Ford 1W7Z-9F593-AA Injector Assembly

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To remove the air intake plenum (upper intake manifold) and throttle body on a 5.0L engine, first disconnect the negative battery cable, then 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. Disconnect 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 the upper intake manifold and throttle body as an assembly from the lower intake manifold. During installation, ensure the gasket is in place, position the new gasket(s) onto the lower intake mounting face, and secure the air intake plenum and throttle body assembly with the six upper intake manifold retaining bolts, tightening them to the specified torque. For the throttle body on 5.0L and 4.6L engines, begin by detaching the negative battery cable and the throttle position sensor and throttle air bypass valve electrical connectors. Disconnect the accelerator cable and Throttle Valve (TV) cable (if equipped), as well as the PCV vent closure hose (if present). Remove the four throttle body mounting nuts and, on 5.0L engines, carefully separate the throttle body from the EGR spacer, discarding the gasket for 5.0L engines. During installation, ensure the gasket mating surfaces are clean and free of damage, and tighten the throttle body mounting nuts to the specified torque. For the fuel rail assembly, relieve fuel pressure, disconnect the battery cable, and remove 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, then remove the four fuel rail assembly retaining bolts (two on each side) and carefully disengage the fuel rail from the fuel injectors. Installation is the reverse of removal. For the fuel pressure regulator, relieve fuel system pressure, disconnect the battery cable, and detach the vacuum hose from the regulator. On 4.6L engines, remove the fuel rail bolts to access the regulator mounting bolts, then remove the regulator, replace its O-rings, and lubricate them with oil before installation. For fuel injectors, 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. Carefully detach the electrical connectors from the injectors, remove the injectors by pulling up while gently rocking them from side-to-side, and 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.

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.