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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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Summarization of Contents
Intake Manifold Removal Procedures
Disconnect Battery and Fluid Lines
Disconnect battery ground cable, drain coolant system, and disconnect water outlet hose.
Remove Air Cleaner and Cable Systems
Remove air cleaner outlet tube, accelerator cable shield, and associated cables/springs.
Disconnect Vacuum and Electrical Connections
Disconnect various vacuum lines, fuel injector, and ignition coil electrical connectors.
Remove EGR and Related Components
Disconnect EGR transducer, TPS connectors, vacuum lines, and remove EGR bracket and tube.
Remove Engine Accessories
Remove generator, ignition coils, fuel injection supply manifold, and thermostat housing.
Separate Intake Manifold Sections
Remove intake manifold bolts and separate upper and lower intake manifold sections.
Intake Manifold Installation Procedures
Prepare and Position Intake Manifold
Position lower intake manifold gasket and upper intake manifold, loosely install bolts.
Reinstall Fuel and Ignition Components
Install fuel injector supply manifold, ignition coils, and connect related lines/connectors.
Reattach Air Systems and EGR Components
Install throttle body adapter, EVR bracket, EGR components, and connect vacuum lines.
Final Connections and System Checks
Connect accelerator cables, vacuum lines, and battery ground cable, fill cooling system.
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