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Home >> Ford >> 2000 >> Contour SE, 2.5 L, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 729 (Engine - 6.0L Diesel - F250-F550 Super Duty) >> In-Vehicle Repair >> Intake Manifold >> Removal

Intake Manifold: Removal

WARNING: This page is about a different car, the 2004 Ford Pickup, 2004 Ford F550 Super Duty, 2004 Ford F450 Super Duty, 2004 Ford Excursion, and 2004 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

    All vehicles 

  1. Remove the auxiliary battery. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  2. Remove the cooling fan stator - 6.0L diesel engine. For additional information, refer to ENGINE COOLING .
  3. Remove the degas bottle. For additional information, refer to ENGINE COOLING .
  4. Remove the upper radiator hose.
    Fig 1: Removing Upper Radiator Hose
    G03899083Courtesy of FORD MOTOR CO.
    5. NOTE: Engine side shown, charge air cooler side similar.
    Fig 2: Removing Turbocharger-To-Charge Air Cooler Duct
    G03899084Courtesy of FORD MOTOR CO.
  5. Remove the turbocharger-to-charge air cooler duct.

    6. Vehicles with dual generators 

  6. Remove the accessory drive belt.
    Fig 3: Rotating Drive Belt Tensioner Clockwise
    G03887086Courtesy of FORD MOTOR CO.
  7. Remove the bolt and the accessory drive belt tensioner.
    Fig 4: Locating Accessory Drive Belt Tensioner Bolt
    G03887087Courtesy of FORD MOTOR CO.
  8. Remove the accessory drive belt.
    Fig 5: Rotating Accessory Drive Belt Tensioner
    G03887088Courtesy of FORD MOTOR CO.
  9. Remove the bolts, bracket and accessory drive belt idler pulley.
    Fig 6: Locating Bracket And Accessory Drive Belt Idler Pulley Bolts
    G03887089Courtesy of FORD MOTOR CO.
  10. Remove the bolts and the accessory drive belt tensioner.
    Fig 7: Locating Accessory Drive Belt Tensioner Bolts
    G03887090Courtesy of FORD MOTOR CO.
  11. Disconnect the wire retainer, generator electrical connector and B+ wire.
    Fig 8: Locating Wire Retainer And Generator Electrical Connectors
    G03907090Courtesy of FORD MOTOR CO.
  12. Remove the bolts and the generator with mounting bracket.
    Fig 9: Identifying Generator Mounting Bracket Bolts
    G03887092Courtesy of FORD MOTOR CO.

    13. Vehicles with single generator 

  13. Remove the accessory drive belt.
    Fig 10: Rotating Accessory Drive Belt Tensioner
    G03906750Courtesy of FORD MOTOR CO.

    14. All vehicles 

  14. Position the boot back and disconnect the generator B+ wire and electrical connector.
    Fig 11: Positioning Boot Back
    G03899093Courtesy of FORD MOTOR CO.
  15. Remove the three bolts and the generator.
    Fig 12: Locating Generator Bolts
    G03907094Courtesy of FORD MOTOR CO.
  16. Remove the turbocharger and the turbocharger pedestal. For additional information, refer to FUEL CHARGING & CONTROLS - TURBOCHARGER .

    17. Early build 

    NOTE: Engine side shown, charge air cooler side similar.
    Fig 13: Loosening Clamps
    G03899095Courtesy of FORD MOTOR CO.
  17. Loosen the clamps and remove the charge air cooler duct.

