This procedure covers the removal and replacement of the upper and lower intake manifold assembly on the 2015-2020 Ford F-150 with the 5.0L Coyote V8 engine.

Warnings

Tools required

Parts

• Intake manifold gasket set (upper and lower) × 1 — Use OEM specification
• Throttle body gasket × 1 — Use OEM specification
• Fuel rail O-rings (if applicable) × 8 — Use OEM specification
• PCV valve grommet (if damaged) × 1 — Use OEM specification
• Engine coolant × 2 — Motorcraft Orange Coolant

Fluids

• Motorcraft Orange Coolant — 2 qt

Preparation

1. Ensure engine is completely cold before starting work
2. Disconnect negative battery cable and wait 10 minutes for airbag system to discharge
3. Remove engine cover by pulling upward on front edge then lifting away
4. Relieve fuel system pressure by locating the fuel pump fuse in the passenger compartment fuse box, starting the engine, and allowing it to stall
5. Place drain pan under radiator and drain approximately 2 quarts of coolant from the petcock valve
6. Label all vacuum hoses, electrical connectors, and fuel lines with tape for reinstallation reference

Procedure

1. 1

   Remove air intake system
   Loosen clamp at throttle body and disconnect mass airflow sensor electrical connector. Remove air intake tube from throttle body to air box. Remove air box by pulling upward to release mounting grommets. Set aside entire air intake assembly.
2. 2

   Disconnect throttle body and electrical connections
   Disconnect throttle position sensor connector on throttle body. Remove four throttle body mounting bolts and carefully lift throttle body away from intake manifold. Disconnect all electrical connectors from intake manifold including fuel injector connectors, manifold absolute pressure sensor, and any temperature sensors. Use labeling for reference during reassembly.
   Torque spec

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

   Disconnect fuel system
   Use fuel line disconnect tool to separate fuel supply line from fuel rail at the quick-connect fitting on passenger side. Have shop towels ready to catch residual fuel. Disconnect fuel injector electrical harness and set aside. Cap open fuel line to prevent contamination.
   ⚠️Fuel will spray from disconnected lines even after pressure relief. Wear safety glasses and have fire extinguisher nearby.
4. 4

   Remove PCV system components
   Disconnect PCV hose from passenger side valve cover. Remove PCV valve from valve cover by rotating counterclockwise. Disconnect any additional vacuum lines connected to intake manifold, referencing your labels. Remove brake booster vacuum line from rear of intake manifold.
   Torque spec

   PCV Valve8 Nm (6 lb-ft)
5. 5

   Disconnect coolant hoses
   Locate coolant bypass hoses connected to front of intake manifold. Use hose clamp pliers to release spring clamps and carefully disconnect both coolant hoses. Keep drain pan positioned to catch coolant spillage. Plug hoses with rubber caps if available.
6. 6

   Remove upper intake manifold
   Remove all upper intake manifold mounting bolts in reverse order of tightening sequence (working from outside toward center). There are typically 10 bolts securing the upper manifold. Carefully lift upper intake manifold assembly straight up and away from lower manifold. Inspect gasket condition and discard gasket.
   ⚠Upper intake manifold is bulky and may bind on studs during removal. Wiggle gently if necessary but do not pry against sealing surfaces.
   Torque spec

   Intake Manifold Bolts25 Nm (18 lb-ft)
7. 7

   Remove fuel rail assembly
   Remove fuel rail mounting bolts securing fuel rail to lower intake manifold. Carefully pull fuel rail straight up with fuel injectors still attached. Wiggle gently if injectors are stuck in bores. Remove and discard fuel injector O-rings if replacing. Cover exposed injector bores with clean shop towels to prevent debris entry.
   ⚠Fuel injectors may stick in bores. Do not pry on fuel rail or use excessive force which can damage injectors.
   Torque spec

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

   Remove lower intake manifold
   Remove all lower intake manifold bolts working from outside toward center. There are typically 8 bolts around perimeter. Carefully lift lower intake manifold from cylinder heads. The manifold may be sealed with RTV in addition to gaskets. Use plastic pry tool if needed to break seal, applying gentle pressure only at reinforced boss areas, never at sealing surfaces.
   Torque spec

