IN-VEHICLE SERVICE

Intake Manifold

Upper
Removal
1. Remove air cleaner outlet tube (9B659) . Refer to Section 03-12.
2. Disconnect accelerator cable (9A758) at throttle body (9E926) . Disconnect speed control actuator (9A825) (if equipped).
3. Remove retaining bolts from accelerator cable bracket (9723) and position cables aside.
4. Disconnect vacuum lines at intake manifold (9424) .
5. Disconnect necessary electrical connectors.
6. Disconnect one crankcase ventilation tube (6758) at the upper intake manifold and at positive crankcase ventilation valve (PCV valve) (6A666) .
7. Remove throttle body if necessary. Refer to Section 03-04A.
8. Remove the EGR valve (EGR valve) (9D475) from the upper intake manifold . Refer to Section 03-08.
9. Remove the nut and bolt retaining engine support and wiring retainer bracket located at the LH front of the intake manifold and set aside with ignition wires.
10. Remove upper intake manifold retaining bolts/studs.
11. Remove upper intake manifold and intake manifold upper gasket (9H486) .




Installation
1. NOTE: Use locating pins to secure position of intake manifold upper gasket between intake manifolds .
NOTE: When the upper intake manifold is removed, always use a new intake manifold upper gasket upon reassembly.
Position new intake manifold upper gasket and intake manifold on top of lower intake manifold .
2. NOTE: Apply a light coat of Pipe Sealant with Teflon D8AZ-19554-A or equivalent meeting Ford specification WSK-M2G350-A2 to retaining bolts and stud bolt threads
prior to installation.
Install bolts and stud bolts in original locations.
Tighten in sequence as shown under Removal Step 18, in three steps:
10 Nm (8 Lb-Ft)
20 Nm (15 Lb-Ft)
32 Nm (24 Lb-Ft)
Section 03-01A: Engine, 3.8L 1995 Mustang Workshop Manual
Item Part Number Description
1 N804839-S2 Bolt (5 Req'd)
2 245905-S2 Stud Bolt
3 9424 Lower Intake Manifold
4 Locating Pins (2 Req'd)
5 9H486 Intake Manifold Upper Gasket
6 9424 Upper Intake Manifold
A Tighten in sequence in three steps:
10 Nm (8 Lb-Ft)
20 Nm (15 Lb-Ft)
32 Nm (24 Lb-Ft)
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3. Install engine support and wiring bracket and retaining nut and bolt to LH front of the intake manifold . Tighten retainers to 20-30 Nm (15-22 lb-ft).
4. Install the EGR valve as outlined in Section 03-08.
5. Install throttle body if removed. Cross-tighten retaining nuts to 20-30 Nm (15-22 lb-ft).




6. Connect rear crankcase ventilation tube at positive crankcase ventilation valve on the upper intake manifold .

Fuel Injection Supply Manifold





7. Connect necessary fuel charging wiring connectors.
8. Connect necessary vacuum hoses.
9. Position accelerator cable bracket . Install and tighten retaining bolts to 14-20 Nm (10-15 lb-ft).
10. Connect accelerator cable at throttle body . Connect speed control actuator (if equipped).
11. Install air cleaner outlet tube . Refer to Section 03-12.
12. Check and adjust accelerator cable if necessary. Refer to Section 10-02.
13. Check and, if necessary, adjust engine idle airflow. Refer to Powertrain Control Emission Diagnosis Manual.
Item Part Number Description
1 9424 Upper Intake Manifold
2 Stud (Part of 9424)
3 9E936 Throttle Body Gasket
4 9E926 Throttle Body
5 N805620 Stud Bolt
6 N804178 Nut (3 Req'd)
A Tighten to 20-30 Nm (15-22 Lb-Ft)
Item Part Number Description
1 N805117-S8M Bolt (4 Req'd)
2 9F792 Fuel Injection Supply Manifold
3 9424 Intake Manifold
4 N606691-S2 Bolt
5 6049 Cylinder Head
A Tighten to 8-11.5 Nm (6-8.5 Lb-Ft)
B Tighten to 20-30 Nm (15-22 Lb-Ft)
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14. Check and adjust speed control actuator if necessary. Refer to Section 10-03.

