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Crankshaft Front Seal > < Valve Clearance

Focus RS 2003 (09.2002-)

Engine - 2.0L Duratec-RS (Zetec) - Intake Manifold Focus RS 2003 (09/2002-)
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  310-00A 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 intake tube.

  1. Disconnect the vaccum hose from the throttle body intake housing.

  1. Disconnect the intake air temperature (IAT) sensor electrical connector.

  1. Detach the accelerator cable from the throttle body.
    1. Detach the accelerator outer cable from the throttle body bracket.
    1. Detach the accelerator inner cable from the throttle body lever.

  1. Disconnect the vacuum hoses from the throttle body.

  1. Disconnect the brake booster vacuum pipe.

  1. Disconnect the fuel pressure regulator vacuum hose.

  1. Disconnect the fuel injection wiring harness electrical connector.

  1. Disconnect the cylinder head temperature (CHT) sensor electrical connector (generator shown removed for clarity).

  1. Disconnect the throttle position (TP) sensor electrical connector.
  1. Remove the fuel rail shield.

  1. Disconnect the fuel injector electrical connectors and remove the fuel injection wiring harness (throttle body shown removed for clarity).

  1. Detach the positive crankcase ventilation (PCV) hose from the valve cover.

  1. Disconnect the camshaft position (CMP) sensor electrical connector and position it to one side.

  1. Disconnect the fuel supply and return lines from the fuel rail. For additional information, refer to Section  310-00A Fuel System - General Information.

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

  1. Remove the intake manifold retaining nuts and bolts (seven) (engine shown removed for clarity).

  1. Remove the intake manifold (engine shown removed for clarity).
    • Remove the intake manifold stud.
    • Discard the gaskets.

  1. NOTE:
    NOTE:Disconnect the oil pressure switch electrical connector to remove the intake manifold.
    Remove the intake manifold (engine shown removed for clarity).
    • Remove the nuts and bolts (seven).
    • Remove the intake manifold stud.
    • Disconnect the cylinder head temperature (CHT) sensor electrical connector.
    • Discard the intake manifold gaskets.

Installation

  1. NOTE:
    NOTE:Install new intake manifold gaskets.
    To install, reverse the removal procedure.

Crankshaft Front Seal > < Valve Clearance