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Home >> Ford >> 2000 >> Contour SE, 2.5 L, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 2246 (Engine - 6.0L (99P E-Series) Diesel) >> In-Vehicle Servicing >> Intake Manifold >> Removal

Intake Manifold: Removal

WARNING: This page is about a different car, the 2008 Ford Econoline, 2008 Ford E450 Super Duty, and 2008 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 article.
  2. Remove the cooling fan stator. For additional information, refer to ENGINE COOLING article.
  3. Remove the turbocharger pedestal. For additional information, refer to FUEL CHARGING AND CONTROLS - TURBOCHARGER article.

    4. Vehicles with dual generator 

  4. Remove the accessory drive belt.
    5. Fig 1: Rotating Drive Belt Tensioner Clockwise
    G03887086Courtesy of FORD MOTOR CO.
  5. Remove the bolt and the accessory drive belt tensioner.
    6. Fig 2: Locating Accessory Drive Belt Tensioner Bolt
    G03887087Courtesy of FORD MOTOR CO.
  6. Remove the accessory drive belt.
    7. Fig 3: Rotating Accessory Drive Belt Tensioner
    G03887088Courtesy of FORD MOTOR CO.
  7. Remove the 3 bolts, the bracket and the accessory drive belt idler pulley.
    8. Fig 4: Locating Bracket And Accessory Drive Belt Idler Pulley Bolts
    G03887089Courtesy of FORD MOTOR CO.
  8. Remove the 2 bolts and the accessory drive belt tensioner.
    9. Fig 5: Locating Accessory Drive Belt Tensioner Bolts
    G03887090Courtesy of FORD MOTOR CO.
  9. Disconnect the generator electrical connector and the B+ wire.
    10. Fig 6: Generator Electrical Connector & B+ Wire
    GF0011810Courtesy of FORD MOTOR CO.
  10. Remove the 4 bolts and the generator and mounting bracket as an assembly.
    11. Fig 7: Identifying Generator Mounting Bracket Bolts
    G03887092Courtesy of FORD MOTOR CO.

