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 heater water hoses.
8. Disconnect the two PCV heater hoses from the water heater tube





9. Disconnect the upper radiator hose.





10. Remove the water bypass hose.
1 Loosen the water bypass hose clamps.
2 Remove the water bypass hose.





11. Disconnect the eight fuel injector electrical connectors.
12. Disconnect the fuel line.





13. Disconnect the ground strap at the rear of the lower intake manifold.





14. Disconnect the water temperature indicator sender electrical connector.
15. Remove the camshaft position (CMP) sensor and the camshaft synchronizer.





16. Remove the bolts.





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

Installation





1. Note: Use Metal Surface Cleaner F4AZ-19A536-RA or equivalent meeting Ford specification WSE-M5B392-A to clean the gasket surfaces of the lower intake manifold, cylinder heads, and the cylinder block.

Apply a 1.6 mm (0.06) bead of sealer in the corners where the cylinder head and cylinder block meet.
- Use Silicone Gasket and Sealant F7AZ-19554-EA or equivalent meeting Ford specification WSE-M4G323-A4.





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 in two steps.
- Step 1: Tighten to 10 Nm (89 inch lbs.).
- Step 2: Tighten to 32 Nm (24 ft. lbs.).
5. Install the camshaft position (CMP) sensor and the camshaft synchronizer.





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





7. Connect the water temperature indicator sender electrical connector.





8. Connect the eight fuel injector electrical connectors.
9. Reconnect the fuel line.





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





11. Connect the upper radiator hose.





12. Connect the heater water hoses.





13. Install the wire harness retainer nut.





14. Connect the engine coolant temperature (ECT) electrical connector.





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