Ford Freestar, Monterey 2004-2006

Upper Intake Manifold (Plenum)


Removal & Installation

  1. Remove or disconnect the following:

    Negative battery cable
    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



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).

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