54060/54061 Instructions

60. Connect the EGR vacuum regulator solenoid vacuum
supply. See illustration #54.
INSTALLATION INSTRUCTIONS
64. Connect the evaporative emissions return line as shown.
See illustration #58.
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For 1999-'04 4.6L 2V Mustang Intake Manifold
58
61. Connect the EGR vacuum regulator solenoid electrical
connector. See illustration #55
65. Install the breather tube as shown below. See illustration
#59.
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59
While these instructions apply specifically to the 2001 model
year, other years are similar. Note that this manifold can be
used on 1996-'98 engines if 1999 or later heads are used.
Removal of stock manifold:
1. We recommend that you allow the engine to cool so that
you don't accidentally burn yourself.
2. Disconnect the fuel line. This requires a special tool that is
readily available in most auto parts stores. A good bet would
be your local NAPA store.
3. Disconnect the battery ground (negative) cable.
4. Remove the air cleaner outlet tube from the throttle body.
5. Drain the engine's cooling system into a pan so that you
can save the coolant for reuse.
6. Remove the accessory drive belt. Set aside for reuse.
7. Disconnect the upper radiator hose from the coolant outlet
adapter. See illustration #1.
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10. Remove the breather tube. See illustration #4.
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4
62. Connect the hoses to the differential pressure feedback
EGR transducer. See illustration #56.
66. Position the cables and install the bracket. Tighten bolts
to 89 lb. in. See illustration #60.
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60
8. Disconnect the accelerator cable, speed control actuator
cable and return spring. See illustration #2.
11. Disconnect the evaporative emissions return line. See
illustration #5.
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5
63. Connect the differential pressure feedback EGR electrical
connector. See illustration #57.
67. connect the accelerator cable, speed control actuator and
return spring. See illustration #61.
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57
9. Remove the bolts and position the cables and bracket out
of the way. See illustration #3.
For maximum results, use a Professional Products
Upper Plenum and larger throttle body.
Kit Contents:
(1)
(1)
(9)
(4)
(1)
73. Refill engine cooling system.
74. Start engine. Allow engine to reach operating temperature. Check engine thoroughly for fuel or water leaks.
Recheck all electrical connections if engine is not operating
properly.
75. After a test drive, re-torque all bolts to specifications.
68. Connect the upper radiator hose to the water outlet
adapter. See illustration #1.
69. Install the accessory drive belt.
70. Connect the fuel line.
71. Install the air cleaner outlet tube.
72. Connect the battery ground cable.
8
Aluminum Intake Manifold
Stainless Steel Alternator Brkt.
8mm Intake Manifold Bolts
6mm Upper Plenum Bolts
Upper Plenum to Manifold Gasket
The stock intake manifold bolts are too short and the nine
bolts supplied in this kit must be used. The two stock bolts
that go through the thermostat area of the manifold can be
used. The four bolts holding the upper plenum to the manifold are too long and you must use the supplied kit bolts.
Upper Plenum
Polished Finish- #54154
Satin Finish #54155
1
Throttle Body
70mm Polished
75mm Polished
70mm Satin 75mm Satin -
- #69220
- #69221
#69222
#69223
12. Disconnect the differential pressure feedback EGR electrical connector. See illustration #6.
16. Remove bolts retaining the EGR vacuum regulator solenoid bracket to the intake manifold. See illustration #10
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10
13. Disconnect the hoses from the differential pressure feedback EGR transducer. See illustration #7.
17. Disconnect the exhaust gas recirculation (EGR) tube
from the EGR valve. See illustration #11.
11
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14. Disconnect the EGR vacuum regulator solenoid electrical
connector. See illustration #8.
18. Disconnect the positive crankshaft ventilation (PCV) hose
from the base of the throttle body. See illustration #12.
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8
15. Disconnect the EGR vacuum regulator solenoid vacuum
supply. See illustration #9.
19. Disconnect the hose from the PCV valve. See illustration
#13 below.
