Dorman 615-375 Engine Intake Manifold Instruction Manual

1. Introduction

This manual provides essential information for the Dorman 615-375 Engine Intake Manifold. This component is engineered to precisely match the fit and function of the original manifold in specific Ford vehicles, ensuring reliable performance and durability. It has undergone thorough testing to meet high-quality OEM standards.

Key Features:

• Ideal Replacement: Precision-engineered and durably manufactured to match the fit and function of the stock manifold.
• Reliable Construction: Tested to ensure top-quality OEM performance and durability.
• Perfect Fit: Designed to match all specifications of the original part for convenient, trouble-free installation.
• Trustworthy Design: Built by an industry leader in aftermarket manifolds.

2. Product Overview

Figure 2.1: Top view of the Dorman 615-375 Engine Intake Manifold, showcasing its overall structure and connection points.

Figure 2.2: Underside view of the Dorman 615-375 Engine Intake Manifold, highlighting the integrated gaskets and runner design.

What's in the Box:

• 1 x Dorman 615-375 Engine Intake Manifold

3. Compatibility

This Dorman 615-375 Engine Intake Manifold is compatible with select Ford models. To ensure accurate fitment for your vehicle, it is crucial to verify compatibility using a vehicle fitment tool or by consulting your vehicle's specific service manual.

Known Compatible Vehicles:

• Ford E-150: 2007, 2008
• Ford E-250: 2007, 2008
• Ford F-150: 2007, 2008
• Ford Lobo: 2007, 2008

Note: This list may not be exhaustive. Always confirm fitment for your specific vehicle trim level.

4. Installation

Installation of an engine intake manifold requires mechanical expertise and specialized tools. It is highly recommended that this procedure be performed by a qualified mechanic. Always refer to your vehicle's specific shop manual for detailed, step-by-step instructions, torque specifications, and safety precautions.

General Installation Considerations:

• Ensure the engine is cool before beginning any work.
• Disconnect the vehicle's battery to prevent electrical hazards.
• Carefully remove all components obstructing access to the intake manifold, such as air intake ducts, fuel lines, electrical connectors, and vacuum hoses. Labeling connections can aid reassembly.
• Thoroughly clean the mating surfaces on the cylinder heads to ensure a proper seal with the new manifold.
• Install the new Dorman intake manifold, ensuring all gaskets are correctly seated.
• Tighten fasteners to the manufacturer's specified torque sequence and values.
• Reconnect all removed components, ensuring all connections are secure and hoses are properly routed.
• Refill coolant and check for leaks after installation.

Installation Video Reference:

5. Maintenance

The Dorman 615-375 Engine Intake Manifold is designed for long-term reliability. Regular engine maintenance, as recommended by your vehicle manufacturer, will contribute to the longevity of this component. This includes timely oil changes, air filter replacements, and inspection of all engine components for wear or damage.

Important Note on Related Components:

For certain General Motors 1.4L Ecotec engines (e.g., Chevy Cruze, Sonic, Trax, Buick Encore), the intake manifold and valve cover are directly related. A problem with one can impact the other. The original equipment intake manifold design can lead to the internal PCV valve becoming dislodged, causing excessive oil consumption and vacuum that can damage the PCV diaphragm in the valve cover. Dorman's OE Fix intake manifold for these specific GM applications features a redesigned retaining feature to prevent the valve from dislodging. While this product is for Ford models, the principle of inspecting related components for a reliable repair is universally applicable.

6. Troubleshooting

If you experience issues after installing the intake manifold, consider the following common troubleshooting steps:

• Vacuum Leaks: Check all vacuum lines and connections for proper seating and integrity. A vacuum leak can cause rough idling, misfires, and illuminated check engine light.
• Coolant Leaks: Inspect all coolant hose connections and the manifold's sealing surfaces for any signs of leakage. Ensure proper torque on all fasteners.
• Fuel Leaks: Verify that fuel injector O-rings are correctly installed and not damaged, and that fuel lines are securely connected.
• Check Engine Light: If the check engine light illuminates, retrieve diagnostic trouble codes (DTCs) using an OBD-II scanner. These codes can help pinpoint the specific issue.
• PCV System Issues: As discussed in the maintenance section, ensure the PCV system is functioning correctly. Inspect the PCV valve and related hoses for blockages or damage.

For persistent issues, consult a qualified automotive technician or refer to your vehicle's service manual for advanced diagnostic procedures.

7. Specifications

8. Support & Warranty

For technical assistance, installation guidance, or warranty inquiries regarding your Dorman 615-375 Engine Intake Manifold, please contact Dorman customer support directly. Refer to the product packaging or Dorman's official website for the most current contact information and warranty details.

Dorman is committed to providing quality automotive replacement parts and support.