How to remove the upper intake manifold from the EGR tube.

Question edited for clarity.
Question moved to model category.

I cant find where the knock sensor is located on my 1998

JustAnswer https://www.justanswer.com > Ford Repair

Mar 15, 2020 - Ok give me a minute to look it up. It is under the lower intake manifold. You have to remove that to replace the knock sensor. The block, you ...

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How to replace upper intake manifold gaskets - Ford Explorer

Generally the Air charge temp sensor is in the intake tube between the air box & the intake. However, there is a possibility that it is part of the Mass air flow sensor.

Fig. 4: Exploded view of the EGR system and related components for the 4.0L engine (click over pic for zoom)

REMOVAL & INSTALLATION

PFE/DPFE Sensor
This component is found on all engines, and is also referred to as the backpressure transducer.

1. Disconnect the negative battery cable.
2. Detach and label the wiring harness connector from the PFE/DPFE sensor.
3. Disconnect all of the hoses from the sensor.
4. Remove the mounting nuts, then separate the sensor from the mounting bracket.
5. If necessary, remove the EVR solenoid and the PFE/DPFE mounting bracket from the upper intake manifold.

To install:

1. If removed, install the EVR solenoid and mounting bracket onto the upper intake manifold.
2. If applicable, install the EGR tube heat shield.
3. Position the PFE/DPFE sensor on the mounting bracket, then install and tighten the mounting nuts until snug.
4. Attach all necessary hoses and wiring to the sensor.
5. Connect the negative battery cable.

EGR Vacuum Regulator (EVR) Solenoid
The EVR solenoid is mounted either on the same bracket as the PFE/DPFE sensor, attached to the upper intake manifold, or near the EGR valve on its own bracket.

1. Disconnect the negative battery cable.
2. Label and detach the wiring harness connector from the EVR solenoid.
3. Detach the main emission vacuum control connector from the solenoid.
4. Remove the retaining nuts, then separate the solenoid from the mounting bracket.

To install:

1. Position the solenoid on its mounting bracket and install the retaining nuts.
2. Attach the main emission vacuum control connector and the wiring harness connector to the EVR solenoid.
3. Connect the negative battery cable.

EGR Valve
See Figures 6 and 7

1. Disconnect the negative battery cable.
2. If necessary, remove the air inlet tube from the throttle body and air cleaner housing.
3. Label and detach all vacuum hoses from the EGR valve.
4. Label and detach any electrical wiring harness connectors from the EGR valve.
5. Disconnect the EGR valve-to-exhaust manifold tube from the EGR valve.
6. Remove the EGR valve mounting fasteners, then separate the valve from the upper intake manifold.
7. Remove and discard the old EGR valve gasket, and clean the gasket mating surfaces on the valve and the intake manifold.
   

Fig. 6: Cutaway view of a base entry type EGR valve

Fig. 7: Cutaway view of a side entry type EGR valve

To install:

1. Install the EGR valve, along with a new gasket, on the upper intake manifold, then install and tighten the mounting bolts to 4-22 ft. lbs. (20-30 Nm) on 3.8L engines, or to 106-49 inch lbs. (1-18 Nm) on 5.0L engines.
2. Connect the EGR valve-to-exhaust manifold tube to the valve, then tighten the tube nut to 30 ft. lbs. (41 Nm).
3. Connect all wiring or hoses to the EGR valve.
4. Install the air inlet tube.
5. Connect the negative battery cable.

Hope this helps, good luck (remember to rate this comments).

3.8L Engine (most common) Upper Intake Manifold To Remove:

1. Drain the cooling system.
2. Remove or disconnect the following:
   • Negative battery cable.
   • Fuel injector sight shield.
   • Air cleaner intake duct.
   • Right spark plug wires from the ignition control module and reposition.
3. Relieve the fuel pressure.
4. Remove or disconnect the following:
   • Fuel rail assembly.
   • Brake booster hose from the vacuum source manifold in the upper intake manifold.
   • Exhaust Gas Recirculation Valve (EGR) wiring harness heat shield nut, bolt and the EGR heat shield.
   • Throttle body support bracket upper bolt.
5. Disconnect the electrical connectors from the following:
   • EVAP purge solenoid
   • Throttle Position (T/P) sensor
   • Idle Air Control (IAC) valve
   • Manifold Absolute Pressure (MAP) sensor
   • Mass Air Flow (MAF) sensor
   • EVAP purge solenoid vacuum line from the throttle body.
   • Accelerator and the cruise control cables with the bracket from the throttle body.
6. Remove or disconnect the following:
   • Upper intake manifold bolts and stud.
   • Clean the upper intake manifold bolt threads.
7. Remove or disconnect the following:
   • Upper intake manifold by lifting the back of the intake and sliding the manifold forward from the throttle body support bracket.
   • Upper-to-lower intake manifold carrier gasket from the upper intake manifold.
8. If the upper intake manifold is being replaced, remove the following:
   • Throttle body assembly.
   • Manifold Absolute Pressure (MAP) sensor.
   • Positive Crankcase Ventilation (PCV) valve.
   • Vacuum source manifold.

