2003 Ford Windstar BaseFACTORY OEM SERVICE PROCEDURE

Lower Intake Manifold: Installation

  1. Refer to the illustration for intake manifold sealing component locations.
    Fig 1: Installing Lower Intake Manifold Sealing & Gasket
    G01307660Courtesy of FORD MOTOR CO.
  2. Install the lower intake manifold front and rear end seals.
    1. Apply a bead of silicone gasket and sealant to the intake manifold front and rear end seal mounting points as shown.
    2. Install the lower intake manifold front and rear end seals.
      Fig 2: Identifying Lower Intake Manifold Front & Rear End Seals
      G01307661Courtesy of FORD MOTOR CO.
  3. Install the intake manifold gaskets.
    Fig 3: Identifying Intake Manifold Gaskets
    G01307662Courtesy of FORD MOTOR CO.
    4. NOTE: The lower intake manifold must be installed within four minutes of applying sealant.
  4. Position the lower intake manifold.
    1. Apply a bead of silicone gasket and sealant to the lower intake manifold mounting at the points shown.
    2. Position the lower intake manifold.
      Fig 4: Identifying Lower Intake Manifold
      G01307663Courtesy of FORD MOTOR CO.
    5. NOTE: Make sure the bolts are installed in the correct locations.
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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.

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