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Intake Manifold (6.8L): Removal

WARNING: This page is about a different car, the 2003 Ford Econoline. However, it is still accessible from the selected car via links, so may be relevant.
  1. Disconnect negative battery cable. On vehicles with dual batteries, see DUAL BATTERIES  under MISCELLANEOUS. Remove engine cover. See ENGINE COVER  under MISCELLANEOUS. Relieve fuel pressure and disconnect fuel hose spring lock couplings. See FUEL SYSTEM PRESSURE RELEASE  and FUEL LINE CONNECTORS  under FUEL SYSTEMS. Drain cooling system.
  2. Remove 4 air cleaner assembly bolts and loosen air cleaner outlet pipe clamp. Position air cleaner assembly to gain access to Mass Airflow (MAF) sensor electrical connector and disconnect MAF sensor electrical connector. Remove air cleaner assembly. Disconnect 2 hoses on air cleaner outlet pipe, loosen clamp at throttle body and remove air cleaner outlet pipe. Remove accelerator cable splash shield.
  3. Compress and slide upper radiator hose clamp back and disconnect hose from thermostat housing. Disconnect Engine Coolant Temperature (ECT) electrical connector. Remove bolt and bracket at thermostat housing. Remove bolts and generator upper support bracket. Disconnect heater hoses at intake manifold.
  4. Disconnect Throttle Position (TP) sensor electrical connector and detach harness routing clip. Disconnect accelerator cable, speed control actuator cable and remove throttle return spring. Remove bolts and position accelerator cable bracket and cables aside.
  5. Remove transmission fluid level indicator tube bracket retaining nut near accelerator cable bracket and from rear bracket. Position tube aside. Remove 4 retainers from fuel charging wiring harness and position wiring harness away from fuel injection supply manifold. If equipped, disconnect auxiliary heater hoses and position aside.
  6. Disconnect Evaporative Emission (EVAP) canister purge valve hose and vacuum hose. Remove 2 evaporative emission canister purge valve bracket nuts and position valve and bracket assembly aside.
  7. Disconnect and remove Idle Air Control (IAC) valve fresh air hose and disconnect IAC valve electrical connector.
  8. If equipped, disconnect Exhaust Gas Recirculation (EGR) vacuum regulator solenoid connector.
  9. Remove engine vacuum harness by disconnecting the following:
    • EGR valve, if equipped.
    • EGR vacuum regulator solenoid, if equipped.
    • Vacuum source.
    • Fuel pressure regulator.
    See Figure.
  10. If equipped, remove exhaust manifold-to-EGR valve tube. Disconnect and remove Positive Crankcase Ventilation (PCV) hose. Disconnect brake booster vacuum hose and position aside.
  11. Remove the 4 throttle body bolts. Remove throttle body and adapter as an assembly. Discard throttle body adapter gasket.
  12. Disconnect the 10 fuel injector and ignition coil electrical connectors and position harness aside. Remove the coil screws and remove the 10 coils. Disconnect Cylinder Head Temperature (CHT) sensor electrical connector.
  13. Remove thermostat housing bolts, thermostat housing and thermostat. Remove intake manifold bolts, intake manifold and intake manifold gaskets. If necessary, remove the 10 bolts attaching lower intake manifold to the upper intake manifold. Separate upper and lower intake manifolds. Discard all intake manifold gasket.
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