Ford D7TZ-9424-K Manifold Assembly - Inlet

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Disconnect the cable from the negative battery terminal. Disconnect electrical connectors from all components on the upper intake manifold and throttle body, marking them for reference. Remove the accelerator cable shield, if present. Detach the accelerator cable, automatic transmission throttle valve cable (if applicable), and cruise control cable. Mark and detach vacuum hoses, PCV system hose, air cleaner-to-throttle body tubes, and canister purge lines. Disconnect coolant lines if equipped. Unscrew the tube nut and detach the tube from the EGR valve. Remove upper intake manifold bolts and separate the upper manifold and throttle body. Clean mating surfaces, place a new gasket on the lower manifold, and reinstall the upper manifold. For the throttle body, disconnect the air intake duct, wires from air bypass valve and throttle position sensor, canister purge lines, and coolant lines if equipped. Remove the accelerator cable shield, detach the accelerator cable, and remove the throttle body bolts. Discard the gasket and reinstall after cleaning surfaces. For the fuel rail assembly, relieve fuel pump pressure, remove the upper intake manifold, disconnect fuel lines and injector connectors, and remove the fuel rail carefully. Reinstallation is in reverse. The fuel pressure regulator is removed by detaching the vacuum line, removing retaining screws, and replacing the regulator, gasket, and O-ring during installation. For fuel injectors, relieve fuel pressure, remove the upper intake manifold and fuel rail, and replace O-rings if necessary. Check the plastic hat covering the pintle for damage. Installation is in reverse. For 3-port and 6-port tank selector valves, relieve fuel pressure, raise the vehicle, disconnect the electrical connector, detach fuel lines, and remove the valve. Reinstall in reverse. Single or dual-function reservoir removal involves relieving fuel pressure, raising the vehicle, detaching fuel lines, and removing the reservoir. Reinstallation is in reverse. To remove the Powertrain Control Module (EECIV), detach the battery cable, locate the PCM connector, unplug it, and remove the module from under the left-side kick panel. Reinstall in reverse. For EEC Power and Fuel Pump relays, locate the relay box, lift the cover, and remove the relays by pulling them straight out of the relay box.

Disconnect the cable from the negative battery terminal. Disconnect electrical connectors from all components on the upper intake manifold and throttle body, marking them for reference. Remove the accelerator cable shield, if present. Detach the accelerator cable, automatic transmission throttle valve cable (if applicable), and cruise control cable. Mark and detach vacuum hoses, PCV system hose, air cleaner-to-throttle body tubes, and canister purge lines. Disconnect coolant lines if equipped. Unscrew the tube nut and detach the tube from the EGR valve. Remove upper intake manifold bolts and separate the upper manifold and throttle body. Clean mating surfaces, place a new gasket on the lower manifold, and reinstall the upper manifold. For the throttle body, disconnect the air intake duct, wires from air bypass valve and throttle position sensor, canister purge lines, and coolant lines if equipped. Remove the accelerator cable shield, detach the accelerator cable, and remove the throttle body bolts. Discard the gasket and reinstall after cleaning surfaces. For the fuel rail assembly, relieve fuel pump pressure, remove the upper intake manifold, disconnect fuel lines and injector connectors, and remove the fuel rail carefully. Reinstallation is in reverse. The fuel pressure regulator is removed by detaching the vacuum line, removing retaining screws, and replacing the regulator, gasket, and O-ring during installation. For fuel injectors, relieve fuel pressure, remove the upper intake manifold and fuel rail, and replace O-rings if necessary. Check the plastic hat covering the pintle for damage. Installation is in reverse. For 3-port and 6-port tank selector valves, relieve fuel pressure, raise the vehicle, disconnect the electrical connector, detach fuel lines, and remove the valve. Reinstall in reverse. Single or dual-function reservoir removal involves relieving fuel pressure, raising the vehicle, detaching fuel lines, and removing the reservoir. Reinstallation is in reverse. To remove the Powertrain Control Module (EECIV), detach the battery cable, locate the PCM connector, unplug it, and remove the module from under the left-side kick panel. Reinstall in reverse. For EEC Power and Fuel Pump relays, locate the relay box, lift the cover, and remove the relays by pulling them straight out of the relay box.

Remove the lines from the fuel rail.

Disconnect the chain at the carburetor and remove the servo bracket assembly attaching nuts. Position the assembly so it will not interfere with manifold removal.

Disconnect the crankcase vent hose leading from the manifold to the valve cover.

Remove the lines from the fuel rail.

If the manifold was disassembled, reassemble it by reversing the disassembly procedure. When installing the temperature sending unit, coat the threads with electrical conductive sealant and coat the thermostat gasket with a thin film of RTV sealant.

Remove the EGR tube. Remove the three EGR spacer attaching screws from the manifold. With the EGR adapter and valve attached, work the EGR spacer loose from the manifold and remove the spacer and gasket.