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Home >> Ford >> 2011 >> F 450 4WD Super Duty V10-6.8L >> Repair and Diagnosis >> Engine, Cooling and Exhaust >> Engine >> Intake Manifold >> Service and Repair >> Removal and Replacement

Removal and Replacement




Intake Manifold





Wiring Harness Electrical Connectors









Coolant Hoses, Vacuum Hoses and Electrical Connectors









Fuel Supply Tube and Electrical Connectors









Coolant Crossover and Intake Manifold









Removal

WARNING: Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.

WARNING: Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury.

1. Release the fuel system pressure. For additional information, refer to Fuel System - General Information - Gasoline and Diesel Service and Repair.

2. Disconnect the fuel supply tube quick connect coupling from the fuel rail. For additional information, refer to Fuel System - General Information - Gasoline and Diesel Quick Connect Coupling.

3. Drain the cooling system. For additional information, refer to Engine Cooling - Gasoline Engines Cooling System Draining, Filling and Bleeding.

4. Remove the Air Cleaner (ACL) outlet pipe. For additional information, refer to Intake Air Distribution and Filtering [1][2]Diagrams.

5. Remove the generator. For additional information, refer to Charging System Service and Repair.

6. Disconnect the heater coolant hose and PCV coolant hose from the engine coolant crossover assembly.

7. Disconnect the Intake Manifold Runner Control (IMRC) actuator electrical connector.

8. Disconnect the 10 fuel injector electrical connectors.

9. Disconnect the PCV tube quick connect coupling from the intake manifold. For additional information, refer to Fuel System - General Information - Gasoline and Diesel Quick Connect Coupling.

10. Disconnect the Evaporative Emission (EVAP) tube quick connect coupling from the EVAP canister purge valve. For additional information, refer to Fuel System - General Information - Gasoline and Diesel Quick Connect Coupling.

11. Disconnect the EVAP canister purge valve electrical connector.

12. Disconnect the quick connect coupling and remove the crankcase ventilation tube. For additional information, refer to Fuel System - General Information - Gasoline and Diesel Quick Connect Coupling.

13. Disconnect the vacuum hose and remove the vacuum cap from the rear of the intake manifold.

14. Disconnect the Throttle Position (TP) sensor and Electronic Throttle Control (ETC) electrical connectors.

15. Disconnect the middle PCM connector and wiring harness retainer.

16. Disconnect the engine control harness electrical connector.

17. Detach the 3 wiring harness retainers from the RH valve cover studs.

18. Disconnect the 5 RH ignition coil-on-plug electrical connectors.

19. Disconnect the 3 engine wiring harness retainers from the intake manifold.

20. Disconnect the heated PCV fitting lower coolant hose.

21. Remove the 12 intake manifold bolts.

22. NOTICE: 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: Do not disconnect the upper radiator hose unless servicing the thermostat housing or coolant crossover manifold.

Remove the 3 bolts and position the engine coolant crossover manifold assembly aside.

- Discard the 2 engine coolant crossover manifold gaskets.

- Clean and inspect the sealing surfaces with silicone gasket remover and metal surface prep. Follow the directions on the packaging.

23. Position the intake manifold forward and disconnect the wiring harness retainer from the rear of the intake manifold.

24. NOTICE: 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.

Remove the intake manifold and discard the 10 gaskets.

- Clean and inspect the sealing surfaces with silicone gasket remover and metal surface prep. Follow the directions on the packaging.

Installation

1. Position the intake manifold onto the engine and attach the wiring harness connector onto the back of the intake manifold.

2. NOTICE: 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 is found, install a new intake manifold. Failure to follow these instructions can result in engine damage.

Using 10 new intake manifold gaskets, install the intake manifold.

3. Using 2 new gaskets, position the engine coolant crossover manifold assembly and install the 3 bolts.
- Tighten to 10 Nm (89 lb-in).

4. Install the intake manifold bolts and tighten in 2 stages in the sequence shown.
- Stage 1: Tighten to 2 Nm (18 lb-in).

- Stage 2: Tighten to 10 Nm (89 lb-in).





5. Connect the heated PCV fitting lower coolant hose.

6. Connect the 3 engine wiring harness position retainers to the intake manifold.

7. Connect the 5 RH ignition coil-on-plug electrical connectors.

8. Attach the 3 wiring harness retainers to the RH valve cover studs.

9. Connect the engine control harness electrical connector.

10. Connect the middle PCM connector and wiring harness retainer.

11. Connect the TP sensor and ETC electrical connectors.

12. Connect the vacuum hose and install the vacuum cap on the rear of the intake manifold.

13. Position the crankcase ventilation tube and connect the quick connect coupling. For additional information, refer to Fuel System - General Information - Gasoline and Diesel Quick Connect Coupling.

14. Connect the Evaporative Emission (EVAP) canister purge valve electrical connector.

15. Connect the EVAP tube quick connect coupling to the EVAP canister purge valve. For additional information, refer to Fuel System - General Information - Gasoline and Diesel Quick Connect Coupling.

16. Connect the PCV tube quick connect coupling to the intake manifold. For additional information, refer to Fuel System - General Information - Gasoline and Diesel Quick Connect Coupling.

17. Connect the 10 fuel injector electrical connectors.

18. Connect the IMRC actuator electrical connector.

19. Connect the fuel supply tube quick connect coupling to the fuel rail. For additional information, refer to Fuel System - General Information - Gasoline and Diesel Quick Connect Coupling.

20. Connect the heater coolant hose and the heated PCV coolant hose to the coolant crossover assembly.

21. Install the generator. For additional information, refer to Charging System Service and Repair.

22. Install the ACL outlet pipe. For additional information, refer to Intake Air Distribution and Filtering [1][2]Diagrams.

23. Fill and bleed the engine cooling system. For additional information, refer to Engine Cooling - Gasoline Engines Cooling System Draining, Filling and Bleeding.

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