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

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.
   

1. 1. Disconnect the crankcase pressure sensor electrical connector.
      
   2. Unclip the retainer and position the wire harness aside.
      

1. 1. Disconnect the turbocharger boost pressure sensor electrical connector.
      
   2. Detach the retainers.
      
   3. Detach the retainer and position the wire harness aside.
      

1. 1. Disconnect the coupling.
      
   2. Detach and remove the crankcase pressure sensor tube.
      

1. Disconnect the coupling and position the tube aside.
   

1. Disconnect the IAT2 sensor electrical connector.
   

1. 1. Disconnect the bypass valve electrical connector.
      
   2. Release the clamp and disconnect the bypass valve tube.
      Use the General Equipment: Hose Clamp Remover/Installer

1. Remove the bolt.
   Torque: 71 lb.in (8 Nm)

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).
   

1. If equipped.
   Remove the retainers and the underbody shield.
   

1. Loosen the clamp and disconnect the CAC intake tube.
   Torque: 44 lb.in (5 Nm)

1. Loosen the clamp and remove the CAC intake pipe.
   Torque: 44 lb.in (5 Nm)

Installation

1. Inspect the turbocharger or engine air intake system components and clean, if necessary.
   

1. To install, reverse the removal procedure.