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1999 F-Super Duty 250-550 Workshop Manual
SECTION 303-01B: Engine — 6.8L
IN-VEHICLE REPAIR
Intake Manifold
Removal
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 (14301).
2. Drain the coolant system; refer to
Section
3. Compress and slide the hose clamp and disconnect the water outlet hose.
4. Remove the air cleaner outlet tube, refer to
5. Remove the accelerator cable snow shield.
6. Disconnect the accelerator and speed control cables and the return spring.
7. Position the accelerator cable bracket aside.
Remove the bolts.
Position the bracket and cables aside.
8. Disconnect the vacuum lines:
PCV.
brake booster.
engine sensor control wiring harness.
http://www.fordtechservice.dealerconnection.com/pubs/content/~WSXO/~MUS~LEN/20/...
303-03.
Section
303-12.
1999 F-Super Duty 250-550 Workshop Manual
Procedure revision date: 01/26/2000
1/16/2011
14
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Summary of Contents for Ford F-Super Duty 250 1999
- Page 1 1999 F-Super Duty 250-550 Workshop Manual SECTION 303-01B: Engine — 6.8L 1999 F-Super Duty 250-550 Workshop Manual IN-VEHICLE REPAIR Procedure revision date: 01/26/2000 Intake Manifold Removal 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.
- Page 2 1999 F-Super Duty 250-550 Workshop Manual 9. Remove the bolt (RH) and position the capacitor aside. 10. Disconnect the vacuum line. 11. Disconnect the five RH fuel injector electrical connectors and five ignition coil electrical connectors. 12. Disconnect the idle air control motor electrical connector and the bypass hose. http://www.fordtechservice.dealerconnection.com/pubs/content/~WSXO/~MUS~LEN/20/...
- Page 3 1999 F-Super Duty 250-550 Workshop Manual 13. Disconnect the heater hose. 14. Disconnect the EGR transducer and the throttle position sensor connectors. 15. Disconnect the EGR transducer vacuum lines. 16. Remove the EGR transducer bracket. 17. Position the EGR valve to exhaust manifold tube aside. Disconnect the upper fitting.
- Page 4 1999 F-Super Duty 250-550 Workshop Manual 19. NOTE: The EGR valve is shown removed for clarity. Disconnect the EVR solenoid electrical and vacuum harness. 20. Remove the throttle body adapter. Remove the four bolts. Remove the throttle body adapter. Remove the throttle body adapter gasket. 21.
- Page 5 1999 F-Super Duty 250-550 Workshop Manual 23. Disconnect the water temperature indicator sender unit electrical connectors. 24. Remove the generator (GEN) (10300); refer to Section 414-02. 25. Remove the ignition coils. Remove the ten bolts. Remove the ten ignition coils. 26.
- Page 6 1999 F-Super Duty 250-550 Workshop Manual 28. Disconnect the cylinder head temperature sensor. 29. Remove the water thermostat and housing. 30. Remove the bolts, the upper intake manifold and the intake manifold gaskets (9439). Discard the intake manifold gaskets. 31. If required, remove the fuel injection supply manifold. Remove the seven bolts.
- Page 7 1999 F-Super Duty 250-550 Workshop Manual CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the aluminum retainer plate. These tools cause scratches and gouges, which make leak paths. Clean all mating surfaces. Installation 1.
- Page 8 1999 F-Super Duty 250-550 Workshop Manual 3. If required, install the fuel injector supply manifold. Position the fuel injection supply manifold. Install the seven bolts. 4. Position the thermostat and water outlet connector. 5. Install the upper intake manifold. Position the upper intake manifold gaskets and the intake manifold, and loosely install the bolts. 6.
- Page 9 1999 F-Super Duty 250-550 Workshop Manual 7. Connect the engine sensor control wiring harness to the cylinder head temperature sensor. 8. Install the radio interference capacitor. 9. Connect the fuel lines and the vacuum line to the fuel injection supply manifold. 10.
- Page 10 1999 F-Super Duty 250-550 Workshop Manual 13. Connect the five LH fuel injector electrical connectors and five LH ignition coil connectors. 14. Install the EVR solenoid bracket. Position the bracket. Install the bolts. 15. Install the throttle body adapter. Position a new throttle body adapter gasket. Position the throttle body adapter.
- Page 11 1999 F-Super Duty 250-550 Workshop Manual 16. NOTE: The EGR valve is shown removed for clarity. Connect the EVR solenoid vacuum and electrical connectors. 17. Connect the EGR valve vacuum line. 18. Install the EGR valve-to-exhaust manifold tube. Hand-tighten the fittings. Tighten the upper fitting to 55-65 Nm (41-47 lb/ft).
- Page 12 1999 F-Super Duty 250-550 Workshop Manual 21. Connect the EGR transducer and throttle position sensor electrical connectors. 22. Connect the heater hose. 23. Connect the idle air control motor bypass hose and connector. 24. Connect the five RH fuel injector electrical connectors and five RH ignition coil connectors. http://www.fordtechservice.dealerconnection.com/pubs/content/~WSXO/~MUS~LEN/20/...
- Page 13 1999 F-Super Duty 250-550 Workshop Manual 25. Connect the vacuum line. 26. Install the RH radio interference capacitor. Position the capacitor. Install the bolt. 27. Connect the vacuum lines to the: PCV. brake booster. engine control sensor wiring harness. 28. Install the accelerator bracket. Position the bracket.
- Page 14 1999 F-Super Duty 250-550 Workshop Manual 31. Install the air cleaner outlet tube, refer to Section 303-12. 32. Connect the engine water outlet hose and position the hose clamp. 33. Fill the cooling system; refer to Section 303-03. 34. Connect the battery ground cable. http://www.fordtechservice.dealerconnection.com/pubs/content/~WSXO/~MUS~LEN/20/...