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Home >> Ford >> 2003 >> Cutaway 7.3 F >> Repair and Diagnosis >> External Pages >> Different car >> Section 2580 (Engine Mechanical - 6.2L (2V) -- F250-F350 Super Duty) >> In-Vehicle Repair >> Intake Manifold >> Removal

Intake Manifold: Removal

WARNING: This page is about a different car, the 2011 Ford Pickup and 2011 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.
WARNING: Do not smoke, carry lighted tobacco or have an 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 serious personal injury.
WARNING: Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury.
  1. Release the fuel pressure. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION - GASOLINE AND DIESEL article.
  2. Remove the 8 ignition coils. For additional information, refer to ENGINE IGNITION - 6.2L (2V) article.
  3. Remove the generator. For additional information, refer to CHARGING SYSTEM article.
  4. Remove the 4 bolts and the generator support bracket.
  5. Disconnect the fuel supply tube quick connect coupling. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION - GASOLINE AND DIESEL article.
  6. Disconnect the Electronic Throttle Control (ETC) electrical connector and wiring harness retainer.
  7. Remove the 4 bolts and the Throttle Body (TB).
    • Inspect the TB O-ring seal for damage and install a new O-ring seal if necessary.
  8. Disengage the clamp and disconnect the brake booster vacuum hose from the intake manifold.
  9. Disconnect the Evaporative Emission (EVAP) tube quick connect coupling from the EVAP canister purge valve. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION - GASOLINE AND DIESEL article.
  10. Disconnect the EVAP canister purge valve electrical connector.
  11. Disconnect the quick connect couplings and remove the PCV tube. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION - GASOLINE AND DIESEL article.
  12. Disconnect the 8 fuel injector electrical connectors.
    13. NOTE: The fuel rail is removed with the intake manifold as an assembly.
  13. Remove the 4 fuel rail bolts.
  14. Disconnect the 4 wiring harness retainers from the rear of the intake manifold.
  15. Loosen the 12 intake manifold bolts.
    16. NOTE: 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.
  16. Remove the intake manifold.
    • Clean and inspect the cylinder head sealing surfaces with metal surface prep. Follow the directions on the packaging.
    • Inspect the 8 intake manifold gaskets for damage and install new gaskets if necessary.
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