2000 Ford ZX2 StandardFACTORY OEM SERVICE PROCEDURE

Intake Manifold: Removal

WARNING: This page is about a different car, the 2003 Ford Focus. However, it is still accessible from the selected car via links, so may be relevant.
  1. Remove the fuel injection supply manifold. For additional information, refer to REMOVAL & INSTALLATION .
  2. Raise and support the vehicle. For additional information, refer to JACKING & HOISTING .
  3. Remove the intake manifold lower retaining bolt.
    Fig 1: Removing Intake Manifold Lower Retaining Bolt
    G01615556Courtesy of FORD MOTOR CO.
  4. Lower the vehicle.
  5. Detach the engine lifting eye from the cylinder head.
    Fig 2: Detaching Engine Lifting Eye From Cylinder Head
    G01615557Courtesy of FORD MOTOR CO.
  6. Disconnect the idle air control (IAC) sensor electrical connector.
    Fig 3: Disconnecting Idle Air Control Sensor Electrical Connector
    G01615558Courtesy of FORD MOTOR CO.
  7. Disconnect the throttle position (TP) sensor electrical connector.
    Fig 4: Disconnecting Throttle Position Sensor Electrical Connector
    G01615559Courtesy of FORD MOTOR CO.
  8. Detach the intake manifold runner control (IMRC) actuator cable from the IMRC lever (intake manifold assembly shown removed for clarity).
    1. Rotate the IMRC lever.
    2. Remove the IMRC actuator cable.
      Fig 5: Detaching Intake Manifold Runner Control Actuator Cable
      G01615560Courtesy of FORD MOTOR CO.
  9. Disconnect the IMRC actuator cable from the intake manifold assembly (intake manifold assembly shown removed for clarity).
    • Release the IMRC actuator cable locking tangs.
      Fig 6: Disconnecting IMRC Actuator Cable From Intake Manifold Assembly
      G01615561Courtesy of FORD MOTOR CO.
  10. Disconnect the vacuum hoses from the throttle body.
    Fig 7: Disconnecting Vacuum Hoses From Throttle Body
    G01615562Courtesy of FORD MOTOR CO.
  11. Detach the brake booster pipe from the intake manifold.
    • Release the quick release coupling and pull out the brake booster pipe.
      Fig 8: Detaching Brake Booster Pipe From Intake Manifold
      G01615563Courtesy of FORD MOTOR CO.
  12. Separate the two sections of the intake manifold.
    Fig 9: Separating Two Sections Of Intake Manifold
    G01615564Courtesy of FORD MOTOR CO.
  13. Detach the knock sensor (KS) electrical connector from the intake manifold inner section.
    Fig 10: Detaching Knock Sensor Electrical Connector From Intake Manifold Inner Section
    G01615565Courtesy of FORD MOTOR CO.
  14. Remove the intake manifold inner section locknut and bolts (intake manifold shown removed for clarity).
    • Discard the locknut.
      Fig 11: Removing Intake Manifold Inner Section
      G01615566Courtesy of FORD MOTOR CO.
  15. Remove the intake manifold inner section retaining stud.
    Fig 12: Removing Intake Manifold Inner Section Retaining Stud
    G01615567Courtesy of FORD MOTOR CO.
  16. Remove the intake manifold sections.
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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.