Page 1 of 6 Section 03-01C: Engine 3.4L SHO 1999 Taurus/Sable Workshop Manual IN-VEHICLE SERVICE Procedure revision date: 06/25/1998 Intake Manifold Upper Removal 1. Disconnect battery ground cable (14301). Refer to Section 14-01. 2. Remove engine appearance cover as described. 3. Remove right half of cowl top vent screen as described in Section 01-02. 4. Remove throttle body (9E926) as described in Section 03-04C. 5. Disconnect the main emission vacuum supply hose from the surge tank vacuum fitting and EGR valve (EGR valve) (9D475). Position vacuum supply hose out of the way. 6. Disconnect vacuum tube from intake manifold vacuum union. 7. Remove the two retaining bolts for the transducer mounting bracket (9J432) from the surge tank. Position the transducer mounting bracket out of the way. 8. Remove the two intake manifold supports (9J444) from the surge tank and cylinder head (6049). Transducer Mounting Bracket and Intake Manifold Support Installation 1 95027-08016 Bolt (2 Req'd) 2 9J432 Transducer Mounting Bracket 3 A9908 Stud Bolt (2 Req'd) 4 95824-08035 Bolt (2 Req'd) 5 9J444 Intake Manifold Support (2 Req'd) 6 9D477 EGR Valve to Exhaust Manifold Tube 7 9D475 EGR Valve B Tighten to 25-35 Nm (19-25 Lb-Ft) 9. Remove EGR valve. Refer to In-Vehicle Service in Section 03-08. 10. Remove retaining bolts and surge tank stay from front of surge tank. 11. Remove bolt, nuts and surge tank stay from rear of surge tank. 12. Disconnect crankcase ventilation tube (6758) from valve cover (6582). 13. Disconnect crankcase ventilation tube from surge tank. 14. Disconnect vacuum tube to fuel pressure regulator (9C968). 15. Remove power steering pressure hose-to-surge tank retainer. 16. Disconnect RH crankcase ventilation hose (6853) and position aside. 17. Remove heater hose bracket-to-surge tank retainers.

Page 2 of 6 18. Loosen intake air connector hose clamps and remove surge tank from engine. Surge Tank Installation 1 9424 Intake Manifold 2 8287 Hose Clamp 3 95024-08016 Flange Bolt 4 9J444 Rear Surge Tank Stay 5 95704-06500 Nut 6 90116-06606 Stud Bolt 7 9J444 Front Surge Tank Stay 8 95024-08016 Bolt 9 95024-08035 Bolt 10 9F722 Air Tube to Throttle Body Hose (2 Req'd) B Tighten to 5-7 Nm (45-61 Lb-In) 19. Remove radio ignition interference capacitor bracket retaining bolt and position radio ignition interference capacitor (18801) aside. 20. CAUTION: When removing engine components, always remove retaining bolts in reverse of tightening sequence (as shown) or damage to engine components may occur. Remove intake manifold retaining bolts in standard loosening sequence. 21. Remove upper intake manifold (9424) and intake manifold upper gaskets (9H486) from lower intake manifold and discard intake manifold upper gaskets. Installation 1. CAUTION: New upper intake manifold gaskets must be used or damage to the engine may occur. Position new upper intake manifold gaskets on lower intake manifold. 2. CAUTION: Upper intake manifold bolts must be tightened in sequence shown or damage to the engine may occur. Position upper intake manifold on lower intake manifold and install retaining bolts. Tighten bolts in standard tightening sequence to 18-28 Nm (14-20 lb-ft). 3. Install radio ignition interference capacitor bracket and retaining bolt. Tighten retaining bolt to 8-12 Nm (71-106 lb-in). 4. Position surge tank on engine and align intake air connector clamps as shown. Tighten clamps securely. Intake Air Connector Hose Clamp Orientation

