Ford F150 Pickup. Manual — part 1284

Fig. 7: Intake Manifold Spacer Tightening Sequence (4.2L)
Courtesy of FORD MOTOR CO.

Removal & Installation (4.2L - Lower Intake Manifold)

1. Remove upper intake manifold. See REMOVAL (4.2L - UPPER INTAKE MANIFOLD) . Remove

intake manifold spacer. See REMOVAL & INSTALLATION (4.2L - INTAKE MANIFOLD
SPACER) . Disconnect injector harness connectors. Disconnect wiring harness from fuel supply
manifold. See Fig. 10 . Disconnect EGR valve vacuum hose and upper tube fitting. Disconnect upper
radiator hose from engine. Disconnect fuel lines, IMRC harness connector and fuel pressure regulator
hose.

2. Disconnect by-pass hose and PCV heater hose from lower intake manifold. Remove lower intake

manifold bolts, noting position of short and long bolts. See Fig. 11 . Remove lower intake manifold.
Clean all mating surfaces.

3. To install, apply a bead of silicone gasket and sealant to the intake manifold front and rear end seal

mounting points. See Fig. 8 . Install lower intake manifold front and rear end seals. Apply a bead of
silicone gasket and sealant to the lower intake manifold mounting. See Fig. 9 . Position lower intake
manifold. Install lower manifold with short bolts and long bolts in proper positions. See Fig. 11 . To
complete installation, reverse removal procedure. Tighten fasteners in sequence to specification. See Fig.

2003 Ford Pickup F150

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

12 . See TORQUE SPECIFICATIONS . Fill and bleed the engine cooling system.

Fig. 8: Applying Silicone To Intake Manifold End Seals (4.2L - 1 Of 2)
Courtesy of FORD MOTOR CO.

2003 Ford Pickup F150

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

Fig. 9: Applying Silicone To Intake Manifold End Seals (4.2L - 2 Of 2)
Courtesy of FORD MOTOR CO.

2003 Ford Pickup F150

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

Fig. 10: Removing Wiring Harness From Fuel Injector Supply Manifold (4.2L)
Courtesy of FORD MOTOR CO.

2003 Ford Pickup F150

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