How to Replace the Intake/Exhaust Manifold in a Ford Focus

Written by ehow cars editor
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Ford introduced the Focus in 2000 as its new entry-level vehicle. Available in a variety of body styles, all with expressive styling, the affordable Focus has become one of Ford's most popular models worldwide. From 2000 to 2003, the Focus was equipped with a 2.0L engine. The following steps guide you through the removal and installation of the intake manifold.

Skill level:

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    Remove the Intake Manifold

  1. 1

    Relieve the pressure in the fuel system and then disconnect the negative cable of the battery. Remove the air cleaner and the intake duct. Pull the accelerator cable.

  2. 2

    Take out the brake booster vacuum hose from the lower portion of the intake manifold by squeezing the connecting to release it. Follow the injection wiring harness back to the multi-plug behind the power steering fluid reservoir.

  3. 3

    Disconnect the plug then disconnect the wiring plug from the camshaft position sensor at the rear of the cylinder head (transmission end).

  4. 4

    Pull the fuel supply and return lines from the fuel rail. Loosen and remove the manifold bolts as well as the nut at either end. Unscrew the studs from the cylinder head after the nuts are removed.

  5. 5

    Make sure all connections are removed from the manifold. Take the manifold from the engine, keeping it level so that fuel does not spill from the attached fuel rail.

  6. 6

    Remove the four gaskets and discard them. Clean the mating surfaces of the manifold and cylinder head. Remove any old gasket debris and carbon deposits.

    Install the Intake Manifold

  1. 1

    Install new gaskets on the cylinder head. Align the manifold over the gaskets.

  2. 2

    Set the nuts in place by hand. Torque the nuts in sequence, working out from the center in a criss-cross pattern, to 156 inch pounds in four passes.

  3. 3

    Replace, reinstall and reconnect all components in the reverse order of their removal. Reconnect the negative battery cable.

  4. 4

    Start the engine and let it run for several minutes until it is warm. Check for any signs of fuel, vacuum or intake leaks.

Tips and warnings

  • Use a golf tee to plug the line to prevent fuel spillage. Note the color coding on the lines.
  • Raise the front of the car if necessary in order to access the nut from below. Lower the car to continue working and then raise the vehicle again to reinstall the nut. Always make sure the supports are secure.
  • Road test the vehicle for proper operation.

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