Ford 3W3Z-9424-BB
Intake Manifold

Start intake manifold upper servicing or repair by taking off the air cleaner outlet tube and the accelerator control splash shield. Proceed by disconnecting the accelerator cable and speed control cable along with their return spring followed by the fuel vapor hose. Uninstall the vacuum hose while taking off speed control cable and accelerator control cable from their mounting brackets. To separate the acceleration control cables start by removing their bolt afterwards you should place the cables aside before taking out the bolt and bracket. The maintenance process requires removal of the Exhaust Gas Recirculation (EGR) system module tube as well as disconnecting the Throttle Position (TP) sensor and Idle Air Control (IAC) sensor electrical connectors, the Positive Crankcase Ventilation (PVC) tube, and the EGR system module electrical connector. The vacuum hoses combined with PCV coolant hoses require disconnection from their installation points. After removing upper intake manifold assembly bolts according to their specified order, remove the intake manifold assembly and clean sealing surfaces for inspection. The procedure for mounting starts with applying a new upper intake manifold gasket then proceeding to install both the upper intake manifold and bolts by following the specified sequence. Connect all vacuum hoses along with PCV coolant hoses and the EGR system module electrical connector and the PVC tube. Fuse up electrical connections for TP sensor and IAC sensor and the EGR system module tube one after the other. Secure the bracket with its bolt afterward reattach the acceleration control cables together with the vacuum line. For the final step reinstall the accelerator control cables and hook up the fuel vapor hose with attachment of the accelerator cable and speed control cable and return spring. Then replace the accelerator control splash shield and air cleaner outlet tube.

Install the ignition coils and tighten the bolts, followed by the crash bracket, which should be loosely secured with a bolt and a stud.

Connect the isolation valve jumper to the fuel charging wiring electrical connector, followed by the engine coolant temperature sensor, the fuel temperature sensor, and the fuel pressure sensor.

Install the generator and its bolts, followed by the crossover tube, ensuring to inspect and replace O-ring seals if needed.

Disconnect the main chassis vacuum supply hose from the throttle body adapter, the crankcase ventilation tube at two locations, and the vacuum hose from the throttle body adapter.

Install the intake manifold fasteners and tighten them in the specified sequence.

Disconnect the EGR system module tube nut from the EGR system module.