Ford Fusion: Engine Emission Control - 1.5L EcoBoost (118kW/160PS) – I4 / Crankcase Vent Oil Separator. Removal and Installation

Special Tool(s) / General Equipment

Removal

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

1. Remove the intake manifold.
   Refer to: Intake Manifold (303-01A Engine - 1.5L EcoBoost (118kW/160PS) – I4, Removal and Installation).
   

1. Remove the starter motor.
   Refer to: Starter Motor (303-06A Starting System - 1.5L EcoBoost (118kW/160PS) – I4, Removal and Installation).
   

1. 1. Disconnect the upper crankcase ventilation tube and clamp from the lower crankcase ventilation tube and then position the upper crankcase ventilation tube out of the way.
      Use the General Equipment: Hose Clamp Remover/Installer
   2. Remove the lower crankcase ventilation tube retaining bolt.
      
   3. Disconnect the lower crankcase ventilation tube quick release coupling from the crankcase oil separator and then remove the lower crankcase ventilation tube.
      Refer to: Quick Release Coupling (310-00A Fuel System - General Information - 1.5L EcoBoost (118kW/160PS) – I4, General Procedures).
      

1. Detach the knock sensor wiring harness from the harness retainers. Remove the crankcase vent oil separator bolts and then remove the crankcase vent oil separator.
   

Installation

NOTICE: Make sure that the mating faces are clean and free of foreign material.

1. Inspect the crankcase vent oil separator gasket and the O-ring seal. Replace as needed. Lubricate the crankcase oil separator O-ring seal with clean engine oil.
   

1. Push the spigot into the engine block while installing the crankcase oil separator, then install and tighten the crankcase oil separator bolts in the stages and in the sequence shown.
   Torque:
     Stage 1:  Tighten bolts 1, 2 and 3 to: :   53 lb.in (6.0 Nm)
     Stage 2:  Tighten bolts 4, 5, 6, 7 and 8 to: :   53 lb.in (6.0 Nm)
     Stage 3:  Tighten all bolts in sequence to: :   89 lb.in (10.0 Nm)

1. Attach the knock sensor wiring harness to the harness retainers.
   

1. 1. Install the lower crankcase ventilation tube and connect the lower crankcase ventilation tube quick release coupling to the crankcase oil separator.
      Refer to: Quick Release Coupling (310-00A Fuel System - General Information - 1.5L EcoBoost (118kW/160PS) – I4, General Procedures).
      
   2. Install and tighten the lower crankcase ventilation tube retaining bolt.
      Torque: 89 lb.in (10 Nm)
   3. Connect the upper crankcase ventilation tube and clamp to the lower crankcase ventilation tube.
      Use the General Equipment: Hose Clamp Remover/Installer

1. Install the starter motor.
   Refer to: Starter Motor (303-06A Starting System - 1.5L EcoBoost (118kW/160PS) – I4, Removal and Installation).
   

1. Install the intake manifold.
   Refer to: Intake Manifold (303-01A Engine - 1.5L EcoBoost (118kW/160PS) – I4, Removal and Installation).