Ford 5C3Z-9424-CRM
Intake Manifold

Start servicing or repairing the intake manifold only when there is no presence of smoking or open flames because fuel-related components possess flammable properties. The service process requires draining fuel system pressure before unfastening fuel lines. First disconnect the fuel supply coupling from the fuel rail by removing its spring lock before draining the cooling system then extracting the generator. You should first remove the air cleaner outlet pipe and disconnect the upper radiator hose from the thermostat housing before disconnecting the heater coolant hose from the coolant crossover assembly. The service should begin by disconnecting the fuel rail pressure and temperature sensor electrical connector together with its vacuum connector while also separating the 10 fuel injector electrical connectors and intake manifold runner control (IMRC) actuator electrical connector. Disconnections are required for the positive crankcase ventilation (PCV) tube quick connect coupling from the intake manifold as well as the evaporative emissions (EVAP) tube quick connect couplings and the brake booster and engine vacuum hose connections from the rear of the intake manifold and the 2 heated PCV coolant hoses. Cut the right connections for throttle position (TP) and electronic throttle control after disconnecting both cables then remove the engine wiring harness position retainers found on top of the intake manifold. The installation of new intake manifold gaskets requires first removing all 12 bolts and afterwards cleaning the sealing surface using a silicone gasket remover and plastic scraping tool before discarding old gaskets. Install the intake manifold with new gaskets first and then position the coolant crossover tube with new gaskets before fastening its two bolts to 10 Nm (89 inch lbs.). The maintenance team should install intake manifold bolts through two steps starting at 2 Nm (18 inch lbs.) then tightening them to 10 Nm (89 inch lbs.). The service procedure requires the TP sensor and electronic throttle control electrical connectors to be reconnected with the engine wiring harness position retainers and PCV tube quick connect coupling while including brake booster and engine vacuum hose connections and EVAP tube quick connect couplings and 2 heated PCV coolant hoses. The installation process involves reattaching the 10 fuel injector electrical connectors as well as reconnecting the fuel rail pressure and temperature sensor electrical connector and vacuum connector and the IMRC actuator electrical connector. The final step includes connecting the fuel supply spring lock coupling to the fuel rail while also attaching the heater coolant hose to the coolant crossover assembly as well as mating the heated PCV coolant hose with the coolant crossover assembly and securing the upper radiator hose to the thermostat housing. Safely reattach the generator along with the air cleaner outlet pipe before processing engine cooling system filling and bleeding procedures.

Lubricate new O-ring seals with clean engine oil and install them on each fuel injector before assembling the injectors onto the fuel rail and securing them with the locking clips.

Disconnect the Positive Crankcase Valve (PCV) tube, vacuum tubes, heated PCV coolant hose, and vacuum tube.

Remove the 6 bolts from the fuel rail assembly to take out the fuel rail and fuel injectors as an assembly.