Ford Escape: Engine / Removal and Installation - Intake Manifold

Removal

1. With the vehicle in NEUTRAL, position it on a hoist.
   Refer to: Jacking and Lifting - Overview (100-02 Jacking and Lifting, Description and Operation).
   

1. Remove the fasteners and undershield.
   

1. Remove the nut, release the engine appearance cover from the ball-studs, then remove the cover.
   

1. Remove the air cleaner outlet pipe.
   Refer to: Air Cleaner Outlet Pipe (303-12C Intake Air Distribution and Filtering, Removal and Installation).
   

1. Disconnect the hoses and the EGR cooler electrical connector.
   

1. Remove the bolts and position the EGR outlet tube.
   

1. Discard the EGR outlet tube gasket.
   

1. Remove the wire harness pin-type retainer.
   

1. Remove the pin-type retainer and disconnect the KS .
   

1. Disconnect the fuel vapor tube and remove the pin-type retainers.
   Refer to: Quick Release Coupling (310-00 Fuel System - General Information - 2.5L Duratec – Hybrid (121kW/164PS) (BG)) .
   

1. Disconnect the MAP sensor electrical connector.
   

1. Disconnect the throttle body electrical connector and remove the pin-type.
   

1. Remove the bolts and position out the intake manifold.
   

1. Disconnect the crankcase vent oil separator tube and remove the intake manifold.
   Refer to: Quick Release Coupling (310-00 Fuel System - General Information - 2.5L Duratec – Hybrid (121kW/164PS) (BG)) .
   

Installation

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

1. Connect the crankcase vent oil separator tube and position back the intake manifold.
   

1. Install the intake manifold bolts and tighten in sequence shown.
   Torque: 159 lb.in (18 Nm)

1. Connect the throttle body electrical connector and the pin-type retainers.
   

1. Connect the MAP sensor electrical connector.
   

1. Connect the fuel vapor tube and install the pin-type retainers.
   Refer to: Quick Release Coupling (310-00 Fuel System - General Information - 2.5L Duratec – Hybrid (121kW/164PS) (BG)) .
   

1. Install the pin-type retainer and connect the KS .
   

1. Install the wire harness pin-type retainer.
   

1. Install a new EGR outlet tube gasket.
   

1. Position back the EGR outlet tube and install the bolts.
   Torque: 89 lb.in (10 Nm)

1. Install the hoses and connect the EGR cooler electrical connector.
   

1. Install the air cleaner outlet pipe.
   Refer to: Air Cleaner Outlet Pipe (303-12C Intake Air Distribution and Filtering, Removal and Installation).
   

1. Install the engine appearance cover to the ball-studs, then install and tighten the nut.
   Torque: 97 lb.in (11 Nm)

1. Install the undershield.