Mercury 1W7Z-9424-AA Manifold Assembly - Inlet

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Various components that should be disconnected include the accelerator cable, automatic transmission cable, speed control linkage, ignition wire brackets, boots, wires, alternator, ignition coils, CID sensor, and multiple electrical connectors.

After the installation of the intake manifold, the engine oil should be changed and the cooling system should be refilled. The engine should then be started and carefully checked for oil and coolant leaks at the intake manifold joints.

Disconnect them and set them out of the way.

Disconnect the radiator, heater, and water pump bypass hoses from the water outlet. Disconnect the throttle body cooler hoses. Note: The heater outlet and coolant bypass tubes are pressed in and cannot be removed.

Relieve fuel pressure, remove the air intake plenum assembly on 5.0L engines or the air intake assembly on 4.6L engines, and remove the fuel rail assembly. Detach the electrical connectors from the injectors, remove the injectors, inspect and replace injector O-rings and other components as needed. Lubricate new O-rings with oil before installation and twist to install the injectors. The remainder of the installation is the reverse of removal.

Use a gasket scraper to remove all traces of sealant and old gasket material, then clean the mating surfaces with lacquer thinner or acetone. If there's old sealant or oil on the mating surfaces when the manifold is installed, oil or vacuum leaks may develop. When working on the heads and block, cover the lifter valley with shop rags to keep debris out of the engine. Use a vacuum cleaner to remove any gasket material that falls into the intake ports in the heads.

Remove the PCV and canister purge hoses.

Start by disconnecting the negative battery cable. Following that, unplug electrical connectors at the air bypass valve, throttle position sensor, and EGR position sensor. Detach the accelerator cable and transmission linkage from the throttle body assembly, remove the accelerator cable/Throttle Valve (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.