OEM 2003 Ford Mustang Intake Manifold

2003 Ford Mustang Intake Manifold Parts Q&A

• Q: How to service and repair the lower intake manifold on 2003 Ford Mustang?

  A: Start the repair and servicing process for the lower intake manifold by taking off the upper intake manifold then draining part of the cooling system while cutting off fuel system pressure. Remove the electrical connector of the Fuel Rail Pressure (FRP) sensor followed by disconnecting its vacuum hose before taking out the fuel supply tube spring lock coupling. You should position the engine wire harness aside before unhooking the intake manifold runner control (IMRC) electrical connector and removing both the heater bypass tube and heater hose. These steps include cutting the connection of Exhaust Gas Recirculation (EGR) vacuum tube as well as EGR tube from the EGR valve and removing the radiator upper hose together with the coolant bypass hose. First disconnect the electrical connector before removing the fuel injection supply manifold with fuel injectors as one piece while documenting the positions of short and long bolts for next installation. You need to eliminate eight short bolts along with six long bolts to disconnect the lower intake manifold before disposing of all intake manifold gaskets. Partial installation of the unit requires users to apply silicone gasket and sealant onto the intake manifold front and rear end seal points followed by installation of front and rear end seals and finally intake manifold gaskets. The lower intake manifold requires cleaning using metal surface cleaner followed by drying if it cannot achieve secure installation within four minutes. Install the lower intake manifold while applying silicone gasket and sealant to its mounting points and follow the bolt placement established during removal. Finish the bolt installation process by torquing each bolt first to 5 Nm and then increasing it to 10 Nm. The entire fuel injection supply manifold assembly must be installed and then reconnected with its electrical connector and coolant hoses as well as EGR tube and EGR vacuum tube. The O-ring requires water lubricant before the heater hose and heater bypass tube get installed. The engine wire harness requires pin-type retainers to connect before fitting the fuel supply tube spring lock coupling and reattaching the IMRC electrical connector. The procedure ends by connecting the FRP sensor electrical connector and vacuum hose followed by upper intake manifold installation and proper cooling system bleeding procedures for correct engine cooling maintenance.