2005 Taurus Intake Plenum Gasket Removal

The 2005 Ford Taurus base model was offered with a 3.0-liter six-cylinder overhead valve engine and an automatic transmission. The upper intake manifold provides connections for all vacuum-controlled sensors, and houses the throttle body and EGR valve. To replace the upper intake manifold gaskets the EGR valve has to be removed, along with all of the vacuum connections and throttle control cables.

Instructions

Removal

1

Lift the vehicle hood and support it with the hood prop rod. Loosen the screw clamps for the air intake tube at the intake manifold and air cleaner box. Disconnect the electrical connector for the intake air temperature sensor and the vent tubes. Remove the air intake tube from the engine bay.

2

Pry up on the pin-style retainers for the throttle cable splash guard with the flat-head screwdriver. Remove the throttle cable splash shield. Disconnect the throttle return spring with needle-nose pliers and set the spring aside. Rotate the throttle by hand and remove the throttle cable and speed control cable from the throttle body. Remove the throttle cable bracket bolts with the socket and ratchet. Set the throttle cables and bracket aside.

3

Disconnect the electrical connectors for the throttle position sensor and the intake air control from the throttle body. Disconnect the wiring harness retainer from the throttle body stud bolt and put the wiring harness aside. Label all the vacuum lines attached with tape and a marker. Remove each vacuum line individually and mark its connection with the tape and marker to aid with assembly.

4

Remove the upper intake manifold support bracket bolt and nut with the socket and ratchet. Place the bracket and harness aside. Loosen the nut fitting for the EGR valve tube with the line wrench. Disconnect the EGR valve tube from the EGR valve. Disconnect the PCV tube from the PCV valve and the upper intake manifold and set it aside.

5

Disconnect the EGR valve vacuum regulator and intake manifold runner control electrical connectors. Pry up on the pin type harness retainer with the flat-head screwdriver and position the harness aside. Pry up on the spark plug wire holder with the flat-head screwdriver. Disconnect the electrical connector for the radio interference capacitor.

6

Perform a visual inspection of the upper intake manifold to ensure there are no vacuum lines connected and all wiring harness plugs are removed from the attached sensors. Remove the three manifold bolts and one stud bolt from the intake manifold. Remove the intake manifold from the engine. Remove and discard the three upper intake to lower intake mating gaskets.

Installation

7

Clean the mating surfaces of the lower and upper intake manifolds with the wire brush. Install new gaskets and position the upper intake manifold onto the lower intake manifold. Install the manifold bolts hand tight. Tighten the intake manifold bolts to 89 inch-pounds with the inch-pounds torque wrench, starting with the bolt third from the left and working left. Tighten the stud bolt last.

8

Push the spark plug wire holder into position on the valve cover. Connect the electrical connector for the radio interference capacitor. Connect the EGR vacuum and IMRC electrical connectors. Press the wiring harness connector into position on the intake manifold.

9

Install the PCV tube to the PCV valve and intake manifold. Connect all the vacuum lines one by one according to the taped markers on the vacuum lines and the vacuum connections on the upper intake manifold. Remove the tape from the manifold connectors before you install each line.

10

Install the EGR tube to the EGR valve and tighten the fitting by hand. Tighten the EGR tube fitting to 41 foot-pounds of torque with the torque wrench and crowfoot attachment. Install the upper intake manifold support bracket nut and bolt. Tighten the bolt to 37 foot-pounds with the torque wrench. Tighten the nut to 53 inch-pounds with the inch-pounds torque wrench.

11

Connect the throttle position sensor and IAC electrical connectors at the throttle body. Push the wiring harness retainer over the throttle body stud bolt. Install the throttle cable bracket and tighten the bolts to 13 foot-pounds with the torque wrench. Connect the throttle cable and speed control cable to the throttle body. Install the throttle return spring. Set the throttle body splash shield into position into position over the throttle cables and install the push pin retainers.

12

Install the intake air tube to the throttle body and air cleaner box. Tighten the retaining clamps with the screwdriver. Attach the vent tubes to the intake air tube. Plug in the IAT sensor electrical connector. Shut the vehicle hood.