Reinstalling Upper Intake & Valve Covers

Due to an unfortunate timing, I need to have the Mustang driving again so I can have some repairs done to the epoxy coating on the garage floor.  I have a new intake to install but time doesn't allow for it now.  That is for the best as removing the stock intake pointed out a few things I would need to do the new intake install perfectly.  This allows me some time to get those things together so the intake install goes much more smoothly when the time comes.

Putting it back together is rather straight forward.  This gave me the opportunity to clean up the spark plugs and confirm they were gapped to .054".  They a new Motorcraft plugs but since I didn't install them originally, you always have that doubt something could be off.  This put that to rest as they are all now perfect.  Before cleaning them, I inspected them all and there was no sign of oil or other trouble with the engine.  

While installing the spark plugs, I wiped off all the header tubes and swapped out the header bolts one at a time.  I'm using stainless ARP 400-1102 bolts which look great.  I was able to swap them all in except for one on the passenger side.  That bolt will not come out unless I completely remove the header.  Since I don't have a gasket on hand, I'm installing all the bolts except for that one and will come back to it later.

I spent a good amount of time wiping down the mating surfaces of the valve covers and tops of the heads to get a good seal.  I used Fel Pro VS 13264T gaskets and the stock bolts.  They don't look any better than they did before removal but they work. I purchased a set of nice ARP valve cover bolts but I'm saving them until I put on a set of nicer valve covers.  

I mounted the original intake using the stock bolts and a Fel Pro MS 94555 gasket.  I torqued it down to 18 ft/lbs. per the manual and even reconnected the strange support bracket at the back of the intake.  With it mounted, I then meticulously reconnected the coolant hoses, vacuum hoses, throttle cable, cruise control cable, PCV value, and cold air intake.  The only thing that I question is that the connection to the vacuum tee now seems a little more loose in the back of the intake as it will twist slightly.  However, it didn't impact driving when I went for a test drive.

I have a good list of items that I would want to get for the new intake installation.  This isn't a complete list as I've been collecting a few items already.  The items I need include:

• Injector O-Rings (LRS-SK1-K or Fel-Pro ES 70599 @ Summit) 
• New Throttle Cable (LRS-9758A-K)
• PVC Grommet & Filter Screen (LRS-66631 & LRS-6892-A)
• 1/8" NPT to 1/4" Barb Fitting (Charcoal System)
• 3/8" NPT to 3/8" Barb
• 3/8" Barb T Adapter
• Thermostat
• Throttle Body

I'll ultimately want to swap out the two long bolts for the intake with some ARP bolts (ARP 651-4750) but they are custom order and probably wouldn't be here in time so I'll order them a bit later.