Ford Workshop Service and Repair Manuals

NOTE:Make a note of the position of the charge air cooler outlet hose retaining clamp. Remove the charge air cooler outlet pipe. Loosen the retaining clamps. Remove the retaining nuts. Discard the hose retaining clamp.

Disconnect the EGR valve electrical connector.

Disconnect the intake manifold and EGR valve vacuum lines.

Remove the turbocharger. For additional information, refer to: Turbocharger - 75 PS/90 PS, Vehicles With: Fixed Vane Turbocharger (303-04C Fuel Charging and Controls - Turbocharger, Removal and Installation).

5. Remove the components in the order indicated in the following illustration(s) and table(s).

6. To install, reverse the removal procedure.

CAUTION:The intake manifold to charge air cooler intake pipe hose retaining clamp must be installed in the same position as removed. Failure to follow this instruction may cause premature failure of adjacent components. Install a new intake manifold to charge air cooler pipe hose and clamp. Remove and discard the intake manifold to charge air cooler pipe hose and clamp. Install a new intake manifold to charge air cooler pipe hose. Install a new turbocharger to charge air cooler pipe hose clamp in the same position as when removed.

CAUTION:The charge air cooler outlet hose retaining clamp must be installed in the same position as removed. Failure to follow this instruction may cause premature failure of adjacent components. NOTE:Make sure that the inside of the charge air cooler outlet hose is clean and free from any oil residue, as this will reduce the installation grip of the hose to the charge air cooler. Install the charge air cooler outlet pipe. Clean the inside of the charge air cooler outlet hose. Install a new charge air cooler outlet hose retaining clamp in the same position as when removed.

Removal Details

Item 1 : Intake manifold retaining nuts

NOTE:Discard the intake manifold retaining nuts.

Item 4 : Intake manifold gasket

NOTE:Discard the intake manifold gasket.

Installation Details

Item 4 : Intake manifold gasket

NOTE:Install a new intake manifold gasket.

Item 1 : Intake manifold retaining nuts

NOTE:Install new intake manifold retaining nuts.