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Home >> Ford >> 2002 >> Mustang Base, 2D Convertible, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 1633 (Engine - 6.0L Diesel -- F250-F550 Super Duty 6.0L (99P F450/550)) >> In-Vehicle Servicing >> Intake Manifold >> Removal >> All vehicles

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WARNING: This page is about a different car, the 2007 Ford Pickup, 2007 Ford F550 Super Duty, 2007 Ford F450 Super Duty, and 2007 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.
  1. Remove the auxiliary battery. 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 degas bottle. For additional information, refer to ENGINE COOLING article.
    4. Fig 1: Upper Radiator Hose & Clamp
    GF0005667Courtesy of FORD MOTOR CO.
  4. Disconnect the upper radiator hose.
    5. Fig 2: Charge Air Cooler (CAC) Clamp, Engine Side
    GF0005668Courtesy of FORD MOTOR CO.
    NOTE: Engine side shown, charge air cooler (CAC) side similar.
  5. Remove the turbocharger-to-CAC duct.


Fig 1: Generator B+ Wire & Electrical Connector
GF0005669Courtesy of FORD MOTOR CO.
  1. Position the boot back and disconnect the generator B+ wire and electrical connector.
    2. Fig 2: Locating Generator Bolts
    G03907094Courtesy of FORD MOTOR CO.
  2. Remove the 3 bolts and the generator.
  3. Remove the turbocharger and the turbocharger pedestal. For additional information, refer to FUEL CHARGING AND CONTROLS - TURBOCHARGER article.
    4. Fig 3: Locating Charge Air Cooler Duct Bolt
    GF0005670Courtesy of FORD MOTOR CO.
    NOTE: Engine side shown, CAC side similar.
  4. Loosen the clamps and remove the CAC duct.
    5. Fig 4: Heater Hose Tube & Bolts
    GF0005671Courtesy of FORD MOTOR CO.
  5. Remove the bolts and position the heater hose tube aside.
    • Remove and discard the O-ring.
    6. Fig 5: Manifold Absolute Pressure (MAP) Sensor Hose
    GF0005672Courtesy of FORD MOTOR CO.
  6. Disconnect the manifold absolute pressure (MAP) sensor hose.
    7. Fig 6: Engine Coolant Vent Hose
    GF0005673Courtesy of FORD MOTOR CO.
  7. Disconnect the engine coolant vent hose.
  8. Remove the fuel injector control module. For additional information, refer to ELECTRONIC ENGINE CONTROLS - DIESEL ENGINE article.
    9. Fig 7: Locating Harness Retainer Nut And Ground Wire Nut
    G03906757Courtesy of FORD MOTOR CO.
  9. Remove the nuts from the heat shield bracket and disconnect the ground wire from the stud.
    10. Fig 8: Locating Wiring Retainer
    G03906758Courtesy of FORD MOTOR CO.
  10. Disconnect the wiring retainer from the heat shield bracket.
    11. Fig 9: Locating Heat Shield Bracket Bolts
    G03906759Courtesy of FORD MOTOR CO.
  11. Remove the bolts and heat shield bracket.
    12. Fig 10: Locating Turbocharger Heat Shield Bolts
    G03907003Courtesy of FORD MOTOR CO.
  12. Remove the 3 bolts and the turbocharger heat shield.
    13. Fig 11: Wiring Retainer & Injection Pressure Regulator (IPR) Valve Electrical Connectors
    GF0005674Courtesy of FORD MOTOR CO.
  13. Position back the heat insulating wrap and disconnect the wiring retainer and injection pressure regulator (IPR) valve electrical connectors.
    14. Fig 12: Identifying Exhaust Gas Recirculation (EGR) Valve Electrical Connector
    G03887106Courtesy of FORD MOTOR CO.
  14. Disconnect the exhaust gas recirculation (EGR) valve electrical connector.
    15. Fig 13: Locating Engine Oil Pressure Sensor Electrical Connector
    G03887107Courtesy of FORD MOTOR CO.
  15. Disconnect the engine oil pressure (EOP) sensor electrical connector.
    16. Fig 14: Locating Engine Oil Temperature Sensor
    G03887108Courtesy of FORD MOTOR CO.
  16. Disconnect the engine oil temperature (EOT) sensor electrical connector.
    17. Fig 15: Identifying Pin-Type Retainer And Engine Coolant Temperature (ECT) Sensor Electrical Connector
    G03887109Courtesy of FORD MOTOR CO.
  17. Disconnect the pin-type retainer and engine coolant temperature (ECT) sensor.
    18. Fig 16: Intake Air Temperature (IAT2) Sensor Electrical Connector
    GF0005675Courtesy of FORD MOTOR CO.
  18. Disconnect the intake air temperature (IAT2) sensor electrical connector.
    19. Fig 17: Identifying Fuel Injector Electrical Connector & Retainer Clip
    G03887113Courtesy of FORD MOTOR CO.
  19. Disconnect the 8 fuel injectors electrical connectors.
    20. Fig 18: Fuel Tube Fittings
    GF0005676Courtesy of FORD MOTOR CO.
    NOTE: It is necessary to remove the fuel filter and drain the housing.
  20. Disconnect the fuel tube fittings.
    • Remove and discard the sealing washers.
    21. Fig 19: Oil Filter Housing Bolts
    GF0005677Courtesy of FORD MOTOR CO.
    NOTE: It is necessary to remove the oil filter and drain the housing.
  21. Remove the 4 bolts and the oil filter housing.
    • Remove and discard the O-ring seal.
    22. Fig 20: Locating Oil Filter Return Tube Bolt
    G04519770Courtesy of FORD MOTOR CO.
  22. Remove the bolt and the oil filter return tube.
    23. Fig 21: Fuel Tube Bolts
    GF0005678Courtesy of FORD MOTOR CO.
  23. Remove the fuel tube.
    • Remove the bolt and the banjo fitting from the fuel tube.
    • Discard the sealing washers and remove the fuel tube.
    24. Fig 22: EGR Cooler Hose
    GF0005679Courtesy of FORD MOTOR CO.
    NOTE: Align the flat edge with the index feature located on the coolant supply port.
  24. Pull the EGR cooler clamp forward, twist and then slide the EGR cooler hose rearward to remove.
    25. Fig 23: Identifying Adapter Pipe Bolts
    G03899293Courtesy of FORD MOTOR CO.
    NOTE: LH shown, RH similar.
  25. Loosen the nuts and bolts from the turbocharger adapter pipe.
    26. Fig 24: Locating EGR Cooler V-Clamp
    G03899122Courtesy of FORD MOTOR CO.
  26. Loosen the EGR cooler V-clamp.
    27. Fig 25: Intake Manifold Bolts
    GF0005680Courtesy of FORD MOTOR CO.
    NOTE: Keep the EGR cooler V-clamp with the turbo adapter pipe.
  27. Remove the bolts and the intake manifold.
    28. Fig 26: Locating Intake Manifold Gasket And Front Module O-Ring Seal
    G03887125Courtesy of FORD MOTOR CO.
  28. 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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