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Mondeo 1997 Engine - In-Vehicle Repair - Intake Manifold

Engine - Vehicles Built From: 05/1998 1.6L/1.8L/2.0L - Intake Manifold Mondeo 1997 (08/1996-09/2000)
In-vehicle Repair

Removal

All vehicles
  1. Disconnect the battery negative lead. For additional information, refer to Section  414-01 Battery, Mounting and Cables.

  1. Remove the intake pipe.
    1. Pull out the plug of the mass air flow sensor (MAF sensor).
    1. Pull out the plug of the intake air temperature sensor (IAT sensor).
    1. Remove the bolt and the two nuts.
    1. Open the clips.

  1. Detach the brake booster vacuum pipe from the intake manifold.
    • Unlock the quick-release coupling and disconnect the pipe.
    • Disconnect the PCV hose from the intake manifold.

  1. Disconnect the vacuum hoses from the intake manifold.

  1. Pull out the plug of the cylinder head wiring harness and detach the engine wiring harness from the intake manifold.
    1. Multiplugs.
    1. Wiring harness.

  1. Detach the accelerator cable and the cruise control system operating cable (if equipped) from the throttle body.
    • Unhook the cable.
    • Pull off the plastic clip and lay the accelerator cable to one side.
Vehicle with exhaust gas recirculation (EGR)
  1. Detach the exhaust gas recirculation (EGR valve) system.
    1. Detach the EGR line from the ignition coil.
    1. Detach the EGR valve from the EGR pipe.

  1. Detach the EGR line bracket.
All vehicles
  1. Detach the throttle position sensor (TP) multiplug.

  1. Remove the throttle housing.

  1. Disconnect the camshaft position (CMP) sensor multiplug.
  1. Release fuel pressure. For additional information, refer to Section  310-00A Fuel System - General Information / 310-00B Fuel System - General Information.

  1. WARNING:
    WARNING:Escaping fuel. Observe the safety regulations for working with fuel.
    Separate fuel lines.
    • Detach the fuel line bracket from the intake manifold.

  1. Disconnect the fuel injector plug.

  1. Disconnect the idle air control (IAC) valve connector.

  1. Detach the intake manifold (eight bolts, two nuts).
    • Detach the injector wiring harness (two bolts).

  1. Pull off the crankcase ventilation vacuum hose.

  1. Remove the intake manifold studs and remove the intake manifold.

Installation

All vehicles
  1. Position the intake manifold on the cylinder head and screw in new intake manifold studs.

  1. Push on the crankcase ventilation vacuum hose.

  1. NOTE:
    NOTE:Only use a new gasket when the old is faulty.
    Attach the intake manifold (eight bolts, two nuts).
    • Attach the injector wiring harness (two bolts).

  1. Connect the idle air control (IAC) valve connector.

  1. Push on the fuel injector connector.

  1. NOTE:
    NOTE:The pipes are marked.
    Connect the fuel pipes.
    • Attach the fuel pipe bracket to the intake manifold.

  1. Connect the CMP sensor plug.

  1. NOTE:
    NOTE:Use a new gasket.
    Install the throttle body.

  1. Connect the TP sensor multiplug.
Vehicles with EGR system
  1. Install the EGR system.
    1. Install the EGR valve on the EGR pipe.
    1. Install the EGR line on the ignition coil.

  1. Attach the bracket to the EGR line.
All vehicles
  1. Install the accelerator cable and the cruise control system operating cable (if equipped) to the throttle body and adjust.
    1. Install the cable in the bracket and slide on the plastic clip.
    • Hook the cable in place.
    1. Pull the clip off the accelerator cable.
    • Pull the inner cable a few clicks out from the outer cable.
    • Fully depress the accelerator pedal once and slide the clip back on.
    • Check that the throttle plate opens fully when the accelerator pedal is depressed. If not, repeat the adjustment procedure.

  1. Attach the engine wiring harness to the intake manifold and connect the plug of the cylinder head wiring harness.
    1. Wiring harness.
    1. Plugs.

  1. Connect the vacuum hoses to the intake manifold.

  1. NOTE:
    NOTE:Engage the vacuum pipe properly.
    Install the brake servo vacuum hose on the intake manifold (shown from below).
    • Insert the vacuum hose in the quick-fit coupling and allow it to engage.
    • Press the PCV hose into place on the intake manifold.

  1. Install the intake pipe.
    1. Connect the plug of the MAF sensor.
    1. Connect the IAT sensor plug to the intake pipe.
    1. Install the bolt and the two nuts.
    1. Close the clips.
  1. Connect the battery ground cable. For additional information, refer to Section  414-01 Battery, Mounting and Cables.

Valve Springs > < Crankshaft Front Seal