Ford 1L5Z-9424-DA Manifold Assembly - Inlet

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For the above procedures involving the removal of upper intake manifold and throttle body, the following are the steps required for sohc four cylinder engines, The air cleaner housing and the splash shield for the accelerator linkage should be taken off; the accelerator cable should as well be disconnected from the throttle body. Then, remove the connection of the electrical wires coming from the throttle position sensor, idle air control valve and EGR vacuum regulator control if present, and the ground wire of the engine if exist. Remove the PCV hose and mark the vacuum hoses from manifold vacuum tee. Disconnect the transducer hoses for the EGR and the EGR valve and take out the upper intake manifold bolts and studs. Remove any old gasket material from the surfaces, fit a new gasket on the lower intake manifold, place the upper manifold in position and tighten the bolts in a star pattern to the recommended torque. The process of installation is done in a opposite way whereby the removal process was done. To expose the bug, remove the throttle body splash shield disconnecting also the accelerator cable and the electrical connector of the Throttle Position Sensor. The air inlet duct; free the clips or bolts and disconnect the air inlet duct and then remove the bolts that are holding the throttle body and remove the throttle body. Scrub that mating surfaces and set in a new gasket before repositioning the throttle body and fastening the screws. When dealing with fuel rail and injectors, steam clean the engine if required, then refer to the fuel system pressure relief procedure, next remove the negative battery cable and finally the air inlet tube. Remove the fuel supply hose and the return hose from the fuel injectors, then remove the bolts holding the fuel rail then disconnect the electrical connectors from the injectors. Delicately raise the fuel rail and its injectors, if necessary disconnecting the injectors. For installation, the injector O-rings must be checked for damage, if so, it must be replaced and lubed with the engine oil then the injectors must be fitted to the fuel rail. At last, rotate the key ON/OFF to pressurise the fuel system and look for any signs of leakage.

Take out the mounting bolts and discard the gasket as you remove the throttle body. Clean the gasket mating surfaces and use a new gasket when installing, tightening the bolts securely. To detach the upper intake manifold, disconnect the battery and then remove the air cleaner outlet tube, accelerator cable splash shield bracket, and cable from the throttle body. Remove the manifold mounting bolts lift it off of the fuel rail and discard the gasket. Installation involves cleaning and inspection of mounting faces, placing a new gasket onto lower intake mounting face, and securing manifold and throttle body assembly to lower intake manifold.

Tighten the nuts and bolts in four stages, following the sequence.

Tighten the bolts to the torque specification, starting with the center bolts and working towards the ends.

Clean all traces of old gasket material from the mating surfaces using a scraper. Use a solvent such as lacquer thinner or acetone if necessary.

Remove the distributor.

Remove the intake manifold mounting bolts. Lift up the manifold to access and remove the PCV fitting bolts from the manifold.

Apply RTV sealant around the coolant ports and to the front sealing surface, as well as a bead of sealant to the four corners where the manifold meets the engine.

Reconnect the battery and refill the cooling system.

Remove the engine oil dipstick, then unscrew the bolts and remove the dipstick tube.

Clean the manifold and head mating surfaces and check the manifold for cracks.

Disconnect all hoses and clips along with any engine wiring harness retainers from the manifold.

Tighten the bolts in stages, starting with the center bolts and working towards the ends.

Clean and inspect the mounting faces, place a new gasket onto the lower intake mounting face, and secure the upper intake manifold and throttle body assembly onto the lower intake manifold.

Install the manifold to the cylinder heads, making sure the bolt holes are aligned. Install the bolts and tighten them finger-tight, ensuring not to move the manifold back and forth to avoid displacing the O-ring seals.

Install the bolts and following the recommended tightening sequence, tighten them to the torque (Lower intake manifold bolt tightening sequence).

The remaining installation steps are the reverse of removal. Change the engine oil and refill the cooling system. Start the engine and check carefully for oil and coolant leaks at the intake manifold joints.

Remove the valve covers and remove the cooling fan and shroud.

The remainder of installation is the reverse of removal.