Lincoln Corsair: Engine - 2.0L EcoBoost (177kW/240PS) – MI4 / Removal and Installation - Intake Manifold

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. 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. Remove the following items:
   1. Remove the air cleaner outlet pipe.
      Refer to: Air Cleaner Outlet Pipe (303-12A Intake Air Distribution and Filtering - 2.0L EcoBoost (177kW/240PS) – MI4, Removal and Installation).
      
   2. Remove the air cleaner.
      Refer to: Air Cleaner (303-12A Intake Air Distribution and Filtering - 2.0L EcoBoost (177kW/240PS) – MI4, Removal and Installation).
      
   3. Remove the EVAP canister purge valve.
      Refer to: Evaporative Emission Canister Purge Valve (303-13B Evaporative Emissions - 2.3L EcoBoost (199kW/270PS), Removal and Installation).
      

1. Detach the coolant tube retainers from the engine lift eye and intake manifold and position aside.
   

1. • Disconnect the MAP sensor wiring harness electrical connector.
     
   • Detach and disconnect the RH KS wiring harness electrical connector.
     
   • Detach the wiring harness retainers.
     

1. • Disconnect the EGR cooler outlet temperature sensor wiring harness electrical connector.
     
   • Detach and disconnect the LH KS wiring harness electrical connector.
     
   • Detach and disconnect the fuel rail wiring harness electrical connector.
     
   • Detach the wiring harness retainers.
     

1. • Disconnect the wiring harness electrical connectors and retainer.
     
   • Loosen the clamps and remove the EGR transducer hoses.
     
   • Remove the bolt and the EGR transducer assembly.
     

1. Remove the stud bolt, nut, bolts and the EGR bracket.
   

1. Remove the bolts and the EGR valve.
   

1. Remove and discard the EGR valve gaskets.
   

1. Remove the bolts and the EGR outlet tube assembly.
   

1. Remove and discard the EGR outlet tube assembly O-ring seal.
   

1. Remove the retainers and the underbody shield.
   

1. • Detach the coolant hose retainer from the CAC outlet pipe.
     
   • Disconnect the turbocharger boost pressure sensor wiring harness electrical connector.
     

1. Loosen the clamp and position the CAC outlet pipe aside.
   

1. Disconnect the throttle body wiring harness electrical connector and retainer.
   

1. Remove the bolts and position the intake manifold forward.
   

1. Disconnect the crankcase vent oil separator tube quick release coupling and remove the intake manifold.
   Refer to: Quick Release Coupling (310-00B Fuel System - General Information - 2.3L EcoBoost (199kW/270PS), General Procedures).
   

1. NOTICE: 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. Failure to follow these instructions can result in engine damage.

   • Visually inspect the intake manifold for metal debris.
     

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

Installation

1. Install the intake manifold and connect the crankcase vent oil separator tube quick release coupling.
   Refer to: Quick Release Coupling (310-00B Fuel System - General Information - 2.3L EcoBoost (199kW/270PS), General Procedures).
   

1. Position the intake manifold and install the bolts.
   Torque: 18 lb.ft (25 Nm)

1. Connect the throttle body electrical connector and retainer.
   

1. Position the CAC outlet pipe and tighten the clamp.
   Torque: 44 lb.in (5 Nm)

1. • Connect the turbocharger boost pressure sensor wiring harness electrical connector.
     
   • Attach the coolant hose retainer to the CAC outlet pipe.
     

1. Install the underbody shield and the retainers.
   Torque: 13 lb.in (1.5 Nm)

1. Install a new EGR outlet tube assembly O-ring seal and lubricate with clean engine oil.
   

1. Install the EGR outlet tube assembly and the bolts finger tight.
   

1. Install new EGR valve gaskets.
   

1. Install the EGR valve and bolts finger tight.
   

1. Install the EGR bracket the stud bolt, nut, bolts finger tight.
   

1. 1. Tighten the stud bolt.
      Torque: 97 lb.in (11 Nm)
   2. Tighten the nut.
      Torque: 97 lb.in (11 Nm)
   3. Tighten the bolt.
      Torque: 97 lb.in (11 Nm)

1. 1. Tighten the EGR inlet tube bolts.
      Torque: 97 lb.in (11 Nm)
   2. Tighten the EGR valve bolts.
      Torque: 97 lb.in (11 Nm)
   3. Tighten the EGR bracket-to- EGR valve bolts.
      Torque: 97 lb.in (11 Nm)
   4. Tighten the EGR outlet tube bolts.
      Torque: 97 lb.in (11 Nm)

1. • Install the EGR transducer assembly and the bolt.
     Torque: 97 lb.in (11 Nm)
   • Install the EGR transducer hoses.
     
   • Connect the wiring harness electrical connectors and retainer.
     

1. • Attach the wiring harness retainers.
     
   • Connect and attach the fuel rail wiring harness electrical connector.
     
   • Connect and attach the LH KS wiring harness electrical connector.
     
   • Connect the EGR cooler outlet temperature sensor wiring harness electrical connector.
     

1. • Attach the wiring harness retainers.
     
   • Connect and attach the RH KS wiring harness electrical connector.
     
   • Connect the MAP sensor wiring harness electrical connector.
     

1. Position and attach the coolant tube retainers to the engine lift eye and intake manifold.
   

1. Install the following items:
   1. Install the EVAP canister purge valve.
      Refer to: Evaporative Emission Canister Purge Valve (303-13B Evaporative Emissions - 2.3L EcoBoost (199kW/270PS), Removal and Installation).
      
   2. Install the air cleaner.
      Refer to: Air Cleaner (303-12A Intake Air Distribution and Filtering - 2.0L EcoBoost (177kW/240PS) – MI4, Removal and Installation).
      
   3. Install the air cleaner outlet pipe.
      Refer to: Air Cleaner Outlet Pipe (303-12A Intake Air Distribution and Filtering - 2.0L EcoBoost (177kW/240PS) – MI4, Removal and Installation).
      

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