Intake Manifold: Removal

WARNING: This page is about a different car, the 2019 Ford F-550 Super Duty and 2019 Ford F-450 Super Duty. However, it is still accessible from the selected car via links, so may be relevant.

For information on Ford Color Coded Illustrations refer to OEM Color Coding

NOTE: During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces, that enters the oil passages, coolant passages or the oil pan, can cause engine failure.

NOTE: Removal steps in this procedure may contain installation details.

Release the fuel system pressure. Refer to: Fuel System Pressure Release .
Disconnect the battery ground cable. Refer to: Battery Disconnect and Connect .
Drain the engine cooling system. Refer to: Engine Cooling System Draining, Vacuum Filling And Bleeding .
Remove the following items:
1. Air cleaner outlet pipe. Refer to: Air Cleaner Outlet Pipe .
2. Generator. Refer to: Generator - 6.8L Triton-30V - V10 .
3. EVAP canister purge valve. Refer to: Evaporative Emission Canister Purge Valve .
Disconnect the fuel supply tube quick release coupling. Refer to: Quick Release Coupling .

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Disconnect the quick release coupling and remove the crankcase ventilation tube. Refer to: Quick Release Coupling .

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Release the clamp and disconnect the coolant hose.

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Disconnect the quick release couplings and remove the crankcase ventilation tube. Refer to: Quick Release Coupling .

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Disconnect the oil pressure switch electrical connector and detach the wiring harness retainers.

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Disconnect the LH and RH fuel injector electrical connectors.

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- Disconnect the engine wiring harness electrical connector and detach the retainer from the valve cover stud bolt.
- Disconnect the LH ignition coil-on-plugs electrical connectors.
- Detach the wiring harness retainers from the LH valve cover studs.
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Remove the nut and position the LH radio interference capacitor aside.
Torque: 18 lb.ft (25 Nm)

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- Disconnect the electronic throttle control and TP sensor electrical connectors.
- Detach the wiring harness retainers from the intake manifold.
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Remove the intake manifold bolts and the stud bolt.

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- Position the intake manifold toward the rear of the engine.
- NOTE: Do not disconnect the upper radiator hose unless servicing the thermostat housing or coolant crossover manifold.
  
  Remove the bolts and position the coolant crossover manifold aside.
  
  Torque: 89 lb.in (10 Nm)
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Remove and discard the coolant crossover manifold gaskets.

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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 if found, install a new intake manifold. Failure to follow these instructions can result in engine damage.

Remove the intake manifold.

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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: Clean and inspect all sealing surfaces of the cylinder heads.

Remove and discard the intake manifold gaskets.

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