Ford F150 Pickup. Instruction — part 1285

Fig. 11: Identifying Short & Long Bolt Locations (4.2L)
Courtesy of FORD MOTOR CO.

2003 Ford Pickup F150

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

Fig. 12: Lower Intake Manifold Tightening Sequence (4.2L)
Courtesy of FORD MOTOR CO.

Removal & Installation (4.6L)

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

Remove upper radiator hose. Remove appearance cover mounting bracket, if equipped.

2. Disconnect the accelerator cable, speed control actuator cable and accelerator return spring. Remove the

accelerator cable bracket bolts and position the bracket and cables aside. See Fig. 13 . Disconnect the
main vacuum harness. Disconnect the fuel pressure regulator vacuum hose. Disconnect the climate
control vacuum hose. See Fig. 14 . Remove the Idle Air Control (IAC) fresh air hose.

3. Disconnect the Exhaust Gas Recirculation (EGR) vacuum regulator solenoid connections. Disconnect the

IAC and Throttle Position (TP) sensor electrical connectors. See Fig. 15 . Disconnect the EGR valve
vacuum hose and the evaporative emission canister purge valve hose and position them aside. Disconnect
the evaporative emission canister purge valve vacuum hose and remove the vacuum harness.

4. Remove the nut and disconnect the brake booster vacuum tube. Position the bracket and tube aside.

Position the crankcase ventilation hose aside. Disconnect differential pressure feedback EGR system
electrical connector. Disconnect the upper exhaust manifold to EGR valve tube fitting. Loosen the lower
fitting and position the tube aside.

2003 Ford Pickup F150

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

5. Relieve fuel system pressure. See FUEL SYSTEM PRESSURE RELEASE under FUEL SYSTEMS.

Disconnect the fuel hose spring lock coupling. See FUEL LINE CONNECTORS under FUEL
SYSTEMS. Disconnect the heater hose and the heated throttle body hose. Disconnect the Positive
Crankcase Ventilation (PCV) hose.

6. Remove the four bolts and move the throttle body adapter forward slightly. See Fig. 16 . Disconnect the

heated throttle body hose and remove the throttle body adapter. Discard the throttle body adapter-to-
intake manifold gasket. Inspect the throttle body and adapter for damage. Remove power steering
reservoir upper mounting bracket. See Fig. 17 . Remove 8 ignition coils. See IGNITION COILS under
IGNITION SYSTEMS. Disconnect fuel injector harness connectors.

7. Remove drive belt from the alternator pulley. Remove generator upper mounting bracket. Remove

generator lower mounting bolts and position generator aside. Relieve fuel system pressure. See FUEL
SYSTEM PRESSURE RELEASE under FUEL SYSTEMS. Remove thermostat housing. Discard
thermostat housing "O" ring seal.

8. Remove nine intake manifold bolts. Lift the intake manifold (1). See Fig. 18 . Disconnect intake manifold

tuning valve connector (2). Remove intake manifold assembly. Discard the gaskets (3). Inspect the intake
manifold assembly for damage. Clean all the sealing surfaces.

9. Position the new intake manifold gaskets. Position intake manifold. Loosely install nine intake manifold

bolts. Connect the intake manifold tuning valve electrical connector. Install the thermostat housing using
a NEW "O" ring seal and loosely install the bolts. Tighten fasteners in sequence. See Fig. 19 . See
TORQUE SPECIFICATIONS .

10. To complete installation, reverse removal procedure. Install the exhaust manifold to EGR valve tube

hand-tight. Tighten upper fitting, then lower fitting. Fill and bleed the engine cooling system.

CAUTION: Do not use metal scrapers, power abrasive discs or any abrasive

means to clean the sealing surfaces, these tools cause scratches and
gouges that make leak paths. Use a plastic scraper only.

NOTE:

The thermostat housing bolts are tightened in sequence with the intake
manifold bolts.

2003 Ford Pickup F150

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

Fig. 13: Locating Accelerator Cable Bracket Bolts (4.6L)
Courtesy of FORD MOTOR CO.

2003 Ford Pickup F150

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