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Home >> Ford >> 2002 >> Cutaway 7.3 F >> Repair and Diagnosis >> External Pages >> Different car >> Section 2436 (Engine - 6.4L 99R Diesel -- F250-F550 Super Duty) >> In-Vehicle Servicing >> Intake Manifold - Body Off >> Installation

Intake Manifold - Body Off: Installation

WARNING: This page is about a different car, the 2008 Ford Pickup, 2008 Ford F550 Super Duty, 2008 Ford F450 Super Duty, and 2008 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.
    NOTE: The locating tabs on the gaskets must be up and positioned toward the center of the engine or a leak will occur.
  1. Install the intake manifold gaskets.
  2. Position the fuel return tube, if removed. Install the intake manifold and 16 bolts and tighten in 2 stages, in the sequence shown.
    • Stage 1: Loosely assemble all bolts in the sequence shown.
    • Stage 2: Tighten to 11 Nm (97 lb-in).
    3. Fig 1: Installing Intake Manifold Bolts In Sequence
    GF0048484Courtesy of FORD MOTOR CO.
    NOTE: Only use banjo bolts with a green hex head. The green-headed bolts do not contain a check valve. When viewed from the inner end, the correct bolt will appear open. Failure to install the correct banjo bolt may result in damage to the high-pressure fuel injection pump.
    NOTE: Remove the caps and plugs as needed.
  3. Position the fuel injector return tube. Install new copper sealing washers and the 2 banjo bolts at the cylinder heads.
    • Tighten to 38 Nm (28 lb-ft).
    4. Fig 2: Locating LH & RH Banjo Bolts & Copper Sealing Washers
    GF0048483Courtesy of FORD MOTOR CO.
  4. Install the 2 bolts for the fuel injector return tube.
    • Tighten to 13 Nm (115 lb-in).
    5. Fig 3: Locating Fuel Injector Return Tube Retainer Bolts
    GF0048482Courtesy of FORD MOTOR CO.
  5. Install the nut on the fuel injector return tube bracket.
    • Tighten to 11 Nm (97 lb-in).
    6. Fig 4: Locating Nut For Fuel Injector Return Tube Bracket
    GF0048481Courtesy of FORD MOTOR CO.
  6. Install the fuel filter module and 3 bolts.
    • Tighten to 13 Nm (115 lb-in).
    7. Fig 5: Locating Fuel Filter Module Bolts
    GF0048480Courtesy of FORD MOTOR CO.
    NOTE: Only use banjo bolts with a green hex head. The green-headed bolts do not contain a check valve. When viewed from the inner end, the correct bolt will appear open. Failure to install the correct banjo bolt may result in damage to the high-pressure fuel injection pump.
    NOTE: Remove the Fuel System Caps as needed.
  7. Install new copper sealing washers and the banjo bolts at the fuel filter module.
    • Tighten the M14 banjo bolt to 47 Nm (35 lb-ft).
    • Tighten the M12 banjo bolt to 38 Nm (28 lb-ft).
    8. Fig 6: Locating Copper Sealing Washers
    GF0048479Courtesy of FORD MOTOR CO.
    NOTE: Do not bend or flex the heater supply tube or damage to the tube may occur.
    NOTE: Install a new O-ring seal.
  8. Install the RH heater supply tube, bolt and nut.
    • Tighten to 13 Nm (115 lb-in).
    9. Fig 7: Locating Nut, Bolt & RH Heater Supply Tube
    GF0048478Courtesy of FORD MOTOR CO.
  9. Install the glow plug module bracket and 3 bolts.
    • Tighten to 13 Nm (115 lb-in).
    10. Fig 8: Locating Glow Plug Module Bracket Bolts
    GF0048477Courtesy of FORD MOTOR CO.
    NOTE: The engine harness must be positioned between the glow plug module bracket and the heater supply tube.
  10. Position the engine wiring harness and install the heater supply tube bolt.
    • Tighten to 13 Nm (115 lb-in).
