2007 Ford Expedition RWDFACTORY OEM SERVICE PROCEDURE

Intake Manifold Assembly: Assembly

  1. Install the engine noise shield insulator onto the intake manifold.
    2. NOTE: Lubricate the new O-ring seal with clean engine oil prior to installation.
  2. Using a new O-ring seal, install the PCV heater element and the 2 bolts.
    • Tighten to 6 Nm (53 lb-in).
  3. Position the CMCV and install the stud bolt and the 2 bolts.
    • Tighten to 10 Nm (89 lb-in).
  4. Install the CMCV rod locking clips.
    5. NOTE: Lubricate the new O-ring seal with clean engine oil prior to installation.
  5. Install new O-ring seals on each of the fuel injectors.
  6. Assemble the fuel injectors onto the fuel rail and install the locking clips.
  7. Install the fuel rail and fuel injector assembly onto the intake manifold.
  8. Install the 4 fuel rail bolts.
    • Tighten to 10 Nm (89 lb-in).
    9. NOTE: Lubricate the TB-to-intake manifold gasket with clean engine coolant prior to installation.
  9. Install the TB, the vibration damper and tighten the bolts in 2 stages.
    • Stage 1: Tighten to 9 Nm (80 lb-in).
    • Stage 2: Tighten an additional 90 degrees.
Factory Service Tools

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.