Ford 1W7Z-9424-AB
Intake Manifold

Position the gasket tabs exactly on the slots of the block before installing new intake manifold gaskets. Check that the gasket tabs align with the slots of the block then position the intake manifold before applying a hand torque on its specified mounting bolts. Start by installing eight ignition coils which require equivalent eight bolt tightening before adding and securing the fuel injection supply manifold to four studs. The procedure begins with installing the crash bracket bolt and stud in a loose manner followed by water thermostat and water outlet adapter bolt attachment with loose tightening. The coolant sensor connector should be connected alongside the fuel charging wiring harness position retainer near the back of the intake manifold. Following this step tighten the bolts according to the specified sequence while fastening the stud. The cables should be connected to the crash bracket which requires bolt tightening before you install and tighten the throttle body. Install the nut and bolt while positioning the wiring bracket and connect wiring connectors to the bracket which should include the LH heated oxygen sensor electrical connector. One must install the EGR tube to the EGR valve after attaching the fuel charging wiring harness pin-type retainer to the crash bracket. Install the EGR tube heat shield while securing its bolts followed by wiring up the ground connector at the RH rear stud. After attaching the heater water hose the clamp must be positioned before connecting electrical connectors to both IAC control valve and TP sensor. Put the upper radiator hose in position before placing the clamps in place and then mount and bolt the generator bracket. Install the generator harness position retainer to the LH front studs while connecting the generator electrical connector, cable and harness pin-type retainer. First position the vacuum harness before connecting it to the EVAP canister purge valve and mains and EGR vacuum regulator solenoid through wires. Begin with attaching the PCV tube before installing the vacuum harness between the EVAP canister purge valve and main chassis vacuum supply line and EGR valve. Attach the cables to the EGR tube heat shield before you proceed to connect the accelerator cable with the speed control actuator cable and throttle return spring. Wire the electrical connectors of fuel charging to all eight fuel injectors and ignition coils as well as the electrical connectors of differential pressure feedback EGR. When executing this step, raise the vehicle to install the EGR tube onto the exhaust manifold and join electrical connectors to the PSP switch and the oil pressure sensor while adding the oil bypass filter. Secure the pin-type retainer on the A/C compressor bracket after connecting its electrical connector between the A/C compressor and CKP sensor. After installation of the RH catalytic converter assembly proceed with lowering the vehicle along with drive belt installation. Insert the wiper mounting arm with pivot shaft and then fit the fuel line before installing the air cleaner outlet tube. Add the battery ground cable before inspecting engine oil and completing the engine cooling system filling procedure.

Install the intake manifold by placing gasket tabs inside the block slots prior to adding new intake manifold gaskets. You should install the intake manifold before slowly tightening the specified bolts by hand. The next step involves placing eight ignition coils then tightening their bolts and after that comes the fuel injection supply manifold installation with four stud tightening. First position the crash bracket bolt along with the stud while the water thermostat and water outlet adapter bolts remain loose. Affix the coolant sensor connector along with the fuel charging wiring harness position retainer behind the intake manifold. Tighter bolts need to be installed in their specified sequence while the stud requires a final lock. Attach crash bracket cables then tighten their bolts before installing the throttle body with secured bolts. Secure the wiring bracket in position by installing the nut and bolt followed by wiring connector attachment and LH heated oxygen sensor electrical connector connection. The pin-type retainer of the fuel charging wiring harness needs attachment to the crash bracket while the EGR tube must be connected to the EGR valve. Install bolts on the EGR tube heat shield followed by attaching the ground connector at the RH rear stud position. Place the heater water hose while applying the clamp before plugging in both connection wires to the IAC control valve and TP sensor. First install the upper radiator hose along with clamps before installing the generator mounting bracket along its bolts. Connect the generator electrical connector along with its cable and pin-type retainer before installing the generator harness position retainer on the LH front studs. Position the vacuum harness and then link the vacuum hose to the EVAP canister purge valve before connecting its electrical connector alongside vacuum supply to the EGR vacuum regulator solenoid. The first process involves installing the PCV tube after which you must connect both the vacuum harness and vacuum hoses used on the EVAP canister purge valve and the main chassis vacuum supply line with the EGR valve. The cables require relocation onto the EGR tube heat shield then you should connect the accelerator cable alongside the speed control actuator cable and throttle return spring. Attach the eight fuel injector and ignition coil wiring electrical connectors together with the differential pressure feedback EGR electrical connectors. Before putting up the vehicle for installation of the EGR tube and exhaust manifold connection start with the PSP switch and oil pressure sensor electrical connector and end by installing the oil bypass filter. The electrical connector for the A/C compressor and CKP sensor must be joined followed by attachment of the pin-type retainer to the A/C compressor bracket. After installing the RH catalytic converter assembly proceed by lowering the vehicle to finish with the installation of the drive belt. Connect the fuel line before you install the air cleaner outlet tube and the wiper mounting arm alongside pivot shaft. The technician finishes by attaching the battery ground cable before testing the engine oil. They then complete the process by filling the engine cooling system.

Connect the fuel charging wiring electrical connectors to the engine coolant temperature sensor, the fuel temperature sensor, the fuel pressure sensor, the eight ignition coils, and the eight fuel injectors.

Clean the sealing surfaces.

Attach the upper generator support bracket and tighten its bolts.

Disconnect the electrical connector and remove the fuel injection supply manifold and fuel injectors as an assembly, noting the location of the short and long bolts for ease of installation.

Position the engine wire harness aside, disconnect the intake manifold runner control (IMRC) electrical connector, and remove the heater bypass tube and heater hose.

Disconnect the electrical connector and remove the fuel injection supply manifold and fuel injectors as an assembly, noting the location of the short and long bolts for ease of installation.

Remove the eight short bolts and six long bolts to take off the lower intake manifold, discarding the intake manifold gaskets.

Remove the oil bypass filter and disconnect the oil pressure sensor and Power Steering Pressure (PSP) switch electrical connectors.

Disconnect the accelerator cable, speed control actuator cable, and throttle return spring.

Remove the bolts and the water outlet adapter, disconnect the cooling sensor electrical connector, and remove the water thermostat.