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Home >> Ford >> 2015 >> Taurus SHO >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> Engine - 3.5L GTDI >> In-Vehicle Repair >> Intake Manifold >> Removal

Intake Manifold: Removal

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.
GFD82368Courtesy of FORD MOTOR COMPANY

  1. 4.

    Disconnect the LH turbocharger bypass valve hose from the RH Charge Air Cooler (CAC) tube.
GFD82369Courtesy of FORD MOTOR COMPANY

  1. 5.

    NOTE: Mark the location of each hose for installation.

    Disconnect the 3 turbocharger wastegate hoses.

GFD82370Courtesy of FORD MOTOR COMPANY

  1. 6.

    Disconnect the RH turbocharger bypass valve electrical connector.
GFD82371Courtesy of FORD MOTOR COMPANY

  1. 7.

    Disconnect the RH turbocharger bypass valve hose from the RH turbocharger intake tube.
GFD82372Courtesy 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.

GFD82373Courtesy of FORD MOTOR COMPANY

  1. 9.

    Loosen the clamp for the RH CAC tube.
GFD82374Courtesy of FORD MOTOR COMPANY

  1. 10.

    Loosen the clamp and remove the RH CAC tube from the RH turbocharger.
GFD82375Courtesy of FORD MOTOR COMPANY

  1. 11.

    If equipped, remove the noise generator. For additional information, refer to Intake Air System Components - Exploded View in Intake Air Distribution and Filtering .

  1. 12.

    Loosen the clamp and position CAC outlet pipe-to-Throttle Body (TB) aside.
GFD82376Courtesy of FORD MOTOR COMPANY

  1. 13.

    Disconnect the Throttle Position (TP) sensor and electronic TB electrical connectors.
GFD82377Courtesy of FORD MOTOR COMPANY

  1. 14.

    Disconnect the quick connect coupling from the intake manifold. For additional information, refer to Fuel System General Information .
GFD82378Courtesy of FORD MOTOR COMPANY

  1. 15.

    Disconnect the quick connect coupling Evaporative Emission (EVAP) tube from the intake manifold. For additional information, refer to Fuel System General Information .
GFD82379Courtesy of FORD MOTOR COMPANY

  1. 16.

    Detach the EVAP purge valve from the intake manifold.
GFD82380Courtesy of FORD MOTOR COMPANY

  1. 17.

    Remove the fuel tube-to-engine front cover bracket bolt and position the fuel tube aside.
GFD82381Courtesy of FORD MOTOR COMPANY

  1. 18.

    Disconnect the PCV tube quick connect coupling from the intake manifold. For additional information, refer to Fuel System General Information .
GFD82382Courtesy of FORD MOTOR COMPANY

  1. 19.

    Detach and disconnect the 2 fuel injector wiring harness electrical connectors.
GFD82383Courtesy of FORD MOTOR COMPANY

  1. 20.

    Disconnect the Manifold Absolute Pressure (MAP) /Intake Air Temperature 2 (IAT2) sensor electrical connector.
GFD82384Courtesy of FORD MOTOR COMPANY

  1. 21.

    Disconnect the turbocharger wastegate regulating valve electrical connector.
GFD82385Courtesy of FORD MOTOR COMPANY

  1. 22.

    Detach the 2 wire harness-to-intake manifold retainers.
GFD82386Courtesy of FORD MOTOR COMPANY

  1. 23.

    Detach the 2 wire harness retainers from the LH valve cover stud bolt.
GFD82387Courtesy of FORD MOTOR COMPANY

  1. 24.

    Detach the 2 wire harness retainers from the LH valve cover.
GFD82388Courtesy of FORD MOTOR COMPANY

  1. 25.

    Disconnect the 2 coolant heater hoses from the intake manifold.
GFD82389Courtesy of FORD MOTOR COMPANY

  1. 26.

    Disconnect the 2 turbocharger coolant hoses from the intake manifold.
GFD82390Courtesy of FORD MOTOR COMPANY

  1. 27.

    Disconnect the lower radiator hose from the thermostat housing.
GFD82391Courtesy of FORD MOTOR COMPANY

  1. 28.

    Remove the bolt and ground wire from the engine front cover.
GFD82392Courtesy of FORD MOTOR COMPANY

  1. 29.

    Disconnect the upper radiator hose at the intake manifold and position the hose aside.
GFD82393Courtesy of FORD MOTOR COMPANY

  1. 30.

    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.
GFD82394Courtesy of FORD MOTOR COMPANY
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