Intake Manifold: Removal

WARNING: This page is about a different variant/trim than selected.

Remove the fuel rail pressure (FRP) sensor. For additional information, refer to FUEL RAIL PRESSURE (FRP) SENSOR -- 2.0L ZETEC .
Unfasten the cable ties if necessary and install new ones when reinstalling.
Remove the accessory drive belt.
Remove the coolant expansion tank bolt.

Fig 1: Removing Coolant Expansion Tank Bolt
Courtesy of FORD MOTOR CO.
Detach the coolant expansion tank from the retaining clip and position it aside.

Fig 2: Detaching Coolant Expansion Tank From Retaining Clip
Courtesy of FORD MOTOR CO.
Detach the power steering fluid reservoir and position it aside.

Fig 3: Detaching Power Steering Fluid Reservoir
Courtesy of FORD MOTOR CO.
Disconnect the cylinder head temperature (CHT) sensor electrical connector.

Fig 4: Disconnecting Cylinder Head Temperature (CHT) Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
Remove the bolt and disconnect the ground cable.

Fig 5: Removing Bolt And Disconnecting Ground Cable
Courtesy of FORD MOTOR CO.

NOTE: Mark the position of the engine mount for reference during installation.

Fig 6: Removing Front Engine Mount Bolts

G04033855

Courtesy of FORD MOTOR CO.

Remove the front engine mount bolts.
Slide the engine towards the front of the vehicle and loosely install one of the bolts into the rearward bolt hole to prevent the engine from moving backwards.

Fig 7: Installing Bolt Into Rearward Bolt Hole
Courtesy of FORD MOTOR CO.

CAUTION: The generator must be protected from contamination. Always protect the generator with a lint-free material. Failure to follow this instruction may cause premature failure of the generator.

Fig 8: Removing Inboard Generator Bolt

G04033857

Courtesy of FORD MOTOR CO.

Remove the inboard generator bolt.
Unscrew the generator bolt fully.

Fig 9: Unscrewing Generator Bolt Fully
Courtesy of FORD MOTOR CO.
Remove the bolt and position the generator aside.
- Secure the generator using mechanic's wire.
Fig 10: Removing Bolt And Positioning Generator Aside
Courtesy of FORD MOTOR CO.
Remove the air cleaner housing.
1. Pull off the mass air flow (MAF) sensor connector.
2. Detach the crankcase ventilation hose.
3. Detach the intake hose.
- Pull out the air cleaner housing from the rubber bushings.
Fig 11: Removing Air Cleaner Housing
Courtesy of FORD MOTOR CO.
Detach the accelerator cable and the speed control cable (if equipped) from the throttle body.

Fig 12: Detaching Accelerator Cable And Speed Control Cable
Courtesy of FORD MOTOR CO.
Detach the EGR valve and EGR pipe bracket.

Fig 13: Detaching EGR Valve And EGR Pipe Bracket
Courtesy of FORD MOTOR CO.
Pull off the vacuum hoses.

Fig 14: Pulling Off Vacuum Hoses
Courtesy of FORD MOTOR CO.
Disconnect the fuel injector wiring.

Fig 15: Disconnecting Fuel Injector Wiring
Courtesy of FORD MOTOR CO.
Disconnect the camshaft position (CMP) sensor.

Fig 16: Disconnecting Camshaft Position (CMP) Sensor
Courtesy of FORD MOTOR CO.
Disconnect the positive crankcase ventilation (PCV) hose from the intake manifold.

Fig 17: Disconnecting Positive Crankcase Ventilation (PCV) Hose
Courtesy of FORD MOTOR CO.
Remove the bolt and position the engine lifting eye aside.

Fig 18: Removing Bolt And Positioning Engine Lifting Eye Aside
Courtesy of FORD MOTOR CO.
Disconnect the knock sensor (KS) electrical connector.

Fig 19: Disconnecting Knock Sensor (KS) Electrical Connector
Courtesy of FORD MOTOR CO.
Disconnect the oil pressure sensor electrical connector and remove the intake manifold.

Fig 20: Disconnecting Oil Pressure Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
Remove the 5 bolts, 2 nuts and the intake manifold.

Fig 21: Removing 5 Bolts, 2 Nuts And Intake Manifold
Courtesy of FORD MOTOR CO.