Ford Mustang (1999-2004) Service Manual: 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 Section.
3. Relieve the fuel system pressure. For additional information, refer to Section.
4. Disconnect the fuel rail pressure (FRP) sensor electrical connector and vacuum hose.
5. Disconnect the fuel supply tube spring lock coupling. For additional information, refer to Section.
6. Disconnect and position the engine wire harness aside.
7. Disconnect the intake manifold runner control (IMRC) electrical connector.
8. Remove the heater bypass tube. For additional information, refer to Section.
9. Disconnect the heater hose.
10. Disconnect the exhaust gas recirculation (EGR) vacuum tube.
11. Disconnect the EGR tube from the EGR valve.
12. Disconnect the radiator upper hose and coolant bypass hose.
13. Disconnect the electrical connector.
14. NOTE: Remove the fuel injection supply manifold and fuel injectors as an assembly.
Remove the bolts and the fuel injection supply manifold.
15. NOTE: For ease in installation, record the location of the short bolts and the long bolts.
Remove the lower intake manifold.
1. Remove the eight short bolts.
2. Remove the six long bolts.
3. Remove the lower intake manifold.
16. Remove and discard the intake manifold gaskets.
Lower Intake Manifold
Material
...
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 ...
Other materials:
Halfshaft Joint
Special Tool(s)
Driver
205-199 (T83T-3132-A1)
Hub Bearing Cup Replacer
205-147 (T80T-4000-P)
Sensing Ring Replacer
206-041 (T89P-20202-A)
Disassembly
1. CAUTION: Do not disassemble the halfshaft assembly. Install a new
assem ...
Installation
1. Position the fuel charging wiring in the vehicle and attach to the rear of
the intake manifold.
2. NOTE: Make sure the locking clips are fully engaged into the bracket.
Reposition the accelerator cable and the speed control cable (if equipped)
and ...
Disassembly
Initial disassembly
1. Remove the differential housing cover (4033) and drain the lubricant into
a suitable container.
2. Wipe the lubricant from the internal working parts and inspect the parts for
wear and damage.
3. Using the special tool, measure and n ...