Ford Ecosport: Engine - 2.0L Duratec-HE (129kW/175PS) / Removal and Installation - Intake Manifold

Materials

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. Disconnect the battery ground.
   Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures).
   

1. NOTICE: Do not pull the engine appearance cover forward or sideways to remove. Failure to press straight upward on the underside of the cover at the attachment points may result in damage to the cover or engine components.

   1. Place your hand under the engine appearance cover at each grommet location and push straight up to release each grommet from the studs.
      
   2. After all of the grommets have been released from the studs, remove the appearance cover from the engine.
      

1. If equipped, remove the bolts and the underbody shield.
   

1. • Detach the wiring harness retainer.
     
   • Detach the KS wiring harness connector retainers and position the wiring harness aside.
     

1. Remove the bottom intake manifold mounting bolt.
   

1. • Detach the wiring harness retainer.
     
   • Detach the wiring harness connector retainer and position the wiring harness aside.
     

1. Remove the air cleaner outlet pipe.
   Refer to: Air Cleaner Outlet Pipe (303-12C Intake Air Distribution and Filtering - 2.0L Duratec-HE (129kW/175PS), Removal and Installation).
   

1. Disconnect the throttle body electrical connector and detach the wire harness retainers.
   

1. Disconnect the EVAP canister purge valve tube quick release coupling.
   Refer to: Quick Release Coupling (310-00 Fuel System - General Information - 2.0L Duratec-HE (129kW/175PS), 2.0L Duratec-HE (125kW/170PS) – MI4, 2.0L Duratec-HE Flex Fuel (129kW/175PS)) .
   

1. 1. Depress the red quick connect locking ring.
      
   2. Pull the vacuum tube out of the quick connect locking ring.
      

1. NOTE: Position back the intake manifold to allow access to disconnect the crankcase ventilation oil separator tube from the intake manifold.

   
   
   • Remove the bolts and the intake manifold.
     
   • Disconnect the crankcase vent oil separator tube.
     

1. • Visually inspect the intake manifold gaskets for nicks, cuts and abrasions. If these conditions are not present, the gaskets may be reused.
     
   • Install new intake manifold gaskets if necessary.
     
   • Clean and inspect all of the sealing surfaces of the intake manifold.
     

1. • 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.
     

Installation

1. NOTE: Make sure the KS wiring connectors are properly routed and not trapped behind the intake manifold while installing the intake manifold.

   • Connect the crankcase vent oil separator tube.
     
   • Install the intake manifold and the bolts finger tight.
     

1. Install the bottom intake manifold mounting bolt finger tight.
   

1. Tighten the intake manifold bolts in sequence shown.
   Torque: 177 lb.in (20 Nm)

1. 1. Depress the red quick connect locking ring.
      
   2. Install the vacuum tube in the quick connect locking ring.
      

1. Connect the EVAP canister purge valve tube quick release coupling.
   Refer to: Quick Release Coupling (310-00 Fuel System - General Information - 2.0L Duratec-HE (129kW/175PS), 2.0L Duratec-HE (125kW/170PS) – MI4, 2.0L Duratec-HE Flex Fuel (129kW/175PS)) .
   

1. Connect the throttle body electrical connector and attach the wire harness retainers.
   

1. Install the air cleaner outlet pipe.
   Refer to: Air Cleaner Outlet Pipe (303-12C Intake Air Distribution and Filtering - 2.0L Duratec-HE (129kW/175PS), Removal and Installation).
   

1. • Attach the wiring harness connector retainer.
     
   • Attach the wiring harness retainer.
     

1. • Attach the KS wiring harness connector retainers.
     
   • Attach the wiring harness retainer.
     

1. If equipped, install the underbody shield and the retainers.
   

1. NOTE: Lubricating the grommets with silicone grease will aid in the installation of the engine appearance cover, and any future removal and installation of the cover.

   1. Lubricate each grommet with silicone grease.
      Material: Motorcraft® Silicone Brake Caliper Grease and Dielectric Compound / XG-3-A (ESA-M1C200-A) (ESE-M1C171-A)
   2. Position the engine appearance cover onto engine with the grommets aligned with the studs.
      
   3. Press down on the engine appearance cover at each grommet location to attach the grommets onto the studs.
      

1. Connect the battery ground.
   Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures).