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Home >> Ford >> 2000 >> Taurus LX, 3.0 2, AX4N >> Repair and Diagnosis >> External Pages >> Different car >> Section 1664 (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 2011 Mercury Milan, 2011 Lincoln MKZ, and 2011 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 article.
    2. 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.
  2. Depower the vehicle high voltage electrical system. For additional information, refer to HIGH VOLTAGE TRACTION BATTERY -- FUSION HYBRID, MILAN HYBRID & MKZ HYBRID article.
  3. Remove the fuel rail. For additional information, refer to FUEL CHARGING & CONTROLS - 2.5L -- FUSION HYBRID, MILAN HYBRID & MKZ HYBRID article.
  4. Remove the Throttle Body (TB). For additional information, refer to FUEL CHARGING & CONTROLS - 2.5L -- FUSION HYBRID, MILAN HYBRID & MKZ HYBRID article.
  5. Remove the accessory drive belt tensioner. For additional information, refer to ACCESSORY DRIVE - FUSION HYBRID, MILAN HYBRID & MKZ HYBRID article.
  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 ENGINE COOLING SYSTEM -- (HYBRID) article.
  16. Remove the 3 A/C compressor bolts and position the compressor aside.
    • To install, tighten to 25 Nm (18 lb-ft).
    17. NOTE: The cylinder head side of the intake manifold is showing the location of the 7 bolts.
    Fig 1: Locating Intake Manifold Mounting Bolts
    G07781894Courtesy of FORD MOTOR CO.
  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).
  18. Squeeze the 2 PCV hose connector tabs and disconnect the PCV hose from the intake manifold.
    Fig 2: Locating Intake Manifold PCV Hose
    G07781895Courtesy of FORD MOTOR CO.
  19. Remove the intake manifold and gaskets.
    20. 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.
  20. To install, reverse the removal procedure.
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