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Focus 1999 (08.1998-12.2004)

Engine - 1.4L/1.6L - Intake Manifold Focus 1999 (08/1998-12/2004)
In-vehicle Repair

Removal

  1. Release the fuel system pressure. For additional information, refer to Section  310-00A Fuel System - General Information / 310-00B Fuel System - General Information / 310-00C Fuel System - General Information.
  1. Disconnect the battery negative lead. For additional information, refer to Section  414-01 Battery, Mounting and Cables.

  1. Unclip the power steering reservoir and lay it to one side.

  1. Slacken and remove the drive belt.

  1. Remove the air cleaner with air intake hose.
    1. Air intake hose.
    1. Disconnect the mass air flow sensor (MAF sensor) connector.
    • Detach the PCV hose from the cylinder head cover.

  1. Disconnect the plug.
    1. Ignition coil (EI).
    1. Condenser.

  1. Pull off the connector and the hose.
    1. Idle air control (IAC) valve connector.
    1. Positive crankcase ventilation.

  1. Detach the hoses and plugs.
    1. Brake booster vacuum hose.
    1. Vacuum hose - fuel pressure control.
    1. Throttle position sensor (TP sensor) multiplug.
    1. Knock sensor (KS) plug.

  1. Unclip the wiring harness.

  1. Detach the accelerator cable.
    1. Pull off the clip.
    1. Unscrew the cable from the bracket.

  1. Unclip the hose bracket and lay it to one side.

  1. Pull off the injector connectors and lay the engine wiring harness on the cover of the cylinder head cover.
    • Open the injector connector clips.

  1. Detach the generator.

  1. NOTE:
    NOTE:The fuel feed line unions are white or are identified with a white ring. The fuel return line unions are red or are identified with a red ring.
    Detach the fuel pipes.

  1. Detach the fuel rail.
    • Remove two bolts.

  1. NOTE:
    NOTE:Following job step.
    Detach the intake manifold.
    • Detach the oil dipstick tube bracket.

  1. Detach the carbon canister vacuum line.
    • Remove the intake manifold.

Installation

All vehicles
  1. Position the intake manifold and install the EVAP canister vacuum line.

  1. Install the intake manifold using a new two-part gasket.
    • Install the oil dipstick tube bracket.

  1. CAUTION:
    CAUTION:Do not apply silicone grease to the injector O-rings, otherwise the injectors will become blocked.
    NOTE:
    NOTE:Install new injector O-rings.
    Install the fuel rail.
    • Coat the injector O-rings with clean engine oil before installation.

  1. Connect the fuel pipes.

  1. Attach the generator.

  1. Push on the injection nozzle connector.

  1. Clip the hose retainer in place.

  1. Attach the accelerator cable.
    1. Push on the clip.
    1. Screw the cable into the bracket.

  1. Clip the wiring harness in place.

  1. Connect the hoses and connnectors.
    1. Brake servo vacuum hose.
    1. Vacuum hose - fuel pressure control.
    1. TP sensor multiplug.
    1. KS plug.

  1. Push on the connector and the hose.
    1. IAC valve connector.
    1. Crankcase ventilation.

  1. Connect the plug.
    1. Ignition coil (EI).
    1. Condenser.

  1. Install the air filter with air intake hose.
    1. Air intake hose.
    1. MAF connector.
    • Attach the PCV hose to the cylinder head cover.

  1. Fit and tension the drive belt.

  1. Clip on the power steering reservoir.
  1. Connect the battery negative lead. For additional information, refer to Section  414-01 Battery, Mounting and Cables.
Vehicles with front and rear power windows
  1. Initialize the door window motors. For additional information, refer to Section  501-11 Glass, Frames and Mechanisms.

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