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Home >> Ford >> 2012 >> Taurus SEL, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 2930 (Engine - 3.5L GTDI) >> In-Vehicle Repair >> Intake Manifold >> Removal

Intake Manifold: Removal

WARNING: This page is about a different car, the 2016 Lincoln MKS. 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. 1.

    Drain the cooling system. For additional information, refer to Engine Cooling .

  1. 2.

    Remove the Air Cleaner (ACL) outlet pipe. For additional information, refer to Intake Air Distribution and Filtering .

  1. 3.

    Disconnect the LH turbocharger bypass valve electrical connector.
GFD87631Courtesy of FORD MOTOR COMPANY

  1. 4.

    Disconnect the LH turbocharger bypass valve hose from the RH Charge Air Cooler (CAC) tube.
GFD87632Courtesy of FORD MOTOR COMPANY

  1. 5.

    NOTE: Mark the location of each hose for installation.

    Disconnect the 3 turbocharger wastegate hoses.

GFD87633Courtesy of FORD MOTOR COMPANY

  1. 6.

    Disconnect the RH turbocharger bypass valve electrical connector.
GFD87634Courtesy of FORD MOTOR COMPANY

  1. 7.

    Disconnect the RH turbocharger bypass valve hose from the RH turbocharger intake tube.
GFD87635Courtesy of FORD MOTOR COMPANY

  1. 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.

    Remove the RH CAC tube nut from the intake manifold.

GFD87636Courtesy of FORD MOTOR COMPANY

  1. 9.

    Loosen the clamp for the RH CAC tube.
GFD87637Courtesy of FORD MOTOR COMPANY

  1. 10.

    Loosen the clamp and remove the RH CAC tube from the RH turbocharger.
GFD87638Courtesy of FORD MOTOR COMPANY

  1. 11.

    Loosen the clamp and position CAC outlet pipe-to-Throttle Body (TB) aside.
GFD87639Courtesy of FORD MOTOR COMPANY

  1. 12.

    Disconnect the Throttle Position (TP) sensor and electronic TB electrical connectors.
GFD87640Courtesy of FORD MOTOR COMPANY

  1. 13.

    Disconnect the quick connect coupling from the intake manifold. For additional information, refer to Fuel System - General Information .
GFD87641Courtesy of FORD MOTOR COMPANY

  1. 14.

    Disconnect the quick connect coupling Evaporative Emission (EVAP) tube from the intake manifold. For additional information, refer to Fuel System - General Information .
GFD87642Courtesy of FORD MOTOR COMPANY

  1. 15.

    Detach the EVAP purge valve from the intake manifold.
GFD87643Courtesy of FORD MOTOR COMPANY

  1. 16.

    Remove the fuel tube-to-engine front cover bracket bolt and position the fuel tube aside.
GFD87644Courtesy of FORD MOTOR COMPANY

  1. 17.

    Disconnect the PCV tube quick connect coupling from the intake manifold. For additional information, refer to Fuel System - General Information .
GFD87645Courtesy of FORD MOTOR COMPANY

  1. 18.

    Detach and disconnect the 2 fuel injector wiring harness electrical connectors.
GFD87646Courtesy of FORD MOTOR COMPANY

  1. 19.

    Disconnect the Manifold Absolute Pressure (MAP) /Intake Air Temperature 2 (IAT2) sensor electrical connector.
GFD87647Courtesy of FORD MOTOR COMPANY

  1. 20.

    Disconnect the turbocharger wastegate regulating valve electrical connector.
GFD87648Courtesy of FORD MOTOR COMPANY

  1. 21.

    Detach the 2 wire harness-to-intake manifold retainers.
GFD87649Courtesy of FORD MOTOR COMPANY

  1. 22.

    Detach the 2 wire harness retainers from the LH valve cover stud bolt.
GFD87650Courtesy of FORD MOTOR COMPANY

  1. 23.

    Detach the 2 wire harness retainers from the LH valve cover.
GFD87651Courtesy of FORD MOTOR COMPANY

  1. 24.

    Disconnect the 2 coolant heater hoses from the intake manifold.
GFD87652Courtesy of FORD MOTOR COMPANY

  1. 25.

    Disconnect the 2 turbocharger coolant hoses from the intake manifold.
GFD87653Courtesy of FORD MOTOR COMPANY

  1. 26.

    Disconnect the lower radiator hose from the thermostat housing.
GFD87654Courtesy of FORD MOTOR COMPANY

  1. 27.

    Remove the bolt and ground wire from the engine front cover.
GFD87655Courtesy of FORD MOTOR COMPANY

  1. 28.

    Disconnect the upper radiator hose at the intake manifold and position the hose aside.
GFD87656Courtesy of FORD MOTOR COMPANY

  1. 29.

    NOTE: Note the routing of the 2 fuel rail wiring harnesses for installation.

    Remove the 12 bolts and the intake manifold.

    • Remove and discard the intake manifold gaskets and the coolant crossover and thermostat housing gaskets.
    • Clean and inspect all sealing surfaces.
GFD87657Courtesy of FORD MOTOR COMPANY
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