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303-01A-1 303-01A-1Engine — 3.0L (2V)

IN-VEHICLE REPAIR

Upper Intake Manifold

Removal

1. Disconnect the battery ground cable. Foradditional information, refer to Section 414-01.

2. Disconnect the tubes, loosen the clamps and

remove the air cleaner outlet pipe.

5. Remove the bolts and position the accelerator

cables and bracket aside.

3. Remove the pin-type retainers and the snow

shield.

6. Disconnect the throttle position (TP) sensor and

the intake air control (IAC) electrical

connectors.

• Detach the harness retainer from the throttle

body stud bolt.

4. Disconnect the accelerator cable, speed control

cable and throttle return spring from the throttlebody.

Copyright  2003, Ford Motor CompanyLast updated: 1/6/2005 2004 Taurus/Sable, 9/2003

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303-01A-2 303-01A-2Engine — 3.0L (2V)

IN-VEHICLE REPAIR (Continued)

7. Disconnect the vacuum hose and the 10. Disconnect the positive crankcase ventilation

evaporative emissions (EVAP) return tube. (PCV) tube from the upper intake manifold.

8. Remove the upper intake manifold support 11. Disconnect the fuel supply manifold pressure

bracket bolt and nut. sensor vacuum tube.• Position the bracket and harness aside.

12. Disconnect the PCV tube from the PCV valve

and remove the tube.9. Loosen the nut and disconnect the exhaust gas

recirculation (EGR) tube from the EGR valve.

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303-01A-3 303-01A-3Engine — 3.0L (2V)

IN-VEHICLE REPAIR (Continued)

13. Disconnect the EGR vacuum regulator solenoid 16. Remove the bolts and the upper intake

and intake manifold tuning valve (IMTV) manifold.

electrical connectors.

• Detach the pin-type harness retainer from

the upper intake manifold.

Installation

1. NOTE: Clean all of the sealing surfaces.

Inspect the upper intake manifold gaskets and14. Detach the spark plug wire holder from theinstall new gaskets as necessary.valve cover stud and disconnect the radio

interference capacitor electrical connector. Install the upper intake manifold. Tighten bolts

in 2 stages in the sequence shown.

• Stage 1: Tighten the bolts hand tight.

• Stage 2: Tighten the bolts to 10 Nm (89

lb-in).

15. Remove the 2 nuts and position the EGR

vacuum regulator solenoid and bracket aside.

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303-01A-4 303-01A-4Engine — 3.0L (2V)

IN-VEHICLE REPAIR (Continued)

2. Position the EGR vacuum regulator solenoid 5. Connect the PCV tube from the PCV valve.

and bracket and install the nuts.

6. Connect the fuel supply manifold pressure

3. Attach the spark plug wire holder to the valve sensor vacuum tube.

cover stud and connect the radio interferencecapacitor electrical connector.

7. Connect the PCV tube to the upper intake

manifold.

4. Connect the EGR vacuum regulator solenoid

and IMRC electrical connectors.

• Attach the pin-type harness retainer to the

upper intake manifold.

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303-01A-5 303-01A-5Engine — 3.0L (2V)

IN-VEHICLE REPAIR (Continued)

8. Connect the EGR tube to the EGR valve and

tighten the fitting.

12. Position the accelerator cable bracket and install

the bolts.

9. Position the upper intake manifold support

bracket and install bolt and nut.

13. Connect the accelerator cable, speed controlcable and throttle return spring to the throttle

body.10. Connect the vacuum hose and the EVAP return

tube.

11. Connect the TP sensor and the IAC electrical

connectors.

• Attach the harness retainer from the throttle

body stud bolt.

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303-01A-6 303-01A-6Engine — 3.0L (2V)

IN-VEHICLE REPAIR (Continued)

14. Install the pin-type retainers and the snow

shield.

16. Connect the battery ground cable. For additional

information, refer to Section 414-01.

15. Position the air cleaner outlet pipe, connect the

tubes and tighten the clamps.

2004 Taurus/Sable, 9/2003