How to Replace the Intake Manifold in a Ford Taurusby Contributor; Updated November 07, 2017
How to Replace the Intake Manifold in a Ford Taurus. The Ford Taurus hit the market in 1986 and became an American sensation. Aerodynamic styling and a comfortable, roomy cabin shot Taurus to the top of popularity list. Within a year, it was Ford's best selling car. From 2000 to 2006, the Taurus offered a 3.0L V6. The following steps walk you through the removal and installation of the intake manifold on the VIN S series.
Remove the Intake Manifold
Remove the negative battery cable from the terminal. Remove the windshield wipers and cowl top inner panels.
Take out the cruise control cable, accelerator cable and bracket, the intake Air Control (IAC) valve hose, the IAC connector and any vacuum hoses blocking the removal of the intake manifold.
Disconnect the Throttle Position (TP) sensor connector and the EGR valve as well as the secondary air injection valve bracket. Remove the upper intake manifold.
Label and disconnect the fuel lines. Use a golf tee to plug the lines to prevent fuel spillage. Remove the fuel injector wiring harness. Take out the Intake Manifold Runner Control (IMRC) cable.
Tag the spark plug wires and their corresponding connections and remove the wires. Loosen the bolts and remove the lower intake manifold.
Discard the old gasket. Clean the mating surfaces of the manifold. Scrape off any old gasket material and carbon deposits. Use a solvent to thoroughly clean the surfaces and inspect them for damage.
Install the Intake Manifold
Position the new gasket on the head and then position the lower intake manifold over the gasket. Tighten the bolts in sequence working out from the center. Torque the bolts to 71 to 106 inch pounds over a series of three or four passes.
Connect the spark plug wires, the IMRC cable, the fuel injector wiring harness and the fuel lines. Position the upper intake manifold and tighten the bolts in sequence, also to 71 to 106 inch pounds.
Set the secondary air injection valve bracket in place, the install the EGR valve, the TP sensor and IAC connector, the IAC valve supply hose and any vacuum hoses that were removed. Connect the accelerator cable and bracket and the cruise control cable.
Install Windshield wipers and cowl top inner panels. Reconnect the negative battery cable to the terminal and secure it.
Start the engine and let it run until it is warm. Check for leaks and make sure the engine is operating properly.