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Home >> Ford >> 2003 >> Excursion 7.3 F, RWD >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 14 (Engine - 6.0L Diesel) >> In-Vehicle Repair >> Intake Manifold >> Installation
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Intake Manifold: Installation

WARNING: This page is about a different variant/trim than selected.
  1. Install the intake manifold gaskets.
    Fig 1: Identifying Intake Manifold Bolts
    G01549451Courtesy of FORD MOTOR CO.
  2. Install the intake manifold and bolts and tighten in the following sequence.
    1. Loosely install the bolts.
    2. Tighten bolts 9-16 to 11 Nm (8 lb-ft).
    3. Tighten all bolts to 11 Nm (8 lb-ft) in the sequence shown.
    Fig 2: Intake Manifold Bolt Tightening Sequence
    G01549452Courtesy of FORD MOTOR CO.
  3. Install the gasket and the EGR cooler V-clamp.
    Fig 3: Tightening EGR Cooler V-Clamp
    G01549453Courtesy of FORD MOTOR CO.
  4. Slide the EGR cooler hose up and rotate flat to lock.
    Fig 4: Sliding EGR Cooler Hose Up
    G01549454Courtesy of FORD MOTOR CO.
  5. Install the turbocharger heat shield and the nuts.
    Fig 5: Installing Heat Shield
    G01549455Courtesy of FORD MOTOR CO.
  6. Install the fuel line.
    • Install new sealing washers.
    • Install the fuel line.
    • Install the banjo fitting and the bolt.
    Fig 6: Installing Fuel Line
    G01549456Courtesy of FORD MOTOR CO.
  7. Install the oil filter return tube and bolt.
    • On new oil filter return tubes, tighten to 6 Nm (53 lb-in).
    • On used oil filter return tubes, tighten to 3 Nm (27 lb-in).
    Fig 7: Installing Oil Filter Return Tube
    G01549457Courtesy of FORD MOTOR CO.
  8. Install the oil filter and the four bolts.
    Fig 8: Installing Oil Filter & Four Bolts
    G01549458Courtesy of FORD MOTOR CO.
  9. Connect the fuel line fittings.
    Fig 9: Tightening Fuel Line Fittings
    G01549459Courtesy of FORD MOTOR CO.
  10. Position the fuel injector harness and install the retaining nut. Connect the eight fuel injectors electrical connectors.
    Fig 10: Installing Fuel Injector Harness
    G01549460Courtesy of FORD MOTOR CO.
  11. Position the engine wiring harness and connect the CMP sensor electrical connector.
    Fig 11: Connecting CMP Sensor Electrical Connector
    G01549461Courtesy of FORD MOTOR CO.
  12. Connect the retaining clip and exhaust backpressure sensor electrical connector.
    Fig 12: Connecting Exhaust Backpressure Sensor Electrical Connector
    G01549462Courtesy of FORD MOTOR CO.
  13. Connect the wiring retainer and the IAT sensor electrical connector.
    Fig 13: Connecting IAT Sensor Electrical Connector
    G01549463Courtesy of FORD MOTOR CO.
  14. Connect the water temperature sensor and the pin-type retainer.
    Fig 14: Connecting Water Temperature Sensor
    G01549464Courtesy of FORD MOTOR CO.
  15. Connect the TP sensor electrical connector.
    Fig 15: Connecting TP Sensor Electrical Connector
    G01549465Courtesy of FORD MOTOR CO.
  16. Connect the TP control module electrical connector, if equipped.
    Fig 16: Connecting TP Control Module Electrical Connector
    G01549466Courtesy of FORD MOTOR CO.
  17. Connect the oil temperature sensor electrical connector.
    Fig 17: Connecting Oil Temperature Sensor Electrical Connector
    G01549467Courtesy of FORD MOTOR CO.
  18. Connect the oil pressure sensor electrical connector.
    Fig 18: Connecting Oil Pressure Sensor Electrical Connector
    G01549468Courtesy of FORD MOTOR CO.
  19. Connect the EGR valve electrical connector.
    Fig 19: Connecting EGR Valve Electrical Connector
    G01549469Courtesy of FORD MOTOR CO.
  20. Connect the wiring retainer, injector pressure regulator and ICP sensor electrical connectors.
    Fig 20: Connecting Injector Pressure Regulator & ICP Sensor Electrical Connectors
    G01549470Courtesy of FORD MOTOR CO.
  21. Connect the 12-pin and 8-pin electrical connectors.
    Fig 21: Connecting 12-Pin & 8-Pin Electrical Connectors
    G01549471Courtesy of FORD MOTOR CO.
  22. Connect the PCM electrical connector.
    Fig 22: Connecting PCM Electrical Connector
    G01549472Courtesy of FORD MOTOR CO.
  23. Install the injector driver module. Refer to INJECTOR DRIVER MODULE .
  24. Connect the engine coolant vent hose and clamp.
    Fig 23: Connecting Engine Coolant Vent Hose & Clamp
    G01549473Courtesy of FORD MOTOR CO.
  25. Connect the MAP sensor hose.
    Fig 24: Connecting MAP Sensor Hose
    G01549474Courtesy of FORD MOTOR CO.
  26. Install the heater hose tube and bolts.
    NOTE: Install a new O-ring on the heater hose tube.
    Fig 25: Installing Heater Hose Tube & Bolts
    G01549475Courtesy of FORD MOTOR CO.
  27. Install the turbocharger pedestal and turbocharger. Refer to TURBOCHARGER and TURBOCHARGER PEDESTAL .
  28. Install the generator and the three bolts.
    Fig 26: Installing Generator & Three Bolts
    G01549476Courtesy of FORD MOTOR CO.
  29. Connect the generator B+ wire and electrical connector and position the boot back.
    Fig 27: Connecting Generator B+ Wire & Electrical Connector
    G01549477Courtesy of FORD MOTOR CO.
  30. Install the accessory drive belt.
    Fig 28: Installing Accessory Drive Belt
    G01549478Courtesy of FORD MOTOR CO.
  31. Install the charge air cooler-to-engine tube.
    NOTE: Engine side shown, charge air cooler side similar.
    Fig 29: Installing Charge Air Cooler-To-Engine Tube
    G01549479Courtesy of FORD MOTOR CO.
  32. Install the turbocharger-to-charge air cooler tube.
    NOTE: Engine side shown, charge air cooler side similar.
    Fig 30: Installing Turbocharger-To-Charge Air Cooler Tube
    G01549480Courtesy of FORD MOTOR CO.
  33. Install the coolant reservoir.
  34. Install the upper radiator hose.
    Fig 31: Installing Upper Radiator Hose
    G01549481Courtesy of FORD MOTOR CO.
  35. Install the LH battery.
  36. Connect both battery ground cables. Refer to DUAL BATTERIES .
  37. Install the air cleaner assembly. Refer to AIR CLEANER .
  38. Install the cooling fan blade, clutch and shroud, 6.0L diesel engine. Refer to COOLING FAN .
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