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SECTION 303-01B: E ngine — 6.8L 1999 F-Super Duty 2 50-550 Workshop Manual
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1999 F
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Super Duty 250
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550 Workshop Manual
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IN-VEHICLE REPAIR
Intake Manifold
Removal
WARNING: Do not smoke or carry lighted tobacco or open fl ame of any type when working on or near any fuel-related co mponents. Highly flammable mixtures are always
present and can be ignited, resulting in possible personal injury.
WARNING: Fuel in the fuel system remains under high press ure even when the engine is not running.
1. Disconnect the battery ground cable (14301).
2. Drain the coolant system; refer to Section 303-03.
3. Compress and slide the hose clamp and disconnect the water outlet hose.
4. Remove the air cleaner outlet tube, refer to Section 303-12.
5. Remove the accelerator cable snow shield.
Procedure revision date: 01/26/2000
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.
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1999 F
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Super Duty 250
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550 Workshop Manual
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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 an d the bypass hose.
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13. Disconnect the heater hose.
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1999 F
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Super Duty 250
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550 Workshop Manual
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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.
Loosen the lower fitting.
Position the tube aside.
18. Disconnect the EGR valve v acuum line.
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19. NOTE: The EGR valve is sho wn removed for clarity.
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1999 F
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Super Duty 250
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550 Workshop Manual
1/16/2011
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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. Remove the EVR bracket.
Remove the bolts.
Remove the bracket.
22. Disconnect the five LH fuel injector electrical connectors.
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1999 F
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Super Duty 250
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550 Workshop Manual
1/16/2011
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...
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. Disconnect the fuel injection supply manifold.
Disconnect the fuel lines.
Disconnect the vacuum connector from the fuel pressure regulator.
27. Position the radio interference capacitor (LH) aside.
Remove the bolt.
Position the capacitor aside.
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1999 F
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Super Duty 250
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550 Workshop Manual
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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 t he intake manifold gaskets.
31. If required, remove the fuel injection supply manifold.
Remove the seven bolts.
Remove the fuel injection supply manifold.
32. Separate the upper and low er intake manifolds (9424).
Remove the ten bolts.
Discard the intake manifold gasket.
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1999 F
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Super Duty 250
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550 Workshop Manual
1/16/2011
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33. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the aluminum retainer plate. These tools c ause
scratches and gouges, which make leak paths.
Clean all mating surfaces.
Installation
1. Position the lower intake manifold gasket (9461) and the upper intake manifold on the intake man ifold and loosely install the ten bolts.
2. NOTE: Tighten the bolts in two stages.
Tighten the bolts in the sequen ce shown.
Stage 1: Tighten to 2 Nm (18 lb/in)
Stage 2: Tighten to 8-12 Nm (71-106 lb/in)
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1999 F
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Super Duty 250
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550 Workshop Manual
1/16/2011
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3. If required, install the fuel injector supply manifold.
Position the fuel injection supply manifold.
Install the seven bolts.
4. Position the thermostat and wat er outlet connector.
5. Install the upper intake manifold.
Position the upper intake manifold gaskets and the intake manifold, and loosely install the bolts.
6. Tighten the bolts in two stages in the sequence shown.
Stage 1: Tighten to 2 Nm (18 lb/in)
Stage 2: Tighten to 20-30 Nm (15-22 lb/ft)
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1999 F
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550 Workshop Manual
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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. Install the ignition coils.
Position the ten ignition coils.
Install the ten bolts.
11. Install the generator; refer to Section 414-02.
12. Connect the water temperature indicator sending unit electrical connector.
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1999 F
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550 Workshop Manual
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13. Connect the five LH fuel inject or electrical connectors and five LH ignition coil connectors.
14. Install the EVR solenoid brack et.
Position the bracket.
Install the bolts.
15. Install the throttle body adapter.
Position a new throttle body adapter gasket.
Position the throttle body adap ter.
Install four bolts and tighten in two stages.
Stage 1: Tighten to 8-10 Nm (71-88 lb/in).
Stage 2: Tighten an additional 85-95 degrees.
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16. NOTE: The EGR valve is sho wn removed for clarity.
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1999 F
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Super Duty 250
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550 Workshop Manual
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Connect the EVR solenoid vacuum and electrical connectors.
17. Connect the EGR valve vac uum 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).
Tighten the lower fitting to 55-65 Nm (41-47 lb/ft).
19. Install the EGR transducer bracket.
Position the bracket.
Install the bolts.
20. Connect the vacuum lines.
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1999 F
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Super Duty 250
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550 Workshop Manual
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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.
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25. Connect the vacuum line.
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1999 F
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Super Duty 250
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550 Workshop Manual
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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.
Install the bolts.
29. Connect the accelerator and speed control cables and return spring.
30. Install the accelerator cable snow shield.
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14
1999 F
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Super Duty 250
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550 Workshop Manual
1/16/2011
http://www.fordtechservice.dealerconnection.com/pubs/content/~WSXO/~MUS~LEN/20/
...
31. Install the air cleaner outlet tube, refer to Section 303-12.
32. Connect the engine water ou tlet hose and position the hose clamp.
33. Fill the cooling system; refer to Section 303-03.
34. Connect the battery ground cable.
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