Lower
REMOVAL1. Drain the cooling system.
2. Disconnect the radiator overflow hose and position aside.
3. Remove the upper intake manifold.
4. Disconnect the coolant bypass hose from the water heater tube.
5. Disconnect the engine coolant temperature (ECT) electrical connector.
6. Remove the water heater tube nut.
7. Disconnect the two heater core hoses.
8. Disconnect the water heater tube from the intake manifold and remove.
9. Disconnect the upper radiator hose from the intake manifold.
10 .Remove the water bypass hose.
a. Loosen the water bypass hose clamps.
b. Remove the water bypass hose.
11. Disconnect the eight fuel injector electrical connectors.
12. Disconnect the fuel lines.
13. Disconnect the ground strap at the rear of the lower intake manifold.
14. Disconnect the water temperature indicator sender connector.
15. Remove the camshaft position sensor (CMP sensor) and camshaft synchronizer.
16. Remove the twelve lower intake manifold bolts.
17. Remove the lower intake manifold and discard the lower intake manifold gaskets.
INSTALLATION
1. Use combustion chamber cleaner and a suitable wire brush to remove carbon buildup from the EGR passages in the upper and lower intake manifolds and cylinder head.
^ Use Metal Surface Cleaner F4AZ-19A536-RA or equivalent meeting Ford specification WSE-MSB392-A to clean the gasket surfaces of the lower intake manifold, cylinder heads, and cylinder block.
NOTE: Before installing the lower intake manifold, the EGR exhaust port must be clean and free of obstructions.
2. Apply sealer in the corners where the cylinder head and block meet.
^ Use Silicone Gasket and Sealant F6AZ-19562-AA or equivalent meeting Ford specification WSE-M4G323-A6.
3. Position the four lower intake manifold gaskets.
^ Install the intake manifold seal tabs to notch in the lower intake manifold gaskets.
^ Press firmly along the entire length of the intake manifold seal until silicone sealant is visible.
4. Position the lower intake manifold and start the twelve lower intake manifold bolts.
5. Tighten the lower intake manifold in two stages.
^ Stage 1: 6-14 Nm (5-10 ft. lbs.).
^ Stage 2: 31-34 Nm (23-25 ft. lbs.).
6. Install the camshaft position sensor and camshaft synchronizer.
7. Connect the rear ground strap to the rear of the lower intake manifold.
8. Connect the water temperature indicator sender connector.
9. Connect the eight fuel injector electrical connectors.
10. Reconnect the fuel lines.
11. Install the water bypass hose.
a. Position the water bypass hose.
b. Install the two water bypass hose clamps.
12. Connect the upper radiator hose.
13. Position the water heater tube nut and install the fitting into the intake manifold.
14. Connect the two heater core hoses.
15. Install the water heater tube nut.
16. Connect the ECT electrical connector.
17. Connect the water heater bypass hose to the heater tube.
18. Install the upper intake manifold.
19. Fill the cooling system.