FixVault
Home › Ford › 2005 › Excursion 5.4 L, RWD › Repair and Diagnosis › External Pages › Different variant/trim › Section 5 (Engine - 6.0L Diesel) › In-Vehicle Repair › Intake Manifold › Installation

Intake Manifold: Installation

WARNING: This page is about a different variant/trim than selected.

    All vehicles 

    NOTE: The locating tabs on the gaskets must be up and toward the center of the engine, or a leak will occur.
    Fig 1: Installing Intake Manifold Gaskets And Front Module O-Ring Seal
    G03887125Courtesy of FORD MOTOR CO.
  1. Install the intake manifold gaskets and front module O-ring seal.
    2. NOTE: To keep the EGR gasket in place when installing the manifold, apply a slight amount of all purpose grease to the mating surface of the EGR cooler.
    NOTE: Install the EGR cooler V-clamp loosely in place on the turbo adapter pipe.
    Fig 2: Tightening Bolts In Sequence
    G03887127Courtesy of FORD MOTOR CO.
  2. Install the intake manifold and loosely install the bolts. Tighten the intake manifold bolts in the sequence shown.
    1. Tighten bolts 9-16 to 11 Nm (8 lb-ft).
    2. Tighten all bolts to 11 Nm (8 lb-ft) in the sequence shown.
    3. NOTE: Do not tighten the clamp.
    Fig 3: Locating Y-Pipe-To-EGR Cooler Clamp
    G03899122Courtesy of FORD MOTOR CO.
  3. Position the EGR cooler V-clamp over the EGR cooler.
  4. If equipped, install the turbocharger heat shield and the nuts.
    Fig 4: Installing Turbocharger Heat Shield Nuts With Torque Specifications
    G03906783Courtesy of FORD MOTOR CO.
  5. Slide the EGR cooler hose forward and rotate flat to lock.
    Fig 5: Sliding EGR Cooler Hose Forward
    G03906784Courtesy 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 With Torque Specifications
    G03906785Courtesy 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 Bolt
    G04519770Courtesy of FORD MOTOR CO.
  8. Install the oil filter housing and the 4 bolts.
    • Clean and inspect the housing O-rings. Install new O-rings if necessary.
    Fig 8: Installing O-Ring With Torque Specifications
    G03906787Courtesy of FORD MOTOR CO.
    9. NOTE: Install new sealing washers on the banjo fitting.
    Fig 9: Connecting Fuel Line Fittings With Torque Specifications
    G03906788Courtesy of FORD MOTOR CO.
  9. Connect the fuel line fittings.
  10. Position the ground wire and install the retaining nut. Connect the 8 fuel injectors electrical connectors.
    Fig 10: Connecting Fuel Injectors Electrical Connectors With Torque Specifications
    G03906789Courtesy of FORD MOTOR CO.
  11. Connect the exhaust pressure sensor electrical connector.
    Fig 11: Connecting Exhaust Pressure Sensor Electrical Connector
    G03906769Courtesy of FORD MOTOR CO.
  12. Connect the IAT2 sensor electrical connector.
    Fig 12: Connecting Sensor Electrical Connector
    G03906768Courtesy of FORD MOTOR CO.
  13. Connect the engine coolant temperature (ECT) sensor and the pin-type retainer.
    Fig 13: Connecting Engine Coolant Temperature Sensor And Pin-Type Retainer
    G03887109Courtesy of FORD MOTOR CO.
  14. If equipped, connect the EGR throttle position sensor electrical connector.
    Fig 14: Connecting EGR Throttle Position Sensor Electrical Connector
    G03906793Courtesy of FORD MOTOR CO.
  15. If equipped, connect the EGR throttle position control module electrical connector.
    Fig 15: Connecting EGR Throttle Position Control Module Electrical Connector
    G03906765Courtesy of FORD MOTOR CO.
  16. Connect the engine oil temperature (EOT) sensor electrical connector.
    Fig 16: Locating Engine Oil Temperature Sensor
    G03887108Courtesy of FORD MOTOR CO.
  17. Connect the engine oil pressure (EOP) sensor electrical connector.
    Fig 17: Locating Engine Oil Pressure Sensor Electrical Connector
    G03887107Courtesy of FORD MOTOR CO.
  18. Connect the EGR valve electrical connector.
    Fig 18: Locating EGR Valve Assembly Electrical Connector
    G03887106Courtesy of FORD MOTOR CO.
  19. Connect the wiring retainer and IPR valve electrical connector. Position back the heat insulating wrap.
    Fig 19: Connecting Wiring Retainer And IPR Valve Electrical Connector
    G03906761Courtesy of FORD MOTOR CO.
    20. NOTE: Early build shown, late build similar.
    Fig 20: Installing Bolts With Torque Specifications
    G03906799Courtesy of FORD MOTOR CO.
  20. Install the top 2 bolts to the injector IPR heat shield.
  21. If equipped with a heat shield bracket, install the heat shield bracket and bolts.
    Fig 21: Locating Bolts And Heat Shield Bracket
    G03906759Courtesy of FORD MOTOR CO.
  22. If equipped with a heat shield bracket, connect the wiring retainer to the back of the heat shield bracket.
    Fig 22: Locating Wiring Retainer At Back Of Heat Shield Bracket
    G03906758Courtesy of FORD MOTOR CO.
  23. If equipped with a heat shield bracket, position back the ground wire and install the retaining nuts.
    Fig 23: Identifying Ground Wire Retaining Nuts
    G03906757Courtesy of FORD MOTOR CO.
  24. Install the fuel injector control module. For additional information, refer to ELECTRONIC ENGINE CONTROLS - DIESEL ENGINE .
  25. Connect the engine coolant vent hose and clamp.
    Fig 24: Installing Fuel Injector Control Module
    G03906756Courtesy of FORD MOTOR CO.
  26. Connect the MAP sensor hose.
    Fig 25: Connecting MAP Sensor Hose
    G03906804Courtesy of FORD MOTOR CO.
    27. NOTE: Install a new O-ring on the heater hose tube.
    Fig 26: Installing Heater Hose Tube Bolts With Torque Specifications
    G03906805Courtesy of FORD MOTOR CO.
  27. Install the heater hose tube and bolts.
    28. NOTE: Engine side shown, charge air cooler side similar.
    Fig 27: Charge Air Cooler Duct And Clamp With Torque Specification
    G03906806Courtesy of FORD MOTOR CO.
  28. Install the charge air cooler duct and tighten the clamp.
  29. Install the turbocharger pedestal and turbocharger. For additional information, refer to FUEL CHARGING & CONTROLS - TURBOCHARGER .
  30. Install the generator and the 3 bolts.
    Fig 28: Generator And Bolts With Torque Specification
    G03906807Courtesy of FORD MOTOR CO.
  31. Connect the generator B+ wire land electrical connector and position the boot back.
    Fig 29: Connecting Generator B+ Wire Land Electrical Connector With Torque Specifications
    G03906808Courtesy of FORD MOTOR CO.

