Lower

REMOVAL
1. Drain the engine cooling system.
2. Disconnect the radiator overflow hose and position aside.
3. Remove the upper intake manifold.





4. Disconnect the water bypass hose from the water heater tube.





5. Disconnect the Engine Coolant Temperature (ECT) electrical connector.





6. Remove the wire harness retainer nut.





7. Disconnect the two heater water hoses.





8. Remove the two PCV heater hoses from the water heater tube and 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.
1 Loosen the water bypass hose clamps.
2 Remove the water bypass hose.





11. Disconnect the 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 bolts in the sequence shown.





17. Remove the lower intake manifold and discard the lower gasket.

INSTALLATION





1. Apply sealer in the corners where the cylinder head and cylinder block meet.
- Use Silicone Gasket and Sealant F6AZ-19562-AA or equivalent meeting Ford specification WSE-M4G323-A6.

NOTE: 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.





2. Position the four lower 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.





3. Position the lower intake manifold and start the bolts.
4. Tighten the lower intake manifold bolts in the sequence shown using two steps.
- Step 1: Tighten to 6-14 Nm (5-10 ft. lbs.).
- Step 2: Tighten to 31-34 Nm (23-25 ft. lbs.).

5. Install the camshaft position sensor and camshaft synchronizer.





6. Connect the rear ground strap to the rear of the lower intake manifold.





7. Connect the water temperature indicator sender connector.





8. Connect the fuel injector electrical connectors.
9. Reconnect the fuel lines.





10. Install the water bypass hose.
1 Position the water bypass hose.
2 Install the two clamps.





11. Connect the upper radiator hose.





12. Position the nut and install the fitting into the intake manifold.





13. Connect the two heater water hoses.





14. Install the nut.





15. Connect the ECT electrical connector.





16. Connect the water heater bypass hose to the heater tube.
17. Connect the two PCV heater hoses to the heater tube.
18. Install the upper intake manifold.
19. Fill the engine cooling system.