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

Upper Intake Manifold: Installation

Install new intake manifold gaskets and position the intake manifold.
Install the 8 intake manifold bolts and tighten the upper intake manifold bolts in 2 stages in the sequence shown.
- Stage 1: Tighten to 6 Nm (53 lb-in).
- Stage 2: Tighten to 10 Nm (89 lb-in).
  
  Fig 1: Identifying Tightening Sequence Of Intake Manifold Bolts
  Courtesy of FORD MOTOR CO.
Connect the 2 engine harness pin-type retainers.

Fig 2: Locating Engine Harness Pin-Type Retainers
Courtesy of FORD MOTOR CO.
Connect the 4 engine harness pin-type retainers.

Fig 3: Locating Engine Harness Pin-Type Retainers
Courtesy of FORD MOTOR CO.
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

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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.