1998 F -150/250 Workshop Manual Page 1 of 13ww2.justanswer.com/uploads/apjp02/2009-12-20_232403... · 2009. 12. 20. · 9. Remove the throttle return spring. 10. If equipped, disconnect

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 414-01.

2. Perform pre-service procedures. For additional information, refer to Section 310-00A (Gasoline and Diesel) or Section 310-00B (NGV).

3. Drain the cooling system. For additional information, refer to Section 303-03.

4. 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 303-12.

6. 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.

SECTION 303-01B: Engine — 4.6L and 5.4L 1998 F-150/250 Workshop Manual

IN-VEHICLE REPAIR Procedure revision date: 03/07/2000

Page 1 of 131998 F-150/250 Workshop Manual

12/20/2009http://www.fordtechservice.dealerconnection.com/pubs/content/~WSW1/~MUS~LEN/20...

9. 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)



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 310-01A (Gasoline and Diesel) or Section 310-01B (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.



5.4L 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



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 303-07C.

24. Remove the drive belt (8620).For additional information, refer to Section 303-05.

25. Remove the generator (GEN) (10300); refer to Section 414-02.

26. Remove the bolts and the throttle body.

27. Disconnect the hose clamp and remove the heater water hose (18472).

28. Remove the studs.



29. Remove the water thermostat (8575). For additional information, refer to Section 303-03.

30. 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.



33. 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)



2. 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 (71-106 lb/in)

5. Install the studs.



6. 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 303-03.

9. Tighten the bolts in two stages, in the sequence shown. Stage 1: 2 Nm (18 lb/in) Stage 2: 20-30 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.



12. Install the generator. For additional information, refer to Section 414-02.

13. Install the drive belt. For additional information, refer to Section 303-05.

14. On 5.4L engines, install the eight ignition coils. For additional information, refer to Section 303-07C.

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



4.6L 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 35-45 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 55-65 Nm (41-47 lb/ft).

5.4L Engine



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 310-01A (Gasoline and Diesel) or Section 310-01B (NGV).

24. Connect the climate control vacuum hose.

25. Install the throttle return spring.



26. 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 303-12.

30. Install the upper radiator hose and reposition the clamp.

31. Fill the cooling system. For additional information, refer to Section 303-03.

32. Connect the battery ground cable.



Documents

1998 F -150/250 Workshop Manual Page 1 of 13ww2.justanswer.com/uploads/apjp02/2009-12-20_232403... · 2009. 12. 20. · 9. Remove the throttle return spring. 10. If equipped, disconnect