Ford 6W7Z-9424-AA Manifold Assembly - Inlet 0

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The manifold will probably be stuck to the cylinder heads and force may be required to break the gasket seal. A prybar 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.

Continue by disconnecting the PCV system and, if present, the canister purge line and EGR spacer coolant lines, draining the coolant if needed. Remove the six upper intake manifold retaining bolts and lift off the upper intake manifold and throttle body as an assembly from the lower intake manifold.

Disconnect them and set them out of the way.

Use a gasket scraper to remove all traces of sealant and old gasket material, then clean the mating surfaces with lacquer thinner or acetone.

Start by relieving fuel pressure, disconnecting the battery cable, and removing the air intake plenum assembly on 5.0L engines or the air intake assembly on 4.6L engines. Use a special spring lock coupling tool to disconnect the fuel feed and return lines from the fuel rail assembly. Remove the four fuel rail assembly retaining bolts and carefully disengage the fuel rail from the fuel injectors. The installation process is the reverse of removal.

The mating surfaces of the cylinder heads, block, and manifold must be perfectly clean when the manifold is installed. Gasket removal solvents in aerosol cans are available at most auto parts stores and may be helpful when removing old gasket material that's stuck to the heads and manifold (since the manifold is made of aluminum, aggressive scraping can cause damage!) Be sure to follow directions printed on the container.