Lower Intake Manifold: Installation

WARNING: This page is about a different car, the 2003 Mercury Sable and 2003 Ford Taurus. However, it is still accessible from the selected car via links, so may be relevant.

Using metal surface cleaner, clean all the sealing surfaces.

Fig 1: Identifying Sealing Surfaces Of Lower Intake Manifold
Courtesy of FORD MOTOR CO.

NOTE: If the lower intake manifold is not secured within four minutes, the sealant must be removed and the sealing area cleaned with metal surface cleaner. Allow to dry until there is no sign of wetness or four minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.

Fig 2: Identifying Silicone Gasket

Courtesy of FORD MOTOR CO.

Apply silicone gasket and sealant at the four cylinder block-to-cylinder head seams.
Install the lower intake manifold gaskets and end seals.
- Position the intake manifold gaskets.
- Position the intake manifold end seals.
Fig 3: Identifying Lower Intake Manifold Gaskets And End Seals
Courtesy of FORD MOTOR CO.
Install the intake manifold. Tighten the bolts in two stages in the sequence shown.
- Stage 1: Tighten to 15 Nm (11 lb-ft).
- Stage 2: Tighten to 32 Nm (24 lb-ft).
Fig 4: Identifying Bolts Of Lower Intake Manifold
Courtesy of FORD MOTOR CO.
Install the camshaft position (CMP) sensor. For additional information, refer to REMOVAL & INSTALLATION .
Connect the upper radiator hose to the thermostat housing.

Fig 5: Connecting Camshaft Position (CMP) Sensor Of Lower Intake Manifold
Courtesy of FORD MOTOR CO.
Connect the engine coolant temperature (ECT) sensor electrical connector and the degas bottle hose.

Fig 6: Connecting Engine Coolant Temperature (ECT) Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
Connect the heater hose and the ECT sender electrical connector.

Fig 7: Connecting Heater Hose And ECT Sender Electrical Connector
Courtesy of FORD MOTOR CO.
Install the fuel injection supply manifold and fuel injectors as an assembly.

Fig 8: Installing Fuel Injection Supply Manifold
Courtesy of FORD MOTOR CO.
Connect the fuel injector electrical connectors.

Fig 9: Connecting Fuel Injector Electrical Connectors
Courtesy of FORD MOTOR CO.
Connect the fuel rail pressure (FRP) sensor electrical and vacuum connections.

Fig 10: Connecting Fuel Rail Pressure (FRP) Sensor Electrical And Vacuum Connections
Courtesy of FORD MOTOR CO.
Install both valve covers. For additional information, refer to VALVE COVER LH and VALVE COVER RH .
Install the upper intake manifold. For additional information, refer to UPPER INTAKE MANIFOLD .
Connect the fuel tube spring lock coupling. For additional information, refer to FUEL TANK & LINES .
Fill and bleed the engine cooling system. For additional information, refer to ENGINE COOLING .