Ford Freestar, Monterey 2004-2006

Intake Manifold


Removal & Installation

Lower Manifold
  1. Remove or disconnect the following:
    The lower intake manifold is sealed at each corner with sealer. To break the seal it may be necessary to pry on the front of the intake manifold with a prybar. If it is necessary, use care to prevent damage to the machined surfaces.

    Fuel system pressure
    Upper intake manifold
    Fuel supply manifold
    Water bypass tube from the heater water outlet tube
    Heater hoses from manifold
    Upper radiator hose
    Electrical wiring harnesses
    Lower intake manifold retaining bolts. Note the location of the 6 long bolts and 8 short bolts.

    Lower intake manifold

    Click image to see an enlarged view

    Fig. Lower intake manifold and related components-3.9L and 4.2L engines



To install:

  1. Thoroughly clean all gasket mating surfaces.
    When using silicone rubber sealer, assembly must occur within 5 minutes after sealer application. After this time, the sealer may start to set up and its sealing effectiveness may be reduced.

  3. Install or connect the following:

    Apply a 3mm bead of RTV silicone sealer at each corner where the cylinder head joins the engine block

    Click image to see an enlarged view

    Fig. Lower intake manifold bolt torque sequence-3.9L and 4.2L engines

    Front and rear intake manifold seals
    Lower intake manifold into position on the cylinder block, using new gaskets
    Install intake bolts in their original locations. Tighten in 2 steps in sequence to 44 inch lbs. (5 Nm), then again to 89 inch lbs. (10 Nm).
    Heater hoses
    Water bypass hose
    Fuel supply manifold
    Upper intake manifold
    Upper radiator hose

  5. Fill and bleed the cooling system.
  7. Start the engine and check for leaks.