Mustang L4-140 2.3L VIN A 1-bbl (1983)
Intake Manifold: Service and Repair
Fuel Charging Assembly, Replace
4-140 Turbocharged Engine
1.
Disconnect the following electrical connectors:
a. Air bypass valve
b. Throttle position sensor.
c. Injector wiring harness.
d. Knock sensor.
e. Fan and coolant temperature sensor.
2.
Disconnect top manifold vacuum connections.
3.
Disconnect throttle linkage.
4.
On 1986 Mustang SVO models, remove air cooler assembly.
5.
On all models except 1986 Mustang SVO, remove two cast tube assembly to turbocharger assembly attaching bolts.
6.
On all models, remove four air throttle body to fuel charging assembly attaching nuts or two nuts and two bolts.
7.
On all models except 1986 Mustang SVO, separate cast tube from turbocharger assembly and remove gasket.
8.
On all models, remove throttle body and cast tube, then disconnect PCV hose from fitting on underside of upper intake manifold.
9.
Disconnect water bypass hose at lower intake manifold.
10.
Disconnect EGR tube from EGR valve, then remove upper intake manifold attaching nuts.
11.
Remove upper intake manifold assembly.
12.
Disconnect fuel return line from fuel supply manifold using tool No. T82L-9500-AH or equivalent.
13.
Remove oil dipstick/fuel injector wiring harness bracket attaching bolt.
14.
Disconnect all four fuel injector electrical connectors and position harness to one side.
15.
Remove fuel supply manifold attaching bolts, then the fuel supply manifold.
16.
Remove lower intake manifold attaching bolts, then the lower intake manifold assembly.
17.
Reverse procedure to install, noting the following:
a. Ensure that mating surfaces of fuel charging assembly and cylinder head are clean and not damaged.
b. Clean and lubricate manifold stud threads before installation.
c. Install new gasket on lower intake manifold assembly.
d. Torque EGR tube flange nuts to 6 - 8.5 ft. lbs.
e. Install new gasket on fuel charging assembly air throttle body mounting flange.
f.
Torque two cast tube attaching bolts to 14 - 21 ft. lbs.
g. Torque four air throttle body/cast tube assembly to fuel charging assembly attaching nuts and/or bolts to 12 - 15 ft. lbs.
