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Home >> Ford >> 2003 >> Cutaway 7.3 F >> Repair and Diagnosis >> External Pages >> Different car >> Section 2471 (Engine Mechanical - 6.4L 99R Diesel -- F250-F550 Super Duty) >> In-Vehicle Repair >> Intake Manifold - Body Off >> Installation

Intake Manifold - Body Off: Installation

WARNING: This page is about a different car, the 2010 Ford Pickup, 2010 Ford F550 Super Duty, 2010 Ford F450 Super Duty, and 2010 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 in the illustration.
    • Stage 1: Loosely assemble all bolts in the sequence shown in the illustration.
    • Stage 2: Tighten to 11 Nm (97 lb-in).
      Fig 1: Identifying Intake Manifold Bolts Tightening Sequence
      G06774082Courtesy of FORD MOTOR CO.
    3. 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 sealing washers and the 2 banjo bolts at the cylinder heads.
    • For Viton® sealing washers, tighten to 25 Nm (18 lb-ft).
    • For copper sealing washer, tighten to 38 Nm (28 lb-ft).
      Fig 2: Locating Fuel Injector Return Tube Banjo Bolts And Sealing Washers
      G06774081Courtesy of FORD MOTOR CO.
  4. Install the 2 bolts for the fuel injector return tube.
    • Tighten to 13 Nm (115 lb-in).
      Fig 3: Locating Fuel Injector Return Tube Retainer Bolts
      G06774080Courtesy of FORD MOTOR CO.
  5. Install the nut on the fuel injector return tube bracket.
    • Tighten to 11 Nm (97 lb-in).
      Fig 4: Locating Fuel Injector Return Tube Bracket Nut
      G06774079Courtesy of FORD MOTOR CO.
  6. Install the fuel filter module and 3 bolts.
    • Tighten to 13 Nm (115 lb-in).
      Fig 5: Locating Fuel Filter Module Bolts
      G06778014Courtesy of FORD MOTOR CO.
    7. 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 sealing washers and the banjo bolts at the fuel filter module.
    • For M14 banjo bolt with Viton® sealing washers, tighten to 28 Nm (21 lb-ft).
    • For M14 banjo bolt with copper sealing washer, tighten to 47 Nm (35 lb-ft).
    • For M12 banjo bolt with Viton® sealing washers, tighten to 25 Nm (18 lb-ft).
    • For M12 banjo bolt with copper sealing washer, tighten to 38 Nm (28 lb-ft).
      Fig 6: Locating Fuel Supply Banjo Bolts And Fuel Filter Module Return Tubes
      G06778013Courtesy of FORD MOTOR CO.
    8. 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).
      Fig 7: Locating Nut, Bolt And RH Heater Supply Tube
      G06778012Courtesy of FORD MOTOR CO.
  9. Install the glow plug module bracket and 3 bolts.
    • Tighten to 13 Nm (115 lb-in).
      Fig 8: Locating Glow Plug Module Bracket Bolts
      G06774075Courtesy of FORD MOTOR CO.
    10. 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).
      Fig 9: Locating Heater Supply Tube Bolt
      G06778330Courtesy of FORD MOTOR CO.
  11. Connect the glow plug module electrical connectors and the pin-type retainers.
    Fig 10: Locating Glow Plug Module Electrical Connectors And Pin-Type Retainers
    G06774073Courtesy of FORD MOTOR CO.
  12. Connect the LH fuel charging harness electrical connector and pushpin retainer.
    Fig 11: Locating LH Fuel Charging Harness Electrical Connector And Pushpin Retainer
    G06778010Courtesy of FORD MOTOR CO.
    13. 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).
      Fig 12: Locating Engine Oil Temperature And Engine Oil Pressure Electrical Connectors
      G06774071Courtesy of FORD MOTOR CO.
  14. Connect the ECT  sensor electrical connector and wire retainer.
    Fig 13: Locating ECT Sensor Electrical Connector And Wire Retainer
    G06778008Courtesy of FORD MOTOR CO.
