Ford Freestar, Monterey 2004-2006

Upper Intake Manifold (Plenum)

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Removal & Installation



  1. Remove or disconnect the following:

    Negative battery cable
     
    Coolant
     
    Fuel system pressure
     
    Wiper motor and pivot assembly
     
    Cowl top panel
     
    Air cleaner outlet tube
     
    Accelerator cable
     
    Cruise control cable
     
    Cable bracket
     
    Evaporative (EVAP) return tube
     
    Brake booster vacuum hose
     
    Exhaust Gas Recirculation (EGR) tubes and connector
     
    Remaining electrical connectors
     
    Spark plug wires
     
    Coolant hoses
     
    Intake manifold

    Click image to see an enlarged view

    Fig. Upper intake manifold-3.9L and 4.2L engines



    Click image to see an enlarged view

    Fig. Upper intake manifold tightening sequence-3.9L and 4.2L engines

     

  2.  

To install:

  1. 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).
     

  2.  
  3. Fill and bleed the engine cooling system.
  4.  
  5. Connect the negative battery cable.
  6.  
  7. Start the engine and check for leaks.
  8.  

 
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