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Quick n Easy COP Replacement

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Old 02-12-2018, 03:11 PM
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Quick n Easy COP Replacement

I had to replace my 2001 COPs last night, took me just under an hour, didn't have a chance for pics but here is my quick checklist:

Front bank:
Disconnect 1x COP plug from COP, unbolt and remove.
Replace plug if required
Replace and reconnect COP
Repeat for other 2 COPs on front bank. Doing each COP one at a time removes any possibility of COP wires getting mixed up...

Rear bank:
Remove air filter box from throttle body (MAF connector and hose clamp)
Remove throttle cable mounts from manifold (3 bolts 10mm head), unhook the throttle cable from the throttle body
Unbolt EGR from rear right (as facing the engine) of the manifold (2x 10mm head)
Unbolt cable mount bracket from manifold to rear of EGR (1x nut 8mm head)
Remove 3x vacuum pipes from rear of manifold (2 pull off, one has a clamp)
Unbolt upper manifold (8x captive bolts 8mm head)
Unsecure two large wring connectors mounted on plastic standoff at rear left (facing engine), of manifold

Lift upper manifold, unhook EGR pipe from manifold as it lifts, secure the manifold with cord to the bonnet catch to keep 4in clearance below manifold.

Cover the intakes with cloth.

Disconnect 1x COP plug from COP, unbolt and remove.
Replace plug if required
Replace and reconnect COP
Repeat for other 2 COPs on rear bank

Double-check all the COP connections, remove the cloth covering over the intakes you placed there earlier, lower the upper manifold back into place, working the EGR pipe into the manifold as you do so.

Reconnect everything you removed

Start up and road test!

Mine runs smoother, seems a bit more power and the hesitation/shudder at 1500rpm in o/drive is gone...
 
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Old 02-14-2018, 05:54 AM
G Ford Fan
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Good write up, thanks! I have the 2.3 so mines considerably easier. Good reference for folks thinking about tackling this job on the V6
 
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Old 02-26-2018, 06:28 PM
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Best repair ever - long highway run before gave highest mpg of 26 (Euro gallons), after COP replacement a similar run yielded 29!!!
 
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