Intake manifold

Withdrawal

Endura-E engines

Depressurize the fuel system. Remove the negative terminal from the battery. Remove the engine air supply pipe and disconnect the accelerator cable from the throttle.

Label and disconnect the high voltage wires from the spark plugs. Remove the fuel injectors and fuel line.

Tag and disconnect the coolant supply hoses, vacuum hoses, and crankcase ventilation hoses from the manifold and throttle body. Disconnect the connectors from the sensors in the intake manifold. Unscrew 7 bolts of fastening and remove a collector from a head of the block of cylinders. Remove the gasket.

Clean the remnants of the old gasket from the mating surfaces of the manifold and cylinder head.

RTE engines

The intake manifold consists of two parts, bolted together.

Drain the coolant from the cooling system. Depressurize the fuel system. Remove the negative terminal from the battery. Remove the engine air supply hose and disconnect the accelerator cable from the throttle. Remove the fuel injectors and fuel line. Mark and disconnect the coolant supply hoses, vacuum hoses and crankcase ventilation hoses from the manifold.

Disconnect the connectors from the sensors located on the intake manifold. Unscrew bolts of fastening and remove a collector from a head of the block of cylinders. Remove the gasket. Clean all traces of the old gasket from the mating surfaces of the manifold and block head.

Zetec and Zetec-E engines

Depressurize the fuel system. Remove the negative terminal from the battery. Remove the air supply pipe to the engine and disconnect the accelerator cable from the throttle.


Disconnect the crankcase ventilation hose from the cylinder head cover.

Unscrew the bolt securing the upper part of the heat-resistant shield of the exhaust manifold.

On Zetec-E engines, loosen the bushing nut securing the EGR pipe to the manifold and unscrew the screws securing the pipe to the ignition coil hanger. Unscrew the bushing nut securing the pipe to the EGR valve. Remove the 2 screws securing the fuel line wiring harness to the top of the manifold. Disconnect the electrical connectors from the camshaft position sensor coolant temperature sensor and the ignition coil. Remove the 3 screws securing the electrical wiring at the back of the manifold. Disconnect the large electrical connector (next to the fuel pressure regulator), to disconnect the manifold wiring harness from the engine wiring harness. Mark and disconnect the vacuum hoses from the manifold and throttle body.

Equalize the pressure in the tank by removing the filler cap, then disconnect the supply and return fuel lines from the engine. Close tubes with stoppers. Remove the base plate mounting bolt and engine lifting lugs from the rear of the cylinder head.

Unscrew bolts and nuts of fastening of a collector to a head of the block of cylinders. Remove the manifold. Clean the traces of the old gasket from the mating surfaces of the manifold and block head.

Installation

Installation is done in sequence. Reverse withdrawal In this case, the following conditions must be met:

• install a new gasket and manifold;
• tighten bolts and nuts in 3-4 stages until the required torque is reached. If necessary, add coolant to the cooling system;
• before starting the engine, check the adjustment of the accelerator cable;
• after warming up the engine, check the tightness of the fuel system, air supply systems and vacuum hoses.