Intake Manifold Gasket

This procedure involves removing the upper intake manifold, replacing the intake manifold gaskets, and reinstalling all components on the 2015-2020 Ford F-150 5.0L Coyote V8 engine.

Warnings

Tools required

Parts

• Intake manifold gasket set × 1 — Use OEM Ford gasket set
• Throttle body gasket × 1 — Use OEM specification
• PCV valve grommet × 1 — Replace if damaged
• Coolant (for top-off) × 1 — Motorcraft Orange Coolant

Fluids

• Motorcraft Orange Coolant — 1 qt

Preparation

1. Ensure engine is completely cool to the touch
2. Disconnect negative battery terminal and wait 10 minutes for system discharge
3. Remove engine cover by pulling upward on all four corners
4. Relieve fuel system pressure by removing fuel pump fuse and cranking engine until it stalls
5. Place drain pan under lower radiator hose and drain approximately 2 quarts of coolant
6. Label all vacuum lines and electrical connectors with tape for easy identification during reassembly

Procedure

1. 1

   Remove Air Intake System
   Disconnect mass airflow sensor electrical connector. Loosen clamp at throttle body and remove air intake tube assembly. Remove air filter housing if needed for additional clearance.
2. 2

   Disconnect Throttle Body Components
   Disconnect throttle position sensor and electronic throttle control electrical connectors from throttle body. Disconnect cruise control cable if equipped. Remove PCV hose from valve cover to intake manifold connection.
   ℹ️Electronic throttle bodies are delicate. Do not force connectors or damage pins.
3. 3

   Remove Throttle Body
   Remove four throttle body mounting bolts. Carefully lift throttle body away from intake manifold. Plug intake opening with clean shop towels to prevent debris entry.
   Torque spec

   Throttle Body Bolts10 Nm (7 lb-ft)
4. 4

   Disconnect Fuel System
   Disconnect fuel supply line from fuel rail using quick-disconnect tool or by pressing release tabs. Cap open fuel line with appropriate plug. Disconnect fuel injector electrical connectors (8 total). Release wiring harness from clips along fuel rails.
   ⚠Have shop towels ready to catch residual fuel from lines. Dispose of fuel-soaked rags properly.
5. 5

   Remove Fuel Rails
   Remove four fuel rail mounting bolts (two per rail). Gently wiggle and pull fuel rails with injectors upward to release injectors from intake manifold. Set fuel rail assembly aside in safe location. Remove and discard fuel injector O-rings if replacing.
   Torque spec

   Fuel Rail Bolts12 Nm (9 lb-ft)
6. 6

   Disconnect Engine Sensors and Hoses
   Disconnect intake manifold runner control (IMRC) actuator electrical connectors on both sides. Disconnect manifold absolute pressure (MAP) sensor. Disconnect all vacuum hoses from intake manifold including brake booster, EVAP purge valve, and PCV connections. Remove coolant crossover tube if equipped by removing mounting bolts.
7. 7

   Disconnect EGR System
   If equipped with EGR, disconnect EGR valve electrical connector. Remove EGR valve mounting bolts and separate EGR valve from intake manifold. Remove and discard EGR gasket.
8. 8

   Remove PCV Valve
   Twist and pull PCV valve from valve cover grommet. Inspect grommet for damage and replace if cracked or hardened.
9. 9

   Remove Intake Manifold
   Remove intake manifold mounting bolts in reverse order from center outward (typically 10 bolts total). Keep bolts organized as they may be different lengths. Carefully lift intake manifold straight up and away from engine. If manifold is stuck, gently pry at designated pry points only - never between gasket surfaces.
   ⚠Manifold may be heavy and awkward. Use caution when lifting to avoid dropping on engine components.
   Torque spec

