Ford F150 Pickup. Manual — part 1290

Fig. 28: Exploded View Of Intake Manifold Components (5.4L 2V)
Courtesy of FORD MOTOR CO.

Removal & Installation (5.4L 4V - Upper Intake Manifold)

2003 Ford Pickup F150

2003 ENGINE PERFORMANCE Removal & Installation - Blackwood, Expedition, F150 Pickup & Navigator - Gasoline

1. Disconnect the battery ground cable. Remove the cowl grille. Remove the bolts and five clips and the

wiring harness shield. See Fig. 29 . Remove the air cleaner outlet tube. Disconnect the Mass Airflow
(MAF) sensor electrical connector and remove the air cleaner assembly. Partially drain the cooling
system. Remove the engine cover.

2. Disconnect the accelerator cable, speed control cable, and the return spring. Remove the bolts and

position the cables and bracket aside. See Fig. 30 . Disconnect Evaporative (EVAP) emission return line,
Positive Crankcase Ventilation (PCV) tube and coolant lines. See Fig. 31 . Disconnect the electrical
connector from the intake tuning valve. See Fig. 32 . Remove the bolts, stud and balance tube. See Fig.
33 .

3. Use a plastic scraping tool to remove all traces of old sealant. Remove and discard the gaskets and clean

the sealing surfaces. Disconnect the Throttle Position (TP) sensor. Disconnect the Idle Air Control (IAC)
valve. Disconnect the vacuum lines and the electrical connector from the EGR Vacuum Regulator (EVR)
valve. See Fig. 34 . Disconnect the two hoses and the electrical connector from the Differential Pressure
Feedback EGR (DPFE). See Fig. 35 . Remove the EGR valve nut and bolts. Remove the bolts from
power steering reservoir bracket, located at the front side of the left cylinder head and position aside. See
Fig. 36 .

4. Remove the stud and position the oil fill tube aside. Disconnect the brake booster vacuum line and other

vacuum lines and position vacuum harness aside. Remove the bolts from the EGR adapter. See Fig. 37 .
Remove and discard upper intake retaining bolts. Remove upper intake manifold and gaskets.

5. Install the upper intake manifold gaskets. Position the upper intake manifold and loosely install NEW

bolts. Tighten upper intake manifold bolts in sequence to specification. See Fig. 38 . See TORQUE
SPECIFICATIONS . To complete installation, reverse removal procedure.

CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or

other abrasive means to clean the sealing surfaces. These tools
cause scratches and gouges which make leak paths. Upper intake
gasket may be reused, if undamaged. Upper intake manifold bolts
must be replaced.

2003 Ford Pickup F150

2003 ENGINE PERFORMANCE Removal & Installation - Blackwood, Expedition, F150 Pickup & Navigator - Gasoline

Fig. 29: Locating Wiring Harness Shield Retainers (5.4L 4V)
Courtesy of FORD MOTOR CO.

2003 Ford Pickup F150

2003 ENGINE PERFORMANCE Removal & Installation - Blackwood, Expedition, F150 Pickup & Navigator - Gasoline

Fig. 30: Locating Accelerator Cable Bracket Bolts (5.4L 4V)
Courtesy of FORD MOTOR CO.

2003 Ford Pickup F150

2003 ENGINE PERFORMANCE Removal & Installation - Blackwood, Expedition, F150 Pickup & Navigator - Gasoline