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Home › Ford › 2004 › Focus SVT, 4D Hatchback › Repair and Diagnosis › External Pages › Different variant/trim › Section 16 (Engine - 2.0L ZETEC) › In-Vehicle Repair › Intake Manifold › Installation

Intake Manifold: Installation

WARNING: This page is about a different variant/trim than selected.
  1. Position the intake manifold and install the 5 bolts and 2 nuts.
    Fig 1: Positioning Intake Manifold And Installing 5 Bolts And 2 Nuts
    G04033871Courtesy of FORD MOTOR CO.
  2. Position the engine lifting eye and install the bolt.
    Fig 2: Positioning Engine Lifting Eye
    G04033872Courtesy of FORD MOTOR CO.
  3. Connect the oil pressure sensor electrical connector.
    Fig 3: Connecting Oil Pressure Sensor Electrical Connector
    G04033873Courtesy of FORD MOTOR CO.
  4. Connect the KS electrical connector.
    Fig 4: Connecting KS Electrical Connector
    G04033874Courtesy of FORD MOTOR CO.
  5. Connect the positive crankcase ventilation (PCV) hose to the intake manifold.
    Fig 5: Connecting Positive Crankcase Ventilation (PCV) Hose To Intake Manifold
    G04033875Courtesy of FORD MOTOR CO.
  6. Connect the vacuum hoses.
    Fig 6: Connecting Vacuum Hoses
    G04033876Courtesy of FORD MOTOR CO.
  7. Position the generator and install the bolts.
    Fig 7: Positioning Generator
    G04033877Courtesy of FORD MOTOR CO.
  8. Slide the engine towards the rear of the vehicle and remove the bolt.
    Fig 8: Removing Bolt
    G04033878Courtesy of FORD MOTOR CO.
  9. Using the alignment marks made during removal, install the bolts.
    Fig 9: Installing Engine Mount Bolts
    G04033879Courtesy of FORD MOTOR CO.
  10. Position the ground cable and install the bolt.
    Fig 10: Installing Ground Cable Bolt
    G04033880Courtesy of FORD MOTOR CO.
  11. Connect the CHT sensor electrical connector.
    Fig 11: Connecting CHT Sensor Electrical Connector
    G04033881Courtesy of FORD MOTOR CO.
  12. Attach the power steering fluid reservoir.
    Fig 12: Attaching Power Steering Fluid Reservoir
    G04033882Courtesy of FORD MOTOR CO.
  13. Attach the coolant expansion tank to the retaining clip and install the bolt.
    Fig 13: Attaching Coolant Expansion Tank To Retaining Clip
    G04033883Courtesy of FORD MOTOR CO.
  14. Install the accessory drive belt.
  15. Install the fuel rail pressure (FRP) sensor. For additional information, refer to FUEL RAIL PRESSURE (FRP) SENSOR -- 2.0L ZETEC .
  16. Connect the camshaft position (CMP) sensor.
    Fig 14: Connecting Camshaft Position (CMP) Sensor
    G04033884Courtesy of FORD MOTOR CO.
  17. Connect the fuel injector wiring.
    Fig 15: Connecting Fuel Injector Wiring
    G04033885Courtesy of FORD MOTOR CO.
  18. Install the EGR valve with a new gasket and EGR pipe bracket.
    Fig 16: Installing EGR Valve With New Gasket And EGR Pipe Bracket
    G04033886Courtesy of FORD MOTOR CO.
  19. Install the accelerator cable and the speed control cable (if equipped) to the throttle body.
    Fig 17: Installing Accelerator Cable And Speed Control Cable
    G04033887Courtesy of FORD MOTOR CO.
  20. Install the air cleaner housing.
    • Insert the air filter housing into the rubber bushings.
    1. Attach the mass air flow (MAF) sensor connector.
    2. Attach the crankcase ventilation hose.
    3. Attach the intake hose.
    Fig 18: Installing Air Cleaner Housing
    G04033888Courtesy of FORD MOTOR CO.
  21. If necessary, install new cable ties when reinstalling.
    22. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy.
  22. Connect the battery ground cable.
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