OEM 2003 Ford Excursion Intake Manifold

2003 Ford Excursion Intake Manifold Parts Questions & Experts Answers

• Q: How to service the intake manifold on 2003 Ford Excursion?

  A: Your service process for the intake manifold starts with disconnecting the battery ground cable followed by draining the coolant system. First remove the air cleaner outlet tube after which you should slide and compress the hose clamp to disconnect the water outlet hose together with the accelerator cable splash shield. Service access begins by pumping the fuel system pressure then taking off the accelerator and speed control cables and the return spring. First separate the accelerator cable bracket from its position before taking out the bolts to disconnect the PCV vacuum and coolant hoses and the vacuum lines for brake booster and engine sensor control wiring harness. At the beginning of the right-hand bolt removal step position the radio interference capacitor aside before disconnecting the vacuum line followed by the five right-hand fuel injector and ignition coil electrical connectors. The technician disconnects the idle air control motor electrical connector together with both the bypass hose and heater hose. The installation process requires disconnection of throttle position sensor and EGR transducer connectors and removal of the EGR transducer vacuum lines along with its bracket from the vehicle. Afterward, position the EGR valve to the exhaust manifold tube. The upper fitting should be disconnected while the lower fitting needs loosening before disconnecting the EGR valve vacuum line when installed. Start by removing the throttle body adapter through four bolt removal along with its gasket then detach the brackets with bolts from the EVR unit when present. Follow this procedure to disconnect the left-hand fuel injector and ignition coil connectors as well as the water temperature indicator sender unit electrical connectors and generator and ignition coils by removing their ten bolts. Begin the disconnection of the fuel injection supply manifold by removing fuel lines together with the vacuum connector from the fuel pressure regulator and then remove and set aside the capacitor. The GCT sensor must disconnect first, then the water thermostat and its housing before the upper intake manifold can be removed together with its intake manifold gaskets. Discard all gaskets. The fuel injection supply manifold can be removed by unbolt the four fasteners followed by disconnecting upper and lower intake manifolds by taking out their ten bolts. Cleaning the aluminum retainer plate must be done without metal scrapers or abrasive tools. The installation process begins with placing the bottom intake manifold onto the top intake manifold before attaching the ten bolts just enough for a first-stage 2 Nm (18 inch lbs.) torque then tightening them to 10 Nm (89 inch lbs.). You should install the fuel injector supply manifold by using seven bolts followed by positioning the water thermostat and housing. The final stage of installation includes the upper intake manifold and its gaskets requiring two-step bolt tightening at 2 Nm (18 inch lbs.) first and 25 Nm (18 ft. lbs.) ultimately. Connect the cylinder head temperature sensor after installing the left-hand radio interference capacitor and attaching both fuel lines and vacuum lines to the fuel injection supply manifold. The installation requires ten bolts to mount the ignition coils along with reinstallation of the generator and connection of the water temperature indicator sending unit electrical connector. The left-hand fuel injector and ignition coil connectors should be connected together and if fitted the EVR solenoid bracket requires installation after fitting its bolts. The throttle body adapter requires new gasket installation followed by installation of four bolts which need two-step tightening where the first step reaches 9 Nm (80 inch lbs.) then adds an additional 85 - 95 degrees. You should install the EGR valve-to-exhaust manifold tube followed by fastening its upper and lower fittings to 40 - 60 Nm (30 - 44 ft. lbs.) torque. Additionally, connect the EVR solenoid vacuum and electrical connectors with the EGR valve vacuum line if available. Fitting the EGR transducer bracket requires attaching all vacuum lines together with EGR transducer and throttle position sensor electrical connectors. The heater hose installation should be followed by attaching the idle air control motor bypass hose and connector and five right-hand fuel injector and ignition coil connectors. Furthermore, finish the installation by connecting the vacuum line then installing the right-hand radio interference capacitor before joining vacuum lines to brake booster and engine control sensor wiring harness. Add PCV vacuum and coolant hoses. Set up the accelerator bracket along with cables and their splash shield and the air cleaner outlet tube and lastly the engine water outlet hose and cooling system and battery ground cable. The procedure for the left-hand valve cover begins by selecting the battery ground cable for removal then proceeding to eliminate the engine air cleaner alongside the outlet tube and the crankcase ventilation tube from the valve cover. To begin the replacement process disconnect both the fuel injector and ignition coil wires from the left-hand side followed by nut removal from the engine harness bracket and lifting of the fuel charging wiring off the valve cover studs. Following plastic scraping of all sealing surfaces you can remove the left-hand valve cover while checking the gasket and cleaning the cylinder head mating surface. Place silicone gasket sealant around the engine front cover to cylinder head junction then put in place the valve cover with its gasket before installing the bolts with lightweight tension. In the specified order tighten valve cover bolts while placing fuel charging wiring across the studs followed by reconnecting left-side electrical components. Attach the crankcase ventilation tube and install the engine bracket after securing retaining nuts. Then reconnect the engine air cleaner along with its outlet tube followed by the battery ground cable transmission.