Removal and Installation — Intake Manifold

Removal

1. 1
   Position the vehicle in NEUTRAL on the lift.
   Refer to: Jacking and Lifting - Overview (100-02 Jacking and Lifting, Description and Operation).
2. 2
   Remove the brackets and the lower splash shield.

   

3. 3
   Remove the nut, release the engine outer cover from the ball studs, then remove the cover.

   

4. 4
   Remove the air cleaner outlet tube.
   Refer to: Air Cleaner Outlet Tube (303-12C Intake Air Distribution and Filtering, Removal and Installation).
5. 5
   Disconnect the hoses and electrical connector from the EGR cooler.

   

6. 6
   Remove the bolts and the EGR outlet tube.

   

7. 7
   Discard the EGR outlet tube gasket.

   

8. 8
   Remove the wiring harness pin retainer.

   

9. 9
   Remove the pin retainer and disconnect the KS.

   

10. 10
    Disconnect the fuel vapor tube and remove the pin retainers.
    Refer to: Quick Release Coupling (310-00 Fuel System - General Information — 2.5 L Duratec — Hybrid (121 kW/164 L PS) (BG)).

    

11. 11
    Disconnect the MAP sensor electrical connector.

    

12. 12
    Disconnect the throttle body electrical connector and remove the pin.

    

13. 13
    Unscrew the bolts and remove the intake manifold.

    

14. 14
    Disconnect the crankcase ventilation oil separator tube and remove the intake manifold.
    Refer to: Quick Release Coupling (310-00 Fuel System - General Information — 2.5 L Duratec — Hybrid (121 kW/164 L PS) (BG)).

    

Installation

1. 1

   

2. 2
   Connect the crankcase ventilation oil separator tube and reinstall the intake manifold.

   

3. 3
   Install the intake manifold bolts and tighten in the sequence shown.
   Torque: 159 lb-in (18 N·m)

   

4. 4
   Connect the throttle body electrical connector and pin retainers.

   

5. 5
   Connect the MAP sensor electrical connector.

   

6. 6
   Connect the fuel vapor tube and install the pin retainers.
   Refer to: Quick Release Coupling (310-00 Fuel System - General Information — 2.5 L Duratec — Hybrid (121 kW/164 L PS) (BG)).

   

7. 7
   Install the pin retainer and connect the KS.

   

8. 8
   Install the wiring harness pin retainer.

   

9. 9
   Install a new EGR outlet tube gasket.

   

10. 10
    Reinstall the EGR outlet tube and install the bolts.
    Torque: 89 lb-in (10 N·m)

    

11. 11
    Install the hoses and connect the EGR cooler electrical connector.

    

12. 12
    Install the air cleaner outlet tube.
    Refer to: Air Cleaner Outlet Tube (303-12C Intake Air Distribution and Filtering, Removal and Installation).
13. 13
    Install the engine outer cover onto the ball studs, then install and tighten the nut.
    Torque: 97 lb-in (11 N·m)

    

14. 14
    Install the splash shield.