Ford F150 Pickup. Instruction — part 1311

Fig. 108: Removing Fuel Pump Module
Courtesy of FORD MOTOR CO.

FUEL RAILS & INJECTORS

Removal (4.2L)

1. Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE . Remove upper intake manifold.

See INTAKE MANIFOLD under AIR INDUCTION SYSTEMS. Disconnect vacuum hose from fuel
pressure regulator.

2. Disconnect fuel charging wiring harness from fuel rail. See Fig. 109 . Disconnect fuel lines. See FUEL

LINE CONNECTORS . Disconnect wiring harness at fuel injectors. Remove 4 fuel rail bolts. See Fig.
110 . Carefully disengage fuel injectors by lifting and gently rocking rail.

3. Remove injectors from fuel rail, using a slight lifting/rocking motion. Place removed components in a

clean container to avoid dirt or other contamination.

2003 Ford Pickup F150

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

Fig. 109: Disconnecting Fuel Charging Wiring Harness (4.2L)
Courtesy of FORD MOTOR CO.

2003 Ford Pickup F150

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

Fig. 110: Locating Fuel Rail Bolts (4.2L)
Courtesy of FORD MOTOR CO.

Installation

Lubricate NEW injector "O" rings with light oil. DO NOT use silicone grease. Carefully install fuel supply
manifold and injectors into lower manifold, one side at a time. To complete installation, reverse removal
procedure. Tighten fasteners to specification. See TORQUE SPECIFICATIONS .

Removal & Installation (4.6L)

1. Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE . Disconnect negative battery

cable. Partially drain cooling system. Remove the air cleaner outlet pipe. Disconnect the accelerator
cable. Disconnect the speed control cable. Disconnect the return spring.

2. Disconnect the following electrical connectors: Idle Air Control (IAC), Throttle Position (TP) sensor and

Exhaust Gas Recirculation (EGR) vacuum regulator solenoid. Disconnect the vacuum connections on the
right side of the throttle body and the fuel pressure regulator.

3. Disconnect the following vacuum connections: EGR vacuum regulator solenoid and EVAP canister purge

solenoid. Position the vacuum harness aside. Remove the brake booster vacuum tube bracket nut.
Disconnect and position the vacuum tube aside. Disconnect the EGR tube upper fitting. Loosen the EGR
tube lower fitting. Position the EGR tube aside. Remove the coolant hoses from the intake manifold.

4. Remove the Positive Crankcase Ventilation (PCV) valve from the valve cover. Remove the throttle body

adapter retaining bolts. See Fig. 16 . Position the throttle body adapter slightly forward and disconnect the
PCV coolant hose. Remove the throttle body adapter assembly. Disconnect the fuel tube spring lock
coupling. Disconnect the eight fuel injector electrical connectors.

2003 Ford Pickup F150

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

5. Remove the 4 bolts and lift the fuel injection supply manifold and the injectors upward out of the intake

manifold. See Fig. 111 . To install, reverse removal procedure. Tighten fasteners to specification. See
TORQUE SPECIFICATIONS . Bleed cooling system.

Fig. 111: Locating Fuel Injection Supply Manifold Bolts (4.6L)
Courtesy of FORD MOTOR CO.

Removal & Installation (5.4L 2V)

1. Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE . Disconnect negative battery

cable. Remove air cleaner outlet pipe. Disconnect the accelerator cable. Disconnect the speed control
cable. Disconnect the return spring. Remove the air tubes from the throttle body adapter and the valve
cover. See Fig. 112 .

2. Disconnect the vacuum hoses from the Evaporative (EVAP) emission canister purge solenoid and the fuel

pressure regulator. Disconnect the following:

z

Exhaust Gas Recirculation (EGR) tube from the EGR valve.

z

Differential Pressure Feedback EGR (DPFE) vacuum and electrical connections.

z

Throttle Position (TP) sensor electrical connector.

z

EGR vacuum hose.

z

EVAP canister purge solenoid vapor hose at the throttle body adapter.

z

EGR vacuum regulator solenoid electrical and vacuum connections.

z

Vacuum tap at throttle body adapter.

2003 Ford Pickup F150

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