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Home › Ford › 2002 › ZX2 Automatic › Repair and Diagnosis › Engine Mechanical › Mechanical › Engine - 2.0L › In-Vehicle Repair › Intake Manifold › Removal

Intake Manifold: Removal

    WARNING: Fuel supply lines will remain pressurized for long periods of time after engine shut down. This pressure must be relieved before disconnecting any fuel lines or fuel system components to prevent possible injury.
  1. Relieve the fuel system pressure. For additional information, refer to FUEL SYSTEM PRESSURE RELEASE .
  2. Remove the air cleaner outlet tube (9B659). .
  3. Disconnect the throttle position sensor wiring.
    Fig 1: Disconnecting Throttle Position Sensor Wiring
    G02207071Courtesy of FORD MOTOR CO.
  4. Raise the vehicle. .
  5. Drain the cooling system. For additional information, refer to ENGINE COOLING .
  6. Remove the splash shield.
  7. Remove the bolt.
    Fig 2: Removing Bolt
    G02207072Courtesy of FORD MOTOR CO.
  8. Lower the vehicle.
  9. Disconnect the heater hoses from the heater core.
    Fig 3: Disconnecting Heater Hoses From Heater Core
    G02207073Courtesy of FORD MOTOR CO.
  10. Disconnect the main engine control sensor wiring (12A581). Remove the connectors from the mounting bracket.
    Fig 4: Disconnecting Main Engine Control Sensor Wiring
    G02207074Courtesy of FORD MOTOR CO.
  11. Disconnect the vacuum supply hoses from the intake manifold (9424) by squeezing the tabs, twisting the hoses and pulling them away from the intake manifold.
    Fig 5: Disconnecting Vacuum Supply Hoses From Intake Manifold
    G02207075Courtesy of FORD MOTOR CO.
  12. Disconnect the crankcase ventilation hose (6853) from the valve cover (6582).
  13. Remove the drive belt (8620). For additional information, refer to SPECIFICATIONS & DRIVE BELT ROUTING .
  14. Remove the bolts. Position the generator (GEN) (10300) out of the way. For additional information, refer to GENERATOR .
  15. Disconnect the fuel line. For additional information, refer to FUEL SYSTEMS .
  16. Disconnect accelerator and speed control cables.
  17. Disconnect fuel charging wiring harness. For additional information refer to FUEL SYSTEMS .
  18. Remove the intake manifold.
    • Remove the two nuts and seven bolts in the sequence shown.
    • Remove the intake manifold.
    Fig 6: Removing Intake Manifold
    G02207076Courtesy of FORD MOTOR CO.
  19. Inspect the intake manifold gaskets (9439).
  20. If required, remove the intake manifold gaskets. Discard the intake manifold gaskets.
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