303-01A-1 Engine — 4.

0L SOHC 303-01A-1

IN-VEHICLE REPAIR
2. Remove the air cleaner outlet pipe. For
Intake Manifold additional information, refer to Section
303-04A.
Removal and Installation
3. Illustration 1 of 4. Remove the components in
the order indicated in the following illustration
1. Disconnect the battery ground cable. For and table.
additional information, refer to Section 414-00.

Item Part Number Description Item Part Number Description

1 — Accelerator cable 3 9E498 Vacuum hose
Removal Note 4 — Vacuum hose clamp
2 — Speed control cable 5 — Vacuum hose
Removal Note
(Continued)

2003 Explorer/Mountaineer, 9/2002

303-01A-2 Engine — 4.0L SOHC 303-01A-2

IN-VEHICLE REPAIR (Continued)

4. Illustration 2 of 4. Remove the components in
the order indicated in the following illustration
and table.

Item Part Number Description

6 14A464 Throttle position (TP) sensor
electrical connector
7 14A464 Idle air control (IAC) sensor
electrical sensor
8 12B637 Wiring harness retainer

2003 Explorer/Mountaineer, 9/2002

303-01A-3 Engine — 4.0L SOHC 303-01A-3

IN-VEHICLE REPAIR (Continued)

5. Illustration 3 of 4. Remove the components in
the order indicated in the following illustration
and table.

Item Part Number Description Item Part Number Description

9 9E498 Vacuum hose 13 W704310 EGR vacuum regulator
10 12B637 Wiring harness retainer solenoid mounting bolts
11 14A464 Exhaust gas recirculation 14 — EGR vacuum regulator
(EGR) vacuum regulator solenoid mounting bracket
solenoid electrical connector 15 9E469 EGR tube upper fitting
12 9E498 Vacuum hoses
(Continued)

2003 Explorer/Mountaineer, 9/2002

303-01A-4 Engine — 4.0L SOHC 303-01A-4

IN-VEHICLE REPAIR (Continued)

6. Illustration 4 of 4. Remove the components in
the order indicated in the following illustration
and table.

Item Part Number Description Item Part Number Description

16 9E498 Positive crankcase ventilation 20 9462 Intake manifold
(PCV) vacuum hose 21 9461 Intake manifold gaskets
17 95479 Vacuum hose clamp Removal Note
18 9G297 Vacuum hose
7. To install, reverse the removal procedure.
19 95479 Intake manifold mounting
bolts
(Continued)

2003 Explorer/Mountaineer, 9/2002

303-01A-5 Engine — 4.0L SOHC
IN-VEHICLE REPAIR (Continued)
Items 1 and 2: Accelerator Cable and Speed
Control Cable Removal Note
1. Disconnect the accelerator and the speed control
cables from the throttle body.
2. Remove the accelerator cable and the speed
control cable from the bracket. Position the
cables away from the intake manifold.
3. Disconnect the accelerator cable and the speed
control cable routing clips. Disconnect the
vacuum hose.
303-01A-5
4. CAUTION: It is important to twist the
spark plug wire boots while pulling upward
to avoid possible damage to the spark plug
wires.
NOTE: Spark plug wires must be connected to
the correct ignition coil terminal. Mark spark
plug wire locations before removing them.
Disconnect the spark plug wires.
5. Disconnect the knock sensor (KS) electrical
connector retainer.
2003 Explorer/Mountaineer, 9/2002
303-01A-6 Engine — 4.0L SOHC 303-01A-6

IN-VEHICLE REPAIR (Continued)

Item 21: Intake Manifold Gaskets Removal Note
1. CAUTION: Do not use metal scrapers,
wire brushes, power abrasive discs or other
abrasive means to clean the sealing surfaces.
These tools can cause scratches and gouges
which can make leak paths.
Clean the sealing surfaces, inspect the gaskets
and install new gaskets if necessary.

2003 Explorer/Mountaineer, 9/2002