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The lower intake manifolds on some Ford vehicle models are not fitting correctly after machining

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Engine Builders: Some AERA members have reported that the lower intake manifolds on some Ford vehicle models are not fitting correctly after machining. To reduce the likelihood of coolant contamination of engine oil, a revised, thicker intake gasket is now available for the 3.8L and 4.2L Ford car and truck engines. These models have VIN codes 4 and 2 and were manufactured between 1996 and 1998.

To align the lower intake when these gaskets are installed, install and tighten the #3 and #4 center bolts first to facilitate the installation of the remaining bolts.

To complete the installation of this manifold, follow the sequence shown in Figure 1. Torque all bolts in sequence to 71 in.lbs. (8 Nm). Then, rotate all bolts in sequence another 90 degrees.

Engine Builders: Ford 3.8L and 4.2L V6 engine timing cover gaskets tend to leak coolant, externally or internally, after extended service.

To reduce the likelihood of coolant loss and/or oil contamination, Ford recommends:

1. Carefully remove all old gasket by hand scraping the timing cover and block. Avoid using any abrasives.

2. Tighten the timing cover bolts. The socket head cap screws should be tightened to 16 ft.lbs. (22 Nm) and all other bolts should be tightened to 20 ft.lbs.

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Exceeding these revised torque values may result in timing cover damage and/or coolant loss.

Engine Builders: Since the valve lash on 1993-

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