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Home >> Ford >> 2003 >> Cutaway 7.3 F >> Repair and Diagnosis >> External Pages >> Different car >> Section 2581 (Engine Mechanical - 6.8L (3V) -- F450 & F550 Super Duty) >> In-Vehicle Repair >> Intake Manifold >> Installation

Intake Manifold: Installation

WARNING: This page is about a different car, the 2011 Ford F550 Super Duty and 2011 Ford F450 Super Duty. However, it is still accessible from the selected car via links, so may be relevant.
  1. Position the intake manifold onto the engine and attach the wiring harness connector onto the back of the intake manifold.
    2. NOTE: If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions can result in engine damage.
  2. Using 10 new intake manifold gaskets, install the intake manifold.
  3. Using 2 new gaskets, position the engine coolant crossover manifold assembly and install the 3 bolts.
    • Tighten to 10 Nm (89 lb-in).
  4. Install the intake manifold bolts and tighten in 2 stages in the sequence shown.
    • Stage 1: Tighten to 2 Nm (18 lb-in).
    • Stage 2: Tighten to 10 Nm (89 lb-in).
    Fig 1: Identifying Intake Manifold Bolts Tightening Sequence
    G07480011Courtesy of FORD MOTOR CO.
  5. Connect the heated PCV fitting lower coolant hose.
  6. Connect the 3 engine wiring harness position retainers to the intake manifold.
  7. Connect the 5 RH ignition coil-on-plug electrical connectors.
  8. Attach the 3 wiring harness retainers to the RH valve cover studs.
  9. Connect the engine control harness electrical connector.
  10. Connect the middle PCM connector and wiring harness retainer.
  11. Connect the TP  sensor and ETC  electrical connectors.
  12. Connect the vacuum hose and install the vacuum cap on the rear of the intake manifold.
  13. Position the crankcase ventilation tube and connect the quick connect coupling. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION - GASOLINE AND DIESEL article.
  14. Connect the Evaporative Emission (EVAP) canister purge valve electrical connector.
  15. Connect the EVAP  tube quick connect coupling to the EVAP canister purge valve. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION - GASOLINE AND DIESEL article.
  16. Connect the PCV tube quick connect coupling to the intake manifold. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION - GASOLINE AND DIESEL article.
  17. Connect the 10 fuel injector electrical connectors.
  18. Connect the IMRC  actuator electrical connector.
  19. Connect the fuel supply tube quick connect coupling to the fuel rail. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION - GASOLINE AND DIESEL article.
  20. Connect the heater coolant hose and the heated PCV coolant hose to the coolant crossover assembly.
  21. Install the generator. For additional information, refer to CHARGING SYSTEM article.
  22. Install the ACL  outlet pipe. For additional information, refer to INTAKE AIR DISTRIBUTION SYSTEM & INTAKE AIR FILTERING SYSTEM article.
  23. Fill and bleed the engine cooling system. For additional information, refer to ENGINE COOLING - GASOLINE ENGINES article.
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