Ford 4L5Z-9424-A
Intake Manifold

Service and repair operations on the intake manifold must start with disconnecting the battery ground cable. Start the process by removing the bolts which secure the shield followed by unfastening the air cleaner outlet pipe while detaching its tube from the Mass Air Flow sensor wiring. Advanced the clamps while extracting the pipe. Service operations should start with disconnecting the Idle Air Control (IAC) valve electrical connector and the Throttle Position Sensor (TPS) electrical connector and the Exhaust Gas Recirculation (EGR) valve vacuum hose. .gdx engine speed cables must be detached from the throttle body assembly along with bracket support before placing them out of the way. Detach the exhaust manifold-to-EGR valve tube by loosening its fitting before disconnecting the EGR valve vacuum regulator electrical connection and its vacuum lines. The brake booster vacuum hose must be disconnected by unlocking the clamp. Right-hand spark plug wires must be detached from the coil carefully by twisting spark plug wire boots in an upward direction as a protective measure while marking their positions in advance. Start by removing the wiring harness bracket retainer then place the wiring harness to the side before proceeding to the accelerator cable routing clip pushpin followed by the wiring harness pushpin. First disconnect the vacuum hoses and then remove all bolts and the bolt that secures the coil with its bracket. Unscrew the nut and detach the Powertrain Control Module (PCM) electrical connector and follow it with removal of ground wires before placing the wiring harness to the side. The electrical connector retainer needs to be detached before removing intake manifold bolts which makes it possible to lift the intake manifold. The heated PCV fittings together with the heated PCV hose retainers require removal before the intake manifold can be stripped. Follow the reverse order of removal to install the affected components.

One should start by draining engine coolant along with separating the radiator overflow hose for lower intake manifold servicing work. First disconnect the water heater tube from the water bypass hose then remove the upper intake manifold followed by the engine coolant temperature (ECT) electrical connector. First disconnect the heater water hoses together with the PCV heater hoses from the water heater tube while removing the wire harness retainer nut. Proceed by disconnecting the upper radiator hose and you must also remove the water bypass hose using the clamps. The first step involves cutting the connections for eight fuel injector electrical connectors along with the fuel line followed by disconnecting the ground strap at the back of the lower intake manifold and the water temperature indicator sender electrical connector. The first step involves taking out the CMP sensor together with the camshaft synchronizer and unfastening the bolts to extract the lower intake manifold. Discard the lower gasket during this procedure. For installation, clean the gasket surfaces of the lower intake manifold, cylinder heads, and cylinder block using Metal Surface Cleaner F4AZ-19A536-RA or an equivalent that meets Ford specification WSE-M5B392-A. Apply a 1.6 mm (0.06) bead of Silicone Gasket and Sealant F7AZ-19554-EA or an equivalent that meets Ford specification WSE-M4G323-A4 in the corners where the cylinder head and cylinder block meet, then position the four lower gaskets, ensuring the intake manifold seal tabs fit into the notches of the lower intake manifold gaskets. Press along the entire intake manifold seal to make silicone sealant appear before placing the lower intake manifold and starting the bolts. The installation of lower intake manifold requires a two-step procedure where initial pressure reaches 10 Nm (89 inch lbs.) before advancing to 32 Nm (24 ft. lbs.). After reinstalling the camshaft position (CMP) sensor along with the camshaft synchronizer, reconnect the rear ground strap as well as the water temperature indicator sender electrical connector and eight fuel injector electrical connectors. First attach the fuel line followed by mounting the water bypass hose through its two clamps before installing the upper radiator hose and heater water hoses and wire harness retainer nut. The last sequence includes engine coolant temperature (ECT) electrical connector connection along with the water heater bypass hose attachment to heater tube, two PCV heater hoses securement to heater tube followed by upper intake manifold installation and radiator overflow hose reconnection before engine cooling system filling.

Service of the intake manifold starts with disconnecting the battery ground cable. Remove the bolts from the shield followed by the air cleaner outlet pipe. Proceed by detaching the accelerator and speed control cables from the throttle body and bracket then place the cables to the side. The service of the intake manifold begins with disconnecting the idle air control (IAC) valve and throttle position (TP) sensor electrical connectors which releases the TP sensor wiring routing clip. You should disconnect the exhaust gas recirculation valve's vacuum hose and tube and remove vacuum and electrical connections of the EGR vacuum regulator solenoid. The user can disconnect the brake booster vacuum hose by releasing the clamp. To prevent damage you need to carefully twist the boots at the end of a spark plug wire while extracting them upward until you confirm proper connections to the correct ignition coil terminals. Mark the wire locations before beginning removal. The right-hand spark plug wires collect at the coil location from where the wires detach. Then the wires receive a safe position beyond reach. The wiring harness bracket retainer and wiring pin-type retainer need removal before setting the wiring harness bracket to the side. You should remove two pin-type retainers which secure the accelerator cable routing clip as well as the wiring harness. Proceed by removing the lower and upper bolts from the ignition coil bracket and put the coil to the side. As a first step disconnect the vacuum hoses and remove the nut followed by disconnecting the powertrain control module (PCM) electrical connector. Break the ground wires connection while setting the wiring harness to the side before disconnecting the knock sensor electrical connector retainer. To replace the intake manifold start by removing its bolts and raising it upward before disassembling the retainers of the heated positive crankcase ventilation (PCV) hoses and its fitting. When ready to install the intake manifold use the opposite process of removal installation.

The initial step for servicing and repairing the lower intake manifold requires disconnecting thebattery ground cable to maintain safety under the existing fuel pressure in the system. Remove the accessory drive belt next before you detach the oil level indicator tube by unscrewing its bolt. Unfasten the upper intake manifold next then detach the A/C compressor with its bracket by removing one stud alongside three bolts. First disconnect the intake manifold stud ground cable from the dash panel then remove the wiring connector from its retainer position at the lower intake manifold before taking out the spring lock coupling. When servicing the fuel injectors it is essential to disconnect both the engine control wiring connectors. The engine lifting eye requires removing one bolt and one nut before continuing with lower intake manifold removal through bolt-holding eight points then throwing away the gasket. To install replace the removal steps while tightening the lower intake manifold bolts in two stages using an initial torque of 7 - 10 Nm (62 - 88 inch lbs.) before completing the installation torques at 26 - 38 Nm (20 - 28 ft. lbs.) in proper bolt sequence.

Connect the IAC valve electrical connector and the fuel supply tube spring lock coupling, followed by the MAP sensor and TP sensor electrical connectors.

Disconnect the throttle position (TP) sensor and idle air control (IAC) valve electrical connectors, along with the wire retainer.

Remove the heated PCV hose retainers and the heated PCV fitting.

Remove the nut and disconnect the PCM electrical connector, along with the ground wires.

Disconnect the two vacuum connections from the front of the intake manifold, the vapor management valve (VMV) purge line, and the brake booster vacuum supply line.

To install, reverse the removal procedure.

Detach the vapor purge tube quick connect coupling, engine vacuum harness, brake booster hose, crankcase breather hose, and two coolant hoses.

Remove the five bolts securing the intake manifold.

Remove the wiring harness pushpin from the bottom of the intake manifold, disconnect the fuel manifold vacuum hose, and remove the five bolts securing the intake manifold.

Disconnect the vacuum hose, engine vacuum harness, brake booster hose, crankcase breather hose, and coolant hoses.

Disconnect the battery ground cable and the Intake Air Temperature (IAT) sensor.

Remove the oil indicator tube bracket nut and the upper intake manifold support bracket stud bolt.

Detach them from the accelerator bracket and the accelerator cable from the brake booster vacuum hose.