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Home >> Ford >> 2004 >> Excursion 5.4 L, RWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 1171 (Engine - 6.0L (99P F450/550) Diesel -- F250-F550 Super Duty) >> In-Vehicle Repair >> Intake Manifold >> Removal

Intake Manifold: Removal

WARNING: This page is about a different car, the 2006 Ford Pickup, 2006 Ford F550 Super Duty, 2006 Ford F450 Super Duty, and 2006 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

    All vehicles 

  1. Remove the auxiliary battery. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  2. Remove the cooling fan stator. For additional information, refer to ENGINE COOLING .
  3. Remove the degas bottle. For additional information, refer to ENGINE COOLING .
  4. Disconnect the upper radiator hose.
    Fig 1: Locating Upper Radiator Hose
    G04648344Courtesy of FORD MOTOR CO.
    5. NOTE: Engine side shown, charge air cooler (CAC) side similar.
    Fig 2: Locating Turbocharger-To-CAC Duct
    G04648345Courtesy of FORD MOTOR CO.
  5. Remove the turbocharger-to-CAC duct.

    6. Vehicles with dual generators 

  6. Remove the accessory drive belt.
    Fig 3: Rotating Drive Belt Tensioner Clockwise
    G03887086Courtesy of FORD MOTOR CO.
  7. Remove the bolt and the accessory drive belt tensioner.
    Fig 4: Locating Accessory Drive Belt Tensioner Bolt
    G03887087Courtesy of FORD MOTOR CO.
  8. Remove the accessory drive belt.
    Fig 5: Rotating Accessory Drive Belt Tensioner
    G03887088Courtesy of FORD MOTOR CO.
  9. Remove the bolts, bracket and accessory drive belt idler pulley.
    Fig 6: Locating Bracket And Accessory Drive Belt Idler Pulley Bolts
    G03887089Courtesy of FORD MOTOR CO.
  10. Remove the bolts and the accessory drive belt tensioner.
    Fig 7: Locating Accessory Drive Belt Tensioner Bolts
    G03887090Courtesy of FORD MOTOR CO.
  11. Disconnect the wiring harness retainer, generator electrical connector and B+ wire.
    Fig 8: Locating Wire Retainer And Generator Electrical Connectors
    G03907090Courtesy of FORD MOTOR CO.
  12. Remove the bolts and the generator with mounting bracket.
    Fig 9: Identifying Generator Mounting Bracket Bolts
    G03887092Courtesy of FORD MOTOR CO.

    13. Vehicles with single generator 

  13. Remove the accessory drive belt.
    Fig 10: Rotating Accessory Drive Belt Tensioner
    G03906750Courtesy of FORD MOTOR CO.

