Ford Sable, Taurus 2000-05

Intake Manifold

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Removal & Installation



3.0L Engine
VIN S Engine
  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Disconnect or remove:

    Negative battery cable
     
    Windshield wipers and cowl top inner panels
     
    Cruise control cable
     
    Accelerator cable and bracket
     
    Vacuum hoses
     
    Intake Air Control (IAC) valve supply hose
     
    IAC connector
     
    Throttle Position (TP) sensor connector
     
    Exhaust Gas Recirculation (EGR) valve
     
    Secondary air injection valve bracket
     
    Upper intake manifold
     
    Fuel lines
     
    Fuel injector wiring harness
     
    Intake Manifold Runner Control (IMRC) cable
     
    Spark plug wires
     
    Lower intake manifold

    Click image to see an enlarged view

    Fig. Lower intake manifold bolt removal sequence-2001-04 3.0L (VIN S) engine

     

  4.  

To install:

Click image to see an enlarged view

Fig. Lower intake manifold torque sequence-2001-04 3.0L (VIN S) engine



Click image to see an enlarged view

Fig. Upper intake manifold torque sequence-2001-04 3.0L (VIN S) engine

  1. Install the lower intake manifold. Use new gaskets and tighten the bolts in sequence to 71-106 inch lbs. (8-12 Nm).
  2.  
  3. Install or connect the following:

    Spark plug wires
     
    IMRC cable
     
    Fuel injector wiring harness
     
    Fuel lines
     

  4.  
  5. Install the upper intake manifold. Use new gaskets and tighten the bolts in sequence to 71-106 inch lbs. (8-12 Nm).
  6.  
  7. Install or connect the following:

    Secondary air injection valve bracket
     
    EGR valve
     
    TP sensor connector
     
    IAC connector
     
    IAC valve supply hose
     
    Vacuum hoses
     
    Accelerator cable and bracket
     
    Cruise control cable
     
    Windshield wipers and cowl top inner panels
     
    Negative battery cable
     

  8.  
  9. Run the engine and check for leaks and proper engine operation.
  10.  

  1. Before servicing the vehicle, refer to the precautions at the beginning of this section.
  2.  
  3. Disconnect or remove:

    Negative battery cable
     
    Windshield wipers and cowl top inner panels
     
    Cruise control cable
     
    Accelerator cable and bracket
     
    Vacuum hoses
     
    Intake Air Control (IAC) valve supply hose
     
    IAC connector
     
    Throttle Position (TP) sensor connector
     
    Exhaust Gas Recirculation (EGR) valve
     
    Secondary air injection valve bracket
     
    Upper intake manifold
     
    Fuel lines
     
    Fuel injector wiring harness
     
    Intake Manifold Runner Control (IMRC) cable
     
    Spark plug wires
     
    Lower intake manifold

    Click image to see an enlarged view

    Fig. Lower intake manifold bolt removal sequence-3.0L (VIN S) engine

     

  4.  

To install:

Click image to see an enlarged view

Fig. Lower intake manifold torque sequence-3.0L (VIN S) engine



Click image to see an enlarged view

Fig. Upper intake manifold torque sequence-3.0L (VIN S) engine

  1. Install the lower intake manifold. Use new gaskets and tighten the bolts in sequence to 71-106 inch lbs. (8-12 Nm).
  2.  
  3. Install or connect the following:

    Spark plug wires
     
    IMRC cable
     
    Fuel injector wiring harness
     
    Fuel lines
     

  4.  
  5. Install the upper intake manifold. Use new gaskets and tighten the bolts in sequence to 71-106 inch lbs. (8-12 Nm).
  6.  
  7. Install or connect the following:

    Secondary air injection valve bracket
     
    EGR valve
     
    TP sensor connector
     
    IAC connector
     
    IAC valve supply hose
     
    Vacuum hoses
     
    Accelerator cable and bracket
     
    Cruise control cable
     
    Windshield wipers and cowl top inner panels
     
    Negative battery cable
     

  8.  
  9. Run the engine and check for leaks and proper engine operation.
  10.  

