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Crankshaft Pulley > < Diagnosis and Testing|Engine

Maverick 2001 (12.2000-07.2004)

Engine - 2.0L Zetec-E (Zetec) - Intake Manifold Maverick 2001 (12/2000-07/2004)
In-vehicle Repair

Removal

  1. WARNING:
    WARNING:Fuel supply lines will remain pressurized for long periods of time after engine shut down. This pressure must be relieved before disconnecting any fuel lines or fuel system components to prevent possible injury. Failure to follow these instructions may result in personal injury.
    Remove the fuel injection supply manifold. For additional information, refer to Section 303-04A Fuel Charging and ControlsSection 303-04B Fuel Charging and Controls.

  1. Disconnect the throttle position (TP) sensor electrical connector.

  1. Disconnect the idle air control (IAC) electrical connector and unclip the harness from the bracket.

  1. Disconnect the main engine control sensor wiring and remove the connector from the mounting bracket.

  1. Disconnect the powertrain control module (PCM) wire harness from the bracket.

  1. Disconnect the brake booster vacuum supply hose.

  1. Disconnect the four vacuum lines.

  1. Disconnect the positive crankcase ventilation (PCV) vacuum line.

  1. Disconnect the knock sensor (KS) electrical connector.
  1. Lower the vehicle.
  1. Remove the generator. For additional information, refer to Section 414-02 Generator and Regulator.

  1. NOTE:
    NOTE:Illustration shown with throttle body removed for clarity.
    Remove the intake manifold.
    • Remove the two nuts and five bolts in the sequence shown.
  1. Remove and inspect the intake manifold gaskets.
    • Discard if damaged.

Installation
  1. NOTE:
    NOTE:Illustration shown with the throttle body removed for clarity.
    NOTE:
    NOTE:Install new intake manifold gaskets if damaged.
    Install the intake manifold and tighten using the sequence shown.
  1. Install the generator. For additional information, refer toSection 414-02 Generator and Regulator.
  1. Raise the vehicle.

  1. Connect the KS electrical connector
  1. Lower the vehicle.

  1. Connect the PCV vacuum line.

  1. Connect the four vacuum lines.

  1. Connect the brake booster vacuum supply hose to the intake manifold.

  1. Connect the PCM wire harness to the bracket.

  1. Connect the main engine control sensor wiring.

  1. Connect the IAC electrical connector and reattach the harness to the bracket.

  1. Connect the TP sensor electrical connector.
  1. Install the fuel injection supply manifold. For additional information, refer to Section 303-04A Fuel Charging and ControlsSection 303-04B Fuel Charging and Controls.

Crankshaft Pulley > < Diagnosis and Testing|Engine