Lower

Removal
1. Remove the upper intake manifold.





2. Disconnect the fuel injector electrical connectors.





3. Disconnect the Exhaust Gas Recirculation (EGR) valve vacuum hose.





4. Remove the EGR valve to exhaust manifold tube upper fitting.
5. Remove the upper radiator hose from the lower intake manifold.





6. Disconnect the IMRC electrical connector and the fuel pressure regulator vacuum line.
7. Disconnect the fuel lines.





8. Disconnect the water bypass hose.
1 Release and slide the hose clamp.
2 Disconnect the water bypass hose.





9. Note: Remove the lower intake manifold including the fuel injection supply manifold, the fuel injectors and the IMRC.

Note: If the lower intake manifold will be replaced, the fuel injection supply manifold, fuel injectors and the IMRC will need to be transferred.

Remove the bolts and the lower intake manifold.








10. Remove and discard the lower intake manifold sealing components.


Installation

1. Refer to the illustration for intake manifold sealing component locations.





2. Install the lower intake manifold front and rear end seals.
1 Apply a bead of sealant to the intake manifold front and rear end seal mounting points as indicated.
- Use Silicone Gasket and Sealant F7AZ-19554-EA or equivalent meeting Ford specification WSE-M4G323-A4.
2 Install the lower intake manifold front and rear end seals.





3. Install the intake manifold gaskets.





4. Note: The lower intake manifold must be installed within four minutes of applying sealant.

Position the lower intake manifold.
1 Apply a bead of sealant to the lower intake manifold mounting at the points indicated.
- Use Silicone Gasket and Sealant F7AZ-19554-EA or equivalent meeting Ford specification WSE-M4G323-A4.
2 Position the lower intake manifold.





5. Note: Refer to the location note made during removal and make sure the bolts are installed in the correct location.

Install the six long bolts.





6. Install the eight short bolts.





7. Tighten the bolts in the sequence shown in two stages.
- Stage 1: Tighten the bolts to 5 Nm (44 inch lbs.).
- Stage 2: Tighten the bolts to 10 Nm (89 inch lbs.).





8. Connect the water bypass hose.
1 Position the water bypass hose.
2 Position the hose clamp.
9. Connect the fuel lines, if necessary.





10. Connect the fuel pressure regulator vacuum line and the IMRC electrical connector.
11. Install the upper radiator hose to the lower intake manifold.





12. Connect the EGR valve vacuum hose.





13. Install the EGR valve to exhaust manifold tube upper fitting.





14. Connect the fuel injector electrical connectors.
15. Install the upper intake manifold.