Engine Controls - Remove/install/overhaul Ford Taurus II

INTRODUCTION

Removal, overhaul and installation procedures (when available from manufacturer) are covered in this article. If component removal and installation is primarily an unbolt and bolt-on procedure, only a torque specification may be furnished.

Removal & Installation (Except Probe 2.5L)

1. Remove high tension lead and distributor cap. Rotate crankshaft in direction of normal rotation until piston No. 1 is at TDC of compression stroke. Disconnect negative battery cable.
2. Ensure timing marks are aligned. Disconnect distributor wiring from harness. Mark distributor rotor and housing position for installation reference. Remove distributor hold-down bolt(s) and clamp. Some engines may be equipped with a security-type distributor hold-down bolt.
3. If necessary, use Distributor Hold-Down Wrench (T82L-12270-A) to remove bolt. Remove distributor. Inspect distributor "O" ring and replace if necessary. To install, reverse removal procedure. Set base ignition timing. See ADJUSTMENTS article in the ENGINE PERFORMANCE Section.

Removal & Installation (Probe 2.5L)

1. Disconnect negative battery cable. Remove fresh air duct nuts/bolts. Loosen spring clamp and slide air cleaner assembly forward. Remove fresh air duct. Disconnect distributor connectors. Remove distributor cap and gasket. Disconnect air duct from Volume Airflow (VAF) meter. Disconnect VAF meter connector.
2. Remove fuel pressure regulator control solenoid from air cleaner, and position solenoid out of way. Remove air cleaner assembly. Remove 2 distributor hold-down bolts and distributor. To install, reverse removal procedure. Set base ignition timing. See ADJUSTMENTS article in the ENGINE PERFORMANCE Section.

DISTRIBUTOR OVERHAUL

Note. Overhaul is not recommended on Escort, Probe or Tracer. If distributor is defective, replace entire unit. The Ignition Control Module (ICM) on 3.8L, Cougar 5.0L and Thunderbird 5.0L engines is not mounted on distributor. On Continental, Sable and Taurus, ICM is located at right rear of engine compartment on cowling. On Cougar and Thunderbird, ICM is located on right side of radiator support bracket.

Disassembly

1. On models with distributor mounted ICM, remove 2 module screws. Pull right side of module down and back up distributor mounting flange to disengage module terminals from connector in distributor base. Remove module by pulling toward flange and away from distributor. CAUTION: Attempting to remove ignition module without first moving entire module toward distributor flange will break module pins at connector.
2. On all models, hold gear, and loosen armature screws. DO NOT hold armature. Remove screws and armature. Using a felt-tip pen, mark armature and gear for installation reference. Remove and discard roll pin in gear.
3. Place distributor in Axle Bearing Remover (T75L-1165-B). Press off gear using arbor press and Pinion Bearing Cone Remover (D79L-4621-A). Remove armature. Using emery cloth, remove burrs from distributor shaft. Remove shaft from distributor assembly. (Scheme 1)or (Scheme 2).
4. Remove thrust washer from distributor (if equipped), and save for installation. Remove screw and octane rod assembly (if equipped). Remove stator assembly screws and stator.
5. Inspect base bushing, "O" ring and distributor housing for wear, cracks or other damage. If necessary, replace "O" ring. If distributor housing or bushings are worn, replace entire distributor assembly.

Scheme 1

Scheme 2

Reassembly

1. Place stator assembly over bushing, and press down to seat. Place stator connector in position. Tab should fit in notch of base, and fastening eyelets should align with screw holes. Position wires away from moving parts. Install and tighten stator screws.
2. On models with distributor mounted ICM, install octane rod through distributor base hole. Place end of rod onto same post as original stator. Install and tighten octane rod screw. On all models, lubricate distributor shaft, just below armature, with light oil. DO NOT over lubricate.
3. Install shaft through base bushing. Place a 1/2" deep well socket over shaft, invert assembly and place in arbor press. Place thrust washer (if equipped) and distributor drive gear on shaft. Align marks made during removal.
4. Place a 5/8" deep well socket over shaft and gear. Press gear until holes align with holes in shaft. If holes do not line up, press gear off and try again. DO NOT try to align holes using a drift or roll pin. Insert new roll pin through gear and shaft.
5. If armature has been removed, install armature. Tighten armature screws. Check distributor for freedom of rotation. If armature contacts stator, replace distributor. On models with distributor mounted ICM, clean back of module and distributor contact plate.
6. Apply Silicone Dielectric Compound (D7AZ-19A331-A) to back of module, and spread evenly. Invert distributor base so stator connector is in full view. Insert module.
7. Ensure module pins are inserted into stator connector. Fully seat module into connector and against base. Install and tighten module screws.

