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Intake Manifold: Removal

WARNING: This page is about a different car, the 2011 Ford Taurus. 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. For additional information, refer to ENGINE COOLING SYSTEM Article.
  2. Remove the Air Cleaner (ACL) outlet pipe. For additional information, refer to INTAKE AIR DISTRIBUTION SYSTEM & INTAKE AIR FILTERING SYSTEM Article.
  3. Disconnect the LH turbocharger bypass valve electrical connector.
  4. Disconnect the LH turbocharger bypass valve hose from the RH Charge Air Cooler (CAC) tube.
  5. Disconnect the turbocharger wastegate regulating valve hose from the RH CAC tube.
  6. Disconnect the RH turbocharger bypass valve electrical connector.
  7. Disconnect the RH turbocharger bypass valve hose from the RH turbocharger intake tube.
    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.
  8. Remove the RH CAC tube nut from the intake manifold.
  9. Loosen the clamp and remove the RH CAC tube.
  10. Loosen the clamp and remove the RH CAC tube from the RH turbocharger.
  11. Remove the noise generator. For additional information, refer to Intake Air System Components - Exploded View in INTAKE AIR DISTRIBUTION SYSTEM & INTAKE AIR FILTERING SYSTEM Article.
  12. Loosen the clamp and position CAC outlet pipe-to-Throttle Body (TB).
  13. Disconnect the Throttle Position (TP) sensor and electronic TB electrical connectors.
  14. Disconnect the quick connect coupling Evaporative Emission (EVAP) tube from the intake manifold. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION Article.
  15. Detach the EVAP purge valve from the intake manifold.
  16. Disconnect the brake booster vacuum hose from the intake manifold.
  17. Remove the fuel tube-to-engine front cover bracket bolt and position the fuel tube.
  18. Disconnect the PCV tube quick connect coupling from the intake manifold. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION Article.
  19. Detach and disconnect the 2 fuel injector wiring harness electrical connectors.
  20. Disconnect the Manifold Absolute Pressure (MAP)/Intake Air Temperature 2 (IAT2) sensor electrical connector.
    21. NOTE: Mark the location of each hose for installation.
  21. Disconnect the 2 hoses from the turbocharger wastegate regulating valve.
  22. Disconnect the turbocharger wastegate regulating valve electrical connector.
  23. Detach the 2 wire harness-to-intake manifold retainers.
  24. Detach the 2 wire harness retainer from the LH valve cover stud bolt.
  25. Detach the 2 wire harness retainer from the LH valve cover.
  26. Disconnect the 2 coolant heater hoses from the intake manifold.
  27. Disconnect the 2 turbocharger coolant hoses from the intake manifold.
  28. Disconnect the lower radiator hose from the thermostat housing.
  29. Remove the bolt and ground wire from the engine front cover.
  30. Disconnect the upper radiator hose at the intake manifold and position the hose.
    31. NOTE: Note the routing of the 2 fuel rail wiring harnesses for installation.
  31. Remove the 12 bolts and the intake manifold.
    • Remove and discard the intake manifold, coolant crossover and thermostat housing gaskets.
    • Clean and inspect all sealing surfaces.
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