vacuum FORD MUSTANG 2003 Workshop Manual

REMOVAL AND INSTALLATION
Exhaust Manifold to Exhaust Gas Recirculation (EGR)
Valve Tube
Removal and Installation
NOTE:
3.8L shown, 4.6L (2V) similar.
1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Section 100 - 02 .
2. Disconnect the exhaust gas recirculation (EGR) valve tube from the exhaust manifold.
3. Remove the differential feedback exhaust gas recirculation (EGR) system vacuum hoses and the bracket bolts. Position the bracket assembly aside.
4. Disconnect the EGR tube from the EGR valve.
SECTION 303-
08: Engine Emission Control 2003 Mustang Workshop Manual Klj . 1 ba
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REMOVAL AND INSTALLATION
Exhaust Gas Recirculation (EGR) Vacuum Regulator
Solenoid
Mach I vehicles
1. Remove the air intake scoop. For additional information, refer to Section 303 - 12 .
All vehicles 2. Remove the exhaust gas recirculation (EGR) vacuum regulator solenoid. zDisconnect the electrical connector.
z Remove the bolts.
3. To install, reverse the removal procedure.
SECTION 303-
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SPECIFICATIONS
a
Refer to the procedure
SECTION 303-
12: Intake Air Distribution and Filtering 2003 Mustang Workshop Manual Torque Specifications
Description Nm lb-
ft lb-
in Air cleaner and duct assembly bolt 7 62 —
Coolant supply and return manifold
a — — —
Charge air cooler bolts
a — — —
Supercharger mounting bolts
a — — —
Air intake scoop bolts 25 18 —
Air intake scoop bracket bolt 25 18 —
Air intake scoop bracket nuts 25 18 —
Air intake scoop bracket throttle body nut 9 — 80
Exhaust gas recirculation (EGR) vacuum regulator solenoid bolts 10 — 89 Klj . 1 ba
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DESCRIPTION AND OPERATION
Intake Air Distribution and Filtering —
Supercharger,
Charge Air Cooler
The supercharger (SC) is a positive displacement pump. Its purpose is to supply an excess volume of
intake air to the engine by increasing air pressure and density in the intake manifold. The supercharger
is matched to the engine by its displacement and belt ratio, and can provide excess airflow at any
engine speed.
NOTE: The supercharger is repaired only as an assembly. Disassembly of the supercharger unit may
void the warranty.
NOTE: The supercharger is not a bolt- on option. It is part of an integrated engine system. Many
components of the supercharged engine are not interchangeable with similar parts from a non-
supercharged engine.
The supercharger contains two three- lobed rotors. The helical shape and specialized porting provide a
smooth discharge flow and low level of noise during operation. The rotors are supported by ball
bearings in front and needle bearings at the rear. The drive gears are pressed into place, therefore the
supercharger is installed new as a unit, and is not repairable.
The supercharger system is a blow- through type with the fuel injected directly into the intake ports. The
supercharger is belt driven off the crankshaft through an idler pulley. The throttle body controls the
amount of intake air to the supercharger through the intake plenum. Air from the supercharger is
routed through the charge air cooler (CAC), then to the intake manifold. The resulting denser air
charge in the combustion chamber provides for a higher power output of the engine over a non-
supercharged engine of the same displacement.
NOTE: It is not possible to increase manifold pressure or engine power output by altering the bypass
valve or the actuator.
At partial- throttle opening or when vacuum is present in the intake system, a vacuum- controlled
bypass valve reroutes some discharged air from the supercharger back through the intake plenum.
This prevents the supercharger from cavitating, causing reduced performance, increased
temperatures, and poor fuel economy.
The supercharger has a self- contained oiling system that does not require a fluid change for the life of
the vehicle. However, at every 30,000 mile interval, the supercharger fluid level should be checked.
The vehicle should be parked on a level surface, the engine cool, and not running. To check the oil,
remove the Allen head plug located at the front of the supercharger. The oil level should be at the
bottom of the fill plug threads when cold. If the fluid level is low, add Synthetic Supercharger Fluid
E9SZ- 19577- A or equivalent meeting Ford specification ESE-M99C115–A
Supercharged vehicles are equipped with a charge air cooler (CAC). The CAC cools the pressurized
air from the supercharger, increasing the air density, which improves combustion efficiency, engine
horsepower and torque. SECTION 303-
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REMOVAL AND INSTALLATION
Air Cleaner Outlet Pipe —
4.6L (4V)
Removal and Installation
Cobra 1. Disconnect the intake air temperature (IAT) sensor.
All vehicles 2. Disconnect the vacuum hose.
3. Disconnect the breather hose.
NOTE: Cobra shown, Mach I similar.
4. Loosen the clamps and remove the air cleaner outlet pipe.
SECTION 303-
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REMOVAL AND INSTALLATION
Air Intake Scoop Bracket
Removal and Installation
1. Remove the air intake scoop. For additional information, refer to Air Intake Scoop in this section.
2. Remove the air intake scoop bracket nut at the throttle body.
3. Remove the exhaust gas recirculation (EGR) vacuum regulator solenoid bolts and position the EGR vacuum regulator solenoid aside.
4. Remove the air intake scoop bracket nuts and the air intake scoop bracket bolt and remove the air intake scoop bracket from the engine.
5. To install, reverse the removal procedure.
SECTION 303-
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8. Disconnect the vacuum hose.
9. Disconnect the fuel supply spring lock coupler. For additional information, refer to
Section 310 -
00 .
10. Disconnect the accelerator controls. zDisconnect the accelerator cable.
z If equipped, disconnect the speed control cable. 11. Remove the accelerator cable bracket bolts. Klj . 2 ba
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12. Remove the throttle body and spacer assembly.
13. Release the clip and position the accelerator cable bracket and the cables aside.
14. Disconnect the electrical connectors from the fuel pulse damper, EGR vacuum regulator
solenoid, supercharger bypass vacuum solenoid, and the differential pressure feedback EGR
system.
15. Disconnect the vacuum hoses from the differential pressure feedback EGR system. Klj . 3 ba
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16. Disconnect the vacuum hoses from the supercharger bypass vacuum solenoid, and the
actuator.
17. Disconnect the vacuum hoses from the fuel pulse damper and the EGR vacuum regulator solenoid.
18. Disconnect the vacuum hose from the EGR valve.
19. Disconnect the vacuum hoses at the back of the supercharger and position the vacuum harness aside. Klj . 4 ba
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20. Remove the vacuum accessory bracket mounting nut.
21. Remove the mounting bolts, and the vacuum accessory bracket.
22. Disconnect the exhaust manifold to EGR valve tube.
23. Disconnect the barometric pressure (BARO) sensor electrical connector. Klj . 5 ba
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