How to Replace the Intake Manifold in a Mercury Villager

Drain the cooling system and relieve the pressure in the fuel system. Disconnect the negative battery cable, the air intake duct, the IAC valve connectors, the throttle position sensor and switch connectors, and the EGR solenoid valve.

Pull the EVAP canister vacuum and purge hoses, the vacuum hoses from the EVAP, the brake cylinder, pressure regulator and EGR tube. Tag and disconnect the spark plug wires. Remove the distributor cap.

Take out the three left bank injector connectors, the thermal transmitter, the ground harness, breather pipe and the upper manifold. Disconnect the fuel feed and return lines and plug them with golf tees to prevent fuel spillage.

Locate the right injector harness connectors and disconnect them as well as the fuel rail and injectors. Remove the coolant temperature switch harness connector and the water hose from the thermostat.

Loose the bolts on the lower manifold in sequence. Remove the bolts and left the intake manifold from the engine. Remove the gasket and discard it.

Clean the mating surfaces by scraping the old gasket material and carbon deposits. Clean the surfaces with solvent and inspect them for damage.

Put a new gasket in place and install the lower intake manifold to the engine. Tighten the bolts in sequence as follows: first pass-35 inch pounds; second pass-78 inch pounds and third pass 70 to 84 inch pounds.

Connect the ECT sensor connector, the fuel supply manifold and the right bank injector connectors. Connect the fuel lines and then install the upper intake manifold. Put the breather pipe in position.

Install the intake manifold ground cable, the thermal transmitter, the left bank injector connectors and the distributor. Reconnect the spark plug wires.

Continue reconnecting all the components, reversing the order in which they were removed. Connect the negative battery cable to the terminal. Refill the cooling system with the appropriate coolant.

Start the engine. Check for fuel or vacuum leaks.