    11. Fig 9: Locating Heater Supply Tube Bolt & Engine Wiring Harness
    GF0048476Courtesy of FORD MOTOR CO.
  11. Connect the glow plug module electrical connectors and the pin-type retainers.
    12. Fig 10: Locating Glow Plug Module Electrical Connectors
    GF0048475Courtesy of FORD MOTOR CO.
  12. Connect the LH fuel charging harness electrical connector and push pin retainer.
    13. Fig 11: Locating LH Fuel Charging Harness Electrical Connector & Push Pin Retainer
    GF0048474Courtesy of FORD MOTOR CO.
    NOTE: Make sure the engine harness is positioned on the stud at the fuel filter prior to installing the bolt.
  13. Install the bolt for the engine wire harness. Connect the EOP and EOT sensor electrical connectors.
    • Tighten to 8 Nm (71 lb-in).
    14. Fig 12: Locating Engine Oil Temperature (EOT) & Engine Oil Pressure (EOP) Electrical Connectors
    GF0048473Courtesy of FORD MOTOR CO.
  14. Connect the ECT sensor electrical connector and wire retainer.
    15. Fig 13: Locating ECT Sensor Electrical Connector & Wire Retainer
    GF0048472Courtesy of FORD MOTOR CO.
  15. Connect the fuel temperature sensor electrical connector.
    16. Fig 14: Locating Fuel Temperature Sensor Electrical Connector
    GF0048471Courtesy of FORD MOTOR CO.
  16. Connect the RH fuel charging harness electrical connector and wire retainer. Connect the IAT2 and MAP sensor electrical connector.
    17. Fig 15: Locating Intake Air Temperature 2 (IAT2) & Manifold Absolute Pressure (MAP) Sensor Electrical Connectors
    GF0048470Courtesy of FORD MOTOR CO.
  17. Connect the pin-type retainers to the crankcase vent oil separator tube.
    18. Fig 16: Locating Pin-Type Retainer From Crankcase Vent Oil Separator Tub
    GF0048469Courtesy of FORD MOTOR CO.
  18. Install a new press-in-place gasket. Install the intake throttle adapter and loosely install the 4 bolts.
    19. Fig 17: Locating Intake Throttle Adapter Bolts
    GF0048468Courtesy of FORD MOTOR CO.
  19. Connect the EGR valve and TB electrical connectors.
    20. Fig 18: Locating EGR Valve And Throttle Body (TB) Electrical Connectors
    GF0048467Courtesy of FORD MOTOR CO.
    NOTE: Install a new horizontal EGR cooler gasket prior to installing the vertical EGR cooler.
  20. Position the vertical EGR cooler assembly and loosely install the 5 bolts.
    21. Fig 19: Locating Vertical EGR Cooler Assembly Bolts
    GF0048466Courtesy of FORD MOTOR CO.
  21. Install a new vertical EGR cooler gasket and the stud.
    • Tighten to 31 Nm (23 lb-ft).
    22. Fig 20: Locating Vertical EGR Cooler Stud
    GF0048465Courtesy of FORD MOTOR CO.
  22. Install the nut and bolt for the vertical EGR cooler.
    • Tighten to 31 Nm (23 lb-ft).
    23. Fig 21: Locating Nut & Bolt For Vertical EGR Cooler
    GF0048464Courtesy of FORD MOTOR CO.
  23. Install the retaining clip and retaining nut on the stud.
    • Tighten to 12 Nm (106 lb-in).
    24. Fig 22: Locating Retaining Nut & Retaining Clip
    GF0048463Courtesy of FORD MOTOR CO.
  24. Connect the EGRT sensor electrical connector. Connect the EGR cooler hose and connect to the retaining clips.
    • Tighten to 4 Nm (35 lb-in).
    25. Fig 23: Locating Hose & Retaining Clips At Vertical EGR Cooler
    GF0048462Courtesy of FORD MOTOR CO.
