Lower

REMOVAL
1. Drain engine cooling system .
2. Remove upper intake manifold.





3. Remove fuel injectors and fuel injection supply manifold.
4. Remove heater water outlet hose.
5. Remove lower intake manifold retaining bolts/studs.
6. Remove lower intake manifold.

CAUTION: The lower intake manifold is sealed at each end with silicone sealer. To break the seal, it may be necessary to pry on the front of the lower intake manifold with a prybar. If it is necessary to pry on the lower intake manifold, use care to prevent damage to machined surfaces.

7. Remove and discard intake manifold gaskets and end seals.





8. If lower intake manifold is to be disassembled perform the following:
- Remove water outlet connection and water thermostat.
- Remove engine coolant temperature sensor (ECT sensory).
- Remove heater elbow.
- Remove all vacuum and electrical fittings.

INSTALLATION
1. The lower intake manifold, cylinder head and cylinder block mating surfaces should be clean and free of old gasketing material. Use a suitable solvent to clean these surfaces.

NOTE: Lightly oil all retaining bolt and stud threads before installation with Super Premium SAE 5W30 Motor Oil XO-5W30-QSP or equivalent oil meeting Ford specification WSS-M2C153-G.

2. If lower intake manifold was disassembled:
a. Apply Pipe Sealant with Teflon D8AZ-19554-A or equivalent meeting Ford specification WSK-M2G350-A2 and ESR-M18P7-A to the threads of the engine coolant temperature sensor, all vacuum fittings, heater elbows, and electrical fittings (if equipped).
b. Install water hose connection (note direction) and water thermostat. Tighten retaining bolts to 8-11 Nm (71-97 in. lbs.).

3. Apply a 3-4 mm (0.125 inch) bead of Silicone Gasket and Sealant F6AZ-19562-AA or equivalent meeting Ford specifications WSE-M4G323-AA at each corner where the cylinder head joins the cylinder block.

NOTE:
- Prior to applying sealer, clean sealing surfaces of cylinder heads and lower intake manifold with Metal Surface Cleaner F4AZ-19A536-RA or equivalent meeting Ford specification WSE-M5B392-A to remove all residues that may interfere with the sealer's ability to adhere.
- When the lower intake manifold is removed, always use new intake manifold gaskets upon reassembly.
- When using silicone sealer, assembly must occur within 7 minutes after sealer application. After this time, the sealer may start to set up, and its sealing effectiveness may be reduced.

4. Install new front and rear intake manifold end seals.








5. Install new intake manifold gaskets
6. Carefully lower intake manifold into position on cylinder block and cylinder head. Use locating pins as necessary to guide lower intake manifold.





7. Install bolts and stud bolt in their original locations.





8. Tighten bolts and stud bolts in numerical sequence to the following specifications in two steps:
a. 5 Nm (45 in. lbs.).
b. 8-12 Nm (71-106 in. lbs.).
9. Install front crankcase ventilation tube so that the mounting bracket sits over the lower intake manifold stud. Tighten nut on stud to 20-30 Nm (15-22 ft. lbs.).
10. Install fuel injectors and fuel injection supply manifold. Tighten fuel injection supply manifold to lower intake manifold bolts to 8-11 Nm (71-97 in. lbs.). Tighten fuel pressure bracket bolt to 20-30 Nm (15-22 ft. lbs.).
11. Install upper intake manifold.
12. Fill engine cooling system.

CAUTION: This engine has aluminum cylinder heads and requires a special corrosion inhibiting coolant to avoid cooling system damage.

13. Start engine and check for leaks.