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Home › Mercury › 1993 › Villager LS › Repair and Diagnosis › Engine Performance › Remove, Overhaul & Install › Engine Controls - Removal, Overhaul & Installation › Fuel Systems › Intake Plenum › Removal

Intake Plenum: Removal

  1. Drain cooling system.
  2. Disconnect negative battery cable.
  3. Remove air duct and resonance chamber. See AIR DUCT  .
  4. Disconnect Throttle Position (TP) sensor electrical connector. See Figure .
  5. Remove TP sensor or electrical connector from EGR Control (EGRC) bracket.
  6. Disconnect idle switch electrical connector.
  7. Disconnect and plug front throttle body coolant hose.
  8. Disconnect and plug coolant hose which is connected to top heater pipe.
  9. Disconnect EGRC solenoid-to-throttle body vacuum hose.
  10. Disconnect EGR valve-to-EGRC solenoid vacuum hose.
  11. Remove two EGRC bracket bolts then lower EGRC bracket from intake plenum.
  12. Disconnect carbon canister-to-intake plenum vacuum hose. See Fig 1 .
    Fig 1: Disconnecting Carbon Canister-To-Intake Plenum
    G00154544Courtesy of FORD MOTOR CO.
  13. Noting position for reassembly reference, disconnect Nos. 1, 3, and 5 spark plug wires from spark plugs then remove spark plug wire boots from in between intake plenum runners.
  14. Remove two spark plug wire bracket bolts and brackets from intake plenum.
  15. Remove distributor cover.
    16. NOTE: Distributor cap screws are not removable from distributor cap.
  16. Unscrew three distributor cap screws.
  17. Remove distributor cap from distributor. Position distributor cap and wires aside to gain access to main engine wiring harness.
  18. Disconnect rear heater valve vacuum hose from right side of intake plenum, if equipped. See Fig 2 .
    Fig 2: Disconnecting Rear Heater Valve Vacuum Hose
    G00154545Courtesy of FORD MOTOR CO.
  19. Remove wiring harness bracket from right side of intake plenum and set aside.
  20. Disconnect speed control cable from throttle lever, if equipped.
  21. Disconnect accelerator cable from throttle lever. See Fig 3 .
    Fig 3: Disconnecting Accelerator Cable
    G00154546Courtesy of FORD MOTOR CO.
  22. Remove speed control cable from hanging support, if equipped.
  23. Remove accelerator cable from bracket attached to top of intake plenum.
  24. Remove speed control cable, if equipped, then accelerator cable from bracket on top of intake plenum and position aside.
  25. Disconnect brake booster vacuum hose from left side of intake plenum. See Fig 4 .
    Fig 4: Disconnecting Brake Booster Vacuum Hose
    G00154547Courtesy of FORD MOTOR CO.
  26. Remove Exhaust Gas Recirculation (EGR) pipe from EGR valve.
  27. Disconnect Exhaust Gas Recirculation Temperature (EGRT) sensor electrical connector, if equipped.
  28. Disconnect Bypass Air (BPA) valve electrical connector.
  29. Disconnect Idler Control-Fast Idle Control (IAC-FIC) assembly connectors. See Fig 5 .
    Fig 5: Disconnecting Idle Air Control-Fast Idle Control Connectors
    G00154548Courtesy of FORD MOTOR CO.
  30. Disconnect fuel pressure regulator-to-intake manifold vacuum line from fuel pressure regulator.
  31. Disconnect main engine wiring harness clips from breather tube brackets.
  32. Remove two ground wire bolts from intake plenum and position ground wires and main wiring harness aside. See Fig 6 .
    Fig 6: Removing Two Ground Wire Bolts From Plenum
    G00154549Courtesy of FORD MOTOR CO.
  33. Remove two front breather tube bracket-to-intake plenum bolts.
  34. Disconnect front breather hose from front rocker arm cover. See Fig 7 .
    Fig 7: Disconnecting Front Breather Hose From Rocker Arm Cover
    G00154550Courtesy of FORD MOTOR CO.
  35. Remove five Allen-head intake plenum bolts. See Fig 8 .
    Fig 8: Remove Five Allen-Head Intake Plenum Bolts
    G00154551Courtesy of FORD MOTOR CO.
  36. Remove intake plenum. Discard gasket.
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