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, Upper

 
 

Removal

  1. Remove engine air cleaner intake tube (9A624) from upper intake manifold.

  1. Remove throttle body shield.

  1. Disconnect electrical connectors at idle air control valve (IAC valve) (9F715), throttle position sensor (TP sensor) (9B989) and EGR position sensor.

  1.  CAUTION: When disconnecting throttle cable from ball stud, use a screwdriver or similar tool close to the stud and pry slowly. Pulling by hand may damage the cable.

    Disconnect throttle linkage at throttle ball. Remove two bolts securing accelerator cable bracket (9723) to intake. Position accelerator cable bracket with cables out of way.

  1. Disconnect upper intake manifold vacuum fitting connections by disconnecting all vacuum lines to vacuum tree, vacuum lines to EGR external pressure valve (9F483) and vacuum line to fuel pressure regulator (9C968).

  1. Disconnect PCV system by disconnecting hose from fitting on top front of upper intake manifold (9424).

  1. Disconnect EGR transducer hoses from EGR tube.

  1. Disconnect electrical connector from EGR transducer (9J433).

  1. For 5.0L engine, remove two bolts from EGR transducer bracket and remove EGR transducer.

    For 5.8L engine, remove two nuts from EGR transducer bracket and remove EGR transducer.

  1. Remove canister purge line(s) from fitting(s) on throttle body (9E926).

  1. NOTE: Place drain pan under vehicle.

    Disconnect water heater lines from the throttle body.

  1. Disconnect EGR tube from EGR external pressure valve by removing flange nut.

  1. Remove bolt from upper intake support bracket to upper intake manifold.

  1. Remove six upper intake manifold retaining bolts.

  1. For 5.0L only, remove intake manifold shield (9471).

  1. Remove upper intake manifold and throttle body as an assembly from lower intake manifold.

 

Installation

  1.  CAUTION: Do not use solutions such as brake cleaner, carburetor cleaner, etc., as these solutions can leave a residue on the machined surfaces. Use only a cleaner which meets or exceeds Ford specification WSE-M5B392-A, such as Metal Surface Cleaner F4AZ-19A536-RA or equivalent.

    Clean and inspect the mounting faces of the lower and upper intake manifolds.

  1. Position new gasket on lower intake mounting face. The use of alignment studs may be helpful.

  1. Install upper intake manifold and throttle body assembly to lower intake manifold making sure gasket remains in place (if alignment studs are not used).

  1. For 5.0L only, install intake manifold shield.

  1. Position EGR transducer. For 5.0L engine, install two bolts and tighten to 12-16 Nm (9-12 lb-ft). For 5.8L engine, install two nuts and tighten to 17-24 Nm (12-18 lb-ft).

  1. Connect electrical connector to EGR transducer.

  1. Connect EGR transducer hoses to EGR tube.

  1. Install six upper intake manifold retaining bolts and tighten to 17-24 Nm (13-18 lb-ft).

  1. Install upper intake support bracket to upper manifold attaching bolt.

  1. Install EGR tube. For 5.8L, tighten flange nuts to 41-54 Nm (30-40 lb-ft). For 5.0L, tighten nuts to 34-47 Nm (25-35 lb-ft) at the valve and 27-34 Nm (20-25 lb-ft) at the intake.

  1. Install canister purge lines to fittings on throttle body.

  1. Connect water heater lines to the throttle body.

  1. Connect PCV hose to rear of upper intake manifold.

  1. Connect vacuum lines to vacuum tree, EGR external pressure valve and fuel pressure regulator.

  1. Position accelerator cable bracket with cables to upper intake manifold. Install two retaining bolts and tighten to 11-13 Nm (97-115 lb-in). Connect throttle cable to throttle body.

  1. Connect electrical connectors at idle air control valve, throttle position sensor and EGR position sensor.

  1. Install throttle body shield.

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

    Intake Manifold

    ItemPart NumberDescription
    156703Bolt
    29J433EGR Transducer
    39A474Intake Manifold Vacuum Outlet Fitting and Cap
    49A474Connector
    59424Intake Manifold (Upper)
    69H486Intake Manifold Upper Gasket
    79471Intake Manifold Shield
    8390358Bolt (5 Req'd)
    9390249Screw
    A—Tighten to 17-24 Nm
    (12-18 Lb-Ft)