  15. Connect the fuel temperature sensor electrical connector.
    Fig 14: Locating Fuel Temperature Sensor Electrical Connector
    G06774069Courtesy of FORD MOTOR CO.
  16. Connect the RH fuel charging harness electrical connector and wire retainer. Connect the IAT2  and MAP  sensor electrical connector.
    Fig 15: Locating Intake Air Temperature 2 And Manifold Absolute Pressure Sensor Electrical Connectors
    G06778006Courtesy of FORD MOTOR CO.
  17. Connect the pin-type retainers to the crankcase vent oil separator tube.
    Fig 16: Locating Crankcase Vent Oil Separator Tube Pin-Type Retainer
    G06774067Courtesy of FORD MOTOR CO.
  18. Install a new press-in-place gasket. Install the intake throttle adapter and loosely install the 4 bolts.
    Fig 17: Locating Intake Throttle Adapter Bolts
    G06778005Courtesy of FORD MOTOR CO.
  19. Connect the EGR valve and TB  electrical connectors.
    Fig 18: Locating EGR Valve And Throttle Body Electrical Connectors
    G06774065Courtesy of FORD MOTOR CO.
    20. NOTE: Install a new horizontal EGR cooler gasket prior to installing the vertical EGR cooler.
    Fig 19: Locating Vertical EGR Cooler Assembly Bolts
    G06778003Courtesy of FORD MOTOR CO.
  20. Position the vertical EGR cooler assembly and loosely install the 5 bolts.
  21. Install a new vertical EGR cooler gasket and the stud.
    • Tighten to 17 Nm (150 lb-in).
      Fig 20: Locating Vertical EGR Cooler Stud
      G06778002Courtesy of FORD MOTOR CO.
  22. Install the nut and bolt for the vertical EGR cooler.
    • Tighten to 31 Nm (23 lb-ft).
      Fig 21: Locating Vertical EGR Cooler Nut And Bolt
      G06778001Courtesy of FORD MOTOR CO.
  23. Connect the EGRT  sensor electrical connector.
    Fig 22: Locating Exhaust Gas Recirculation Temperature Sensor Electrical Connector
    G06778000Courtesy of FORD MOTOR CO.
  24. Connect the coolant hose to the vertical EGR cooler.
    Fig 23: Locating Vertical EGR Cooler Coolant Hose Clamp
    G06777999Courtesy of FORD MOTOR CO.
    25. 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).
      Fig 24: Locating Vertical EGR Cooler Retaining Nuts
      G06777998Courtesy of FORD MOTOR CO.
    26. 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).
      Fig 25: Locating EGR Cooler Hose Clamp
      G06777997Courtesy 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).
      Fig 26: Locating Vertical EGR Cooler Assembly Bolts
      G06778003Courtesy of FORD MOTOR CO.
    28. NOTE: Vertical EGR cooler removed from art for clarity.
  28. Tighten the 4 bolts for the intake throttle adapter.
    • Tighten to 10 Nm (89 lb-in).
      Fig 27: Locating Intake Throttle Adapter Bolts
      G06778005Courtesy of FORD MOTOR CO.
    29. NOTE: Install a new O-ring seal.
  29. Install the EGR cooler coolant tube and bolt.
    • Tighten to 10 Nm (89 lb-in).
      Fig 28: Locating EGR Cooler Coolant Tube Bolt
      G06777996Courtesy of FORD MOTOR CO.
    30. 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).
      Fig 29: Locating Nuts, Bolts And FEAD Assembly
      G06777995Courtesy of FORD MOTOR CO.
    31. 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).
      Fig 30: Locating Power Steering Pump Bolts
      G06777994Courtesy of FORD MOTOR CO.
  32. Install the retaining nut for the power steering hose and tube.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 31: Locating Power Steering Hoses Retaining Nut
      G06774112Courtesy of FORD MOTOR CO.
  33. If equipped, install the A/C drive belt.
    Fig 32: Locating A/C Drive Belt
    G06777986Courtesy of FORD MOTOR CO.