   Gasket Surface Bolts26 Nm (19 lb-ft)
9. 9

   Clean all mating surfaces
   Use plastic gasket scraper to carefully remove all old gasket material from intake manifold mating surfaces and cylinder head surfaces. Clean surfaces thoroughly with brake cleaner and lint-free shop towels. Inspect surfaces for scratches, gouges, or warping. Ensure all bolt holes are clear of debris. Verify no gasket material or debris has fallen into cylinder head ports or coolant passages.
   ⚠Never use metal scrapers or abrasive pads on aluminum surfaces. Surface damage will cause vacuum leaks and coolant leaks.
10. 10

    Install new gaskets and lower intake manifold
    Position new lower intake manifold gaskets on cylinder heads, ensuring alignment pins or tabs are properly seated. Apply small dab of RTV sealant at front and rear corners where gasket meets block (if specified by gasket manufacturer). Carefully lower intake manifold into position, ensuring gaskets do not shift. Install all lower manifold bolts finger-tight first, then torque in sequence from center outward in three stages: 50% torque, 75% torque, then final torque specification.
    ⚠Consult service manual for exact bolt tightening sequence diagram. Incorrect sequence causes uneven gasket compression and leaks.
    Torque spec

    Gasket Surface Bolts26 Nm (19 lb-ft)
11. 11

    Install fuel rail and injectors
    If removed, install new O-rings on fuel injectors, lubricating lightly with clean engine oil. Install fuel injectors into fuel rail if removed. Position fuel rail assembly over injector bores and press down firmly to seat all injectors. Install fuel rail mounting bolts and torque to specification in sequence if provided in service manual.
    Torque spec

    Fuel Rail Bolts12 Nm (9 lb-ft)
12. 12

    Install upper intake manifold
    Position new upper intake manifold gasket on lower manifold, ensuring proper alignment. Carefully lower upper intake manifold onto lower manifold, aligning all bolt holes. Install all upper manifold bolts finger-tight, then torque in sequence from center outward to specification. Verify proper seating around entire perimeter.
    ⚠Upper intake manifold must be seated evenly before tightening bolts. Uneven seating causes vacuum leaks and poor engine performance.
    Torque spec

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

    Reconnect coolant hoses and vacuum lines
    Reconnect coolant bypass hoses to front of intake manifold and secure with spring clamps. Reconnect brake booster vacuum line to rear of manifold. Install PCV valve into valve cover and torque to specification. Reconnect PCV hose. Reconnect all vacuum lines to their original positions using your labels as reference.
    Torque spec

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

    Reconnect fuel system and electrical connections
    Reconnect fuel supply line to fuel rail, ensuring quick-connect fitting clicks securely into place. Tug gently to verify connection. Reconnect all fuel injector electrical connectors and intake manifold sensors using your installation labels. Verify all connectors are fully seated and locked.
15. 15

    Install throttle body and air intake system
    Install new throttle body gasket onto intake manifold. Position throttle body and install mounting bolts, torquing to specification in cross pattern. Reconnect throttle position sensor electrical connector. Reinstall air box by pressing down onto mounting grommets. Install air intake tube and tighten clamp at throttle body. Reconnect mass airflow sensor connector.
    Torque spec

    Throttle Body Bolts10 Nm (7 lb-ft)

Reassembly

1. Reconnect negative battery cable
2. Refill cooling system with Motorcraft Orange Coolant to proper level, adding approximately 2 quarts or as needed to reach full mark
3. Reinstall engine cover
4. Reinstall fuel pump fuse in passenger compartment fuse box

Verification

• Turn ignition to ON position (do not start) and listen for fuel pump priming. Check all fuel connections for leaks
• Start engine and allow to reach operating temperature while monitoring for coolant leaks, fuel leaks, and vacuum leaks
• Check for smooth idle with no surging or rough running. Proper idle speed should be approximately 650-750 RPM when warm
• Verify no check engine light illumination and scan for diagnostic trouble codes if available
• Test drive vehicle to verify normal acceleration, throttle response, and no hesitation under load
• After test drive, recheck all coolant hoses and fuel connections for leaks with engine hot
• Recheck coolant level after engine cools and top off if necessary

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