Intake Manifold. Removal and Installation

Special Service Tools / General Equipment

Hose Clamp Removal/Installation Tool

Materials

Removal

1. 1
   Disconnect the battery ground cable.
   Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures).
2. 2
   Remove the following components:

   1. Remove the air cleaner.
      REFER TO: Air Cleaner Element (303-12A Intake Air Distribution and Filtering - 1.5 L EcoBoost (118 kW/160 L PS) - I4, Removal and Installation).
   2. Remove the upper air cleaner outlet tube.
      Refer to: Air Cleaner Outlet Tube (303-12A Intake Air Distribution and Filtering – 1.5 L EcoBoost (118 kW/160 L PS) – I4, Removal and Installation).
   3. Remove the EVAP canister purge valve.
      Refer to: Evaporative Emission Canister Purge Valve (303-13A Evaporative Emissions — 1.5 L EcoBoost (118 kW/160 L hp) — I4, Removal and Installation).
   4. Remove the charge air cooler (CAC).
      Refer to: Charge Air Cooler (CAC) (303-12A Intake Air Distribution and Filtering — 1.5 L EcoBoost (118 kW/160 L hp) — I4, Removal and Installation).
   5. Remove the generator.
      Refer to: Generator - 1.5 L EcoBoost (118 kW/160 L PS) - I4 (414-02 Generator and Regulator, Removal and Installation).
3. 3
   • Disconnect the crankcase pressure sensor harness electrical connector.

   • Release the clamps and move the crankcase ventilation tube aside.
     Use common shop equipment: hose clamp removal/installation tool.

   

4. 4
   Disconnect the electrical connectors and the wiring harness retainer.

   

5. 5
   1. Loosen the CAC inlet tube clamp.

   2. Remove the CAC inlet tube bolt.

   

6. 6
   Disconnect the CAC inlet tube from the throttle body.

   

7. 7
   • Disconnect and set the ventilation tube aside.

   • Loosen the clamps and remove the hose.
     Use common shop equipment: hose clamp removal/installation tool.

   

8. 8
   1. Disconnect the knock sensors (KS).

   2. Disconnect the knock sensors (KS).

   

9. 9
   Disconnect the electrical connectors and the wiring harness clips.

   

10. 10
    Disconnect the throttle body electrical connector and the harness retainer.

    

11. 11
    Disconnect the wiring harness clips and set the wiring harness aside.

    

12. 12
    Remove the intake manifold support bracket bolt.

    

13. 13
    Remove the retainer and set the vacuum tube aside.

    

14. 14
    Unscrew the bolts and 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
   Visually inspect the intake manifold gasket for dents, cuts, and scratches. If these conditions are not present, the gaskets may be reused.

   

2. 2
   Install the intake manifold and tighten the bolts in the sequence shown.
   Material: Motorcraft® Threadlock 262 / TA-26 (WSK-M2G351-A6)
   Torque:
   Step 1: Tighten bolts 1, 2, and 7 to: 18 lb-in (2 N·m)
   Step 2: Tighten bolts 3 and 4 to: 18 lb-in (2 N·m)
   Step 3: Tighten bolts 1 and 2 to: 159 lb-in (18 N·m)
   Step 4: Tighten bolts 3, 4, 5, and 6 to: 89 lb-in (10 N·m)
   Step 5: Tighten bolts 1 and 2 to: 159 lb-in (18 N·m)
   Step 6: Tighten bolt 7 to: 159 lb-in (18 N·m)
   Step 7: Tighten bolts 3, 4, 5, and 6 to: 89 lb-in (10 N·m)

   

3. 3
   Position the vacuum tube and install the retainer.
   Torque: 89 lb-in (10 N·m)

   

4. 4
   Install the intake manifold support bracket bolt.
   Torque: 159 lb-in (18 N·m)

   

5. 5
   Position the wiring harness and attach the wiring harness clips.

   

6. 6
   Connect the throttle body electrical connector and the harness retainer.

   

7. 7
   Connect the electrical connectors and harness clips.

   

8. 8
   1. Connect the knock sensors (KS).

   2. Connect the knock sensors (KS).

   

9. 9
   • Install the hose.
     Use common shop equipment: hose clamp removal/installation tool.

   • Connect the breather tube.

   

10. 10
    Install the CAC inlet tube onto the throttle body.

    

11. 11
    1. Tighten the CAC inlet tube clamp.
       Torque: 44 lb-in (5 N·m)

    2. Install the CAC inlet tube bolt.
       Torque: 71 lb-in (8 N·m)

    

12. 12
    Connect the electrical connectors and the wiring harness retainer.

    

13. 13
    • Position the crankcase ventilation tube and loosen the clamp.
      Use common shop equipment: hose clamp removal/installation tool.

    • Connect the crankcase pressure sensor harness electrical connector.

    

14. 14
    Install the following components:

    1. Install the alternator.
       Refer to: Alternator — 1.5 L EcoBoost (118 kW/160 L hp) — I4 (414-02 Generator and Regulator, Removal and Installation).
    2. Install the charge air cooler (CAC).
       Refer to: Charge Air Cooler (CAC) (303-12A Intake Air Distribution and Filtering — 1.5 L EcoBoost (118 kW/160 L hp) — I4, Removal and Installation).
    3. Install the EVAP canister purge valve.
       Refer to: Fuel Vapor Management Valve (303-13A Evaporative Emission Control — 1.5 L EcoBoost (118 kW/160 L hp) — I4, Removal and Installation).
    4. Install the upper air cleaner outlet pipe.
       Refer to: Air Cleaner Outlet Pipe (303-12A Intake Air Distribution and Filtering - 1.5 L EcoBoost (118 kW/160 L PS) - I4, Removal and Installation).
    5. Install the air cleaner.
       REFER TO: Air Cleaner Element (303-12A Intake Air Distribution and Filtering - 1.5 L EcoBoost (118 kW/160 L PS) - I4, Removal and Installation).
15. 15
    Connect the battery ground cable.
    Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures).