Mustang V8-4.6L DOHC (1996)
Intake Manifold: Service and Repair
Upper
1. Turn ON ignition and wipers, turn OFF ignition to position wipers in mid cycle (straight up).
2. Disconnect battery ground cable, then remove wiper module.
3. Drain engine cooling system into a suitable container, then relieve fuel system pressure.
4. Remove air cleaner outlet tube.
5. Remove engine drive belt.
6. Remove ignition wire covers from valve covers.
7. Disconnect ignition wires at spark plugs and coils.
NOTE: Do not pull on wires, pull on caps only. Remove ignition wires and guides from engine.
8. Disconnect wiring connectors from alternator and mounting bracket.
9. Remove alternator to intake manifold mounting brackets.
10. Disconnect and remove water bypass tube.
11. Mark and disconnect all wiring connectors to upper intake manifold components.
12. Remove alternator from engine.
13. Disconnect accelerator and speed control cables and brackets.
14. Mark and disconnect all vacuum hose connections to intake manifold components.
15. Disconnect PCV hose, then remove idle air control valve inlet tube.
16. Disconnect and remove as required for bolt access:
a. EGR valve.
b. Idle Air Control (IAC) valve.
c. Throttle body.
17. Remove upper intake manifold retaining bolts, then upper intake manifold.
18. Reverse procedure to install, noting following:
a. Ensure mating surfaces of manifolds are clean and free of burrs and gouges and seal is properly positioned.
Upper Intake Manifold Tightening Sequence
b. Install upper intake manifold and lightly tighten bolts in sequence, then tighten to 5.9-8.8 ft lb.
c. Lubricate coolant bypass tube O-rings with a suitable rubber lube, use extreme care not to cut O-rings during installation.
d. Use a suitable ohmmeter to ensure a good ground for temperature sender mounted on coolant bypass tube.
e. Fill and bleed cooling system.
f.
Do not allow engine coolant to come into contact with serpentine drive belt and pulleys, if necessary remove belt and flush with clean water.
