2003 Ford ZX2 AutomaticFACTORY OEM SERVICE PROCEDURE

Intake Manifold: Material

WARNING: This page is about a different car, the 2003 Lincoln LS. However, it is still accessible from the selected car via links, so may be relevant.
Fig 1: Material Specification Chart
G01286028Courtesy of FORD MOTOR CO.
  1. Disconnect the battery ground cable. For additional information, Refer to BATTERY AND CHARGING SYSTEM .
  2. Remove the air cleaner outlet tube.
    3. CAUTION: The coolant drain procedure must be followed exactly or damage to the engine can occur.
  3. Drain the engine cooling system. For additional information, Refer to ENGINE COOLING .
  4. Remove the cowl vent screen. For additional information, Refer to BODY SYSTEM - INTERIOR .
  5. Remove the engine compartment brace.
    Fig 2: Removing Engine Compartment Brace
    G01286029Courtesy of FORD MOTOR CO.
  6. Disconnect the fuel line. For additional information, Refer to FUEL SYSTEM .
  7. Remove the exhaust gas recirculation (EGR) system module. For additional information, Refer to EXHAUST GAS RECIRCULATION (EGR) VALVE .
  8. Illustration 1 of 4. Remove the components in the order indicated in the following illustration and table.
    Fig 3: Identifying Intake Manifold Connectors And Hose Pipe
    G01286030Courtesy of FORD MOTOR CO.
  9. Illustration 2 of 4. Remove the components in the order indicated in the following illustration and table.
    Fig 4: Identifying Intake Manifold Engine Appearance Cover Support Bracket (RH And LH Side)
    G01286031Courtesy of FORD MOTOR CO.
  10. Illustration 3 of 4. Remove the components in the order indicated in the following illustration and table.
    Fig 5: Removing Injectors
    G01286032Courtesy of FORD MOTOR CO.
  11. Illustration 4 of 4. Remove the components in the order indicated in the following illustration and table.
    Fig 6: Removing Intake Manifold
    G01286033Courtesy of FORD MOTOR CO.
  12. To install, reverse the removal procedure.
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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.