Lower Manifold
  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Release the fuel system pressure.
  4.  
  5. Disconnect the fuel hose quick release coupling from the fuel supply manifold.
  6.  
  7. Remove the upper intake manifold.
  8.  
  9. Disconnect the fuel injection pressure and temperature sensor vacuum tube and the electrical connector.
  10.  
  11. Disconnect the fuel injector electrical connectors.
  12.  
  13. Remove the intake manifold bolts in the sequence shown, and remove the lower intake manifold.

    Click image to see an enlarged view

    Fig. Lower intake manifold loosening sequence-2005 3.0L (VIN S) engine

  14.  
  15. Remove and discard the gaskets from the lower intake manifold.
  16.  

To install:


NOTE
Clean and inspect all mating surfaces and install new gaskets in the lower intake manifold.

  1. Install the lower intake manifold and tighten the bolts in the sequence shown to 89 inch lbs. (10 Nm).

    Click image to see an enlarged view

    Fig. Lower intake manifold tightening sequence-2005 3.0L (VIN S) engine

  2.  
  3. Connect the fuel injector electrical connectors.
  4.  
  5. Connect the fuel injection pressure and temperature sensor vacuum tube and the electrical connector.
  6.  
  7. Connect the fuel hose quick release coupling to the fuel supply manifold.
  8.  
  9. Install the upper intake manifold.
  10.  

Upper Manifold
  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the air cleaner outlet pipe.
  6.  
  7. Remove the accelerator cable splash shield.
  8.  
  9. Disconnect the accelerator cable, the cruise control cable and the throttle return spring.
  10.  
  11. Remove the bolts and position the bracket and cables aside.
  12.  
  13. Disconnect the Throttle Position (TP) sensor and the Idle Air Control (IAC) valve electrical connectors.
  14.  
  15. Detach the harness retainer from the throttle body stud bolt.
  16.  
  17. Disconnect the heated throttle body coolant tubes.
  18.  
  19. Disconnect the Positive Crankcase Ventilation (PCV) hose.
  20.  
  21. Disconnect the vacuum supply hose.
  22.  
  23. Disconnect the brake booster and Evaporative Emissions (EVAP) vacuum hoses.
  24.  
  25. Remove the Exhaust Gas Recirculation (EGR) valve as follows:
    1. Disconnect the vacuum hose.
    2.  
    3. Remove the nuts and bolts.
    4.  
    5. Remove the EGR valve.
    6.  

  26.  
  27. Remove the EGR Vacuum Regulator (EVR) valve as follows:
    1. Disconnect the vacuum hose.
    2.  
    3. Disconnect the electrical connector.
    4.  
    5. Remove the bolts.
    6.  
    7. Remove the valve.
    8.  

  28.  
  29. Remove the eight bolts and the upper intake manifold.
  30.  
  31. Remove and discard the gaskets.
  32.  
  33. Clean all mating surfaces.
  34.  

To install:

  1. Position new gaskets in the upper intake manifold.
  2.  
  3. Position the upper intake manifold and install the bolts in the sequence shown. Tighten to 89 inch lbs. (10 Nm).

    Click image to see an enlarged view

    Fig. Upper intake manifold torque sequence-2005 3.0L (VIN S) engine

  4.  
  5. Install the EGR vacuum regulator valve and tighten the retainers to 53 inch lbs. (6 Nm).
  6.  
  7. Install the EGR valve. Tighten the bolts to 18 ft. lbs. (25 Nm) and the nuts to 89 inch lbs. (10 Nm).
  8.  
  9. Connect the brake booster and PCV vacuum hoses.
  10.  
  11. Connect the vacuum supply hose.
  12.  
  13. Connect the PCV valve hose.
  14.  
  15. Connect the TP and IAC valve electrical connectors.
  16.  
  17. Attach the harness retainer to the throttle body stud bolt.
  18.  
  19. Connect the heated throttle body coolant tubes.
  20.  
  21. Position the bracket and cables and install the bolts.
  22.  
  23. Connect the throttle return spring, accelerator cable and the cruise control cable.
  24.  
  25. Install the accelerator cable splash shield.
  26.  
  27. Install the air cleaner outlet pipe.
  28.  
  29. Connect the negative battery cable.
  30.  

