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Home >> Ford >> 2003 >> Mustang Base, 2D Convertible, Automatic >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> Engine-3.8L >> In-Vehicle Repair >> Upper Intake Manifold >> Installation
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Upper Intake Manifold: Installation

  1. Install a new upper intake manifold gasket.
    Fig 1: Installing Upper Intake Manifold Gasket
    G01623502Courtesy of FORD MOTOR CO.
    2. NOTE: Refer to the location note made during removal and make sure the bolts are installed in the correct locations.
  2. Install the upper intake manifold. Tighten the bolts in two stages in the sequence shown.
    • Stage 1: Tighten to 10 Nm (89 lb-in).
    • Stage 2: Rotate an additional 90 degrees (1/4 turn).
      Fig 2: Installing Upper Intake Manifold
      G01623503Courtesy of FORD MOTOR CO.
  3. Connect the vacuum hose.
    Fig 3: Connecting Vacuum Hose
    G01623504Courtesy of FORD MOTOR CO.
  4. Connect the following:
    • Ignition coil electrical connector.
    • Radio interference capacitor electrical connector.
    • Spark plug wires.
      Fig 4: Connecting Components
      G01623505Courtesy of FORD MOTOR CO.
  5. Connect the vacuum hoses.
    Fig 5: Connecting Vacuum Hoses
    G01623506Courtesy of FORD MOTOR CO.
  6. Connect the PCV tube.
    Fig 6: Connecting PCV Tube
    G01623507Courtesy of FORD MOTOR CO.
  7. Connect the differential pressure feedback EGR system electrical and vacuum connections.
    Fig 7: Connecting Differential Pressure Feedback EGR System Electrical And Vacuum Connections
    G01623508Courtesy of FORD MOTOR CO.
  8. Connect the EGR vacuum regulator solenoid electrical and vacuum connections.
    Fig 8: Connecting EGR Vacuum Regulator Solenoid Electrical And Vacuum Connections
    G01623509Courtesy of FORD MOTOR CO.
  9. Position the accelerator cable bracket and install the bolts.
    Fig 9: Installing Accelerator Cable Bracket
    G01623510Courtesy of FORD MOTOR CO.
  10. Connect the accelerator and speed control cables to the throttle body cam.
    Fig 10: Connecting Accelerator And Speed Control Cables To Throttle Body Cam
    G01623511Courtesy of FORD MOTOR CO.
  11. Connect the EVAP return tube and the TP sensor electrical connector.
    Fig 11: Connecting EVAP Return Tube And TP Sensor Electrical Connector
    G01623512Courtesy of FORD MOTOR CO.
  12. Connect the vacuum hose and the IAC valve electrical connector.
    Fig 12: Connecting Vacuum Hose And IAC Valve Electrical Connector
    G01623513Courtesy of FORD MOTOR CO.
  13. Install the engine air cleaner outlet pipe.
  14. Connect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .
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