Removal (2.3L Turbo)
- Disconnect electrical connectors at air by-pass valve, TPS, CTS, injector wiring harness, detonation (knock) sensor and fan temperature sensor. Disconnect all upper intake manifold vacuum fittings at cast tube, rear vacuum line from dash panel tee, vacuum line to EGR valve and vacuum line to fuel pressure regulator.
- Disconnect throttle linkage. Unbolt accelerator cable from bracket and position cable out of way. On SVO Mustang models, remove air cooler. On all other models, remove 2 bolts that attach cast tube to turbocharger assembly. Remove 2 nuts and bolts that secure air throttle body to upper intake manifold.
- Separate cast tube from turbocharger assembly. Remove and discard gasket. Remove throttle body and cast tube. Disconnect PCV hose from bottom of upper intake manifold. Disconnect hose at water by-pass valve at lower intake manifold.
- Disconnect EGR tube and valve by removing flange nut. Remove fuel injector pulse dampener mounting bracket. Remove upper intake manifold assembly by removing 2 or 3 studded bolts and 2 plain bolts. Disconnect push connect fuel supply line. Disconnect push connect fittings at return and supply lines at fuel supply manifold.
- Disconnect wiring from all 4 fuel injectors and move harness aside. Remove 2 fuel supply manifold retaining bolts. Carefully remove fuel supply manifold. Remove 4 bottom retaining bolts from lower manifold. Remove 4 upper retaining bolts from lower manifold. Remove lower intake manifold.