Ford F150 Pickup. Instruction - part 1292

Fig. 35: Disconnecting DPFE System (5.4L 4V) 
Courtesy of FORD MOTOR CO. 

 

2003 Ford Pickup F150 

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

  

Fig. 36: Locating Power Steering Reservoir Bracket Bolts (5.4L 4V) 
Courtesy of FORD MOTOR CO. 

 

2003 Ford Pickup F150 

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

  

Fig. 37: Locating EGR Adapter Bolts (5.4L 4V) 
Courtesy of FORD MOTOR CO. 

 

2003 Ford Pickup F150 

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

  

Fig. 38: Upper Intake Manifold Tightening Sequence (5.4L 4V) 
Courtesy of FORD MOTOR CO. 

Removal & Installation (5.4 4V - Lower Intake Manifold) 

1. Remove upper intake manifold. See REMOVAL & INSTALLATION (5.4L 4V - UPPER INTAKE 

MANIFOLD) . Disconnect the fuel lines. Disconnect the engine water bypass hose. Disconnect the water 
temperature indicator sender electrical connector. See Fig. 39 . Disconnect the upper radiator hose, the 
heated water inlet hose and the heated Positive Crankcase Ventilation (PCV) hose.  

2. Remove the four bolts and the generator upper support bracket. Disconnect the 8 fuel injector electrical 

connectors. Disconnect the vacuum hose from the fuel injector pressure regulator and position the hose 
aside. See 

Fig. 40

 . Disconnect the wiring harness pin type retainer. Remove and discard lower intake 

manifold bolts. Remove lower intake manifold. Remove the bolts and the radio ignition interference 
capacitors. See Fig. 41 . 

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

other abrasive means to clean the sealing surfaces. These tools 
cause scratches and gouges which make leak paths. Lower intake 
gaskets may be reused, if undamaged. Lower intake manifold bolts 
must be replaced.

 

2003 Ford Pickup F150 

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