Ford Mustang (1999-2004) Service Manual: Charge Air Cooler

Material

Item Specification
Silicone Gasket and Sealant F7AZ-19554-EA or equivalent WSE-M4G323-EA

Removal and Installation

1. Drain the supercharger coolant. For additional information, refer to Section.

2. Release the fuel pressure. For additional information, refer to Section.

3. Disconnect the supercharger degas hose.

Charge Air Cooler

4. Disconnect the coolant hose.

Charge Air Cooler

5. Remove the supercharger belt. For additional information, refer to Section.

6. Remove the air cleaner outlet tube. For additional information, refer to Section.

7. Disconnect the throttle position (TP) sensor and the idle air control (IAC) valve electrical connectors.

Charge Air Cooler

8. Disconnect the vacuum hose.

Charge Air Cooler

9. Disconnect the fuel supply spring lock coupler.

10. Disconnect the accelerator controls.

  • Disconnect the accelerator cable.
  • If equipped, disconnect the speed control cable.

Charge Air Cooler

11. Remove the accelerator cable bracket bolts.

Charge Air Cooler

12. Remove the throttle body and spacer assembly.

Charge Air Cooler

13. Release the clip and position the accelerator cable bracket and the cables aside.

Charge Air Cooler

14. Disconnect the electrical connectors from the fuel pulse damper, EGR vacuum regulator solenoid, supercharger bypass vacuum solenoid, and the differential pressure feedback EGR system.

Charge Air Cooler

15. Disconnect the vacuum hoses from the differential pressure feedback EGR system.

Charge Air Cooler

16. Disconnect the vacuum hoses from the supercharger bypass vacuum solenoid, and the actuator.

Charge Air Cooler

17. Disconnect the vacuum hoses from the fuel pulse damper and the EGR vacuum regulator solenoid.

Charge Air Cooler

18. Disconnect the vacuum hose from the EGR valv

Charge Air Cooler

19. Disconnect the vacuum hoses at the back of the supercharger and position the vacuum harness aside.

Charge Air Cooler

20. Remove the vacuum accessory bracket mounting nut.

Charge Air Cooler

21. Remove the mounting bolts, and the vacuum accessory bracket.

Charge Air Cooler

22. Disconnect the exhaust manifold to EGR valve tube.

Charge Air Cooler

23. Disconnect the barometric pressure (BARO) sensor electrical connector.

Charge Air Cooler

24. Disconnect the positive crankcase ventilation (PCV) hose.

Charge Air Cooler

25. Separate the fuel charging wiring harness from the fuel injection supply manifold in four places and position the harness aside.

Charge Air Cooler

26. Remove the ten bolts, the intake manifold, supercharger and fuel supply manifold as an assembly.

Charge Air Cooler

27. Disconnect and remove the PCV hoses.

Charge Air Cooler

28. Remove the coolant supply and return manifold.

Charge Air Cooler

29. Remove the coolant supply and return tubes and seals.

Charge Air Cooler

29. Remove the coolant supply and return tubes and seals.

Charge Air Cooler

31. Remove the fuel supply manifold and fuel injectors as an assembly.

Charge Air Cooler

32. Remove the bolts, the supercharger and charge air cooler (CAC) assembly.

Charge Air Cooler

33. Remove the bolts and the CAC in the sequence shown.

Charge Air Cooler

34. Inspect the CAC plenum gasket and install a new gasket if necessary.

Charge Air Cooler

35. To install, reverse the removal procedure 36. Apply a bead of sealant in the areas shown on the supercharger flange between the CAC and the supercharger.

Charge Air Cooler

37. NOTE: Once the torque procedure has been started, final tightening must be finished within five minutes maximum.

Tighten the CAC bolts in the sequence shown in two stages.

1. Tighten to 2 Nm (18 lb-in).

2. Tighten to 6 Nm (53 lb-in).

Charge Air Cooler

38. Tighten the supercharger and CAC cooler assembly-to-lower intake manifold bolts in the sequence shown in three stages.

1. Tighten to 2 Nm (18 lb-in).

2. Tighten to 25 Nm (18 lb-ft).

3. Tighten an additional 90 degrees.

Charge Air Cooler

39. Tighten the coolant supply and return manifold in two stages.

1. Tighten to 10 Nm (89 lb-ft).

2. Tighten an additional 90 degrees.

Charge Air Cooler

40. NOTE: Inspect the intake manifold gaskets and install new gaskets, if necessary.

Tighten the lower intake manifold bolts in the sequence shown.

Charge Air Cooler

41. Fill and bleed the supercharger cooling system.

 

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