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Home >> Ford >> 2000 >> Contour SE, 2.0 3, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 726 (Engine 6.0L Diesel (99P E-Series & 99P F450/550)) >> In-Vehicle Repair >> Intake Manifold >> Removal

Intake Manifold: Removal

WARNING: This page is about a different car, the 2004 Ford RV Cutaway, 2004 Ford Econoline, 2004 Ford E450 Super Duty, and 2004 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.

    ALL VEHICLES 

  1. Disconnect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  2. Remove the cooling fan stator. For additional information, refer to ENGINE COOLING .
  3. Remove the turbocharger pedestal. For additional information, refer to FUEL CHARGING & CONTROLS-TURBOCHARGER .

    4. VEHICLES WITH DUAL GENERATOR 

  4. Remove the accessory drive belt.
    Fig 1: Removing Accessory Drive Belt
    G02764337Courtesy of FORD MOTOR CO.
  5. Remove the bolt and the accessory drive belt tensioner.
    Fig 2: Removing Bolt And Accessory Drive Belt Tensioner
    G02764338Courtesy of FORD MOTOR CO.
  6. Remove the accessory drive belt.
    Fig 3: Removing Accessory Drive Belt
    G02764339Courtesy of FORD MOTOR CO.
  7. Remove the bolts, bracket and accessory drive belt idler pulley.
    Fig 4: Removing Bolts, Bracket And Accessory Drive Belt Idler Pulley
    G02764340Courtesy of FORD MOTOR CO.
  8. Remove the bolts and the accessory drive belt tensioner.
    Fig 5: Removing Bolts And Accessory Drive Belt Tensioner
    G02764341Courtesy of FORD MOTOR CO.
  9. Disconnect the generator electrical connector and the B+ wire.
    Fig 6: Disconnecting Generator Electrical Connector
    G02764342Courtesy of FORD MOTOR CO.
  10. Remove the bolts and the generator with mounting bracket.
    Fig 7: Removing Bolts And Generator With Mounting Bracket
    G02764343Courtesy of FORD MOTOR CO.

