Ford Freestar, Monterey 2004-2006
Upper Intake Manifold (Plenum)
Removal & Installation
Remove or disconnect the following:
Negative battery cable
Fuel system pressure
Wiper motor and pivot assembly
Cowl top panel
Air cleaner outlet tube
Cruise control cable
Evaporative (EVAP) return tube
Brake booster vacuum hose
Exhaust Gas Recirculation (EGR) tubes and connector
Remaining electrical connectors
Spark plug wires
Fig. Upper intake manifold-3.9L and 4.2L engines
Fig. Upper intake manifold tightening sequence-3.9L and 4.2L engines
Installation is the reverse of the removal procedure, using the following torque specifications.
Intake manifold bolts and tighten all bolts in steps in sequence to 53 inch lbs. (6 Nm), then to 89 inch lbs. (10 Nm).
Fill and bleed the engine cooling system.
Connect the negative battery cable.
Start the engine and check for leaks.