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Home >> Ford >> 2002 >> Cutaway 7.3 F >> Repair and Diagnosis >> External Pages >> Different car >> Section 2436 (Engine - 6.4L 99R Diesel -- F250-F550 Super Duty) >> In-Vehicle Servicing >> Intake Manifold - Body On >> Removal

Intake Manifold - Body On: Removal

WARNING: This page is about a different car, the 2008 Ford Pickup, 2008 Ford F550 Super Duty, 2008 Ford F450 Super Duty, and 2008 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.
NOTE: It is recommended that this component be serviced with the vehicle body removed. If the body can be removed, refer to Intake Manifold - Body Off .
  1. Remove the turbocharger. Carry out the Turbocharger - Body On procedure. For additional information, refer to FUEL CHARGING AND CONTROLS - TURBOCHARGER article.
  2. Remove the EGR-Oxidation Catalytic Converter (OC) pipe from the vehicle.
    3. Fig 1: Locating EGR-Oxidation Catalytic Converter (OC) Pipe
    GF0048486Courtesy of FORD MOTOR CO.
    NOTE: Engine removed from the vehicle for clarity.
  3. Remove the bolt and the 5 retaining nuts for the high-pressure fuel injection pump heat shield. Remove the fuel tube bracket and position the ground strap.
    4. Fig 2: Locating Bolt & Retaining Nuts
    GF0048444Courtesy of FORD MOTOR CO.
    NOTE: High-pressure fuel injection pump heat shield removed for clarity.
  4. Remove the remaining 2 bolts and the high-pressure fuel injection pump heat shield.
    5. Fig 3: Locating High-Pressure Fuel Injection Pump Heat Shield Bolts
    GF0048487Courtesy of FORD MOTOR CO.
  5. Remove the RH turbocharger inlet pipe.
    • In order to remove the RH turbocharger inlet pipe, roll it to the left side of the vehicle and then remove the turbocharger inlet pipe.
    6. Fig 4: Locating RH Turbocharger Inlet Pipe
    GF0048488Courtesy of FORD MOTOR CO.
  6. Remove the cooling fan stator. For additional information, refer to ENGINE COOLING article.
  7. Remove the accessory drive belt.
    8. Fig 5: Locating Accessory Drive Belt
    GF0048454Courtesy of FORD MOTOR CO.
  8. If equipped, remove the A/C drive belt.
    • Remove the belt from the bottom of the A/C clutch pulley, then remove it from the crankshaft pulley.
    9. Fig 6: Locating Belt From Bottom Of A/C Clutch Pulley
    GF0048455Courtesy of FORD MOTOR CO.
  9. Disconnect the crankcase vent oil separator tube from the crankcase vent oil separator.
    10. Fig 7: Locating Crankcase Vent Oil Separator Tube From Crankcase Vent Oil Separator
    GF0048441Courtesy of FORD MOTOR CO.
  10. Remove the 4 bolts and the crankcase vent oil separator.
    • Remove and discard the press-in-place gasket.
    11. Fig 8: Locating Crankcase Vent Oil Separator Bolts
    GF0048442Courtesy of FORD MOTOR CO.
  11. Disconnect the heater hose from the heater supply tube.
    12. Fig 9: Locating Heater Hose From Heater Supply Tube
    GF0048489Courtesy of FORD MOTOR CO.
  12. Remove and discard the 3 push nuts. Remove the glow plug module heat shield.
    13. Fig 10: Locating Push Nuts On Glow Plug Module Heat Shield
    GF0048443Courtesy of FORD MOTOR CO.
  13. Remove the 2 bolts from the fuel rail supply tube retainers.
    14. Fig 11: Locating Fuel Rail Supply Tube Retainers Bolts
    GF0048445Courtesy of FORD MOTOR CO.
    NOTE: Fuel injection equipment is manufactured to very precise tolerances and fine clearances. To prevent fuel system damage, it is essential that absolute cleanliness is observed when working with these components. Always install Fuel System Caps to any open orifices or tubes.
  14. Disconnect the fuel injector return tube at the check valve.
    15. Fig 12: Locating Fuel Injector Return Tube At Check Valve
    GF0048446Courtesy of FORD MOTOR CO.
  15. Disconnect the high-pressure fuel injection pump electrical connector. Disconnect the pin-type retainer and position the harness aside.
    16. Fig 13: Locating High-Pressure Fuel Injection Pump Electrical Connector
    GF0048447Courtesy of FORD MOTOR CO.
