OEM 2003 Mercury Sable Intake Manifold

2003 Mercury Sable Intake Manifold Parts Questions & Experts Answers

• Q: How to service and repair the lower intake manifold on 2003 Mercury Sable?

  A: The lower intake manifold repair process requires the engine cooling system drain and the removal of the fuel tube spring lock coupling. Start the service by removing the upper intake manifold before proceeding with left-hand and right-hand valve cover removal. Disconnect both electrical connections and vacuum lines of the Fuel Rail Pressure sensor and unwrap the electrical connectors of the fuel injectors. The technician should disconnect the heater hose followed by the separation of the Engine Coolant Temperature (ECT) sender electrical connector and ECT sensor electrical connector and degas bottle hose while removing the fuel injection supply manifold with its attached fuel injectors. The work begins with disconnecting the upper radiator hose from the thermostat housing followed by removal of the Camshaft Position (CMP) sensor and proceeds with unfastening the bolts that secure the lower intake manifold. Remove intake manifold gaskets while also removing end seals from their positions. Begin by using a metal surface cleaner to clean all surfaces which need to be sealed. Per the installation steps the lower intake manifold must be sealed within four minutes after which the sealant should be removed to allow for a second cleaning before drying. Use silicone gasket and sealant on the four cylinder block-to-cylinder head seams while simultaneously placing the correct orientation of lower intake manifold gaskets and end seals into position. The installation requires two-step torquing process beginning with 15 Nm (11 ft. lbs.) before proceeding to 32 Nm (24 ft. lbs.). The work sequence consists of reinstalling the CMP sensor followed by connecting the upper radiator hose to the thermostat housing and reconnecting both ECT sensor electrical connector as well as degas bottle hose after which the heater hose and ECT sender electrical connector should be installed. The fuel injection supply manifold should be installed as one piece with fuel injectors along with fuel injector electrical connector hookups followed by FRP sensor electrical and vacuum connections. Complete the installation by putting on both valve covers along with the upper intake manifold and the fuel tube spring lock coupling while performing engine cooling system fill then bleeding.