Ford 9W7Z-9424-A
Intake Manifold

Service the intake manifold by first hoisting the vehicle on a lift at NEUTRAL position. Beginning the intake manifold service requires the removal of fuel tube spring lock coupling and battery ground cable together with draining engine cooling system fluid. Start by uninstalling the ACL with its outlet pipe and thorough removal of wiper mounting arm along with pivot shaft. The service starts by removing five retainer screws along with the two nuts from Evaporative Emission (EVAP) canister purge valve bracket and the right-hand cowl extension. Disconnect the electrical wiring harness connector at the same time remove the 3 retention screws before taking out the LH cowl extension. Before removal disconnect the 8 fuel injector electrical connectors while removing all 8 ignition coil-on-plugs. Remove the shield bolts from the manifold intakes and detach the shield followed by disconnecting the brake booster vacuum hose attached to the manifold. The technician disconnects the EVAP canister purge valve hose quick connect couplings which are linked to the Throttle Body (TB) spacer and EVAP canister purge valve and the PCV tube quick connect coupling which connects to the TB spacer. Disconnect all electrical and vacuum tubes connecting the EGR system module and the intake manifold-to-TB spacer and the generator electric connector. Remove the 4 generator bracket bolts and separate the bracket after disconnection of generator wiring harness retainers from the generator bracket. First remove the coolant thermostat followed by the throttle control and Throttle Position (TP) sensor electrical connector and then free the heater hose through its spring clamp. The installer should first remove the EGR system module tube then detach the wire harness retainer from the intake manifold crash bracket followed by removal of the intake manifold crash bracket bolt by securing the bracket away from the cylinder head with a rubber band or tie strap. The second crash bracket bolt needs to be removed on the intake manifold followed by the unclipping of vacuum connectors from the fuel rail pressure and temperature sensor then unfastening the rear wire harness retainer from the intake manifold. Dispose of the intake manifold gaskets after extracting the 8 bolts to finally proceed with cleaning the sealing surfaces. The installation requires proper alignment between the gasket locator tabs and cylinder head slots before adding new intake manifold gaskets. Engine replacement or repair due to upper engine failure requires a metal debris check of the intake manifold before installing a new one when metal contamination is detected. Use hand force to start the 8 intake manifold bolts before installing the 8 ignition coil-on-plugs. Fit the intake manifold crash bracket first before installing its bolts at(engine tourque of 25 Nm [18lb-ft]) while tightly tightening the intake manifold bolts at the specified order. The EGR system module tube then follows EGR system module tube installation with subsequent 10 Nm (89 lb-in) bolt installation on the intake manifold shield's two bolts. Tighten the throttle control and TP sensor electrical connectors before installing the coolant thermostat along with generator bracket screws at 10 Nm torque (89 lb-in). Plug in the generator electrical connector while fixing generator wiring harness retainers onto the generator bracket and uniting EVAP canister purge valve hose quick connect couplings with the TB and the EVAP canister purge valve. Attach the intake manifold vacuum hose to the TB spacer and join both the EGR system module vacuum and electrical connectors along with the PCV tube quick connect coupling to the TB spacer. Start by connecting the brake booster vacuum hose to the intake manifold and installing the heater hose with spring clamp and connecting the fuel rail pressure and temperature sensor vacuum and electrical connectors. First secure all 8 fuel injector electrical connectors before installing the wire harness retainer to the intake manifold rear side and connecting it to the crash bracket of the intake manifold. The LH cowl extension can be installed through three retainer screws with wiring harness electrical connector attachment before proceeding to attach the RH cowl extension with five retainer screws and tightening the 2 EVAP canister purge valve bracket nuts to 10 Nm torque (89 lb-in). The wiper mounting arm and pivot shaft installation process should be followed by connecting the fuel spring lock coupling then installing the ACL and outlet pipe before finally connecting the battery ground cable and filling and bleeding the engine cooling system.

Remove the air cleaner and outlet pipe, wiper mounting arm, and pivot shaft.

Connect it to the RH rear fuel rail stud bolt.