No worries pal.
Step 1-Removing the Manifold
Disonnect the battery negative terminal
Remove the plastic cover from over the top of the engine
Underneath the car, remove the lower oil dipstick tube retaining bolt (13mm socket) then the intake manifold lower retaining bolt (10mm spanner)
Remove the air intake pipe from the throttle body by releasing the clip and pulling it off (no pun intended)
Remove the throttle cable from the throttle body by unclipping the end (looks like a white plastic banjo over a black rubber washer) then remove it from the securing bracket by twisting it and pulling it off
Unplug the electrical connectors from the throttle position sensor and the idle air control valve (both on the same piece of loom)
Carefully remove the vaccuum hoses for the brakes (comes from the brake servo and takes a bit of pulling but comes off eventually if you persevere), the fuel pulse damper (comes from the top of the fuel rail) and the purge valve (comes over the top of the manifold and attaches on the front of it)
Detach the wiring loom from across the top of the manifold (you will have to pull off quite a few of the securing clips and also remove a few of the wiring connectors from around where the HT leads come from on the right hand side of the engine. Marking them up can help when putting it all back together)
Remove the upper retaining bolt for the oil level dipstick tube and remove the dipstick tube from the engine (fear not, as long as the engine is not over filled with oil and the car is parked on level ground, no oil will piss out)
(Apparently it isn't neccessary but I found it a little easier to complete the next step by removing the throttle body first. See how you go on but at the end of the day it's only four more bolts and it's off)
Unscrew the remaining 7 bolts securing the intake manifold and manoeuvre it out of the engine bay taking care not to damage the EGR pipe which sticks out of the engine on the right hand side. I found this picture of great help when trying to locate these seven bolts as not all of them can be seen and I had to use three different lenghts of extension bar to get them out -
http://www.robertjenkins.co.uk/images/mondeo-manifold-1.jpg (cheers for that rob)
Step 2-Fixing the Manifold
After removing the manifold remove the vaccuum actuator unit from the side of it by removing the three torx screws and pulling it off
Next, pull the little arm off the end of the bar that the butterflies sit on
Using a screwdriver, pop out the blanking cap that covers the opposite end of the bar
Basically, the bar just needs knocking out of the manifold now and the butterflies will just fall out. The bar can be seized into the butterflies quite well though so try a bit of WD40 or something to free it up a bit then just bash it out with a hammer and a small screwdriver or a 3/8 socket extension bar or something of the like
Now that the butterflies have been removed most of the work is done
Clean up the inserts and the inside of the manifold where the inserts sit with some solvent and glue the inserts in with some super glue (not sure of this is neccessary but it's better safe than sorry eh?)
Now just clean out the holes at either end of the manifold where the rod sat with solvent then fill them with epoxy resin (one thing to note is that if you're replacing the actuator unit then there's a locating dowel that sits in the hole so don't fill it up too much)
Replace the actuator without the arm that fits on the rod then refit the manifold
Notes
I don't know how much difference it makes but I replaced the vaccuum actuator and reconnected it to the hose. It doesn't do anything to the butterflies any more but it saves blanking the hose off.
New gaskets for the inlet manifold should be used
A new gasket and O ring for the EGR and the dipstick tube SHOULD be used but I didn't bother
If you remove the dipstick tube first and replace it last then it makes removing and replacing the lower intake manifold retaining bolt much easier
The more of the pipes and wiring you remove, the easier the manifold is to remove
If you struggle to replace the manifold retaining bolts then use a small amount of masking tape to secure the bolt to the socket
