Ford 6.0L PowerStroke Intake Removal and Installation Guide

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There are many reasons one would need to remove the intake on a Ford 6.0L Powerstroke engine.  You could be replacing the gaskets, the oil cooler, the high pressure pump, EGR cooler with either an OEM product or an aftermarket EGR Cooler Upgrade, or a complete EGR Delete Kit. You could also be tearing down the engine getting ready to rip the cylinder heads off. No matter the reason, I will take you through this step by step.

There are some things you should be well aware of on the Ford 6.0L Powerstroke Diesel.  There are two distinctive engine designs.  One is referred to as the 2003 engine (all 2003 and early 2004) and the other is the 2004-2007 (up to 2010 E series).  This guide was written with the later design in mind, but several important steps have been inserted concerning the first design. 

Several things are different between designs: EGR cooler, high pressure oil pump and housing, ICP, turbo, intake manifold, oil rail design to name a few.  A quick search on the net will deal you a list detailing every change made for each year.  Double check that any parts you order fit your engine build date.  If in doubt, you can always call your local Ford dealer with your VIN handy.

Some helpful tips while the intake is off: You should remove the IPR to look at the condition of the screen. If the screen is missing, you really should inspect the screen in the high pressure pump reservoir.  The reservoir is located under the oil cooler.  If you are replacing the EGR cooler because it failed, it is wise to replace the oil cooler as well.  The intake gaskets are defined as being reusable, but the large rubber oring under the intake manifold is not. An oil change is recommended after high pressure oil pump or oil cooler replacement.  A quick read through Common 6.0L Problems may be in order.

There is definitely a handful of tools that you will need.  Any pnuematic or power tools can and should be used to save you valuable time and energy, especially air ratchets. Any specialty tools are also listed during the step requiring their use, but most tools required are in basic mechanic tool sets. Check out my article Master Recommended Tool List to see some of the tools I recommend to put in your toolbox.

Make sure your work area is clean and free of large amounts of debris.  Be sure to work in a well ventilated environment that has access to plenty of light.  The more light you have, the better off you are. You will need cleaning supplies like brake clean, carb clean, scrubbing brushes, rags, and maybe even gloves. As you remove everything, you should lay all your bolts out in a neat order.  In this application, you can use the slots located in the cowl (under the wipers) to hold your bolts and nuts but you should be very careful that none fall down into the unprotected engine.  It would be wise to use cardboard or tape to seal open intake ports in the head to protect against expensive accidents.

Here is a list of parts you may want on hand when you remove and replace the intake manifold on the 6.0L Powerstroke...
Sinister Basic Solution Kit - Includes EGR delete, Oil Cooler, all needed gaskets, bolts

Now, onto the project on the next page...

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