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Old 09-22-2013, 10:20 PM   #1
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How to on IM install??

Has anyone posted a how to for changing the intake manifolds on the zetec? I looked and checked the stickies... Lots of people doing the 2000 im switch... I've purchased one, have ported it and will be tackling the swap when I get back from vacation... Which is in about two weeks... I understand from what I've read in various threads that there is a issue with the bolt behind the alternator... Wondering if anyone knows the torxs size to remove the stud behind the alternator?? Also does anyone have any specific tips to make the install go smoother?? Any info would help and if I missed a how-to I apologize...


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Old 09-23-2013, 12:18 AM   #2
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X2 on this stuff.
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Old 09-24-2013, 09:45 PM   #3
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I haven't installed mine yet, but taking it off at the junk yard I can tell you that one bolt is just like many other ford intake/exhaust bolts where it's a stud with like an inverse-torx kind of end and it sticks out so far it's not easy to get a wrench or socket on it, and then taking off the manifold is also very difficult because of it being 1" or so thick, there's less room between that stud and the alternator than you need.

I fully intend to make a how-to when I do this, but it should be fairly straightforward. If there already is one I'd also like to see it. If not I'll make one before long
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Old 09-24-2013, 09:52 PM   #4
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The socket needed is an E8 reverse (or inverse) torx. Should be able to find one at Sears.
Removing this stud makes the job SOOOOO much easier! I have done several including junkyard removals and it is a bear to remove the intake with the stud still intact.
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Old 09-24-2013, 09:52 PM   #5
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Awesome thanks... When are u planning on doing the install?
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Old 09-24-2013, 10:06 PM   #6
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Perfect info... I had heard to remove that stud... Wasn't sure what size it was... Makes it easier to kno what I need then having to try and get one once I got it half apart...
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Old 09-24-2013, 10:06 PM   #7
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It's been sitting in my basement for a while, I just need to decide to put it on and whether or not I'm gonna wait for a new tb. I'm thinking in the next month if I get a free weekend.
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Old 09-25-2013, 09:27 AM   #8
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Sorry, I have put my intake manifold on and off so many times and I have never documented it.

There are two studs. its easier to just remove both. one my the alternator and the other by the EGR tube.

You need to pull the injectors, fuel rail, and TB. Watch for the retaining clips for the throttle cables.

The Stud by the alternator has a metal retainer square on it that you will need to pull before you have access to the nut. You will have to remove that.

The stud is easy to remove. just like ARP studs are only hand tight, these once you brake the stud and start backing it off you can use your fingers to unthread it the rest of the way.

If you have a strut tower brace you will want to remove that also.

Make sure you disconnect the IAC wire harness, and there are a few connectors that are routed though the runners. the temp sensor and knock sensor (IIRC) need to be disconnected also. Make sure you are careful with the wire harness, these have oil and gunk all on them and have gone through thermal cycles so can be brittle.

You then have all the vacuum lines. these are easy to remove... most the time. take your time and try a twist and pull method. there are two large ones also. one at the very bottom that has a press in clamp style that you kind of need two hand to remove (but can be done with 1 hand). and a larger one below the 4 smaller ports by the TB. since the lines are molded they are easy to know where they go back on when you reinstall. just make sure you hook them all back up.


Hope this helps. I can mock up my motor to show you these things, but my motor is not in the car so not sure how much help that would be.

Once you have everything removed and disconnected you have to kind of angle the top of the intake towards you (thus pushing the bottom of the intake manifold towards the cabin) and then pull up.
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Old 09-25-2013, 10:33 AM   #9
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Awesome bro... Pics would be great... But this def helps a lot... I can't wait to do the swap... Just worried its gonna take a long time for me to do the swap... I like to have all the info I can before I start...
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Old 09-25-2013, 10:59 AM   #10
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Went to the junk yard to find my 2000 intake and it took all of perhaps 30 min to remove the old one. would likely take same length of time to install it. But I have done it a few times.

I will see what I can do to get pictures in the next day or two. I like putting my motor together....

Also to note that the injectors are held in by a wire clip, you will want to use needle nose pliers to pull them off. and helps if you magnetize the pliers or use a magnetic picker upper. they sometimes fly off so take care on the removal.
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