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Ford Mustang 2002 User Manual

Ford Mustang 2002
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Intake Manifold
Removal
1. Drain the engine cooling system. For additional information, refer to Section 303-03.
2. Remove the air cleaner outlet tube. For additional information, refer to Section 303-12.
3. Disconnect the fuel line. For additional information, refer to Section 310-00.
4. Disconnect the upper radiator hose from the water outlet connector.
5. Disconnect and remove the upper radiator hose.
6. Disconnect the accelerator cable, speed control actuator cable and return spring.
7. Remove the bolts and position the cables and bracket out of the way.
8. Remove the breather tube.
SECTION 303-01B: Engine — 4.6L (2V) 2002 Mustang Workshop Manual
IN-VEHICLE REPAIR
Procedure revision date: 07/25/2001
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2002 Mustang Workshop Manual
7/15/2010
http://www.fordtechservice.dealerconnection.com/pubs/content/~WS2B/~MUS~LEN/19/S
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Ford Mustang 2002 Specifications

General IconGeneral
BrandFord
ModelMustang 2002
CategoryAutomobile
LanguageEnglish

Summary

Intake Manifold Removal

Drain Engine Cooling System

Drain the engine cooling system for additional information.

Remove Air Cleaner Outlet Tube

Remove the air cleaner outlet tube for additional information.

Disconnect Fuel Line

Disconnect the fuel line for additional information.

Disconnect Upper Radiator Hose

Disconnect the upper radiator hose from the water outlet connector.

Disconnect and Remove Upper Radiator Hose

Disconnect and remove the upper radiator hose.

Disconnect Cables and Spring

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

Remove Cables and Bracket

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

Remove Breather Tube

Remove the breather tube.

Disconnect Evaporative Emissions Return Line

Disconnect the evaporative emissions return line.

Disconnect EGR Electrical Connector

Disconnect the differential pressure feedback EGR electrical connector.

Disconnect EGR Transducer Hoses

Disconnect the hoses from the differential pressure feedback EGR transducer.

Disconnect EGR Vacuum Regulator Solenoid Connector

Disconnect the EGR vacuum regulator solenoid electrical connector.

Disconnect EGR Vacuum Regulator Solenoid Vacuum Supply

Disconnect the EGR vacuum regulator solenoid vacuum supply.

Remove EGR Vacuum Regulator Solenoid Bracket

Remove bolts retaining the EGR vacuum regulator solenoid bracket.

Disconnect EGR Tube

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

Disconnect PCV Hose

Disconnect the positive crankcase ventilation (PCV) hose.

Disconnect Hose from PCV Valve

Disconnect the hose from the PCV valve.

Disconnect Vacuum Hose from EGR Valve

Disconnect the vacuum hose from the EGR valve.

Disconnect IAC Valve Connector

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

Disconnect Main Vacuum Supply

Disconnect the main vacuum supply from the throttle body adapter.

Disconnect TPS Electrical Connector

Disconnect the throttle position sensor (TPS) electrical connector.

Remove Throttle Body and Adapter Assembly

Remove throttle body and adapter as an assembly; inspect surfaces.

Disconnect Fuel Pressure Sensor Connector and Hose

Disconnect fuel pressure sensor electrical connector and vacuum hose.

Disconnect Fuel Charging Ground Wire

Disconnect the fuel charging ground wire.

Disconnect Ignition Coils and Fuel Injectors

Disconnect the ignition coils and the fuel injectors.

Disconnect Climate Control Vacuum Hoses and Harness

Disconnect climate control vacuum supply hoses and remove vacuum harness.

Remove Four Studs

Remove the four studs.

Remove Injectors and Fuel Injection Supply Manifold

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

Remove Ignition Coils

Remove the ignition coils.

Disconnect Battery Terminal

Disconnect the battery terminal.

Remove Generator Support Brace

Remove the generator support brace.

Disconnect Generator Electrical Connector

Disconnect the electrical connector.

Remove Generator

Remove the generator.