    11. VEHICLES WITH SINGLE GENERATOR 

  11. Remove the accessory drive belt.
    Fig 8: Removing Accessory Drive Belt
    G02764344Courtesy of FORD MOTOR CO.

    12. ALL VEHICLES 

  12. Remove the bolt and position the ground wire aside. Disconnect the electrical connector push pin.
    Fig 9: Removing Bolt And Position Ground Wire Aside
    G02764345Courtesy of FORD MOTOR CO.
  13. Remove the conduit and position the wiring aside.
    • Disconnect the locking tab.
    • Remove the bolts.
    • Disconnect the push pin and remove the wiring harness from the conduit.
    Fig 10: Removing Wiring Harness From Conduit
    G02764346Courtesy of FORD MOTOR CO.
  14. Remove the bolts for the charge air cooler tube and oil fill tube.
    Fig 11: Removing Bolts For Charge Air Cooler Tube And Oil Fill Tube
    G02764347Courtesy of FORD MOTOR CO.
  15. Disconnect the oil fill tube at the valve cover.
    Fig 12: Disconnecting Oil Fill Tube
    G02764348Courtesy of FORD MOTOR CO.
  16. Remove the retaining nuts, charge air cooler tube, oil fill tube and bracket.
    Fig 13: Removing Retaining Nuts, Charge Air Cooler Tube, Oil Fill Tube And Bracket
    G02764349Courtesy of FORD MOTOR CO.
  17. Disconnect the generator electrical connector and the B+ wire. Disconnect the wiring push pin.
    Fig 14: Disconnecting Generator Electrical Connector
    G02764350Courtesy of FORD MOTOR CO.
  18. Remove the retaining nut for the transmission fluid indicator and tube.
    Fig 15: Removing Retaining Nut
    G02764351Courtesy of FORD MOTOR CO.
  19. Disconnect the push pin retainer. Remove the retaining nut and position the transmission fluid indicator and tube aside.
    Fig 16: Disconnecting Push Pin Retainer
    G02764352Courtesy of FORD MOTOR CO.
  20. Remove the three bolts, ground wire and the generator.
    Fig 17: Removing Three Bolts, Ground Wire And Generator
    G02764353Courtesy of FORD MOTOR CO.
  21. Remove the bolts and position the heater hose tube aside.
    • Remove and discard the O-ring.
    Fig 18: Removing O-Ring
    G02764354Courtesy of FORD MOTOR CO.
    22. NOTE: It will be necessary to position back or remove the heat insulating wrap.
    Fig 19: Disconnecting Wiring Retainer
    G02764355Courtesy of FORD MOTOR CO.
  22. Remove the retaining nut and disconnect the wiring retainer and the injection pressure regulator valve electrical connector.
  23. Disconnect the exhaust gas recirculation (EGR) valve electrical connector.
    Fig 20: Disconnecting Exhaust Gas Recirculation (EGR) Valve Electrical Connector
    G02764356Courtesy of FORD MOTOR CO.
  24. Disconnect the engine oil pressure (EOP) sensor electrical connector.
    Fig 21: Disconnecting Engine Oil Pressure (EOP) Sensor Electrical Connector
    G02764357Courtesy of FORD MOTOR CO.
  25. Disconnect the engine oil temperature (EOT) sensor electrical connector.
    Fig 22: Disconnecting Engine Oil Temperature (EOT) Sensor Electrical Connector
    G02764358Courtesy of FORD MOTOR CO.
  26. Disconnect the EGR throttle position control module electrical connector.
    Fig 23: Disconnecting EGR Throttle Position Control Module Electrical Connector
    G02764359Courtesy of FORD MOTOR CO.
  27. Disconnect the EGR throttle position sensor electrical connector.
    Fig 24: Disconnecting EGR Throttle Position Sensor Electrical Connector
    G02764360Courtesy of FORD MOTOR CO.
  28. Disconnect the pin-type retainer and engine coolant temperature (ECT) sensor.
    Fig 25: Disconnecting Pin-Type Retainer And Engine Coolant Temperature (ECT) Sensor
    G02764361Courtesy of FORD MOTOR CO.
  29. Remove the ECT sensor.
    • Plug or cap the opening as needed.
    Fig 26: Removing ECT Sensor
    G02764362Courtesy of FORD MOTOR CO.
  30. Disconnect the intake air temperature (IAT2) sensor electrical connector.
    Fig 27: Disconnecting IAT2 Sensor Electrical Connector
    G02764363Courtesy of FORD MOTOR CO.
  31. Remove the IAT2 sensor.
    • Plug or cap the opening as needed.
    Fig 28: Removing IAT2 Sensor
    G02764364Courtesy of FORD MOTOR CO.
    32. NOTE: Only one fuel injector shown, others similar.
    Fig 29: Disconnecting Fuel Injector Electrical Connectors
    G02764365Courtesy of FORD MOTOR CO.
  32. Disconnect the eight fuel injector electrical connectors and wiring connectors.
    33. NOTE: One retainer shown, other similar.
    Fig 30: Disconnecting Harness Retainers
    G02764366Courtesy of FORD MOTOR CO.
  33. Disconnect the harness retainers. Position the engine wiring harness as needed for intake manifold removal.
  34. Disconnect the manifold absolute pressure (MAP) sensor hose.
    Fig 31: Disconnecting Manifold Absolute Pressure (MAP) Sensor Hose
    G02764367Courtesy of FORD MOTOR CO.
  35. Disconnect the engine coolant vent hose.
    Fig 32: Disconnecting Engine Coolant Vent Hose
    G02764368Courtesy of FORD MOTOR CO.
  36. Remove the secondary fuel filter and remove all fuel from the filter housing.
    Fig 33: Removing Secondary Fuel Filter
    G02764369Courtesy of FORD MOTOR CO.
  37. Disconnect the fuel tube fittings at the secondary fuel filter.
    • Remove and discard the copper sealing washers.
    Fig 34: Removing Copper Sealing Washers
    G02764370Courtesy of FORD MOTOR CO.
  38. Disconnect the fuel tube at the fuel filter housing. Remove the retaining nut.
    Fig 35: Disconnecting Fuel Tube At Fuel Filter Housing
    G02764371Courtesy of FORD MOTOR CO.
  39. Remove the banjo bolt and fuel tube.
    • Discard the copper sealing washers.
    Fig 36: Removing Banjo Bolt And Fuel Tube
    G02764372Courtesy of FORD MOTOR CO.
  40. Remove the bolts and the secondary fuel filter assembly.
    Fig 37: Removing Bolts And Secondary Fuel Filter Assembly
    G02764373Courtesy of FORD MOTOR CO.
  41. Remove the nuts and turbocharger heat shield.
    Fig 38: Removing Nuts And Turbocharger Heat Shield
    G02764374Courtesy of FORD MOTOR CO.
    42. NOTE: Align the flat edge with the index feature located on the coolant supply port.
    Fig 39: Pulling EGR Cooler Clamp Forward
    G02764375Courtesy of FORD MOTOR CO.
  42. Pull the EGR cooler clamp forward, twist and then slide the EGR cooler hose rearward to remove.
  43. Remove the bolts and the intake manifold.
    Fig 40: Removing Bolts And Intake Manifold
    G02764376Courtesy of FORD MOTOR CO.
  44. Remove the intake manifold gaskets.
    • Clean and inspect the gaskets. Install new gaskets if necessary.
    • Clean and inspect the sealing surfaces.
    • Remove and discard the front module O-ring seal.
    Fig 41: Removing Front Module O-Ring Seal
    G02764377Courtesy of FORD MOTOR CO.
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