303-01A-1

Engine 3.0L (2V)

303-01A-1

IN-VEHICLE REPAIR
Upper Intake Manifold
Removal
1.

Disconnect the battery ground cable. For

additional information, refer to Section 414-01.

2.

Disconnect the tubes, loosen the clamps and

remove the air cleaner outlet pipe.

3.

5.

Remove the bolts and position the accelerator

cables and bracket aside.

6.

Disconnect the throttle position (TP) sensor and

the intake air control (IAC) electrical
connectors.

Remove the pin-type retainers and the snow

shield.

4.

Detach the harness retainer from the throttle

body stud bolt.

Disconnect the accelerator cable, speed control

cable and throttle return spring from the throttle
body.

Copyright 2003, Ford Motor Company

Last updated: 1/6/2005

2004 Taurus/Sable, 9/2003

303-01A-2

Engine 3.0L (2V)

303-01A-2

IN-VEHICLE REPAIR (Continued)

7.

Disconnect the vacuum hose and the

evaporative emissions (EVAP) return tube.

10. Disconnect the positive crankcase ventilation

(PCV) tube from the upper intake manifold.

8.

Remove the upper intake manifold support

bracket bolt and nut.

11. Disconnect the fuel supply manifold pressure

sensor vacuum tube.

9.

Position the bracket and harness aside.

Loosen the nut and disconnect the exhaust gas

recirculation (EGR) tube from the EGR valve.

12. Disconnect the PCV tube from the PCV valve

and remove the tube.

2004 Taurus/Sable, 9/2003

303-01A-3

Engine 3.0L (2V)

303-01A-3

IN-VEHICLE REPAIR (Continued)

13. Disconnect the EGR vacuum regulator solenoid
and intake manifold tuning valve (IMTV)
electrical connectors.

16. Remove the bolts and the upper intake

manifold.

Detach the pin-type harness retainer from

the upper intake manifold.

Installation
1.
14. Detach the spark plug wire holder from the
valve cover stud and disconnect the radio
interference capacitor electrical connector.

NOTE: Clean all of the sealing surfaces.

Inspect the upper intake manifold gaskets and
install new gaskets as necessary.
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.

2004 Taurus/Sable, 9/2003

303-01A-4

Engine 3.0L (2V)

303-01A-4

IN-VEHICLE REPAIR (Continued)

2.

3.

4.

Position the EGR vacuum regulator solenoid

and bracket and install the nuts.

5.

Connect the PCV tube from the PCV valve.

6.

Connect the fuel supply manifold pressure

sensor vacuum tube.

7.

Connect the PCV tube to the upper intake

manifold.

Attach the spark plug wire holder to the valve

cover stud and connect the radio interference
capacitor electrical connector.

Connect the EGR vacuum regulator solenoid

and IMRC electrical connectors.

Attach the pin-type harness retainer to the

upper intake manifold.

2004 Taurus/Sable, 9/2003

303-01A-5

Engine 3.0L (2V)

303-01A-5

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.

10. Connect the vacuum hose and the EVAP return

tube.

13. Connect the accelerator cable, speed control

cable and throttle return spring to the throttle
body.

11. Connect the TP sensor and the IAC electrical

connectors.

Attach the harness retainer from the throttle

body stud bolt.
2004 Taurus/Sable, 9/2003

303-01A-6

Engine 3.0L (2V)

303-01A-6

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