Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
2005 Ford Freestar BaseFACTORY OEM SERVICE PROCEDURE
Upper Intake Manifold: Installation
- Install new intake manifold gaskets and the intake manifold.
- Install the 8 intake manifold bolts and tighten the upper intake manifold bolts in 2 stages in the sequence shown in illustration.
- Stage 1: Tighten to 6 Nm (53 lb-in).
- Stage 2: Tighten to 10 Nm (89 lb-in).
- Connect the 2 engine harness pin-type retainers.
- Connect the 4 engine harness pin-type retainers.
- Connect the coolant outlet hose to the intake manifold.
- Connect the coolant inlet hose to the intake manifold.
- Connect the vacuum tube connector to the upper intake manifold.
CAUTION:
Make sure the spark plug boots are positioned so the spark plug wires do not contact the exhaust manifold.
Factory Service Tools
Use the Manual With the Right Hardware
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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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