FORD MUSTANG 2003 Workshop Manual

IN-
VEHICLE REPAIR
Upper Intake Manifold
Removal 1. Disconnect the battery ground cable. For additional information, refer to Section 414 - 01 .
2. Remove the engine air cleaner outlet pipe. For additional information, refer to Section 303 - 12 .
3. Disconnect the vacuum hose and the idle air control (IAC) valve electrical connector.
4. Disconnect the throttle position (TP) sensor electrical connector and the evaporative emissions (EVAP) return tube.
5. Disconnect the accelerator and the speed control cables from the throttle body cam. 6. Remove the bolts and position the accelerator cable bracket assembly aside. SECTION 303-
01A: Engine — 3.8L 2003 Mustang Workshop Manual Klj . 1 ba
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7. Disconnect the differential pressure feedback exhaust gas recirculation (EGR) system electrical
and vacuum connections.
8. Disconnect the EGR vacuum regulator solenoid electrical and vacuum connections.
9. Disconnect the positive crankcase ventilation (PCV) tube. 10. Disconnect the vacuum hoses. Klj . 2 ba
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11. Disconnect the following:
zIgnition coil electrical connector.
z Radio interference capacitor electrical connector.
z Spark plug wires.
12. Disconnect the vacuum hose.
13. NOTE: For ease in installation, record the location of the long bolts and the short bolts.
Remove the upper intake manifold. 1. Remove the 12 bolts.
2. Remove the upper intake manifold. Klj . 3 ba
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14. Remove and discard the upper intake manifold gasket.
Installation 1. Install a new upper intake manifold gasket.
2. NOTE: Refer to the location note made during removal and make sure the bolts are installed in
the correct locations.
Install the upper intake manifold. Tighten the bolts in two stages in the sequence shown. Klj . 4 ba
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z
Stage 1: Tighten to 10 Nm (89 lb- in).
z Stage 2: Rotate an additional 90 degrees (1/4 turn).
3. Connect the vacuum hose.
4. Connect the following: zIgnition coil electrical connector.
z Radio interference capacitor electrical connector.
z Spark plug wires. Klj . 5 ba
82003 Mustang Workshop Manual
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5. Connect the vacuum hoses.
6. Connect the PCV tube.
7. Connect the differential pressure feedback EGR system electrical and vacuum connections.
8. Connect the EGR vacuum regulator solenoid electrical and vacuum connections. Klj . 6 ba
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9. Position the accelerator cable bracket and install the bolts.
10. Connect the accelerator and speed control cables to the throttle body cam.
11. Connect the EVAP return tube and the TP sensor electrical connector.
12. Connect the vacuum hose and the IAC valve electrical connector. Klj . 7 ba
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13. Install the engine air cleaner outlet pipe. For additional information, refer to
Section 303 - 12 .
14. Connect the battery ground cable. For additional information, refer to Section 414 - 01 . Klj . 8 ba
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IN-
VEHICLE REPAIR
Lower Intake Manifold
Removal 1. Remove the upper intake manifold. For additional information, refer to Upper Intake Manifold in
this section.
2. Partially drain the cooling system. For additional information, refer to Section 303 - 03A .
3. Relieve the fuel system pressure. For additional information, refer to Section 310 - 00 .
4. Disconnect the fuel rail pressure (FRP) sensor electrical connector and vacuum hose.
5. Disconnect the fuel supply tube spring lock coupling. For additional information, refer to Section 310 - 00 .
6. Disconnect and position the engine wire harness aside.
7. Disconnect the intake manifold runner control (IMRC) electrical connector.
SECTION 303-
01A: Engine — 3.8L 2003 Mustang Workshop Manual Material
Item Specification
Silicone Gasket and Sealant
F7AZ-
19554- EA or equivalent WSE-
M4G323-
A4 Metal Surface Cleaner
F4AZ-
19A536- RA or
equivalent WSE-
M5B392- A Klj . 1 ba
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8. Remove the heater bypass tube. For additional information, refer to
Section 303 - 03A .
9. Disconnect the heater hose.
10. Disconnect the exhaust gas recirculation (EGR) vacuum tube.
11. Disconnect the EGR tube from the EGR valve.
12. Disconnect the radiator upper hose and coolant bypass hose. Klj . 2 ba
92003 Mustang Workshop Manual
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