This procedure covers removal and installation of the intake manifold on the 2011-2014 Ford F-150 5.0L Coyote V8 engine, including fuel system depressurization, disconnection of sensors and hoses, and proper torque sequence for reassembly.

Warnings

Tools required

Parts

• Intake manifold gaskets (set of 8) × 1 — Motorcraft DY-1324 or equivalent
• Throttle body gasket × 1 — Use OEM specification
• PCV valve (if replacement needed) × 1 — Motorcraft EV-279 or equivalent
• Fuel injector O-rings (if disturbed) × 1 — Use OEM specification

Fluids

• Motorcraft 5W-20 Synthetic Blend Engine Oil (for oil changes during service) — 7.5 qt
• Motorcraft Orange Coolant (replacement if drained) — 16 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Allow engine to cool completely for minimum 2 hours
3. Disconnect negative battery terminal and wait 10 minutes
4. Remove engine cover by pulling upward on cover (press-fit clips)
5. Place drip pans under work area to catch fuel and coolant spillage
6. Relieve fuel system pressure by removing fuel pump fuse (fuse 27 in battery junction box), starting engine, and allowing it to run until it stalls
7. Photograph or label all vacuum lines, electrical connectors, and hose positions for reference during reassembly

Procedure

1. 1

   Remove air intake system
   Disconnect mass airflow sensor electrical connector. Loosen clamps on air intake tube at throttle body and air filter housing. Remove entire air intake tube assembly. Remove air filter housing if additional access is needed by disconnecting any mounting bolts and fresh air ducting.
2. 2

   Disconnect throttle body and cruise control cables
   Disconnect throttle position sensor and electronic throttle control electrical connectors from throttle body. If equipped with mechanical cruise control cable, disconnect cable from throttle linkage by depressing locking tab and sliding cable end out of bracket.
3. 3

   Disconnect fuel lines and fuel rail
   Using fuel line disconnect tools, disconnect fuel supply and return lines from fuel rail. Have shop towels ready to catch residual fuel. Disconnect fuel injector electrical connectors (8 total). Remove fuel rail mounting bolts and carefully lift fuel rail with injectors attached away from intake manifold. Cap or plug fuel rail openings to prevent contamination.
   ⚠Even with fuel pressure relieved, residual fuel will spray when lines are disconnected. Have fire extinguisher nearby and ensure adequate ventilation.
   Torque spec

   Fuel Rail Bolts12 Nm (9 lb-ft)
4. 4

   Remove throttle body
   Remove four throttle body mounting bolts and carefully separate throttle body from intake manifold. Remove and discard old throttle body gasket. Cover throttle body opening with clean shop towel to prevent debris entry.
   Torque spec

   Throttle Body Bolts10 Nm (7 lb-ft)
5. 5

   Disconnect vacuum lines and PCV system
   Disconnect brake booster vacuum line from intake manifold (large diameter line on driver side rear). Disconnect PCV hose from valve cover to intake manifold connection. Disconnect any EVAP purge valve lines and vacuum lines to intake manifold. Remove PCV valve from valve cover if replacing or if obstructing manifold removal.
6. 6

   Disconnect electrical connectors and sensors
   Disconnect intake manifold runner control (IMRC) actuator electrical connectors (both banks). Disconnect charge motion control valve (CMCV) electrical connectors if equipped. Disconnect any coolant temperature sensors or other sensors mounted in intake manifold. Release any wiring harness clips attached to intake manifold.
7. 7

   Disconnect coolant hoses
   Place drain pan under work area. Disconnect heater core supply and return hoses from rear of intake manifold (passenger side). Disconnect coolant bypass hose if routed through intake manifold. Allow coolant to drain into pan. Be prepared for approximately 1-2 quarts of coolant loss.
   ⚠Coolant will drain when hoses are disconnected. Ensure engine is completely cool and drain pan is properly positioned.
8. 8

   Remove intake manifold mounting bolts
   Remove all intake manifold mounting bolts in reverse order of tightening sequence (outside to center pattern). There are typically 16 bolts securing the intake manifold. Use long extensions and swivel adapters to access rear bolts. Keep bolts organized by location as some may be different lengths. Note that some bolts also secure brackets or ground straps.
   Torque spec

   Intake Manifold Bolts25 Nm (18 lb-ft)
9. 9

   Remove intake manifold assembly
   Carefully lift intake manifold assembly straight up and away from cylinder heads. Manifold may be stuck due to gasket seal; gently work it loose without prying against aluminum sealing surfaces. Once free, place manifold on clean work surface with gasket surface facing up. Immediately cover cylinder head ports with clean shop towels to prevent debris entry into engine.
   ⚠️Do not allow any debris, tools, or fasteners to fall into open cylinder head ports. Foreign object damage to valves or cylinders will require extensive engine disassembly.
10. 10

