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Puma 1998 (06.1997-12.2001)

Engine - 1.4L Zetec-SE (Sigma)/1.6L - Intake Manifold Puma 1998 (06/1997-12/2001)
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. Raise the vehicle. For additional information, refer to Section  100-02 Jacking and Lifting.

  1. Remove the drive belt cover.

  1. Slacken and remove the drivebelt (vehicle up to MY 98 shown).
  1. Lower the vehicle.

  1. Detach the air intake hose and disconnect the throttle position sensor (TP sensor) multiplug.

  1. Disconnect the idle air control valve (IAC valve) multiplug and the hose.

  1. Detach the accelerator cable.
    1. Pull off the clip.
    1. Twist the cable out of the bracket.

  1. Remove the throttle housing bracket.

  1. Disconnect the vacuum hose.
    • Brake booster vacuum hose
    • Fuel pressure regulator vacuum hose.
Vehicles built up to 07/1998
  1. Remove the generator.
    1. Disconnect the connector.
    1. Disconnect the lead.
    1. Unscrew the three screws.
Vehicles built from 08/1998
  1. Remove the generator and lay it to one side.
    1. Disconnect the plugs.
    1. Disconnect the positive cable.
    • Remove the studs.
    1. Detach the generator.
All vehicles
  1. Remove the three lower intake manifold bolts from the cylinder block and detach the engine oil dipstick tube.

  1. Remove the intake manifold.

Installation

All Vehicles
  1. Install the intake manifold and the new two- part gasket.

  1. Install the three lower intake manifold bolts and attach the engine oil dipstick tube.
Vehicles built up to 07/1998
  1. Install the generator.
    1. Three bolts
    1. Connect the lead.
    1. Connect the plug.
Vehicles built from 08/1998
  1. Install the generator.
    • Install the studs.
All vehicles
  1. Connect the vacuum hoses.
    • Brake booster vacuum hose
    • Fuel pressure regulator vacuum hose.

  1. Install the throttle housing bracket.

  1. Attach the throttle cable.
    1. Install the clip.
    1. Twist the cable into the bracket.

  1. Connect the plug to the IAC valve and connect the crankcase breather hose.

  1. Connect the multiplug to the TP sensor and the air intake hose.
  1. Raise the vehicle. For additional information, refer to Section  100-02 Jacking and Lifting.

  1. Install and tension the drive belt.

  1. Install the drive belt cover.
  1. Lower the vehicle.
  1. Connect the battery negative lead. For additional information, refer to Section  414-01 Battery, Mounting and Cables.

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