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Home >> Ford >> 2000 >> Taurus LX, 3.0 2, AX4N >> Repair and Diagnosis >> External Pages >> Different car >> Section 1345 (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 Milan and 2010 Ford Fusion. 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 .
  2. Depower the vehicle high voltage electrical system. For additional information, refer to HIGH-VOLTAGE TRACTION BATTERY SYSTEMS DEPOWERING .
    NOTE: Before removing the high voltage cables, the vehicle electrical system must be completely shut down for at least 5 minutes to allow for the high voltage capacitors to discharge.
  3. Remove the fuel rail. For additional information, refer to REMOVAL .
  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 REMOVAL AND INSTALLATION .
  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 vacuum tube from the intake manifold.
  10. Detach the 3 wiring retainers from the intake manifold near the throttle body mounting area.
  11. Disconnect the auxiliary coolant pump electrical connector and detach the 2 wiring retainers.
  12. Detach the lower radiator hose retainer from the intake manifold.
  13. Detach the engine wiring harness retainer and the vehicle high voltage electrical system wire retainer from the intake manifold.
  14. Disconnect the Knock Sensor (KS) electrical connector and detach the retainer from the intake manifold.
  15. Remove the cooling fan motor and shroud. For additional information, refer to REMOVAL AND INSTALLATION .
  16. Remove the 3 A/C compressor bolts and position the compressor aside.
    • To install, tighten to 25 Nm (18 lb-ft).
  17. 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).
    NOTE: The cylinder head side of the intake manifold is showing the location of the 7 bolts.
    Fig 1: Locating Intake Manifold Aside & Bolts
    G06271703Courtesy of FORD MOTOR CO.
  18. Squeeze the 2 PCV hose connector tabs and disconnect the PCV hose from the intake manifold.
    Fig 2: Locating PCV Hose Connector Tabs
    G06095172Courtesy of FORD MOTOR CO.
  19. Remove the intake manifold and gaskets.
  20. To install, reverse the removal procedure.
    • Inspect and install new intake manifold gaskets if necessary.
    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.
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