    Remove old gaskets and clean sealing surfaces
    Remove all old intake manifold gaskets from both cylinder heads (8 total gaskets). Use plastic scraper to carefully remove all gasket material from cylinder head sealing surfaces and intake manifold sealing surfaces. Do not use metal scrapers that could gouge aluminum surfaces. Clean all surfaces thoroughly with brake cleaner and lint-free shop towels. Inspect manifold and cylinder head surfaces for cracks, warping, or damage. Vacuum any debris from cylinder head valley area.
11. 11

    Install new gaskets and position intake manifold
    Install new intake manifold gaskets on cylinder head ports. Gaskets should fit snugly in place without adhesive (some gaskets have alignment features). Remove shop towels from cylinder head ports immediately before manifold installation. Carefully lower intake manifold into position, aligning all port openings with gaskets. Ensure all gaskets remain properly seated and no gasket edges are folded or pinched.
12. 12

    Install and torque intake manifold bolts
    Install all intake manifold mounting bolts finger-tight, ensuring any brackets or ground straps are in correct positions. Using torque wrench, tighten bolts to 25 Nm (18 lb-ft) following proper sequence from center outward as specified in Ford service manual. Typical sequence starts at center bolts and works outward in a spiral pattern. Verify all bolts are torqued by performing second pass through sequence.
    ⚠Intake manifold bolt torque sequence is critical. Improper sequence will cause vacuum leaks or coolant leaks. Consult factory service manual for exact bolt sequence diagram.
    Torque spec

    Intake Manifold Bolts25 Nm (18 lb-ft)
13. 13

    Reconnect coolant hoses and PCV system
    Reconnect heater core supply and return hoses to rear of intake manifold, ensuring hose clamps are properly positioned. Reconnect coolant bypass hose if applicable. Install PCV valve to valve cover using 8 Nm (6 lb-ft) torque if removed. Reconnect PCV hose between valve cover and intake manifold. Reconnect brake booster vacuum line and all other vacuum lines per reference photos.
    Torque spec

    PCV Valve8 Nm (6 lb-ft)
14. 14

    Install throttle body
    Install new throttle body gasket on intake manifold. Position throttle body and install four mounting bolts. Torque throttle body bolts to 10 Nm (7 lb-ft) in crossing pattern (opposite corners). Reconnect throttle position sensor and electronic throttle control electrical connectors.
    Torque spec

    Throttle Body Bolts10 Nm (7 lb-ft)
15. 15

    Install fuel rail and reconnect fuel system
    If fuel injector O-rings were disturbed, install new O-rings lightly lubricated with clean engine oil. Carefully position fuel rail with injectors into intake manifold ports, ensuring all injectors seat properly. Install fuel rail mounting bolts and torque to 12 Nm (9 lb-ft) per service manual sequence. Reconnect all eight fuel injector electrical connectors. Reconnect fuel supply and return lines, ensuring disconnect fittings click into locked position.
    Torque spec

    Fuel Rail Bolts12 Nm (9 lb-ft)
16. 16

    Reconnect remaining components
    Reconnect all electrical connectors to sensors on intake manifold including IMRC actuators, CMCV valves, and temperature sensors. Secure all wiring harness clips to intake manifold. Reconnect any remaining vacuum lines per reference photos. Install air intake tube assembly, connecting to throttle body and air filter housing. Tighten all hose clamps securely. Reconnect mass airflow sensor electrical connector.
17. 17

    Final checks and battery reconnection
    Perform visual inspection of all connections, ensuring no electrical connectors, vacuum lines, or hoses were missed. Verify all tools and shop towels are removed from engine bay. Reconnect negative battery terminal. Reinstall fuel pump fuse. Add coolant to system as needed to replace coolant lost during hose disconnection, using Motorcraft Orange Coolant only.

Reassembly

1. Ensure all 16 intake manifold bolts are torqued to specification in proper center-outward sequence
2. Verify fuel rail bolts are torqued in correct sequence per service manual
3. Confirm all coolant hoses are connected with clamps properly tightened
4. Double-check that all eight fuel injector connectors are fully seated and locked
5. Verify brake booster vacuum line is securely connected
6. Confirm PCV system is fully reconnected between valve covers and intake manifold
7. Ensure air intake system is sealed with all clamps tight to prevent unmetered air entry
8. Install engine cover by pressing down firmly until clips engage

Verification

• With engine off, turn ignition to ON position (do not start) and listen for fuel pump priming for 2-3 seconds. Check for fuel leaks around fuel rail and fuel line connections
• Inspect all coolant hose connections for leaks while system is cold
• Start engine and allow to idle. Listen for any vacuum leaks (hissing sound) around intake manifold perimeter and throttle body
• Monitor engine temperature gauge during warm-up to verify proper coolant circulation and no overheating from air pockets
• Check coolant level after engine reaches operating temperature and top off if needed. Burp cooling system to remove air pockets by squeezing upper radiator hose while engine is running
• With engine at operating temperature, check for coolant or fuel leaks around all connections made during service
• Verify engine idles smoothly with no misfire or rough running conditions. Check for diagnostic trouble codes using scan tool
• Test drive vehicle to verify normal power delivery and throttle response. Monitor for any check engine light or drivability issues
• Recheck coolant level after test drive and top off if necessary

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