Mercury 1W7Z-9424-BA Kit - Manifold Hardware

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After completing the installation, you should reassemble the components and check for oil and coolant leaks at the intake manifold joints after starting the engine.

The electrical and vacuum connectors need to be disconnected from the coolant temperature sending unit, air charge temperature sensor, throttle positioner, idle speed control solenoid, EGA sensors, fuel injectors, and fuel charging assembly.

Carefully set the manifold in place while the sealant is still wet. Caution: Don't disturb the gaskets and don't move the manifold fore-and-aft after it contacts the seals on the block. Make sure the end seals haven't been disturbed.

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.

Disconnect the electrical connector.

Disconnect the electrical connectors from the ignition coils, camshaft sensor, coolant temperature sending unit, air charge temperature sensor, throttle positioner, idle speed control solenoid, EGR sensors, fuel injectors, and fuel charging assembly.

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.

During installation, ensure the gasket mating surfaces are clean and free of damage. Tighten the throttle body mounting nuts to the specified torque.