Removal & Installation (Lower)
WARNING: This page is about a different car, the 2002 Mercury Villager. However, it is still accessible from the selected car via links, so may be relevant.
- Relieve fuel system pressure. Remove upper intake manifold. See REMOVAL & INSTALLATION (UPPER) . Disconnect 6 fuel injector electrical connectors. Disconnect engine coolant temperature sensor connector. Remove 2 ground wire bolts. Disconnect oxygen sensor connector. Remove crossover breather tube from engine front cover. Position breather tube and wiring harness aside. Disconnect water temperature sender connector.
- Disconnect fuel lines. Remove fuel rail and position fuel rail and insulators aside. Remove upper radiator hose from intake manifold. Remove upper radiator hose bracket bolt. Remove water by-pass hose from intake manifold. Remove bolt attaching water hose connection to engine front cover. Remove heater hose from top heater core pipe.
- Remove intake manifold bolts and nuts in 2 steps in sequence. See Fig 1. Remove lower intake manifold and discard gaskets. To install, reverse removal procedure using NEW gaskets. Install and tighten bolts and nuts in 3 steps in sequence to specification. See Fig 2. See TORQUE SPECIFICATIONS .
NOTE:
If installing a NEW lower intake manifold, cylinder head gasket must also be replaced.