On the back of the upper intake manifold (passenger's side), there is a plug with three connections for hoses. One is for the egr/vacuum system. The other two are at 2 'oclock and 5 'oclock. They go back to where?
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Yes there are cooling system hoses under the intake, here are instructions to remove the intake.
Remove the Intake Manifold
1Drain 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.
2Pull 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.
3. 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.
4Locate 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.
5Loose 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.
6Clean the mating surfaces by scraping the old gasket material and carbon deposits. Clean the surfaces with solvent and inspect them for damage.
Install the Intake Manifold
7Put 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.
8Connect 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.
9Install the intake manifold ground cable, the thermal transmitter, the left bank injector connectors and the distributor. Reconnect the spark plug wires.
10Continue 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.
11Start the engine. Check for fuel or vacuum leaks.
Your intake manifold has a coolant hose attached to the top of it at the back left corner (passenger side). They are bad about cracking at the neck of the fitting. Ford as an updated Intake Manifold to address this issue so your not alone. It cannot be repaired without complete relacement.
The thermostat is on passenger side right center of engine .Stand at passenger side with hood open look down and over at center and toward the right at the intake manifold...it is hard to see without removing engine components....Follow upper radiator hose from radiator to the intake where the other end of hose connects and that is where the thermostat is.....Be sure engine is not running and cool to the touch for safety reasons while looking........SAFETY FIRST
Hope this will help you......................................................Metalpoet
Disconnect the negative battery cable. Place a clean drain pan under the radiator, open the drain **** and drain the cooling system.
Remove the air cleaner assembly and the fuel injector sight shield.
Disconnect the cables from the throttle body and mount bracket.
Remove the coolant recovery reservoir.
Remove the inner fender electrical cover on the right side.
Remove the right rear crossover pipe heat shield.
Disconnect the fuel lines from the fuel rail and from the cable bracket.
Remove the alternator and brace.
Remove the throttle body cable mounting bracket with the vacuum lines and disconnect the vacuum lines.
Tag and detach the electrical connections at the throttle body and both banks of fuel injectors.
Disconnect the vacuum hoses from the canister purge solenoid valve and transaxle module and intake connection.
Unbolt the power steering pump and move forward. DO NOT disconnect the fluid lines.
Tag and disconnect the spark plug wires position lay aside.
Disconnect the coolant bypass hose from the intake manifold.
Remove the solenoid valve mounting bracket and power steering support brace from the intake manifold.
Disconnect the heater pipes from the intake and front cover.
Remove the alternator support brace from the intake.
Disconnect the upper radiator hose from the housing.
Remove the thermostat housing and thermostat from the intake.
Detach the electrical connector from the temperature sensor and sensor switch.
Unfasten the intake manifold bolts, then remove the manifold as an assembly. Remove and discard the gaskets.
If separating the upper manifold from the lower, proceed as follows:
Remove the fuel rail and fuel injectors.
Detach the coolant sensor switch.
Remove the manifold end cap cover.
Remove the upper intake manifold and throttle body assembly from the lower manifold. Remove and discard the gaskets.
Thoroughly clean all gasket mating surfaces.
If replacing the upper manifold, proceed as follows:
Apply a 1⁄16 in. bead of Loctite® Instant Gasket Eliminator 51845 or equivalent to the lower manifold mating surface. Make sure to circle all bolt holes.
Carefully lower the upper manifold and throttle body assembly onto the lower manifold.
Tighten the upper manifold retaining bolts to 19 ft. lbs. (26 Nm).
Install the manifold end cap cover and the coolant sensor switch.
Install the fuel injectors and rail to the manifold assembly.
Clean the mating surfaces and install the intake manifold gaskets and seals. Apply sealer to the ends of the of the intake manifold seals.
Position the intake manifold and apply a suitable thread lock compound to the bolt threads. Tighten the retaining bolts to 88 inch lbs. (10 Nm), twice, in the sequence shown in the accompanying figure.
Attach the electrical connector to the temperature sensor and sensor switch.
Install the thermostat housing and thermostat with a new gasket.
Connect the alternator support brace to the intake.
