Ford Fusion: Engine - 1.5L EcoBoost (118kW/160PS) – I4 / Intake Manifold. Removal and Installation

Special Tool(s) / General Equipment

Materials

Removal

1. Disconnect the battery ground cable.
   Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures).
   

1. Remove the following items:
   1. Remove the air cleaner.
      Refer to: Air Cleaner (303-12A Intake Air Distribution and Filtering - 1.5L EcoBoost (118kW/160PS) – I4, Removal and Installation).
      
   2. Remove the upper air cleaner outlet pipe.
      Refer to: Air Cleaner Outlet Pipe (303-12A Intake Air Distribution and Filtering - 1.5L EcoBoost (118kW/160PS) – I4, Removal and Installation).
      
   3. Remove the EVAP canister purge valve.
      Refer to: Evaporative Emission Canister Purge Valve (303-13A Evaporative Emissions - 1.5L EcoBoost (118kW/160PS) – I4, Removal and Installation).
      
   4. Remove the charge air cooler.
      Refer to: Charge Air Cooler (CAC) (303-12A Intake Air Distribution and Filtering - 1.5L EcoBoost (118kW/160PS) – I4, Removal and Installation).
      
   5. Remove the generator.
      Refer to: Generator - 1.5L EcoBoost (118kW/160PS) – I4 (414-02 Generator and Regulator, Removal and Installation).
      

1. • Disconnect the crankcase pressure sensor wiring harness electrical connector.
     
   • Release the clamps and position the crankcase vent tube aside.
     Use the General Equipment: Hose Clamp Remover/Installer

1. Disconnect the wiring harness electrical connectors and retainer.
   

1. 1. Loosen the CAC intake pipe clamp.
      
   2. Remove the CAC intake pipe bolt.
      

1. Position the CAC intake pipe off the throttle body.
   

1. • Disconnect and position the vent tube aside.
     
   • Release the clamps and remove the hose.
     Use the General Equipment: Hose Clamp Remover/Installer

1. 1. Detach the (KS) knock sensors.
      
   2. Disconnect the (KS) knock sensors.
      

1. Disconnect the electrical connectors and the wiring harness retainers.
   

1. Disconnect the throttle body electrical connector and the wiring harness retainer.
   

1. Detach the wiring harness retainers and position the wire harness aside.
   

1. Remove the intake manifold support bracket bolt.
   

1. Remove the retainer and position the vacuum tube aside.
   

1. NOTE: The bolts remain captured in the intake manifold.

   Loosen the bolts and remove the intake manifold.
   

Installation

NOTICE: 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.

1. Visually inspect the intake manifold gasket for nicks, cuts and abrasions. If these conditions are not present, the gaskets may be re-used.
   

1. NOTE: Apply threadlock 262 to the intake manifold bolt threads.

   NOTE: Make sure the KS wiring connectors are properly routed and not trapped behind the intake manifold while installing the intake manifold.

   Install the intake manifold and tighten the bolts in sequence shown.
   Material: Motorcraft® Threadlock 262 / TA-26 (WSK-M2G351-A6)
   Torque:
     Stage 1:  Tighten bolts 1, 2 and 7 to:   18 lb.in (2 Nm)
     Stage 2:  Tighten bolts 3 and 4 to:   18 lb.in (2 Nm)
     Stage 3:  Tighten bolts 1 and 2 to:   159 lb.in (18 Nm)
     Stage 4:  Tighten bolts 3, 4, 5 and 6 to:   89 lb.in (10 Nm)
     Stage 5:  Retighten bolts 1 and 2 to:   159 lb.in (18 Nm)
     Stage 6:  Tighten bolt 7 to:   159 lb.in (18 Nm)
     Stage 7:  Retighten bolts 3, 4, 5 and 6 to:   89 lb.in (10 Nm)

1. Position the vacuum tube and install the retainer.
   Torque: 89 lb.in (10 Nm)

1. Install the intake manifold support bracket bolt.
   Torque: 159 lb.in (18 Nm)

1. Position the wire harness and attach the wiring harness retainers.
   

1. Connect the throttle body electrical connector and the wiring harness retainer.
   

1. Connect the electrical connectors and the wiring harness retainers.
   

1. 1. Connect the (KS) knock sensors.
      
   2. Attach the (KS) knock sensors.
      

1. • Install the hose.
     Use the General Equipment: Hose Clamp Remover/Installer
   • Connect the vent tube.
     

1. Install the CAC intake pipe on the throttle body.
   

1. 1. Tighten the CAC intake pipe clamp.
      Torque: 44 lb.in (5 Nm)
   2. Install the CAC intake pipe bolt.
      Torque: 71 lb.in (8 Nm)

1. Connect the wiring harness electrical connectors and retainer.
   

1. • Position the crankcase vent tube and release clamp.
     Use the General Equipment: Hose Clamp Remover/Installer
   • Connect the crankcase pressure sensor wiring harness electrical connector.
     

1. Install the following items:
   1. Install the generator.
      Refer to: Generator - 1.5L EcoBoost (118kW/160PS) – I4 (414-02 Generator and Regulator, Removal and Installation).
      
   2. Install the charge air cooler.
      Refer to: Charge Air Cooler (CAC) (303-12A Intake Air Distribution and Filtering - 1.5L EcoBoost (118kW/160PS) – I4, Removal and Installation).
      
   3. Install the EVAP canister purge valve.
      Refer to: Evaporative Emission Canister Purge Valve (303-13A Evaporative Emissions - 1.5L EcoBoost (118kW/160PS) – I4, Removal and Installation).
      
   4. Install the upper air cleaner outlet pipe.
      Refer to: Air Cleaner Outlet Pipe (303-12A Intake Air Distribution and Filtering - 1.5L EcoBoost (118kW/160PS) – I4, Removal and Installation).
      
   5. Install the air cleaner.
      Refer to: Air Cleaner (303-12A Intake Air Distribution and Filtering - 1.5L EcoBoost (118kW/160PS) – I4, Removal and Installation).
      

1. Connect the battery ground cable.
   Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures).