Ford Fusion Manuals

Ford Fusion: Intake Air Distribution and Filtering - 1.5L EcoBoost (118kW/160PS) – I4 / Charge Air Cooler (CAC) Intake Pipe. Removal and Installation

Special Tool(s) / General Equipment

Hose Clamp Remover/Installer

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.

NOTE: Removal steps in this procedure may contain installation details.

  1. With the vehicle in N, position it on a hoist.
    Refer to: Jacking and Lifting - Overview (100-02 Jacking and Lifting, Description and Operation).
  1. Remove the engine appearance cover.
Ford Fusion. Charge Air Cooler (CAC) Intake Pipe. Removal and Installation
    1. Disconnect the crankcase pressure sensor electrical connector.
    1. Unclip the retainer and position the wire harness aside.
Ford Fusion. Charge Air Cooler (CAC) Intake Pipe. Removal and Installation
    1. Disconnect the turbocharger boost pressure sensor electrical connector.
    1. Detach the retainers.
    1. Detach the retainer and position the wire harness aside.
Ford Fusion. Charge Air Cooler (CAC) Intake Pipe. Removal and Installation
    1. Disconnect the coupling.
    1. Detach and remove the crankcase pressure sensor tube.
Ford Fusion. Charge Air Cooler (CAC) Intake Pipe. Removal and Installation
  1. Disconnect the coupling and position the tube aside.
Ford Fusion. Charge Air Cooler (CAC) Intake Pipe. Removal and Installation
  1. Disconnect the IAT2 sensor electrical connector.
Ford Fusion. Charge Air Cooler (CAC) Intake Pipe. Removal and Installation
    1. Disconnect the bypass valve electrical connector.
    1. Release the clamp and disconnect the bypass valve tube.
      Use the General Equipment: Hose Clamp Remover/Installer
Ford Fusion. Charge Air Cooler (CAC) Intake Pipe. Removal and Installation
  1. Remove the bolt.
    Torque: 71 lb.in (8 Nm)
Ford Fusion. Charge Air Cooler (CAC) Intake Pipe. Removal and Installation
  1. Disconnect the quick release couplings.
    Refer to: Quick Release Coupling (310-00A Fuel System - General Information - 1.5L EcoBoost (118kW/160PS) – I4, General Procedures).
Ford Fusion. Charge Air Cooler (CAC) Intake Pipe. Removal and Installation
  1. If equipped.
    Remove the retainers and the underbody shield.
Ford Fusion. Charge Air Cooler (CAC) Intake Pipe. Removal and Installation
  1. Loosen the clamp and disconnect the CAC intake tube.
    Torque: 44 lb.in (5 Nm)
Ford Fusion. Charge Air Cooler (CAC) Intake Pipe. Removal and Installation
  1. Loosen the clamp and remove the CAC intake pipe.
    Torque: 44 lb.in (5 Nm)
Ford Fusion. Charge Air Cooler (CAC) Intake Pipe. Removal and Installation

Installation

  1. Inspect the turbocharger or engine air intake system components and clean, if necessary.
  1. To install, reverse the removal procedure.

    Charge Air Cooler (CAC) Coolant Pump. Removal and Installation

    Special Tool(s) / General Equipment Hose Clamp(s) Hose Clamp Remover/Installer Materials Name Specification Motorcraft® Orange Prediluted Antifreeze/CoolantVC-3DIL-B WSS-M97B44-D2  Removal NOTE: Removal steps in this procedure may contain installation details...

    Charge Air Cooler (CAC) Radiator. Removal and Installation

    Special Tool(s) / General Equipment Cable Ties Hose Clamp Remover/Installer Removal NOTE: Removal steps in this procedure may contain installation details...

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    The tire pressure monitoring system measures pressure in your road tires and sends the tire pressure readings to your vehicle. You can view the tire pressure readings through the information display. The low tire pressure warning light will turn on if the tire pressure is significantly low. Once the light is illuminated, your tires are under-inflated and need to be inflated to the manufacturer’s recommended tire pressure. Even if the light turns on and a short time later turns off, your tire pressure still needs to be checked.

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