This procedure covers the removal and replacement of the intake manifold on a 2011-2014 Ford F-150 with the 3.5L EcoBoost engine, including removal of upper and lower intake components, fuel rails, and associated sensors.

Warnings

Tools required

Parts

• Lower intake manifold gaskets × 2 — Use OEM Ford specification
• Upper intake manifold gasket × 1 — Use OEM Ford specification
• Throttle body gasket × 1 — Use OEM Ford specification
• Fuel rail O-rings × 6 — Use OEM Ford specification
• PCV valve O-ring or gasket × 1 — Use OEM Ford specification

Preparation

1. Ensure engine is completely cool to the touch, minimum 3 hours after last operation
2. Park vehicle on level surface and engage parking brake
3. Disconnect negative battery terminal and wait 10 minutes for airbag system capacitors to discharge
4. Relieve fuel system pressure: remove fuel pump fuse, start engine and let it run until it stalls, then crank for 5 seconds
5. Remove engine cover by pulling upward on clip attachments
6. Label or photograph all vacuum lines, electrical connectors, and hose connections for reference
7. Place fuel-safe drain pan under work area to catch residual fuel

Procedure

1. 1

   Disconnect air intake system
   Disconnect the mass airflow sensor electrical connector. Loosen the clamps securing the air intake tube to the throttle body and air filter housing. Remove the entire air intake tube assembly and set aside.
2. 2

   Remove throttle body
   Disconnect the throttle position sensor electrical connector. Remove the four throttle body mounting bolts and carefully lift the throttle body away from the upper intake manifold. Remove and discard the old throttle body gasket. Cover the intake opening with a clean shop towel to prevent debris entry.
   Torque spec

   Throttle Body Bolts10 Nm (7 lb-ft)
3. 3

   Disconnect vacuum lines and PCV system
   Disconnect the brake booster vacuum line from the upper intake manifold. Disconnect all vacuum lines to the intake manifold, including EVAP purge line and any vacuum-operated actuators. Remove the PCV valve from the valve cover by rotating counterclockwise, noting its position for reinstallation.
   ℹ️Mark each vacuum line with tape labels showing their connection points to avoid misrouting during reassembly.
   Torque spec

   PCV Valve8 Nm (6 lb-ft)
4. 4

   Disconnect electrical connections
   Disconnect all electrical connectors from the upper intake manifold area including: fuel injector harness connectors (both banks), intake manifold runner control actuators, charge motion control valve actuators, and any temperature or pressure sensors mounted on the intake manifold. Use a plastic trim tool if necessary to release locking tabs without damage.
5. 5

   Remove upper intake manifold
   Remove all upper intake manifold bolts in reverse of the tightening sequence (consult Ford service manual for exact sequence diagram). There are typically 10 bolts securing the upper intake. Carefully lift the upper intake manifold assembly upward, working it free from any remaining connections. Inspect and note the condition of the gasket surface.
   ⚠Upper intake manifold is heavy and awkward. Use care when lifting to avoid dropping it onto engine components or fuel rails.
   Torque spec

   Intake Manifold Bolts25 Nm (18 lb-ft)
6. 6

   Relieve residual fuel pressure and disconnect fuel lines
   Place towels around fuel rail connections to absorb residual fuel. Using proper fuel line disconnect tools, disconnect the high-pressure fuel supply line from the fuel rail. Disconnect the fuel return line if equipped. Cap or plug open fuel lines immediately to prevent contamination and fuel spillage.
   ⚠️Even after relieving system pressure, residual fuel will spray from connections. Wear safety glasses and have fire extinguisher nearby.
7. 7

   Remove fuel rails and injectors
   Remove the fuel rail mounting bolts on both driver and passenger side fuel rails following the proper loosening sequence per Ford service manual. Carefully lift each fuel rail with injectors still attached straight up to avoid damaging injector O-rings. Place fuel rails on clean shop towels away from work area. If injectors remain in manifold, use care when removing them.
   ⚠Do not allow fuel injectors to hang by their wiring harnesses. Support the fuel rail assembly to prevent injector damage.
   Torque spec

   Fuel Rail Bolts12 Nm (9 lb-ft)
8. 8

   Remove intake manifold cover components
   Remove any remaining cover plates or shields attached to the lower intake manifold using appropriate sockets. Remove cover bolts and set hardware aside in organized manner for reinstallation.
   Torque spec

   Cover Bolts19 Nm (14 lb-ft)
9. 9

   Remove lower intake manifold
   Remove all lower intake manifold mounting bolts in reverse sequence from tightening pattern (outside-in pattern, consult Ford service manual diagram). The lower intake is secured to the cylinder heads with multiple bolts. Carefully lift the lower intake manifold assembly upward, breaking the gasket seal. Rock gently if needed but avoid prying against gasket surfaces.
   ⚠Lower intake manifold is heavy. Have an assistant help lift it clear of the engine bay to avoid dropping it on turbochargers or other components.
   Torque spec

