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Home >> Ford >> 2000 >> Contour SE, 2.5 L, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 2409 (Engine Mechanical - 2.5L (Except Hybrid)) >> In-Vehicle Repair >> Intake Manifold >> Removal and Installation

Removal and Installation

WARNING: This page is about a different car, the 2010 Mercury Mariner and 2010 Ford Escape. However, it is still accessible from the selected car via links, so may be relevant.
  1. With vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING & LIFTING -- ESCAPE, ESCAPE HYBRID, MARINER & MARINER HYBRID .
  2. Remove the fuel rail. For additional information, refer to FUEL CHARGING & CONTROLS - 2.5L .
  3. Disconnect the vacuum supply hose.
    • Depress the quick release locking ring.
    • Pull the vacuum hose out of the quick release fitting.
      Fig 1: Locating Vacuum Hose And Quick Release Fitting
      G06094835Courtesy of FORD MOTOR CO.
  4. Disconnect the fuel vapor return hose from the intake manifold.
  5. Disconnect the Manifold Absolute Pressure (MAP) electrical connector.
  6. Disconnect the Evaporative Emission (EVAP) canister purge valve electrical connector.
  7. Disconnect the electronic throttle control electrical connector.
  8. Disconnect the Knock Sensor (KS) electrical connector.
    • Detach the wire harness pin-type retainer.
  9. Detach the heater hose pin-type retainer.
  10. Detach all wiring harness pin-type retainers from the intake manifold and position the wiring harness aside.
  11. Loosen the clamp and disconnect Air Cleaner (ACL) outlet pipe from the Throttle Body (TB).
    • To install, tighten to 4 Nm (35 lb-in).
  12. Remove the intake manifold lower bolt.
    • To install, tighten to 18 Nm (159 lb-in).
      Fig 2: Locating Intake Manifold Lower Bolt
      G06094836Courtesy of FORD MOTOR CO.
  13. Remove the 6 bolts and position the intake manifold aside to access the crankcase vent oil separator tube and the EGR tube.
    • To install, tighten to 18 Nm (159 lb-in).
  14. Squeeze the 2 crankcase vent oil separator tube tabs and disconnect the tube from the intake manifold.
  15. Remove the EGR tube.
    • To install, tighten to 55 Nm (41 lb-ft).
  16. Remove the intake manifold and gaskets.
    17. NOTE: If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions can result in engine damage.
  17. To install, reverse the removal procedure.
    • Inspect and install new intake manifold gaskets if necessary.
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