To start with the 3.7L engine, the mechanic should first, turn off the ignition by retracting the key and joining the black negative terminal with the battery terminal, then unbolt the engine cover and if available the strut tower cross brace. Remove the air intake duct that is mated to the throttle body, PCV tube, EVAP canister vent solenoid, and throttle body electrical connectors and the line from the EVAP canister vent solenoid. Disconnect the brake booster vacuum hose and crankcase vent hose for the upper intake manifold, and also the bolting for the upper intake manifold, after which unbolt the upper intake manifold support bracket, and cover the ports with shop rags to prevent contamination. To service, the following steps are observed: removal of old gaskets, cleaning the mating faces, placing of new gaskets, and txkening of the bolts at the predetermined pattern. For the lower intake manifold, one has to wait for the engine to cool, then relieve fuel system pressure, then drain the cooling system, cover the drivebelt, then remove the thermostat housing. Lose the fuel line from the fuel rail, take off the fuel rail insulators, and pulled the electrical connectors from the injectors. Tighten the intake manifold mounting bolts only enough so that you can turn them with your hands next, then remove the bolts and clean the manifold gasket surfaces, replace the gasket and tighten the bolts where required to the correct measure of torque. Add more coolants and look for a few drips if the engine is running. Before conducting all the procedures mentioned in below for the 4.0L engine, the negative battery terminal should be removed and then the air intake duct should be disconnected, next is the coolant hoses should be clamped off and disconnected and finally the ignition coil and bracket should be removed. Some of the locations which must be disconnected include; various electrical connectors, brake booster vacuum hose and the EGR pipe and the final step is to remove the intake manifold and some mounting bolts which hold the manifold into position over the engine. Take a small scraper to scrape off the carbon deposits on the mating surfaces and replace the O-ring gasket around the intake runners before setting the manifold and tightening the intake manifold bolts finger tight then to the prescribed torque. Last, measure the amount of coolant inside the car and start the engine in order to look for traces of leakage.
Posted by FordPartsGiant Specialist