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

    Remove Old Gaskets and Clean Surfaces
    Remove and discard old intake manifold gaskets. Use plastic scraper to carefully remove all gasket material from intake manifold and cylinder head surfaces. Clean surfaces thoroughly with brake cleaner and lint-free towels. Inspect surfaces for damage, warping, or deep scratches. Cover intake ports with tape or towels to prevent debris from entering engine.
    ⚠️Never allow debris or gasket material to fall into intake ports or engine. This will cause severe engine damage.
    ⚠Aluminum surfaces scratch easily. Use only plastic scrapers, never metal tools.
11. 11

    Install New Gaskets and Position Manifold
    Remove protective covering from intake ports. Position new intake manifold gaskets on cylinder heads ensuring proper alignment with all port openings and bolt holes. Gaskets should fit without forcing. Carefully lower intake manifold onto gaskets, aligning all bolt holes. Verify gaskets remain properly seated.
    ℹ️Some gaskets have specific orientation (top/bottom markings). Verify correct installation before proceeding.
12. 12

    Install and Torque Intake Manifold Bolts
    Hand-thread all intake manifold bolts to prevent cross-threading. Torque bolts in sequence from center outward in three passes: first to 10 Nm (7 lb-ft), second to 18 Nm (13 lb-ft), and final pass to specification. Follow tightening sequence to ensure even gasket compression and prevent leaks.
    ⚠Over-torquing can crack intake manifold. Under-torquing will cause vacuum leaks. Use calibrated torque wrench.
    Torque spec

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

    Reinstall PCV Valve and EGR System
    Install PCV valve into valve cover grommet with firm twisting motion until seated. If equipped with EGR, install new EGR gasket, position EGR valve, and torque mounting bolts. Reconnect EGR electrical connector.
14. 14

    Reinstall Fuel Rails and Injectors
    Lubricate new fuel injector O-rings with clean engine oil. Press fuel injectors into intake manifold ports ensuring proper seating. Position fuel rails over injectors and press down firmly. Install and torque fuel rail mounting bolts. Reconnect all fuel injector electrical connectors and secure wiring harness to clips. Reconnect fuel supply line ensuring positive click engagement.
    Torque spec

    Fuel Rail Bolts12 Nm (9 lb-ft)
15. 15

    Reinstall Throttle Body and Sensors
    Install new throttle body gasket. Position throttle body and install mounting bolts, torquing to specification. Reconnect throttle position sensor and electronic throttle control connectors. Reinstall coolant crossover tube if equipped and torque bolts. Reconnect all vacuum hoses, MAP sensor, IMRC actuators, and remaining electrical connectors per photos taken during disassembly.
    Torque spec

    Throttle Body Bolts10 Nm (7 lb-ft)
16. 16

    Reinstall Air Intake System
    Reinstall air filter housing if removed. Connect air intake tube to throttle body and tighten clamp securely. Reconnect mass airflow sensor electrical connector. Install engine cover by pressing down on all four corners until clips engage.
17. 17

    Refill Coolant and Final Checks
    Refill cooling system with Motorcraft Orange Coolant to proper level. Reconnect negative battery terminal. Turn ignition to ON position (do not start) and check for fuel leaks around fuel rail and supply line. Verify all electrical connectors are secured and no tools are left in engine bay.
    ⚠Do not start engine if any fuel leaks are detected. Repair leaks before proceeding.

Reassembly

1. Torque all fasteners to specifications in proper sequence to prevent leaks
2. Replace all single-use gaskets including throttle body gasket and EGR gasket if equipped
3. Ensure all electrical connectors are fully seated with audible clicks
4. Verify all vacuum lines are connected per reference photos
5. Double-check that no tools or rags are left in engine compartment

Verification

• Start engine and allow to idle. Listen for vacuum leaks (hissing sounds) around intake manifold
• Check for fuel leaks at fuel rail connections with engine running
• Check for coolant leaks at crossover tube connections if equipped
• Verify smooth idle with no rough running or check engine light
• Allow engine to reach operating temperature and verify coolant level is stable
• Rev engine to 2500 RPM and release throttle - should return to smooth idle without hesitation
• Test drive vehicle to verify normal acceleration and no performance issues
• Scan for diagnostic trouble codes after test drive - address any stored codes

Related trouble codes on this vehicle

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