Ford F150 Pickup. Instruction — part 1121
Courtesy of FORD MOTOR CO.
Fig. 7: Exhaust System Components - Lightning & Harley Davidson Supercab
Courtesy of FORD MOTOR CO.
2003 Ford Pickup F150
2003 ENGINE Exhaust - F150 Pickup
Fig. 8: Exhaust System Co Exhaust System Components - Harley Davidson SuperCrew
Courtesy of FORD MOTOR CO.
DIAGNOSIS & TESTING
EXHAUST SYSTEM
Inspection & Verification
1. Verify the customer's concern by running the engine or road testing the vehicle to duplicate the condition.
2. Visually inspect for obvious signs of mechanical and electrical damage. Refer to the following chart.
2003 Ford Pickup F150
2003 ENGINE Exhaust - F150 Pickup
Fig. 9: Visual Inspection Chart
Courtesy of FORD MOTOR CO.
3. If the fault is not visually evident, determine the symptom and GO to SYMPTOM CHART .
SYMPTOM CHART
Fig. 10: Exhaust System Symptom Chart
Courtesy of FORD MOTOR CO.
GENERAL PROCEDURES
EXHAUST SYSTEM ALIGNMENT
1. Raise and support the vehicle. For additional information, refer to JACKING & HOISTING
2. Check for loose, damaged, or missing heat shields. Install new heat shields as necessary. Check for any
trapped debris between the heat shields and the exhaust system components.
3. Loosen all exhaust component fasteners and clamps from the exhaust manifolds to muffler inlet pipe.
NOTE:
Make sure the exhaust insulators are hanging straight up and down and
2003 Ford Pickup F150
2003 ENGINE Exhaust - F150 Pickup
4. Beginning at the front of the vehicle, align the exhaust system to establish the maximum clearance. Make
sure the muffler extension pipe and the muffler inlet pipe are pushed all the way into the preceding pipe
and the notches are correctly lined up with the tabs.
5. Beginning at the front of the vehicle, tighten all fasteners and clamps to specification. For additional
information, refer to SPECIFICATIONS .
6. Start the engine and check the exhaust system for leaks.
REMOVAL & INSTALLATION
DUAL CONVERTER Y-PIPE - RH & LH
Removal & Installation
All Vehicles
1. Raise and support the vehicle. For additional information, refer to JACKING & HOISTING .
2. Remove the muffler and tail pipe assembly and, if equipped, the muffler extension pipe.
Vehicles With 4.6L And 5.4L Engines
3. Disconnect the HO2S and the catalyst monitor sensor.
are free to move.
NOTE:
To ease the removal and installation of the exhaust components, lubricate the
insulators using Aerosol Silicone Lubricant F5AZ-19553-AA or equivalent
meeting Ford Specification ESR-M13P4-A.
NOTE:
On the 4.2L engine, the two upstream Heated Oxygen Sensors (HO2S) are
located on the exhaust manifolds (9430) and do not need to be removed.
2003 Ford Pickup F150
2003 ENGINE Exhaust - F150 Pickup
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