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Home >> Mercury >> 2009 >> Mariner Base, 2.5 7, AWD >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 20 (Engine Mechanical - 2.5L - (Hybrid)) >> In-Vehicle Repair >> Intake Manifold >> Removal and Installation

Removal and Installation

WARNING: This page is about a different variant/trim than selected.
  1. With vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING & LIFTING .
  2. Release the fuel pressure. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION .
    3. 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. Disable the vehicle high voltage electrical system. For additional information, refer to HIGH VOLTAGE TRACTION BATTERY .
  4. Remove the cooling fan motor and shroud. For additional information, refer to ENGINE COOLING - HYBRID .
  5. Remove the fuel rail. For additional information, refer to FUEL CHARGING & CONTROLS - 2.5L .
  6. Remove the Throttle Body (TB). For additional information, refer to FUEL CHARGING & CONTROLS - HYBRID .
  7. Remove the accessory drive belt tensioner. For additional information, refer to ACCESSORY DRIVE - HYBRID .
  8. Disconnect the Engine Oil Pressure (EOP) switch electrical connector.
  9. Disconnect the Manifold Absolute Pressure (MAP) sensor electrical connector.
  10. Disconnect the Evaporative Emission (EVAP) canister purge valve electrical connector.
  11. Disconnect the EVAP tube-to-EVAP canister purge valve quick connect coupling and the brake booster vacuum tube from the intake manifold.
  12. Disconnect the Knock Sensor (KS) electrical connector and detach the 2 pin-type retainers.
    Fig 1: Locating Knock Sensor Electrical Connector And Pin-Type Retainers
    G06096027Courtesy of FORD MOTOR CO.
  13. Detach the 2 wiring retainers from the intake manifold near the throttle body mounting area.
  14. Detach the transaxle shift cable routing retainer from the intake manifold.
    15. NOTE: The cylinder head side of the intake manifold is showing the location of the 7 bolts.
  15. 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
      G06096028Courtesy of FORD MOTOR CO.
  16. Squeeze the 2 PCV hose connector tabs and disconnect the PCV hose from the intake manifold.
    Fig 3: Locating PCV Hose Connector
    G06095172Courtesy of FORD MOTOR CO.
  17. Remove the intake manifold and gaskets.
    18. 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.
  18. To install, reverse the removal procedure.
    • Inspect and install new intake manifold gaskets if necessary.
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