VIN U Engine
  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:
    NOTE
    Note the position of the CMP sensor electrical connector. Installation requires that the connector be located in the same position.


    NOTE
    Before removing the CMP sensor, position the engine at Top Dead Center (TDC) of the No. 1 cylinder compression stroke.



    Negative battery cable
     
    Air cleaner and outlet tube
     
    Cruise control cable
     
    Accelerator cable and bracket
     
    Fuel lines
     
    Vacuum lines
     
    Exhaust Gas Recirculation (EGR) valve
     
    EGR transducer
     
    EGR vacuum solenoid
     
    Throttle Position (TP) sensor connector
     
    Intake Air Control (IAC) valve connector
     
    Camshaft Position (CMP) sensor connector
     
    Engine Coolant Temperature (ECT) sensor connector
     
    Coolant temperature indicator sender connector
     
    Coolant hoses
     
    Upper alternator bracket
     
    Engine control sensor wiring harness and bracket
     
    Upper intake manifold
     

  6.  
  7. Remove or disconnect the following:

    CMP sensor and housing
     
    Spark plug wires
     
    Ignition coil
     
    Valve covers
     
    No. 3 cylinder intake valve rocker arm and pushrod
     
    Lower intake manifold

    Click image to see an enlarged view

    Fig. Exploded view of the upper intake manifold mounting-2001-04 3.0L (VIN U) engine

     

  8.  

To install:

Click image to see an enlarged view

Fig. Lower intake manifold torque sequence-2001-04 3.0L (VIN U) engine

  1. Install the lower intake manifold. Use new gaskets and tighten the bolts in sequence as follows:
    1. Step 1: 15-22 ft. lbs. (20-30 Nm).
    2.  
    3. Step 2: 19-24 ft. lbs. (26-32 Nm).
      NOTE
      A special Synchro Positioning tool T95T-12200-A must be used when installing the CMP sensor housing.

    4.  

  2.  
  3. Attach the Synchro Position tool T95T-12200-A as follows:
    1. Engage the CMP sensor housing vane into the radial slot of the tool.
    2.  
    3. Rotate the tool on the CMP sensor housing until the tool boss engages the notch in the CMP sensor housing.
    4.  
    5. Install the CMP sensor housing so the drive gear engagement occurs when the arrow on the locator tool is pointed about 75 degrees counterclockwise from the rear face of the cylinder block. This step will locate the CMP sensor electrical connector in the same position as was noted on removal.
    6.  
    7. Install the hold-down clamp and tighten the bolt to 14-22 ft. lbs. (19-30 Nm).
    8.  

  4.  
  5. Remove the Synchro Position tool.
  6.  
  7. Install or connect the following:

    CMP sensor
     
    No. 3 cylinder intake valve rocker arm and pushrod
     
    Valve covers
     
    Ignition coil and tighten the bolts to 30-40 ft. lbs. (40-55 Nm)
     
    Spark plug wires
     
    Upper intake manifold and tighten the bolts to 15-22 ft. lbs. (20-30 Nm)
     
    Engine control sensor wiring harness and bracket
     
    Upper alternator bracket
     
    Coolant hoses
     
    Coolant temperature indicator sender connector
     
    ECT sensor connector
     
    CMP sensor connector
     
    IAC valve connector
     
    TP sensor connector
     
    EGR vacuum solenoid
     
    EGR transducer
     
    EGR valve
     
    Vacuum lines
     
    Fuel lines
     
    Accelerator cable and bracket
     
    Cruise control cable
     
    Air cleaner and outlet tube
     
    Negative battery cable
     

  8.  
  9. Fill the cooling system.
  10.  
  11. Start the engine and check for leaks and proper operation.
  12.  



