Removal
Endura-E Engines
De-seal 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.
Label and disconnect the spark plug wires. Remove the fuel injectors and fuel line.
Label and disconnect the coolant, vacuum, and PCV hoses from the manifold and throttle body. Disconnect the connectors from the sensors in the intake manifold. Remove the 7 mounting bolts and remove the manifold from the cylinder head. Remove the gasket.
Clean any remaining old gasket from the mating surfaces of the manifold and cylinder head.
RTE engines
The intake manifold consists of two parts, fastened with bolts.
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. Label and disconnect the coolant supply hoses, vacuum hoses, and PCV hoses from the manifold.
Disconnect the connectors from the sensors located on the intake manifold. Unscrew the mounting bolts and remove the manifold from the cylinder head. Remove the gasket. Clean all traces of the old gasket from the mating surfaces of the manifold and the cylinder 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 exhaust manifold heat shield.
On Zetec-E engines, loosen the grommet nut securing the EGR pipe to the manifold and remove the screws securing the pipe to the ignition coil hanger. Remove the grommet nut securing the pipe to the EGR valve. Remove the 2 screws securing the fuel rail wiring to the top of the manifold. Disconnect the electrical connectors from the camshaft position sensor, coolant temperature sensor, and ignition coil. Remove the 3 screws securing the wiring at the rear of the manifold. Disconnect the large electrical connector (near the fuel pressure regulator) to disconnect the manifold wiring harness from the engine wiring harness. Label 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 fuel feed and return lines from the engine. Close the lines with plugs. Unscrew the support plate mounting bolt, and the engine lifting eyes from the rear of the cylinder head.
Unscrew the bolts and nuts securing the manifold to the cylinder head. Remove the manifold. Clean any traces of the old gasket from the mating surfaces of the manifold and cylinder head.
Installation
Installation is carried out in the reverse order of removal. The following conditions must be met:
- install a new gasket and manifold;
- tighten the 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 fuel system, air supply system and vacuum hoses for leaks.