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Old 06-22-2013, 09:04 PM   #1
Mark Wilson
 
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Vehicle: 2002 Mustang GT
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Default 2002 GT intake manifold replacement ????

I am going to attempt (that is attempt) to replace my intake manifold in order to save money. I broke the heater hose barb off and it cracked down to the actual manifold. Made a mess! So I am going to have to replace the manifold because there is no way to save this one.

So I have some general questions:

1) I know that I need the PI manifold but what sort of gaskets and extras would I have to buy? Summit shows 2 different gaskets... the FEL-MS92121 and the FEL-MS92123 (what's the difference?)??

2) Should I be doing any type of preventive maintenance when I have everything off the top of the motor?? Service??

3) Are there any sort of specialty tools that I will need?

4) Are there any step-by-step videos or documents that I can access on the internet on replacing this?

I'm in no real hurry as this is my secondary means of transportation now. However, the sooner the better on replies. I would appreciate any comments or suggestions. Possibly where to get a new PI intake manifold for the lowest price.

If you have done this job... give me some motivation and confidence. I am by no means a mechanic but I know how to take things apart and put them back together fine.

Thanks forum,
Mark W.
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Old 06-22-2013, 09:39 PM   #2
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BTW... will this manifold work? I have seen these for this price and the ones at Summit and American Muscle are $240. Are they the same manifold????

Dorman 615-175 Intake Manifold : Amazon.com : Automotive Dorman 615-175 Intake Manifold : Amazon.com : Automotive
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Old 06-23-2013, 01:40 AM   #3
JC316
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That manifold will work fine. The only thing you need to check while you have the intake off is the heater hose that is under the intake, make sure it's in good shape. The job is stupid easy. You will need a fuel line tool to disconnect the fuel line and you will need a good sized wrench for the EGR screw, thinking it's a 15/16 wrench and then a torque wrench. You will need to tighten the bolts in the correct order.

A beginner will have no difficulties on this.
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Old 06-23-2013, 06:23 AM   #4
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+1, very easy. When you disconnect the fuel rail make sure you have a rag underneath to catch the fuel that spills.
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Old 06-23-2013, 07:27 AM   #5
slipperman
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I replaced mine last year using a Ford Racing manifold and Felpro gaskets.
I'm not sure about the part numbers, I'll see if I can locate my receipt.

I replaced the water pump, alternator, serpentine belt and all hoses including the heater core hoses and the coolant line under the manifold.

I also had my fuel injectors serviced by Cruzin Performance.
Also, replace your fuel filter at this time since you'll need the same tool as the fuel lines under the hood.

I labeled every connection that needed to be separated on both sides so nothing would be missed during re-assembly.
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Old 06-23-2013, 09:41 AM   #6
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While the Dorman will work, if you care about performance I'd pay extra and get the Ford racing intake. The Dormans I've seen looks like it has smaller intake runners.

Anyways, if you have a decent set of tools you should have no problem.
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Old 06-24-2013, 12:18 AM   #7
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It's not really necessary to disconnect the fuel lines you can just push them out of the way.
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Old 06-24-2013, 09:22 PM   #8
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Just did mine last Saturday. I had never even changed my oil before. Detailed instructions help though if you’re not familiar with working on cars. If you look for my posts I started a thread (Misfire Problem) in which another forum member posted a link to a manifold remove and replace; it was very helpful. I also picked up a Chilton’s repair manual but found the instructions less novice friendly.

In regards to your parts the first one FEL-MS92121 looks like it has both manifold gaskets, which you do need, in addition to a throttle body/plenum gasket. I’m not sure about the Dorman but if you buy the FFRP intake (I’d recommend it) it will come with this gasket already in the manifold. I bought mine from AmericanMuscle. $239.99 with free shipping. The second part you listed I could not find.

You don’t need too many specialty tools. You don’t have to break the fuel line but if you want to for added maneuvering room, which I did, you’ll need a fuel line quick disconnect. You can pick one up at any auto parts store. I believe I used a 5/8ths but I would just pick up a combo pack. It’s not expensive and if you ever want to change you fuel filter I think you need a different size. I found an air wrench for loosening and pre tightening (NOT TIGHTENING) to be time saving. You will need a torque wrench for both ft/lb and in/lb to torque to specs.

As far as preventative maintenance I’ll leave that to more knowledgeable members. Like I said earlier I hadn’t worked on my car at all before. No leaks yet. Take your time, be patient, and you’ll get it done.
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Old 06-24-2013, 10:23 PM   #9
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Quick edit. That is a FRPP intake manifold. Mind was moving faster than my hands.
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Old 06-24-2013, 10:32 PM   #10
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Here is the intake manifold RnR from the shop manual. As others have said you do not need to break the fuel line, just remove the fuel rails with the injectors still inserted and tie them up and toward the sides of the engine compartment...
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Old 06-24-2013, 10:32 PM
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