Install and tighten retaining bolts to 14-20 Nm (11-14 ft. lbs.).
10. Connect accelerator cable at throttle body. Connect speed control actuator cable (if equipped).
11. Install air cleaner outlet tube. Refer to Powertrain Management.
12. Check and adjust accelerator cable if necessary.
13. Check and, if necessary, adjust engine idle airflow. Refer to Powertrain Management.
14. Check and adjust speed control actuator cable if necessary.