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Home >> Ford >> 2000 >> Contour SE, 2.5 L, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 2411 (Engine Mechanical - 2.5L (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 RAIL .
  3. Remove the cooling fan motor and shroud. For additional information, refer to COOLING FAN MOTOR AND SHROUD .
  4. Remove the Throttle Body (TB). For additional information, refer to THROTTLE BODY .
  5. Remove the accessory drive belt tensioner. For additional information, refer to ACCESSORY DRIVE BELT TENSIONER .
  6. Disconnect the Engine Oil Pressure (EOP) switch electrical connector.
  7. Disconnect the Manifold Absolute Pressure (MAP) sensor electrical connector.
  8. Disconnect the Evaporative Emission (EVAP) canister purge valve electrical connector.
  9. Disconnect the EVAP  tube-to- EVAP  canister purge valve quick connect coupling and the brake booster vacuum tube from the intake manifold.
  10. Disconnect the Knock Sensor (KS) electrical connector and detach the 2 pin-type retainers.
    Fig 1: Locating Knock Sensor (KS) Electrical Connector And Pin-Type Retainers
    G06389799Courtesy of FORD MOTOR CO.
  11. Detach the 2 wiring retainers from the intake manifold near the TB  mounting area.
  12. Detach the engine wiring harness retainer from the intake manifold.
  13. Remove the 3 electric A/C compressor bolts and position aside.
    • To install, tighten to 25 Nm (18 lb-ft).
    14. NOTE: The cylinder head side of the intake manifold is showing the location of the 7 bolts.
  14. Remove the 7 bolts and position the intake manifold aside to access the PCV hose connector.
    • To install, tighten to 18 Nm (159 lb-in).
      Fig 2: Locating Intake Manifold Bolts
      G06389800Courtesy of FORD MOTOR CO.
  15. Squeeze the 2 PCV hose connector tabs and disconnect the PCV hose from the intake manifold.
    Fig 3: Locating Crankcase Vent Oil Separator Tube
    G06389801Courtesy of FORD MOTOR CO.
  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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