Disconnect Heater Hose

Disconnect the heater hose.

Separate and Position Engine Harness

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

Disconnect Water Temperature Indicator Sender

Disconnect the water temperature indicator sender.

Remove Water Outlet Connector

Remove the water outlet connector.

Remove Water Thermostat and O-ring

Remove water thermostat and O-ring; inspect O-ring.

Remove Intake Manifold and Gaskets

Remove intake manifold and gaskets; gaskets reusable if undamaged.

Intake Manifold Installation

Install Intake Manifold and Gaskets

Install intake manifold and gaskets, tighten bolts in sequence.

Install Water Thermostat and O-ring

Install water thermostat and O-ring; install new O-ring if necessary.

Install Water Outlet Adapter

Install the water outlet adapter.

Connect Water Temperature Indicator Sender

Connect the water temperature indicator sender.

Position and Attach Engine Harness

Position engine harness and attach to intake manifold in two locations.

Connect Heater Hose

Connect the heater hose.

Install Generator

Install the generator.

Connect Generator Electrical Connector

Connect the electrical connector.

Connect Battery Lead

Connect the battery lead.

Install Generator Support Brace

Install the generator support brace.

Install Ignition Coils

Install the ignition coils.

Install Fuel Injection Supply Manifold and Injectors

Install fuel injection supply manifold and fuel injectors as an assembly.

Install Four Studs

Install four studs.

Connect Climate Control Vacuum Hoses

Position vacuum harness and connect to climate control vacuum supply hoses.

Connect Ignition Coils and Fuel Injectors

Connect ignition coils and fuel injectors.

Connect Fuel Charging Ground Wire

Connect the fuel charging ground wire.

Connect Fuel Pressure Sensor Connector and Hose

Connect fuel pressure sensor electrical connector and vacuum hose.

Install Throttle Body and Adapter Assembly

Install throttle body and adapter as an assembly.

Tighten Throttle Body Bolts

Tighten bolts in the sequence shown.

Connect TPS Electrical Connector

Connect the throttle position sensor (TPS) electrical connector.

Connect Main Vacuum Supply

Connect main vacuum supply to the base of the throttle body adapter.

Connect IAC Valve Electrical Connector

Connect the idle air control (IAC) valve electrical connector.

Connect Vacuum Hose to EGR Valve

Connect the vacuum hose to the EGR valve.

Connect Hose to PCV Valve

Connect the hose to the PCV valve.

Connect PCV Hose to Throttle Body

Connect PCV hose to the base of the throttle body assembly.

Connect EGR Tube to EGR Valve

Connect the EGR tube to the EGR valve.

Install EGR Vacuum Regulator Solenoid Bracket

Install the EGR vacuum regulator solenoid bracket.

Connect EGR Vacuum Regulator Solenoid Vacuum Supply

Connect the EGR vacuum regulator solenoid vacuum supply.

Connect EGR Vacuum Regulator Solenoid Electrical Connector

Connect the EGR vacuum regulator solenoid electrical connector.

Connect Hoses to EGR Transducer

Connect hoses to the differential pressure feedback EGR transducer.

Connect Differential Pressure Feedback EGR Electrical Connector

Connect the differential pressure feedback EGR electrical connector.

Connect Evaporative Emissions Return Line

Connect the evaporative emissions return line.

Install Breather Tube

Install the breather tube.

Position Cables and Install Bracket

Position the cables and install the bracket.

Connect Accelerator Cable, Speed Control Cable, and Spring

Connect accelerator cable, speed control actuator cable, and return spring.

Connect Upper Radiator Hose

Connect the upper radiator hose.

Connect Upper Radiator Hose to Water Outlet Adapter

Connect the upper radiator hose to the water outlet adapter.

Connect Fuel Line

Connect the fuel line for additional information.

Install Air Cleaner Outlet Tube

Install the air cleaner outlet tube for additional information.

Refill Engine Cooling System

Refill the engine cooling system for additional information.

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