OEM 2004 Ford Mustang Intake Manifold

2004 Ford Mustang Intake Manifold Parts Q&A

• Q: How to service and repair the lower intake manifold on 2004 Ford Mustang?

  A: Attend to repairs of the lower intake manifold by first unfastening the upper intake manifold while partially draining the cooling system and easing the fuel system pressure. First disconnect the FRP sensor electrical connector with the vacuum hose and afterwards separate the spring lock coupling of the fuel supply tube. Swap the engine harness aside then disconnect both the IMRC electrical connector and remove the heater bypass tube and heater hose. The maintenance process includes removing the exhaust gas recirculation (EGR) vacuum tube along with the EGR tube of the EGR valve while separating the radiator upper hose and coolant bypass hose. After disconnecting the electrical connector you can remove the fuel injection supply manifold with fuel injectors as one piece then take out the bolts which secure the supply manifold. To remove the lower intake manifold you first need to uninstall the eight short bolts and six long bolts before taking out the manifold and discarding both intake manifold gaskets. The lower intake manifold should be installed within a four-minute timeframe because failure to do so requires cleaning the sealing area using metal surface cleaner followed by drying it before reinstallation. The installation process requires you to use silicone gasket and sealant on front and rear end joints before applying intake manifold gaskets. Mount the lower intake manifold while using silicone gasket and sealant at the points and torque the bolts in two steps to achieve an initial 5 Nm torque followed by 10 Nm torque by keeping track of correct bolt positions noted in extraction. Connect all wiring and bolts associated with the fuel injection supply manifold then reinstall the electrical connector, coolant hoses alongside EGR tube and EGR vacuum tube. Water should be used for lubricating the O-ring before installing both the heater hose and heater bypass tube. Reinstall the IMRC electrical connector then position the engine wire harness with pin-type retainers and connect the fuel supply tube by using spring lock coupling and align the FRP sensor with its electrical connector and vacuum hose. The last step includes installation of the upper intake manifold while performing a cooling system bleeding procedure because correct engine cooling depends on proper cooling system bleeding.