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Home >> Ford >> 2003 >> Cutaway 7.3 F >> Repair and Diagnosis >> External Pages >> Different car >> Section 2471 (Engine Mechanical - 6.4L 99R Diesel -- F250-F550 Super Duty) >> In-Vehicle Repair >> Intake Manifold - Body On >> Removal

Intake Manifold - Body On: Removal

WARNING: This page is about a different car, the 2010 Ford Pickup, 2010 Ford F550 Super Duty, 2010 Ford F450 Super Duty, and 2010 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 .
  2. Remove the EGR-Oxidation Catalytic Converter (OC) pipe from the vehicle.
    Fig 1: Locating EGR-Oxidation Catalytic Converter Pipe
    G06777908Courtesy of FORD MOTOR CO.
    3. NOTE: Engine removed from the vehicle for clarity.
    Fig 2: Locating High-Pressure Fuel Injection Pump Heat Shield Bolt And Retaining Nuts
    G06774043Courtesy of FORD MOTOR CO.
  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. NOTE: High-pressure fuel injection pump heat shield removed for clarity.
    Fig 3: Locating High-Pressure Fuel Injection Pump Heat Shield Bolts
    G06774131Courtesy of FORD MOTOR CO.
  4. Remove the remaining 2 bolts and the high-pressure fuel injection pump heat shield.
  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.
      Fig 4: Locating RH Turbocharger Inlet Pipe
      G06777909Courtesy of FORD MOTOR CO.
  6. Remove the cooling fan stator. For additional information, refer to ENGINE COOLING .
  7. Remove the accessory drive belt.
    Fig 5: Locating Accessory Drive Belt
    G06777985Courtesy 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.
      Fig 6: Locating A/C Drive Belt
      G06777986Courtesy of FORD MOTOR CO.
  9. Disconnect the crankcase vent oil separator tube from the crankcase vent oil separator.
    Fig 7: Locating Crankcase Vent Oil Separator Tube Clamp
    G06778116Courtesy of FORD MOTOR CO.
  10. Remove the 4 bolts and the crankcase vent oil separator.
    • Remove and discard the press-in-place gasket.
      Fig 8: Locating Crankcase Vent Oil Separator Bolts
      G06777988Courtesy of FORD MOTOR CO.
  11. Disconnect the heater hose from the heater supply tube.
    Fig 9: Locating Heater Hose Clamp
    G06777989Courtesy of FORD MOTOR CO.
  12. Remove and discard the 3 pushnuts. Remove the glow plug module heat shield.
    Fig 10: Locating Glow Plug Module Heat Shield Pushnuts
    G06777990Courtesy of FORD MOTOR CO.
  13. Remove the 2 bolts from the fuel rail supply tube retainers.
    Fig 11: Locating Fuel Rail Supply Tube Retainers Bolts
    G06774044Courtesy of FORD MOTOR CO.
    14. 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.
    Fig 12: Locating Fuel Injector Return Tube At Check Valve
    G06777871Courtesy of FORD MOTOR CO.
  14. Disconnect the fuel injector return tube at the check valve.
  15. Disconnect the high-pressure fuel injection pump electrical connector. Disconnect the pin-type retainer and position the harness aside.
    Fig 13: Locating High-Pressure Fuel Injection Pump Electrical Connector
    G06777992Courtesy of FORD MOTOR CO.
  16. Remove the 2 retaining nuts for the high-pressure fuel injection pump supply tube.
    Fig 14: Locating High-Pressure Fuel Injection Pump Supply Tube Retaining Nuts
    G06774047Courtesy of FORD MOTOR CO.
    17. 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 injection pump from turning. If the fittings move, the high-pressure fuel injection pump fittings must be retightened. Refer to Fuel Injection Pump Fitting Re-Torque in FUEL CHARGING AND CONTROLS - 6.4L DIESEL .
    NOTE: It will be necessary to use a thin or low profile wrench to hold the fittings on the high-pressure fuel injection pump.
  17. Remove the 2 nuts and the 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 sealing washers.
      Fig 15: Locating High-Pressure Fuel Injection Pump Nuts And Sealing Washers
      G06774048Courtesy of FORD MOTOR CO.
  18. Remove the retaining nut for the power steering hoses.
    Fig 16: Locating Power Steering Hoses Retaining Nut
    G06774112Courtesy of FORD MOTOR CO.
    19. NOTE: Raise the supply tube up to clear the Engine Coolant Temperature (ECT) sensor connector when positioning the power steering pump aside.
    Fig 17: Locating Power Steering Pump Bolts
    G06777994Courtesy of FORD MOTOR CO.
  19. Remove the 3 bolts and position the power steering pump aside.
    20. 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.
    Fig 18: Locating Nuts, Bolts And FEAD Assembly
    G06777995Courtesy of FORD MOTOR CO.
  20. Remove the 2 nuts and 2 bolts and position the FEAD  bracket forward.
  21. Remove the bolt and the EGR cooler coolant tube.
    • Remove and discard the O-ring seal.
