Ford Mustang (1999-2004) Service Manual: 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.

Lower Intake Manifold

2. Install the intake manifold gaskets.

Lower Intake Manifold

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.

Lower Intake Manifold

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:

  • Stage 1: Tighten the bolts to 5 Nm (44 lb-in).
  • Stage 2: Tighten the bolts to 10 Nm (89 lb-in).

Lower Intake Manifold

5. NOTE: Install the fuel injection supply manifold and fuel injectors as an assembly.

Install the fuel injector supply manifold and bolts.

Lower Intake Manifold

6. Connect the electrical connector.

Lower Intake Manifold

7. Connect the coolant hoses.

Lower Intake Manifold

8. Connect the EGR tube.

Lower Intake Manifold

9. Connect the EGR vacuum tube.

Lower Intake Manifold

10. Lubricate the O-ring with water and install the heater hose.

Lower Intake Manifold

11. Install the heater bypass tube. For additional information, refer to Section.

12. Connect the IMRC electrical connector.

Lower Intake Manifold

13. Position and connect the engine wire harness. Install the pin-type retainers.

Lower Intake Manifold

14. Connect the fuel supply tube spring lock coupling. For additional information, refer to Section.

15. Connect the FRP sensor electrical connector and the vacuum hose.

Lower Intake Manifold

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.

    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 Sect ...

    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. ...

    Other materials:

    Piston
    Special Tool(s) Piston Pin Tool or equivalent 303-D034 (D81L-6135-A) Material Item Specification SAE 5W-20 Premium Synthetic Blend Motor Oil XO-5W20-QSP or equivalent WSS-M2C153- H Disassembly 1. Using the special tool, ...

    Master Cylinder Priming - In-Vehicle or Bench
    WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If take ...

    Final disassembly
    32. If not done previously, remove the bolts. 33. CAUTION: Do not damage the bolt hole threads. If not done previously, insert a punch in the bolt holes and drive off the differential ring gear. 34. Using the special tools, remove the differential bearin ...