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Ford Workshop Service and Repair Manuals

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Intake Manifold - Vehicles With: Common Rail Fuel Injection > < Intake Manifold - Vehicles Built From: 04-2003, Vehicles Without: Common Rail Fuel Injection

Transit 2000.5 (01.2000-05.2006)

Engine - 2.4L Duratorq-Di (Puma) Diesel/2.4L Duratorq-TDCi (Puma) Diesel - Intake Manifold—Vehicles Built Up To: 04/2003, Vehicles Without: Common Rail Fuel Injection Transit 2000.5 (01/2000-05/2006)
In-vehicle Repair

Removal

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

  1. NOTE:
    NOTE:Make sure that the windshield wiper motor is in the park position.
    Remove the windshield wiper arms.

  1. Remove the cowl panel upper retaining screws.
    • Remove the screw covers.
  1. Raise the hood.

  1. Remove the hood seal.

  1. NOTE:
    NOTE:The windshield washer hose is routed through the cowl panel.
    Remove the cowl panel.
    1. Remove the lower retaining screws.
    1. Detach the windshield washer hose.
    1. Detach the clips.

  1. Remove the water drain pipe retaining clips.

  1. Remove the A-pillar exterior trim panel lower retaining screws.

  1. Remove the windshield wiper motor bracket retaining bolt.

  1. Remove the water drain panel.
Vehicles with exhaust gas recirculation (EGR)
  1. Remove the EGR valve. For additional information, refer to Section  303-08 Engine Emission Control.
Vehicles without EGR
  1. Disconnect the charge air cooler outlet pipe from the intake manifold tube.

  1. Disconnect the fuel injection pump vacuum line from the intake manifold tube.

  1. Remove the intake manifold tube.
    • Discard the O ring seal.
All vehicles
  1. Remove the intake manifold (engine shown removed for clarity).
    • Discard the gasket.

Installation

All vehicles
  1. NOTE:
    NOTE:Install a new intake manifold gasket.
    To install, reverse the removal procedure.
Vehicles without EGR
NOTE:
NOTE:Install a new charge air cooler outlet pipe to intake manifold tube O ring seal.

All vehicles

Intake Manifold - Vehicles With: Common Rail Fuel Injection > < Intake Manifold - Vehicles Built From: 04-2003, Vehicles Without: Common Rail Fuel Injection