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    Fusion 2.0 - Stock Intake Removal


    AnotherGreenFusion
    Pictures and instructions developed with 2015 2.0T AWD, some variance may apply between model years.
     
    Before starting remove the engine cover and disconnect the positive (red +) terminal on the battery.
    01 - Removing Stock Intake 2013-2016 Ford Fusion.jpg
     
    Step 1. Loosen intake pipe clamps and remove sensors

    02 - Step 1 Loosen intake pipe clamps and remove sensors.jpg

    7mm socket for clamps

     

    Step 2. Remove pipe retention bolt and remove intake pipe

    03 - Step 2 Remove pipe retention bolt and remove intake pipe.jpg

    13mm deep socket for bolt
     
    Bolt is not on all models
     
     

    Intake pipe removed with retention bolt

    04 - Intake pipe removed with retention bolt.jpg

     

    Step 3. Unclip top of box and remove air filter

    05 - Step 3 Unclip top of box and remove air filter.jpg

    Remove sensor clips with flat head screwdriver, I removed the clip from the box rather than remove the harness  from the clip.

     

    Airbox top and filter removed

    06 - Airbox top and filter removed.jpg

     

    Step 4. Unbolt intake snorkel

    07 - Step 4 Unbolt intake snorkel.jpg

    7mm scoket

    Step 5. Pull up on the air box until it pops out of its rubber grommets

    08 - Step 5 Pull up on the air box until it pops out of its rubber grommets.jpg

    A bit of gentle upward force will be required, be careful not to pull to quickly.

     

    Step 6. Remove TIP (If needed)

    09 - Step 6 Remove TIP If needed.jpg

    Unbolt tip and disconnect the vac and pcv lines. Losen the clamp where the TIP meets the turbo inlet behind the engine. Once loose, wiggle the TIP out, pulling up and pushing toward the firewall worked best for me.

     

    Step 7. Unbolt snorkel from airbox

    10 - Step 7 Unbolt snorkel from airbox.jpg

    (Do this only if needed)
     
    8mm socket

    Step 8. CAREFULLY remove the snorkel from the airbox

    11 - Step 8 CAREFULLY remove the snorkel from the airbox.jpg

    (Do this only if needed)
     
    The snorkel is held into the airbox by 3 plastic tabs at the end of the snorkel. The 2 tabs on the top of the snorkel are stationary and attached to the main body. The one tab on the bottom (and to the side) of the snorkel is actually on a flexible (and easy to crack) strip of plastic. Feel along this rim until you find the 3rd tab near the drivers side (right side from when in front of car) of the snorkel, gently press the tab up and out of the way of the edge of the box while tilting the bottom of the snorkel out of the box. Once clear of the edge you can gently let go of the plastic tab and tilt the snorkel the rest of the way out.

    Fixing the Snorkel Step 1. Find Crack

    12 - Fixing the Snorkel Step 1 Find Crack.jpg

    The plastic on the snorkel is brittle and even if you follow above you might still crack it. This should be repaired before re-install as the break may cause undesirable noise, or it may just bother you that it is broken.

    Fixing the Snorkel Step 2. Use a qucik drying/curing super glue

    13 - Fixing the Snorkel Step 2  Use a qucik dryingcuring super glue.jpg

    Clamping this part for a good flexible RTV seal is tough so we want to hold it with some basic superglue first. I had some Gorilla glue around, it has a 24 hour cure time but dries solid enough to hold that part together after 30-60 seconds.

     

    After Glue application

    14 - After Glue application.jpg

     

    Fixing the Snorkel Step 3. Apply RTV

    15 - Fixing the Snorkel Step 3 Apply RTV.jpg

    RTV or liquid gasket is tough and flexible, a coat of this over the crack should allow the part to behave as before and perhaps even be a bit less brittle. RTV will also give you a chance to smooth things out a bit to prevent any unwanted noises from the distorted snorkel mouth.

     

    RTV applied after 18 hours glue cure time

    16 - RTV applied after 18 hours glue cure time .jpg

    17 - RTV applied after 18 hours glue cure time .jpg

    RTV was allowed to cure for 6 hours before installation

     

    Edited by AnotherGreenFusion

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