Ford Freestar, Monterey 2004-2006

Intake Manifold

Print

Removal & Installation



Lower Manifold
  1. Remove or disconnect the following:
    NOTE
    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.



    Coolant
     
    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

     

  2.  

To install:

  1. Thoroughly clean all gasket mating surfaces.
    NOTE
    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.

  2.  
  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
     

  4.  
  5. Fill and bleed the cooling system.
  6.  
  7. Start the engine and check for leaks.
  8.  

 
label.common.footer.alt.autozoneLogo