Lower
Removal
1. Drain engine cooling system as outlined in Section 03-03.
2. Remove upper intake manifold as outlined.
3. Remove fuel injectors (9F593) and fuel injection supply manifold (9F792) . Refer to Section 03-04A.
4. Remove heater water outlet hose.
5. Remove lower intake manifold retaining bolts/studs.
6. CAUTION: The intake manifold is sealed at each end with silicone sealer. To break the seal, it may be necessary to pry on the front of the intake manifold with a
prybar. If it is necessary to pry on the intake manifold , use care to prevent damage to machined surfaces.
Remove lower intake manifolds .
7. Remove and discard intake manifold gaskets (9439) and end seals.
8. If lower intake manifold is to be disassembled, perform the following:
Remove water hose connection (8592) and water thermostat (8575) .
Remove engine coolant temperature sensor (ECT sensor) (12A648) .
Remove heater elbow.
Remove all vacuum and electrical fittings.


Water Thermostat





Installation
1. NOTE: Lightly oil all retaining bolt and stud threads before installation.
The lower intake manifold cylinder head, and cylinder block mating surfaces should be clean and free of old gasketing material. Use a suitable solvent to clean these surfaces.
2. If intake manifold was disassembled:
a. Apply Pipe Sealant with Teflon D8AZ-19554-A or equivalent meeting Ford specification WSK-M2G350-A2 to the threads of the engine coolant temperature sensor , all
vacuum fittings, heater elbows, and electrical fittings (if equipped). Refer to Specifications.
b. Install water hose connection (note direction) and water hose connection gasket (8255) . Install water hose connection . Tighten retaining bolts to 20-30 Nm (15-22 lb-ft).
3. NOTE: Prior to applying sealer, clean sealing surfaces of cylinder heads (6049) and intake manifold with Metal Surface Cleaner F4AZ-19A536-RH or equivalent meeting
Ford specification WSE-M5B392-A, to remove all residues that may interfere with the sealer's ability to adhere.
NOTE: When the lower intake manifold is removed, always use new intake manifold gaskets upon reassembly.
Apply a dab of Gasket and Trim Adhesive D7AZ-19B508-B or equivalent meeting Ford specifications ESR-M11P17-A and ESE-M2G52-A to each cylinder head mating surface.
Press new intake manifold gasket into place, using location pins as necessary to aid in assembly.
4. NOTE: When using silicone sealer, assembly must occur within 15 minutes after sealer application. After this time, the sealer may start to set-up, and its sealing
effectiveness may be reduced.
Apply a 3-4 mm (1/8 inch) bead of Silicone Rubber D6AZ-19562-BA or AA or equivalent meeting Ford specifications ESB-M4G92-A or ESE-M4G195-A at each corner where the
cylinder head joins the cylinder block (6010) .
5. Install new front and rear intake manifold end seals.
Item Part Number Description
1 Bolt (2 Req'd)
2 8592 Water Hose Connection
3 8255 Water Hose Connection Gasket
4 8575 Water Thermostat
A Tighten to 20-30 Nm (15-22 Lb-Ft)
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Intake Manifold Gaskets





6. Carefully lower intake manifold into position on cylinder block and cylinder head . Use locating pins as necessary to guide intake manifold .
7. Install bolts and stud bolt in their original locations.




8. Tighten bolts and stud bolt in numerical sequence to the following specifications in two steps:
a. 18 Nm (13 lb-ft).
b. 22 Nm (16 lb-ft).


Item Part Number Description
1 9439 Intake Manifold Gasket
2 End Seal (Part of 9439)
3 6049 Cylinder Head
4 Locating Pin (4 Req'd)
5 6051 Head Gasket
Item Part Number Description
1 Stud Bolt (2 Req'd)
2 Bolt (12 Req'd)
3 9424 Lower Intake Manifold
4 9439 Intake Manifold Gasket
5 End Seal (Part of 9439)
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9. Install front crankcase ventilation tube so that the mounting bracket sits over the lower intake manifold stud. Tighten nut on stud to 20-30 Nm (15-22 lb-ft).
10. Install fuel injectors and fuel injection supply manifold . Tighten screws to 8-11 Nm (71-97 lb-in).
11. Install upper intake manifold as outlined.
12. CAUTION: This engine has aluminum cylinder heads and requires a special corrosion inhibiting coolant to avoid cooling system damage. Refer to Section 03-03 for
the coolant specifications.
Fill engine cooling system as outlined in Section 03-03.
13. Start engine and check for leaks.










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