Iowa Chapter Director
Join Date: Jul 2002
Location: Ames, Iowa
hey guys. Not real sure where to start there's a lot to cover, hah. Let's see. Differences in intakes between years:
89-90 intakes had the heater bypass run through the intake itself via two hose barbs on either side of the inlet neck right after the throttle body. Later years do not have this, they have a seperate metal pipe that runs from the front of the intake, underneath the inlet neck, to the back, which is held on by two bolts, one at the back of the drivers side head, and one at the throttle linkage bracket.
there are slight differences in vacuum ports between years, but they're all essentially the same, just different locations, plus or minus one small vacuum port depending on the year.
96-97 intakes use smaller bolts on the large 4 bolts in the center of the intake. If you have a 96-97, make sure you use another 96-97 intake.
There is a tube underneath the upper intake that runs to the EGR (i believe) it sucks to put back on after you've installed the upper intake, so try and put it on there while the upper intake is unbolted so its easier to reach.
No matter what year it is you'll have to disconnect these things to get it off:
1. 6 bolts that hold it to the lower intake. 4 center ones, and 2 on either side.
2. support bracket at front of upper intake that conects to a lower intake manifold stud.
3. throttle linkage from throttle body
4. EGR solenoid (2 10mm studs)
5. IAC and TPS wiring harnesses
6. vacuum lines. 1 main vac line, one small EGR pressure sensor vac line, and one evaporative emissions line.
7. heater bypass hose on 89-90 intakes.
Thats all I can think of.
The upper intake manifold gasket IS reusable, I've used one 4 or 5 times before, it wont leak unless you tear it upon removal. Get a new EGR solenoid gasket and get new valve cover gaskets if they are leaking. You should not have to remove your fuel rail to get the valve covers off. I know I didnt have to.
1988 Notch Mustang: - 438W, direct port n2o, t56
2003 SVT Focus: - SCT X3 tuner