    18. Late build 

    NOTE: Engine side shown, charge air cooler side similar.
    Fig 14: Loosening Clamps
    G03899096Courtesy of FORD MOTOR CO.
  18. Loosen the clamps and remove the charge air cooler duct.
  19. Remove the bolts and position the heater hose tube aside.
    • Remove and discard the O-ring.
      Fig 15: Removing Heater Hose Tube
      G03899097Courtesy of FORD MOTOR CO.
  20. Disconnect the manifold absolute pressure (MAP) sensor hose.
    Fig 16: Disconnecting Manifold Absolute Pressure Sensor Hose
    G03899098Courtesy of FORD MOTOR CO.
  21. Disconnect the engine coolant vent hose.
    Fig 17: Disconnecting Engine Coolant Vent Hose
    G03899099Courtesy of FORD MOTOR CO.
  22. Remove the fuel injector control module. For additional information, refer to ELECTRONIC ENGINE CONTROLS - DIESEL ENGINES .
  23. Remove the top two bolts from the injector pressure regulator (IPR) heat shield.
    Fig 18: Removing Heat Shield Bolts
    G03899100Courtesy of FORD MOTOR CO.
  24. Remove or position aside the heat insulating wrap.
    Fig 19: Removing Heat Insulating Wrap
    G03899101Courtesy of FORD MOTOR CO.
  25. Disconnect the wiring retainer, IPR valve and injector control pressure (ICP) sensor (if equipped) electrical connectors.
    Fig 20: Disconnecting Wiring Retainer
    G03899102Courtesy of FORD MOTOR CO.
  26. Disconnect the exhaust gas recirculation (EGR) valve electrical connector.
    Fig 21: Identifying Exhaust Gas Recirculation (EGR) Valve Electrical Connector
    G03887106Courtesy of FORD MOTOR CO.
  27. Disconnect the engine oil pressure (EOP) sensor electrical connector.
    Fig 22: Locating Engine Oil Pressure Sensor Electrical Connector
    G03887107Courtesy of FORD MOTOR CO.
  28. Disconnect the engine oil temperature (EOT) sensor electrical connector.
    Fig 23: Locating Engine Oil Temperature Sensor
    G03887108Courtesy of FORD MOTOR CO.
  29. Disconnect the exhaust gas recirculation (EGR) throttle position control module electrical connector.
    Fig 24: Disconnecting Exhaust Gas Recirculation Throttle Position Control Module Electrical Connector
    G03899106Courtesy of FORD MOTOR CO.
  30. Disconnect the EGR throttle position sensor electrical connector.
    Fig 25: Disconnecting Throttle Position Sensor Electrical Connector
    G03899107Courtesy of FORD MOTOR CO.
  31. Disconnect the pin-type retainer and engine coolant temperature (ECT) sensor.
    Fig 26: Identifying Pin-Type Retainer And Engine Coolant Temperature (ECT) Sensor Electrical Connector
    G03887109Courtesy of FORD MOTOR CO.
  32. Disconnect the intake air temperature (IAT2) sensor electrical connector and wiring connector.
    Fig 27: Disconnecting Intake Air Temperature Sensor Electrical Connector
    G03899109Courtesy of FORD MOTOR CO.
  33. Disconnect the exhaust backpressure sensor and retaining clip.
    Fig 28: Disconnecting Exhaust Backpressure Sensor And Retaining Clip
    G03899110Courtesy of FORD MOTOR CO.
    34. NOTE: Left side shown, right side similar.
    Fig 29: Disconnecting Eight Fuel Injectors Electrical Connectors
    G03899111Courtesy of FORD MOTOR CO.
  34. Disconnect the eight fuel injectors electrical connectors. Remove the nut and the fuel injector wiring harness.
    35. NOTE: It is necessary to remove the fuel filter and drain the housing.
    Fig 30: Disconnecting Fuel Line Fittings
    G03899112Courtesy of FORD MOTOR CO.
  35. Disconnect the fuel line fittings.
    36. NOTE: It is necessary to remove the oil filter and drain the housing.
    Fig 31: Removing Oil Filter Housing Bolts
    G03899113Courtesy of FORD MOTOR CO.
  36. Remove the four bolts and the oil filter housing.
  37. Remove the bolt and the oil filter return tube.
    Fig 32: Locating Oil Filter Return Tube Bolt
    G04519770Courtesy of FORD MOTOR CO.
  38. Remove the fuel line.
    • Remove the bolt, and the banjo fitting from the fuel line.
    • Discard the sealing washers and remove the fuel line.
      Fig 33: Removing Bolt
      G03899115Courtesy of FORD MOTOR CO.
    39. NOTE: Align the flat edge with the index feature located on the coolant supply port.
    Fig 34: Pulling EGR Cooler Clamp
    G03899116Courtesy of FORD MOTOR CO.
  39. Pull the EGR cooler clamp forward, twist and then slide the EGR cooler hose rearward to remove.

    40. Early build 

  40. Remove the nuts and the turbocharger heat shield.
    Fig 35: Removing Nuts Turbocharger Heat Shield
    G03899117Courtesy of FORD MOTOR CO.
    41. NOTE: Intake removed for clarity.
    Fig 36: Removing EGR Cooler V-Clamp And Gasket
    G03899118Courtesy of FORD MOTOR CO.
  41. Remove the EGR cooler V-clamp and gasket.
  42. Remove the bolts and the intake manifold.
    Fig 37: Removing Bolts Intake Manifold
    G03899119Courtesy of FORD MOTOR CO.

    43. Late build 

  43. Remove the nuts and the turbocharger heat shield.
    Fig 38: Removing Nuts Turbocharger Heat Shield
    G03899120Courtesy of FORD MOTOR CO.
    44. NOTE: LH shown, RH similar.
    Fig 39: Identifying Adapter Pipe Bolts
    G03899293Courtesy of FORD MOTOR CO.
  44. Loosen the nuts and bolts from the turbocharger adapter pipe.
  45. Loosen the EGR cooler V-clamp.
    Fig 40: Locating EGR Cooler V-Clamp
    G03899122Courtesy of FORD MOTOR CO.
    46. NOTE: Keep the EGR cooler V-clamp with the turbo adapter pipe.
    Fig 41: Removing Intake Manifold Bolts
    G03899123Courtesy of FORD MOTOR CO.
  46. Remove the bolts and the intake manifold.

    47. All vehicles 

  47. 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 42: Locating Intake Manifold Gasket And Front Module O-Ring Seal
      G03887125Courtesy of FORD MOTOR CO.
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