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