Ford 9L3Z-9424-H
Intake Manifold

The first step when removing the intake manifold requires avoiding any sources of fuel proximity to smoking or open flames because this area contains flammable combinations. The procedure needs you to reduce fuel system pressure prior to unfastening any fuel tubes. First disconnect the fuel supply spring lock coupling from the fuel rail before draining the cooling system and removing the generator operation. The Air Cleaner (ACL) outlet pipe should be taken off first along with disconnecting the upper radiator hose from the thermostat housing after detaching the heater coolant hose and PCV coolant hose from the engine coolant crossover assembly. Disconnect the electrical connectors of the IMRC actuator along with the fuel rail pressure sensor, temperature sensor and vacuum connector and 10 fuel injectors. Start by disconnecting the quick connect coupling of the PCV tube followed by the Evaporative Emission tube coupling attached to the intake manifold and finally detach the crankcase ventilation tube. You should remove the wiring and vacuum harness retainers from the intake manifold back while also detaching engine vacuum hose links and cutting the 2 heated PCV coolant hoses. First disconnect the Throttle Position (TP) sensor connector together with the Electronic Throttle Control (ETC) electrical connector. Then remove the 12 bolts from the intake manifold. Clean all surface areas with a plastic scraper combined with silicone remover which leads to discarding old gaskets. Inspection for metal debris in the intake manifold needs to be performed after engine repairs for upper engine failure and replacement should occur when such debris is found. Place the intake manifold onto position using 10 new gaskets followed by installing the engine coolant crossover manifold assembly with 2 new gaskets along with its 3 bolts which should have a torque of 10 Nm (89 lb-in). The installation process for intake manifold bolts should follow steps one and two: initiate with 2 Nm (18 lb-in) and complete with 10 Nm (89 lb-in). Reinstall the TP sensor electrical connector and the ETC electrical connector followed by reattachment of engine wiring harness position retainers together with reconnection of engine vacuum hoses and wiring harness retainers while reinstalling both PCV and EVAP tube quick connect couplings along with installation of the 2 heated PCV coolant hoses into position. Secure the IMRC actuator electrical connector followed by connecting the vacuum and electrical connectors for the fuel rail pressure and temperature sensors and the 10 fuel injector electrical connectors and vacuum connector. You must perform the following last procedures: connect the fuel supply spring lock coupling along with the heater coolant hose, heated PCV coolant hose, upper radiator hose, crankcase ventilation tube, reinstall the generator and ACL outlet pipe and fill the engine cooling system before bleeding it.

Disconnect the battery ground cable.

Disconnect the quick connect couplings to remove the crankcase vent tube.