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WARNING: This page is about a different car, the 2007 Ford Pickup, 2007 Ford F550 Super Duty, 2007 Ford F450 Super Duty, and 2007 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: Locating Intake Manifold Gasket And Front Module O-Ring Seal

Courtesy of FORD MOTOR CO.

NOTE: The locating tabs on the gaskets must be up and positioned toward the center of the engine or a leak will occur.

Install the intake manifold gaskets and front module O-ring seal.

Fig 2: Intake Manifold Torque Sequence

Courtesy of FORD MOTOR CO.

Install the intake manifold and bolts and tighten in 3 stages, in the sequence shown.
- Stage 1: Loosely install bolts 1 through 8.
- Stage 2: Tighten bolts 9 through 16 to 11 Nm (8 lb-ft).
- Stage 3: Tighten all bolts to 11 Nm (8 lb-ft).
Position the EGR cooler V-clamp over the EGR tube.

Fig 3: Locating EGR Cooler V-Clamp

Courtesy of FORD MOTOR CO.

Install the gasket and the EGR cooler V-clamp.
- Tighten to 6 Nm (53 lb-in).

Fig 4: EGR Cooler Hose

Courtesy of FORD MOTOR CO.

Slide the EGR cooler hose forward and rotate flat to lock.

Fig 5: Fuel Tube Bolts

Courtesy of FORD MOTOR CO.

Using new sealing washers, install the fuel tube banjo fitting bolt and the support bracket bolt.
- Tighten the fuel tube banjo fitting bolt to 38 Nm (28 lb-ft).
- Tighten the bolt to 13 Nm (10 lb-ft).

Fig 6: Locating Oil Filter Return Tube Bolt

Courtesy of FORD MOTOR CO.

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: Oil Filter Housing Bolts

Courtesy of FORD MOTOR CO.

NOTE: Install a new O-ring seal.

Install the oil filter housing and the 4 bolts.
- Tighten to 15 Nm (11 lb-ft).

Fig 8: Fuel Tube Fittings

Courtesy of FORD MOTOR CO.

NOTE: Install new sealing washers on the banjo fitting.

Connect the fuel tube fittings.
1. Tighten to 26 Nm (19 lb-ft).
2. Tighten to 38 Nm (28 lb-ft).
3. Tighten to 26 Nm (19 lb-ft).
4. Tighten to 43 Nm (32 lb-ft).

Fig 9: Identifying Fuel Injector Electrical Connector & Retainer Clip

Courtesy of FORD MOTOR CO.

Connect the 8 fuel injectors electrical connectors.

Fig 10: Intake Air Temperature (IAT2) Sensor Electrical Connector

Courtesy of FORD MOTOR CO.

Connect the IAT2 sensor electrical connector.

Fig 11: Identifying Pin-Type Retainer And Engine Coolant Temperature (ECT) Sensor Electrical Connector

Courtesy of FORD MOTOR CO.

Connect the ECT sensor and the pin-type retainer.

Fig 12: Locating Engine Oil Temperature Sensor

Courtesy of FORD MOTOR CO.

Connect the EOT sensor electrical connector.

Fig 13: Locating Engine Oil Pressure Sensor Electrical Connector

Courtesy of FORD MOTOR CO.

Connect the EOP sensor electrical connector.

Fig 14: Identifying Exhaust Gas Recirculation (EGR) Valve Electrical Connector

Courtesy of FORD MOTOR CO.

Connect the EGR valve electrical connector.

Fig 15: Wiring Retainer & Injection Pressure Regulator (IPR) Valve Electrical Connectors

Courtesy of FORD MOTOR CO.

Connect the wiring retainer and injector pressure regulator electrical connector. Position back the heat insulating wrap.

Fig 16: Turbocharger Heat Shield Bolts

Courtesy of FORD MOTOR CO.

Position the turbocharger heat shield and install the 3 bolts.
- Tighten to 49 Nm (36 lb-ft).
- Tighten to 11 Nm (8 lb-ft).

Fig 17: Locating Heat Shield Bracket Bolts

Courtesy of FORD MOTOR CO.

Install the heat shield bracket and bolts.

Fig 18: Locating Wiring Retainer

Courtesy of FORD MOTOR CO.

Connect the wiring retainer to the back of the heat shield bracket.

Fig 19: Locating Harness Retainer Nut And Ground Wire Nut

Courtesy of FORD MOTOR CO.

Position back the ground wire and install the retaining nuts.
Install the fuel injector control module. For additional information, refer to ELECTRONIC ENGINE CONTROLS - DIESEL ENGINE article.

Fig 20: Engine Coolant Vent Hose

Courtesy of FORD MOTOR CO.

Connect the engine coolant vent hose and clamp.

Fig 21: Manifold Absolute Pressure (MAP) Sensor Hose

Courtesy of FORD MOTOR CO.

Connect the MAP sensor hose.

Fig 22: Heater Hose Tube & Bolts

Courtesy of FORD MOTOR CO.

NOTE: Install a new O-ring seal on the heater hose tube.

Install the heater hose tube and the 2 bolts.
- Tighten to 13 Nm (10 lb-ft).

Fig 23: Locating Charge Air Cooler Duct Bolt

Courtesy of FORD MOTOR CO.

NOTE: Engine side shown, CAC side similar.

Install the CAC duct and tighten the clamps.
- Tighten to 12 Nm (9 lb-ft).
Install the turbocharger pedestal and turbocharger. For additional information, refer to FUEL CHARGING AND CONTROLS - TURBOCHARGER article.

Fig 24: Identifying Adapter Pipe Bolts

Courtesy of FORD MOTOR CO.

NOTE: Alternately tighten the bolts to specification.

Tighten the nuts and bolts in the adapter pipe.
- Tighten to 27 Nm (20 lb-ft).

Fig 25: Locating Generator Bolts

Courtesy of FORD MOTOR CO.

Install the generator and the 3 bolts.
- Tighten to 47 Nm (35 lb-ft).

Fig 26: Generator B+ Wire & Electrical Connector

Courtesy of FORD MOTOR CO.

Connect the generator B+ wire, the electrical connector and position the boot back.
- Tighten to 8 Nm (71 lb-in).

Fig 1: Charge Air Cooler (CAC) Clamp, Engine Side

Courtesy of FORD MOTOR CO.

NOTE: Engine side shown, CAC side similar.

NOTE: If there is any oil residue, clean both connecting ports and the inside surface of the charge air cooler duct to prevent the duct from blowing off.

Install the turbocharger-to-CAC duct.
- Tighten to 12 Nm (9 lb-ft).

Fig 2: Upper Radiator Hose & Clamp

Courtesy of FORD MOTOR CO.

Connect the upper radiator hose.
Install the degas bottle. For additional information, refer to ENGINE COOLING article.
Install the auxiliary battery. For additional information, refer to BATTERY, MOUNTING AND CABLES article.
Install the cooling fan stator. For additional information, refer to ENGINE COOLING article.