Click image to see an enlarged view

Fig. Exploded view of the upper intake manifold mounting-3.0L (VIN U) engine

  1. Before servicing the vehicle, refer to the precautions at the beginning of this section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:
    NOTE
    Note the position of the CMP sensor electrical connector. Installation requires that the connector be located in the same position.


    NOTE
    Before removing the CMP sensor, position the engine at Top Dead Center (TDC) of the No. 1 cylinder compression stroke.



    Negative battery cable
     
    Air cleaner and outlet tube
     
    Cruise control cable
     
    Accelerator cable and bracket
     
    Fuel lines
     
    Vacuum lines
     
    Exhaust Gas Recirculation (EGR) valve
     
    EGR transducer
     
    EGR vacuum solenoid
     
    Throttle Position (TP) sensor connector
     
    Intake Air Control (IAC) valve connector
     
    Camshaft Position (CMP) sensor connector
     
    Engine Coolant Temperature (ECT) sensor connector
     
    Coolant temperature indicator sender connector
     
    Coolant hoses
     
    Upper alternator bracket
     
    Engine control sensor wiring harness and bracket
     
    Upper intake manifold
     

  6.  
  7. Remove or disconnect the following:

    CMP sensor and housing
     
    Spark plug wires
     
    Ignition coil
     
    Valve covers
     
    No. 3 cylinder intake valve rocker arm and pushrod
     
    Lower intake manifold
     

  8.  

To install:

Click image to see an enlarged view

Fig. Intake manifold torque sequence-3.0L (VIN U) engine

  1. Install the lower intake manifold. Use new gaskets and tighten the bolts in sequence as follows:
    1. Step 1: 15-22 ft. lbs. (20-30 Nm).
    2.  
    3. Step 2: 19-24 ft. lbs. (26-32 Nm).
      NOTE
      A special Synchro Positioning tool T95T-12200-A must be used when installing the CMP sensor housing.

    4.  

  2.  
  3. Attach the Synchro Position tool T95T-12200-A as follows:
    1. Engage the CMP sensor housing vane into the radial slot of the tool.
    2.  
    3. Rotate the tool on the CMP sensor housing until the tool boss engages the notch in the CMP sensor housing.
    4.  
    5. Install the CMP sensor housing so the drive gear engagement occurs when the arrow on the locator tool is pointed about 75 degrees counterclockwise from the rear face of the cylinder block. This step will locate the CMP sensor electrical connector in the same position as was noted on removal.
    6.  
    7. Install the hold-down clamp and tighten the bolt to 14-22 ft. lbs. (19-30 Nm).
    8.  

  4.  
  5. Remove the Synchro Position tool.
  6.  
  7. Install or connect the following:

    CMP sensor
     
    No. 3 cylinder intake valve rocker arm and pushrod
     
    Valve covers
     
    Ignition coil and tighten the bolts to 30-40 ft. lbs. (40-55 Nm)
     
    Spark plug wires
     
    Upper intake manifold and tighten the bolts to 15-22 ft. lbs. (20-30 Nm)
     
    Engine control sensor wiring harness and bracket
     
    Upper alternator bracket
     
    Coolant hoses
     
    Coolant temperature indicator sender connector
     
    ECT sensor connector
     
    CMP sensor connector
     
    IAC valve connector
     
    TP sensor connector
     
    EGR vacuum solenoid
     
    EGR transducer
     
    EGR valve
     
    Vacuum lines
     
    Fuel lines
     
    Accelerator cable and bracket
     
    Cruise control cable
     
    Air cleaner and outlet tube
     
    Negative battery cable
     

  8.  
  9. Fill the cooling system.
  10.  
  11. Start the engine and check for leaks and proper operation.
  12.  

