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Home >> Ford >> 2000 >> Contour SE, 2.5 L, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 798 (Engine - 6.8L- 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.
WARNING: Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related components. Highly flammable mixtures are always present and can be ignited. Failure to follow these instructions may result in personal injury.
WARNING: Fuel in the fuel system remains under high pressure, even when the engine is not running. Do not work on any fuel system component until fuel system pressure has been relieved. Failure to follow these instructions may result in personal injury.
  1. Relieve the fuel system pressure. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION .
  2. Disconnect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  3. Remove the air cleaner and the air cleaner outlet tube. For additional information, refer to INTAKE AIR DISTRIBUTION & FILTERING .
  4. Remove the engine cover. For additional information, refer to INTERIOR TRIM AND ORNAMENTATION .
  5. Drain the cooling system. For additional information, refer to ENGINE COOLING .
  6. Remove the generator. For additional information, refer to HEATING & VENTILATION .
  7. Disconnect the fuel hose spring lock coupling. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION .
  8. Compress and slide the hose clamp and disconnect the coolant hose.
    Fig 1: Disconnecting Coolant Hose
    G03885092Courtesy of FORD MOTOR CO.
    9. NOTE: The red clip must be pulled out before disconnecting the electrical connector.
    Fig 2: Identifying Electronic Throttle Body (TB) Electrical Connector
    G03885272Courtesy of FORD MOTOR CO.
  9. Disconnect the electronic throttle body (TB) electrical connector.
    10. NOTE: The red clip must be pulled out before disconnecting the electrical connector.
    Fig 3: Disconnecting Throttle Position Sensor Electrical Connector
    G03885271Courtesy of FORD MOTOR CO.
  10. Disconnect the throttle position (TP) sensor electrical connector.
  11. Disconnect the positive crankcase ventilation (PCV) hose and engine vacuum harness.
    Fig 4: Disconnecting Positive Crankcase Ventilation Hose And Engine Vacuum Harness
    G03886328Courtesy of FORD MOTOR CO.
  12. Disconnect the PCV coolant hoses.
    Fig 5: Disconnecting PCV Coolant Hoses
    G03886329Courtesy of FORD MOTOR CO.
  13. Disconnect the brake booster and evaporative emission hose.
    Fig 6: Disconnecting Brake Booster And Evaporative Emission Hose
    G03886330Courtesy of FORD MOTOR CO.
  14. Remove the four bolts, the throttle body and adapter as an assembly.
    • Discard the throttle body adapter gasket.
      Fig 7: Removing Bolts
      G03886331Courtesy of FORD MOTOR CO.
  15. Disconnect the heater hose.
    Fig 8: Identifying Heater Hose
    G03886332Courtesy of FORD MOTOR CO.
  16. Disconnect the vacuum connector.
    Fig 9: Disconnecting Vacuum Connector
    G03886333Courtesy of FORD MOTOR CO.
  17. Disconnect the fuel rail pressure (FRP) sensor electrical connector.
    Fig 10: Disconnecting Fuel Rail Pressure Sensor Electrical Connector
    G03885250Courtesy of FORD MOTOR CO.
  18. Disconnect the 10 fuel injector electrical connectors.
    Fig 11: Identifying Fuel Injector Electrical Connector
    G03886335Courtesy of FORD MOTOR CO.
  19. Disconnect the 10 ignition coil electrical connectors.
    Fig 12: Identifying Ignition Coil Electrical Connector
    G03886336Courtesy of FORD MOTOR CO.
  20. Remove the retaining nut for the transmission fluid indicator and tube.
    Fig 13: Removing Nuts
    G03886337Courtesy of FORD MOTOR CO.
  21. Remove the transmission fluid level indicator tube bracket retaining nut and position the tube aside.
    Fig 14: Removing Transmission Fluid Level Indicator Tube Bracket Retaining Nut
    G03886338Courtesy of FORD MOTOR CO.
  22. Remove the stud bolts and position the RH fuel charge wiring harness aside.
    Fig 15: Removing Stud Bolts
    G03886339Courtesy of FORD MOTOR CO.
  23. Remove the bolts and position the LH fuel charge wiring harness aside.
    Fig 16: Removing Bolts
    G03886340Courtesy of FORD MOTOR CO.
  24. Remove the screws and the 10 coils.
    Fig 17: Removing Screws Coils
    G03885163Courtesy of FORD MOTOR CO.
  25. Disconnect the pushpin retainer from the intake manifold bracket.
    Fig 18: Disconnecting Pushpin Retainer From Intake Manifold Bracket
    G03886342Courtesy of FORD MOTOR CO.
  26. Remove the bolts, thermostat housing and thermostat.
    • Remove and discard the O-ring seal.
      Fig 19: Removing O-Ring
      G03885109Courtesy of FORD MOTOR CO.
  27. Remove the bolts, the intake manifold and the intake manifold gaskets.
    Fig 20: Removing Bolts Intake Manifold
    G03886344Courtesy of FORD MOTOR CO.
    28. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the aluminum retainer plate. These tools cause scratches and gouges, which make leak paths. Use a plastic scraping tool to clean sealing surfaces.
  28. Clean and inspect the mating surfaces.
    • Clean the intake manifold mating surface of the cylinder heads with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
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