Removal (5.4L)

WARNING: This page is about a different car, the 2003 Ford Pickup, 2003 Ford F550 Super Duty, 2003 Ford F450 Super Duty, 2003 Ford Excursion, and 2003 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

Disconnect the battery ground cable. Relieve the fuel system pressure. See FUEL SYSTEM PRESSURE RELEASE under FUEL SYSTEMS. Drain the engine cooling system.
Disconnect the Idle Air Control (IAC) fresh air tube and crankcase ventilation tube from the air cleaner outlet pipe. Loosen the clamp and disconnect the air cleaner outlet pipe from the throttle body. Release the clamp and separate the air cleaner outlet housing from the air cleaner inlet housing.
Disconnect the Mass Air Flow (MAF) sensor electrical connector and remove the air cleaner, air cleaner outlet housing and the air cleaner outlet pipe from the vehicle. Compress and slide the hose clamp and disconnect the upper radiator hose. Rotate the belt tensioner and remove the belt from the generator pulley.
Remove the harness routing clips from the generator stud and the engine front cover. Remove the generator upper mounting bracket stud and bolt. See Fig 1. Remove the generator lower mounting bolts and position the generator aside. See Fig 2. Remove the accelerator control splash shield. See Fig 3. Disconnect the accelerator cable. If equipped, disconnect the speed control cable. Remove the throttle return spring. Remove the accelerator cable bracket bolts. See Fig 4. Position the accelerator cable bracket aside.
Disconnect the Throttle Position (TP) sensor electrical connector. Release the IAC fresh air tube from the routing clip and remove it from the vehicle. Disconnect the evaporative emission canister purge valve vacuum hose from the throttle body adapter. See Fig 5. Disconnect the brake booster vacuum hose and main vacuum harness from the throttle body adapter. Disconnect the IAC electrical connector.
On vehicles with an EGR system, disconnect the upper EGR tube fitting. See Fig 6. Loosen the lower fitting. Position the exhaust manifold to EGR valve tube aside. Remove the Differential Pressure Feedback EGR (DPFE) sensor bracket bolts. See Fig 7. Position the DPFE bracket aside. Disconnect the EGR vacuum regulator solenoid connections. Disconnect the EGR valve vacuum hose.
On all vehicles, remove the four throttle body adapter bolts. See Fig 8. Remove the throttle body adapter. Remove and discard the throttle body gasket. Disconnect the fuel tubes. Disconnect the Positive Crankcase Ventilation (PCV) valve tube from the intake manifold. Disconnect the fuel pressure regulator vacuum hose. See Fig 9.
Disconnect the 8 ignition coil electrical connectors and remove the coils. Disconnect the 8 fuel injector electrical connectors. Disconnect the hose clamp and remove the heater water hose. Remove the bolts, water thermostat housing, O-ring seal and the water thermostat. See Fig 10. Discard the O-ring seal.
Remove the intake manifold bolts. Remove the intake manifold. Lift the intake manifold. Remove and discard the intake manifold gaskets. Clean all mating surfaces.

Fig 1: Locating Generator Upper Mounting Bracket Bolts

Courtesy of FORD MOTOR CO.

Fig 2: Locating Generator Lower Mounting Bolts

Courtesy of FORD MOTOR CO.

Fig 3: Locating Accelerator Control Splash Shield

Courtesy of FORD MOTOR CO.

Fig 4: Locating Accelerator Cable Bracket Bolts

Courtesy of FORD MOTOR CO.

Fig 5: Locating EVAP Canister Purge Valve Vacuum Hose

Courtesy of FORD MOTOR CO.

Fig 6: Locating EGR Tube Fittings

Courtesy of FORD MOTOR CO.

Fig 7: Locating DPFE Sensor Bracket Bolts

Courtesy of FORD MOTOR CO.

Fig 8: Locating Throttle Body Adapter Bolts

Courtesy of FORD MOTOR CO.

Fig 9: Locating Fuel Pressure Regulator Vacuum Hose

Courtesy of FORD MOTOR CO.

Fig 10: Locating Thermostat Housing Bolts

Courtesy of FORD MOTOR CO.

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 that make leak paths.