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Home >> Ford >> 2003 >> ZX2 Automatic >> Repair and Diagnosis >> External Pages >> Different car >> Section 632 (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 2004 Ford RV Cutaway, 2004 Ford Econoline, 2004 Ford E450 Super Duty, and 2004 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. Do not work on any fuel system component until fuel system pressure has been relieved. Failure to follow these instructions may result in personal injury.
  1. Relieve the fuel system pressure. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION-GASOLINE & DIESEL .
  2. Disconnect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  3. Remove the air cleaner and the air cleaner outlet tube. For additional information, refer to INTAKE AIR DISTRIBUTION & FILTERING .
  4. Remove the interior engine cover. For additional information, refer to INTERIOR TRIM AND ORNAMENTATION .
  5. Drain the cooling system. For additional information, refer to ENGINE COOLING .
  6. Disconnect the fuel hose spring lock coupling. For additional information, Refer to FUEL SYSTEM-GENERAL INFORMATION-GASOLINE & DIESEL .
  7. Remove the accelerator cable splash shield.
    Fig 1: Removing Accelerator Cable Splash Shield
    G02763753Courtesy of FORD MOTOR CO.
  8. Compress and slide the hose clamp and disconnect the coolant hose.
    Fig 2: Disconnecting Coolant Hose
    G02763754Courtesy of FORD MOTOR CO.
  9. Disconnect the coolant temperature sensor electrical connector.
    Fig 3: Disconnecting Coolant Temperature Sensor Electrical Connector
    G02763755Courtesy of FORD MOTOR CO.
  10. Remove the bolt and the bracket.
    Fig 4: Removing Bolt And The Bracket
    G02763756Courtesy of FORD MOTOR CO.
  11. Remove the bolts and the generator upper support bracket.
    Fig 5: Removing Bolts And Generator Upper Support Bracket
    G02763757Courtesy of FORD MOTOR CO.
  12. Discount the heater hose.
    Fig 6: Discounting Heater Hose
    G02763758Courtesy of FORD MOTOR CO.
  13. Disconnect the throttle position (TP) sensor.
    • Disconnect the electrical connector.
    • Detach the harness routing clip.
    Fig 7: Disconnecting TP Sensor Electrical Connector
    G02763759Courtesy of FORD MOTOR CO.
  14. Disconnect the throttle body control linkage.
    1. Disconnect the accelerator pedal.
    2. Disconnect the speed control actuator cable.
    3. Disconnect the throttle control return spring.
    Fig 8: Disconnecting Throttle Control Return Spring
    G02763760Courtesy of FORD MOTOR CO.
  15. Remove the bolts and position the accelerator cable bracket and cables aside.
    Fig 9: Removing Bolts And Position Accelerator Cable Bracket
    G02763761Courtesy of FORD MOTOR CO.
  16. Remove the transmission fluid level indicator tube bracket retaining nut and position the tube aside.
    Fig 10: Removing Transmission Fluid Level Indicator Tube Bracket
    G02763762Courtesy of FORD MOTOR CO.
  17. Remove the four retainers from the fuel charging wiring harness and position the wiring harness away from the fuel injection supply manifold.
    Fig 11: Removing Four Retainers From Fuel Charging Wiring Harness
    G02763763Courtesy of FORD MOTOR CO.
  18. Remove the nut from the transmission fluid indicator tube rear bracket and position the tube aside.
    Fig 12: Removing Nut From Transmission Fluid Indicator Tube
    G02763764Courtesy of FORD MOTOR CO.
  19. If equipped, disconnect the auxiliary heater hoses and position them aside. For additional information, refer to CLIMATE CONTROL SYSTEM-GENERAL INFORMATION .
    Fig 13: Disconnecting Auxiliary Heater Hoses And Position Aside
    G02763765Courtesy of FORD MOTOR CO.
  20. Disconnect the evaporative emission canister purge valve hose and the vacuum hose.
    Fig 14: Disconnecting Evaporative Emission Canister Purge Valve Hose
    G02763766Courtesy of FORD MOTOR CO.
  21. Remove the two evaporative emission canister purge valve bracket nuts and position the valve and bracket assembly aside.
    Fig 15: Removing Two Evaporative Emission Canister Purge Valve Bracket Nuts And Position Valve And Bracket
    G02763767Courtesy of FORD MOTOR CO.
  22. Disconnect and remove the idle air control (IAC) valve fresh air hose.
    Fig 16: Disconnecting And Removing Idle Air Control (IAC) Valve Fresh Air Hose
    G02763768Courtesy of FORD MOTOR CO.
  23. Disconnect the IAC valve electrical connector.
    Fig 17: Disconnecting IAC Valve Electrical Connector
    G02763769Courtesy of FORD MOTOR CO.
  24. Disconnect and remove the positive crankcase ventilation (PCV) hose.
  25. Disconnect the brake booster and the main engine vacuum harness and position aside.
    Fig 18: Disconnecting Brake Booster And Main Engine Vacuum Harness
    G02763770Courtesy of FORD MOTOR CO.
  26. Remove the four bolts, the throttle body and adapter as an assembly.
    • Discard the throttle body adapter gasket.
    Fig 19: Discarding Throttle Body Adapter Gasket
    G02763771Courtesy of FORD MOTOR CO.
  27. Disconnect the 10 fuel injector electrical connectors.
    Fig 20: Disconnecting Fuel Injector Electrical Connectors
    G02763772Courtesy of FORD MOTOR CO.
  28. Disconnect the 10 ignition coil electrical connectors.
    Fig 21: Disconnecting Ignition Coil Electrical Connectors
    G02763773Courtesy of FORD MOTOR CO.
  29. Remove the screws and the 10 coils.
    Fig 22: Removing Screws And Coils
    G02763774Courtesy of FORD MOTOR CO.
  30. Disconnect the cylinder head temperature (CHT) sensor electrical connectors.
    Fig 23: Disconnecting Cylinder Head Temperature (CHT) Sensor Electrical Connectors
    G02763775Courtesy of FORD MOTOR CO.
  31. Remove the bolts and the thermostat housing.
    Fig 24: Removing Bolts And Thermostat Housing
    G02763776Courtesy of FORD MOTOR CO.
  32. Remove the bolts, the intake manifold and the intake manifold gaskets.
    Fig 25: Removing Intake Manifold And Gaskets
    G02763777Courtesy of FORD MOTOR CO.
  33. Clean and inspect the mating surfaces.
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