    Vehicles with single generator

  32. Install the accessory drive belt.
    Fig 30: Rotating Accessory Drive Belt Tensioner Clockwise
    G03906750Courtesy of FORD MOTOR CO.

    Vehicles with dual generators

  33. Install the generator with mounting bracket and bolts.
    Fig 31: Locating Bolts And Generator Mounting Bracket With Torque Specification
    G03887159Courtesy of FORD MOTOR CO.
  34. Connect the B+ wire, generator electrical connector and wire retainer.
    Fig 32: Locating Generator Electrical Connector, Harness and Retainer With Torque Specification
    G03906811Courtesy of FORD MOTOR CO.
  35. Install the accessory drive belt tensioner and bolts.
    Fig 33: Primary Accessory Drive Belt Tensioner Bolts With Torque Specification
    G03887161Courtesy of FORD MOTOR CO.
  36. Position the accessory drive belt idler pulley. Install the bracket and bolts.
    Fig 34: Secondary Accessory Drive Belt Idler Pulley Bolts With Torque Specification
    G03887162Courtesy of FORD MOTOR CO.
  37. Install the accessory drive belt.
    Fig 35: Rotating Accessory Drive Belt Tensioner Clockwise
    G03887088Courtesy of FORD MOTOR CO.
  38. Install the accessory drive belt tensioner and bolt.
    Fig 36: Secondary Accessory Drive Belt Tensioner Bolt With Torque Specification
    G03907183Courtesy of FORD MOTOR CO.
  39. Install the accessory drive belt.
    Fig 37: Rotating Drive Belt Tensioner Clockwise
    G03887086Courtesy of FORD MOTOR CO.

    40. All vehicles 

    NOTE: Engine side shown, charge air cooler side similar.
    Fig 38: Turbocharger-To-Charge Air Cooler Duct Clamp With Torque Specification
    G03907177Courtesy of FORD MOTOR CO.
  40. Install the turbocharger-to-charge air cooler duct.
  41. Install the upper radiator hose.
    Fig 39: Installing Upper Radiator Hose
    G03906741Courtesy of FORD MOTOR CO.
  42. Install the degas bottle. For additional information, refer to ENGINE COOLING .
  43. Install the auxiliary battery. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  44. Install the cooling fan stator - 6.0L diesel engine. For additional information, refer to ENGINE COOLING .
About FixVault