1997 Explorer/Mountaineer Intake Manifold Service and Repair

Download 1. Disconnect the battery ground cable. 2. Remove the air cleaner outlet tube; refer to Section 303-12 3. Disconnect the ignition coil electrical connector and the noise suppressor electrical connector. 4. Disconnect the idle air control (IAC) electrical connector. 5. Disconnect the EGR backpressure transducer electrical connector. 6. Disconnect the EVR solenoid electrical and vacuum connectors. 7. Disconnect the brake booster vacuum hose from the upper intake manifold. 8. Disconnect the vacuum connector from the upper intake manifold. 9. Disconnect the vacuum connector from the fuel pressure regulator and remove the vacuum harness from the engine. 10. Disconnect the throttle position (TP) sensor electrical connector. 11. Disconnect the hoses from the EGR backpressure transducer ports. 12. Disconnect the six spark plug wires from the spark plugs. 13. Disconnect the spark plug wires from the seven retaining clips. 14. Remove the four ignition coil bolts and the ignition coil from the upper intake manifold.… Read More

2001 Ford Lincoln LS Intake Manifold Upper

Download 1. Disconnect the battery ground cable. For additional information, refer to Section 414-01. 2. Drain the engine cooling system. For additional information, refer to Section 303-03 . 3. Remove the engine appearance cover. 4. Remove the air cleaner outlet tube. For additional information, refer to Section 303-12 . 5. Disconnect the throttle position (TP) sensor and the idle air control (IAC) solenoid electrical connectors. 6. Disconnect the accelerator and speed control cables. 7. Remove the cable bracket. 1. Remove the bolts. 2. Remove the bracket. 8. Disconnect the throttle body hoses. 1. Disconnect the coolant hoses. 2. Disconnect the positive crankcase ventilation (PCV) hose. 3. Disconnect the vapor purge hose. 9. Disconnect the vacuum hose. 10. Disconnect the EGR to exhaust manifold tube nut. 11. Remove the cowl vent screen. For additional information, refer to Section 501-02 . 12. Remove the brace. 13. Remove the vacuum hoses from the mounting bracket.… Read More

2001 Ford Windstar COWL TOP VENT PANEL Installation Instructions

Download 1. Remove windshield wiper pivot arms. Remove cowl top vent panel retaining screws. Release cowl top vent panel retaining clips. Remove windshield wiper fluid hose. Remove cowl top vent panel. 2. To install, reverse removal procedure. Tighten bolts and nuts to specification. See TORQUE SPECIFICATIONS . INTAKE MANIFOLD Removal 1. Remove cowl top vent panel. See COWL TOP VENT PANEL . Release fuel pressure and disconnect fuel lines. See FUEL PRESSURE RELEASE & FUEL LINE CONNECTIONS . 2. Disconnect negative battery cable. Drain cooling system. Remove air cleaner assembly and heat tube. Disconnect control cables and linkage at throttle body. Disconnect accelerator cable bracket, and secure aside. 3. Disconnect necessary linkages at intake manifold. Disconnect wiring harness connectors, vacuum hoses, coolant hoses and PCV hoses as necessary. Remove heater tube with fuel lines attached. 4. Remove A/C compressor support bracket (if equipped). Remove throttle body and EGR valve assembly. Note location of upper intake manifold bolts and studs.… Read More

2006 Ford Five Hundred SE UPPER INTAKE MANIFOLD

Download Identifying Upper Intake Manifold Components (1 Of 3) (With Torque Specifications) Courtesy of FORD MOTOR CO. Item Specification Threadlock and Sealer TA-25 WSK-M2G351-A5. Removal All vehicles 1. Drain the cooling system. For additional information, refer to DRAINING . 2. Disconnect the battery ground cable. For additional information, refer to REMOVAL AND INSTALLATION . 3. Remove the air cleaner outlet pipe. For additional information, refer to REMOVAL AND INSTALLATION . 4. Remove the 4 transaxle roll restrictor cross brace bolts. 5. Remove the bolt and the transaxle roll restrictor cross brace. 6. Disconnect the evaporative emissions (EVAP) canister purge valve tube from the upper intake manifold and detach the retainer. 7. Disconnect the positive crankcase ventilation (PCV), brake booster and vacuum harness tubes from the upper intake manifold. 8. Detach the fuel tube retainer from the upper intake manifold. 9. Disconnect the exhaust gas recirculation (EGR) system module electrical connector and vacuum tube.… Read More

1998 Buick Park Avenue Engine Coolant Consumption or Coolant Leak

Download Engine Coolant Consumption or Coolant Leak (Inspect For Material Degradation/Replace Intake Manifolds) Models: 1995-1997 Buick Riviera 1995-1999 Buick LeSabre, Park Avenue 1996-1999 Buick Regal 1998-1999 Chevrolet Lumina, Monte Carlo 1995-1996 Oldsmobile Ninety-Eight 1995-1999 Oldsmobile Eighty-Eight 1998-1999 Oldsmobile Intrigue 1995-1999 Pontiac Bonneville 1997-1999 Pontiac Grand Prix with 3.8L Engine (VIN K — RPO L36) Condition Some customers may comment on excessive engine coolant consumption, or an engine coolant leak near or under the throttle body area of the upper intake manifold. Cause Upper intake manifold composite material may degrade around the EGR stove pipe and could result in an internal or external coolant leak. Correction 1. Follow the upper intake manifold removal instructions found in the Engine Unit Repair Section of the Service Information Manual. 2. Refer to the arrow in the illustration of the upper intake manifold above. Inspect the inner diameter of the EGR passage for signs of material degradation.… Read More

