Section 03-01B: Engine, 5.0L and 5.8L MFI
1996 F-150, F-250, F-350 and Bronco Vehicles Equipped with 5.0L or 5.8L MFI Engines Workshop Manual
IN-VEHICLE SERVICE

Intake Manifold, Lower

 
 

Removal

  1. Remove upper intake manifold (9424) and throttle body (9E926) as outlined in this section, prior to lower intake manifold removal.

  1. Drain cooling system.

  1. Remove distributor assembly, distributor cap (12106) and wires. Mark position of distributor and rotor during removal so that they can be installed in their original position.

  1. Disconnect the electrical connections at the engine coolant temperature sensor (ECT sensor) (12A648), engine temperature sending unit and intake air temperature sensor (IAT sensor) (12A697).

  1. Disconnect radio ignition interference capacitor (18801), electrical connector and coil wire from coil.

  1. Disconnect electrical connector and vacuum harness from EGR vacuum regulator solenoid (9J459).

  1. Disconnect electrical connector and vacuum harness from secondary air injection vacuum regulator solenoid (9S448).

  1. Remove nut from ignition coil mounting bracket to exhaust manifold stud and two nuts for coil mounting bracket and remove coil and bracket.

  1. Disconnect electrical connector from injector.

  1. Remove two retaining nuts for emission brackets.

  1. Perform all preservice procedures as outlined to relieve any fuel system pressure as described in Section 03-04B.

  1. Disconnect fuel supply and return line retaining clips. Disconnect fuel supply and return lines from fuel rails, using Disconnect Tool D87L-9280-A (3/8-inch) and D87L-8280-B (1/2-inch) or equivalents. Refer to Section 03-04B for fuel injection supply manifold procedure.

  1. Remove water hose connection (8592).

  1. Remove heater outlet hose at intake manifold.

  1. Remove intake retaining bolts and studs, noting location of studs and bolts.

  1. Remove lower intake manifold assembly.

    Lower Intake Manifold

    ItemPart NumberDescription
    1—ECT Sensor Location
    (Part of 9424)
    29F593Fuel Injector
    39C968Fuel Pressure Regulator
    49D280Fuel Injection Supply Manifold
    59D930Fuel Charging Wiring
    6—Fuel Return Tube
    (Part of 9F792 Assembly)
    7—IAT Sensor Location
    (5.8L, 49 States Only)
    (Part of 9424)
    8—Water Temperature Sender Location (Part of 9424)
    9—Pressure Relief Valve
    (Part of 9F792)
 

Installation

  1. Clean and inspect the mounting faces of the lower intake manifold and cylinder block surfaces. Refer to Section 03-00.

  1. Apply 1.6mm (1/16-inch) bead of Silicone Rubber F4AZ-19562-B sealer or equivalent meeting Ford specification WSE-M4G323-A1 to the end seals (junction).

    ItemPart NumberDescription
    1—Sealer (4 Joints)
    26049Cylinder Head
    39439Intake Manifold Gasket
    49A424Intake Manifold Seal (LH)
    59A425Intake Manifold Seal (RH)
    6—Sealer (4 Seal Ends)
    76010Cylinder Block

  1. NOTE: This sealer sets up within 15 minutes after application. To ensure effective sealing, assembly should proceed promptly.

    NOTE: The gaskets must be interlocked with the seal tabs.

    Install end seals on the cylinder block (6010) and new gaskets on the cylinder heads (6049).

  1. Install two locator pins into opposite corners.

  1. Carefully lower intake manifold assembly into position.

    Lower Intake Manifold, 5.8L

    ItemPart NumberDescription
    1—Nut (Part of 9K461)
    29F792Fuel Injection Supply Manifold
    3391445Stud
    4—Locating Pin (4 Places)
    (Part of 9K461)
    59424Intake Manifold (Lower)
    6391443Bolt
    7—Clip (Part of 9K461)
    A—Tighten to 11-13 Nm
    (8-10 Lb-Ft)
    B—Tighten to 31-34 Nm
    (23-25 Lb-Ft)

  1. Install intake manifold bolts and studs. Tighten all bolts and studs using the sequence shown in two steps as follows:

    Step 1. Tighten all to 7-14 Nm (5-10 lb-ft).

    Step 2. Tighten all to 31-34 Nm (23-25 lb-ft).

    Tightening Sequence

  1. Install nut from ignition coil mounting bracket to exhaust manifold stud and two nuts for coil mounting bracket and install coil and bracket. Tighten nuts securely.

  1. Connect electrical connector and vacuum harness-to- secondary air injection vacuum regulator solenoid.

  1. Connect electrical connector and harness to EGR vacuum regulator solenoid.

  1. Connect radio ignition interference capacitor, electrical connector and coil wire to coil.

  1. Connect electrical connections at the engine coolant temperature sensor, engine temperature sending unit and intake air temperature sensor.

  1. Install distributor assembly, distributor cap and wires and adjust distributor timing.

  1. Install upper intake manifold as outlined.

  1. Fill and bleed the cooling system. Refer to Section 03-03.

  1. Perform all post-service procedures. Refer to Section 03-04B.