Ford 5L1Z-9424-A
Intake Manifold

Start the repair process of the intake manifold by first removing its four throttle body bolts before unscrewing the four fuel rail bolts. First detach the locking clip for fuel injectors and fuel rail then remove fuel injectors from the rail and dispose the 2 O-ring seal from each injector. Starting with the vacuum tube assembly removal from the intake manifold proceed to remove the rod locking clips of the charge motion control valve before extracting the stud bolt then the 2 bolts and finally removing the complete CMCV. Two positive crankcase ventilation (PCV) heater element bolts need removal while discarding the O-ring seal. You need to detach the engine noise shield insulator present on the intake manifold. Remarkably begin the process of assembly by attaching the engine noise shield insulator to the intake manifold. Install a new O-ring seal first while lubricating it with engine oil then fit the PCV heater element before tightening the 2 bolts to 6 Nm (53 inch lbs.). Secure the CMCV by adding the stud bolt with two bolts which receive 10 Nm (89 inch lbs.) torque before placing CMCV rod locking clips. Fasten the vacuum tubing onto the intake manifold before adding clean engine oil to new O-ring seals and then inserting them onto each fuel injector. The fuel rail gets its fuel injectors put together through locking clips before install onto the intake manifold with fuel rail bolts secured at 10 Nm (89 inch lbs.). Start by installing the throttle body and finish the bolt installation process by securing them at 9 Nm (80 inch lbs.) followed by rotating them an extra 90 degrees.

The process of servicing or repairing the intake manifold starts with bolt removal from the throttle body and four manifold bolts and then proceeds to the fuel rail bolt removal. The service requires removal of fuel injector-to-fuel rail locking clips before separating the injectors from the rail and discarding the 2 O-ring seals for each injector. Start by removing the vacuum tube assembly then unfasten the rod locking clips from the charge motion control valve (CMCV) before extracting the stud bolt and 2 bolts and CMCV itself. To proceed with the intake manifold maintenance, remove the 2 bolts together with the positive crankcase ventilation (PCV) heater element while discarding the O-ring seal and then detach the engine noise shield insulator. To begin the assembly process you should first fit the engine noise shield insulator onto the intake manifold. Install the PCV heater element by applying clean engine oil on the new O-ring seal before fastening it with 2 bolts at 6 Nm (53 inch lbs.). Position the CMCV before installing its stud bolt and two bolts which should be tightened to 10 Nm (89 inch lbs.) then insert the CMCV rod locking clips. The vacuum tube assembly requires attachment to the intake manifold while all new O-ring seals must receive engine oil lubrication before their installation onto fuel injector components. Fasten the fuel injectors to the fuel rail by using locking clips to mount them. Install the fuel rail component with the attached fuel injectors onto the intake manifold by tightening 4 fuel rail bolts to 10 Nm (89 inch lbs.). Complete installation of the TB by bolting it down in two steps that require first a 9 Nm (80 inch lbs.) torque followed by an additional 90 degrees rotation.

Remove the nine intake manifold bolts and the intake manifold, discarding the intake manifold gaskets while inspecting the assembly for damage.

Position the fuel rail and secure it with the 4 bolts, tightening them to 10 Nm (89 inch lbs.).

Position and connect the PCV tube and EVAP tube.

Reconnect the 10 fuel injector electrical connectors, the fuel rail pressure and temperature sensor electrical connector and vacuum connector, and the IMRC actuator electrical connector.

Install the assembly and tighten the 6 fuel rail bolts to 10 Nm (89 inch lbs.).

Ensure the long bolts are installed in positions 1, 2, 3, 4, 11, and 12.

Install the fuel filter module and bolts, tightening to 13 Nm (115 lb-inch), and use green hex head banjo bolts with new copper sealing washers.

The sealant must be removed, and the sealing area cleaned to prevent future oil leakage.

Begin by disconnecting the fuel supply spring lock coupling and removing the upper intake manifold.

Begin by disconnecting the fuel supply spring lock coupling and removing the upper intake manifold.

Position the TB spacer and install the 2 upper TB spacer bolts in two stages: first to 9 Nm (80 inch lbs.) and then an additional 90 degrees. Repeat for the 4 lower TB spacer bolts.

Disconnect the brake booster vacuum hose from the intake manifold vacuum tube.

Ensure that electrical and vacuum harnesses do not restrict the movement of the charge motion control valve (CMCV) control rods.

Move the wiring harness aside after disconnecting the retainers from the LH valve cover studs.