1998 F-150/250 Workshop Manual
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1 Page 1 of 13 SECTION B: Engine 4.6L and 5.4L 1998 F-150/250 Workshop Manual IN-VEHICLE REPAIR Procedure revision date: 03/07/2000 Intake Manifold Removal WARNING: Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related components. Highly flammable mixtures are always present and can be ignited. Failure to follow these instructions may result in personal injury. All Vehicles 1. Disconnect the battery ground cable (14301). For additional information, refer to Section Perform pre-service procedures. For additional information, refer to Section A (Gasoline and Diesel) or Section B (NGV). 3. Drain the cooling system. For additional information, refer to Section Compress and slide the hose clamp and disconnect the upper radiator hose (8260). 5. Remove the engine air cleaner (ACL) (9600) and air cleaner outlet tube (9B659). For additional information, refer to Section Remove the accelerator control splash shield. 1. Remove the bolts. 2. Remove the accelerator control splash shield. 7. Disconnect the accelerator cable (9A758) from the accelerator cable bracket (9723). 1. Remove the bolt. 2. Slide the accelerator cable up to remove it from the accelerator cable bracket. 8. Disconnect the accelerator cable from the throttle body cam. 1. Roll the throttle body cam forward. 2. Slide the accelerator cable end from the throttle body cam.
2 Page 2 of Remove the throttle return spring. 10. If equipped, disconnect the speed control actuator cable (9A825) from the throttle body (9E926). 1. Remove the speed control actuator cable to the bolt. 2. Disconnect the (A) speed control actuator cable from the (B) throttle body cam and position aside. 11. Disconnect the climate control vacuum hose. 12. Remove the bolt and the brake booster vacuum hose and bracket. 13. Disconnect the connector from the throttle position (TP) sensor (9B989). 4.6L Engine 14. Disconnect the following throttle body hose connections: vapor management hose (1) positive crankcase ventilation valve (PCV valve) (6A666) (2) power brake booster (2005) (3)
3 Page 3 of 13 All Vehicles 15. On 4.6L engines, remove the (A) brake booster vacuum hose bracket nut from the (B) brake booster vacuum hose bracket. 16. Disconnect the fuel lines. For additional information, refer to Section A (Gasoline and Diesel) or Section B (NGV). 17. Disconnect the PCV and PCV coolant hoses. 18. Disconnect the following electrical connectors: differential pressure feedback (DPFE) transducer engine vacuum regulator (EVR) sensor 4.6L Engine 19. Remove the EGR valve to exhaust manifold tube (9D477). Disconnect the upper and lower EGR valve to exhaust manifold tube fittings. Disconnect the two DPFE hoses.
4 Page 4 of L Engine 4.6L engine 20. Disconnect the following vacuum connections: 1. EGR vacuum hose 2. vacuum supply port 3. EVR vacuum hose 4. fuel pressure regulator vacuum hose 5.4L Engine
5 Page 5 of 13 All Vehicles 21. Disconnect the RH fuel injector electrical connectors. 22. Disconnect the LH fuel injector electrical connectors. 23. On 5.4L engines, disconnect and remove the eight ignition coils (12029). For additional information, refer to Section C. 24. Remove the drive belt (8620).For additional information, refer to Section Remove the generator (GEN) (10300); refer to Section Remove the bolts and the throttle body. 27. Disconnect the hose clamp and remove the heater water hose (18472). 28. Remove the studs.
6 Page 6 of Remove the water thermostat (8575). For additional information, refer to Section Remove the nine bolts. 31. Remove the upper intake manifold (9424). 1. Lift the intake manifold. 2. Disconnect the intake manifold tuning valve (IMTV) connector.(4.6l engine and 5.4L NGV Only) 3. Remove and discard the upper intake manifold gaskets (9439). 32. Remove the bolts.
7 Page 7 of Separate the upper intake manifold from the lower intake manifold and discard the lower intake manifold gasket (9461). 34. Remove the (A) pushpin from the (B) intake manifold insulator and remove from the (C) lower intake manifold. 35. Remove the (A) bolts from the (B) intake manifold tuning valve and remove the intake manifold tuning valve.(4.6l engine and 5.4L NGV only) Installation All Vehicles 1. Position the intake manifold tuning valve and install the bolts. (4.6L engine and 5.4L NGV only)
8 Page 8 of Install the intake manifold insulator on the lower intake manifold and install the pushpin. 3. Position the lower intake manifold gasket and the upper intake manifold on the lower intake manifold and loosely install the eight bolts. 4. Tighten the bolts in two stages, in the sequence shown. Stage 1: 2 Nm (18 lb/in) Stage 2: 8-12 Nm ( lb/in) 5. Install the studs.
9 Page 9 of Install the upper intake manifold. Position the upper intake manifold gaskets. Position the upper intake manifold. Loosely install the nine bolts. 7. Connect the intake manifold tuning valve connector.(4.6l engine and 5.4L NGV only) 8. Install the water thermostat. For additional information, refer to Section Tighten the bolts in two stages, in the sequence shown. Stage 1: 2 Nm (18 lb/in) Stage 2: Nm (15-22 lb/ft) 10. Position the throttle body onto the upper intake manifold and install the bolts. 11. Install the heater water hose and position the clamp.
10 Page 10 of Install the generator. For additional information, refer to Section Install the drive belt. For additional information, refer to Section On 5.4L engines, install the eight ignition coils. For additional information, refer to Section C. 15. Connect the LH fuel injector electrical connectors. 16. Connect the RH fuel injector electrical connectors. 17. NOTE: For 4.6L engine-equipped vehicles, perform the following step. Connect the following vacuum connections: 1. EGR vacuum hose 2. vacuum supply port 3. EVR vacuum hose 4. fuel pressure regulator vacuum hose 5.4L Engine
11 Page 11 of L Engine 18. Connect the EGR valve to exhaust manifold tube upper fitting. On 4.6L engines, tighten both fittings starting at the top in two stages. Stage 1:Hand tighten. Stage 2:Tighten to Nm (26-33 lb/ft). On 5.4L engines, tighten both fittings starting at the top in two stages. Stage 1:Hand tighten. Stage 2:Tighten to Nm (41-47 lb/ft). 5.4L Engine
12 Page 12 of 13 All Vehicles 19. Connect the following electrical connectors: differential pressure feedback (DPFE) transducer engine vacuum regulator (EVR) sensor 20. Connect the PCV and PCV coolant hoses. 21. On 4.6L engines, position the brake booster vacuum hose bracket and install the nut. 22. Connect the following electrical connectors: DPFE transducer engine vacuum regulator sensor 23. Connect the fuel lines. For additional information, refer to Section A (Gasoline and Diesel) or Section B (NGV). 24. Connect the climate control vacuum hose. 25. Install the throttle return spring.
13 Page 13 of Connect the accelerator cable to throttle body cam. 1. Rotate the throttle body cam forward. 2. Slide the accelerator cable into the throttle body cam. 27. Connect the accelerator cable to accelerator cable bracket. 1. Slide the accelerator cable into the accelerator cable bracket. 2. Install the bolt. 28. Install the accelerator control splash shield. 29. Install the air cleaner outlet tube and the engine air cleaner. For additional information, refer to Section Install the upper radiator hose and reposition the clamp. 31. Fill the cooling system. For additional information, refer to Section Connect the battery ground cable.
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