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

  1. Disconnect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  2. Remove the engine air cleaner outlet pipe.
  3. Disconnect the vacuum hose and the idle air control (IAC) valve electrical connector.
    Fig 1: Disconnecting Vacuum Hose And Idle Air Control (IAC) Valve Electrical Connector
    G01623490Courtesy of FORD MOTOR CO.
  4. Disconnect the throttle position (TP) sensor electrical connector and the evaporative emission (EVAP) return tube.
    Fig 2: Disconnecting Throttle Position (TP) Sensor Electrical Connector And Evaporative Emission (EVAP) Return Tube
    G01623491Courtesy of FORD MOTOR CO.
  5. Disconnect the accelerator and the speed control cables from the throttle body cam.
    Fig 3: Disconnecting Accelerator And Speed Control Cables From Throttle Body Cam
    G01623492Courtesy of FORD MOTOR CO.
  6. Remove the bolts and position the accelerator cable bracket assembly aside.
    Fig 4: Removing Accelerator Cable Bracket Assembly
    G01623493Courtesy of FORD MOTOR CO.
  7. Disconnect the differential pressure feedback exhaust gas recirculation (EGR) system electrical and vacuum connections.
    Fig 5: Disconnecting Differential Pressure Feedback Exhaust Gas Recirculation (EGR) System Electrical And Vacuum Connections
    G01623494Courtesy of FORD MOTOR CO.
  8. Disconnect the EGR vacuum regulator solenoid electrical and vacuum connections.
    Fig 6: Disconnecting EGR Vacuum Regulator Solenoid Electrical And Vacuum Connections
    G01623495Courtesy of FORD MOTOR CO.
  9. Disconnect the positive crankcase ventilation (PCV) tube.
    Fig 7: Disconnecting Positive Crankcase Ventilation (PCV) Tube
    G01623496Courtesy of FORD MOTOR CO.
  10. Disconnect the vacuum hoses.
    Fig 8: Disconnecting Vacuum Hoses
    G01623497Courtesy of FORD MOTOR CO.
  11. Disconnect the following:
    • Ignition coil electrical connector.
    • Radio interference capacitor electrical connector.
    • Spark plug wires.
    Fig 9: Disconnecting Components
    G01623498Courtesy of FORD MOTOR CO.
  12. Disconnect the vacuum hose.
    Fig 10: Disconnecting Vacuum Hose
    G01623499Courtesy of FORD MOTOR CO.
    13. NOTE: For ease in installation, record the location of the long bolts and the short bolts
  13. Remove the upper intake manifold.
    1. Remove the 12 bolts.
    2. Remove the upper intake manifold.
      Fig 11: Removing Upper Intake Manifold
      G01623500Courtesy of FORD MOTOR CO.
  14. Remove and discard the upper intake manifold gasket.
    Fig 12: Removing Upper Intake Manifold Gasket
    G01623501Courtesy of FORD MOTOR CO.
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