Friday, March 16, 2012

How to replace Intake Manifold On Ford Mustang?

The Intake Manifold replacing detail is as follows:---


2010 Ford Mustang Intake Manifold
REMOVAL & INSTALLATION details:--
The Procedure is also for other years mustang car models:----

4.0L engine
4.6L engine
5.4L engine.
4.0L Engine
Specific to:
Ford Mustang 2009-2010

NOTE
During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces that enters the oil passages, coolant passages or the oil pan, can cause engine failure.

  1. Remove the Air Cleaner (ACL) outlet pipe.
  2. Disconnect the radio capacitor electrical connector.
  3. Disconnect the RH spark plug wires from the ignition coil.
  4. Detach the RH spark plug wire retainer from the intake manifold.
  5. Remove the 2 ignition coil bracket upper bolts.
  6. Remove the 2 ignition coil lower bolts. Position the ignition coil and bracket assembly aside.
  7. Disconnect the EGR system module electrical connector.
  8. Disconnect the EGR system module tube from the EGR system module.
  9. Disconnect the brake booster vacuum hose from the intake manifold.
  10. Disconnect the vacuum tube from the fuel rail pressure and temperature sensor.
  11. Disconnect the vapor tube from the intake manifold.
  12. Remove the PCV tube.
  13. Detach the Knock Sensor (KS) electrical connector retainer from the intake manifold.
  14. Disconnect the Throttle Position (TP) sensor and Throttle Body (TB) electrical connectors.
  15. Remove the 8 bolts and the intake manifold.

    Click image to see an enlarged view
    Fig. Exploded view of the intake manifold (1 of 2) (4.0L engine)


    Click image to see an enlarged view
    Fig. Exploded view of the intake manifold (1 of 2) (4.0L engine)
To install:

NOTE
If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions can result in engine damage.


NOTE
Clean and inspect all sealing surfaces. Inspect and install new gaskets as necessary.

  1. Position the intake manifold and install the 8 bolts. Tighten in the sequence shown to 89 inch lbs. (10 Nm).

    Click image to see an enlarged view
    Fig. Identifying the intake manifold bolt tightening sequence (4.0L engine)
  2. Connect the TP sensor and TB electrical connectors.
  3. Attach the KS electrical connector retainer to the intake manifold.
  4. Install the PCV tube.
  5. Connect the vapor tube to the intake manifold.
  6. Connect the vacuum tube to the fuel rail pressure and temperature sensor.
  7. Connect the brake booster vacuum hose to the intake manifold.
  8. Connect the EGR system module tube to the EGR system module. Tighten to 30 ft. lbs. (40 Nm).
  9. Connect the EGR system module electrical connector.
  10. Position the ignition coil and bracket assembly. Install the 2 lower bolts. Tighten the M8 bolt to 18 ft. lbs. (24 Nm). Tighten the M12 bolt to 25 ft. lbs. (34 Nm).
  11. Install the 2 ignition coil bracket upper bolts. Tighten to 80 inch lbs. (9 Nm).
  12. Attach the RH spark plug wire retainer to the intake manifold.
  13. Connect the RH spark plug wires to the ignition coil.
  14. Connect the radio capacitor electrical connector.
  15. Install the ACL outlet pipe.
4.6L Engine
Specific to:
Ford Mustang 2009-2010

WARNING
Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.


WARNING
Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury.

  1. If equipped, remove the 4 nuts and the strut tower cross brace.
  2. Release the fuel system pressure.
  3. Remove the Air Cleaner (ACL) outlet pipe.
  4. Remove the fuel rail and injectors.
  5. Disconnect the Evaporative Emission (EVAP) tube from the intake manifold and position the tube aside.
  6. Disconnect the PCV tube from the intake manifold, LH valve cover and remove.
  7. Disconnect the Throttle Position (TP) sensor and electronic Throttle Body (TB) electrical connectors.
  8. Disconnect the Charge Motion Control Valve (CMCV) electrical connector.
  9. Detach the wiring retainers from the intake manifold stud bolt and the CMCV bracket and then position the wiring harness aside.
  10. Disconnect the vacuum hose from the T-fitting.
    NOTE
    Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.


    NOTE
    Clean and inspect the sealing surfaces with metal surface prep. Follow the directions on the packaging.
  11. Remove the 9 bolts, the stud bolt and the intake manifold. Discard the gaskets.

    Click image to see an enlarged view
    Fig. Exploded view of the intake manifold (4.6L engine)


    Click image to see an enlarged view
    Fig. Removing the intake manifold (4.6L engine)
To install:

NOTE
If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions can result in engine damage.


NOTE
Electrical and vacuum harnesses must not restrict movement of the CMCV control rods at rear of the intake manifold. Use extreme care on installation of the intake manifold to prevent any pinching of electrical and vacuum harnesses.

  1. Using new intake manifold gaskets, position the intake manifold.
  2. Install the 9 intake manifold bolts and stud bolt. Tighten in the sequence shown to 89 inch lbs. (10 Nm).

