Intake Manifold Removal on 2003 Ford Focus?

Intake Manifold :---

Removal & Installation

2.0L (VIN 3) Engine

1. Before servicing the vehicle, refer to the Precautions Section.
2. Drain the cooling system.
3. Relieve the fuel system pressure.
4. Remove or disconnect the following:
   
   
   Negative battery cable

   Air cleaner outlet tube

   Throttle Position (TP) sensor connector

   Bolt that secures the pipe located by the crankshaft pulley

   Heater hoses

   Main engine control sensor wiring

   Connectors from the mounting bracket

   Intake manifold vacuum lines

   Positive Crankcase Ventilation (PCV) hose

   Drive belt

   Alternator

   Fuel line

   Intake manifold

To install:

1. Install or connect the following:
   
   
   Intake manifold. Tighten the fasteners to 13 ft. lbs. (18 Nm).

   Fuel line

   Alternator

   Drive belt

   PCV hose

   Intake manifold vacuum lines

   Connectors in the mounting bracket

   Main engine control sensor wiring

   Heater hoses

   Bolt that secures the pipe located by the crankshaft pulley. Tighten the bolt to 71-97 inch lbs. (8-11 Nm).

   TP sensor electrical connection

   Air cleaner outlet tube

   Negative battery cable
2. Fill the cooling system.
3. Start the engine and check for leaks.

2.0L (VIN 5) Engine

1. Before servicing the vehicle, refer to the Precautions Section.
2. Remove the fuel injection supply manifold.
3. Raise and support the vehicle.
4. Remove the intake manifold lower retaining bolt.
   
   
   

   

   Fig. Intake manifold lower retaining bolt-2.0L (VIN 5) engine
5. Lower the vehicle.
6. Remove the engine lifting eye from the cylinder head.
7. Disconnect the idle air control (IAC) sensor electrical connector.
8. Disconnect the throttle position (TP) sensor electrical connector.
9. Remove the intake manifold runner control (IMRC) actuator cable from the IMRC lever.
10. Disconnect the IMRC actuator cable from the intake manifold assembly.
11. Disconnect the vacuum hoses from the throttle body.
12. Release the quick release coupling and pull out the brake booster pipe.
13. Separate the two sections of the intake manifold.
14. Disconnect the knock sensor (KS) electrical connector from the intake manifold inner section.
15. Remove the intake manifold inner section locknut and bolts. Discard the locknut.
16. Remove the intake manifold inner section retaining stud.
17. Remove the intake manifold sections.

To install:

NOTE

Clean and inspect the intake manifold gasket. Install a new intake manifold gasket if necessary.

NOTE

Install a new intake manifold locknut.

1. Install the intake manifold sections.
2. Install the intake manifold inner section retaining stud and tighten it to 88 inch lbs. (10 Nm).
3. Install the intake manifold inner section locknut and bolts. Tighten the fasteners to 13 ft. lbs. (18 Nm).
4. Connect the knock sensor (KS) electrical connector to the intake manifold inner section.
5. Connect the two sections of the intake manifold.
6. Install the brake booster pipe.
7. Connect the vacuum hoses from the throttle body.
8. Connect the IMRC actuator cable from the intake manifold assembly.
9. Install the intake manifold runner control (IMRC) actuator cable from the IMRC lever.
10. Connect the throttle position (TP) sensor electrical connector.
11. Connect the idle air control (IAC) sensor electrical connector.
12. Install the engine lifting eye from the cylinder head. Tighten the bolts to 26 ft. lbs. (35 Nm).
13. Raise the vehicle.
14. Install the intake manifold lower retaining bolt. 
15. Lower the vehicle.
16. Install the fuel injection supply manifold.

2.0L (VIN N) Engine

1. Before servicing the vehicle, refer to the Precautions Section.
2. Remove or disconnect the following:
   
   NOTE

   There are 3 different size bolts used. Mark the location of the bolts to ensure installation in the correct location.
   
   
   
   
   Cooling fan motor and shroud

   Lower intake manifold bolt

   Air cleaner outlet tube

   Accelerator control snow shield

   Emissions breather tube

   Throttle cable and cruise control cable, if equipped, from the throttle linkage

   Throttle position (TP) sensor electrical connector and position the wiring harness aside

   Idle air control (IAC) valve electrical connector and position the wiring harness aside

   Evaporative emissions hose

   Power brake booster vacuum hose

   Vacuum hose from the fuel pressure regulator

   Intake manifold runner control (IMRC) actuator electrical connector

   Manifold absolute pressure (MAP) sensor electrical connector

   Secondary air injection (AIR) vacuum supply hose, if equipped

   Swirl control valve electrical connector

   Oil level indicator tube
   
   
   
   
   Seven intake manifold bolts
3. Raise the intake manifold enough to gain clearance to disconnect the knock sensor (KS) wiring harness.
4. Disconnect the positive crankcase ventilation (PCV) hose.
5. Remove the exhaust gas recirculation (EGR) tube.
6. Remove the intake manifold.
   
