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HOMESERVICE MANUALSFORD2004FOCUS ZX3, 2.3 Z, STANDARDREPAIR AND DIAGNOSISENGINE MECHANICALMECHANICALENGINE - 2.3LIN-VEHICLE REPAIRINTAKE MANIFOLDREMOVAL
2004 Ford Focus ZX3, 2.3 Z, Standard

Intake Manifold: Removal

2004 Ford Focus ZX3, 2.3 Z, StandardSECTION Removal
  1. Remove the cooling fan motor and shroud. For additional information, refer to ENGINE COOLING .
  2. Remove the lower intake manifold bolt.
    Fig 1: Removing Lower Intake Manifold Bolt
    G04035370Courtesy of FORD MOTOR CO.
  3. Remove the accelerator control snow shield.
    Fig 2: Removing Accelerator Control Snow Shield
    G04035371Courtesy of FORD MOTOR CO.
  4. Remove the air cleaner outlet tube.
    • Loosen the retaining clamps.
    • Remove the emissions breather tube.
    • Remove the air cleaner outlet tube.
    Fig 3: Removing Air Cleaner Outlet Tube
    G04035372Courtesy of FORD MOTOR CO.
  5. Disconnect the throttle position (TP) sensor electrical connector and position the wiring harness aside.
    Fig 4: Disconnecting Throttle Position Sensor Electrical Connector
    G04035373Courtesy of FORD MOTOR CO.
  6. Disconnect the idle air control (IAC) valve electrical connector and position the wiring harness aside.
    Fig 5: Disconnecting Idle Air Control Valve Electrical Connector
    G04035374Courtesy of FORD MOTOR CO.
  7. Disconnect the throttle cables from the intake manifold.
    1. Disconnect the accelerator cable and speed control cable (if so equipped) from the throttle linkage.
    2. Remove the bolts from the accelerator cable bracket and position aside.
    Fig 6: Removing Bolts From Accelerator Cable Bracket
    G04035375Courtesy of FORD MOTOR CO.
  8. Remove the evaporative emissions hoses.
    Fig 7: Removing Evaporative Emissions Hoses
    G04035376Courtesy of FORD MOTOR CO.
  9. Disconnect the temperature manifold absolute pressure (TMAP) sensor electrical connector.
    Fig 8: Disconnecting Temperature Manifold Absolute Pressure Sensor Electrical Connector
    G04035377Courtesy of FORD MOTOR CO.
  10. Disconnect the electrical connectors and position the wiring harness aside.
    Fig 9: Disconnecting Electrical Connectors And Position Wiring Harness
    G04035378Courtesy of FORD MOTOR CO.
  11. Disconnect the outward intake manifold runner control (IMRC) actuator electrical connector.
    Fig 10: Disconnecting Outward Intake Manifold Runner Control Actuator Electrical Connector
    G04035379Courtesy of FORD MOTOR CO.
  12. Disconnect the vacuum hose from the fuel pressure regulator.
    Fig 11: Disconnecting Vacuum Hose From Fuel Pressure Regulator
    G04035380Courtesy of FORD MOTOR CO.
  13. Loosen the fuel injection supply manifold retainers.
    Fig 12: Loosening Fuel Injection Supply Manifold Retainers
    G04035381Courtesy of FORD MOTOR CO.
  14. Disconnect the power brake booster vacuum tube.
    • Disconnect the quick release coupling and pull out the line.
    Fig 13: Disconnecting Quick Release Coupling
    G04035382Courtesy of FORD MOTOR CO.
  15. Remove the two oil level indicator tube bolts.
    Fig 14: Removing Oil Level Indicator Tube Bolts
    G04035383Courtesy of FORD MOTOR CO.
    16. NOTE: Engine shown removed for clarity.
RENDER: 1.0x

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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.