LEMON Manuals: Even more car manuals for everyone: 1960-2025
Home >> Ford >> 2003 >> Mustang Base, 2D Convertible, Standard >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> Engine-3.8L >> In-Vehicle Repair >> Lower Intake Manifold >> Installation
April 5, 2026: LEMON Manuals is launched! Read the announcement.

Lower Intake Manifold: Installation

    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
  1. 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.
      Fig 1: Installing Lower Intake Manifold Front And Rear End Seals
      G01623526Courtesy of FORD MOTOR CO.
  2. Install the intake manifold gaskets.
    Fig 2: Installing Intake Manifold Gaskets
    G01623527Courtesy of FORD MOTOR CO.
    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 procedures can cause future oil leakage
  3. 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.
      Fig 3: Positioning Lower Intake Manifold
      G01623528Courtesy of FORD MOTOR CO.
    4. NOTE: Refer to the location note made during removal and make sure the bolts are installed in the correct location.
  4. 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).
      Fig 4: Identifying Tightening Sequence Of Bolts
      G01623529Courtesy of FORD MOTOR CO.
    5. NOTE: Install the fuel injection supply manifold and fuel injectors as an assembly.
    Fig 5: Installing Fuel Injector Supply Manifold And Bolts
    G01623530Courtesy of FORD MOTOR CO.
  5. Install the fuel injector supply manifold and bolts.
  6. Connect the electrical connector.
    Fig 6: Connecting Electrical Connector
    G01623531Courtesy of FORD MOTOR CO.
  7. Connect the coolant hoses.
    Fig 7: Connecting Coolant Hoses
    G01623532Courtesy of FORD MOTOR CO.
  8. Connect the EGR tube.
    Fig 8: Connecting EGR Tube
    G01623533Courtesy of FORD MOTOR CO.
  9. Connect the EGR vacuum tube.
    Fig 9: Connecting EGR Vacuum Tube
    G01623534Courtesy of FORD MOTOR CO.
  10. Lubricate the O-ring with water and install the heater hose.
    Fig 10: Installing Heater Hose
    G01623535Courtesy of FORD MOTOR CO.
  11. Install the heater bypass tube. For additional information, refer to ENGINE COOLING .
  12. Connect the IMRC electrical connector.
    Fig 11: Connecting IMRC Electrical Connector
    G01623536Courtesy of FORD MOTOR CO.
  13. Position and connect the engine wire harness. Install the pin-type retainers.
    Fig 12: Positioning And Connecting Engine Wire Harness
    G01623537Courtesy of FORD MOTOR CO.
  14. Connect the fuel supply tube spring lock coupling. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION .
  15. Connect the FRP sensor electrical connector and the vacuum hose.
    Fig 13: Connecting FRP Sensor Electrical Connector And Vacuum Hose
    G01623538Courtesy of FORD MOTOR CO.
  16. Install the upper intake manifold. For additional information, refer to UPPER INTAKE MANIFOLD .
    17. CAUTION: Correct cooling system bleeding is critical for correct engine cooling
  17. Fill and bleed the cooling system. For additional information, refer to ENGINE COOLING .
scientia non olet · About LEMON Manuals