Upper intake manifold bolt torque sequence (3.8L engine)

To Install:

1. If the manifold was replaced, install or connect the following:
   • Vacuum source manifold.
   • Positive Crankcase Ventilation (PCV) valve.
   • Manifold Absolute Pressure (MAP) sensor.
   • Throttle body assembly.
   • Upper-to-lower intake manifold carrier gasket to the upper intake manifold.
2. Carefully place the upper intake manifold onto the lower intake manifold. Ensure that the alignment pins in the upper intake manifold align with the holes in the lower intake manifold. NOTE: Apply thread lock compound, to the bolt threads before assembly.
   
3. Install or connect the following:
   • Upper intake manifold. Tighten the upper intake manifold bolts in sequence to 89 in lbs (10 Nm)
   • Accelerator and the cruise control cables with the bracket to the throttle body.
   • EVAP purge solenoid vacuum line to the throttle body.
4. Connect the electrical connectors to the following:
   • Mass Air Flow (MAF) sensor
   • Manifold Absolute Pressure (MAP) sensor
   • Idle Air Control (IAC) valve
   • Throttle Position (T/P) sensor
   • EVAP purge solenoid
5. Install or connect the following:
   • Throttle body upper support bracket bolt. Tighten the bolt to 89 in lbs (10 Nm)
   • EGR valve wiring harness heat shield, nut and the bolt. Tighten the nut and the bolt to 89 in lbs (10 Nm)
   • Brake booster hose to the vacuum source manifold.
   • Fuel rail assembly.
   • Right spark plug wires.
   • Air cleaner intake duct.
   • Fuel injector sight shield.
6. Connect the negative battery cable.
7. Fill the cooling system.
8. Inspect for fluid or vacuum leaks.

Lower Intake Manifold (W/O Supercharger) To Remove:

1. Remove or disconnect the following:
   • Upper intake manifold.
   • Generator brace.
   • Drive belt tensioner with the mounting bracket and the heater water bypass inlet pipe.
   • Exhaust gas recirculation EGR outlet pipe bolt from the lower intake manifold.
   • Radiator inlet hose from the water outlet housing.
   • ECT sensor electrical connector.
   • Right upper engine mount strut bracket.
   • Generator brace bracket bolts.
   • Generator brace bracket.
   • Lower intake manifold bolts.
   • Lower intake manifold.
   • Lower intake manifold seals.
   • Lower intake manifold gaskets.
2. If replacing the lower intake manifold, Remove or disconnect:
   • Water outlet housing bolt and stud
   • Water outlet housing
   • Gasket and the thermostat.
   • ECT sensor.
3. Inspect the flatness of inlet flanges.
4. Clean the intake manifold mating surfaces.
5. Clean the intake manifold bolts and bolt holes of adhesive compound.

To Install:

1. If removed, install the ECT sensor.
   • Tighten the ECT sensor to 18 ft. lbs. (25 Nm)
2. If removed, install the thermostat, the gasket, and the water outlet housing.
3. If removed, install the water outlet housing bolt and the stud.
   • Tighten the bolt and stud to 20 ft. lbs. (27 Nm)
4. Install or connect the following:
   • Lower intake manifold gaskets. NOTE: Apply sealer GM P/N 12346286 (Canadian P/N 10953472) or equivalent to the ends of the intake manifold seals.
     
   • Lower intake manifold seals.
   • Lower intake manifold.
   • Lower intake manifold bolts.
   NOTE: Apply thread lock compound GM P/N 12345382 (Canadian P/N 10953489) or equivalent to the two hidden bolts and ensure they are installed.
   
5. Tighten the lower intake manifold bolts in sequence to 11 ft. lbs. (15 Nm)
   
   
6. Install or connect the following:
   • Generator brace bracket.
   • Generator brace bracket bolts. Tighten the bolts to 37 ft. lbs. (50 Nm)
   • Right upper engine mount strut bracket.
   • ECT sensor electrical connector.
   • Radiator inlet hose to the water outlet housing.
   • EGR outlet pipe to the lower intake manifold.
   • EGR outlet pipe bolt to the lower intake manifold. Tighten the bolt to 21 ft. lbs. (29 Nm)
   • Drive belt tensioner.
   • Generator brace.
   • Upper intake manifold.
7. Inspect for leaks.

