LEMON Manuals: Even more car manuals for everyone
Home >> Ford >> 2000 >> Contour SE, 2.0 3, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 799 (Engine - 6.0L Diesel -- E350 & E450) >> In-Vehicle Repair >> Intake Manifold >> Removal

Intake Manifold: Removal

WARNING: This page is about a different car, the 2005 Ford RV Cutaway, 2005 Ford Econoline, 2005 Ford E450 Super Duty, and 2005 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: Rotating Drive Belt Tensioner Clockwise
    G03887086Courtesy of FORD MOTOR CO.
  5. Remove the bolt and the accessory drive belt tensioner.
    Fig 2: Removing Bolt Accessory Drive Belt Tensioner
    G03887087Courtesy of FORD MOTOR CO.
  6. Remove the accessory drive belt.
    Fig 3: Rotating Accessory Drive Belt Tensioner Clockwise
    G03887088Courtesy of FORD MOTOR CO.
  7. Remove the bolts, bracket and accessory drive belt idler pulley.
    Fig 4: Removing Bolts
    G03887089Courtesy of FORD MOTOR CO.
  8. Remove the bolts and the accessory drive belt tensioner.
    Fig 5: Removing Bolts Accessory Drive Belt Tensioner
    G03887090Courtesy of FORD MOTOR CO.
  9. Disconnect the generator electrical connector and the B+ wire.
    Fig 6: Disconnecting Generator Electrical Connector
    G03887091Courtesy of FORD MOTOR CO.
  10. Remove the bolts and the generator with mounting bracket.
    Fig 7: Removing Bolts Generator With Mounting Bracket
    G03887092Courtesy of FORD MOTOR CO.

    11. Vehicles with single generator 

  11. Remove the accessory drive belt.
    Fig 8: Rotating Accessory Drive Belt Tensioner Clockwise
    G03887093Courtesy of FORD MOTOR CO.

