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Home >> Ford >> 2006 >> Focus ZX5 SE, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 1127 (Engine - 6.8L) >> In-Vehicle Servicing >> Intake Manifold >> Removal

Intake Manifold: Removal

WARNING: This page is about a different car, the 2008 Ford Econoline, 2008 Ford E450 Super Duty, and 2008 Ford Cutaway. 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. Remove the engine cover. For additional information, refer to INTERIOR TRIM AND ORNAMENTATION article.
  2. Disconnect the fuel supply hose spring lock coupling. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION - GASOLINE AND DIESEL article.
  3. Disconnect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES article.
  4. Drain the cooling system. For additional information, refer to ENGINE COOLING article.
  5. Remove the air cleaner and the air cleaner outlet pipe. For additional information, refer to INTAKE AIR DISTRIBUTION AND FILTERING article.
  6. Remove the generator. For additional information, refer to GENERATOR AND REGULATOR article.
  7. Compress and slide the hose clamp and disconnect the coolant hose.
    8. Fig 1: Coolant Hose & Clamp
    GF0011732Courtesy of FORD MOTOR CO.
    NOTE: The red clip must be pulled out before disconnecting the electrical connector.
  8. Disconnect the electronic throttle body (TB) electrical connector.
    9. Fig 2: Electronic Throttle Body (TB) Electrical Connector
    G03885272Courtesy of FORD MOTOR CO.
    NOTE: The red clip must be pulled out before disconnecting the electrical connector.
  9. Disconnect the throttle position (TP) sensor electrical connector.
    10. Fig 3: Identifying Throttle Position Sensor Electrical Connector
    G03885271Courtesy of FORD MOTOR CO.
  10. Disconnect the PCV tube quick connect coupling. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION - GASOLINE AND DIESEL article.
    11. Fig 4: Positive Crankcase Ventilation (PCV) Tube Quick Connect Coupling
    GF0011733Courtesy of FORD MOTOR CO.
  11. Disconnect the 2 coolant hoses and the vacuum tube connector.
    12. Fig 5: Coolant Hoses & Vacuum Tube Connector
    GF0011734Courtesy of FORD MOTOR CO.
  12. Disconnect the brake booster vacuum hose and the evaporative emission (EVAP) hose quick connect coupling. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION - GASOLINE AND DIESEL article.
    13. Fig 6: Brake Booster Vacuum Hose & Evaporative Emission (EVAP) Hose Quick Connect Coupling
    GF0011735Courtesy of FORD MOTOR CO.
  13. Remove the 4 bolts and the TB and adapter as an assembly.
    • Discard the TB adapter gasket.
    14. Fig 7: Throttle Body & Adapter Bolts
    GF0011736Courtesy of FORD MOTOR CO.
  14. Disconnect the heater coolant hose.
    15. Fig 8: Heater Coolant Hose
    GF0011737Courtesy of FORD MOTOR CO.
  15. Disconnect the vacuum connector.
    16. Fig 9: Vacuum Connector
    GF0011738Courtesy of FORD MOTOR CO.
  16. Disconnect the fuel rail pressure and temperature sensor electrical connector and vacuum connector.
  17. Disconnect the 10 fuel injector electrical connectors.
    18. Fig 10: Identifying Fuel Injector Electrical Connector
    G03886335Courtesy of FORD MOTOR CO.
  18. Disconnect the 10 ignition coil electrical connectors.
    19. Fig 11: Identifying Ignition Coil Electrical Connector
    G03886336Courtesy of FORD MOTOR CO.
  19. Remove the nut for the transmission fluid indicator and tube.
    20. Fig 12: Transmission Fluid Indicator Tube Nut
    GF0011739Courtesy of FORD MOTOR CO.
  20. Remove the transmission fluid level indicator tube bracket retaining nut and position the tube aside.
    21. Fig 13: Identifying Transmission Fluid Level Indicator Tube And Retaining Nut
    G03886338Courtesy of FORD MOTOR CO.
  21. Remove the stud bolts and position the RH fuel charge wiring harness aside.
    22. Fig 14: Stud Bolts
    G03886339Courtesy of FORD MOTOR CO.
  22. Remove the bolts and position the LH fuel charge wiring harness aside.
    23. Fig 15: Fuel Charge Wiring Harness Bolts
    G03886340Courtesy of FORD MOTOR CO.
  23. Remove the 10 bolts and the 10 ignition coils.
  24. Disconnect the push pin retainer from the intake manifold bracket.
    25. Fig 16: Push Pin Retainer
    GF0011740Courtesy of FORD MOTOR CO.
  25. Remove the 2 bolts, thermostat housing and thermostat.
    • Discard the O-ring seal.
  26. Remove the 11 bolts, the intake manifold and the intake manifold gaskets.
    • Discard the intake manifold gaskets.
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