   
   

   

   Fig. Location of the intake manifold mounting bolts - 2.0L (VIN N) engine.

To install:

1. Inspect and install new intake manifold gaskets, if necessary.
2. Position the intake manifold and install the PCV hose and then install the exhaust gas recirculation (EGR) tube. Tighten the EGR tube to 41 ft. lbs. (55 Nm).
3. Connect the KS wiring harness.
   
   NOTE

   Be sure to install the bolts in the previously marked locations.
4. Install the seven mounting bolts. Tighten the bolts to 13 ft. lbs. (18 Nm).
5. Install or connect the following:
   
   
   Oil level indicator tube

   Swirl control valve electrical connectors

   AIR vacuum supply hose, if equipped

   Lower intake bolt and tighten to 13 ft. lbs. (18 Nm)

   MAP sensor electrical connector

   IMRC actuator electrical connector

   Vacuum hose from the fuel pressure regulator

   Power brake booster vacuum hose

   Evaporative emissions hose

   IAC wiring harness and connector

   TP sensor electrical wiring harness and connector

   Throttle cable and cruise control cable, if equipped, to the throttle linkage

   Accelerator control snow shield

   Air cleaner outlet tube

   Cooling fan motor and shroud
6. Start the engine and check for leaks.
   
   
   

   

   Fig. Exploded view of the intake manifold and related components-2.0L (VIN N) and 2.3L (VIN Z) engine

2.0L (VIN P) Engine

1. Before servicing the vehicle, refer to the Precautions Section.
2. Drain the cooling system.
3. Relieve the fuel system pressure.
4. Remove or disconnect the following:
   
   
   Negative battery cable

   Air cleaner outlet tube
5. Tag and disconnect the vacuum hoses from the following components:
   
   
   Exhaust gas Recirculation (EGR) valve

   Positive Crankcase Ventilation (PCV) valve

   Throttle body

   Fuel pressure regulator

   Intake manifold
6. Remove or disconnect the following:
   
   
   Accelerator cable, throttle control lever and if equipped, the speed control cable

   Speed control cable bracket bolt, if equipped

   Idle Air Control (IAC) valve and Throttle Position (TP) sensor electrical connections

   Engine oil dipstick tube bracket bolt that attaches the tube to the intake manifold

   EGR manifold tube located below the EGR valve

   Engine oil dipstick tube from the block

   Intake manifold lower nuts

   Intake manifold upper nuts

   Intake manifold

To install:

1. Clean and oil the intake manifold mounting studs.
2. Install or connect the following:
   
   
   Intake manifold with a new gasket. Tighten the nuts to 15-22 ft. lbs. (20-30 Nm).

   Engine oil dipstick tube

   EGR manifold tube. Tighten it to 15-20 ft. lbs. (20-28 Nm).

   IAC valve and TP sensor electrical connections

   Speed control cable bracket bolt, if equipped. Tighten to 71-88 inch lbs. (8-10 Nm).

   Throttle control lever, accelerator cable and if equipped, the speed control cable
3. Connect the vacuum hoses to the following components:
   
   
   EGR valve

   PCV valve

   Throttle body

   Fuel pressure regulator

   Intake manifold

   Air cleaner outlet tube

   Negative battery cable
4. Fill the cooling system.
5. Start the engine and check for coolant leaks.

2.3L (VIN Z) Engine

1. Before servicing the vehicle, refer to the Precautions Section.
2. Remove or disconnect the following:
   
   NOTE

   There are two different size bolts used. Mark the location of the bolts to ensure installation in the correct location.
   
