Ford 1L5Z-9424-DA Inlet Manifold Assembly

Take out the mounting bolts and discard the gasket as you remove the throttle body. Clean the gasket mating surfaces and use a new gasket when installing, tightening the bolts securely. To detach the upper intake manifold, disconnect the battery and then remove the air cleaner outlet tube, accelerator cable splash shield bracket, and cable from the throttle body. Remove the manifold mounting bolts lift it off of the fuel rail and discard the gasket. Installation involves cleaning and inspection of mounting faces, placing a new gasket onto lower intake mounting face, and securing manifold and throttle body assembly to lower intake manifold.

For the above procedures involving the removal of upper intake manifold and throttle body, the following are the steps required for sohc four cylinder engines, The air cleaner housing and the splash shield for the accelerator linkage should be taken off; the accelerator cable should as well be disconnected from the throttle body. Then, remove the connection of the electrical wires coming from the throttle position sensor, idle air control valve and EGR vacuum regulator control if present, and the ground wire of the engine if exist. Remove the PCV hose and mark the vacuum hoses from manifold vacuum tee. Disconnect the transducer hoses for the EGR and the EGR valve and take out the upper intake manifold bolts and studs. Remove any old gasket material from the surfaces, fit a new gasket on the lower intake manifold, place the upper manifold in position and tighten the bolts in a star pattern to the recommended torque. The process of installation is done in a opposite way whereby the removal process was done. To expose the bug, remove the throttle body splash shield disconnecting also the accelerator cable and the electrical connector of the Throttle Position Sensor. The air inlet duct; free the clips or bolts and disconnect the air inlet duct and then remove the bolts that are holding the throttle body and remove the throttle body. Scrub that mating surfaces and set in a new gasket before repositioning the throttle body and fastening the screws. When dealing with fuel rail and injectors, steam clean the engine if required, then refer to the fuel system pressure relief procedure, next remove the negative battery cable and finally the air inlet tube. Remove the fuel supply hose and the return hose from the fuel injectors, then remove the bolts holding the fuel rail then disconnect the electrical connectors from the injectors. Delicately raise the fuel rail and its injectors, if necessary disconnecting the injectors. For installation, the injector O-rings must be checked for damage, if so, it must be replaced and lubed with the engine oil then the injectors must be fitted to the fuel rail. At last, rotate the key ON/OFF to pressurise the fuel system and look for any signs of leakage.

Remove the valve covers and remove the cooling fan and shroud.

Disconnect the battery, detach the air cleaner outlet tube, and remove the accelerator cable splash shield, bracket, and cable from the throttle body. Disconnect all remaining hoses and electrical connectors. Additional steps may be required for specific models, such as removing the fuel rail and injectors, as well as any vacuum lines connected to the intake manifold. Once everything is disconnected, carefully unbolt the upper intake manifold from the engine, ensuring to follow the manufacturer's torque specifications for reassembly. Gently lift the manifold off, taking care not to damage any gaskets or seals.

Remove the lower intake manifold bolts and lift the manifold off. If it's stuck, tap it lightly with a soft-face hammer to break the gasket seal. Be cautious not to pry against the gasket surfaces as the manifold is plastic.

Remove the camshaft position sensor.

Tighten the bolts to the torque specification, starting with the center bolts and working towards the ends.

6L2Z9S479A