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Home >> Ford >> 2006 >> Focus ZX5 SE, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 391 (Engine - 2.3L - (Hybrid)) >> In-Vehicle Repair >> Intake Manifold >> Removal and Installation

Removal and Installation

WARNING: This page is about a different car, the 2006 Mercury Mariner and 2006 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 & LIFTING .
  2. Release the fuel system pressure. For additional information, refer to FUEL SYSTEM PRESSURE RELEASE .
    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 .
  4. Remove the fuel rail. For additional information, refer to REMOVAL .
  5. Remove the throttle body. For additional information, refer to REMOVAL AND INSTALLATION .
  6. Remove the accessory drive belt tensioner. For additional information, refer to REMOVAL AND INSTALLATION .
  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 and the pin-type retainer.
  10. Disconnect the swirl control valve electrical connector.
  11. Disconnect the intake manifold runner control (IMRC) actuator electrical connector.
  12. If equipped, disconnect the block heater electrical harness connector.
  13. Disconnect the knock sensor (KS) electrical connector and detach the pin-type retainer.
  14. Disconnect the fuel vapor return hose from the intake manifold.
  15. Disconnect the vacuum tube.
    • Depress the quick release locking ring.
    • Pull the vacuum tube out of the quick release fitting.
      Fig 1: Locating Vacuum Tube
      G04618888Courtesy of FORD MOTOR CO.
    16. NOTE: There are 3 different size bolts used. Mark the location of the bolts to make sure they are installed in the correct location.
  16. 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 N.m (13 lb-ft).
  17. Release the clamp and disconnect the crankcase vent hose.
  18. Remove the EGR tube.
    • To install, tighten to 55 N.m (41 lb-ft).
  19. Remove the intake manifold and gaskets.
  20. To install, reverse the removal procedure.
    • Inspect and install new intake manifold gaskets if necessary.
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