Intake Manifold. Removal and Installation

Special Service Tools / General Equipment

Hose Clamp Removal/Installation Tool

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
   Disconnect the battery ground cable.
   Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures).
3. 3
   Remove the generator.
   Refer to: Generator - 1.6 L EcoBoost (132 kW/180 L PS) - Sigma (414-02 Generator and Regulator, Removal and Installation).
4. 4
   • Disconnect the PCV hose from the valve cover.
     Use general equipment: hose clamp removal/installation tool.

   • Disconnect the quick-connect fitting of the EVAP canister purge valve.

   • Disconnect the wiring harness retainers and disconnect the electrical connectors.

   

5. 5
   • Disconnect the resonator assembly hose. Loosen the clamps and remove the resonator assembly.
     Use general equipment: hose clamp removal/installation tool.

   • Loosen the clamps and set the CAC hose aside.

   

6. 6
   Disconnect the EVAP tube from the CAC outlet tube.

   

7. 7
   • Disconnect the electrical connector.

   • Loosen the clamp, remove the nut and the CAC outlet tube.

   

8. 8
   Remove the intake manifold mounting bolts.

   

9. 9
   Disconnect the electrical connector from the throttle body.

   

10. 10
    Remove the intake manifold.

    

Installation

NOTICE: If the engine is being repaired or replaced due to a major engine failure, usually involving valve or piston damage, inspect the intake manifold for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions may result in engine damage.

1. 1
   Inspect the intake manifold gaskets for dents.

   

2. 2
   Connect the electrical connector to the throttle body.

   

3. 3
   1. Install the intake manifold and bolts.
      Torque: 150 lb-in (17 N·m)

   2. Install the intake manifold mounting bolts.
      Torque: 89 lb-in (10 N·m)

   

4. 4
   1. Install the CAC outlet tube and nut.
      Torque: 133 lb-in (15 N·m)

   2. Tighten the hose clamp and connect the electrical connector.
      Torque: 44 lb-in (5 N·m)

   

5. 5
   Connect the EVAP tube to the CAC outlet tube.

   

6. 6
   • Position the CAC hose and tighten the clamp.
     Torque: 44 lb-in (5 N·m)

   • Install the resonator assembly and connect the resonator assembly hoses.
     Use common service equipment: hose clamp removal/installation tool.

   

7. 7
   • Connect the PCV hose to the valve cover.
     Use common service equipment: hose clamp removal/installation tool.

   • Connect the EVAP canister purge valve quick-connect electrical connector.

   • Secure the wiring harness clips. Connect the electrical connectors.

   

8. 8
   Install the generator.
   Refer to: Generator — 1.6 L EcoBoost (132 kW/180 L PS) — Sigma (414-02 Generator and Regulator, Removal and Installation).
9. 9
   Connect the battery ground cable.
   Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures).