Ford 6W7Z-9424-AA
Intake Manifold 0

The service of an intake manifold starts with disabling the fire suppression system if present followed by placing the vehicle on a hoist while keeping it in NEUTRAL. Service begins by disconnecting the spring lock coupling of the fuel tube along with the ground cable of the battery and the engine cooling system drainage. The servicing process begins by disconnecting the wiper mounting arm together with outlet pipe, air cleaner, pivot shaft. Separate the eight fuel injector electrical connectors from their sockets before taking out the eight ignition coil-on-plugs. Remove the two bolts securing the intake manifold shield and pull out the shield before detaching the vacuums connecting the brake booster to the quick connect EVAP canister purge valve coupling as well as the PCV tube from the throttle body spacer. The technician disconnects all vacuum hoses and electrical connections belonging to the intake manifold-to-TB spacer and the exhaust gas recirculation (EGR) system module as well as the generator electrical connector. First disconnect the bolts from the four generator bracket while also taking off the bracket and removing the coolant thermostat. The first step includes disconnecting the throttle control and throttle position (TP) sensor electrical connector followed by spring clamp release on the heater hose and final disconnect of the hose itself. The EGR system module tube should be removed first followed by wire harness retainer separation from the intake manifold crash bracket when present after which all bracket bolts must be taken out with proper cylinder head clearance. The technician should disconnect the fuel rail pressure and temperature sensor vacuum and electrical connectors while removing the wire harness retainers from the LH front fuel rail stud and the rear of the intake manifold and also disconnecting the ground connector from the RH rear fuel rail stud bolt. Removing the eight bolts securing the intake manifold allows for discarding its gaskets while you must clean all sealing surfaces. Attach the new intake manifold gaskets to their locator tabs before mounting the intake manifold while lightly tightening its eight bolts. Position the crash bracket of the intake manifold while reattaching the eight ignition coil-on-plugs before mounting the bolt and stud bolt loosely. Continued tightening of the eight bolts must begin with 25 Nm (18 ft. lbs.) following the sequence before fastening the crash bracket bolt to the same specification. The EGR system module tube installation requires hand-tightening of two bolts to 12 Nm (9 ft. lbs.) after which the throttle control and TP sensor electrical connectors need to be connected. Connect the generator electrical connector after installing the coolant thermostat and generator bracket which must receive four bolts tightened to 10 Nm (89 inch lbs.). The EVAP canister purge valve hose should be wired from TB toward EVAP canister purge valve, along with the intake manifold vacuum hose attached to TB spacer and EGR system module vacuum and electrical connectors. The port of the PCV tube should attach to the TB spacer then the brake booster intake manifold connection should follow. Afterward, secure the heater hose using a spring clamp. Rejoin the fuel rail pressure and temperature sensor vacuum and electrical connectors as well as the eight fuel injector electrical connectors and wire harness retainers. The ground connector must be attached to the RH rear fuel rail stud bolt after which you should reinstall the wiper mounting arm followed by connecting the fuel spring lock coupling to reattach the air cleaner and outlet pipe. Reconnect the battery ground wire and complete engine cooling system filling and bleeding procedures and reactivate the fire suppression system when it exists.

A hoisted vehicle with NEUTRAL position requires servicing of the intake manifold. You should first disconnect the fuel tube spring lock coupling and the battery ground cable. You must drain your engine coolant and take off the air cleaner with the outlet pipe. Beginning with the wiper mounting arm's removal followed by the pivot shaft and continued removal of RH and LH cowl extensions you should also disconnect the electrical connector from the LH side. The service technician should begin by disconnecting the fuel injector electrical connectors at eight locations. Then, the technician should remove the eight ignition coil-on-plugs. The service will start by removing the two bolts retaining the intake manifold shield then removing the shield followed by unclipping the brake booster vacuum hose and deconnecting the quick connect coupling of the EVAP canister purge valve hoses and the PCV tube from the TB spacer and the EGR system module vacuum and electrical connectors. Disconnect the generator electrical connector along with the intake manifold-to-TB spacer vacuum hose before you remove the 4 generator bracket bolts and bracket. For the procedure begin by disconnecting the coolant thermostat after unbolting the throttle control and TP sensor electrical connections. Then proceed with releasing the heater hose spring clamp and separating the EGR system module tube from its fixture. Begin by detaching the wire harness retainer from the intake manifold crash bracket when equipped before removing the bolt securing the crash bracket while protecting it away from contacting the cylinder head. Eventfully detach the vacuum lines and electrical connectors of the LH front fuel rail stud and the rear intake manifold section. Also remove the wire harness retainers from both locations. First remove the ground wiring from the RH rear fuel rail stud bolt and then separate the intake manifold with its eight retaining bolts which require new gaskets for installation. Thoroughly clean all sealing surfaces. Begin by installing new intake manifold gaskets with their locator tabs properly aligned to the cylinder head slots. Afterward, install the intake manifold followed by hand-tightening the 8 bolts. First connect and loosely fasten the 8 ignition coil-on-plugs then install the intake manifold crash bracket according to the correct sequence of bolts followed by torqueing each bolt to 25 Nm (18 ft. lbs.). After setting the bolt of the intake manifold crash bracket to 25 Nm (18 ft. lbs.), install the EGR system module tube. Install the intake manifold shield while tightening its 2 bolts to 12 Nm (9 ft. lbs.). The throttle control and TP sensor electrical connectors need reinstallation before fitting the coolant thermostat and generator bracket with 4 bolts adjusted to 10 Nm (89 inch lbs.). The generator electrical connector needs attachment while EVAP canister purge valve hoses should be connected to both the TB and EVAP canister purge valve. Also attach the intake manifold vacuum hose to the TB spacer followed by joining the EGR system module vacuum and electrical connectors and PCV tube quick connect coupling to the TB spacer. Party first hook up the brake booster vacuum hose before you attach the heater hose using a spring clamp and then link up all fuel rail pressure and temperature sensor vacuum and electrical connectors and finish by connecting the eight fuel injector electrical connectors. The wire harness retainer must be attached at the rear of the intake manifold before being fastened to the LH front fuel rail stud. The wire harness should be placed over the intake manifold crash bracket before connecting the ground connector to the RH rear fuel rail stud bolt. Finish the installation by installing both LH and RH cowl extensions while tightening bolts with 10 Nm standard torque (89 inch lbs.) followed by wiper mounting arm and pivot shaft replacement, coupling the fuel spring lock together with fuel air cleaner and outlet pipe attachment and ground cable reconnection before the engine cooling system requires filling and bleeding.

Remove the four generator bracket bolts and the bracket, then remove the coolant thermostat.

Take out the coolant thermostat.