Mercury F8AZ-9424-AAA Kit - Manifold Hardware

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First of all, here is how you can remove the plastic intake manifold on the 1996 models. First, relieve the fuel system pressure, drain the cooling system, and disconnect the negative battery cable. The initial things to do are to remove the drivebelt, radiator, heater, water pump bypass hoses, thermostat housing, air inlet tube, and vacuum lines. These components include an accelerator cable, automatic transmission cable, speed control linkage, ignition wire brackets, boots, wires, alternator strap tightener bracket, and tightening nut. Next remove the upper intake manifold by taking apart the wire loom bracket, raising the vehicle, and disconnecting the EGR tube along with oil pressure sending unit electrical connector and fuel supply and return lines. Lastly, carefully lift the lower intake manifold from the cylinder heads by loosening and then removing bolts and nuts. Reassemble the components to complete installation.

The first step in removing the air intake plenum and throttle body on a 5.0L engine involves disconnecting the negative battery cable. Also, unplug electrical connectors at the air bypass valve, throttle position sensor, and EGR position sensor. Disconnect the accelerator cable and transmission linkage from the throttle body assembly, remove the accelerator cable/TV cable bracket from the intake manifold, and label and detach vacuum lines from the upper intake manifold vacuum tree, EGR valve, and fuel pressure regulator. Make sure to disconnect the PCV system or any canister purge line if it is present and also downsize the water pipes of spacer coolant lines for EGR. Unbolt six (6) upper manifold retaining bolts to separate the upper manifold and throttle body as an assembly from the lower manifold. Ensure the gasket is in place during installation, attach new gasket(s) onto lower intake mounting face, and snug up air intake plenum with throttle body assembly by using six (6) upper manifold retaining bolts right up to the recommended torque value.

The first step in removing the air intake plenum and throttle body on a 5.0L engine involves disconnecting the negative battery cable. Also, unplug electrical connectors at the air bypass valve, throttle position sensor, and EGR position sensor. Disconnect the accelerator cable and transmission linkage from the throttle body assembly, remove the accelerator cable/TV cable bracket from the intake manifold, and label and detach vacuum lines from the upper intake manifold vacuum tree, EGR valve, and fuel pressure regulator. Make sure to disconnect the PCV system or any canister purge line if it is present and also downsize the water pipes of spacer coolant lines for EGR. Unbolt six (6) upper manifold retaining bolts to separate the upper manifold and throttle body as an assembly from the lower manifold. Ensure the gasket is in place during installation, attach new gasket(s) onto lower intake mounting face, and snug up air intake plenum with throttle body assembly by using six (6) upper manifold retaining bolts right up to the recommended torque value.

Install the nine intake manifold bolts and tighten them to the torque following the correct tightening sequence.

After disconnecting the electrical and vacuum connectors, the distributor is removed, followed by relieving the fuel system pressure and disconnecting the fuel supply and return lines. If equipped, the carburetor is also removed.

Drain the cooling system.

If the manifold was disassembled, reassemble it. Use electrically conductive sealant on the temperature sending unit threads. Use a new EGR valve gasket.

Reassemble it or transfer all components to the new intake manifold. Use electrically conductive sealant on the temperature sending unit threads and a new EGR valve gasket.