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Home >> Ford >> 2005 >> Excursion 5.4 L, RWD >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 5 (Engine - 6.0L Diesel) >> In-Vehicle Repair >> Intake Manifold >> Removal

Intake Manifold: Removal

WARNING: This page is about a different variant/trim than selected.

    All vehicles 

  1. Remove the auxiliary battery. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  2. Remove the cooling fan stator - 6.0L diesel engine. For additional information, refer to ENGINE COOLING .
  3. Remove the degas bottle. For additional information, refer to ENGINE COOLING .
  4. Remove the upper radiator hose.
    Fig 1: Removing Upper Radiator Hose
    G03906741Courtesy of FORD MOTOR CO.
    5. NOTE: Engine side shown, charge air cooler side similar.
    Fig 2: Removing Turbocharger-To-Charge Air Cooler Duct
    G03906742Courtesy of FORD MOTOR CO.
  5. Remove the turbocharger-to-charge air cooler duct.

    Vehicles with dual generators

  6. Remove the accessory drive belt.
    Fig 3: Rotating Drive Belt Tensioner Clockwise
    G03887086Courtesy of FORD MOTOR CO.
  7. Remove the bolt and the accessory drive belt tensioner.
    Fig 4: Removing Bolt Accessory Drive Belt Tensioner
    G03887087Courtesy of FORD MOTOR CO.
  8. Remove the accessory drive belt.
    Fig 5: Rotating Accessory Drive Belt Tensioner Clockwise
    G03887088Courtesy of FORD MOTOR CO.
  9. Remove the bolts, bracket and accessory drive belt idler pulley.
    Fig 6: Removing Bolts
    G03887089Courtesy of FORD MOTOR CO.
  10. Remove the bolts and the accessory drive belt tensioner.
    Fig 7: Removing Bolts Accessory Drive Belt Tensioner
    G03887090Courtesy of FORD MOTOR CO.
  11. Disconnect the wire retainer, generator electrical connector and B+ wire.
    Fig 8: Disconnecting Wire Retainer
    G03907090Courtesy of FORD MOTOR CO.
  12. Remove the bolts and the generator with mounting bracket.
    Fig 9: Removing Bolts Generator With Mounting Bracket
    G03887092Courtesy of FORD MOTOR CO.

    Vehicles with single generator

  13. Remove the accessory drive belt.
    Fig 10: Rotating Accessory Drive Belt Tensioner Clockwise
    G03906750Courtesy of FORD MOTOR CO.

