Ford Mustang (1999-2004) Service Manual: Removal

1. Drain the engine cooling system.

2. Remove the air cleaner outlet tube.

3. Disconnect the fuel line.

4. Disconnect the upper radiator hose from the water outlet connector.

Intake Manifold

5. Disconnect and remove the upper radiator hose.

Intake Manifold

6. Disconnect the accelerator cable, speed control actuator cable and return spring.

Intake Manifold

7. Remove the bolts and position the cables and bracket out of the way.

Intake Manifold

8. Remove the breather tube.

Intake Manifold

9. Disconnect the evaporative emissions return line.

Intake Manifold

10. Disconnect the differential pressure feedback EGR electrical connector.

Intake Manifold

11. Disconnect the hoses from the differential pressure feedback EGR transducer.

Intake Manifold

12. Disconnect the EGR vacuum regulator solenoid electrical connector.

Intake Manifold

13. Disconnect the EGR vacuum regulator solenoid vacuum supply.

Intake Manifold

14. Remove the bolts retaining the EGR vacuum regulator solenoid bracket to the intake manifold.

Intake Manifold

15. Disconnect the exhaust gas recirculation (EGR) tube from the EGR valve.

Intake Manifold

16. Disconnect the positive crankcase ventilation (PCV) hose from the base of the throttle body and spacer assembly.

Intake Manifold

17. Disconnect the hose from the PCV valve.

Intake Manifold

18. Disconnect the vacuum hose from the EGR valve.

Intake Manifold

19. Disconnect the idle air control (IAC) valve electrical connector.

Intake Manifold

20. Disconnect the main vacuum supply from the base of the throttle body adapter.

Intake Manifold

21. Disconnect the throttle position sensor (TPS) electrical connector.

Intake Manifold

22. Remove the bolts.

Intake Manifold

23. Remove the throttle body and adapter as an assembly.

  • Inspect and clean the sealing surfaces.
  • The gasket is reusable if not damaged.

Intake Manifold

24. Disconnect the fuel pressure sensor electrical connector and the vacuum hose.

Intake Manifold

25. Disconnect the fuel charging ground wire.

Intake Manifold

26. Disconnect the ignition coils and the fuel injectors.

Intake Manifold

27. Disconnect the climate control vacuum supply hoses and remove the vacuum harness.

Intake Manifold

28. Remove the four studs.

Intake Manifold

29. Remove the injectors and fuel injection supply manifold as an assembly.

Intake Manifold

30. Remove the ignition coils.

Intake Manifold

31. Disconnect the battery terminal.

Intake Manifold

32. Remove the generator support brace.

Intake Manifold

33. Disconnect the electrical connector.

Intake Manifold

34. Remove the generator.

Intake Manifold

35. Disconnect the heater hose.

Intake Manifold

36. Separate the engine harness and position it out of the way.

Intake Manifold

37. Disconnect the water temperature indicator sender.

Intake Manifold

38. Remove the water outlet connector.

Intake Manifold

39. Remove the water thermostat and the O-ring.

  • Inspect the O-ring and discard if necessary.

Intake Manifold

40. NOTE: The gaskets are reusable if not damaged.

Remove the bolts in the sequence shown, remove the intake manifold and gaskets.

Intake Manifold

    Installation
    1. Install the intake manifold and gaskets, tighten the bolts in the sequence shown. 2. NOTE: The O-ring is to be installed on the top of the thermostat. Install the water thermostat and the O-rin ...

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