  16. Remove the 2 retaining nuts for the high-pressure fuel injection pump supply tube.
    17. Fig 14: Locating Retaining Nuts For High-Pressure Fuel Injection Pump Supply Tub
    GF0048448Courtesy of FORD MOTOR CO.
    NOTE: Fuel injection equipment is manufactured to very precise tolerances and fine clearances. To prevent fuel system damage, it is essential that absolute cleanliness is observed when working with these components. Always install Fuel System Caps to any open orifices or tubes.
    NOTE: Use a back-up wrench to prevent the fittings in the high-pressure fuel pump from turning.
  17. Remove the 2 nuts and the copper sealing washers for the high-pressure fuel injection pump. Remove the high-pressure fuel injection pump supply tube and high-pressure fuel injection pump-to-fuel cooler return tube.
    • Discard the copper sealing washers.
    18. Fig 15: Locating Nuts & Copper Sealing Washers For High-Pressure Fuel Injection Pump
    GF0048449Courtesy of FORD MOTOR CO.
  18. Remove the retaining nut for the power steering hoses.
    19. Fig 16: Locating Retaining Nut For Power Steering Hoses
    GF0048456Courtesy of FORD MOTOR CO.
    NOTE: Raise the supply tube up to clear the Engine Coolant Temperature (ECT) sensor connector when positioning the power steering pump aside.
  19. Remove the 3 bolts and position the power steering pump aside.
    20. Fig 17: Locating Power Steering Pump Bolts
    GF0048457Courtesy of FORD MOTOR CO.
    NOTE: The Front End Accessory Drive (FEAD) is not removed, it is positioned forward to access the front banjo bolt.
    NOTE: It may be necessary to position the accessory drive tensioner to access the lower bolt. Remove the bottom bolt first.
  20. Remove the 2 nuts and 2 bolts and position the FEAD bracket forward.
    21. Fig 18: Locating Nuts, Bolts & FEAD Assembly
    GF0048458Courtesy of FORD MOTOR CO.
  21. Remove the bolt and the EGR cooler coolant tube.
    • Remove and discard the O-ring seal.
    22. Fig 19: Locating EGR Cooler Coolant Tube & Bolt
    GF0048459Courtesy of FORD MOTOR CO.
    NOTE: The coolant hose clamps used on this engine are constant tension worm gear clamps. Standard worm gear clamps cannot be used. Failure to use the correct coolant hose clamps may result in hose joint failure.
  22. Loosen the clamp and disconnect the EGR cooler hose.
    • Discard the EGR cooler clamp.
    23. Fig 20: Locating EGR Cooler Hose
    GF0048460Courtesy of FORD MOTOR CO.
  23. Remove the 2 retaining nuts for the vertical EGR cooler.
    24. Fig 21: Locating Retaining Nuts For Vertical EGR Cooler
    GF0048461Courtesy of FORD MOTOR CO.
  24. Disconnect the hose and retaining clips at the vertical EGR cooler. Disconnect the Exhaust Gas Recirculation Temperature (EGRT) sensor electrical connector.
    25. Fig 22: Locating Hose & Retaining Clips At Vertical EGR Cooler
    GF0048462Courtesy of FORD MOTOR CO.
  25. Remove the retaining nut and retaining clip.
    26. Fig 23: Locating Retaining Nut & Retaining Clip
    GF0048463Courtesy of FORD MOTOR CO.
  26. Remove the nut and bolt for the vertical EGR cooler.
    27. Fig 24: Locating Nut & Bolt For Vertical EGR Cooler
    GF0048464Courtesy of FORD MOTOR CO.
  27. Remove the vertical EGR cooler stud.
    • Remove and discard the gasket.
    28. Fig 25: Locating Vertical EGR Cooler Stud
    GF0048465Courtesy of FORD MOTOR CO.
  28. Remove the 5 bolts and the vertical EGR cooler assembly.
    • Remove and discard the gasket.
    29. Fig 26: Locating Vertical EGR Cooler Assembly Bolts
    GF0048466Courtesy of FORD MOTOR CO.
  29. Disconnect the Throttle Body (TB) electrical connector.
    30. Fig 27: Locating Throttle Body (TB) Electrical Connector
    GF0048490Courtesy of FORD MOTOR CO.
  30. Remove the 4 bolts and the intake throttle adapter.
    • Remove and discard the press-in-place gasket.
    31. Fig 28: Locating Intake Throttle Adapter Bolts
    GF0048468Courtesy of FORD MOTOR CO.
