2003 Ford Excursion Service and Repair Manual

This factory service and repair manual for the 2003 Ford Excursion has four engines on its list: two turbocharged OHV V8 diesels, the 6.0-liter and the 7.3-liter, alongside the naturally aspirated 6.8-liter SOHC V10 and 5.4-liter SOHC V8 on gasoline. Three trims are covered, Eddie Bauer, Limited and XLT, on the four-door sport utility body. Two diesel families in one year means two sets of injection, starting and charging figures, and the manual keeps their specifications, torque values, wiring diagrams and diagnostics apart.

Engines covered

• 6.0L V8 (363 cu in) — OHV, turbocharged, diesel
• 6.8L V10 (415 cu in) — SOHC, naturally aspirated, gasoline
• 7.3L V8 (445 cu in) — OHV, turbocharged, diesel
• 5.4L V8 (330 cu in) — SOHC, naturally aspirated, gasoline

Body styles covered

• 4-door sport utility

Trims covered

• Eddie Bauer
• Limited
• XLT

Known issues on the 2003 Excursion. Five recalls are on federal record for this year. On 6.0-liter diesel trucks the engine ground stud attaching the negative battery terminal to the block could be loose, letting current pass through the radio suppression strap until it heated and melted. On 7.3-liter diesels the camshaft position sensor could work intermittently and stall the engine. The speed control deactivation switch accounts for two more, and a tail lamp campaign for the fifth. Owners have filed 146 complaints with NHTSA, headed by the electrical system and engine and cooling, the same ground the wiring diagrams and engine diagnostics cover.