Removal & Installation

Disconnect negative battery cable. Remove intake manifold. See REMOVAL & INSTALLATION 1.9L 4-CYLINDER article in ENGINES. Remove CMP sensor mounting screws and CMP sensor from cylinder head. (Scheme 3) To install, replace "O" ring. Install CMP sensor and retaining screws. To complete installation, reverse removal procedure. Tighten CMP sensor screws to specification. See TORQUE SPECIFICATIONS.

Scheme 3

Removal & Installation (3.0L SHO & 3.2L SHO)

Disconnect negative battery cable. Remove engine torque strut. Remove power steering belt. Remove power steering pump pulley. Disconnect sensor connector. Remove sensor bolts and sensor. To install, reverse removal procedure.

Removal & Installation (3.8L)

Disconnect negative battery cable. Disconnect camshaft sensor connector. Remove camshaft sensor mounting screws and remove sensor. To install, reverse removal procedure. Tighten camshaft sensor and mounting screws to 22-31 inch lbs. (2.5-3.5 N.m).

SYNCHRONIZER ASSEMBLY (3.8L)

Removal (3.8L)

Disconnect negative battery cable. Remove camshaft sensor assembly. Remove synchronizer clamp and synchronizer from front engine cover.

Note. The immediate oil pump driveshaft should be removed with synchronizer assembly.

Installation

1. If plastic locator cover tool is not attached to replacement synchronizer assembly, attach Synchro Positioner Tool T89P-12200-A or equivalent as follows: Engage synchronizer vane into radial slot of tool. Rotate tool on synchronizer base until tool boss engages the base notch. The cover tool should be square and in contact with entire top surface of synchronizer base.
2. Transfer intermediate oil pump driveshaft from old synchronizer to replacement synchronizer assembly. Install synchronizer assembly so that gear engagement occurs when arror on locator tool is pointed approximately 30 degrees counterclockwise from front face of engine block (this will locate camshaft sensor connector in pre-removal position.)
3. Install synchronizer base clamp and tighten bolt to 15-22 ft.lbs. (20-30 N.m). Remove Synchro Positioner Tool T89P-12200-A or equivalent. Insatall and connect camshaft sensor and negative battery cable.

Scheme 4

Removal (1.9L)

Disconnect negative battery cable. Raise vehicle. Remove right side splash shield. Disconnect sensor connector. Remove crankshaft sensor screws. Remove sensor.

Position sensor assembly on bracket. Install 2 sensor screws. Tighten screws to specification. See TORQUE SPECIFICATIONS. Ensure sensor is not overtightened. Route sensor wiring harness, and install connector. To complete installation, reverse removal procedure.

Removal (3.0L SHO & 3.2L SHO)

1. Disconnect negative battery cable. Loosen A/C compressor and power steering pump tensioner pulleys. Remove belts from crankshaft pulley. Remove ignition control module and intake manifold crossover tube. Remove upper timing belt cover. Disconnect sensor wiring harness at connector, and route wiring harness through belt cover.
2. Raise vehicle. Remove right front wheel. Using a universal puller, remove crankshaft pulley. Remove lower timing belt cover. Rotate crankshaft by hand to position metal vane of shutter outside of sensor air gap. Remove crankshaft sensor mounting screws and sensor.

1. Route sensor wiring harness through belt cover. Install sensor assembly on mounting pad, and loosely install retaining screws. DO NOT tighten screws at this time.
2. Set clearance between crankshaft sensor and vane on crankshaft pulley to .03" (.8 mm). Tighten screws to specification. See TORQUE SPECIFICATIONS. Install lower timing belt cover. Install crankshaft pulley, and tighten bolt to specification. To complete installation, reverse removal procedure.

Removal (3.8L SC)

Disconnect negative battery cable. Disconnect sensor connector. Raise vehicle. Remove upper and lower damper shield assemblies. Rotate by hand to position metal vane of shutter (attached to rear of damper) outside of sensor air gap. Remove crankshaft sensor bolts. Remove sensor.

