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Home >> Ford >> 2002 >> Focus ZTW, Automatic >> Repair and Diagnosis >> External Pages >> Different car >> Section 1538 (Engine - 6.8L (3V) -- F250-F550 Super Duty) >> In-Vehicle Repair >> Intake Manifold >> Removal

Intake Manifold: Removal

WARNING: This page is about a different car, the 2006 Ford Pickup, 2006 Ford F550 Super Duty, 2006 Ford F450 Super Duty, and 2006 Ford Cab & Chassis. 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 component. Highly flammable mixtures are always present and may 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. Before servicing or disconnecting any of the fuel lines or fuel system components, the fuel system pressure must be relieved to prevent accidental spraying of fuel, causing personal injury or a fire hazard.
  1. Disconnect the fuel supply spring lock coupling from the fuel rail. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION - GASOLINE AND DIESEL .
  2. Drain the cooling system. For additional information, refer to ENGINE COOLING .
  3. Remove the generator. For additional information, refer to GENERATOR AND REGULATOR .
  4. Remove the air cleaner outlet pipe. For additional information, refer to INTAKE AIR DISTRIBUTION & FILTERING .
  5. Disconnect the upper radiator hose from the thermostat housing.
  6. Disconnect the heater coolant hose from the coolant crossover assembly.
  7. Disconnect the intake manifold runner control (IMRC) actuator electrical connector.
  8. Disconnect the fuel rail pressure and temperature sensor electrical connector and vacuum connector.
  9. Disconnect the 10 fuel injector electrical connectors.
  10. Disconnect the positive crankcase ventilation (PCV) tube quick connect coupling from the intake manifold. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION - GASOLINE AND DIESEL .
  11. Disconnect the quick connect couplings and remove the evaporative emissions (EVAP) tube. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION - GASOLINE AND DIESEL .
    Fig 1: Locating Evaporative Emissions (EVAP) Tube Couplings
    G04647561Courtesy of FORD MOTOR CO.
  12. Disconnect the brake booster and engine vacuum hose connections from the rear of the intake manifold and position aside.
  13. Disconnect the 2 heated PCV coolant hoses from the intake manifold.
  14. Disconnect the throttle position (TP) sensor and electronic throttle control electrical connectors.
  15. Disconnect the engine wiring harness position retainers from the intake manifold.
  16. Remove the 12 intake manifold bolts.
    17. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.
  17. Remove the 2 bolts, the coolant crossover tube and discard the gaskets.
    • Clean and inspect the sealing surfaces with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
    18. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.
  18. Remove the intake manifold and discard the gaskets.
    • Clean and inspect the sealing surfaces with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
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