LEMON Manuals: Even more car manuals for everyone
Home >> Ford >> 2012 >> Explorer Limited, 3.5 8, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 23 (Engine Mechanical - 6.8L) >> In-Vehicle Repair >> Intake Manifold >> Coolant Crossover and Intake Manifold >> Removal

Coolant Crossover and Intake Manifold: Removal

WARNING: This page is about a different car, the 2013 Ford F-550 Super Duty and 2013 Ford F-450 Super Duty. 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 system pressure. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION - GASOLINE AND DIESEL .
  2. Disconnect the fuel supply tube quick connect coupling from the fuel rail. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION - GASOLINE AND DIESEL .
  3. Drain the cooling system. For additional information, refer to ENGINE COOLING - GASOLINE ENGINES .
  4. Remove the Air Cleaner (ACL) outlet pipe. For additional information, refer to INTAKE AIR DISTRIBUTION & FILTERING .
  5. Remove the generator. For additional information, refer to CHARGING SYSTEM .
  6. Disconnect the heater coolant hose and PCV coolant hose from the engine coolant crossover assembly.
  7. Disconnect the Intake Manifold Runner Control (IMRC) actuator electrical connector.
  8. Disconnect the 10 fuel injector electrical connectors.
  9. Disconnect the PCV tube quick connect coupling from the intake manifold. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION - GASOLINE AND DIESEL .
  10. 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 .
  11. Disconnect the EVAP canister purge valve electrical connector.
  12. Disconnect the quick connect coupling and remove the crankcase ventilation tube. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION - GASOLINE AND DIESEL .
  13. Disconnect the vacuum hose and remove the vacuum cap from the rear of the intake manifold.
  14. Disconnect the Throttle Position (TP) sensor and Electronic Throttle Control (ETC) electrical connectors.
  15. Disconnect the middle PCM connector and wiring harness retainer.
  16. Disconnect the engine control harness electrical connector.
  17. Detach the 3 wiring harness retainers from the RH valve cover studs.
  18. Disconnect the 5 RH ignition coil-on-plug electrical connectors.
  19. Disconnect the 3 engine wiring harness retainers from the intake manifold.
  20. Disconnect the heated PCV fitting lower coolant hose.
  21. Remove the 12 intake manifold bolts.
  22. 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.
    NOTE: Do not disconnect the upper radiator hose unless servicing the thermostat housing or coolant crossover manifold.

    Remove the 3 bolts and position the engine coolant crossover manifold assembly aside.

    • Discard the 2 engine coolant crossover manifold gaskets.
    • Clean and inspect the sealing surfaces with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
  23. Position the intake manifold forward and disconnect the wiring harness retainer from the rear of the intake manifold.
  24. 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.

    Remove the intake manifold and discard the 10 gaskets.

    • Clean and inspect the sealing surfaces with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
scientia non olet · About LEMON Manuals