Ford F150 Pickup. Instruction — part 984

Fig. 818: Separating Upper & Lower Intake Manifolds - 4.6L

2003 Ford Pickup F150

2003 ENGINE Engine - 4.6L & 5.4L - F150 Pickup

Courtesy of FORD MOTOR CO.

7. Remove the bolts from the intake manifold tuning valve and remove the valve.

Fig. 819: Removing Intake Manifold Tuning Valve - 4.6L
Courtesy of FORD MOTOR CO.

8. Inspect all external and internal surfaces of the upper intake manifold.

Inspect for cracks or other damage.

Inspect for foreign material inside of the manifold.

Clean the upper intake manifold sealing surfaces with silicone gasket remover and
metal surface prep. Follow the directions on the packaging.

CAUTION: If the engine has been internally damaged and metal or

other foreign material has entered the manifold, it is
recommended the manifold be discarded.

NOTE:

If there is no residual gasket material present, metal surface
prep can be used to clean and prepare the sealing surfaces.

2003 Ford Pickup F150

2003 ENGINE Engine - 4.6L & 5.4L - F150 Pickup

9. Allow the upper and lower intake manifolds to dry completely.

Assembly

1. Position the intake manifold tuning valve and install the bolts.

Fig. 820: Positioning Intake Manifold Tuning Valve - 4.6L
Courtesy of FORD MOTOR CO.

2. Position a new lower intake manifold gasket and the upper intake manifold on the lower

intake manifold and loosely install the bolts.

2003 Ford Pickup F150

2003 ENGINE Engine - 4.6L & 5.4L - F150 Pickup

Fig. 821: Installing Upper Intake Manifold On Lower Intake Manifold - 4.6L

2003 Ford Pickup F150

2003 ENGINE Engine - 4.6L & 5.4L - F150 Pickup