How to replace Intake Manifold on Ford Fusion & Mercury Milan?

The procedure is similar for both Ford, Lincoln and Mercury car models:----

Intake Manifold
REMOVAL & INSTALLATION details are as follows:---

2.3L Engine

Specific to:

Ford Fusion 2008-2009

Mercury Milan 2008-2009

1. Raise and safely support the vehicle.
2. Disconnect the battery ground cable.
3. Remove the air cleaner outlet pipe.
4. Remove the bolt, 2 nuts and the generator air inlet duct.
   1. To install, tighten to 53 inch lbs. (6 Nm).
5. Depress the locking ring and disconnect the brake booster vacuum supply tube from the intake manifold.
6. Disconnect the evaporative emissions (EVAP) tube from the intake manifold.
7. Disconnect the 2 swirl control valve electrical connectors.
8. Detach the 2 wiring harness pin-type retainers and remove the fuel rail insulator.
9. Detach the electrical connector pin-type retainer.
10. If equipped, remove the 7 screws and the underbody cover.
11. On vehicles equipped with manual transaxle:
    1. Remove the 2 bolts and position the clutch slave cylinder aside.
    2. To install, tighten to 16 ft. lbs. (22 Nm).
12. On vehicles with secondary air injection (AIR):
    1. Disconnect the AIR pump electrical connector.
    2. Remove the 3 bolts and position the AIR pump aside.
    3. To install, tighten to 22 ft. lbs. (30 Nm).
    4. Disconnect the vacuum hose from the intake manifold.
13. Detach the radiator hose retaining clip from the intake manifold.
14. Remove the intake manifold lower bolt.
    1. To install, tighten to 13 ft. lbs. (18 Nm).
15. Disconnect the Manifold Absolute Pressure (MAP) sensor electrical connector.
16. Disconnect the Intake Manifold Runner Control (IMRC) actuator electrical connector.
17. Disconnect the oil pressure sender electrical connector.
18. Detach the wiring harness pin-type retainer and position the wiring harness aside.
19. Remove the nut and the S-terminal wire from the starter.
    1. To install, tighten to 9 ft. lbs. (12 Nm).
       
       
       

       

       Fig. Exploded view of the intake manifold and related components-2.3L engine
20. Disconnect the throttle body electrical connector.
    
    NOTE

    Discard the throttle body gasket.
21. Remove the 4 bolts and position the throttle body aside.
    1. To install, tighten to 89 inch lbs. (10 Nm).
22. Detach the 2 pin-type retainers from the intake manifold.
    
    NOTE

    There are 2 different size bolts used. Mark the location of the bolts to make sure they are installed in their original locations.
23. Remove the 7 bolts and position the intake manifold aside to access the crankcase vent hose clamp and the EGR tube.
    1. To install, tighten to 13 ft. lbs. (18 Nm).
24. Release the clamp and disconnect the crankcase vent hose.
25. Detach the knock sensor (KS) electrical connector pin-type retainer.
26. Remove the exhaust gas recirculation (EGR) tube.
    1. To install, tighten to 41 ft. lbs. (55 Nm).
27. Remove the intake manifold and discard the gaskets.
    1. To install, tighten to 13 ft. lbs. (18 Nm).
28. To install, reverse the removal procedure. Install new throttle body and intake manifold gaskets

3.0L Engine
Lower Manifold

Specific to:

Ford Fusion 2008-2009

Mercury Milan 2008-2009

CAUTION

Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited, resulting in possible personal injury.

CAUTION

Fuel in the fuel system remains under high pressure even when the engine is not running. Before repairing or disconnecting any of the fuel system components, the fuel system pressure must be relieved to prevent accidental spraying of fuel, causing personal injury or a fire hazard.

1. Release the fuel system pressure, as outlined in the Fuel Section.
2. Disconnect the battery ground cable.
3. Remove the upper intake manifold.
4. Disconnect the fuel supply tube quick connect coupling from the fuel rail.
5. Detach the 2 wiring harness retainers from the LH valve cover stud bolts.
6. Detach the 3 pin-type retainers from the fuel rail.
7. Disconnect the 6 fuel injector electrical connectors.
8. Remove the 8 lower intake manifold bolts and the lower intake manifold.
9. Remove and discard the gaskets.

To install:

NOTE

Clean and inspect all sealing surfaces. Install new gaskets.

1. Position the lower intake manifold and install the 8 bolts. Tighten in the sequence shown to 89 inch lbs. (10 Nm).
   
   
   

   

   Fig. Lower intake manifold bolt tightening sequence-3.0L engine
2. Connect the 6 fuel injector electrical connectors.
3. Attach the 3 pin-type retainers to the fuel rail.
4. Attach the 2 wiring harness retainers to the LH valve cover stud bolts.
5. Connect the fuel supply tube quick connect coupling at the fuel rail.
6. Install the upper intake manifold.
7. Connect the battery ground cable

Upper Manifold

Specific to:

Ford Fusion 2008-2009

Mercury Milan 2008-2009

1. Remove the air cleaner outlet pipe.
2. Disconnect the throttle body electrical connector.
3. Remove the 4 bolts and position the throttle body aside. Discard the gasket.
4. Disconnect the Evaporative emissions (EVAP) tube from the intake manifold.
5. Remove the vacuum tube clamp bolt.
6. Disconnect the vacuum tube from the intake manifold.
7. Disconnect the Positive Crankcase Ventilation (PCV) tube from the intake manifold.
8. Disconnect the Exhaust Gas Recirculation (EGR) valve electrical connector.
9. Loosen the EGR tube-to-EGR valve nut.
10. Disconnect the Manifold Absolute Pressure (MAP) sensor electrical connector and the pin-type retainer.
11. Detach the wiring harness retainer from the front of the upper intake manifold.
12. Remove the 8 bolts and remove the upper intake manifold.
13. Remove and discard the gaskets.
    
    
    

    

    Fig. Exploded view of the upper intake manifold-3.0L engine

To install:

1. Clean and inspect all of the sealing surfaces of the upper intake manifold.
   
   NOTE

   Install new gaskets.
2. Install the upper intake manifold, gaskets and the 8 bolts. Tighten in the sequence shown to 89 inch lbs. (10 Nm).
   
   
   

   

   Fig. Upper intake manifold bolt tightening sequence-3.0L engine
3. Attach the wiring harness retainer to the front of the upper intake manifold.
4. Connect the MAP sensor electrical connector and the pin-type retainer.
5. Install the EGR tube-to-EGR valve nut. Tighten to 30 ft. lbs. (40 Nm).
6. Connect the EGR valve electrical connector.
7. Connect the PCV tube to the intake manifold.
8. Connect the vacuum tube to the intake manifold.
9. Install the vacuum tube clamp bolt. Tighten to 89 inch lbs. (10 Nm).
10. Connect the EVAP tube to the intake manifold.
11. Install a new gasket. Install the gasket, throttle body and 4 bolts. Tighten to 89 inch lbs. (10 Nm).
12. Connect the throttle body electrical connector.
13. Install the air cleaner outlet pipe

These details will help.

Thanks.

FOR MORE HELP GO TO: ---

Car repair guide?

http://technoanswers.blogspot.in/2012/03/car-repair-guide.html