Ford F-Super Duty 250 1999 User Manual

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 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.
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.
SECTION 303-01B: Engine — 6.8L 1999 F-Super Duty 250-550 Workshop Manual
IN-VEHICLE REPAIR
Procedure revision date: 01/26/2000
14
1999 F
-
Super Duty 250
-
550 Workshop Manual
1/16/2011
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Ford F-Super Duty 250 1999 Specifications

General

Brand	Ford
Model	F-Super Duty 250 1999
Category	Automobile
Language	English

Summary

Intake Manifold Removal Procedure

Initial Disconnections

Disconnect battery, drain coolant, and detach water outlet hose and air cleaner tube.

Cable and Vacuum Line Disconnections

Disconnect accelerator/speed control cables, position bracket, and disconnect vacuum lines.

Electrical and Vacuum Connector Removal

Disconnect RH fuel injector and ignition coil connectors, IAC motor connector, and vacuum lines.

EGR System Component Disconnection

Disconnect heater hose, EGR transducer, throttle position sensor, and EGR valve vacuum lines.

EVR and Throttle Body Adapter Removal

Disconnect EVR solenoid harness, remove throttle body adapter and EVR bracket.

Sensor, Coil, and Fuel Manifold Disconnections

Disconnect temp sensor, generator, ignition coils, fuel supply manifold, and radio interference capacitor.

Thermostat and Intake Manifold Removal

Remove thermostat, housing, and the intake manifold assembly with gaskets.

Intake Manifold Installation Procedure

Intake Manifold Gasket and Assembly

Position lower gasket, upper intake manifold, and loosely install bolts.

Manifold Bolt Tightening Sequence

Tighten intake manifold bolts in two stages according to the specified torque sequence.

Fuel Manifold and Thermostat Installation

Install fuel injector supply manifold and the thermostat and water outlet connector.

Upper Intake Manifold Installation

Position upper intake manifold gaskets and manifold, then loosely install bolts.

Wiring Harness and Sensor Connections

Connect engine sensor wiring harness, radio interference capacitor, and ignition coils.

Fuel Lines and Generator Installation

Connect fuel lines, vacuum line to supply manifold, install generator and water temp sensor connector.

LH Injector and EVR Bracket Installation

Connect LH fuel injector and ignition coil connectors, install EVR solenoid bracket.

Throttle Body Adapter Installation

Install throttle body adapter with a new gasket, tightening bolts in stages and degrees.

EGR System Reconnection

Connect EVR solenoid connectors, EGR valve vacuum line, and EGR valve-to-exhaust manifold tube.

Thermostat and Air Cleaner Reconnection

Connect EGR transducer, throttle position sensor connectors, and heater hose.

Final Component and Cable Connections

Connect vacuum lines, accelerator bracket, cables, and install accelerator cable snow shield.

Cooling System and Battery Reconnection

Install air cleaner outlet tube, connect water outlet hose, fill cooling system, and connect battery.