2003 Ford ZX2 AutomaticFACTORY OEM SERVICE PROCEDURE

Intake Manifold: Removal

    WARNING: Fuel supply lines will remain pressurized for long periods of time after engine shut down. This pressure must be relieved before disconnecting any fuel lines or fuel system components to prevent possible injury.
  1. Relieve the fuel system pressure. For additional information, refer to FUEL SYSTEM PRESSURE RELEASE .
  2. Remove the air cleaner outlet tube (9B659). For additional information, refer to AIR INDUCTION SYSTEMS .
  3. Disconnect the throttle position sensor wiring.
    Fig 1: Disconnecting Throttle Position Sensor Wiring
    G01370941Courtesy of FORD MOTOR CO.
  4. Raise the vehicle. For additional information, refer to JACKING & HOISTING .
  5. Drain the cooling system. For additional information, refer to DRAINING .
  6. Remove the splash shield.
  7. Remove the bolt.
    Fig 2: Removing Bolt
    G01370942Courtesy of FORD MOTOR CO.
  8. Lower the vehicle.
  9. Disconnect the heater hoses from the heater core.
    Fig 3: Disconnecting Heater Hoses From Heater Core
    G01370943Courtesy of FORD MOTOR CO.
  10. Disconnect the main engine control sensor wiring (12A581). Remove the connectors from the mounting bracket.
    Fig 4: Removing Connectors From Mounting Bracket
    G01370944Courtesy of FORD MOTOR CO.
  11. Disconnect the vacuum supply hoses from the intake manifold (9424) by squeezing the tabs, twisting the hoses and pulling them away from the intake manifold.
    Fig 5: Disconnecting Vacuum Supply Hoses From Intake Manifold
    G01370945Courtesy of FORD MOTOR CO.
  12. Disconnect the crankcase ventilation hose (6853) from the valve cover (6582).
  13. Remove the drive belt (8620). For additional information, refer to REMOVAL AND INSTALLATION .
  14. Remove the bolts. Position the generator (GEN) (10300) out of the way. For additional information, refer to REMOVAL & INSTALLATION (ZETEC -- DOHC ENGINE) .
  15. Disconnect the fuel line.
  16. Disconnect accelerator and speed control cables.
  17. Disconnect fuel charging wiring harness.
  18. Remove the intake manifold.
    • Remove the two nuts and seven bolts in the sequence shown in Fig 6.
    • Remove the intake manifold.
    Fig 6: Removing Intake Manifold
    G01370946Courtesy of FORD MOTOR CO.
  19. Inspect the intake manifold gaskets (9439).
  20. If required, remove the intake manifold gaskets. Discard the intake manifold gaskets.
Factory Service Tools

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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.

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