FORD MUSTANG 2003 Workshop Manual

13. Disconnect the electrical connector.
14.
NOTE: Remove the fuel injection supply manifold and fuel injectors as an assembly.
Remove the bolts and the fuel injection supply manifold.
15. NOTE: For ease in installation, record the location of the short bolts and the long bolts.
Remove the lower intake manifold. 1. Remove the eight short bolts.
2. Remove the six long bolts.
3. Remove the lower intake manifold. Klj . 3 ba
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16. Remove and discard the intake manifold gaskets.
Installation 1. NOTE: If the lower intake manifold is not secured within four minutes, the sealant must be
removed and the sealing area cleaned with metal surface cleaner. Allow to dry until there is no
sign of wetness, or four minutes, whichever is longer. Failure to follow this procedure can cause
future oil leakage.
Install the lower intake manifold front and rear end seals. 1. Apply a bead of silicone gasket and sealant to the intake manifold front and rear end seal mounting points as indicated.
2. Install the lower intake manifold front and rear end seals. Item Part Number Description
1 9439 Intake manifold gasket—
RH 2 9441 Intake manifold gasket—
LH 3 9A424 Intake manifold rear end seal (part of 9439)
4 9A425 Intake manifold front end seal (part of 9439) Klj . 4 ba
92003 Mustang Workshop Manual
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2. Install the intake manifold gaskets.
3.
NOTE: If the lower intake manifold is not secured within four minutes, the sealant must be
removed and the sealing area cleaned with metal surface cleaner. Allow to dry until there is no
sign of wetness, or four minutes, whichever is longer. Failure to follow this procedure can cause
future oil leakage.
Position the lower intake manifold. 1. Apply a bead of silicone gasket and sealant to the lower intake manifold mounting at the points indicated.
2. Position the lower intake manifold. Klj . 5 ba
92003 Mustang Workshop Manual
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4.
NOTE: Refer to the location note made during removal and make sure the bolts are installed in
the correct location.
Tighten the bolts in two stages in the sequence shown:
zStage 1: Tighten the bolts to 5 Nm (44 lb- in).
z Stage 2: Tighten the bolts to 10 Nm (89 lb- in).
5. NOTE: Install the fuel injection supply manifold and fuel injectors as an assembly.
Install the fuel injector supply manifold and bolts. Klj . 6 ba
92003 Mustang Workshop Manual
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6. Connect the electrical connector.
7. Connect the coolant hoses.
8. Connect the EGR tube.
9. Connect the EGR vacuum tube.
10. Lubricate the O- ring with water and install the heater hose. Klj . 7 ba
92003 Mustang Workshop Manual
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11. Install the heater bypass tube. For additional information, refer to
Section 303 - 03A .
12. Connect the IMRC electrical connector.
13. Position and connect the engine wire harness. Install the pin- type retainers.
14. Connect the fuel supply tube spring lock coupling. For additional information, refer to Section 310 - 00 .
15. Connect the FRP sensor electrical connector and the vacuum hose. Klj . 8 ba
92003 Mustang Workshop Manual
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16. Install the upper intake manifold. For additional information, refer to
Upper Intake Manifold in
this section.
17. CAUTION: Correct cooling system bleeding is critical for correct engine cooling.
Fill and bleed the cooling system. For additional information, refer to Section 303 - 03A . Klj . 9 ba
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IN-
VEHICLE REPAIR
Valve Cover — LH
Removal and Installation 1. Position the ignition wires (12281) aside.
2. Disconnect the positive crankcase ventilation (PCV) valve (6758).
3. Remove the ignition coil and position aside. 1. Disconnect the electrical connector.
2. Disconnect the accelerator control cable retainer.
3. Remove the bolts.
4. Remove the LH valve cover (6A565). zInspect the gasket (6584) and install a new gasket if necessary.
SECTION 303-
01A: Engine — 3.8L 2003 Mustang Workshop Manual Klj . 1 ba
22003 Mustang Workshop Manual
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5. To install, reverse the removal procedure. Klj . 2 ba
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IN-
VEHICLE REPAIR
Valve Cover RH
Removal and Installation 1. Remove the throttle body. For additional information, refer to Section 303 - 04A .
2. Disconnect the crankcase vent hose.
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.
5. Remove the EGR tube.
SECTION 303-
01A: Engine — 3.8L 2003 Mustang Workshop Manual Klj . 1 ba
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