      Fig 19: Locating EGR Cooler Coolant Tube Bolt
      G06777996Courtesy of FORD MOTOR CO.
    22. 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.
      Fig 20: Locating EGR Cooler Hose Clamp
      G06777997Courtesy of FORD MOTOR CO.
  23. Remove the 2 retaining nuts for the vertical EGR cooler.
    Fig 21: Locating Vertical EGR Cooler Retaining Nuts
    G06777998Courtesy of FORD MOTOR CO.
  24. Disconnect the Exhaust Gas Recirculation Temperature (EGRT) sensor electrical connector.
    Fig 22: Locating Exhaust Gas Recirculation Temperature Sensor Electrical Connector
    G06778000Courtesy of FORD MOTOR CO.
  25. Disconnect the coolant hose from the vertical EGR cooler.
    Fig 23: Locating Vertical EGR Cooler Coolant Hose Clamp
    G06777999Courtesy of FORD MOTOR CO.
  26. Remove the nut and bolt for the vertical EGR cooler.
    Fig 24: Locating Vertical EGR Cooler Nut And Bolt
    G06778001Courtesy of FORD MOTOR CO.
  27. Remove the vertical EGR cooler stud.
    • Remove and discard the gasket.
      Fig 25: Locating Vertical EGR Cooler Stud
      G06778002Courtesy of FORD MOTOR CO.
  28. Remove the 5 bolts and the vertical EGR cooler assembly.
    • Remove and discard the gasket.
      Fig 26: Locating Vertical EGR Cooler Assembly Bolts
      G06778003Courtesy of FORD MOTOR CO.
  29. Disconnect the Throttle Body (TB) electrical connector.
    Fig 27: Locating Throttle Body Electrical Connector
    G06778004Courtesy of FORD MOTOR CO.
  30. Remove the 4 bolts and the intake throttle adapter.
    • Remove and discard the press-in-place gasket.
      Fig 28: Locating Intake Throttle Adapter Bolts
      G06778005Courtesy 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.
    Fig 29: Locating Intake Air Temperature 2 And Manifold Absolute Pressure Sensor Electrical Connectors
    G06778006Courtesy of FORD MOTOR CO.
  32. Disconnect the fuel temperature sensor electrical connector. Disconnect the retainer from the stud.
    Fig 30: Locating Fuel Temperature Sensor Electrical Connector
    G06778007Courtesy of FORD MOTOR CO.
  33. Disconnect the ECT  sensor electrical connector and wire retainer.
    Fig 31: Locating ECT Sensor Electrical Connector And Wire Retainer
    G06778008Courtesy of FORD MOTOR CO.
  34. Disconnect the Engine Oil Temperature (EOT) and Engine Oil Pressure (EOP) sensor electrical connectors.
    Fig 32: Locating Engine Oil Temperature And Engine Oil Pressure Sensor Electrical Connectors
    G06778009Courtesy of FORD MOTOR CO.
  35. Disconnect the LH fuel charging harness electrical connector and pushpin retainer.
    Fig 33: Locating LH Fuel Charging Harness Electrical Connector And Pushpin Retainer
    G06778010Courtesy of FORD MOTOR CO.
  36. Disconnect the glow plug module electrical connectors. Disconnect the pin-type retainers.
    Fig 34: Locating Glow Plug Module Electrical Connectors And Pin-Type Retainers
    G06774073Courtesy of FORD MOTOR CO.
  37. Remove the bolt and position the engine wiring harness aside.
    Fig 35: Locating Heater Supply Tube Bolt
    G06778330Courtesy of FORD MOTOR CO.
  38. Remove the 3 bolts and the glow plug module bracket.
    Fig 36: Locating Glow Plug Module Bracket Bolts
    G06774075Courtesy of FORD MOTOR CO.
    39. 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.
      Fig 37: Locating Nut, Bolt And RH Heater Supply Tube
      G06778012Courtesy of FORD MOTOR CO.
    40. 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 sealing washers.
      Fig 38: Locating Fuel Supply Banjo Bolts And Fuel Filter Module Return Tubes
      G06778013Courtesy of FORD MOTOR CO.
  41. Remove the 3 bolts and the fuel filter module.
    Fig 39: Locating Fuel Filter Module Bolts
    G06778014Courtesy of FORD MOTOR CO.
  42. Remove the nut for fuel injector return tube bracket.
    Fig 40: Locating Fuel Injector Return Tube Bracket Nut
    G06774079Courtesy of FORD MOTOR CO.
  43. Remove the 2 bolts for the fuel injector return tube.
    Fig 41: Locating Fuel Injector Return Tube Retainer Bolts
    G06774080Courtesy of FORD MOTOR CO.
    44. 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 in the illustration, LH side similar.
  44. Remove the LH and RH banjo bolts and sealing washers. Position the fuel injector return tube as needed to access the intake manifold fasteners.
    • Discard the sealing washers.
      Fig 42: Locating Fuel Injector Return Tube Banjo Bolts And Sealing Washers
      G06774081Courtesy of FORD MOTOR CO.
    45. 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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