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Home >> Ford >> 2003 >> Excursion 7.3 F, 4WD >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 16 (Engine - 6.8L) >> 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. Position the lower intake manifold to the upper intake manifold and loosely install the 10 bolts.
    Fig 1: Positioning Lower Intake Manifold To Upper Intake Manifold
    G01544556Courtesy of FORD MOTOR CO.
    2. NOTE: Tighten the bolts in two stages.
    Fig 2: Identifying Bolts Tightening Sequence
    G01544557Courtesy of FORD MOTOR CO.
  2. Tighten the bolts in the sequence shown.
    • Stage 1: Tighten to 2 Nm (18 lb-in).
    • Stage 2: Tighten to 10 Nm (89 lb-in).
  3. If necessary, install the fuel injector supply manifold.
    • Position the fuel injection supply manifold.
    • Install the seven bolts.
    Fig 3: Installing Fuel Injector Supply Manifold
    G01544558Courtesy of FORD MOTOR CO.
  4. Position the water thermostat and housing.
  5. Install the upper intake manifold.
    • Position the upper intake manifold gaskets and the intake manifold, and loosely install the bolts.
    Fig 4: Installing Upper Intake Manifold
    G01544559Courtesy of FORD MOTOR CO.
  6. Tighten the bolts in two stages, in the sequence shown.
    • Stage 1: Tighten to 2 Nm (18 lb-in).
    • Stage 2: Tighten to 25 Nm (18 lb-ft).
    Fig 5: Identifying Bolts Tightening Sequence
    G01544560Courtesy of FORD MOTOR CO.
  7. Connect the cylinder head temperature sensor.
    Fig 6: Connecting Cylinder Head Temperature Sensor
    G01544561Courtesy of FORD MOTOR CO.
  8. Install the LH radio interference capacitor.
    Fig 7: Installing LH Radio Interference Capacitor
    G01544562Courtesy of FORD MOTOR CO.
  9. Connect the fuel lines and the vacuum line to the fuel injection supply manifold.
  10. Install the ignition coils.
    • Position the 10 ignition coils.
    • Install the 10 bolts.
    Fig 8: Installing Ignition Coils
    G01544563Courtesy of FORD MOTOR CO.
  11. Install the generator. Refer to GENERATORS & REGULATORS .
  12. Connect the water temperature indicator sending unit electrical connector.
    Fig 9: Connecting Water Temperature Indicator Sending Unit Electrical Connector
    G01544564Courtesy of FORD MOTOR CO.
  13. Connect the five LH fuel injector electrical connectors and five LH ignition coil connectors.
    Fig 10: Connecting Five LH Fuel Injector Electrical Connectors And Five LH Ignition Coil Connectors
    G01544565Courtesy of FORD MOTOR CO.
  14. If equipped, install the EVR solenoid bracket.
    • Position the bracket.
    • Install the bolts.
    Fig 11: Installing EVR Solenoid Bracket
    G01544566Courtesy of FORD MOTOR CO.
    15. NOTE: The idle air control valve is shown removed for clarity.
    Fig 12: Installing Throttle Body Adapter
    G01544567Courtesy of FORD MOTOR CO.
  15. Install the throttle body adapter.
    • Position a new throttle body adapter gasket.
    • Position the throttle body adapter.
    • Install four bolts and tighten in two stages.
      • Stage 1: Tighten to 9 Nm (80 lb-in).
      • Stage 2: Tighten an additional 85-95 degrees.
    16. NOTE: The EGR valve is shown removed for clarity.
    Fig 13: Connecting EVR Solenoid Vacuum And Electrical Connectors
    G01544568Courtesy of FORD MOTOR CO.
  16. If equipped, connect the EVR solenoid vacuum and electrical connectors.
  17. If equipped, connect the EGR valve vacuum line.
    Fig 14: Connecting EGR Valve Vacuum Line
    G01544569Courtesy of FORD MOTOR CO.
  18. If equipped, install the EGR valve-to-exhaust manifold tube.
    • Hand-tighten the fittings.
    • Tighten the upper fitting to 40-60 Nm (30-44 lb-ft).
    • Tighten the lower fitting to 40-60 Nm (30-44 lb-ft).
    Fig 15: Installing EGR Valve-To-Exhaust Manifold Tube
    G01544570Courtesy of FORD MOTOR CO.
  19. If equipped, install the EGR transducer bracket.
    • Position the bracket.
    • Install the bolts.
    Fig 16: Installing EGR Transducer Bracket
    G01544571Courtesy of FORD MOTOR CO.
  20. If equipped, connect the vacuum lines.
    Fig 17: Connecting Vacuum Lines
    G01544572Courtesy of FORD MOTOR CO.
  21. If equipped, connect the EGR transducer and throttle position sensor electrical connectors.
    Fig 18: Connecting EGR Transducer And Throttle Position Sensor Electrical Connectors
    G01544573Courtesy of FORD MOTOR CO.
  22. Connect the heater hose.
    Fig 19: Connecting Heater Hose
    G01544574Courtesy of FORD MOTOR CO.
  23. Connect the idle air control motor bypass hose and connector.
    Fig 20: Connecting Idle Air Control Motor Bypass Hose And Connector
    G01544575Courtesy of FORD MOTOR CO.
  24. Connect the five RH fuel injector electrical connectors and five RH ignition coil connectors.
    Fig 21: Connecting Five RH Fuel Injector Electrical Connectors And Five RH Ignition Coil Connectors
    G01544576Courtesy of FORD MOTOR CO.
  25. Connect the vacuum line.
    Fig 22: Connecting Vacuum Line
    G01544577Courtesy of FORD MOTOR CO.
  26. Install the RH radio interference capacitor.
    • Position the capacitor.
    • Install the bolt.
    Fig 23: Installing RH Radio Interference Capacitor
    G01544578Courtesy of FORD MOTOR CO.
  27. Connect the vacuum lines to the:
    • brake booster.
    • engine control sensor wiring harness.
    Fig 24: Connecting Vacuum Lines To Brake Booster And Engine Control Sensor Wiring Harness
    G01544579Courtesy of FORD MOTOR CO.
  28. Connect the PCV vacuum and coolant hoses.
    Fig 25: Connecting PCV Vacuum And Coolant Hoses
    G01544580Courtesy of FORD MOTOR CO.
  29. Install the accelerator bracket.
    • Position the bracket.
    • Install the bolts.
    Fig 26: Installing Accelerator Bracket
    G01544581Courtesy of FORD MOTOR CO.
  30. Connect the accelerator and speed control cables and return spring.
    Fig 27: Connecting Accelerator And Speed Control Cables And Return Spring
    G01544582Courtesy of FORD MOTOR CO.
  31. Install the accelerator cable splash shield.
    Fig 28: Installing Accelerator Cable Splash Shield
    G01544583Courtesy of FORD MOTOR CO.
  32. Install the air cleaner outlet tube.
  33. Connect the engine water outlet hose and position the hose clamp.
    Fig 29: Connecting Engine Water Outlet Hose And Positioning Hose Clamp
    G01544584Courtesy of FORD MOTOR CO.
  34. Fill the cooling system. Refer to ENGINE COOLING .
  35. Connect the battery ground cable.
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