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Home >> Ford >> 2012 >> Explorer Limited, 3.5 8, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 214 (Engine Mechanical - 3.5L GTDI) >> In-Vehicle Repair >> Intake Manifold >> Removal

Intake Manifold: Removal

WARNING: This page is about a different car, the 2013 Ford Explorer. However, it is still accessible from the selected car via links, so may be relevant.
NOTE: During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces that enters the oil passages, coolant passages or the oil pan, may cause engine failure.
NOTE: Whenever turbocharger air intake system components are removed, always cover open ports to protect from debris. It is important that no foreign material enter the system. The turbocharger compressor vanes are susceptible to damage from even small particles. All components should be inspected and cleaned, if necessary, prior to installation or reassembly.
  1. Drain the cooling system. Refer to COOLING SYSTEM DRAINING, FILLING AND BLEEDING .
  2. Remove the Air Cleaner (ACL) outlet pipe. REFER to INTAKE AIR SYSTEM COMPONENTS - EXPLODED VIEW .
  3. NOTE: Index-mark the Charge Air Cooler (CAC) tube for installation.

    Loosen the clamp and position the CAC tube aside.

    G09069499
  4. Disconnect the LH turbocharger bypass valve electrical connector and turbocharger bypass valve hose.
    G09069500
  5. NOTE: Index-mark the hoses for installation.

    Remove the turbocharger wastegate regulating valve hoses from the RH CAC tube and turbocharger wastegate regulating valve.

    • Disconnect the turbocharger wastegate regulating valve electrical connector.
      G09069501
  6. Disconnect the RH turbocharger bypass valve electrical connector and turbocharger bypass valve hose.
    G09069502
  7. NOTE: Index-mark the CAC  tube position for reference during installation.

    Loosen the clamp and remove the RH CAC  tube from the RH turbocharger.

    G09069503
  8. NOTE: The compression limiter bushing may fall out of the mounting bracket grommet on the Charge Air Cooler (CAC) tube during service. Make sure the bushing is in place when reinstalling the tube or damage to the tube may occur.

    Remove the RH CAC  tube nut from the intake manifold and remove the RH CAC  tube and turbocharger intake tube as an assembly.

    G09069504
  9. NOTE: Index-mark the Charge Air Cooler (CAC) tube for installation.

    Disconnect the TCBP  /CAC  electrical connector and loosen the clamp. Position the CAC  outlet pipe aside.

    G09069505
  10. Disconnect the TP  sensor and electronic TB  electrical connectors.
    G09069506
  11. Disconnect the EVAP  tube and brake booster vacuum hose quick connect couplings from the intake manifold. Refer to QUICK CONNECT COUPLING .
    G09069507
  12. Detach the EVAP  purge valve from the intake manifold.
    G09069508
  13. Disconnect the 2 quick connect couplings and remove the PCV tube. Refer to QUICK CONNECT COUPLING .
    G09069509
  14. Disconnect the Manifold Absolute Pressure (MAP)/Intake Air Temperature 2 (IAT2) sensor electrical connector.
    • Detach and disconnect the 2 fuel injector wiring harness electrical connectors and the 2 wiring harness retainers.
      G09069510
  15. Detach the 2 wire harness retainers from the LH valve cover stud bolt.
    G09069511
  16. Detach the 2 wire harness retainers from the LH valve cover.
    G09069512
  17. Disconnect the 2 heater hoses from the intake manifold.
    G09069513
  18. Disconnect the 2 turbocharger coolant hoses from the intake manifold.
    G09069514
  19. Disconnect the lower radiator hose from the thermostat housing.
    G09069515
  20. Remove the bolt and ground wire from the engine front cover.
    • Disconnect the upper radiator hose from the intake manifold coolant tube.
      G09069516
  21. Remove the coolant tube and remove the fuel tube-to-engine front cover bracket bolt and position the fuel tube aside.
    G09069517
  22. 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.
    NOTE: Note the routing of the 2 fuel rail wiring harnesses for installation.

    Remove the 12 bolts and the intake manifold.

    • Clean and inspect all sealing surfaces.
      G09069518
  23. Remove and discard the intake manifold, coolant crossover and thermostat housing gaskets.
    G09069519
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