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Fiesta 2002.25 (11.2001-)

Engine - 1.25L Duratec-16V (Sigma)/1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma) - Intake Manifold Fiesta 2002.25 (11/2001-)
In-vehicle Repair

Removal

WARNING:
WARNING:Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related components. Highly flammable mixtures are always present and may ignite. Failure to follow these instructions may result in personal injury.
  1. Release the fuel system pressure. For additional information, refer to Section  310-00 Fuel System - General Information.
  1. Disconnect the battery ground cable. For additional information, refer to Section  414-01 Battery, Mounting and Cables.
  1. Remove the air cleaner. For additional information, refer to Section  303-12 Intake Air Distribution and Filtering.

  1. Detach the power steering fluid reservoir from the bracket and position it to one side.
  1. Remove the accessory drive belt. For additional information, refer to Section  303-05 Accessory Drive.

  1. Remove the intake manifold lower retaining bolt.

  1. Disconnect the engine wiring harness electrical connector.

  1. Disconnect the positive crankcase ventilation (PCV) hose from the PCV.

  1. Disconnect the brake booster vacuum line from the intake manifold.

  1. Disconnect the evaporate emission (EVAP) hose from the EVAP valve.

  1. Disconnect the knock sensor (KS) electrical connector.

  1. Detach the oil level indicator tube from the intake manifold.

  1. Disconnect the temperature and manifold absolute pressure (T-MAP) sensor electrical connector.

  1. Disconnect the throttle plate control motor (DC-ISC) electrical connector.

  1. Disconnect the generator electrical connector.

  1. Detach the generator from the engine.
    1. Remove the bolts.
    1. Remove the nut and the stud.

  1. Disconnect the fuel injector electrical connectors and position it with the engine wiring harness to one side.

  1. Disconnect the engine coolant temperature (ECT) sensor electrical connector.

  1. Disconnect the fuel supply line quick release coupling. For additional information, refer to Section  310-00 Fuel System - General Information.

  1. Disconnect the fuel return line quick release coupling. For additional information, refer to Section  310-00 Fuel System - General Information.

  1. Detach the fuel line from the intake manifold and position it to one side.
    • Remove the cable tie.

  1. Remove the fuel supply manifold.
    • Discard the O-ring seals.

  1. Detach the wiring harness and the coolant hose from the intake manifold.

  1. Detach the wiring harness from the intake manifold.

  1. Remove the intake manifold.
    • Discard the gaskets.

Installation
  1. NOTE:
    NOTE:Install new intake manifold gaskets.
    Install the intake manifold.

  1. Attach the wiring harness to the intake manifold.

  1. Attach the wiring harness and the coolant hose to the intake manifold.

  1. NOTE:
    NOTE:Install new injector O-ring seals.
    NOTE:
    NOTE:Coat the O-ring seals with clean engine oil.
    Install the fuel supply manifold.

  1. Connect the fuel return line quick release coupling. For additional information, refer to Section  310-00 Fuel System - General Information.

  1. Connect the fuel supply line quick release coupling. For additional information, refer to Section  310-00 Fuel System - General Information.

  1. Attach the fuel line to the intake manifold.
    • Install the cable tie.

  1. Connect the fuel injector electrical connectors.

  1. Connect the engine coolant temperature (ECT) sensor electrical connector.

  1. Attach the generator to the engine.
    1. Install the stud and nut.
    1. Install the bolts.

  1. Connect the generator electrical connector.

  1. Connect the throttle plate control motor (DC-ISC) electrical connector.

  1. Connect the temperature and manifold absolute pressure (T-MAP) sensor electrical connector.

  1. Attach the oil level indicator tube to the intake manifold.

  1. Connect the knock sensor (KS) electrical connector.

  1. Connect the evaporate emission (EVAP) hose to the EVAP valve.

  1. Connect the brake booster vacuum line to the intake manifold.

  1. Connect the positive crankcase ventilation (PCV) hose to the PCV.

  1. Connect the engine wiring harness electrical connector.

  1. Install the intake manifold lower retaining bolt and the generator bracket retaining bolts.
  1. Install the accessory drive belt. For additional information, refer to Section  303-05 Accessory Drive.

  1. Attach the power steering fluid reservoir to the bracket.
  1. Install the air cleaner. For additional information, refer to Section  303-12 Intake Air Distribution and Filtering.
  1. Connect the battery ground cable. For additional information, refer to Section  414-01 Battery, Mounting and Cables.

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