   Intake Manifold Bolts25 Nm (18 lb-ft)
10. 10

    Clean all gasket surfaces
    Using plastic scrapers only (never metal), carefully remove all old gasket material from the cylinder head mating surfaces, upper intake mating surface, and intake manifold surfaces. Use compressed air to blow debris away from engine valley. Wipe surfaces with clean, lint-free cloths. Inspect for any damage, warping, or cracks on all mating surfaces.
    ⚠Do not allow any gasket material or debris to fall into cylinder head ports or engine valley. Stuff clean towels in openings during cleaning.
11. 11

    Install new lower intake manifold
    Position new intake manifold gaskets on cylinder heads, ensuring proper alignment with dowel pins if equipped. Carefully lower the lower intake manifold into position, verifying gaskets remain properly seated. Hand-thread all intake manifold bolts to prevent cross-threading. Tighten bolts in proper sequence from center outward to the specified torque following Ford service manual sequence diagram.
    ℹ️Intake manifold bolt sequence is critical for proper sealing. Failure to follow sequence can result in vacuum leaks or gasket failure.
    Torque spec

    Intake Manifold Bolts25 Nm (18 lb-ft)
12. 12

    Install intake manifold covers and components
    Reinstall any cover plates or shields that were removed from the lower intake manifold. Torque cover bolts to specification.
    Torque spec

    Cover Bolts19 Nm (14 lb-ft)
13. 13

    Install fuel rails and injectors
    Lubricate new fuel injector O-rings with clean engine oil. Carefully position fuel injectors into their bores in the intake manifold, ensuring proper seating. Lower fuel rails onto injectors, pressing firmly to fully seat all injectors. Install fuel rail mounting bolts and tighten in proper sequence per Ford service manual to specified torque.
    ⚠Fuel injector O-rings must be properly seated. Damaged or twisted O-rings will cause fuel leaks and potential fire hazard.
    Torque spec

    Fuel Rail Bolts12 Nm (9 lb-ft)
14. 14

    Reconnect fuel lines
    Remove caps from fuel lines. Connect high-pressure fuel supply line to fuel rail, ensuring connection clicks and locks properly. Tug gently to verify secure connection. Connect fuel return line if equipped. Verify all connections are secure.
15. 15

    Install upper intake manifold
    Position new upper intake manifold gasket on lower intake manifold. Carefully lower upper intake manifold into position, aligning all mounting bolt holes. Hand-thread all upper intake manifold bolts. Following Ford service manual tightening sequence, torque bolts in sequence to specification.
    Torque spec

    Intake Manifold Bolts25 Nm (18 lb-ft)
16. 16

    Reconnect electrical connections
    Reconnect all electrical connectors that were disconnected during disassembly, including fuel injector harnesses, manifold runner control actuators, charge motion control valve actuators, and all sensors. Ensure all connectors click securely into place and locking tabs are engaged.
17. 17

    Reinstall PCV valve and vacuum lines
    Install PCV valve with new O-ring or gasket into valve cover, torquing to specification. Reconnect all vacuum lines according to photos or labels created during disassembly. Verify brake booster vacuum line is securely connected. Double-check all vacuum connections are tight.
    Torque spec

    PCV Valve8 Nm (6 lb-ft)
18. 18

    Install throttle body
    Position new throttle body gasket on upper intake manifold. Carefully place throttle body onto intake manifold, aligning mounting holes. Install throttle body bolts and torque to specification in a cross-pattern. Reconnect throttle position sensor electrical connector.
    Torque spec

    Throttle Body Bolts10 Nm (7 lb-ft)
19. 19

    Reinstall air intake system
    Position air intake tube assembly connecting throttle body to air filter housing. Tighten hose clamps securely at both ends. Reconnect mass airflow sensor electrical connector. Ensure all connections are tight and properly sealed.

Reassembly

1. Reinstall engine cover, pressing firmly on all mounting points until clips engage
2. Reconnect negative battery terminal and tighten securely
3. Reinstall fuel pump fuse to restore fuel pump operation

Verification

• Turn ignition to ON position (without starting) to allow fuel pump to prime system. Listen for fuel pump operation. Cycle ignition OFF and ON three times to fully prime fuel system
• Inspect all fuel line connections for any signs of fuel leakage while system is pressurized
• Start engine and let idle. Monitor for any fuel leaks, vacuum leaks (rough idle), or unusual noises
• Check for diagnostic trouble codes using OBD-II scanner. Clear any codes related to battery disconnection
• Verify throttle response is normal with no hesitation or sticking
• Let engine reach operating temperature and verify no coolant, fuel, or vacuum leaks are present
• Test drive vehicle to verify proper engine performance, smooth acceleration, and no check engine light illumination
• After test drive, re-inspect all connections and torque specifications while engine is warm, checking for any leaks or loose connections

More procedures for this vehicle