Ford 7T4Z-9424-E
Intake Manifold, Upper

Service of the upper intake manifold begins with taking off the Air Cleaner outlet pipe followed by disconnecting the EVAP tube from the intake manifold and the Throttle Body electrical connector. First detach the EVAP tube pin-type retainer followed by vacuum hose disconnect from the brake booster and PCV tube removal from the PCV valve. The service process requires disconnecting wiring harness retainers followed by upper intake manifold support bracket bolt removal and then proceeding to the fuel tube bracket bolt removal. Finish by taking out all six bolts which maintain the upper intake manifold while discarding the gaskets. Safely clean down along with inspecting both sealing surfaces of the upper and lower intake manifold. If an engine needed an upper engine replacement or repairing then checking for metal objects within the intake manifold becomes necessary to avoid causing engine failure. Engine damage can be prevented by installing new intake manifold parts. Users should apply new gaskets before they fasten the upper intake manifold with its six bolts at 10 Nm (89 lb-in) torque settings maintained for the specified order. Install the fuel tube bracket bolt first at 6 Nm (53 lb-in) and then install the upper intake manifold support bracket bolt at 10 Nm (89 lb-in). Reinstall the wiring harness retainers then join the PCV tube to the PCV valve before connecting the brake booster vacuum hose to the intake manifold as well as the EVAP tube to the intake manifold using a pin-type retainer. The TB electrical connector should be reconnected before installing the ACL outlet pipe.

New intake manifold and thermostat housing gaskets.

Detach the wiring harness retainers from the upper intake manifold.

Discard the old gaskets and clean and inspect all sealing surfaces of the upper and lower intake manifold.

Ensure cleanliness to prevent foreign material from causing engine failure.

Reinstall the fuel rail and fill and bleed the cooling system.

Remove the fuel rail and drain the cooling system.

Reinstall the air cleaner assembly and the fuel rail.

Remove the upper intake manifold short support bracket bolt and the six bolts securing the upper intake manifold, discarding the gaskets.