    14. All vehicles 

  14. Position the boot back and disconnect the generator B+ wire and electrical connector.
    Fig 11: Locating Generator B+ Wire And Electrical Connector
    G04648354Courtesy of FORD MOTOR CO.
  15. Remove the 3 bolts and the generator.
    Fig 12: Locating Generator Bolts
    G03907094Courtesy of FORD MOTOR CO.
  16. Remove the turbocharger and the turbocharger pedestal. For additional information, refer to FUEL CHARGING & CONTROLS - TURBOCHARGER .
    17. NOTE: Engine side shown, CAC side similar.
    Fig 13: Locating CAC Duct
    G04648356Courtesy of FORD MOTOR CO.
  17. Loosen the clamps and remove the CAC duct.
  18. Remove the bolts and position the heater hose tube aside.
    • Remove and discard the O-ring.
      Fig 14: Locating O-Ring
      G04648357Courtesy of FORD MOTOR CO.
  19. Disconnect the manifold absolute pressure (MAP) sensor hose.
    Fig 15: Locating Manifold Absolute Pressure Sensor Hose
    G04648358Courtesy of FORD MOTOR CO.
  20. Disconnect the engine coolant vent hose.
    Fig 16: Locating Engine Coolant Vent Hose
    G04648359Courtesy of FORD MOTOR CO.
  21. Remove the fuel injector control module. For additional information, refer to ELECTRONIC ENGINE CONTROLS - DIESEL ENGINE .
  22. Remove the nuts from the heat shield bracket and disconnect the ground wire from the stud.
    Fig 17: Locating Harness Retainer Nut And Ground Wire Nut
    G03906757Courtesy of FORD MOTOR CO.
  23. Disconnect the wiring retainer from the heat shield bracket.
    Fig 18: Locating Wiring Retainer
    G03906758Courtesy of FORD MOTOR CO.
  24. Remove the bolts and heat shield bracket.
    Fig 19: Locating Heat Shield Bracket Bolts
    G03906759Courtesy of FORD MOTOR CO.
  25. Remove the 3 bolts and the turbocharger heat shield.
    Fig 20: Locating Turbocharger Heat Shield Bolts
    G03907003Courtesy of FORD MOTOR CO.
  26. Position back the heat insulating wrap and disconnect the wiring retainer and injection pressure regulator (IPR) valve electrical connectors.
    Fig 21: Locating Injection Pressure Regulator Valve Electrical Connectors
    G04648364Courtesy of FORD MOTOR CO.
  27. Disconnect the exhaust gas recirculation (EGR) valve electrical connector.
    Fig 22: Identifying Exhaust Gas Recirculation (EGR) Valve Electrical Connector
    G03887106Courtesy of FORD MOTOR CO.
  28. Disconnect the engine oil pressure (EOP) sensor electrical connector.
    Fig 23: Locating Engine Oil Pressure Sensor Electrical Connector
    G03887107Courtesy of FORD MOTOR CO.
  29. Disconnect the engine oil temperature (EOT) sensor electrical connector.
    Fig 24: Locating Engine Oil Temperature Sensor
    G03887108Courtesy of FORD MOTOR CO.
  30. Disconnect the pin-type retainer and engine coolant temperature (ECT) sensor.
    Fig 25: Identifying Pin-Type Retainer And Engine Coolant Temperature (ECT) Sensor Electrical Connector
    G03887109Courtesy of FORD MOTOR CO.
  31. Disconnect the intake air temperature (IAT2) sensor electrical connector.
    Fig 26: Locating Intake Air Temperature Sensor Electrical Connector
    G04648369Courtesy of FORD MOTOR CO.
  32. Disconnect the 8 fuel injectors electrical connectors.
    Fig 27: Identifying Fuel Injector Electrical Connector & Retainer Clip
    G03887113Courtesy of FORD MOTOR CO.
    33. NOTE: It is necessary to remove the fuel filter and drain the housing.
  33. Disconnect the fuel tube fittings.
    • Remove and discard the sealing washers.
      Fig 28: Locating Sealing Washers
      G04648371Courtesy of FORD MOTOR CO.
    34. NOTE: It is necessary to remove the oil filter and drain the housing.
  34. Remove the 4 bolts and the oil filter housing.
    • Remove and discard the O-ring seal.
      Fig 29: Locating O-Ring Seal
      G04648372Courtesy of FORD MOTOR CO.
  35. Remove the bolt and the oil filter return tube.
    Fig 30: Locating Oil Filter Return Tube Bolt
    G04519770Courtesy of FORD MOTOR CO.
  36. Remove the fuel tube.
    • Remove the bolt and the banjo fitting from the fuel tube.
    • Discard the sealing washers and remove the fuel tube.
      Fig 31: Locating Fuel Tube
      G04648374Courtesy of FORD MOTOR CO.
    37. NOTE: Align the flat edge with the index feature located on the coolant supply port.
    Fig 32: Aligning Flat Edge With Index Feature
    G04648375Courtesy of FORD MOTOR CO.
  37. Pull the EGR cooler clamp forward, twist and then slide the EGR cooler hose rearward to remove.
    38. NOTE: LH shown, RH similar.
    Fig 33: Identifying Adapter Pipe Bolts
    G03899293Courtesy of FORD MOTOR CO.
  38. Loosen the nuts and bolts from the turbocharger adapter pipe.
  39. Loosen the EGR cooler V-clamp.
    Fig 34: Locating EGR Cooler V-Clamp
    G03899122Courtesy of FORD MOTOR CO.
    40. NOTE: Keep the EGR cooler V-clamp with the turbo adapter pipe.
    Fig 35: Locating Intake Manifold Bolts
    G04648378Courtesy of FORD MOTOR CO.
  40. Remove the bolts and the intake manifold.
  41. Remove the intake manifold gaskets.
    • Clean and inspect the gaskets. Install new gaskets if necessary.
    • Clean and inspect the sealing surfaces.
      Fig 36: Locating Intake Manifold Gasket And Front Module O-Ring Seal
      G03887125Courtesy of FORD MOTOR CO.
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