Ford F150 Pickup. Instruction — part 1288

Fig. 21: Exploded View Of Intake Manifold (4.6L - 2 Of 2)
Courtesy of FORD MOTOR CO.

2003 Ford Pickup F150

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

Fig. 22: Lower Intake Manifold Tightening Sequence (4.6L)
Courtesy of FORD MOTOR CO.

Removal & Installation (5.4L 2V)

2003 Ford Pickup F150

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

1. Disconnect the battery ground cable. Remove the air cleaner outlet pipe. Drain the engine cooling system.

Compress the hose clamp and disconnect the upper radiator hose. Disconnect the accelerator cable.
Disconnect the speed control actuator cable. Remove the accelerator return spring.

2. Remove the accelerator cable bracket bolts and position the bracket and cables aside. Disconnect the

climate control vacuum hose. See Fig. 14 . Disconnect the Positive Crankcase Ventilation (PCV) hose
from the throttle body adapter. See Fig. 23 . Disconnect the heated throttle body outlet hose from the
throttle body adapter. Disconnect the PCV hose from the intake manifold. Remove the PCV valve.
Position the heated PCV hose harness aside.

3. Disconnect the heater hose. Disconnect the heated throttle body inlet hose. Disconnect the Throttle

Position (TP) sensor electrical connector, and the Exhaust Gas Recirculation (EGR) vacuum regulator
solenoid electrical and vacuum connectors. Disconnect the evaporative emission canister purge valve
hose. Disconnect the EGR valve vacuum hose.

4. Disconnect the main vacuum harness from the throttle body adapter. Remove the Idle Air Control (IAC)

valve fresh air tube. Disconnect the IAC electrical connector. Disconnect the fuel pressure regulator
vacuum hose. Disconnect the evaporative emission canister purge valve vacuum hose and remove the
vacuum harness. See Fig. 24 . Disconnect the fuel hose spring lock coupling. Disconnect the differential
pressure feedback EGR system electrical connector.

5. Remove the bolt and disconnect the brake booster vacuum tube. Position the bracket and tube aside.

Position the crankcase ventilation tube aside. Disconnect the upper exhaust manifold-to-EGR valve tube
fitting. Loosen the lower fitting. Disconnect the 2 Differential Pressure Feedback EGR (DPFE) system
hoses. Position the tube aside.

6. Remove the DPFE system bracket bolt. See Fig. 25 . Remove the 4 bolts and the throttle body adapter.

See Fig. 26 . Discard the throttle body adapter gasket. Remove the power steering reservoir upper
mounting bracket. See Fig. 27 . Disconnect and remove the 8 ignition coils. Disconnect the 8 fuel
injectors.

7. Rotate the belt tensioner clockwise and detach the drive belt from the generator pulley. Loosen the

generator lower mounting bolts. Disconnect the generator harness routing clip. Remove the generator
upper mounting bracket bolts. Position the generator aside. Remove the bolts, water thermostat housing
and the thermostat. Discard the "O" ring seal. Remove the 9 intake manifold bolts. Remove the intake
manifold. Discard the intake manifold gaskets.

8. Install the intake manifold. Position the new intake manifold gaskets. Position the intake manifold.

Loosely install 9 bolts. Install the thermostat with a new "O" ring seal. Install the thermostat housing and
loosely install the bolts. Tighten the 11 bolts in two stages in the sequence shown. See Fig. 19 . See
TORQUE SPECIFICATIONS . To complete installation, reverse removal procedure.

2003 Ford Pickup F150

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

Fig. 23: Locating PCV Hose & Heated Throttle Body Outlet Hose (5.4L 2V)
Courtesy of FORD MOTOR CO.

2003 Ford Pickup F150

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