  34. Install the accessory drive belt.
    Fig 33: Locating Accessory Drive Belt
    G06777985Courtesy of FORD MOTOR CO.
  35. Install the engine cooling fan stator, 2 nuts and 2 bolts.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 34: Locating Engine Cooling Fan Stator Nuts And Bolts
      G06774051Courtesy of FORD MOTOR CO.
    36. 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).
      Fig 35: Removing Engine Cooling Fan Using Fan Clutch Nut Wrench And Fan Hub Nut Wrench
      G06774050Courtesy of FORD MOTOR CO.
  37. Install the cooling fan electrical connector into the stator. Connect the electrical connector for the engine cooling fan.
    Fig 36: Locating Engine Cooling Fan Electrical Connector And Tabs
    G06774049Courtesy of FORD MOTOR CO.
    38. NOTE: Use a back-up wrench to prevent the fittings in the high-pressure fuel injection pump from turning. If the fittings move, the high-pressure fuel injection pump fittings must be retightened. Refer to Fuel Injection Pump Fitting Re-Torque in FUEL CHARGING AND CONTROLS - 6.4L DIESEL .
    NOTE: It will be necessary to use a thin or low profile wrench to hold the fittings on the high-pressure fuel injection pump.
  38. Install new 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.
    • For Viton® sealing washers, tighten to 25 Nm (18 lb-ft).
    • For copper sealing washer, tighten to 38 Nm (28 lb-ft).
      Fig 37: Locating High-Pressure Fuel Injection Pump Nuts And Sealing Washers
      G06774048Courtesy of FORD MOTOR CO.
  39. Install the 2 retaining nuts for the fuel injection pump supply tube.
    • Tighten to 11 Nm (97 lb-in).
      Fig 38: Locating High-Pressure Fuel Injection Pump Supply Tube Retaining Nuts
      G06774047Courtesy of FORD MOTOR CO.
  40. Position back and connect the pin-type retainer. Connect the high-pressure fuel injection pump electrical connector.
    Fig 39: Locating High-Pressure Fuel Injection Pump Electrical Connector
    G06777992Courtesy of FORD MOTOR CO.
    41. NOTE: Use a crowfoot wrench to aid in tightening the fitting.
  41. Connect the fuel injector return tube at the check valve.
    • Calculate the correct torque wrench setting for the following torque. Refer to the illustration.   . See Fig 40.
      Fig 40: Torque Wrench Adapter Formulas
      G00468730
    • Tighten to 28 Nm (21 lb-ft).
      Fig 41: Locating Fuel Injector Return Tube At Check Valve
      G06777871Courtesy of FORD MOTOR CO.
  42. Install the 2 bolts for the fuel rail supply tube retainers.
    • Tighten to 13 Nm (115 lb-in).
      Fig 42: Locating Fuel Rail Supply Tube Retainers Bolts
      G06774044Courtesy of FORD MOTOR CO.
    43. 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.
  43. 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).
      Fig 43: Locating High-Pressure Fuel Injection Pump Heat Shield Bolt And Retaining Nuts
      G06774043Courtesy of FORD MOTOR CO.
    44. NOTE: Use a socket to aid in installing the pushnuts.
    Fig 44: Locating Glow Plug Module Heat Shield Pushnuts
    G06777990Courtesy of FORD MOTOR CO.
  44. Position the glow plug module cover and install the 3 new pushnuts.
    45. NOTE: Install a new press-in-place gasket.
  45. Install the crankcase vent oil separator and 4 bolts.
    • Tighten to 13 Nm (115 lb-in).
      Fig 45: Locating Crankcase Vent Oil Separator Bolts
      G06777988Courtesy of FORD MOTOR CO.
  46. Connect the crankcase vent oil separator tube.
    Fig 46: Locating Crankcase Vent Oil Separator Tube Clamp
    G06778116Courtesy of FORD MOTOR CO.
  47. Install the turbocharger. Carry out the Turbocharger - Body Off procedure. For additional information, refer to FUEL CHARGING AND CONTROLS - TURBOCHARGER .
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