5.0L FORD POWER PACK Installation Instructions

Download ADDITIONAL PARTS REQUIRED: • EGR Spacer to Intake Gasket (Ford #M9464-A50) • Permatex Ultrablue Sealer • Throttle Body to EGR Spacer (Ford #M9933-A50 or Equivalent) • Anti-Seize Compound • Intake Manifold Gaskets (Felpro Gasket, #1250 Or Equivalent) • Oil and Oil Filter • Water Outlet Gasket (Felpro Gasket, #35440 Or Equivalent) • Antifreeze • Thermostat NOTE: Part numbers 98-200 and 201 DO NOT include a throttle body and EGR spacer. It is the customer’s responsibility to obtain this hardware. Either stock or 65-70 mm units are recommended. REMOVAL OF ENGINE ACCESSORIES: 1 – Disconnect the negative cable from the battery. Secure cable to prevent accidental grounding. See Figure 1. Figure 1 Figure 2 2 – Drain the coolant from the radiator. Then remove the block drain plug to drain the coolant from the block. DANGER! COOLANT INSIDE A HOT ENGINE WILL BE UNDER PRESSURE. ALLOW ENGINE TO COOL BEFORE DRAINING COOLANT.… Read More

1998 FORD Ranger 4.0L OHV UPPER ENGINE GASKETS REPLACING INSTRUCTIONS

Download Ford 4.0L (OHV) Upper Intake Manifold Assembly Removal & Installation Removal 1. Disconnect the battery ground cable. 2. I highly recommend taking the hood off. Mark where the bolts connect on the hood to ensure proper alignment upon re-installation. My trick was to use “white-out” to do this, comes with a nice little brush. 3. Remove the air cleaner outlet tube by loosening the clamp next to the MAF and the clamp next to the Throttle Body. 4. Disconnect the accelerator cable from the throttle body arm, and then unclip the accelerator cable from the speed control actuator cable. Move them out of the way. 5. Disconnect the vacuum hoses from the brake vacuum booster, EGR valve and crankcase ventilation hose. 6. Disconnect the wiring harness connectors from the EGR valve, the DPFE sensor, and the idle air control (IAC) valve. 7. Disconnect the DPFE sensor hoses. 8. Disconnect the throttle position sensor (TPS) harness connector.… Read More

2000 Cadillac Catera TIMING BELT REPLACEMENT

Download 2000 Cadillac Catera V6-3.0L VIN R Timing Belt: Service and Repair Timing Belt Replacement. Removal Procedure ^ Tools Required -J 42069 Timing Belt Alignment Kit -J 42098 Crank Hub Torx Socket Notice: Failure to follow the described timing belt inspection and maintenance may result in a broken timing belt and cause severe engine damage. 1.Inspect the cold start counter (also called a heavy duty register) with a scan tool. If there are any cold starts (below -28° C or -20° F) visually inspect the timing belt for cracks. It cracks are noted, do not reuse the belt. Replace the belt and clear the cold start counter. If the belt is okay, and is reused, do not clear the cold start counter. 2.Remove the intake air resonator. Refer to Intake Air Resonator Replacement in Powertrain Management. 3.Remove the intake plenum. Refer to Intake Plenum Replacement. 4.Remove the timing belt cover. Refer to Timing Belt Cover Replacement.… Read More

2002-2004 Ford Focus SVT COLD AIR SYSTEM

Download Part Number 21-451. Read and understand these instructions BEFORE attempting to install this product. 1) Getting Started a) Make sure vehicle is parked on a level surface. b) Set parking brake. c) Jack the front of the vehicle and support using properly rated jack stands d) If engine has run with in the past two hours let it cool down. 2) Removal of the stock intake system. a) Stock system installed on vehicle. b) Remove the wiring harness from the MAF Sensor. c) Remove the clamp securing the primary intake pipe to the throttle body. d) Disconnect the breather hose from the vehicle. e) Remove the stock intake system from the vehicle. f) Upper Stock system removed from vehicle. g) Remove the MAF sensor from the stock intake system. h) Remove the 90 degree plastic fitting from the stock system. i) Remove the battery cover from the vehicle. j) Disconnect the battery.… Read More

2002-2003 Acura RSX Icebox Cold Air Intake Installation Instructions

Download Honda Civic Si & Acura RSX Icebox Cold Air Intake Installation Instructions (2002-2003 Honda Civic Si) (2002-2003 Acura RSX—All) Step #1 Remove Stock Airbox • Before disconnecting battery locate radio code to reactivate radio after installation. (write down preset channels for later use) •Disconnect Negative battery terminal. •Remove battery positive terminal, tie down clamp, battery and plastic tray. •Remove engine cover around throttle body on intake manifold (A). •Remove stock air box lid and filter. •Disconnect Intake Air Temperature (IAT) sensor, remove upper intake hose and clamps (B). •Remove air box mounting bolts and nut. Rotate air box forward and out. Remove rubber grommets and stepped bushings from stock air box*. •Remove Lower Air inlet hose by removing mounting bolt from radiator cross support above cooling fan. •Remove ground strap bracket on side of transmission (C). Relocate ground strap from transmission bracket to top of transmission (D). Step #2 Install Comptech Airbox •Install (3) stock rubber grommets* (E) through large holes on underside of mounting ears on Icebox (a small dab of filter oil may be used to ease this process).… Read More