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Home >> Ford >> 2001 >> Mustang Base, 2D Convertible, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 249 (Engine - 6.8L) >> In-Vehicle Repair >> Intake Manifold >> Removal
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Intake Manifold: Removal

WARNING: This page is about a different car, the 2003 Ford RV Cutaway, 2003 Ford Econoline, 2003 Ford E550 Super Duty, 2003 Ford E450 Super Duty, and 2003 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.
WARNING: Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related components. Highly flammable mixtures are always present and can be ignited, resulting in possible personal injury.
WARNING: Fuel in the fuel system remains under high pressure even when the engine is not running.
  1. Disconnect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  2. Remove the air cleaner assembly and tubes.
  3. Remove the interior engine cover. For additional information, refer to INTERIOR TRIM AND ORNAMENTATION .
  4. Drain the cooling system. For additional information, refer to ENGINE COOLING .
  5. Disconnect the fuel hose spring lock couplings. For additional information, refer to FUEL TANK & LINES-GASOLINE & DIESEL .
  6. Remove the accelerator cable snow shield.
    Fig 1: Removing Accelerator Cable Snow Shield
    G01537156Courtesy of FORD MOTOR CO.
  7. Compress and slide the hose clamp and disconnect the water outlet hose.
    Fig 2: Disconnecting Water Outlet Hose
    G01537157Courtesy of FORD MOTOR CO.
  8. Disconnect the water temperature sensor electrical connector.
    Fig 3: Disconnecting Water Temperature Sensor Electrical Connector
    G01537158Courtesy of FORD MOTOR CO.
  9. Remove the bolt and the bracket.
    Fig 4: Removing Bracket
    G01537159Courtesy of FORD MOTOR CO.
  10. Remove the bolts and the generator upper support bracket.
    Fig 5: Removing Generator Upper Support Bracket
    G01537160Courtesy of FORD MOTOR CO.
  11. Disconnect the heater water hose.
    Fig 6: Disconnecting Heater Water Hose
    G01537161Courtesy of FORD MOTOR CO.
  12. Disconnect the throttle position (TP) sensor.
    1. Disconnect the electrical connector.
    2. Detach the harness routing clip.
    Fig 7: Disconnecting Throttle Position (TP) Sensor
    G01537162Courtesy of FORD MOTOR CO.
  13. Disconnect the throttle body control linkage.
    1. Disconnect the accelerator cable.
    2. Disconnect the speed control actuator cable.
    3. Disconnect the throttle control return spring.
    Fig 8: Disconnecting Throttle Body Control Linkage
    G01537163Courtesy of FORD MOTOR CO.
  14. Remove the bolts and position the accelerator cable bracket and cables aside.
    Fig 9: Removing Accelerator Cable Bracket And Cables
    G01537164Courtesy of FORD MOTOR CO.
  15. Remove the nut from the transmission fluid indicator tube front bracket.
    Fig 10: Removing Nut From Transmission Fluid Indicator Tube Front Bracket
    G01537165Courtesy of FORD MOTOR CO.
  16. Remove the nut from the transmission fluid indicator tube rear bracket and position the tube aside.
    Fig 11: Removing Nut From Transmission Fluid Indicator Tube Rear Bracket
    G01537166Courtesy of FORD MOTOR CO.
  17. If equipped, disconnect the auxiliary heater hoses and position aside. For additional information refer to CLIMATE CONTROL SYSTEM-GENERAL INFORMATION .
    Fig 12: Disconnecting Auxiliary Heater Hoses
    G01537167Courtesy of FORD MOTOR CO.
  18. Disconnect the evaporative emission canister purge valve hose and the vacuum hose.
    Fig 13: Disconnecting Evaporative Emission Canister Purge Valve Hose And The Vacuum Hose
    G01537168Courtesy of FORD MOTOR CO.
  19. Remove the two evaporative emission canister purge valve bracket nuts and position the valve and bracket assembly aside.
    Fig 14: Removing Evaporative Emission Canister Purge Valve Bracket
    G01537169Courtesy of FORD MOTOR CO.
  20. Disconnect and remove the idle air control (IAC) valve fresh air hose.
    Fig 15: Removing Idle Air Control (IAC) Valve Fresh Air Hose
    G01537170Courtesy of FORD MOTOR CO.
  21. Disconnect the idle air control (IAC) valve electrical connector.
    Fig 16: Disconnecting Idle Air Control (IAC) Valve Electrical Connector
    G01537171Courtesy of FORD MOTOR CO.
  22. Disconnect the EGR vacuum regulator solenoid connector, if equipped.
    Fig 17: Disconnecting EGR Vacuum Regulator Solenoid Connector
    G01537172Courtesy of FORD MOTOR CO.
  23. Remove the engine vacuum harness. Disconnect the harness as follows:
    1. Exhaust gas recirculation (EGR) valve, if equipped.
    2. EGR vacuum regulator solenoid, if equipped.
    3. Vacuum source.
    4. Fuel pressure regulator.
    Fig 18: Removing Engine Vacuum Harness
    G01537173Courtesy of FORD MOTOR CO.
  24. Remove the exhaust manifold-to-EGR valve tube, if equipped.
    • Disconnect the upper fitting.
    • Disconnect the lower fitting and remove the tube.
    Fig 19: Removing Exhaust Manifold-To-EGR Valve Tube
    G01537174Courtesy of FORD MOTOR CO.
  25. Disconnect and remove the positive crankcase ventilation (PCV) hose.
  26. Remove the four bolts, and the throttle body and adapter as an assembly.
    • Discard the throttle body adapter gasket.
    Fig 20: Removing Throttle Body And Adapter
    G01537175Courtesy of FORD MOTOR CO.
  27. Disconnect the five RH fuel injector electrical connectors.
    Fig 21: Disconnecting RH Fuel Injector Electrical Connectors
    G01537176Courtesy of FORD MOTOR CO.
  28. Disconnect the five LH fuel injector electrical connectors.
    Fig 22: Disconnecting LH Fuel Injector Electrical Connectors
    G01537177Courtesy of FORD MOTOR CO.
  29. Disconnect and remove the ten ignition coils. For additional information, refer to IGNITION COILS .
  30. Remove the bolts and the water thermostat housing.
    Fig 23: Removing Water Thermostat Housing
    G01537178Courtesy of FORD MOTOR CO.
  31. Remove the bolts, the intake manifold, and the intake manifold gaskets.
    Fig 24: Removing Intake Manifold And Intake Manifold Gaskets
    G01537179Courtesy of FORD MOTOR CO.
  32. Separate the upper and the lower intake manifolds.
    • Remove the ten bolts.
    • Discard the intake manifold gasket.
    Fig 25: Separating Upper And Lower Intake Manifolds
    G01537180Courtesy of FORD MOTOR CO.
  33. Clean and inspect the mating surfaces.
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