Ford D7TZ-9424-K Inlet Manifold Assembly

To eliminate the carbureted models, it is necessary to unscrew the air cleaner and its accessories, then loosen the choke cable and the accelerator cable or linkage at the carburetor, and the accelerator return spring. Then, take out the kick-down rod return spring and the kick-down rod from its linkage, unscrew the fuel inlet line, all the vacuum hoses and the power brake booster vacuum hose from the intake manifold. For the FI models, next is the upper intake manifold, the throttle body and after removing the lines from the fuel rail it is time to pull out the fuel rail together with the injectors from the lower intake manifold. Label and remove the lower intake manifold vacuum hoses, the thermactor bypass valve and tube assembly, and any connectors that were observed. On all models, remove the exhaust pipe from the exhaust manifold and secure it aside, unbolt and unfasten the nuts which hold the intake and exhaust manifolds to the cylinder head and lift the manifolds off the engine. Remove all signs of the old gasket material from the mating surfaces, and if replacement manifolds are to be installed, remove the nuts that hold the intake manifold to the exhaust manifold. For installation, new studs have to be installed at the exhaust manifold which is advised due to the given conditions encountered. If you have unbolted the intake and exhaust manifolds, spread graphite on the contacting surfaces of the two, put the exhaust manifold on the studs on the intake manifold, thread the lock washers and nuts and tighten them with your fingers just enough. insert a new one in the intake manifold-to-head gasket, spread a thin layer of graphite grease on the mating surfaces and fit the manifold assemblies to the cylinder head, put on the attaching washers and tighten the bolts and nuts enough only to hold their positions, then torque them properly. Last but not the least, obtain a new gasket, fit it to the exhaust pipe and bolt it to the exhaust manifold and make sure that the nuts are tightened in the right manner; finally follow the reverse procedure of the mentioned removal process.

To remove the carbureted models, begin by draining the cooling system, then remove the air cleaner and intake duct assemblies. Carefully mark and detach any emissions control connections at the air cleaner, disconnect the upper radiator hose from the thermostat housing, and disconnect the heater hose and water pump by-pass hose at the intake manifold connections. For a 7.5L engine, remove the right valve cover. Mark and disconnect the spark plug wires at the spark plugs, then remove the distributor cap along with the spark plug wires. Disconnect the primary low voltage wires from the coil, marking them for correct reinstallation, and remove the coil mounting bracket and mounting bolt. Remove the carburetor fuel inlet line from the carburetor, positioning it out of the way, and disconnect the vacuum advance hose(s) from the distributor, marking them for proper installation. Remove the distributor and any wires from sensors mounted in the intake manifold or upper thermostat housing. Remove the accelerator cable or linkage connection at the carburetor, the kickdown cable if equipped with an automatic transmission, and the pull cable and activating unit from the intake manifold if cruise control is present. Remove the vacuum hose leading to the power brake booster from the intake manifold and secure it to the firewall. If servicing the carburetor separately, remove it from the intake manifold, and disconnect the crankcase vent hose leading from the manifold to the valve cover. For fuel-injected models, remove the upper intake manifold, drain the cooling system, and remove the distributor. Label and disconnect all electrical harness connectors from lower intake manifold sensors and solenoids, as well as any vacuum hoses from the lower intake manifold. Relieve the fuel system pressure, disconnect the fuel supply and return lines from the fuel rail, and disconnect the fuel injector electrical connectors. Remove the oxygen sensor ground wire from the intake manifold stud, the upper radiator hose from the thermostat housing, and the bypass and outlet hoses from the intake manifold. Remove the coil/solenoid bracket assembly and position it out of the way. For all engines, remove the bolts retaining the intake manifold to the cylinder heads, attach lifting hooks at opposite corners, and lift the intake manifold from the engine, taking care not to damage the mating surfaces. Clean the mating surfaces of the intake manifold and cylinder heads, remove the end gaskets from the top of the engine block, and remove the oil gallery splash pan if equipped. For installation, reassemble the manifold by reversing the disassembly procedure, applying electrical conductive sealant to the temperature sending unit threads and RTV sealant to the thermostat gasket. Apply a bead of RTV sealant to the mating points at the junctions of the cylinder heads and engine block, position the new manifold end seals carefully, and ensure the intake manifold gaskets are aligned correctly with the cylinder heads. Apply a bead of RTV sealant to the interlocking corners of the intake manifold gasket and end seal, install locating pins if necessary, lower the intake manifold into position, and install the retaining bolts, tightening them in sequence to the specified torque. Reinstall the remaining components in reverse order, refill the cooling system, and start the engine, allowing it to reach operating temperature while checking for leaks and adjusting the ignition timing if necessary.

Drain the cooling system and disconnect the cable from the negative battery terminal. Remove the carburetor and the attaching bolts from the accelerator cable mounting bracket, positioning the cable to avoid interference with manifold removal. If equipped with cruise control, disconnect the chain at the carburetor and remove the servo bracket assembly attaching nuts, positioning the assembly similarly. Disconnect the upper radiator hose at the thermostat housing, the coolant bypass hose at the manifold, and the heater tube at the intake manifold, removing the tube support bracket attaching nut. Disconnect the necessary electrical connectors and, if equipped with air conditioning, remove the air compressor support bracket attached to the left front intake manifold attaching bolt. Remove the EGR tube and the three EGR spacer attaching screws from the manifold, then work the EGR spacer loose from the manifold along with the gasket. Remove the PCV line and the intake manifold attaching bolts in reverse order of the tightening sequence before removing the intake manifold, taking care to break the RTV sealant if necessary. Remove the manifold side gaskets, and if disassembly is required, take out the thermostat housing, thermostat, water temperature sending unit, thermactor check valve, and all vacuum fittings. The heater outlet and water bypass tubes are pressed in and not serviceable; if damaged, replace the manifold. If disassembled, apply a coat of pipe sealant to the temperature sending unit, vacuum fittings, spark knock sensor/adapter, and electric PVS, then install them in the manifold. Install the thermostat with the outlet side up, apply a 1/8-inch bead of RTV sealant to the thermostat housing, and tighten it to the specified torque. Install the thermactor check valve using a new gasket in the manifold, apply RTV sealant to each cylinder head mating surface, and press new intake manifold gaskets into place using the locating pins. Apply a 1/8-inch bead of RTV sealant at each corner where the cylinder head joins the cylinder block and a 3/4-inch bead at each end of the cylinder block where the manifold seats against it. Carefully lower the manifold into position on the cylinder block and heads, using the locating pins to prevent smearing the sealant. Apply a thin coat of pipe sealant to the manifold attaching bolt threads and the underside of the bolt heads, then install the 12 bolts and two stud bolts, tightening them in the numerical sequence to the specified torque. Reinstall the remaining components in reverse order of removal, fill the cooling system with the specified coolant, start the engine, and allow it to reach operating temperature while checking for leaks. Finally, shut the engine off and retighten the manifold bolts while the engine is still warm.