    Click image to see an enlarged view
    Fig. Identifying the intake manifold bolt tightening sequence (4.6L engine)
  3. Connect the vacuum hose to the T-fitting.
  4. Position the wiring harness and attach the wiring retainers to the intake manifold stud bolt and the CMCV bracket.
  5. Connect the CMCV electrical connector.
  6. Connect the TP sensor and electronic TB electrical connectors.
  7. Connect the PCV tube to the intake manifold.
  8. Connect the EVAP tube to the intake manifold.
  9. Install the fuel rail and injectors.
  10. Install the ACL outlet pipe.
  11. If equipped, install the strut tower cross brace and the 4 nuts.
  12. Tighten to 26 ft. lbs. (35 Nm).
5.4L Engine
Specific to:
Ford Mustang 2009-2010

WARNING
Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.


WARNING
Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury.


NOTE
During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces that enters the oil passages, coolant passages or the oil pan, can cause engine failure.

  1. Release the fuel system pressure.
  2. Drain the engine cooling system.
  3. Drain the Supercharger (SC) cooling system.
  4. Remove the 4 nuts and the strut tower cross brace.
  5. Remove the Air Cleaner (ACL) outlet pipe.
  6. Disconnect the battery ground cable.
  7. Remove the EGR tube.
  8. Disconnect the Throttle Position (TP) sensor electrical connector.
  9. Remove the 4 bolts and position the Throttle Body (TB) and spacer assembly aside.
  10. Disconnect the Intake Air Temperature 2 (IAT2) sensor electrical connector.
  11. Disconnect the fuel supply tube.
  12. Disconnect the 4 LH fuel injector electrical connectors.
  13. Remove the 2 bolts and the wiring harness retainer from the rear of the intake manifold.
  14. Detach the 2 wiring harness pin-type retainers from the rear of the intake manifold.
  15. Disconnect the fuel rail pressure and temperature sensor electrical connector.
  16. Disconnect the 4 RH fuel injector electrical connectors.
  17. Disconnect the EGR system module electrical connector.
  18. Disconnect the crankcase ventilation tube from the RH side of the SC .
  19. Disconnect the SC bubbler hose from the rear of the SC .
  20. Rotate the SC drive belt tensioner clockwise and remove the drive belt from the SC drive pulley.

    Click image to see an enlarged view
    Fig. Removing the drive belt from the SC drive pulley
  21. Disconnect the 2 upper radiator hoses and the 2 coolant vent hoses from the intake manifold.
  22. Disconnect the 2 coolant hoses from the Charge Air Cooler (CAC).
  23. Disconnect the heater hose located below the rear of the intake manifold.
  24. Remove the 14 bolts and the intake manifold assembly. Discard the gaskets.

    Click image to see an enlarged view
    Fig. Exploded view of the intake manifold (1 of 2) (5.4L engine)


    Click image to see an enlarged view
    Fig. Exploded view of the intake manifold (2 of 2) (5.4L engine)
To install:

NOTE
If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions can result in engine damage.


NOTE
Clean the sealing surfaces with metal surface prep. Follow the directions on the packaging. Inspect the mating surfaces.

  1. Using new intake manifold gaskets, position the intake manifold.
  2. Install the 14 bolts. Tighten in the sequence shown to 89 inch lbs. (10 Nm).

    Click image to see an enlarged view
    Fig. Identifying the intake manifold bolt tightening sequence
  3. Connect the heater hose located below the rear of the intake manifold.
  4. Connect the 2 coolant hoses to the CAC .
  5. Connect the 2 upper radiator hoses and the 2 coolant vent hoses to the intake manifold.
  6. Rotate the SC drive belt tensioner clockwise and install the drive belt onto the SC drive pulley.
  7. Connect the SC bubbler hose to the rear of the SC.
  8. Connect the crankcase ventilation tube to the RH side of the SC.
  9. Connect the EGR system module electrical connector.
  10. Connect the 4 RH fuel injector electrical connectors.
  11. Connect the fuel rail pressure and temperature sensor electrical connector.
  12. Attach the 2 wiring harness pin-type retainers to the rear of the intake manifold.
  13. Install the wiring harness retainer and the 2 bolts onto the rear of the intake manifold.
  14. Connect the 4 LH fuel injector electrical connectors.
  15. Connect the fuel supply tube.
  16. Connect the IAT2 sensor electrical connector.
  17. Install the TB and spacer assembly and the 4 bolts. Tighten to 89 inch lbs. (10 Nm).
  18. Connect the TP sensor electrical connector.
  19. Install the EGR tube.
  20. Install the ACL outlet pipe.
  21. Connect the battery ground cable.
  22. Install the strut tower cross brace and the 4 nuts. Tighten to 26 ft. lbs. (35 Nm).
  23. Fill and bleed the SC cooling system.
  24. Fill and bleed the engine cooling system.

These details will help.
Thanks.

FOR MORE HELP GO TO: ---

Car repair guide?

http://technoanswers.blogspot.in/2012/03/car-repair-guide.html




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