OEM Ford Five Hundred Intake Manifold

Ford Five Hundred Intake Manifold Parts and Q&A

• Intake Manifold
  5F9Z-9424-DA
  Q: How to service and repair the upper intake manifold on Ford Five Hundred?

  A:

  The first step for upper intake manifold maintenance requires you to disconnect the grounding cable of the battery. Service the upper intake manifold by first removing the air cleaner outlet pipe and afterward removing the transaxle roll restrictor cross brace bolt between the four bolts and finally removing the brace itself. The team needs to disconnect the evaporative emissions (EVAP) canister purge valve tube from the upper intake manifold and discard the retaining device. Service of the upper intake manifold starts with PCV tube removal while simultaneously detaching the Brake Booster and vacuum harness tubes and the fuel tube retainer. Disconnect the exhaust gas recirculation (EGR) system module electrical connector while removing the vacuum tube and then separate the vacuum tube from the upper intake manifold vacuum tube retainer. Disconnect the EGR system module tube from its connection to the EGR system module and seal both PCV coolant hoses and the vacuum lines (not required for the related article). First detach the throttle body electrical connector while removing the four upper-to-lower intake manifold screws if the vehicle has them. The eight bolts fastening the upper intake manifold need removal before discarding the gaskets. The installation requires cleaning and inspection of all sealing surfaces before positioning the upper intake manifold before bolting it with eight bolts which should be tightened to 10 Nm (89 lb-in) per manufacturer instruction sequence. The installation process requires attaching the throttle body electrical connector as well as plugging and connecting the two PCV coolant hoses with proper torque at 40 Nm (30 lb-ft). Finally, connect and torque tighten the EGR system module tube to its respective module. Installation requires the attachment of the vacuum tube to the upper intake manifold vacuum tube retainer along with connecting the EGR system module electrical connector and vacuum tube followed by fuel tube retainer attachment to the upper intake manifold. The vacuum harness tubes with the brake booster and PCV need attachment to the upper intake manifold. Then attach the EVAP canister purge valve tube followed by installing the appropriate retainer. Begin by cleaning the four transaxle roll restrictor cross brace bolts using a wire brush and apply new threadlock on their threads before placing the transaxle roll restrictor cross brace in position with four new bolts which need to be tightened to 55 Nm (41 lb-ft). A wire brush should be used to clean the transaxle roll restrictor cross brace-to-roll restrictor bolt before applying new threadlock and installing a new bolt that needs to be tightened to 48 Nm (35 lb-ft). After tightening the battery ground cable you should mount the air cleaner outlet pipe.