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Home >> Ford >> 2000 >> Contour SE, 2.5 L, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 1991 (Engine - 2.3L - (Hybrid)) >> In-Vehicle Servicing >> Intake Manifold >> Removal And Installation

Removal And Installation

WARNING: This page is about a different car, the 2007 Mercury Mariner and 2007 Ford Escape. However, it is still accessible from the selected car via links, so may be relevant.
  1. With vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING AND LIFTING article.
  2. Release the fuel pressure. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION article.
    3. CAUTION: Before removing the high voltage cables, the vehicle electrical system must be completely shut down for at least 5 minutes to allow for the high voltage capacitors to discharge.
  3. Disable the vehicle high voltage electrical system. For additional information, refer to HIGH VOLTAGE TRACTION BATTERY article.
  4. Remove the fuel rail. For additional information, refer to FUEL CHARGING & CONTROLS - HYBRID article.
  5. Remove the throttle body. For additional information, refer to FUEL CHARGING AND CONTROLS - HYBRID article.
  6. Remove the accessory drive belt tensioner. For additional information, refer to ACCESSORY DRIVE - HYBRID article.
  7. Remove the oil level indicator and tube. For additional information, refer to Oil Level Indicator and Tube .
  8. Disconnect the oil pressure sender electrical connector.
  9. Disconnect the temperature manifold absolute pressure (TMAP) sensor electrical connector.
  10. If equipped, disconnect the block heater electrical harness connector.
  11. Disconnect the knock sensor (KS) electrical connector and detach the pin-type retainer.
  12. Disconnect the fuel vapor return hose from the intake manifold.
  13. Disconnect the vacuum tube.
    • Depress the quick release locking ring.
    • Pull the vacuum tube out of the quick release fitting.
    14. Fig 1: Locating Power Brake Booster Vacuum Tube And Quick Release Locking Ring
    GF0024064Courtesy of FORD MOTOR CO.
    NOTE: There are 3 different size bolts used. Mark the location of the bolts to make sure they are installed in the correct location.
  14. Remove the 8 bolts and position the intake manifold aside to access the crankcase vent hose clamp and the exhaust gas recirculation (EGR) tube.
    • To install, tighten to 18 Nm (13 lb-ft).
  15. Release the clamp and disconnect the crankcase vent hose.
  16. Remove the EGR tube.
    • To install, tighten to 55 Nm (41 lb-ft).
  17. Remove the intake manifold and gaskets.
  18. To install, reverse the removal procedure.
    • Inspect and install new intake manifold gaskets if necessary.
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