Intake manifold — removal and installation Ford F150
Warning: Wait until the engine is completely cool before beginning this procedure.
Removal
1. Relieve the fuel system pressure (see Fuel and exhaust systems).
2. Disconnect the cable from the negative battery terminal (see Engine electrical systems).
3. Remove the air intake duct and the air filter housing (see Fuel and exhaust systems).
4. Disconnect the electrical connectors from the throttle body and the fuel injectors (see Fuel and exhaust systems).
5. Label and disconnect the brake booster vacuum line and any other vacuum lines connected to the intake manifold.
6. Disconnect the quick-connect coupling from the PCV tubes.
7. Disconnect the quick-connect coupling from the brake booster (see Brakes) and the EVAP canister purge valve (see Engine electrical systems).
8. Disconnect the fuel supply lines from the fuel rails (see Fuel and exhaust systems).
9. Remove the throttle body (see Fuel and exhaust systems).
10. Detach the electrical harness where it attaches to the valve covers or intake manifold, then disconnect the electrical connectors at the ignition coils.
11. Disconnect the EVAP tube (quick-connect) and the PCV hose.
12. Remove the fuel injector insulators and disconnect the purge valve electrical connector. Disconnect the fuel injector connectors and the wiring harness at the rear of the intake manifold.
13. Remove the four fuel rail bolts and six intake manifold bolts.
14. Lif the manifold from the cylinder heads. If it is stuck, it shouldn’t take more than a little bit of force to jar it loose.
15. Remove the intake manifold 0-ring gaskets and clean all traces of dirt and gasket or sealant material from the sealing surfaces of the cylinder heads and intake manifold.
Caution: The mating surfaces of the cylinder heads and intake manifold must be perfectly clean. Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean sealing surfaces; these tools can scratch and gouge gasket surfaces, which creates leak paths. While the manifold is removed, cover the open engine areas with shop rags to keep debris out of the engine. Use a vacuum cleaner to remove any debris that falls into the intake ports in the cylinder heads.
Installation
16. If you are replacing the manifold, transfer all components to the new unit.
17. Install new 0-ring type intake manifold gaskets into their grooves in the manifold.
18. Carefully set the intake manifold in place.
Intake manifold and fuel rail bolt tightening sequence
19. Install the intake manifold bolts first and, following the recommended tightening sequence, tighten them to the torque listed in this Chapter’s Specifications. Install the fuel rail bolts second and following the recommended sequence, tighten them to the torque listed in this Chapter’s Specifications.
20. The remainder of installation is the reverse of removal.