Lower Manifold
  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Remove the upper intake manifold.
  4.  
  5. Disconnect the fuel tube spring lock coupling.
  6.  
  7. Drain and recycle the engine coolant.
  8.  
  9. Remove the push rods.
  10.  
  11. Disconnect the Fuel Rail Pressure (FRP) sensor electrical and vacuum connections.
  12.  
  13. Disconnect the fuel injector electrical connectors.
  14.  
  15. Disconnect the heater hose and Engine Coolant Temperature (ECT) sender electrical connector.
  16.  
  17. Disconnect the ECT sensor electrical connector and the degas bottle hose.
  18.  
  19. Disconnect the upper radiator hose from the thermostat housing.
  20.  
  21. Remove the bolts and the lower intake manifold.
  22.  
  23. Remove the intake manifold gaskets and the end seals.
  24.  

To install:

Click image to see an enlarged view

Fig. Lower intake manifold torque sequence-2005 3.0L (VIN U) engine

  1. Using metal surface cleaner, clean all the sealing surfaces.
    NOTE
    If the lower intake manifold is not secured within four minutes, the sealant must be removed and the sealing area cleaned with metal surface cleaner. Allow to dry until there is no sign of wetness or four minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.

  2.  
  3. Apply a 0.20-0.23 inch (5-6 mm) bead of silicone gasket and sealant at the four cylinder block-to-cylinder head seams.
  4.  
  5. Install the lower intake manifold gaskets and end seals.
  6.  
  7. Install the intake manifold. Tighten the bolts in two steps in the sequence shown:
    1. Step 1: Tighten to 15 Nm (11 lb-ft).
    2.  
    3. Step 2: Tighten to 24 ft. lbs. (32 Nm.
    4.  

  8.  
  9. Connect the upper radiator hose to the thermostat housing.
  10.  
  11. Connect the ECT sensor electrical connector and the degas bottle hose.
  12.  
  13. Connect the heater hose and the ECT sender electrical connector.
  14.  
  15. Connect the fuel injector electrical connectors.
  16.  
  17. Connect the FRP sensor electrical and vacuum connections.
  18.  
  19. Install the push rods.
  20.  
  21. Connect the fuel tube spring lock coupling.
  22.  
  23. Install the upper intake manifold.
  24.  
  25. Fill and bleed the engine cooling system
  26.  

Upper Manifold
  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Disconnect the tubes, loosen the clamps and remove the air cleaner outlet pipe.
  6.  
  7. Remove the snow shield.
  8.  
  9. Disconnect the accelerator cable, cruise control cable and throttle return spring from the throttle body.
  10.  
  11. Remove the bolts and position the accelerator cables and bracket aside.
  12.  
  13. Disconnect the Throttle Position (TP) sensor and the Intake Air Control (IAC) electrical connectors.
  14.  
  15. Detach the harness retainer from the throttle body stud bolt.
  16.  
  17. Disconnect the vacuum hose and the Evaporative Emissions (EVAP) return tube.
  18.  
  19. Remove the upper intake manifold support bracket bolt and nut.
  20.  
  21. Position the bracket and harness aside.
  22.  
  23. Loosen the nut and disconnect the Exhaust Gas Recirculation (EGR) tube from the EGR valve.
  24.  
  25. Disconnect the Positive Crankcase Ventilation (PCV) tube from the upper intake manifold.
  26.  
  27. Disconnect the fuel supply manifold pressure sensor vacuum tube.
  28.  
  29. Disconnect the PCV tube from the PCV valve and remove the tube.
  30.  
  31. Disconnect the EGR vacuum regulator solenoid and Intake Manifold Tuning valve (IMTV) electrical connectors.
  32.  
  33. Detach the pin-type harness retainer from the upper intake manifold.
  34.  
  35. Detach the spark plug wire holder from the valve cover stud and disconnect the radio interference capacitor electrical connector.
  36.  
  37. Remove the two nuts and position the EGR vacuum regulator solenoid and bracket aside.
  38.  
  39. Remove the bolts and the upper intake manifold.
  40.  

