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.
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.
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).
5. NOTE: Install the fuel injection supply manifold and fuel injectors as an assembly.
Install the fuel injector supply manifold and bolts.
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.
11. Install the heater bypass tube. For additional information, refer to Section.
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.
15. Connect the FRP sensor electrical connector and the vacuum hose.
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:
Installation
NOTE: Do not use a fiber disc to clean the surfaces. Fibers from
the disc can get into the oil pan and
oil and clog the oil bypass valve.
1. Clean and inspect the cylinder head for flatness.
2. Install a new head gasket on the cylinder block with the sma ...
Exhaust Manifold - LH
Removal
1. Raise and support the vehicle. For additional information, refer to
Section.
2. Remove the LH exhaust manifold flange nuts.
3. Remove the RH exhaust manifold flange nuts.
4. Lower the vehicle.
5. NOTE: Discard the exhaust manifold gasket.
...
Parking Brake (Diagnosis and Testing)
Inspection and Verification
1. Verify the customer's concern by operating the parking brake system to
duplicate the condition.
2. Inspect to determine if one of the following mechanical or electrical
concerns apply:
Visual Inspection Chart
Mechanica ...
