F 250 2WD Super Duty V10-6.8L (2009)
7. Disconnect the Intake Manifold Runner Control (IMRC) actuator electrical connector.
8. Disconnect the fuel rail pressure and temperature sensor electrical connector and vacuum connector.
9. Disconnect the 10 fuel injector electrical connectors.
10. Disconnect the PCV tube quick connect coupling from the intake manifold.
11. Disconnect the Evaporative Emission (EVAP) tube quick connect coupling from the intake manifold.
12. Disconnect the quick connect coupling and remove the crankcase ventilation tube.
13. Disconnect the wiring harness and vacuum harness retainers from the rear of the intake manifold.
14. Disconnect the engine vacuum hose connections from the rear of the intake manifold and position aside.
15. Disconnect the 2 heated PCV coolant hoses from the intake manifold.
16. Disconnect the Throttle Position (TP) sensor and Electronic Throttle Control (ETC) electrical connectors.
17. Disconnect the engine wiring harness position retainers from the intake manifold.
18. Remove the 12 intake manifold bolts.
19. 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 3 bolts, the engine coolant crossover manifold assembly and discard the 2 gaskets.
-
Clean and inspect the sealing surfaces with silicone gasket remover and Motorcraft metal surface prep. Follow the directions on the packaging.
20. 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 Motorcraft metal surface prep. Follow the directions on the packaging.
Installation
1. 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, position the intake manifold.
2. Using 2 new gaskets, position the engine coolant crossover manifold assembly and install the 3 bolts.
-
Tighten to 10 Nm (89 lb-in).
3. 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).