Install the solenoid valve mounting bracket and power steering support brace to the intake manifold.
Connect the heater pipes to the intake and front cover.
Attach the coolant bypass hose to the intake manifold.
Install the power steering pump support bracket and tighten to 37 ft. lbs. (50 Nm).
Install the spark plug wires on both sides.
Install the belt tensioner pulley and tighten to 33 ft. lbs. (45 Nm).
Install the power steering pump.
Connect the vacuum hoses to the canister purge solenoid valve and transaxle module and intake connection.
Attach the electrical connections at the throttle body and both banks of fuel injectors.
Install the alternator and brace.
Connect the throttle body cable mounting bracket with the vacuum lines.
Install the right rear crossover pipe heat shield.
Install the cables to the throttle body.
Connect the fuel lines to the fuel rail and mount bracket.
Install the inner fender electrical cover on the right side.
Install the coolant recovery reservoir and upper radiator hose. Fill the cooling system.
Install the air cleaner assembly and the fuel injector sight shield.
Yes, you will have to remove the intake manifold. If you are mechanicallyinclined, it's not that hard. Looks complicated because of all the wires and hoses. Just take your time, keep track of everything you do, take notes if you have to, so everything goes back together the same way it came apart. Since you are going to all this trouble be sure you buy a premium spark plug. I wouldn't use Champion or Ford products. NGK Iridium would be my choice if they are available.
Within the large top radiator hose before it enters the engine. It has bolts holding the receiver to the hose. Drain the radiator when it is cold. There is a drain plug on one side of the bottom if it. Take off the hose. Remove the bolts and it inside. Install the same way you took it out. Clean the old gasket off and replace with a new one before putting it back together. Don't forget to fill the radiator with coolant before checking for leaks.
Ha, you tried to fool me with the bit about a 3.5 L motor--I could find that one...here is the complete procedure from AutoZone.com:
Clean the gasket mounting surfaces. Be sure to inspect the manifold for warpage and/or cracks. If necessary, replace it.
Position the gaskets on the cylinder head with the port blocking plates to the rear and the This Side Up stamps facing upward. Then apply a 3 / 16 in. (5mm) bead of RTV sealant on the front and rear of the engine block at the block-to-manifold mating surface. Extend the bead 1 / 2 in. (13mm) up each cylinder head to seal and retain the gaskets.
Install the lower intake manifold. Tighten the bolts in sequence and in 3 steps, as follows:
Step 1: 26 inch lbs. (3 Nm).
Step 2: 106 inch lbs. (12 Nm).
Step 3: 133 inch. lbs. (15 Nm).
Install or connect the following:
Power steering pumpAlternator bracket bolt near the thermostat housingWiring harness to the lower manifold components, including the injector, EGR valve and ECT sensorAir conditioning compressor bracket-to-the lower intake manifold pencil braces
Install transmission oil dipstick tube, if necessary.
Fuel supply and return lines to the rear of the lower intake
Temporarily reattach the negative battery cable, then pressurize the fuel system (by cycling the ignition without starting the engine) and check for leaks.
Disconnect the negative battery cable.
Install or connect the following:
Heater hose to the lower intakeUpper radiator hose to the thermostat housingDistributor assembly and engage the wiringIgnition coilConnect vacuum hoses to the upper and lower intake manifold.New upper intake manifold gasket, making sure the green sealing lines are facing upwardUpper intake manifoldManifold retainers. Tighten them to 88 inch lbs. (10 Nm) using two passes.Purge solenoid and bracketBrake booster vacuum hose at the upper intake manifoldPCV hose to the rear of the upper intake manifoldVacuum hoses to both the front and rear of the manifold assemblyThrottle bodyThrottle linkage to the upper intakeWiring to the upper intake components including the TP sensor, IAC motor, MAP sensor and the fuel meterEngine coverAir intake assembly
ok there are three places to look! first open hood one the drivers side look at the intake manifold and see if theres a loose vacuum hose if so connect it to the port! second passenger side look on the floor twoards the dash in the center the are vac lines there same goes for the drivers side near gas pedal