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Home >> Mercury >> 2002 >> Villager Base >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> Engine - 3.3L >> In-Vehicle Repair >> Intake Manifold - Lower >> Installation

Intake Manifold - Lower: Installation

  1. Position the lower intake manifold gaskets.
    Fig 1: Positioning Lower Intake Manifold Gaskets
    G03411346Courtesy of FORD MOTOR CO.
  2. Position the lower intake manifold.
    Fig 2: Positioning Lower Intake Manifold
    G03411347Courtesy of FORD MOTOR CO.
  3. Install the lower intake manifold bolts and nuts in the sequence shown.
    • Stage 1: Tighten all bolts and nuts to 4 N.m (35 lb-in).
    • Stage 2: Tighten all bolts and nuts to 9 N.m (80 lb-in).
    • Stage 3: Tighten all bolts and nuts to 9 N.m (80 lb-in).
      Fig 3: Installing Lower Intake Manifold Bolts And Nuts
      G03411348Courtesy of FORD MOTOR CO.
  4. Connect the heater hose to the heater hose pipe.
    1. Connect the heater hose to the heater hose pipe.
    2. Position the clamp.
      Fig 4: Connecting Heater Hose To Heater Hose Pipe
      G03411349Courtesy of FORD MOTOR CO.
  5. Connect the coolant bypass hose to the water hose connection.
    1. Connect the coolant bypass hose to the water hose connection.
    2. Position the clamp.
      Fig 5: Connecting Coolant Bypass Hose To Water Hose Connection
      G03411350Courtesy of FORD MOTOR CO.
  6. Install the upper timing belt cover bolt.
    Fig 6: Installing Upper Timing Belt Cover Bolt
    G03411351Courtesy of FORD MOTOR CO.
  7. Connect the upper radiator hose.
    1. Connect the upper radiator hose.
    2. Position the clamp.
    3. Install the bolt.
      Fig 7: Connecting Upper Radiator Hose
      G03411352Courtesy of FORD MOTOR CO.
    8. CAUTION: Make sure the fuel injection supply manifold insulators are installed with the fuel injection supply manifold.
  8. Install the fuel injection supply manifold and insulators.
    1. Position the fuel injection supply manifold and insulators.
    2. Install the bolts.
      Fig 8: Installing Fuel Injection Supply Manifold And Insulators
      G03411353Courtesy of FORD MOTOR CO.
  9. Position back the fuel line bracket and install the retainers.
    Fig 9: Installing Retainers Positioning Back Fuel Lines
    G03411354Courtesy of FORD MOTOR CO.
  10. Connect the fuel lines.
    1. Position the fuel line.
    2. Install the bolts.
    3. Connect the fuel hose.
    4. Install the clamp.
      Fig 10: Connecting Fuel Lines
      G03411355Courtesy of FORD MOTOR CO.
  11. Install the spark plug wire bracket bolt.
    1. Position the spark plug wire bracket.
    2. Install the bolt.
      Fig 11: Installing Spark Plug Wire Bracket Bolt
      G03411356Courtesy of FORD MOTOR CO.
  12. Connect the water temperature indicator sender electrical connector.
    Fig 12: Connecting Water Temperature Indicator Sender Electrical Connector
    G03411357Courtesy of FORD MOTOR CO.
  13. Position the PCV breather tube and wire harness.
    1. Position the breather tube and wire harness.
    2. Connect the PCV breather hose.
    3. Position the clamp.
    4. Install new wire straps.
      Fig 13: Positioning PCV Breather Tube And Wire Harness
      G03411358Courtesy of FORD MOTOR CO.
  14. Connect the HO2S electrical connector.
    1. Clip the wire harness to the bracket.
    2. Connect the HO2S electrical connector.
      Fig 14: Connecting HO2S Electrical Connector
      G03411359Courtesy of FORD MOTOR CO.
  15. Install the ground wire bolts.
    Fig 15: Installing Ground Wire Bolts
    G03411360Courtesy of FORD MOTOR CO.
  16. Connect the electrical connectors.
    1. Connect the fuel injector electrical connectors.
    2. Connect the ECT sensor electrical connector.
      Fig 16: Connecting Electrical Connectors
      G03411361Courtesy of FORD MOTOR CO.
  17. Install the upper intake manifold. For additional information, refer to INTAKE MANIFOLD - UPPER .
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