    12. All vehicles 

  12. Remove the bolt and position the ground wire aside. Disconnect the electrical connector pushpin.
    Fig 9: Disconnecting Electrical Connector Pushpin
    G03887094Courtesy of FORD MOTOR CO.
  13. Remove the bolt and position the manifold absolute pressure (MAP) assembly aside.
    • Disconnect the pushpin.
      Fig 10: Disconnecting Pushpin
      G03887095Courtesy of FORD MOTOR CO.
  14. Remove the bolts and position the wiring aside.
    Fig 11: Removing Bolts
    G03887096Courtesy of FORD MOTOR CO.
  15. Remove the bolts for the charge air cooler tube and oil fill tube.
    Fig 12: Locating CAC Tube And Oil Fill Tube Bolts
    G03887097Courtesy of FORD MOTOR CO.
  16. Disconnect the oil fill tube at the valve cover.
    Fig 13: Identifying Oil Fill Tube At Valve Cover
    G03887098Courtesy of FORD MOTOR CO.
  17. Remove the retaining nuts, charge air cooler tube, oil fill tube and bracket.
    Fig 14: Locating Bracket Retaining Nuts
    G03887099Courtesy of FORD MOTOR CO.
  18. Disconnect the generator electrical connector and the B+ wire. Disconnect the wiring pushpin.
    Fig 15: Disconnecting Generator Electrical Connector
    G03887100Courtesy of FORD MOTOR CO.
  19. Remove the retaining nut for the transmission fluid indicator and tube.
    Fig 16: Removing Retaining Nut
    G03887101Courtesy of FORD MOTOR CO.
  20. Disconnect the pushpin retainer. Remove the retaining nut and position the transmission fluid indicator and tube aside.
    Fig 17: Disconnecting Pushpin Retainer
    G03887102Courtesy of FORD MOTOR CO.
  21. Remove the three bolts, ground wire and the generator.
    Fig 18: Removing Three Bolts
    G03887103Courtesy of FORD MOTOR CO.
  22. Remove the bolts and position the heater hose tube aside.
    • Remove and discard the O-ring seal.
      Fig 19: Removing O-Ring Seal
      G03887104Courtesy of FORD MOTOR CO.
    23. NOTE: It will be necessary to position back or remove the heat insulating wrap.
    Fig 20: Disconnecting Wiring Retainer
    G03887105Courtesy of FORD MOTOR CO.
  23. Remove the retaining nut and disconnect the wiring retainer and the injection pressure regulator valve electrical connector.
  24. Disconnect the exhaust gas recirculation (EGR) valve electrical connector.
    Fig 21: Locating EGR Valve Assembly Electrical Connector
    G03887106Courtesy of FORD MOTOR CO.
  25. Disconnect the engine oil pressure (EOP) sensor electrical connector.
    Fig 22: Locating Engine Oil Pressure Sensor Electrical Connector
    G03887107Courtesy of FORD MOTOR CO.
  26. Disconnect the engine oil temperature (EOT) sensor electrical connector.
    Fig 23: Locating Engine Oil Temperature Sensor
    G03887108Courtesy of FORD MOTOR CO.
  27. Disconnect the pin-type retainer and engine coolant temperature (ECT) sensor.
    Fig 24: Disconnecting Pin-Type Retainer And Engine Coolant Temperature Sensor
    G03887109Courtesy of FORD MOTOR CO.
  28. Remove the ECT sensor.
    • Plug or cap the opening as needed.
      Fig 25: Removing ECT Sensor
      G03887110Courtesy of FORD MOTOR CO.
  29. Disconnect the intake air temperature (IAT2) sensor electrical connector.
    Fig 26: Disconnecting Intake Air Temperature Sensor Electrical Connector
    G03887111Courtesy of FORD MOTOR CO.
  30. Remove the IAT2 sensor.
    • Plug or cap the opening as needed.
      Fig 27: Removing IAT2 Sensor
      G03887112Courtesy of FORD MOTOR CO.
    31. NOTE: Only one fuel injector shown, others similar.
    Fig 28: Identifying Fuel Injector Electrical Connector & Retainer Clip
    G03887113Courtesy of FORD MOTOR CO.
  31. Disconnect the eight fuel injector electrical connectors.
    32. NOTE: One retainer shown, others similar.
    Fig 29: Disconnecting Harness Retainers
    G03887114Courtesy of FORD MOTOR CO.
  32. Disconnect the harness retainers. Position the engine wiring harness as needed for intake manifold removal.
  33. Disconnect the manifold absolute pressure (MAP) sensor hose.
    Fig 30: Disconnecting Manifold Absolute Pressure Sensor Hose
    G03887115Courtesy of FORD MOTOR CO.
  34. Disconnect the engine coolant vent hose.
    Fig 31: Disconnecting Engine Coolant Vent Hose
    G03887116Courtesy of FORD MOTOR CO.
  35. Remove the secondary fuel filter and remove all fuel from the filter housing.
    Fig 32: Removing Secondary Fuel Filter
    G03887117Courtesy of FORD MOTOR CO.
  36. Disconnect the fuel tube fittings at the secondary fuel filter.
    • Remove and discard the copper sealing washers.
      Fig 33: Removing Copper Sealing Washers
      G03887118Courtesy of FORD MOTOR CO.
  37. Disconnect the fuel tube at the fuel filter housing. Remove the retaining nut.
    Fig 34: Disconnecting Fuel Tube At Fuel Filter Housing
    G03887119Courtesy of FORD MOTOR CO.
  38. Remove the RH banjo bolt and fuel tube.
    • Discard the copper sealing washers.
      Fig 35: Removing RH Banjo Bolt And Fuel Tube
      G03887120Courtesy of FORD MOTOR CO.
  39. Remove the bolts and the secondary fuel filter assembly.
    Fig 36: Removing Bolts Secondary Fuel Filter Assembly
    G03887121Courtesy of FORD MOTOR CO.
  40. If equipped, remove the nuts and turbocharger heat shield.
    Fig 37: Removing Nuts Turbocharger Heat Shield
    G03887122Courtesy of FORD MOTOR CO.
    41. NOTE: Align the flat edge with the index feature located on the coolant supply port.
    Fig 38: Pulling EGR Cooler Clamp
    G03887123Courtesy of FORD MOTOR CO.
  41. Pull the EGR cooler clamp forward, twist and then slide the EGR cooler hose rearward to remove.
  42. Remove the bolts and the intake manifold.
    Fig 39: Removing Bolts Intake Manifold
    G03887124Courtesy of FORD MOTOR CO.
  43. Remove the intake manifold gaskets.
    • Clean and inspect the gaskets and front module O-ring seal. Install new gaskets or O-ring seal if necessary.
    • Clean and inspect the sealing surfaces.
      Fig 40: Removing Intake Manifold Gaskets
      G03887125Courtesy of FORD MOTOR CO.
scientia non olet · About LEMON Manuals