How to Install a Moroso Air/Oil Separator on Your 1996-2004 Mustang GT

This Mustang Parts Installation Guide Works For

Moroso Air/Oil Separator (96-04 GT)DOWNLOAD PDF

Tools Required

Installation Time: 30 Minutes

Installation

  • (1) TANK BODY
  • (1) BILLET CLAMP
  • (1) BALL VALVE
  • (1) 90 DEGREE DRAIN
  • (1) STAINLESS STEEL BRACKET
  • (2) 90 DEGREE BARBED FITTINGS
  • (1) LENGTH OF TUBE
  • (1) DRAIN CAP
  • (2) X 20 SHCS X 5/8
  • (1) X 20 SHCS X 1
  • (1) 8mm Nut
  • (1) 5/8 COUPLING
  • (1) LENGTH OF 5/8 TUBE
moroso-air-oil-separator-96-04-gt

Step 1: Loosen Air Intake hose clamps

moroso-air-oil-separator-96-04-gt

Step 2: Remove lines from Air Intake hose

moroso-air-oil-separator-96-04-gt

Step 3: Remove Air Intake hose from throttle body

moroso-air-oil-separator-96-04-gt

Step 4: Remove Air Intake hose from Air Cleaner Box, and remove from vehicle

moroso-air-oil-separator-96-04-gt

Step 5: Locate PCV Tube (Valve cover Side)

moroso-air-oil-separator-96-04-gt

Step 6: Remove tube from PCV Valve

moroso-air-oil-separator-96-04-gt

Step 7: Locate PCV Tube (Intake Side)

moroso-air-oil-separator-96-04-gt

Step 8: Remove from Intake

moroso-air-oil-separator-96-04-gt

Step 9: Remove PCV tube from Vehicle and put a side

moroso-air-oil-separator-96-04-gt

Step 10: Assemble Billet mount to Stainless Bracket as shown. Note orientation of SHCS

moroso-air-oil-separator-96-04-gt

Step11: Locate 8mm stud as shown and install Billet Stainless Mount

moroso-air-oil-separator-96-04-gt

Step 12: Assemble Air Oil Separator as shown, apply Teflon Tape to all fittings

moroso-air-oil-separator-96-04-gt

Stap13: Insert Air Oil Separator into billet clamp, line up seam on Air Oil Separator to top of Billet Clamp and tighten

moroso-air-oil-separator-96-04-gt

Step 14: cut 1 pc of hose to 34

moroso-air-oil-separator-96-04-gt

Step 15: Insert one end of hose to rear fitting on Air Oil Separator

moroso-air-oil-separator-96-04-gt

Step 16: Route hose from Air Oil Separator to Valve Cover as shown

moroso-air-oil-separator-96-04-gt

Step 17: Remove 90 degree fitting from PCV tube previously removed

moroso-air-oil-separator-96-04-gt

Step 18: Insert Nylon coupling into 90 degree fitting, install 90 degree fitting to PCV valve, trim hose

moroso-air-oil-separator-96-04-gt

Step 19: Insert hose over coupling

moroso-air-oil-separator-96-04-gt

Step 20: cut 1 pc of hose to 20

moroso-air-oil-separator-96-04-gt

Step 21: Insert one end of hose to front fitting on Air Oil Separator

moroso-air-oil-separator-96-04-gt

Step 22 Insert 5/8 end of coupling into 5/8 hose

moroso-air-oil-separator-96-04-gt

Step 23: Insert 5/8 tube over intake nipple

moroso-air-oil-separator-96-04-gt

Step 24: trim hose previously installed from step 21

moroso-air-oil-separator-96-04-gt

Step 25: Insert hose over coupling

moroso-air-oil-separator-96-04-gt

Step 26: Secure hoses with wire ties as needed

moroso-air-oil-separator-96-04-gt

Step 27: Re-Install Air Intake hose to Throttle Body

moroso-air-oil-separator-96-04-gt

Step 28: Re-Install Air Intake hose to Air Box

moroso-air-oil-separator-96-04-gt

Step 29: Re-Install lines

moroso-air-oil-separator-96-04-gt

Step 30: Tighten clamp on throttle body side

moroso-air-oil-separator-96-04-gt

Step 31: Tighten clamp on Air Box side

moroso-air-oil-separator-96-04-gt

Installation Complete

Draining of Air Oil Separator is needed; this will depend on driving conditions (i.e.) normal day to day driving check every 1,000 miles until a baseline is established. A good baseline is to drain the Air Oil Separator when it is about HALF full. This will vary with temperatures (cold winters vs. hot summers). For track usage Air Oil Separator will need to be drained after every outing.

There are several different methods to draining Air Oil Separator. The first and simplest method is to place a cup or MOROSO part # 65805 under drain elbow and open ball valve, once draining is complete close ball valve. The second method is to run a length of hose from elbow to under carriage of vehicle and place drain pan under vehicle at this time open ball valve, when draining is complete close ball valve. This hose may also be permanently installed for future draining.