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HOMESERVICE MANUALSFORD2009FUSION SEL, 3.0 1, FWDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 610 (ENGINE - 2.3L)IN-VEHICLE REPAIRINTAKE MANIFOLDREMOVAL AND INSTALLATION
2009 Ford Fusion SEL, 3.0 1, FWD

Removal and Installation

2009 Ford Fusion SEL, 3.0 1, FWDSECTION Removal and Installation
WARNING: This page is about a different car, the 2006 Mercury Milan and 2006 Ford Fusion. However, it is still accessible from the selected car via links, so may be relevant.

    All vehicles 

  1. With vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING & LIFTING .
  2. Disconnect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  3. Remove the air cleaner outlet pipe. For additional information, refer to INTAKE AIR DISTRIBUTION & FILTERING - 2.3L .
  4. Remove the bolt, 2 nuts and the generator air inlet duct.
    • To install, tighten to 6 Nm (53 lb-in).
      Fig 1: Locating Generator Air Inlet Duct
      G04679927Courtesy of FORD MOTOR CO.
  5. Depress the locking ring and disconnect the brake booster vacuum supply tube from the intake manifold.
    Fig 2: Locating Locking Ring And Brake Booster Vacuum Supply Tube
    G04679928Courtesy of FORD MOTOR CO.
  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.
    Fig 3: Locating Fuel Rail Insulator Retainers
    G04679929Courtesy of FORD MOTOR CO.
  9. Detach the electrical connector pin-type retainer.
    Fig 4: Locating Electrical Connector Pin-Type Retainer
    G04679930Courtesy of FORD MOTOR CO.
  10. If equipped, remove the 7 screws and the underbody cover.
    Fig 5: Locating Underbody Cover Screws
    G04679931Courtesy of FORD MOTOR CO.

    11. Vehicles equipped with manual transaxle 

  11. Remove the 2 bolts and position the clutch slave cylinder aside.
    • To install, tighten to 22 Nm (16 lb-ft).

    12. Vehicles with secondary air injection (AIR) 

  12. Disconnect the AIR pump electrical connector.
  13. Remove the 3 bolts and position the AIR pump aside.
    • To install, tighten to 30 Nm (22 lb-ft).
  14. Disconnect the vacuum hose from the intake manifold.

    15. All vehicles 

  15. Detach the radiator hose retaining clip from the intake manifold.
  16. Remove the intake manifold lower bolt.
    • To install, tighten to 18 Nm (13 lb-ft).
      Fig 6: Locating Intake Manifold Lower Bolt
      G04679932Courtesy of FORD MOTOR CO.
  17. Disconnect the manifold absolute pressure (MAP) sensor electrical connector.
  18. Disconnect the intake manifold runner control (IMRC) actuator electrical connector.
  19. Disconnect the oil pressure sender electrical connector.
    • Detach the wiring harness pin-type retainer and position the wiring harness aside.
  20. Remove the nut and the S-terminal wire from the starter.
    • To install, tighten to 12 Nm (9 lb-ft).
  21. Disconnect the throttle body electrical connector.
    22. NOTE: Discard the throttle body gasket.
  22. Remove the 4 bolts and position the throttle body aside.
    • To install, tighten to 10 Nm (89 lb-in).
  23. Detach the 2 pin-type retainers from the intake manifold.
    Fig 7: Locating Pin-Type Retainers
    G04679933Courtesy of FORD MOTOR CO.
    24. NOTE: There are 2 different size bolts used. Mark the location of the bolts to make sure they are installed in their original locations.
  24. Remove the 7 bolts and position the intake manifold aside to access the crankcase vent hose clamp and the EGR tube.
    • To install, tighten to 18 Nm (13 lb-ft).
  25. Release the clamp and disconnect the crankcase vent hose.
  26. Detach the knock sensor (KS) electrical connector pin-type retainer.
  27. Remove the exhaust gas recirculation (EGR) tube.
    • To install, tighten to 55 Nm (41 lb-ft).
  28. Remove the intake manifold and discard the gaskets.
    • To install, tighten to 18 Nm (13 lb-ft).
  29. To install, reverse the removal procedure.
    • Install new throttle body and intake manifold gaskets.
RENDER: 1.0x

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.