2002 Ford Focus SVTFACTORY OEM SERVICE PROCEDURE

Intake Manifold: Installation

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. Position the intake manifold to the rear of the engine compartment (shown with engine removed).
    Fig 1: Positioning Intake Manifold To Rear Of Engine Compartment
    G01615011Courtesy of FORD MOTOR CO.
    2. NOTE: Use new gaskets.
  2. Install the IMRC manifolds and the two studs (shown with engine removed).
    • Tighten the studs in two stages.
    • Stage 1: 10 Nm.
    • Stage 2: 90 degrees.
      Fig 2: Installing IMRC Manifolds
      G01615012Courtesy of FORD MOTOR CO.
    3. NOTE: Use new gaskets.
  3. Install the intake manifold and retainers (shown with engine removed).
    • Tighten the nuts and bolts in two stages
    • Stage 1: 10 Nm.
    • Stage 2: 90 degrees.
      Fig 3: Installing Intake Manifold And Retainers
      G01615013Courtesy of FORD MOTOR CO.
  4. Connect the fuel lines to the fuel rail. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION .
  5. Connect the electrical connectors.
    1. Ignition coil.
    2. CMP sensor.
    3. IMRC.
      Fig 4: Connecting Electrical Connectors
      G01615014Courtesy of FORD MOTOR CO.
  6. Connect the fuel injector electrical connectors.
    Fig 5: Connecting Fuel Injector Electrical Connectors
    G01615015Courtesy of FORD MOTOR CO.
  7. Install the intake manifold upper support bracket.
    Fig 6: Installing Intake Manifold Upper Support Bracket
    G01615016Courtesy of FORD MOTOR CO.
  8. Raise and support the vehicle. For additional information, refer to JACKING & HOISTING .
  9. Attach the intake manifold bracket.
    • Install the bolts and tighten the nuts.
      Fig 7: Attaching Intake Manifold Bracket
      G01615017Courtesy of FORD MOTOR CO.
  10. Lower the vehicle.
  11. Install the bracket and bolt to the oil level indicator tube.
    Fig 8: Installing Bracket And Bolt
    G01615018Courtesy of FORD MOTOR CO.
  12. Connect the TP sensor and the IAC valve.
    Fig 9: Connecting TP Sensor And IAC Valve
    G01615019Courtesy of FORD MOTOR CO.
  13. Connect the coolant hoses to the intake manifold.
    • Remove the clamps.
      Fig 10: Connecting Coolant Hoses To Intake Manifold
      G01615020Courtesy of FORD MOTOR CO.
  14. Install the vacuum hose assembly.
    Fig 11: Installing Vacuum Hose Assembly
    G01615021Courtesy of FORD MOTOR CO.
  15. Connect the EGR valve.
    • Install a new gasket.
      Fig 12: Connecting EGR Valve
      G01615022Courtesy of FORD MOTOR CO.
  16. Connect the vacuum hoses.
    1. EVAP solenoid valve.
    2. Brake booster.
    3. DPFE system sensor.
    4. EGR valve.
      Fig 13: Connecting Vacuum Hoses
      G01615023Courtesy of FORD MOTOR CO.
  17. Connect the positive crankcase ventilation hoses.
    • Make sure the twist-lock positive crankcase ventilation valve is secure.
      Fig 14: Connecting Positive Crankcase Ventilation Hoses
      G01615024Courtesy of FORD MOTOR CO.
  18. Connect the speed control cable.
    1. Connect the cable.
    2. Position the speed control cable and install the plastic clip.
      Fig 15: Connecting Speed Control Cable
      G01615025Courtesy of FORD MOTOR CO.
  19. Connect the accelerator cable.
    1. Connect the cable.
    2. Position the accelerator cable and install the plastic clip.
      Fig 16: Connecting Accelerator Cable
      G01615026Courtesy of FORD MOTOR CO.
  20. Install the air cleaner housing.
    1. Connect the MAF sensor electrical connector.
    2. Connect the air cleaner outlet hose.
    • Install the air cleaner housing into the rubber bushing.
      Fig 17: Installing Air Cleaner Housing
      G01615027Courtesy of FORD MOTOR CO.
  21. Connect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .
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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.