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Home >> Ford >> 2006 >> Focus ZX5 SE, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 1493 (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 2011 Mercury Milan 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. Remove the Air Cleaner (ACL) outlet pipe. For additional information, refer to INTAKE AIR DISTRIBUTION & FILTERING - 2.5L -- FUSION & MILAN (EXCEPT HYBRID) article.
  3. Disconnect the vacuum supply hose.
    • Depress the quick connect locking ring.
    • Pull the vacuum hose out of the quick connect fitting.
    Fig 1: Locating Vacuum Hose And Locking Ring
    G07780529Courtesy 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 the A/C compressor wiring harness retainer.
  11. Detach the 2 wiring harness pin-type retainers from the intake manifold and position the wiring harness aside.
  12. If equipped, remove the 7 screws and the underbody cover.
    Fig 2: Locating Underbody Cover Screws
    G07780530Courtesy of FORD MOTOR CO.
  13. Remove the intake manifold lower bolt.
    • To install, tighten to 18 Nm (159 lb-in).
    Fig 3: Locating Intake Manifold Lower Bolt
    G07780531Courtesy of FORD MOTOR CO.
  14. 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).
  15. Remove the EGR tube.
    • To install, tighten to 55 Nm (41 lb-ft).
  16. Squeeze the 2 crankcase vent oil separator tube tabs and disconnect the tube from the intake manifold.
    • Remove the intake manifold.
    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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