Section 03-04B: Fuel Charging and Controls—5.0L
1993 Mustang Workshop Manual
REMOVAL AND INSTALLATION

Upper Intake Manifold and Throttle Body

 

Removal

  1. Remove air inlet tube.
  1. Disconnect electrical connectors at idle air control (IAC) valve, throttle position sensor and EGR valve position (VP) sensor 9J460.
  1. Disconnect throttle linkage at throttle ball and transmission linkage from throttle body. Remove two bolts securing bracket to intake manifold and position bracket with cables out of way.
  1. Disconnect upper intake manifold vacuum fitting connections by disconnecting all vacuum lines to vacuum tree, vacuum lines to EGR valve, vacuum line to fuel pressure regulator and canister purge line.
  1. Disconnect PCV system by disconnecting hose from fitting on rear of upper manifold, and disconnect PCV vent closure tube at throttle body.

     WARNING: COOLING SYSTEM MAY BE UNDER PRESSURE. RELEASE PRESSURE AT RADIATOR PRESSURE CAP BEFORE REMOVING HOSES. MAKE SURE ENGINE IS COOL BEFORE REMOVING CAP.

  1. On Mustang only, remove two EGR coolant lines from fittings on EGR spacer.
  1. Remove six upper intake manifold retaining bolts.
  1. Remove upper intake and throttle body as an assembly from lower intake manifold.
 

Installation

  1. Clean and inspect the mounting surfaces of the lower and upper intake manifolds.
  1. Position new gasket on lower intake mounting surface. The use of alignment studs may be helpful.
  1. Install upper intake manifold and throttle body assembly to lower manifold. Ensure gasket remains in place (if alignment studs are not used).
  1. Install six upper intake manifold retaining bolts. Tighten to 16-24 Nm (12-18 lb-ft).
  1. On Mustang only, install EGR coolant lines to fittings on EGR spacer.
  1. Connect PCV hose to rear of upper manifold, and connect PCV vent closure tube to throttle body.
  1. Connect vacuum lines to vacuum tree, EGR valve, fuel pressure regulator and canister purge line.
  1. Position throttle linkage bracket with cables to upper intake manifold. Install two retaining bolts and tighten to 11-13 Nm (98-115 lb-in). Connect throttle cable and AOD transmission cable to throttle body.
  1. Connect electrical connectors at idle air control (IAC) valve, TP sensor, and EGR valve position sensor.
  1. Install air inlet tube.

    NOTE: If lower intake manifold was removed, fill and bleed cooling system as outlined in Section 03-03.



    Mustang





    Item Part Number Description
    1 9E434 Cover Plate
    2A — 5/16-18 x 6.07 Bolt Hex Flange Head (2 Req'd)
    3 9425 Upper Intake Manifold
    4 9H486 Gasket
    5 9K461 Lower Intake Manifold
    6C — 5/16-18 x 4.12 Stud (4 Req'd)
    7A — 5/16-18 Stud (4 Req'd)
    8 14A163 Wiring Bracket
    9B — 8-32 x .71 Screw Oval Head (4 Req'd)
    A    Tighten to 16-24 Nm (12-18 Lb-Ft)
    B    Tighten to 2-3 Nm (18-26 Lb-In)
    C    Tighten to 2.7-5.4Nm
    (2-4 Lb-Ft)


    Cobra





    Item Part Number Description
    1A 390589 Stud 5/16-18 x 1.62
    2A 390653 Bolt 5/16-18 x 6.07 (2 Req'd)
    3A — Bolt 5/16-18 6.85 (2 Req'd)
    4A 390358 Bolt 5/16-18 x 1.62
    5 9425 Upper Intake Manifold
    6 9H486 Gasket
    7 9K461 Lower Intake Manifold
    8B — Stud 5/16-18 x 1.75 (4 Req'd)
    9B — Stud 5/16-18
    10 14A163 Wiring Bracket
    11B — Stud 3/8-16
    A    Tighten to 16-24 Nm (12-18 Lb-Ft)
    B    Tighten to 2.7-5.4Nm
    (2-4 Lb-Ft)