Ford 4L5Z-9424-BA Manifold Assembly - Inlet

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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.

Disconnect the EGR valve vacuum hose and the EVAP canister purge solenoid vacuum hose.

Position the intake manifold gaskets in place over the tabs on the cylinder heads, ensuring the locking tabs on the gaskets are engaged.

The remainder of the installation is the reverse of the removal steps.

Disconnect the EGR pipe from the intake manifold and the exhaust manifold.

Disconnect the EGR transducer hoses from the EGR valve and remove the EGR valve.

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.

Position the new intake manifold gasket on the head, using a light coat of gasket sealant to hold it in place.

Relieve the fuel system pressure.

Clamp-off the coolant hose to the intake manifold and then remove the hose from its fitting.

Disconnect the negative battery cable.

Install the manifold gasket, then apply RTV sealant onto the gasket, around the coolant ports and to the four corners.

Clean away all traces of old gasket material. Remove oil and dirt with a cloth and solvent, such as acetone or lacquer thinner.

The manifold will probably be stuck to the cylinder heads and force may be required to break the gasket seal. A pry bar can be used to pry up the manifold, but make sure all bolts and nuts have been removed first! Caution: Don't pry between the block and manifold or the heads and manifold or damage to the gasket sealing surfaces may occur, leading to vacuum and oil leaks. Pry only at a manifold casting protrusion.

Disconnect the negative cable from the battery and remove the drive belt.