OEM 2009 Ford Mustang Intake Manifold

2009 Ford Mustang Intake Manifold Parts Q&A

• Q: How to service and repair the intake manifold on 2009 Ford Mustang?

  A: Cleanliness must be established before servicing or repairing the intake manifold in order to avoid preventing engine failure from foreign materials. Detach the Air Cleaner outlet pipe then disconnect the radio capacitor electrical connector and remove the RH spark plug wires from the ignition coil followed by the RH spark plug wire retainer from the intake manifold. Detach the two upper and two lower bolts which secure the ignition coil bracket and set the combination of ignition coil and bracket assembly to one side. When performing the diagnosis disconnect the EGR system module electrical connector alongside its tube as well as the brake booster vacuum hose and the vacuum tube from the fuel rail pressure and temperature sensor together with the vapor tube from the intake manifold and the PCV tube. Remove the intake manifold by first disconnecting the Throttle Position (TP) sensor and Throttle Body (TB) electrical connectors then the Knock Sensor (KS) electrical connector retainer before unscrewing its eight bolts. Check for metal damage when installing the intake manifold since engines experiencing upper engine failure need replacement or repair. Install a new manifold when metal contamination is observed in such cases. The mechanic should clean all surfaces that require sealing then proceed to install new gaskets when needed. Attach the intake manifold to its position while installing its eight bolts to a torque of 10 Nm (89 lb-in) in a specific tightening order. The first step is to attach the PCV tube followed by installation of the KS electrical connector retainer. Reconnect the TP sensor and TB electrical connectors while completing the work. Connect the vapor tube together with the vacuum tube to fuel rail pressure and temperature sensor and install the brake booster vacuum hose to the intake manifold. Start by connecting the EGR system module tube first then secure it with 40 Nm (30 lb-ft) torque and proceed to connect the EGR system module electrical connector. Place the ignition coil bracket assembly in its proper position then secure both lower bolts with the M8 bolt at 24 Nm (18 lb-ft) and M12 bolt at 34 Nm (25 lb-ft). The procedure ends by attaching the RH spark plug wire retainer and reconnecting RH spark plug wires to the ignition coil along with reconnecting the radio capacitor electrical connector. Finish the operation by reinstalling the ACL outlet pipe.