Taurus V6-232 3.8L (1989)
Intake Manifold: Service and Repair
Upper Intake Manifold
REMOVAL
1.
Disconnect electrical connectors at Air Bypass Valve, Throttle Position Sensor and EGR Position Sensor.
2.
Disconnect throttle linkage at throttle ball and transmission linkage from throttle body. Remove two bolts securing bracket to intake manifold and
position bracket with cables out of the way.
3.
Disconnect upper intake manifold vacuum fitting connections by disconnecting all vacuum lines to vacuum tree, vacuum lines to EGR valve, and
vacuum line to Fuel Pressure Regulator.
4.
Disconnect PCV system by disconnecting hose from fitting on rear of upper manifold.
5.
Remove nut retaining EGR Transducer to upper intake manifold.
6.
Loosen EGR tube at exhaust manifold and disconnect at EGR Valve. Remove two bolts from EGR Valve to upper intake manifold and remove
EGR Valve and Transducer as an assembly.
7.
Remove two canister purge lines from fitting on throttle body.
8.
Remove six upper intake manifold retaining bolts.
9.
Remove two retaining bolts at front and rear edges of upper intake manifold where manifold support brackets are located.
10.
Remove nut retaining alternator bracket to upper intake manifold and two bolts retaining alternator bracket to water pump and alternator.
11.
Remove upper intake and throttle body as an assembly from lower intake manifold.
INSTALLATION
Upper Intake Manifold
NOTE: Clean and inspect the mounting faces of the lower and upper intake manifolds before installing.
1.
Position a NEW upper intake manifold gasket on top of the lower intake manifold.
2.
Apply a coat of pipe sealant with Teflon (D8AZ-19554-A, or equivalent) to the threads.
3.
Install the bolts and studs in their original locations.
