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Home >> Ford >> 2003 >> Mustang Mach 1, Automatic >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 5 (Engine-Cobra 4.6L 4V) >> In-Vehicle Repair >> Lower Intake Manifold >> Removal and Installation

Removal and Installation

WARNING: This page is about a different variant/trim than selected.
  1. Drain the engine coolant. For additional information, refer to ENGINE COOLING .
  2. Drain the supercharger coolant. For additional information, refer to SUPERCHARGER COOLING .
  3. Release the fuel system pressure. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION .
  4. Disconnect the radiator upper hose, radiator lower hose and the supercharger degas hose.
    Fig 1: Disconnecting Radiator Upper Hose, Radiator Lower Hose And Supercharger Degas Hose
    G01624639Courtesy of FORD MOTOR CO.
  5. Remove the supercharger belt. For additional information, refer to ACCESSORY DRIVE .
  6. Disconnect the coolant hose.
    Fig 2: Disconnecting Coolant Hose
    G01624640Courtesy of FORD MOTOR CO.
  7. Remove the air cleaner outlet tube. For additional information, refer to REMOVAL & INSTALLATION .
  8. Disconnect the throttle position (TP) sensor and the idle air control (IAC) valve electrical connectors.
    Fig 3: Disconnecting Throttle Position (TP) Sensor And Idle Air Control (IAC) Valve Electrical Connectors
    G01624641Courtesy of FORD MOTOR CO.
  9. Disconnect the vacuum hose.
    Fig 4: Disconnecting Vacuum Hose
    G01624642Courtesy of FORD MOTOR CO.
  10. Disconnect the fuel hose spring lock coupling. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION .
  11. Disconnect the accelerator controls.
    • Disconnect the accelerator cable.
    • If equipped, disconnect the speed control cable.
      Fig 5: Disconnecting Accelerator Controls
      G01624643Courtesy of FORD MOTOR CO.
  12. Remove the accelerator cable bracket bolts.
    Fig 6: Remove Accelerator Cable Bracket Bolts
    G01624644Courtesy of FORD MOTOR CO.
  13. Release the clip and position the accelerator cable bracket and the cables aside.
    Fig 7: Releasing Clip And Positioning Accelerator Cable Bracket And Cables Aside
    G01624645Courtesy of FORD MOTOR CO.
  14. Disconnect the electrical connectors from the fuel pulse damper, exhaust gas recirculation (EGR) vacuum regulator solenoid, supercharger bypass vacuum solenoid, and the differential pressure feedback EGR system.
    Fig 8: Disconnecting Electrical Connectors
    G01624646Courtesy of FORD MOTOR CO.
  15. Disconnect the vacuum hoses from the differential pressure feedback EGR system.
    Fig 9: Disconnecting Vacuum Hoses From Differential Pressure Feedback EGR System
    G01624647Courtesy of FORD MOTOR CO.
  16. Disconnect the vacuum hoses from the supercharger bypass vacuum solenoid and the actuator.
    Fig 10: Disconnecting Vacuum Hoses From Supercharger Bypass Vacuum Solenoid And Actuator
    G01624648Courtesy of FORD MOTOR CO.
  17. Disconnect the vacuum hoses from the fuel pulse damper and the EGR vacuum regulator solenoid.
    Fig 11: Disconnecting Vacuum Hoses From Fuel Pulse Damper And EGR Vacuum Regulator Solenoid
    G01624649Courtesy of FORD MOTOR CO.
  18. Disconnect the vacuum hose from the EGR valve.
    Fig 12: Disconnecting Vacuum Hose From EGR Valve
    G01624650Courtesy of FORD MOTOR CO.
  19. Disconnect the vacuum hoses at the back of the supercharger and position the vacuum harness aside.
    Fig 13: Disconnecting Vacuum Hoses At Back Of Supercharger
    G01624651Courtesy of FORD MOTOR CO.
  20. Remove the vacuum accessory bracket mounting nut.
    Fig 14: Removing Vacuum Accessory Bracket Mounting Nut
    G01624652Courtesy of FORD MOTOR CO.
  21. Remove the mounting bolts and the vacuum accessory bracket.
    Fig 15: Removing Mounting Bolts And Vacuum Accessory Bracket
    G01624653Courtesy of FORD MOTOR CO.
  22. Disconnect the exhaust manifold to EGR valve tube.
    Fig 16: Disconnecting Exhaust Manifold To EGR Valve Tube
    G01624654Courtesy of FORD MOTOR CO.
  23. Disconnect the barometric pressure (BARO) sensor electrical connector.
    Fig 17: Disconnecting Barometric Pressure (BARO) Sensor Electrical Connector
    G01624655Courtesy of FORD MOTOR CO.
  24. Disconnect the positive crankcase ventilation hose.
    Fig 18: Disconnecting Positive Crankcase Ventilation Hose
    G01624656Courtesy of FORD MOTOR CO.
  25. Separate the fuel charging wiring harness from the fuel injection supply manifold in four places and position the harness aside.
    Fig 19: Separating Fuel Charging Wiring Harness From Fuel Injection Supply Manifold
    G01624657Courtesy of FORD MOTOR CO.
  26. Remove the ten bolts and the intake manifold, and the supercharger and fuel supply manifold as an assembly.
    Fig 20: Removing Intake Manifold, And Supercharger And Fuel Supply Manifold
    G01624658Courtesy of FORD MOTOR CO.
    27. NOTE: Inspect the intake manifold gaskets and install new gaskets, if necessary.
    NOTE: Install new bypass tube O-rings and lubricate them, using premium engine coolant
  27. To install, reverse the removal procedure.
    • Tighten the intake manifold bolts in the sequence shown.
      Fig 21: Identifying Tightening Sequence Of Intake Manifold Bolts
      G01624659Courtesy of FORD MOTOR CO.
  28. Fill and bleed the engine cooling system. For additional information, refer to ENGINE COOLING in this section.
  29. Fill and bleed the supercharger cooling system. For additional information, refer to SUPERCHARGER COOLING .
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