Page 2137 of 4378
16. Disconnect the vacuum hoses from the supercharger bypass vacuum solenoid, and the
actuator.
17. Disconnect the vacuum hoses from the fuel pulse damper and the EGR vacuum regulator solenoid.
18. Disconnect the vacuum hose from the EGR valve.
19. Disconnect the vacuum hoses at the back of the supercharger and position the vacuum harness aside. Klj . 4 ba
102003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_4464/S3B~us~en~ ...
Page 2138 of 4378
20. Remove the vacuum accessory bracket mounting nut.
21. Remove the mounting bolts, and the vacuum accessory bracket.
22. Disconnect the exhaust manifold to EGR valve tube.
23. Disconnect the barometric pressure (BARO) sensor electrical connector. Klj . 5 ba
102003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_4464/S3B~us~en~ ...
Page 2139 of 4378
24. Disconnect the positive crankcase ventilation (PCV) hose.
25. Separate the fuel charging wiring harness from the fuel injection supply manifold in four places
and position the harness aside.
26. Remove the ten bolts, the intake manifold, supercharger and fuel supply manifold as an assembly.
27. Disconnect and remove the PCV hoses. Klj . 6 ba
102003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_4464/S3B~us~en~ ...
Page 2140 of 4378
28. Remove the coolant supply and return manifold.
29. Remove the coolant supply and return tubes and seals.
30. Remove the fuel supply manifold mounting studs.
31. Remove the fuel supply manifold and fuel injectors as an assembly. Klj . 7 ba
102003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_4464/S3B~us~en~ ...
Page 2141 of 4378
32. Remove the bolts, the supercharger and charge air cooler (CAC) assembly.
33. Remove the bolts and the CAC in the sequence shown.
34. Inspect the CAC plenum gasket and install a new gasket if necessary.
35. To install, reverse the removal procedure
36. Apply a bead of sealant in the areas shown on the supercharger flange between the CAC and
the supercharger. Klj . 8 ba
102003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_4464/S3B~us~en~ ...
Page 2142 of 4378
37.
NOTE: Once the torque procedure has been started, final tightening must be finished within five
minutes maximum.
Tighten the CAC bolts in the sequence shown in two stages. 1. Tighten to 2 Nm (18 lb- in).
2. Tighten to 6 Nm (53 lb- in).
38. Tighten the supercharger and CAC cooler assembly- to-lower intake manifold bolts in the
sequence shown in three stages.
1. Tighten to 2 Nm (18 lb- in).
2. Tighten to 25 Nm (18 lb- ft).
3. Tighten an additional 90 degrees.
39. Tighten the coolant supply and return manifold in two stages. 1. Tighten to 10 Nm (89 lb- ft).
2. Tighten an additional 90 degrees. Klj . 9 ba
102003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_4464/S3B~us~en~ ...
Page 2143 of 4378
40.
NOTE: Inspect the intake manifold gaskets and install new gaskets, if necessary.
Tighten the lower intake manifold bolts in the sequence shown.
41. Fill and bleed the supercharger cooling system. For additional information, refer to Section 303 -
03B . Klj . 10 ba
102003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_4464/S3B~us~en~ ...
Page 2144 of 4378
SPECIFICATIONS
SECTION 303-
13: Evaporative Emissions 2003 Mustang Workshop Manual General Specifications
Item Specification
MERPOL®
O-ring Seal Lubricant ESE-
M99B144- B
Torque Specifications Description Nm lb-
ft lb-
in Evaporative emissions canister and bracket assembly bolts 25 18 —
Evaporative emission canister purge valve nuts 7 — 62 Klj . 1 ba
12003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_4464/S3B~us~en~ ...