Intake Manifold (6.8L): Removal
WARNING: This page does not describe the selected car, but rather 9 other vehicles, including the 2002 Ford RV Cutaway, 2002 Ford Pickup, 2002 Ford F550 Super Duty, 2002 Ford F450 Super Duty, and 2002 Ford Excursion. However, it is still accessible from the selected car via links, so may be relevant.
- Disconnect negative battery cable. Drain coolant system. Remove air cleaner outlet tube. Disconnect water outlet hose. Remove accelerator cable splash shield. Relieve fuel system pressure. See FUEL SYSTEM PRESSURE RELEASE . Disconnect accelerator and speed control cables. Remove return spring. Position accelerator cable bracket aside. Disconnect PCV vacuum hose, coolant hoses, vacuum lines and engine sensor control wiring harness. See Figure.
- Remove bolt and position radio interference capacitor aside. Disconnect fuel injector electrical connectors and ignition coil electrical connectors. Disconnect idle air control motor electrical connector and by-pass hose. Disconnect and remove EGR transducer (if equipped). Disconnect throttle position sensor. Remove EGR valve and tube, if equipped.
- Remove the throttle body adapter. Remove the EVR bracket, if equipped. Disconnect the water temperature indicator sender unit electrical connectors. Remove generator. Remove ignition coils. Disconnect the fuel injection supply manifold. Disconnect the fuel lines. See FUEL LINE CONNECTORS . Disconnect fuel pressure regulator vacuum line.
- Disconnect cylinder head temperature sensor. Remove thermostat and housing. Remove intake manifold assembly bolts and intake manifold assembly. If lower intake manifold removal is necessary, go to next step.
- Remove the fuel injection supply manifold, if necessary. Remove bolts and separate the upper and lower intake manifolds. Clean all mating surfaces.