Lower Intake Manifold (W/ Supercharger) To Remove:

1. Disconnect the negative battery cable.
2. Drain the cooling system.
3. Remove the supercharger.
4. Remove the thermostat housing.
5. Remove the EGR pipe at the intake manifold.
6. Disconnect the electrical connection at the temperature sensor.
7. Remove the intake manifold and gaskets.

NOTE: The coolant bypass tube will release from the intake manifold when the manifold is removed.
To Install:

1. Clean the gasket sealing surfaces.
2. Install the intake manifold gaskets.
3. Align the coolant bypass tube with the opening in the intake manifold and install the manifold. Tighten the bolts to 11 lb ft (15 Nm).
4. Install the electrical connector to the temperature sensor.
5. Install the EGR pipe to the intake manifold.
6. Install the thermostat housing.
7. Install the supercharger.
8. Fill the cooling system.
9. Connect the negative battery cable.

Fig. 11: EGR valve and component mounting-3.0L engine




Fig. 12: EGR valve and component mounting-3.8L engine

Removal:

1. Disconnect the negative battery cable.
2. If necessary, remove the air inlet tube from the throttle body and air cleaner housing.
3. Label and detach all vacuum hoses from the EGR valve.
4. Label and detach any electrical wiring harness connectors from the EGR valve.
5. Disconnect the EGR valve-to-exhaust manifold tube from the EGR valve.
6. Remove the EGR valve mounting fasteners, then separate the valve from the upper intake manifold.
7. Remove and discard the old EGR valve gasket, and clean the gasket mating surfaces on the valve and the intake manifold.
   

To install:

1. Install the EGR valve, along with a new gasket, on the upper intake manifold, then install and tighten the mounting bolts to 15-22 ft. lbs. (20-30 Nm) on 3.8L engines, or to 106-159 inch lbs. (12-18 Nm) on 5.0L engines.
2. Connect the EGR valve-to-exhaust manifold tube to the valve, then tighten the tube nut to 30 ft. lbs. (41 Nm).
3. Connect all wiring or hoses to the EGR valve.
4. Install the air inlet tube.
5. Connect the negative battery cable.

Hope this helps (remember comment and rated this).

Bonneville, LeSabre, Park Avenue 2000-2005 Intake Manifold - Removal & Installation

3.8L Engine
VIN 1 Engine

1. Before servicing the vehicle, refer to the Precautions section.
2. Relieve the fuel system pressure.
3. Drain the cooling system.
4. Remove or disconnect the following:
   Negative battery cable Supercharger Thermostat housing Exhaust Gas Recirculation (EGR) tube at the intake manifold Engine Control Temperature (ECT) sensor Intake manifold

To install:

1. Install or connect the following:
   Intake manifold with new gaskets. Torque the bolts, working from the center out, to 11 ft. lbs. (15 Nm). ECT sensor connector EGR tube to the intake manifold Thermostat housing Supercharger Negative battery cable
2. Refill and bleed the cooling system.
3. Run the engine and check for leaks and proper engine operation.

VIN K Engine

1. Before servicing the vehicle, refer to the Precautions section.
2. Disconnect the negative battery cable.
3. Drain the cooling system.
4. Relieve the fuel system pressure.
5. Remove or disconnect the following:
   Fuel injector sight shield Air inlet duct Spark plug wires from the right side Manifold Absolute Pressure (MAP) sensor Vacuum lines from the intake manifold Fuel lines Fuel injector electrical connectors Fuel regulator vacuum line Fuel rail from the intake manifold Exhaust Gas Recirculation (EGR) heat shield Throttle cable bracket from the cylinder head mounting bracket and the throttle body cables Throttle body support bracket Upper intake plenum and gasket Thermostat housing Electrical connector from the Engine Coolant Temperature (ECT) sensor Drive belt tensioner assembly EGR valve outlet pipe Lower intake manifold
   
   
   Fig. Exploded view of the intake manifold and related components-3.8L (VIN K) engine
   

To install:



Fig. Upper intake manifold torque sequence-3.8L (VIN K) engine



Fig. Lower intake manifold torque sequence-3.8L (VIN K) engine

1. Install or connect the following:
   Intake manifold using new manifold gaskets. Torque the bolts in sequence to 11 ft. lbs. (15 Nm); then, re-torque to 11 ft. lbs. (15 Nm). EGR valve outlet pipe Drive belt tensioner assembly. Torque the tensioner bolts to 37 ft. lbs. (50 Nm). Electrical connector to the ECT sensor Thermostat housing Upper intake plenum. Torque the intake plenum bolts to 88 inch. lbs. (10 Nm). Throttle body support bracket Throttle cable bracket to the cylinder head mounting bracket and the cables to the throttle body lever EGR heat shield Fuel rail. Torque the fuel rail bolts to 88 inch. lbs. (10 Nm). Fuel lines Fuel regulator vacuum line Fuel injector electrical connectors Vacuum lines to the intake manifold MAP sensor Spark plug wires Fuel injector sight shield and air inlet duct Negative battery cable
2. Refill and bleed the cooling system.
3. Run the engine and check for leaks and proper engine operation.

Hope this help (remember rated this).

Yes. You should be able to replace it without removing the intake manifold. The bolts are very hard to reach, but it can be done with the proper set of sockets and universal joint extensions. I know it looks impossible. If in doubt, take it to a reputable repair shop. Don't let anybody charge you for intake manifold removal.

FORD: 1997-2000 EXPLORER, MOUNTAINEER
ISSUE: A "knocking" noise at start up for up to 2 minutes from the left hand front chain cassette area may occur on some vehicles. After engine shutdown, the tensioner oil supply gallery empties. The noise may be due to air entering the left hand tensioner when the engine is restarted.
ACTION: Replace the left hand camshaft tensioner with a revised Tensioner Kit. Refer to the Instruction Sheet within the Tensioner Kit for service procedure details.
WARNING: THE XU2Z-6K254-AA TENSIONER KIT IS FOR INSTALLATION ON THE LEFT SIDE OF THE ENGINE ONLY. INSTALLATION OF THIS KIT ON THE RIGHT SIDE OF THE ENGINE MAY RESULT IN ENGINE FAILURE. IF A TENSIONER IS NEEDED FOR THE RIGHT SIDE OF THE ENGINE, USE KIT XU3Z-6K254-BA.
PART NUMBER PART NAME XU2Z-6K254-AA Tensioner Kit - Left Side XU3Z-6K254-BA Tensioner Kit - Right Side

SECTION 303-01B: Engine — 4.0L SOHC 1998 Explorer/Mountaineer Workshop Manual
IN-VEHICLE REPAIR Timing Drive Components —LH Hydraulic Chain Tensioner Removal and Installation

1. Remove the upper intake manifold. For additional information, refer to Intake Manifold—Upper in this section.

Intake Manifold —Upper Removal

1. Disconnect the battery ground cable (14301). For additional information, refer to Section 414-01 .

1. Remove the air cleaner outlet tube (9B659); refer to Section 303-12 .

1. Remove the bolts and the accelerator control splash shield.

1. Remove the accelerator cable (9A758) and speed control actuator cable (9A825).
   1. Pull up on speed control actuator cable to remove.
   1. Rotate the throttle body cam and remove the accelerator cable from the cam.

1. Remove the screws, the accelerator cable and speed control actuator cable.

1. Disconnect the RH upper intake manifold vacuum connection.

1. Disconnect the idle air control (IAC) valve electrical connector.

1. Disconnect the TP sensor electrical connector.

1. Disconnect the engine vacuum regulator (EVR) and the variable induction system (VIS) solenoid electrical connections.

1. Disconnect the crankcase ventilation hose (6853).

1. Disconnect the power brake booster vacuum line.

1. Remove the 12 bolts.

1. NOTE: Inspect the O-rings and replace as necessary.
   Disconnect the LH fuel vapor management valve (VMV) hose.

1. NOTE: Inspect the O-rings and replace as necessary.
   Disconnect the RH VMV hose and remove the upper intake manifold.

1. Remove the thermostat housing. For additional information, refer to Section 303-03 .

1. Remove the LH camshaft tensioner.
   • If using a new washer, tighten to 44 Nm (32 lb-ft).
   • If using the old washer, tighten to 67 Nm (49 lb-ft).

1. Remove the pipe plug, and the oil volume reduction plug.

1. NOTE: Be sure to install the new oil volume reduction plug supplied with the hydraulic chain tensioner.
   To install, reverse the removal procedure.

please rate as fixed if this helps you

NO you dont have to take the intake off it should be right on the fuel rail with either 1 or 3 bolts if i remember right it will be the only thing on the rail with a vacuum hose on it.