How to Remove and Replace 2.3 Mustang EcoBoost Intake Manifold

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. Remove the nuts and the engine appearance cover.

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1. • Disconnect the EVAP canister purge valve quick release coupling at the front of the intake manifold.
     Refer to: Quick Release Coupling (310-00A Fuel System - General Information - 2.3L EcoBoost (231kW/314PS), General Procedures) .
   • Detach the fuel tube and EVAP tube from the retainer on the intake manifold.
   • Disconnect the EVAP canister purge valve electrical connector.
   • Remove the bolt and position the EVAP canister purge valve aside.

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1. Disconnect the MAPT sensor electrical connector and the wire harness retainers.

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

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

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1. Disconnect the vacuum tube quick release coupling at the rear of the intake manifold.

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1. Remove the nut from the coolant tube on the intake manifold.

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1. Remove the bolts and position intake manifold back.

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1. • Disconnect the PCV tube quick release coupling.
   • Detach the KS electrical connector retainers from the intake manifold.
   • Remove the intake manifold.

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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 gaskets for nicks, cuts and abrasions. If these conditions are not present, the gaskets may be reused.

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Installation

1. • Position the intake manifold for installation.
   • Attach the KS electrical connector retainers to the intake manifold.
   • Connect the PCV tube quick release coupling.

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1. NOTE: Make sure the coolant tube is in position when intake is installed.

   Position the intake manifold on the coolant tube stud.

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1. Install the bolts.
   Torque : 177 lb.in (20 Nm)

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1. Install the nut on the coolant tube.
   Torque : 106 lb.in (12 Nm)

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1. Connect the vacuum tube quick release coupling at the rear of the intake manifold.

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

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1. Connect the throttle body electrical connector and the wire harness retainer.

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1. Connect the MAPT sensor electrical connector and the wire harness retainers.

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1. • Install the EVAP canister purge valve and the bolt.
     Torque : 71 lb.in (8 Nm)
   • Connect the EVAP canister purge valve electrical connector.
   • Attach the fuel tube and EVAP tube to the retainer on the intake manifold.
   • Connect the EVAP canister purge valve quick release coupling at the front of the intake manifold.

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1. Install the engine appearance cover and the nuts.
   Torque : 80 lb.in (9 Nm)

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