    NOTE: Do not bend or twist the exhaust gas recirculation (EGR) cooler bellows or damage to the EGR cooler may occur.
    NOTE: Inspect the corrugation of the vertical EGR cooler inlet to make sure that the corrugation ribs are not touching and are not damaged.
  25. Install the 2 nuts for the vertical EGR cooler.
    • Tighten to 31 Nm (23 lb-ft).
    26. Fig 24: Locating Retaining Nuts For Vertical EGR Cooler
    GF0048461Courtesy of FORD MOTOR CO.
    NOTE: The coolant hose clamps used on this engine are constant tension worm gear clamps. Standard worm gear clamps cannot be used. Failure to use the correct coolant hose clamps may result in hose joint failure.
    NOTE: Install a new clamp on the EGR cooler hose.
  26. Connect the EGR cooler hose and tighten the clamp.
    • Tighten to 4 Nm (35 lb-in).
    27. Fig 25: Locating EGR Cooler Hose
    GF0048460Courtesy of FORD MOTOR CO.
  27. Tighten the 5 vertical EGR cooler mounting bracket bolts.
    • Tighten the M8 bolts to 31 Nm (23 lb-ft).
    • Tighten the M10 bolt to 62 Nm (46 lb-ft).
    28. Fig 26: Locating Vertical EGR Cooler Assembly Bolts
    GF0048466Courtesy of FORD MOTOR CO.
    NOTE: Vertical EGR cooler removed for clarity.
  28. Tighten the 4 bolts for the intake throttle adapter.
    • Tighten to 10 Nm (89 lb-in).
    29. Fig 27: Locating Intake Throttle Adapter Bolts
    GF0048468Courtesy of FORD MOTOR CO.
    NOTE: Install a new O-ring seal.
  29. Install the EGR cooler coolant tube and bolt.
    • Tighten to 10 Nm (89 lb-in).
    30. Fig 28: Locating EGR Cooler Coolant Tube & Bolt
    GF0048459Courtesy of FORD MOTOR CO.
    NOTE: It may be necessary to position the tensioner to install the lower bolt. Install the lower bolt last.
  30. Position back the FEAD assembly. Install the 2 nuts and 2 bolts.
    • Tighten to 47 Nm (35 lb-ft).
    31. Fig 29: Locating Nuts, Bolts & FEAD Assembly
    GF0048458Courtesy of FORD MOTOR CO.
    NOTE: Raise the supply tube up to clear the ECT sensor connector when repositioning the power steering pump.
    NOTE: Make sure the power steering pressure tube retainer is on the retaining stud prior to tightening the bolts for the power steering pump.
  31. Install the power steering pump and 3 bolts.
    • Tighten to 25 Nm (18 lb-ft).
    32. Fig 30: Locating Power Steering Pump Bolts
    GF0048457Courtesy of FORD MOTOR CO.
  32. Install the retaining nut for the power steering hose and tube.
    • Tighten to 25 Nm (18 lb-ft).
    33. Fig 31: Locating Retaining Nut For Power Steering Hoses
    GF0048456Courtesy of FORD MOTOR CO.
  33. If equipped, install the A/C drive belt.
    34. Fig 32: Locating Belt From Bottom Of A/C Clutch Pulley
    GF0048455Courtesy of FORD MOTOR CO.
  34. Install the accessory drive belt.
    35. Fig 33: Locating Accessory Drive Belt
    GF0048454Courtesy of FORD MOTOR CO.
  35. Install the engine cooling fan stator, 2 nuts and 2 bolts.
    • Tighten to 25 Nm (18 lb-ft).
    36. Fig 34: Locating Nuts, Bolts & Engine Cooling Fan Stator
    GF0048453Courtesy of FORD MOTOR CO.
    NOTE: The cooling fan has a LH thread.
  36. Using the Fan Clutch Nut Wrench and Fan Hub Nut Wrench, install the engine cooling fan.
    • Tighten to 150 Nm (111 lb-ft).
