2003 Ford Windstar BaseFACTORY OEM SERVICE PROCEDURE

Lower Intake Manifold: Removal

CAUTION: During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces, that enters the oil passages, coolant passages or the oil pan can cause engine failure.
  1. Partially drain the cooling system. For additional information, refer to ENGINE COOLING .
  2. Remove the upper intake manifold. For additional information, refer to UPPER INTAKE MANIFOLD .
  3. Remove the fuel injection supply manifold. For additional information, refer to ENGINE COOLING .
  4. Disconnect the exhaust gas recirculation (EGR) vacuum hose.
    Fig 1: Identifying Exhaust Gas Recirculation (EGR) Vacuum Hose
    G01307652Courtesy of FORD MOTOR CO.
  5. Loosen the nut and disconnect the EGR-to-exhaust manifold tube.
    Fig 2: Identifying EGR-To-Exhaust Manifold Tube Nut
    G01307653Courtesy of FORD MOTOR CO.
  6. Disconnect the heater hose.
    Fig 3: Identifying heater hose
    G01307654Courtesy of FORD MOTOR CO.
  7. Disconnect the upper radiator hose.
    Fig 4: Identifying Upper Radiator Hose
    G01307655Courtesy of FORD MOTOR CO.
  8. Disconnect the intake manifold runner control (IMRC) electrical connector.
    Fig 5: Locating Intake Manifold Runner Control (IMRC) Electrical Connector
    G01307656Courtesy of FORD MOTOR CO.
  9. Position the water bypass tube aside.
    1. Remove the bolts.
    2. Position the tube aside.
      Fig 6: Identifying Water Bypass Tube Bolt
      G01307657Courtesy of FORD MOTOR CO.
    10. NOTE: Note the location of the six long bolts for installation.
  10. Remove the lower intake manifold.
    1. Remove the bolts.
    2. Remove the intake manifold.
      Fig 7: Identifying Lower Intake Manifold Bolt
      G01307658Courtesy of FORD MOTOR CO.
  11. Remove the intake manifold runner control (IMRC) if necessary. .
  12. Remove and discard the lower intake manifold sealing components.
    Fig 8: Removing Lower Intake Manifold Sealing & Gasket
    G01307659Courtesy of FORD MOTOR CO.
  13. Clean gasket sealing surfaces with metal surface cleaner.
Chapter Navigation
Return to Chapter: Lower Intake Manifold
Factory Service Tools

Use the Manual With the Right Hardware

Pair factory procedures with proven DIY tools so the instructions are easier to execute.

Disclosure: Verified tool recommendations may earn an affiliate commission at no cost to you.

Shop Manual-Ready ToolsCompare Repair QuoteQuote Shield Pro

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.