Help with 1991 Intake Manifold Removal
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Help with 1991 Intake Manifold Removal
Hey everyone, I am needing some assistance. I have a 1991 F150 with a 5.0. I left my manual at work and have already starting taking the truck apart. I am trying to remove the intake manifold in order to replace the valve cover gaskets. I have the throttle body off and all hoses and lines disconnected. Can someone please tell me the steps in removing the manifold and any other info that may be beneficial with replacing the valve cover gaskets. Thanks in advance, I appreciate it.
Cargo Master
Joined: Jul 2009
Posts: 2,538
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From: Des Moines
I'm assuming you mean the upper manifold, as the lower does not need to be removed to replaced the valve cover gaskets.
There should be 6 bolts in all to remove the upper manifold. 2 in the front, 2 in the middle, and 2 in the rear. They should all be the same size except for the inside middle bolt- that will be a torx head, I believe a T40. It's tricky to remove, because the gap is not large enough to allow a 3/8 drive socket [if you had a socket mounted T40] to fit.
What I've done in the past is used a telescoping magnet to place my T40 bit into the bolt head [removing the magnet is tricky], then used a long handled, straight blade screwdriver that fits into the back of my bit. It can't be torqued to spec upon installation this way, but I've not had any trouble from it and I've done it this way several times.
Then, if you're sure the rest of it is unhooked, lift the manifold off the motor.
I would recommend working on the inside middle bolt first, as you'll be able to lean on the upper intake to support yourself as you're removing it.
There should be 6 bolts in all to remove the upper manifold. 2 in the front, 2 in the middle, and 2 in the rear. They should all be the same size except for the inside middle bolt- that will be a torx head, I believe a T40. It's tricky to remove, because the gap is not large enough to allow a 3/8 drive socket [if you had a socket mounted T40] to fit.
What I've done in the past is used a telescoping magnet to place my T40 bit into the bolt head [removing the magnet is tricky], then used a long handled, straight blade screwdriver that fits into the back of my bit. It can't be torqued to spec upon installation this way, but I've not had any trouble from it and I've done it this way several times.
Then, if you're sure the rest of it is unhooked, lift the manifold off the motor.
I would recommend working on the inside middle bolt first, as you'll be able to lean on the upper intake to support yourself as you're removing it.
Fleet Owner
Joined: Oct 2005
Posts: 20,780
Likes: 1,746
From: Kentucky
I have a T40 Torx bit with a 1/4" drive on the other end. I then use my 1/4" ratchet with a long extension to remove that pesky bolt. To reinstall I place a small piece of masking tape on the end of the Torx bit, then press the Torx headed screw onto the taped bit. It has enough grip to keep the bit and bolt attached when lowering it into that canyon the upper intake has. From there I use my torque wrench to tighten down to specification.
FTE Legend
Joined: Jun 2006
Posts: 31,930
Likes: 1,499
From: Ottawa, Ontario
Disconnect all vacuum and electrical lines on the upper intake
Disconnect the EGR tube at the valve or disconnect the valve from the intake.. whatever is easier.
Remove the support bracket between the upper intake and passenger side exhaust manifold.. and throw it away.. it's not needed.
Remove the six bolts connecting the upper to lower.
Remove the upper from the engine bay.
Note: There is no need to remove the throttlebody.
It's Saturday night .. are we partying yet?
Disconnect the EGR tube at the valve or disconnect the valve from the intake.. whatever is easier.
Remove the support bracket between the upper intake and passenger side exhaust manifold.. and throw it away.. it's not needed.
Remove the six bolts connecting the upper to lower.
Remove the upper from the engine bay.
Note: There is no need to remove the throttlebody.
It's Saturday night .. are we partying yet?
Cargo Master
Joined: Jul 2009
Posts: 2,538
Likes: 54
From: Des Moines
Disconnect all vacuum and electrical lines on the upper intake
Disconnect the EGR tube at the valve or disconnect the valve from the intake.. whatever is easier.
Remove the support bracket between the upper intake and passenger side exhaust manifold.. and throw it away.. it's not needed.
Remove the six bolts connecting the upper to lower.
Remove the upper from the engine bay.
Note: There is no need to remove the throttlebody.
It's Saturday night .. are we partying yet?
Disconnect the EGR tube at the valve or disconnect the valve from the intake.. whatever is easier.
Remove the support bracket between the upper intake and passenger side exhaust manifold.. and throw it away.. it's not needed.
Remove the six bolts connecting the upper to lower.
Remove the upper from the engine bay.
Note: There is no need to remove the throttlebody.
It's Saturday night .. are we partying yet?
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