OEM 2003 Ford Focus Intake Manifold

2003 Ford Focus Intake Manifold Parts Q&A

• Q: How to service and repair the intake manifold on 2003 Ford Focus?

  A: You should start intake manifold service and repair operations when the vehicle sits on a hoist in neutral position. First uninstall the snow shield that protects the accelerator control and then cut the ground connection of the battery. The service begins with disconnecting the emissions breather tube after releasing the retaining clamps of the air cleaner outlet tube. Throttle cables need to be detached from the intake manifold by disconnecting the TP sensor and IAC valve connectors. Within this step disconnect the speed control cable from the throttle linkage while also replacing bolts from the accelerator cable bracket. Start the procedure by disconnecting the evaporative emissions and TMAP sensor electrical connector and then remove the air shutoff valves vacuum hoses along with their electrical connectors. After disconnecting the vacuum hose from the fuel pressure regulator, remove the lower intake manifold bolt as well as the lower and upper oil level indicator tube bolts before taking out the tube. Mark the different bolt positions when removing the expansion tank because it uses three distinctive bolt sizes for proper replacement. A technician must first disconnect all necessary components including the knock sensor (KS) electrical connector and positive crankcase ventilation (PCV) hose before they can remove the intake manifold by removing its six bolts. The installation procedure consists of checking and replacing intake manifold gaskets if required followed by installation of the PCV hose and precise placement of mounting bolts according to initial markings during the intake manifold installation of six mounting bolts. Secure the KS electrical connector after installing the coolant expansion tank while also fastening the upper and lower oil level indicator tube bolts with the lower intake bolt. Reinstallation begins with linking the fuel pressure regulator vacuum hose, following steps for vacuum hoses and electrical connectors. The sequence then includes connecting the TMAP sensor electrical connector combined with the evaporative emissions hoses. The repair process starts with reattaching IAC and TP sensor electrical connectors and installing an accelerator cable bracket before attaching both the accelerator cable along with speed control cable if present. The procedure ends with reinstallation of the accelerator control snow shield as well as the air cleaner outlet tube followed by reconnecting the battery ground cable.