    37. Fig 35: Removing Engine Cooling Fan Using Fan Clutch Nut Wrench & Fan Hub Nut Wrench
    GF0048452Courtesy of FORD MOTOR CO.
  37. If equipped, connect the pin-type retainer to the engine cooling fan stator.
    38. Fig 36: Locating Pin-Type Retainer From Engine Cooling Fan Stator
    GF0048451Courtesy of FORD MOTOR CO.
  38. Install the cooling fan electrical connector into the stator. Connect the electrical connector for the engine cooling fan.
    39. Fig 37: Locating Electrical Connector For Engine Cooling Fan
    GF0048450Courtesy of FORD MOTOR CO.
    NOTE: Use a back-up wrench on the high-pressure fuel injection pump fittings.
  39. Install new copper sealing washers, high-pressure fuel injection pump supply tube, high-pressure fuel injection pump-to-fuel cooler return tube and nuts at the high-pressure fuel injection pump.
    • Tighten to 38 Nm (28 lb-ft).
    40. Fig 38: Locating Nuts & Copper Sealing Washers For High-Pressure Fuel Injection Pump
    GF0048449Courtesy of FORD MOTOR CO.
  40. Install the 2 retaining nuts for the fuel injection pump supply tube.
    • Tighten to 11 Nm (97 lb-in).
    41. Fig 39: Locating Retaining Nuts For High-Pressure Fuel Injection Pump Supply Tub
    GF0048448Courtesy of FORD MOTOR CO.
  41. Position back and connect the pin-type retainer. Connect the high-pressure fuel injection pump electrical connector.
    42. Fig 40: Locating High-Pressure Fuel Injection Pump Electrical Connector
    GF0048447Courtesy of FORD MOTOR CO.
  42. Connect the fuel injector return tube at the check valve.
    • Calculate the correct torque wrench setting for the following torque.
    • Tighten to 28 Nm (21 lb-ft).
    43. Fig 41: Locating Fuel Injector Return Tube At Check Valve
    GF0048446Courtesy of FORD MOTOR CO.
  43. Install the 2 bolts for the fuel rail supply tube retainers.
    • Tighten to 13 Nm (115 lb-in).
    44. Fig 42: Locating Fuel Rail Supply Tube Retainers Bolts
    GF0048445Courtesy of FORD MOTOR CO.
    NOTE: Failure to correctly install the fuel pump heat shield may result in engine damage.
    NOTE: Make sure the ground strap is mounted on the stud closest to the glow plug module.
  44. Position the high-pressure fuel injection pump heat shield, ground strap and fuel tube bracket. Install the bolt and 5 retaining nuts.
    • Tighten the fuel line bracket nuts to 7 Nm (62 lb-in).
    • Tighten the remaining fasteners to 13 Nm (115 lb-in).
    45. Fig 43: Locating Bolt & Retaining Nuts
    GF0048444Courtesy of FORD MOTOR CO.
    NOTE: Use a socket to aid in installing the push nuts.
  45. Position the glow plug module cover and install the 3 new push nuts.
    46. Fig 44: Locating Push Nuts On Glow Plug Module Heat Shield
    GF0048443Courtesy of FORD MOTOR CO.
    NOTE: Install a new press-in-place gasket.
  46. Install the crankcase vent oil separator and 4 bolts.
    • Tighten to 13 Nm (115 lb-in).
    47. Fig 45: Locating Crankcase Vent Oil Separator Bolts
    GF0048442Courtesy of FORD MOTOR CO.
  47. Connect the crankcase vent oil separator tube.
    48. Fig 46: Locating Crankcase Vent Oil Separator Tube From Crankcase Vent Oil Separator
    GF0048441Courtesy of FORD MOTOR CO.
  48. Install the turbocharger. Carry out the Turbocharger - Body Off procedure. For additional information, refer to FUEL CHARGING AND CONTROLS - TURBOCHARGER article.
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