   
   
   
   Cooling fan motor and shroud

   Lower intake manifold bolt

   Accelerator control snow shield

   Air cleaner outlet tube

   Emissions breather tube

   Throttle cable and cruise control cable, if equipped, from the throttle linkage

   Throttle position (TP) sensor electrical connector and position the wiring harness aside

   Idle air control (IAC) valve electrical connector and position the wiring harness aside

   Evaporative emissions hose

   Power brake booster vacuum hose

   Vacuum hose from the fuel pressure regulator

   Intake manifold runner control (IMRC) actuator electrical connector

   Manifold absolute pressure (MAP) sensor electrical connector

   Swirl control valve electrical connectors and pin-type retainers

   Oil level indicator tube
   
   
   
   
   Seven intake manifold bolts
3. Raise the intake manifold enough to gain clearance to disconnect the knock sensor (KS) wiring harness.
4. Disconnect the positive crankcase ventilation (PCV) hose.
5. Remove the intake manifold.
   
   
   

   

   Fig. Intake manifold mounting bolt locations-2.3L engine

To install:

1. Inspect and install new intake manifold gaskets, if necessary.
2. Position the intake manifold and install the PCV hose.
3. Connect the KS wiring harness.
   
   NOTE

   Be sure to install the bolts in the previously marked locations.
   
   
   
   NOTE

   To ease the installation of the lower center mounting bolt, use a 6-inch long, ⁵ / ₁₆ -inch diameter hose.
4. Install the seven mounting bolts. Tighten the bolts to 13 ft. lbs. (18 Nm).
5. Install or connect the following:
   
   
   Oil level indicator tube

   Swirl control valve electrical connectors and pin-type retainers

   Lower intake bolt and tighten to 13 ft. lbs. (18 Nm)

   MAP sensor electrical connector

   IMRC actuator electrical connector

   Vacuum hose from the fuel pressure regulator

   Power brake booster vacuum hose

   Evaporative emissions hose

   IAC wiring harness and connector

   TP sensor electrical wiring harness and connector

   Throttle cable and cruise control cable, if equipped, to the throttle linkage

   Accelerator control snow shield

   Air cleaner outlet tube

   Cooling fan motor and shroud
6. Start the engine and check for leaks.

1. Before servicing the vehicle, refer to the Precautions Section.
2. Remove or disconnect the following:
   
   NOTE

   There are 3 different size bolts used. Mark the location of the bolts to ensure installation in the correct location.
   
   
   
   
   Cooling fan motor and shroud

   Lower intake manifold bolt

   Accelerator control snow shield

   Air cleaner outlet tube

   Emissions breather tube

   Throttle cable and cruise control cable, if equipped, from the throttle linkage

   Throttle position (TP) sensor electrical connector and position the wiring harness aside

   Idle air control (IAC) valve electrical connector and position the wiring harness aside

   Evaporative emissions hose

   Power brake booster vacuum hose

   Vacuum hose from the fuel pressure regulator

   Intake manifold runner control (IMRC) actuator electrical connector

   Manifold absolute pressure (MAP) sensor electrical connector

   Swirl control valve electrical connectors and pin-type retainers

   Oil level indicator tube
   
   
   
   
   Seven intake manifold bolts
3. Raise the intake manifold enough to gain clearance to disconnect the knock sensor (KS) wiring harness.
4. Disconnect the positive crankcase ventilation (PCV) hose.
5. Remove the exhaust gas recirculation (EGR) tube.
6. Remove the intake manifold.
   
   
   

   

   Fig. Intake manifold mounting bolt locations-2.3L engine

To install:

1. Inspect and install new intake manifold gaskets, if necessary.
2. Position the intake manifold and install the PCV hose and then install the exhaust gas recirculation (EGR) tube. Tighten the EGR tube to 41 ft. lbs. (55 Nm).
3. Connect the KS wiring harness.
   
   NOTE

   Be sure to install the bolts in the previously marked locations.
   
   
   
   NOTE

   To ease the installation of the lower center mounting bolt, use a 6-inch long, ⁵ / ₁₆ -inch diameter hose.
4. Install the seven mounting bolts. Tighten the bolts to 13 ft. lbs. (18 Nm).
5. Install or connect the following:
   
   
   Oil level indicator tube

   Swirl control valve electrical connectors and pin-type retainers

   Lower intake bolt and tighten to 13 ft. lbs. (18 Nm)

   MAP sensor electrical connector

   IMRC actuator electrical connector

   Vacuum hose from the fuel pressure regulator

   Power brake booster vacuum hose

   Evaporative emissions hose

   IAC wiring harness and connector

   TP sensor electrical wiring harness and connector

   Throttle cable and cruise control cable, if equipped, to the throttle linkage

   Accelerator control snow shield

   Air cleaner outlet tube

   Cooling fan motor and shroud
6. Start the engine and check for leaks.