    14. All vehicles 

  14. Position the boot back and disconnect the generator B+ wire and electrical connector.
    Fig 11: Disconnecting Generator B+ Wire And Electrical Connector
    G03906751Courtesy of FORD MOTOR CO.
  15. Remove the 3 bolts and the generator.
    Fig 12: Removing Bolts Generator
    G03907094Courtesy of FORD MOTOR CO.
  16. Remove the turbocharger and the turbocharger pedestal. For additional information, refer to FUEL CHARGING & CONTROLS - TURBOCHARGER .
    17. NOTE: Engine side shown, charge air cooler side similar.
    Fig 13: Loosening Clamps
    G03908002Courtesy of FORD MOTOR CO.
  17. Loosen the clamps and remove the charge air cooler duct.
  18. Remove the bolts and position the heater hose tube aside.
    • Remove and discard the O-ring.
    Fig 14: Removing O-Ring
    G03921357Courtesy of FORD MOTOR CO.
  19. Disconnect the manifold absolute pressure (MAP) sensor hose.
    Fig 15: Disconnecting Manifold Absolute Pressure Sensor Hose
    G03906804Courtesy of FORD MOTOR CO.
  20. Disconnect the engine coolant vent hose.
    Fig 16: Disconnecting Engine Coolant Vent Hose
    G03906756Courtesy of FORD MOTOR CO.
  21. Remove the fuel injector control module. For additional information, refer to ELECTRONIC ENGINE CONTROLS - DIESEL ENGINE .
  22. If equipped with a heat shield bracket, remove the retaining nuts from the heat shield bracket.
    • Disconnect the ground wire from the stud.
    Fig 17: Identifying Ground Wire Retaining Nuts
    G03906757Courtesy of FORD MOTOR CO.
  23. If equipped with a heat shield bracket, disconnect the wiring retainer from the heat shield bracket.
    Fig 18: Locating Wiring Retainer At Back Of Heat Shield Bracket
    G03906758Courtesy of FORD MOTOR CO.
  24. If equipped with a heat shield bracket, remove the bolts and heat shield bracket.
    Fig 19: Locating Bolts And Heat Shield Bracket
    G03906759Courtesy of FORD MOTOR CO.
    25. NOTE: Early build shown, late build similar.
    Fig 20: Removing Bolts From Injector Pressure Regulator Heat Shield
    G03906760Courtesy of FORD MOTOR CO.
  25. Remove the top 2 bolts from the injector pressure regulator (IPR) heat shield.
  26. Remove or position aside the heat insulating wrap. Disconnect the wiring retainer and the injection pressure regulator (IPR) valve electrical connector.
    Fig 21: Disconnecting Wiring Retainer And Injection Pressure Regulator Valve Electrical Connector
    G03906761Courtesy of FORD MOTOR CO.
  27. Disconnect the exhaust gas recirculation (EGR) valve electrical connector.
    Fig 22: Locating EGR Valve Assembly Electrical Connector
    G03887106Courtesy of FORD MOTOR CO.
  28. Disconnect the engine oil pressure (EOP) sensor electrical connector.
    Fig 23: Locating Engine Oil Pressure Sensor Electrical Connector
    G03887107Courtesy of FORD MOTOR CO.
  29. Disconnect the engine oil temperature (EOT) sensor electrical connector.
    Fig 24: Locating Engine Oil Temperature Sensor
    G03887108Courtesy of FORD MOTOR CO.
  30. If equipped, disconnect the exhaust gas recirculation (EGR) throttle position control module electrical connector.
    Fig 25: Disconnecting Exhaust Gas Recirculation Throttle Position Control Module Electrical Connector
    G03906765Courtesy of FORD MOTOR CO.
  31. If equipped, disconnect the EGR throttle position sensor electrical connector.
    Fig 26: Disconnecting EGR Throttle Position Sensor Electrical Connector
    G03906793Courtesy of FORD MOTOR CO.
  32. Disconnect the pin-type retainer and engine coolant temperature (ECT) sensor.
    Fig 27: Disconnecting Pin-Type Retainer
    G03887109Courtesy of FORD MOTOR CO.
  33. Disconnect the intake air temperature 2 (IAT2) sensor electrical connector.
    Fig 28: Disconnecting Intake Air Temperature Sensor Electrical Connector
    G03906768Courtesy of FORD MOTOR CO.
  34. Disconnect the exhaust pressure sensor electrical connector.
    Fig 29: Disconnecting Exhaust Pressure Sensor Electrical Connector
    G03906769Courtesy of FORD MOTOR CO.
    35. NOTE: LH side shown, RH side similar.
    Fig 30: Disconnecting Fuel Injectors Electrical Connectors
    G03921371Courtesy of FORD MOTOR CO.
  35. Disconnect the 8 fuel injectors electrical connectors. Remove the nut and the ground wire.
    36. NOTE: It is necessary to remove the fuel filter and drain the housing.
    Fig 31: Removing Sealing Washers
    G03921372Courtesy of FORD MOTOR CO.
  36. Disconnect the fuel line fittings.
    • Remove and discard the sealing washers.
    37. NOTE: It is necessary to remove the oil filter and drain the housing.
    Fig 32: Removing Bolts
    G03921373Courtesy of FORD MOTOR CO.
  37. Remove the 4 bolts and the oil filter housing.
  38. Remove the bolt and the oil filter return tube.
    Fig 33: Removing Bolt Oil Filter Return Tube
    G04519770Courtesy of FORD MOTOR CO.
  39. Remove the fuel line.
    • Remove the bolt and the banjo fitting from the fuel line.
    • Discard the sealing washers and remove the fuel line.
    Fig 34: Removing Fuel Line
    G03921375Courtesy of FORD MOTOR CO.
    40. NOTE: Align the flat edge with the index feature located on the coolant supply port.
    Fig 35: Pulling EGR Cooler Clamp
    G03921376Courtesy of FORD MOTOR CO.
  40. Pull the EGR cooler clamp forward, twist and then slide the EGR cooler hose rearward to remove.
  41. If equipped, remove the nuts and the turbocharger heat shield.
    Fig 36: Removing Nuts Turbocharger Heat Shield
    G03906776Courtesy of FORD MOTOR CO.
  42. Loosen the EGR cooler V-clamp.
    Fig 37: Locating Y-Pipe-To-EGR Cooler Clamp
    G03899122Courtesy of FORD MOTOR CO.
    43. NOTE: Keep the EGR cooler V-clamp with the turbo adapter pipe.
    Fig 38: Removing Bolts Intake Manifold
    G03906778Courtesy of FORD MOTOR CO.
  43. Remove the bolts and the intake manifold.
  44. Remove the intake manifold gaskets.
    • Clean and inspect the gaskets. Install new gaskets if necessary.
    • Clean and inspect the sealing surfaces.
    • Remove and inspect the front module O-ring seal.
    Fig 39: Removing O-Ring Seal
    G03887125Courtesy of FORD MOTOR CO.
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