  31. Disconnect the Intake Air Temperature 2 (IAT2) and Manifold Absolute Pressure (MAP) sensor electrical connectors. Disconnect the RH fuel charging harness electrical connector and wire retainer.
    32. Fig 29: Locating Intake Air Temperature 2 (IAT2) & Manifold Absolute Pressure (MAP) Sensor Electrical Connectors
    GF0048470Courtesy of FORD MOTOR CO.
  32. Disconnect the fuel temperature sensor electrical connector. Disconnect the retainer from the stud.
    33. Fig 30: Locating Fuel Temperature Sensor Electrical Connector
    GF0048491Courtesy of FORD MOTOR CO.
  33. Disconnect the ECT sensor electrical connector and wire retainer.
    34. Fig 31: Locating ECT Sensor Electrical Connector & Wire Retainer
    GF0048472Courtesy of FORD MOTOR CO.
  34. Disconnect the Engine Oil Temperature (EOT) and Engine Oil Pressure (EOP) sensor electrical connectors.
    35. Fig 32: Locating Engine Oil Temperature (EOT) & Engine Oil Pressure (EOP) Sensor Electrical Connectors
    GF0048492Courtesy of FORD MOTOR CO.
  35. Disconnect the LH fuel charging harness electrical connector and push pin retainer.
    36. Fig 33: Locating LH Fuel Charging Harness Electrical Connector & Push Pin Retainer
    GF0048474Courtesy of FORD MOTOR CO.
  36. Disconnect the glow plug module electrical connectors. Disconnect the pin-type retainers.
    37. Fig 34: Locating Glow Plug Module Electrical Connectors
    GF0048475Courtesy of FORD MOTOR CO.
  37. Remove the bolt and position the engine wiring harness aside.
    38. Fig 35: Locating Heater Supply Tube Bolt & Engine Wiring Harness
    GF0048476Courtesy of FORD MOTOR CO.
  38. Remove the 3 bolts and the glow plug module bracket.
    39. Fig 36: Locating Glow Plug Module Bracket Bolts
    GF0048477Courtesy of FORD MOTOR CO.
    NOTE: Do not bend or flex the heater supply tube or damage to the tube may occur.
  39. Remove the nut, bolt and the RH heater supply tube.
    • Remove and discard the O-ring seal.
    40. Fig 37: Locating Nut, Bolt & RH Heater Supply Tube
    GF0048478Courtesy of FORD MOTOR CO.
    NOTE: Fuel injection equipment is manufactured to very precise tolerances and fine clearances. To prevent fuel system damage, it is essential that absolute cleanliness is observed when working with these components. Always install Fuel System Caps to any open orifices or tubes.
  40. Remove the banjo bolts for the fuel supply and return tubes at the fuel filter module.
    • Remove and discard the copper sealing washers.
    41. Fig 38: Locating Copper Sealing Washers
    GF0048479Courtesy of FORD MOTOR CO.
  41. Remove the 3 bolts and the fuel filter module.
    42. Fig 39: Locating Fuel Filter Module Bolts
    GF0048480Courtesy of FORD MOTOR CO.
  42. Remove the nut for fuel injector return tube bracket.
    43. Fig 40: Locating Nut For Fuel Injector Return Tube Bracket
    GF0048481Courtesy of FORD MOTOR CO.
  43. Remove the 2 bolts for the fuel injector return tube.
    44. Fig 41: Locating Fuel Injector Return Tube Retainer Bolts
    GF0048482Courtesy of FORD MOTOR CO.
    NOTE: Fuel injection equipment is manufactured to very precise tolerances and fine clearances. To prevent fuel system damage, it is essential that absolute cleanliness is observed when working with these components. Always install Fuel System Caps to any open orifices or tubes.
    NOTE: RH side shown, LH side similar.
  44. Remove the LH and RH banjo bolts and copper sealing washers. Position the fuel injector return tube as needed to access the intake manifold fasteners.
    • Discard the copper sealing washers.
    45. Fig 42: Locating LH & RH Banjo Bolts & Copper Sealing Washers
    GF0048483Courtesy of FORD MOTOR CO.
    NOTE: Clean the area between the engine block and the intake manifold thoroughly before removing the intake manifold. The slope of the block will cause any foreign material not removed to fall into the engine, resulting in engine damage.
    NOTE: Mark the location of the fasteners prior to removing.
  45. Remove the 16 bolts and the intake manifold. Remove the fuel injector return tube, if necessary.
  46. Remove the intake manifold gaskets.
    • Clean and inspect the gaskets. Install new gaskets if necessary.
    • Clean and inspect the sealing surfaces.
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