LEMON Manuals: Even more car manuals for everyone: 1960-2025
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 >> Removal
April 5, 2026: LEMON Manuals is launched! Read the announcement.

Intake Manifold: Removal

WARNING: This page is about a different variant/trim than selected.
  1. Disconnect the LH and RH battery ground cables. Refer to DUAL BATTERIES .
  2. Remove the LH battery.
  3. Remove the air cleaner assembly. Refer to AIR CLEANER .
  4. Remove the cooling fan-blade, clutch and shroud, 6.0L diesel engine. Refer to COOLING FAN .
  5. Remove the upper radiator hose.
    Fig 1: Identifying Upper Radiator Hose Retainer
    G01549419Courtesy of FORD MOTOR CO.
  6. Remove the coolant reservoir. Partially drain cooling system. Disconnect engine vent hose and radiator overflow hose. Disconnect the degas bottle supply hose. Remove the bolts and the degas bottle.
  7. Remove the turbocharger-to-charge air cooler tube.
    NOTE: Engine side shown, charge air cooler side similar.
    Fig 2: Identifying Turbocharger-To-Charge Air Cooler Tube Clamp
    G01549421Courtesy of FORD MOTOR CO.
  8. Remove the charge air cooler-to-engine tube.
    NOTE: Engine side shown, charge air cooler side similar.
    Fig 3: Identifying Charge Air Cooler-To-Engine Tube
    G01549422Courtesy of FORD MOTOR CO.
  9. Remove the accessory drive belt.
    Fig 4: Removing Accessory Drive Belt
    G01549423Courtesy of FORD MOTOR CO.
  10. Position the boot back and disconnect the generator B+ wire and electrical connector.
    Fig 5: Identifying Generator B+ Wire Boot & Electrical Connector
    G01549424Courtesy of FORD MOTOR CO.
  11. Remove the three bolts and the generator.
    Fig 6: Identifying Generator Bolts
    G01549425Courtesy of FORD MOTOR CO.
  12. Remove the turbocharger and the turbocharger pedestal. Refer to TURBOCHARGER .
  13. Remove the bolts and position the heater hose tube aside.
    • Remove and discard the O-ring.
    Fig 7: Identifying Heater Hose Tube Bolt
    G01549426Courtesy of FORD MOTOR CO.
  14. Disconnect the manifold absolute pressure (MAP) sensor hose.
    Fig 8: Identifying MAP Sensor Hose
    G01549427Courtesy of FORD MOTOR CO.
  15. Disconnect the engine coolant vent hose.
    Fig 9: Identifying Engine Coolant Vent Hose
    G01549428Courtesy of FORD MOTOR CO.
  16. Remove the injector driver module. Refer to INJECTOR DRIVER MODULE .
  17. Disconnect the powertrain control module (PCM) electrical connector.
    Fig 10: Identifying PCM Electrical Connector
    G01549429Courtesy of FORD MOTOR CO.
  18. Disconnect the 12-pin and 8-pin electrical connector.
    Fig 11: Identifying 12-Pin & 8-Pin Electrical Connector
    G01549430Courtesy of FORD MOTOR CO.
  19. Disconnect the wiring retainer, injector pressure regulator and injector control pressure (ICP) sensor electrical connector.
    Fig 12: Identifying Injector Pressure Regulator & Injector Control Pressure Sensor Electrical Connector
    G01549431Courtesy of FORD MOTOR CO.
  20. Disconnect the exhaust gas recirculation (EGR) valve electrical connector.
    Fig 13: Disconnecting EGR valve electrical connector
    G01549432Courtesy of FORD MOTOR CO.
  21. Disconnect the oil pressure sensor electrical connector.
    Fig 14: Disconnecting Oil Pressure Sensor Connector
    G01549433Courtesy of FORD MOTOR CO.
  22. Disconnect the oil temperature sensor electrical connector.
    Fig 15: Disconnecting Oil Temperature Sensor Connector
    G01549434Courtesy of FORD MOTOR CO.
  23. Disconnect the throttle position (TP) control module electrical connector, if equipped.
    Fig 16: Disconnecting Throttle Position Control Module Electrical Connector
    G01549435Courtesy of FORD MOTOR CO.
  24. Disconnect the throttle position (TP) sensor electrical connector.
    Fig 17: Disconnecting Throttle Position Sensor Electrical Connector
    G01549436Courtesy of FORD MOTOR CO.
  25. Disconnect the pin-type retainer and water temperature sensor.
    Fig 18: Identifying Water Temperature Sensor
    G01549437Courtesy of FORD MOTOR CO.
  26. Disconnect the intake air temperature (IAT) sensor electrical connector and wiring connector.
    Fig 19: Disconnecting Intake Air Temperature Sensor Electrical Connector
    G01549438Courtesy of FORD MOTOR CO.
  27. Disconnect the exhaust backpressure sensor and retaining clip.
    Fig 20: Disconnecting Exhaust Backpressure Sensor & Retaining Clip
    G01549439Courtesy of FORD MOTOR CO.
  28. Disconnect the camshaft position (CMP) sensor and position the engine wiring harness aside.
    Fig 21: Disconnecting Camshaft Position Sensor
    G01549440Courtesy of FORD MOTOR CO.
  29. Disconnect the eight fuel injectors. Remove the nut and the fuel injector wiring harness.
    NOTE: Left side shown, right side similar.
    Fig 22: Removing Fuel Injector Harness
    G01549441Courtesy of FORD MOTOR CO.
  30. Disconnect the fuel line fittings.
    Fig 23: Identifying Fuel Line Fittings
    G01549442Courtesy of FORD MOTOR CO.
  31. Remove the four bolts and the oil filter housing.
    NOTE: It is necessary to remove the filter and drain the housing.
    Fig 24: Identifying Oil Filter Housing
    G01549443Courtesy of FORD MOTOR CO.
  32. Remove the bolt and the oil filter return tube.
    Fig 25: Identifying Oil Filter Return Tube
    G01549444Courtesy of FORD MOTOR CO.
  33. Remove the fuel line.
    • Remove the bolt, and the banjo fitting from the fuel line.
    • Discard the sealing washers and remove the fuel line.
    Fig 26: Removing Fuel Line
    G01549445Courtesy of FORD MOTOR CO.
  34. Remove the nuts and the turbocharger heat shield.
    Fig 27: Removing Turbocharger Heat Shield
    G01549446Courtesy of FORD MOTOR CO.
  35. Twist the EGR cooler clamp and slide the EGR cooler hose down.
    NOTE: Align the flat edge with the index feature located on the coolant supply port.
    Fig 28: Removing EGR Cooler Hose
    G01549447Courtesy of FORD MOTOR CO.
  36. Remove the EGR cooler V-clamp and gasket.
    NOTE: Intake removed for clarity.
    Fig 29: Removing EGR Cooler V-Clamp & Gasket
    G01549448Courtesy of FORD MOTOR CO.
  37. Remove the bolts and the intake manifold.
    Fig 30: Identifying Intake Manifold Bolts
    G01549449Courtesy of FORD MOTOR CO.
  38. Remove the intake manifold gaskets.
    • Clean and inspect the gaskets. Replace if necessary.
    • Clean and inspect the sealing surfaces.
    Fig 31: Identifying Intake Manifold Bolts
    G01549450Courtesy of FORD MOTOR CO.
scientia non olet · About LEMON Manuals