To install:


NOTE
Clean all of the sealing surfaces. Inspect the upper intake manifold gaskets and install new gaskets as necessary.

  1. Install the upper intake manifold. Tighten bolts in 2 steps in the sequence shown:
    1. Step 1: hand-tighten the bolts.
    2.  
    3. Step 2: Tighten the bolts to 89 inch lbs. (10 Nm).

      Click image to see an enlarged view

      Fig. Upper intake manifold torque sequence-2005 3.0L (VIN U) engine

    4.  

  2.  
  3. Position the EGR vacuum regulator solenoid and bracket and install the nuts.
  4.  
  5. Attach the spark plug wire holder to the valve cover stud and connect the radio interference capacitor electrical connector.
  6.  
  7. Connect the EGR vacuum regulator solenoid and IMRC electrical connectors.
  8.  
  9. Attach the pin-type harness retainer to the upper intake manifold.
  10.  
  11. Connect the PCV tube to the PCV valve.
  12.  
  13. Connect the fuel supply manifold pressure sensor vacuum tube.
  14.  
  15. Connect the PCV tube to the upper intake manifold.
  16.  
  17. Connect the EGR tube to the EGR valve and tighten the fitting to 41 ft. lbs. (55 Nm).
  18.  
  19. Position the upper intake manifold support bracket and install bolt and nut.
  20.  
  21. Connect the vacuum hose and the EVAP return tube.
  22.  
  23. Connect the TP sensor and the IAC electrical connectors.
  24.  
  25. Attach the harness retainer from the throttle body stud bolt.
  26.  
  27. Position the accelerator cable bracket and install the bolts.
  28.  
  29. Connect the accelerator cable, cruise control cable and throttle return spring to the throttle body.
  30.  
  31. Install the snow shield.
  32.  
  33. Install the air cleaner outlet pipe, connect the tubes and tighten the clamps.
  34.  
  35. Connect the negative battery cable.
  36.  

3.4L (VIN N) Engine
  1. Before servicing the vehicle, refer to the precautions at the beginning of this section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Engine appearance cover
     
    Right cowl vent screen
     
    Throttle body
     
    Vacuum lines
     
    Exhaust Gas Recirculation (EGR) valve
     
    EGR transducer and bracket
     
    Surge tank supports
     
    Surge tank
     
    Left and right intake manifold runners

    Click image to see an enlarged view

    Fig. Exploded view of transducer mounting bracket and intake manifold support with torque specification-3.4L (VIN N) engine

     
    Fuel lines
     
    Intake Manifold Runner Control (IMRC) cable
     
    Engine control sensor wiring harness
     
    Lower intake manifold

    Click image to see an enlarged view

    Fig. Exploded view of the lower intake manifold mounting-3.4L (VIN N) engine

     

  4.  

To install:

  1. Install or connect the following:

    Lower intake manifold. Use new gaskets and tighten the bolts to 14-20 ft. lbs. (18-28 Nm).
     
    Engine control sensor wiring harness
     
    IMRC cable
     
    Fuel lines
     
    Left and right intake manifold runners. Tighten the bolts to 14-20 ft. lbs. (18-28 Nm).
     
    Surge tank
     
    Surge tank supports and tighten the fasteners to 14-20 ft. lbs. (18-28 Nm)
     
    EGR transducer and bracket
     
    EGR valve
     
    Vacuum lines
     
    Throttle body
     
    Right cowl vent screen
     
    Engine appearance cover
     
    Negative battery cable
     

  2.  
  3. Run the engine and check for leaks and proper engine operation.

    Click image to see an enlarged view

    Fig. Exploded view of the upper intake manifold mounting-3.4L (VIN N) engine

  4.  

 
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