Replaces

Ford Intake Manifold with Integrated Gaskets Dorman 615-278 - 1AEIM00032

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Part Details

  • Location:   Upper

Our intake manifolds are some of the highest quality replacements on the market!

This injection molded UPPER intake manifold is a new, aftermarket replacement part. It is a direct bolt on that is built to strict quality control standards.

Specifications:

  • Improved Design
    • Original Aluminum Material replaced by Re-engineered reinforced plastic
  • Replaces dealer part numbers: 1L3Z-9424-BA, 3L3Z-9424-DA, F65Z-9424-C, YC2Z-9424-CA, F65Z-9, 1L3Z9424BA, 3L3Z9424DA, F65Z9424C, YC2Z9424CA, F65Z9
  • Direct replacement
  • Built to strict quality standards

Kit includes:

  • Complete improved intake manifold
  • New integrated gaskets and seals
  • Installation instructions with torque specifications and tightening sequence
  • Everything needed to do the job right the 1st time!

This new and improved intake manifold is designed to eliminate problems associated with the original design!

Item Condition: New

WARNING:  This product can expose you to chemicals including Nickel (Metallic), which is known to the State of California to cause cancer. For more information, go to www.P65Warnings.ca.gov.

Lifetime Warranty

This item is backed by a Limited Lifetime Warranty. In the event this item should fail due to manufacturing defects during intended use, we will exchange the part free of charge (excludes shipping charges) for the original purchaser.

  1. step : Disconnecting the Battery (0:40)
    • Disconnect the negative terminal with a ratchet
    • Disconnect the positive terminal with a ratchet
  2. step : Removing the Air Intake Assembly (1:16)
    • Remove the three 10mm bolts from the engine cover
    • Remove the engine cover
    • Loosen the hose clamp on the intake tube
    • Remove the intake from the throttle body
    • Disconnect the air intake sensor
    • Pull the air intake assembly off
    • Remove the air intake assembly
  3. step : Disconnecting the Throttle Body Cable and Vacuum Lines (2:23)
    • Remove the throttle and cruise control cable from the throttle body
    • Remove the spring from the throttle
    • Remove the 10mm bolts from the cable bracket
    • Follow the cables and release the cables from the connections
    • Disconnect the five vacuum lines
    • Disconnect the vacuum line connect on the end of the intake
    • Slide the vacuum cables out of the way
    • Disconnect the two sensor connectors from the throttle body
    • Remove the two 10mm bolts from the other cable bracket
  4. step : Disconnecting the EGR Valve Crossover Pipe (5:50)
    • Remove the 10mm nut from the vacuum tube bracket
    • Remove the rubber hose from the intake
    • Move the tube out of the way
    • Loosen the nut on the EGR tube with an adjustable wrench
  5. step : Removing the Throttle Body (7:08)
    • Remove the rubber hose from behind the throttle body
    • Remove the four 8mm bolts from the throttle body
    • Lift the throttle body forward
    • Disconnect the hose on the backside
    • Remove the throttle body
  6. step : Draining the Coolant (8:41)
    • Open the coolant overflow bottle cap
    • Have a drain pan ready
    • Open the radiator drain counterclockwise
    • Drain the antifreeze
    • Turn the drain clockwise to lock it
    • Loosen the radiator hose clamp from the intake manifold
    • Remove the radiator hose
  7. step : Removing the Alternator (10:13)
    • Remove the 10mm bolts from the bracket atop the thermostat housing
    • Remove the three 10mm bolts from the spark plug wire bracket
    • Insert a 1/4" ratchet into the tensioner
    • Turn the tensioner clockwise
    • Remove the belt from the alternator
    • Remove the two 10mm bolts on the bottom of the alternator
    • Lift the alternator forward and off of the intake manifold
  8. step : Disconnecting the Fuel Lines and Fuel Injectors (12:59)
    • Disconnect the fuel injector wiring harnesses on the intake manifold
    • Disconnect the two temperature sensors
    • Open the Schrader valve on the fuel rail
    • Surround the valve with a rag
    • Press the valve stem down to release the fuel pressure
    • Replace the cap on the valve
    • Remove the 8mm bolts from the fuel rail
    • Pry the fuel injectors out of the intake manifold with a prybar
    • Disconnect the heater hose with a flat tip screwdriver
    • Remove the 10mm bolt from the ground strap
  9. step : Removing the Upper Intake Manifold (17:53)
    • Remove the four bolts on the passenger side from the intake manifold
    • Remove the five bolts on the driver side from the intake manifold
    • Remove the two bolts on the thermostat housing side from the intake manifold
    • Remove the 8mm bolts down the center of the manifold
    • Lift the intake manifold up and out
  10. step : Preparing the Cylinder Head (21:54)
    • Inspect the intake gaskets
    • Gently pull the intake gaskets out, without dropping dirt into the runner holes
    • Stuff the runner holes with paper towels
    • Vacuum dirt and debris from the surface
    • Scrape corrosion from the cylinder heads with a razor
    • Rub an abrasive pad against the cylinder head
    • Spray a rag with brake parts cleaner and clean the cylinder head
    • Remove any seals from the injector rail
    • Press the seals onto the fuel injectors
    • Remove the thermostat housing from the intake manifold
    • Remove the temperature sensors with a 19mm wrench
  11. step : Preparing the New Upper Intake Manifold (28:25)
    • Apply thread sealant to the sensors
    • Screw the sensors in to the crossover pipe
    • Apply the cab to the heater hose slot if needed
    • Flip the intake manifold over
    • Insert the dowel pins into the manifold that match the part number on the lower intake manifold
    • Apply oil to the end of the fuel injectors
    • Push the old injectors into the new upper intake manifold
    • Apply o-rings to the top of the injectors
  12. step : Installing the Upper Intake Manifold (32:10)
    • Remove the paper towels from the runner holes
    • Vacuum out the runner holes
    • Lower the upper intake manifold into place
    • Insert the center bolts into the socket with a piece of tape to secure it
    • Tighten the eight center lower intake manifold bolts
    • Torque the center bolts following the torque sequence to 18 inch-pounds
    • Torque the center bolts following the torque sequence to 106 inch-pounds
    • Insert the thermostat into the thermostat housing
    • Place the thermostat housing cover on
    • Tighten the 10mm bolts to the housing
    • Tighten the four bolts on the passenger side from the intake manifold
    • Tighten the five bolts on the driver side from the intake manifold
    • Torque the exterior manifold bolts to the torque sequence to 18 inch-pounds
    • Torque the exterior manifold bolts to the torque sequence to 18 foot-pounds
  13. step : Reinstalling the Fuel Injectors and Fuel Rail (40:09)
    • Place oil on the injector seals
    • Press the fuel rail onto the fuel injectors
    • Tighten the 10mm bolts to the fuel rail while pushing down on the fuel rail
    • Install the fuel injector connectors
    • Connect the heater hose to the rear of the intake manifold
    • Tighten the hose clamp
  14. step : Reinstalling the Throttle Body (43:33)
    • Scrape off any old gasket adhesive from the throttle body
    • Clean off the mating surface with an abrasive pad
    • Clean out any debris from the elbow without getting cleaner in the throttle body
    • Connect the EGR tube
    • Place the throttle body on the intake
    • Tighten the 10mm bolt to the ground strap
    • Tighten the 10mm bolts to the throttle body
  15. step : Reinstalling the Alternator (45:44)
    • Lift the alternator into place
    • Tighten the 10mm bolts to the bottom of the alternator
    • Tighten the three 10mm bolts to the bracket behind the alternator
    • Turn the tensioner clockwise with a 1/4" drive ratchet
    • Lift the belt onto the alternator
  16. step : Connecting the Throttle Body Cable and Vacuum Lines (47:23)
    • Plug in the two temperature sensors
    • Tighten the 10mm bolts to the power steering bracket
    • Connect the hoses to the throttle body
    • Tighten the crossover pipe with an adjustable wrench
    • Reinstall the bracket with sensors and tighten the 10mm bolts
    • Connect the two hoses and bracket to the throttle body
    • Connect the vacuum hoses and sensors to the throttle body
    • Set the bracket with the throttle and cruise control cables into place
    • Tighten the 10mm bolt to the bracket
    • Hook in the cables to the throttle body
    • Hook in the spring
    • Hook the cables into the clips
    • Reconnect the sensors to the throttle body
  17. step : Reconnecting the Radiator Hose (52:24)
    • Insert the radiator hose into place
    • Tighten the hose clamp
    • Connect the green and white vacuum connection
  18. step : Reconnecting the Air Intake (53:26)
    • Insert the air intake hose to the throttle body
    • Connect the two hoses to the air intake
    • Tighten the hose clamp with a flat blade screwdriver
    • Connect the intake air sensor
    • Press the air filter housing in
    • Attach the engine cover
    • Tighten the 10mm bolts to the engine cover
  19. step : Reconnecting the Battery (54:50)
    • Connect the positive cable
    • Connect the negative cable and tighten the bolt
    • Tighten the positive cable bolt
  20. step : Refilling the Coolant (55:16)
    • Insert antifreeze into the coolant bottle
    • Run the vehicle with the cap off to bleed the system
    • Cap the coolant off
    • Shut the vehicle off
    • Let the vehicle cool down
    • Add anti-freeze as needed

