Ford Fiesta: Engine - 1.6L EcoBoost (132kW/180PS) – Sigma / Intake Manifold. Removal and Installation

Special Tool(s) / General Equipment

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. Remove the generator.
   Refer to: Generator - 1.6L EcoBoost (132kW/180PS) – Sigma (414-02 Generator and Regulator, Removal and Installation).
   

1. • Disconnect the PCV hose from the valve cover.
     Use the General Equipment: Hose Clamp Remover/Installer
   • Disconnect the EVAP canister purge valve quick release connector.
     
   • Detach the wiring harness retainers and disconnect the electrical connectors.
     

1. • Disconnect the resonator assembly hose. Loosen the clamps and remove the resonator assembly.
     Use the General Equipment: Hose Clamp Remover/Installer
   • Loosen the clamps and position aside the CAC hose.
     

1. Disconnect the EVAP tube from the CAC outlet tube.
   

1. • Disconnect the electrical connector.
     
   • Loosen the clamp, remove the nut and the CAC outlet tube.
     

1. NOTE: Note the different lengths of the bolts for installation.

   Remove the intake manifold bolts.
   

1. Disconnect the throttle body electrical connector.
   

1. Remove the intake manifold.
   

Installation

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.

1. NOTE: Visually inspect the intake manifold gaskets for nicks, cuts and abrasions. If these conditions are not present, the gaskets may be re-used.

   Inspect the intake manifold gaskets for nicks.
   

1. Connect the throttle body electrical connector.
   

1. NOTE: There are different length of bolts noted in removal.

   1. Install the intake manifold and the bolts.
      Torque: 150 lb.in (17 Nm)
   2. Install the intake manifold bolts.
      Torque: 89 lb.in (10 Nm)

1. 1. Install the CAC outlet tube and the nut.
      Torque: 133 lb.in (15 Nm)
   2. Tighten the hose clamp and connect the electrical connector.
      Torque: 44 lb.in (5 Nm)

1. Connect the EVAP tube to the CAC outlet tube.
   

1. • Position the CAC hose and tighten the clamp.
     Torque: 44 lb.in (5 Nm)
   • Install the resonator assembly and connect the resonator assembly hoses.
     Use the General Equipment: Hose Clamp Remover/Installer

1. • Connect the PCV hose to the valve cover.
     Use the General Equipment: Hose Clamp Remover/Installer
   • Connect the EVAP canister purge valve quick release connector.
     
   • Attach the wiring harness retainers. Connect the electrical connectors.
     

1. Install the generator.
   Refer to: Generator - 1.6L EcoBoost (132kW/180PS) – Sigma (414-02 Generator and Regulator, Removal and Installation).
   

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