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How-to

1992 Ford F-150 Upper Intake Plenum Removal

1992 Ford F-150 · Repair · Moderate

Documented by SuperMotors from Evan_P’s photos

Removing the upper intake plenum and throttle body on a 1992 Ford F-150 to reach the fuel injectors. The photos show the teardown from the battery disconnect to lifting the plenum off, and the spark plug wires re-routed while it was off.

  1. Step 1

    Disconnect the negative battery cable, then remove the air intake hoses and set them aside. The owner disconnected the battery because the job involves unplugging engine sensors and working around the ignition system.

    This is not a complete write-up. I sorta took these pictures as reference, but figure I would write out how I did it. First I disconnected… (1992 Ford F-150)

  2. Step 2

    Unplug the sensors mounted to the throttle body. The IAC valve is shown; the TPS also has to be unplugged.

    Unplug all of the sensors mounted to the throttle body. Shown is the IAC valve. There is also the TPS to unplug. (1992 Ford F-150)

  3. Step 3

    Remove the cover over the throttle cable if it is still in place, then pop the throttle and cruise cable off the ball stud. The owner used a small flat head screwdriver for this.

    Remove the cover for the throttle cable assuming it is still there and disconnect the throttle/cruise cable. It pops off of a little ball.… (1992 Ford F-150) Remove the cover for the throttle cable assuming it is still there and disconnect the throttle/cruise cable. It pops off of a little ball.… (1992 Ford F-150)

  4. Step 4

    Unbolt the bracket that holds the cables to the upper intake plenum. Fold the cables and bracket out of the way.

    Unbolt the bracket shown above that hold the cable from the upper intake plenum and fold the cables and bracket out of the way. (1992 Ford F-150)

  5. Step 5

    Disconnect all of the vacuum lines from the vacuum tree. Routing varies between trucks, so take reference photos first so the lines are not mixed up on reassembly.

    Next disconnect all of the vacuum lines from the vacuum tree. This is how mine were set up. Yours MAY be different. Always take a few refer… (1992 Ford F-150) Next disconnect all of the vacuum lines from the vacuum tree. This is how mine were set up. Your MAY be different. Always take a few refere… (1992 Ford F-150) Next disconnect all of the vacuum lines from the vacuum tree. This is how mine were set up. Your MAY be different. Always take a few refere… (1992 Ford F-150)

  6. Step 6

    Disconnect the rubber hose running from the solenoid to the throttle body, then disconnect the two coolant lines at the throttle body, one at the top and one at the bottom. Unbolt the EGR from the throttle body rather than from the exhaust manifold.

    Disconnect the rubber hose running to the throttle body from this solenoid. I cannot remember its name. While you are there disconnect the… (1992 Ford F-150)

  7. Step 7

    With everything disconnected, remove the 6 bolts around the perimeter where the upper plenum meets the lower; the inner bolt in the center section is a Torx T40 and sits in a tight spot, which the owner reached with a long extension. Lift the plenum and throttle body off. The owner also replaced the PCV valve while the access was open.

    Once everything is disconnected from the throttle body and upper plenum, there are 6 bolts around the perimeter of the upper plenum where i… (1992 Ford F-150)

  8. Step 8

    With the upper plenum off, the lower intake plenum and fuel rails are exposed. Reaching the fuel injectors was the owner's reason for removing the plenum.

    A look at the lower intake plenum and fuel rails. For me, getting to the fuel injectors was the reason the plenum came off. (1992 Ford F-150)

  9. Step 9

    While the plenum is off, the owner re-routed the spark plug wires to reduce the chance of cross-ignition.

    As you can see I plugged all of the intake holes with paper towel's so I could scrape the old gasket off and not drop anything in it. I als… (1992 Ford F-150)

  10. Step 10

    The album ends with a second view of the engine bay after the plug wires were re-routed. No reassembly steps are shown in the photos.

    Another shot of the re-routed plug wires. Much cleaner looking. (1992 Ford F-150)

Some product links go to the supplier the owner bought from. SuperMotors does not earn a commission today; if that changes, this line will say so and creators will be paid from it.