Tools needed for replacement:

    General Tools

  • Razor Blade / Gasket Scraper
  • Pick
  • Rubber Mallet
  • Drain Pan

  • Materials, Fluids, and Supplies

  • Anti-Freeze
  • Safety Glasses
  • Engine Oil
  • Gloves
  • Paper Towels
  • Anti-Seize Grease
  • Rubber Vacuum Hose
  • Painter's Tape

  • Pliers, Cutters & misc Wrenches

  • Adjustable Wrench
  • Needle nose pliers

  • Ratchets & Related

  • Socket Extensions
  • Torque Wrench
  • 1/2 Inch Ratchet
  • Ratchet

  • Screwdrivers & Related

  • Pry Bar
  • Flat Blade Screwdriver

  • Sockets - Metric

  • 8mm Socket
  • 10mm Socket
  • 11mm Socket

  • Wrenches - Metric

  • 19mm Wrench

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Year Make Model Description
1997-2006Ford E150 Van Ford E150 Van V8 4.6L Upper Intake Manifold with Integrated Gaskets Dorman 615-278
1997-2006Ford E250 Van Ford E250 Van V8 4.6L Upper Intake Manifold with Integrated Gaskets Dorman 615-278
1997-2004Ford Expedition Ford Expedition V8 4.6L Upper Intake Manifold with Integrated Gaskets Dorman 615-278
2004Ford F150 Heritage Truck Ford F150 Heritage Truck V8 4.6L Upper Intake Manifold with Integrated Gaskets Dorman 615-278
1997-2006Ford F150 Truck Ford F150 Truck V8 4.6L Upper Intake Manifold with Integrated Gaskets Dorman 615-278
1997-1999Ford F250 Light Duty Truck Ford F250 Light Duty Truck V8 4.6L Upper Intake Manifold with Integrated Gaskets Dorman 615-278
Part #: 1AEIM00032

Out of Stock

Dorman
Brand #: 615-278

How-to Video:

(56:20 min)