Lincoln Corsair: Intake Air Distribution and Filtering - 2.0L EcoBoost (177kW/240PS) – MI4 / Removal and Installation - Air Cleaner Outlet Pipe

Special Tool(s) / General Equipment

Materials

Removal

NOTICE: The turbocharger compressor vanes can be damaged by even the smallest particles. When removing any turbocharger or engine air intake system component, ensure that no debris enters the system. Failure to do so may result in damage to the turbocharger.

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

1. • Disconnect the quick release couplings and position aside the fuel vapor hoses.
     Refer to: Quick Release Coupling (310-00A Fuel System - General Information - 2.0L EcoBoost (177kW/240PS) – MI4, General Procedures).
     
   • Loosen the clamp and position aside the air bypass hose.
     Use the General Equipment: Hose Clamp Remover/Installer

1. NOTE: The crankcase vent tube may have either a permanent or quick connect connector at one or both ends. If the tube needs to be removed for any reason, the permanent connector(s) must be cut to remove the tube. The tube will then need to be replaced.

   NOTE: If the crankcase vent tube is replaced, the replacement part may not come with a crankcase pressure sensor. If so, the PCM will need to be reprogrammed.

   • If equipped, disconnect the wiring harness electrical connector.
     
   • If necessary, cut the lock tab.
     Use the General Equipment: Side Cutter Pliers
   • Remove the crankcase vent tube.
     
   • If either crankcase vent tube connector was cut, discard the crankcase vent tube.
     

1. • Remove the fasteners.
     
   • Loosen the clamps and remove the air cleaner outlet pipe.
     

1. 1. Loosen the clamp and remove the air cleaner outlet pipe.
      

Installation

1. Inspect the turbocharger or engine air intake system components and clean, if necessary.
   

1. 1. Install the air cleaner outlet pipe and tighten the clamp.
      Torque: 48 lb.in (5.4 Nm)

1. 1. Install the air cleaner outlet pipe and tighten the clamps.
      Torque: 42 lb.in (4.8 Nm)
   2. Install the fasteners.
      Torque: 80 lb.in (9 Nm)

1. • Install the crankcase vent tube. If the crankcase vent tube was previously discarded, install a new crankcase vent tube.
     
   • If the replacement crankcase vent tube part comes with no crankcase pressure sensor, reprogram the PCM .
     Refer to: Module Programming (418-01 Module Configuration, General Procedures).
     
   • If the replacement crankcase vent tube came without a crankcase pressure sensor, tape the wiring harness electrical connector back to the wiring harness.
     
   • If the replacement crankcase vent tube comes with a crankcase pressure sensor, connect the wiring harness electrical connector.
     

1. • Position the air bypass hose and install the clamp.
     Use the General Equipment: Hose Clamp Remover/Installer
   • Position the fuel vapor hoses and connect the quick release couplings.
     Refer to: Quick Release Coupling (310-00A Fuel System - General Information - 2.0L EcoBoost (177kW/240PS) – MI4, General Procedures).
     

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

      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. If the engine appearance cover stud bolt is loosened or removed, it must be installed/tightened into the valve cover.
      Torque: 62 lb.in (7 Nm)
   3. Position the engine appearance cover onto the engine with the grommets aligned with the studs.
      
   4. Press down on the engine appearance cover at each grommet location to attach the grommets onto the studs.
      
   5. Install the engine appearance cover nut.
      Torque: 44 lb.in (5 Nm)