Ford Mustang (1999-2004) Service Manual: Removal

1. Disconnect the battery ground cable. For additional information, refer to Section.

2. Remove the engine air cleaner outlet pipe. For additional information, refer to Section.

3. Disconnect the vacuum hose and the idle air control (IAC) valve electrical connector.

Upper Intake Manifold

4. Disconnect the throttle position (TP) sensor electrical connector and the evaporative emissions (EVAP) return tube.

Upper Intake Manifold

5. Disconnect the accelerator and the speed control cables from the throttle body cam.

Upper Intake Manifold

6. Remove the bolts and position the accelerator cable bracket assembly aside.

Upper Intake Manifold

7. Disconnect the differential pressure feedback exhaust gas recirculation (EGR) system electrical and vacuum connections.

Upper Intake Manifold

8. Disconnect the EGR vacuum regulator solenoid electrical and vacuum connections.

Upper Intake Manifold

9. Disconnect the positive crankcase ventilation (PCV) tube.

Upper Intake Manifold

10. Disconnect the vacuum hoses.

Upper Intake Manifold

11. Disconnect the following:

  • Ignition coil electrical connector.
  • Radio interference capacitor electrical connector.
  • Spark plug wires.

Upper Intake Manifold

12. Disconnect the vacuum hose.

Upper Intake Manifold

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.

Upper Intake Manifold

14. Remove and discard the upper intake manifold gasket.

Upper Intake Manifold

    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 mani ...

    Other materials:

    Disassembly
    1. Inspect the clutch cylinder thrust surfaces, piston bore and clutch plate serrations for scores or burrs. Minor scores or burrs may be removed with crocus cloth. Install a new clutch cylinder if it is badly scored or damaged. 2. Check the fluid passage i ...

    Piston - Ring-to-Groove Clearance
    1. Inspect the piston for ring land damage or accelerated wear. 2. Measure the piston ring-to-groove clearance. Refer to the appropriate section in Group for the procedure. If out of specification, install new components as necessary. Refer to the a ...

    Key Programming - Additional Key With One Programmed Key
    Special Tool(s) Worldwide Diagnostic System (WDS) 418-F224, New Generation STAR (NGS) Tester 418-F052, or equivalent diagnostic tool NOTE: This procedure is used when a customer needs to have an additional key programmed into the veh ...