    Vehicles with single generator 

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

    All vehicles 

  12. Disconnect the electrical connector pushpin and remove the bolt and position the ground wire aside.
    13. Fig 9: Identifying Ground Wire Bolt & Electrical Connector
    G03887094Courtesy of FORD MOTOR CO.
  13. Remove the bolt and position the Manifold Absolute Pressure (MAP) assembly aside.
    14. Fig 10: Manifold Absolute Pressure (MAP) Sensor & Bolts
    GF0011811Courtesy of FORD MOTOR CO.
  14. Remove the 3 bolts and position the wiring aside.
    15. Fig 11: Wiring Bolts
    GF0011812Courtesy of FORD MOTOR CO.
  15. Remove the 3 bolts for the Charge Air Cooler (CAC) tube and oil fill tube.
    16. 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.
    17. Fig 13: Identifying Oil Fill Tube At Valve Cover
    G03887098Courtesy of FORD MOTOR CO.
  17. Remove the 2 nuts, CAC tube, oil fill tube and bracket.
    18. Fig 14: Locating Retaining Nuts, CAC Tube, Oil Fill Tube And Bracket
    G03887099Courtesy of FORD MOTOR CO.
  18. Disconnect the generator electrical connector, the B+ wire and the wiring pushpin.
    19. Fig 15: Generator Electrical Connector, B+ Wire & Wiring Pushpin
    GF0011813Courtesy of FORD MOTOR CO.
  19. Remove the transmission fluid indicator and tube nut.
    20. Fig 16: Transmission Fluid Indicator Tube Nut
    GF0011814Courtesy of FORD MOTOR CO.
  20. Disconnect the pushpin retainer. Remove the retaining nut and position the transmission fluid indicator and tube aside.
    21. Fig 17: Pushpin & Transmission Fluid Indicator Tube Nut
    GF0011815Courtesy of FORD MOTOR CO.
  21. Remove the 3 bolts, ground wire and the generator.
    22. Fig 18: Generator Bolts
    GF0011816Courtesy of FORD MOTOR CO.
  22. Remove the 2 bolts and position the heater hose tube aside.
    • Remove and discard the O-ring seal.
    23. Fig 19: Heater Hose Tube Bolts
    GF0011817Courtesy of FORD MOTOR CO.
    NOTE: It will be necessary to position back or remove the heat insulating wrap.
  23. Disconnect the wiring retainer and the Fuel Injection Pressure Regulator (IPR) valve electrical connector.
    24. Fig 20: Wiring Retainer & Injection Pressure Regulator Valve Electrical Connector
    GF0011818Courtesy of FORD MOTOR CO.
  24. Disconnect the EGR valve electrical connector.
    25. Fig 21: Identifying Exhaust Gas Recirculation (EGR) Valve Electrical Connector
    G03887106Courtesy of FORD MOTOR CO.
  25. Disconnect the Engine Oil Pressure (EOP) sensor electrical connector.
    26. Fig 22: Locating Engine Oil Pressure Sensor Electrical Connector
    G03887107Courtesy of FORD MOTOR CO.
  26. Disconnect the Engine Oil Temperature (EOT) sensor electrical connector.
    27. Fig 23: Locating Engine Oil Temperature Sensor
    G03887108Courtesy of FORD MOTOR CO.
  27. Disconnect the pin-type retainer and Engine Coolant Temperature (ECT) sensor.
    28. Fig 24: Identifying Pin-Type Retainer And Engine Coolant Temperature (ECT) Sensor Electrical Connector
    G03887109Courtesy of FORD MOTOR CO.
  28. Remove the ECT sensor.
    • Plug or cap the opening as needed.
    29. Fig 25: Engine Coolant Temperature (ECT) Sensor
    GF0011819Courtesy of FORD MOTOR CO.
  29. Disconnect the Intake Air Temperature 2 (IAT2) sensor electrical connector.
    30. Fig 26: Identifying Intake Air Temperature (IAT2) Sensor Electrical Connector
    G03887111Courtesy of FORD MOTOR CO.
  30. Remove the IAT2 sensor.
    • Plug or cap the opening as needed.
    31. Fig 27: Intake Air Temperature (IAT2) Sensor
    GF0011820Courtesy of FORD MOTOR CO.
  31. Disconnect the 8 fuel injector electrical connectors.
    32. Fig 28: Identifying Fuel Injector Electrical Connector & Retainer Clip
    G03887113Courtesy of FORD MOTOR CO.
  32. Disconnect the wiring harness retainers and position the engine wiring harness aside as needed for intake manifold removal.
    33. Fig 29: Wiring Harness Retainer
    GF0011821Courtesy of FORD MOTOR CO.
  33. Disconnect the MAP sensor hose.
    34. Fig 30: MAP Sensor Hose
    GF0011822Courtesy of FORD MOTOR CO.
  34. Disconnect the engine coolant vent hose.
    35. Fig 31: Engine Coolant Vent Hose
    GF0011823Courtesy of FORD MOTOR CO.
  35. Remove the secondary fuel filter and remove all fuel from the filter housing.
    36. Fig 32: Secondary Fuel Filter Cover
    GF0011824Courtesy of FORD MOTOR CO.
  36. Disconnect the fuel tube fittings at the secondary fuel filter.
    • Remove and discard the copper sealing washers.
    37. Fig 33: Secondary Fuel Filter Fuel Tube Fittings
    GF0011825Courtesy of FORD MOTOR CO.
  37. Disconnect the fuel tube at the fuel filter housing and remove the nut.
    38. Fig 34: Fuel Tube At Fuel Filter Housing & Nut
    GF0011826Courtesy of FORD MOTOR CO.
  38. Remove the RH banjo bolt and fuel tube.
    • Discard the copper sealing washers.
    39. Fig 35: Rh Banjo Bolt & Fuel Tube
    GF0011827Courtesy of FORD MOTOR CO.
  39. Remove the 2 bolts and the secondary fuel filter assembly.
    40. Fig 36: Locating Secondary Fuel Filter Assembly Bolts
    G03887121Courtesy of FORD MOTOR CO.
    NOTE: Align the flat edge with the index feature located on the coolant supply port.
  40. Pull the EGR cooler clamp forward, twist and then slide the EGR cooler hose rearward to remove.
    41. Fig 37: Pulling EGR Cooler Clamp Forward
    GF0011828Courtesy of FORD MOTOR CO.
  41. Remove the 11 bolts, the 5 stud bolts and the intake manifold.
  42. Remove the intake manifold gaskets and the front module O-ring seal.
    • Discard the front module O-ring seal.
    • Clean and inspect the intake manifold gaskets. Install new gaskets if necessary.
    • Clean and inspect the sealing surfaces.
    43. Fig 38: Locating Intake Manifold Gasket And Front Module O-Ring Seal
    G03887125Courtesy of FORD MOTOR CO.
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