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.

2006 Ford Freestar BaseFACTORY OEM SERVICE PROCEDURE

Lower Intake Manifold: Installation

Clean all gasket sealing surfaces with metal surface cleaner.

NOTE: Front seal shown, rear seal similar.

Install the lower intake manifold front and rear seals.
1. Apply a bead of silicone gasket and sealer to the intake manifold front and rear seal mounting points as shown.
2. Install the new lower intake manifold front and rear seals.
  
  Fig 1: Identifying Lower Intake Manifold Front And Rear Seals
  Courtesy of FORD MOTOR CO.
Install the new intake manifold gaskets.

Fig 2: Locating Intake Manifold Gaskets
Courtesy of FORD MOTOR CO.

NOTE: The lower intake manifold must be installed within 4 minutes of applying sealant.

Position the lower intake manifold.
1. Apply a bead of silicone gasket and sealer to the lower intake manifold mounting points (at the front and rear seal).
2. Position the lower intake manifold.
  
  Fig 3: Identifying Lower Intake Manifold
  Courtesy of FORD MOTOR CO.

NOTE: Make sure the bolts are installed in the correct locations.

Factory Service Tools

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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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