Removal (6.8L)

WARNING: This page is about a different car, the 2003 Ford Pickup, 2003 Ford F550 Super Duty, 2003 Ford F450 Super Duty, 2003 Ford Excursion, and 2003 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

Disconnect negative battery cable. Drain coolant system. Remove air cleaner outlet tube. Disconnect water outlet hose. Remove accelerator cable splash shield. See Fig 1. Relieve fuel system pressure. See FUEL SYSTEM PRESSURE RELEASE . Disconnect accelerator and speed control cables. Remove return spring. Position accelerator cable bracket aside. See Fig 2. Disconnect PCV vacuum hose, coolant hoses, vacuum lines and engine sensor control wiring harness.
Remove bolt and position radio interference capacitor aside. See Fig 3. Disconnect fuel injector electrical connectors and ignition coil electrical connectors. Disconnect idle air control motor electrical connector and by-pass hose. Disconnect throttle position sensor. Disconnect DPFE sensor, if equipped. See Fig 4. Remove DPFE bracket, if equipped. See Fig 5. Remove EGR valve-to-exhaust manifold tube, if equipped. See Fig 6.
Remove the throttle body adapter. See Fig 7. Remove the EVR bracket, if equipped. See Fig 8. Disconnect the water temperature indicator sender unit electrical connector. See Fig 9. Remove generator. Remove ignition coils. Disconnect the fuel injection supply manifold. Disconnect the fuel lines. See FUEL LINE CONNECTORS . Disconnect fuel pressure regulator vacuum line.
Remove bolt and position capacitor aside. See Fig 10. Disconnect cylinder head temperature sensor. See Fig 11. Remove thermostat and housing. Remove intake manifold assembly bolts and intake manifold assembly. If lower intake manifold removal is necessary, go to next step.
Remove the fuel injection supply manifold, if necessary. See Fig 12. Remove bolts and separate the upper and lower intake manifolds. See Fig 13. Clean all mating surfaces.

Fig 1: Locating Accelerator Cable Splash Shield

Courtesy of FORD MOTOR CO.

Fig 2: Locating Accelerator Cable Bracket Bolts

Courtesy of FORD MOTOR CO.

Fig 3: Locating Right Radio Interference Capacitor

Courtesy of FORD MOTOR CO.

Fig 4: Locating DPFE Sensor Connector

Courtesy of FORD MOTOR CO.

Fig 5: Locating DPFE Sensor Bracket Bolts

Courtesy of FORD MOTOR CO.

Fig 6: Locating EGR Valve-To-Exhaust Manifold Tube Fittings

Courtesy of FORD MOTOR CO.

Fig 7: Locating Throttle Body Adapter Bolts

Courtesy of FORD MOTOR CO.

Fig 8: Locating EVR Bracket Bolts

Courtesy of FORD MOTOR CO.

Fig 9: Locating Water Temperature Indicator Sender Connector

Courtesy of FORD MOTOR CO.

Fig 10: Locating Capacitor Mounting Bolt

Courtesy of FORD MOTOR CO.

Fig 11: Locating Cylinder Head Temperature Sensor Connector

Courtesy of FORD MOTOR CO.

Fig 12: Locating Fuel Injection Supply Manifold Bolts

Courtesy of FORD MOTOR CO.

Fig 13: Separating Upper & Lower Intake Manifolds

Courtesy of FORD MOTOR CO.

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.