Removal & Installation (4.0L)
- Disconnect battery ground cable. Remove snow/ice shield. Remove air inlet tube from air cleaner to throttle body.
- Remove fuel cap to relieve tank pressure. Release fuel pressure from fuel system at fuel pressure relief valve on fuel rail assembly.
- Disconnect electrical connectors at air bypass valve, throttle position sensor and air charge temperature sensor. Remove snow/ice shield to expose throttle linkage. Remove throttle cable bracket and disconnect cable from ball stud on throttle body.
- Disconnect upper intake manifold vacuum connectors. Disconnect the PCV valve from rocker cover. Disconnect spark plug wires from rear of manifold. Remove canister purge line from fitting in throttle housing. On Aerostar, remove bolt retaining engine oil dipstick tube.
- Remove bolt retaining A/C line at upper rear of upper manifold. Remove 6 upper intake manifold retaining bolts. See Fig 1
. Remove upper intake and throttle body as an assembly from lower intake and fuel supply manifolds.
- Disconnect fuel supply line fitting at fuel manifold. Disconnect fuel return line from fuel pressure regulator. See PUSH-CONNECT FITTINGS. Remove fuel supply manifold.
Courtesy of FORD MOTOR CO.