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HOMESERVICE MANUALSFORD2003WINDSTAR BASEREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 1333 (ENGINE - 6.8L (3V) -- F250-F550 SUPER DUTY)DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIESINTAKE MANIFOLD ASSEMBLYASSEMBLY
2003 Ford Windstar Base

Intake Manifold Assembly: Assembly

2003 Ford Windstar BaseSECTION Assembly
WARNING: This page is about a different car, the 2006 Ford Pickup, 2006 Ford F550 Super Duty, 2006 Ford F450 Super Duty, and 2006 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.
    NOTE: Lubricate the new O-ring seals with clean engine oil prior to installation.
  1. Install new O-ring seals on each of the fuel injectors.
  2. Assemble the fuel injectors onto the fuel rail and install the locking clips.
  3. Install the fuel rail and fuel injector assembly onto the intake manifold.
  4. Install the 6 fuel rail bolts.
    • Tighten to 10 Nm (89 lb-in).
  5. Position the throttle body (TB) spacer.
  6. Install the 2 upper TB spacer bolts in 2 stages:
    • Stage 1: Tighten to 7 Nm (62 lb-in).
    • Stage 2: Tighten an additional 90 degrees.
  7. Install the 4 lower TB spacer bolts in 2 stages:
    • Stage 1: Tighten to 10 Nm (89 lb-in).
    • Stage 2: Tighten an additional 90 degrees.
  8. Install a new gasket and the throttle body (TB). Tighten the 4 bolts in 2 stages:
    • Stage 1: Tighten to 9 Nm (80 lb-in).
    • Stage 2: Tighten an additional 90 degrees.
  9. Position the intake manifold runner control (IMRC) actuator and install the 3 bolts.
    • Tighten to 10 Nm (89 lb-in).
  10. Install the IMRC rod C-clip.
RENDER: 1.0x

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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.