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13
2
52. Connect the throttle position sensor (TPS) electrical connector. See illustration #46.
56 Connect the hose to the PCV valve as shown below. See
illustration #50.
46
50
53. Connect the main vacuum supply to the base of the throttle body adapter. See illustration #47.
57. Connect the PCV hose to the base of the throttle body.
See illustration #51 below.
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47
54. Connect the idle air control (IAC) valve electrical connector. See illustration #48.
58. Connect the EGR tube to the EGR valve. Tighten to 26
lb. ft. See illustration #52 below.
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48
55. Connect the vacuum line to the EGR valve. See illustration #49 below.
59. Install the bracket as shown. Tighten bolts to 89 lb. in.
See illustration #53 below.
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49
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28. Disconnect the battery terminal from the alternator. See
illustration #22.
32. Disconnect the heater hose from the right rear of the
intake manifold. See illustration #26
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26
33. Separate the engine harness and position it out of the
way. See illustration #27.
29. Remove the upper alternator support bracket. See illustration #23 below.
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40. Install the coolant outlet adapter. Tighten bolts to 18 lb. ft.
See illustration #34
36. Remove the coolant thermostat and o-ring. Inspect o-ring
and replace if damaged. See illustration #30.
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30
37. Remove intake bolts in sequence shown below. Remove
manifold and gaskets. Gaskets are reusable if not damaged.
For new gaskets, use Ford #2L3Z-9439-AA. (2) required.
41. Connect the coolant temperature indicator sensor. See
illustration #35 below.
31
8
5
35
7
3
2
1
4
9
6
30. Disconnect the electrical connector from the alternator.
See illustration #24.
34. Disconnect the water temperature indicator sensor. See
illustration #28.
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Installation of Power+Plus Typhoon Manifold:
38. Remove upper plenum from stock manifold. Bolt it to your
Typhoon manifold using supplied 6mm bolts and supplied
gasket. Torque bolts to 89 lb. in. Install your new Typhoon
manifold onto engine. Use supplied (9) bolts. Tighten bolts in
sequence shown to 18 lb. ft. See illustration #32.
42. Position the engine harness and attach to the intake
manifold in two locations. See illustration #36 below.
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32
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5
7
3
2
1
4
9
6
31. Remove the alternator from the engine. Set it aside. See
illustration #25.
43. Connect the heater hose to fitting in right rear portion of
intake manifold. See illustration #37 below.
35. Remove the coolant outlet adapter. See illustration #29
below.
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29
39. Install thermostat and O-ring. Use new O-ring if existing
one is damaged. See illustration #33 below.
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33
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5
44. Install the alternator to manifold. Tighten bolts to 18 lb. ft.
See illustration #38.
48. Install the eight ignition coils. Tighten bolts to 53 in. lbs.
See illustration #42
42
45 Connect the electrical connector to the alternator. See
illustration #39 below.
49. Attach electrical connections to ignition coils and fuel
injectors. See illustration #43.
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43
46 Connect the battery lead to the alternator. See illustration
#40 below.
50. Connect the fuel charging ground wire as shown. See
illustration #44.
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44
47 Install supplied s/s alternator bracket. Tighten bolts to 89
lb. in. See illustration #41.
51. Connect the fuel pressure damper as shown. See illustration #45 below.
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45
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24. Disconnect the fuel pressure sensor. See illustration #18
below.
20. Disconnect the vacuum lines from the EGR valve. See
illustration #14.
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18
25. Disconnect the fuel charging ground wire. See illustration
#19 below.
21. Disconnect the idle air control (IAC) valve electrical connector. See illustration #15.
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19
26. Disconnect the eight ignition coils and the eight fuel injector connectors. See illustration #20 below.
22. Disconnect the main vacuum supply from the base of the
throttle body adapter. See illustration #16.
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20
27. Remove the ignition coils. Set them aside for later reinstallation. See illustration #21 below.
23. Disconnect the throttle position sensor (TPS) electrical
connector. See illustration #17 below.
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21
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