Page 3 of 6 Surge Tank Installation 1 9424 Intake Manifold 2 8287 Hose Clamp 3 95024-08016 Flange Bolt 4 9J444 Rear Surge Tank Stay 5 95704-06500 Nut 6 90116-06606 Stud Bolt 7 9J444 Front Surge Tank Stay 8 95024-08016 Bolt 9 95024-08035 Bolt 10 9F722 Air Tube to Throttle Body Hose (2 Req'd) B Tighten to 5-7 Nm (45-61 Lb-In) 5. Install heater hose bracket-to-surge retainers. 6. Connect RH crankcase ventilation hose. 7. Install power steering pressure hose bracket-to-surge retainer. 8. Connect vacuum tube from fuel pressure regulator to surge tank fitting. 9. Connect crankcase ventilation tube to surge tank fitting. 10. Connect crankcase ventilation tube to valve cover. 11. Install rear surge tank stay and retaining bolts and two nuts. Tighten bolt and nuts to 18-28 Nm (14-20 lb-ft). 12. Install front surge tank stay and retaining bolts. Tighten retaining bolts to 18-28 Nm (14-20 lb-ft).

Page 4 of 6 13. Install EGR valve. Refer to In-Vehicle Service, Section 03-08. 14. Install two intake manifold supports from surge tank to cylinder head. Tighten retaining bolts to 18-28 Nm (14-20 lb-ft). 15. Position transducer mounting bracket on surge tank and install retaining bolts. Tighten bolts to 18-28 Nm (14-20 lb-ft). Transducer Mounting Bracket and Intake Manifold Support Installation 1 95027-08016 Bolt (2 Req'd) 2 9J432 Transducer Mounting Bracket 3 A9908 Stud Bolt (2 Req'd) 4 95824-08035 Bolt (2 Req'd) 5 9J444 Intake Manifold Support (2 Req'd) 6 9D477 EGR Valve to Exhaust Manifold Tube 7 9D475 EGR Valve B Tighten to 25-35 Nm (19-25 Lb-Ft) 16. Connect vacuum tube to intake manifold vacuum union. 17. Connect main emission vacuum supply hose to the surge tank fitting and EGR valve. 18. Install throttle body as described in Section 03-04C. 19. Install right half of cowl vent screen (018A16). Refer to Section 01-02. 20. Install engine appearance cover as described. 21. Connect battery ground cable. Refer to Section 14-01. Lower Removal 1. Relieve fuel system pressure. Refer to Section 03-04C. 2. Disconnect battery ground cable. Refer to Section 14-01. 3. Remove upper intake manifold as described. 4. Disconnect fuel supply and return lines from fuel injection supply manifold (9F792). Refer to Section 03-04C. 5. Disconnect intake manifold runner control deactivation cable from lower intake manifold (IMRC). Remove cable from bracket and position aside. Intake Air Connector Hose Clamp Orientation

Page 5 of 6 6. Disconnect engine control sensor wiring (12A581) from fuel injectors (9F593) and wiring retainers. Position engine control sensor wiring out of the way. 7. If required, remove fuel injection supply manifold and fuel injectors from lower intake manifold (IMRC). Refer to Section 03-04C. 8. Remove lower intake manifold to cylinder head retaining bolts. 9. Remove lower intake manifold (IMRC) from cylinder heads. 1 95027-08055 Bolt 2 9L490 Lower Intake Manifold (IMRC) 3 9439 Intake Manifold Gasket 4 6049 Cylinder Head A Tighten 18-28 Nm (14-20 Lb-Ft) 10. Remove intake manifold gaskets (9439) from cylinder heads and discard intake manifold gaskets. Installation 1. NOTE: Verify operation of intake manifold runner control plate operation. Follow removal procedure in reverse order using new intake manifold gaskets. 2. Tighten lower intake manifold retaining bolts to 18-28 Nm (14-20 lb-ft). 3. Connect fuel supply and return lines. Refer to Section 10-01.

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