Genuine 2001 Ford Excursion Intake Manifold

2001 Ford Excursion Intake Manifold Parts Questions & Experts Answers

• Q: How to remove and install the intake manifold in diesel engine on 2001 Ford Excursion?

  A: To remove the components, first disconnect the cable from the negative battery terminal and, if applicable, remove the auxiliary battery. Next, take out the cooling fan and fan stator, which requires removing the drive belt; if there are two alternators, also remove the extra drive belts, belt tensioners, and idler pulleys. Proceed to remove the alternator(s) and, if there are two, the auxiliary alternator mounting bracket. Drain the coolant and take out the coolant reservoir, and for 6.4L engines, remove the clamps securing the power steering hoses to the intake manifold, then unbolt and set aside the power steering pump. Remove the upper radiator hose, the turbocharger-to-intercooler duct, the turbocharger and its mount, and the intercooler duct from the intake manifold. Remove the two bolts from the heater coolant tube at the front of the manifold and move it aside. Disconnect the manifold absolute pressure sensor, engine oil pressure sensor, exhaust gas recirculation valve connector, engine oil temperature sensor, engine coolant temperature sensor, intake air temperature sensor, and, if equipped, the exhaust pressure sensor. Disconnect the coolant vent hose and set it aside, then remove the fuel injection control module and the fuel injection pressure regulator heat shield, pulling back the heat wrap to disconnect the wiring connectors beneath it. Disconnect the wiring from all eight fuel injectors, pull back the wiring harnesses, and set them aside. Disconnect the fuel lines from the fuel filter, ensuring to replace the sealing washers with new ones upon reassembly, and remove the fuel filter. Remove the oil filter, unbolt the oil filter housing, and take it out, followed by the mounting bolt and the oil filter return tube. Remove the steel fuel line from the top of the intake manifold and, for 6.4L engines, the bolts securing the fuel rails. Disconnect the EGR coolant hose by pulling the EGR cooler clamp forward, twisting it to align the flat edge with the line on the supply housing, and sliding the hose to the rear. Loosen the fasteners on both sides of the turbocharger pipe and the V-clamp on the EGR cooler line, which will stay with the turbocharger pipe upon removal. Finally, remove the intake manifold bolts and lift the manifold off the engine. For installation, thoroughly clean all sealing surfaces, install new intake manifold gaskets with the tabs up and toward the middle of the engine, and place a new O-ring at the front module. Use a little grease to hold the EGR gasket in place during assembly and set the EGR cooler V-clamp loosely on the turbocharger pipe. Install the manifold and tighten the bolts in two steps to the specified torque, following the correct tightening sequence. The remainder of the installation is the reverse of removal, ensuring to install new sealing washers on the fuel and oil line banjo fittings.