1. Position sensor assembly on bracket. Install 2 sensor screws, but DO NOT tighten. Install Crankshaft Sensor Gauge (T89P-6316-AH) to outside surface of one vane of shutter. NOTE: Gauge is magnetic and will conform to shape of vane.
2. Push sensor housing inward to contact gauge. Tighten bolts to specification. See TORQUE SPECIFICATIONS. Ensure sensor is not overtightened. Overtightening can damage crankshaft sensor.
3. Rotate crankshaft by hand to position shutter vane with gauge outside of air gap. Remove magnetic gauge. To complete installation, reverse removal procedure.

Removal & Installation (4.6L)

1. Disconnect negative battery cable. Remove serpentine drive belt. Raise and support vehicle. Disconnect sensor and A/C compressor connectors. Discharge A/C system using approved refrigerant recovery/recycling equipment.
2. Remove A/C compressor. Remove sensor bolt and sensor. To install, reverse removal procedure. Tighten sensor bolt to specification. See TORQUE SPECIFICATIONS. Evacuate and recharge A/C system.

FUEL SYSTEM PRESSURE RELEASE

1.8L & 1.9L

Depress retaining clips and remove rear seat cushion. Disconnect fuel pump connections. Start engine and operate until it stalls. Turn ignition off. Reconnect fuel pump. Install rear seat cushion.

2.0L A/T & 2.5L

Remove fuel pump relay or move reset switch on Inertia Fuel Shutoff (IFS) switch. Fuel pump relay is located in engine compartment main fuse panel. The IFS switch is located on right side of trunk. Start engine and operate until it stalls. Turn ignition off. Reconnect fuel pump relay or reset IFS switch.

All Others

1. Remove fuel cap to release fuel tank pressure. Remove relief valve cap. Relief valve is located on fuel supply manifold. Using Fuel Pressure Gauge (T80L-9974-B), release fuel pressure from relief valve (Schrader valve).
2. If fuel pressure gauge is not available, disconnect electrical connector to IFS switch. For IFS switch location, see INERTIA FUEL SHUTOFF (IFS) SWITCH LOCATION table. Crank engine for 15 seconds to reduce system pressure. Turn ignition off. Reconnect IFS switch connector.

INERTIA FUEL SHUTOFF (IFS) SWITCH LOCATION

FUEL LINE CONNECTOR

Note. Three types of fuel couplings are used. (Scheme 5)-6. See appropriate REMOVAL & INSTALLATION procedure.

Removal (Spring Lock Coupling)

1. Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE. Using Spring Lock Coupling Remover (D87L-9280-A for 3/8" or D87L-9280-B for 1/2"), remove retaining clip from coupling. Place remover over coupling so protrusion is positioned on cage opening side of coupling. (Scheme 5)
2. Close remover over coupling. Push remover into cage opening to release female fitting from garter spring. Separate male and female halves of coupling. Remove tool from disconnected spring lock coupling.

Scheme 5

1. Ensure garter spring in cage of male fitting is not damaged. Replace if necessary. Clean all dirt from both pieces of coupling. Check "O" rings for damage, and replace using proper fuel resistant "O" rings (if necessary).
2. Lubricate "O" rings and inside of female fitting with clean engine oil. Snap fitting together. Install retaining clip onto coupling. Ensure horseshoe portion of clip is over coupling. DO NOT install retaining clip over rubber fuel line. (Scheme 5)

Removal (Hairpin Clip Fitting)

Hairpin clip type fittings are used on 5/16" and 3/8" fuel lines. To disconnect fuel lines, remove hairpin clip from fitting. (Scheme 6) Spread each clip leg about 1/8" to disengage body. While pulling lightly on triangular end of clip, push legs into fitting. Work assembly clear of tube and fitting. Pull fitting and steel line in axial direction. Use twisting motion to pull fitting loose.

With triangular portion pointing away from fitting opening, insert clip into any 2 adjacent openings. Install clip to fully engage body. Clean end of fitting. Align fitting and tube axially, and push fitting onto tube end. When fitting is engaged, a click will be heard.

Scheme 6

Removal & Installation (Duck-Bill Type Fitting)

1. Duck-bill fittings are used on 1/2" and 1/4" fuel lines. Align slot on Disconnect Tool (T82L-9500-AH) with either tab on clip (90 degrees from slots on die of fitting) and insert tool. (Scheme 7)
2. Holding tool and tube in one hand, pull fitting away from tube. To install, reverse removal procedure. Pull on fitting to ensure it is fully engaged.

Scheme 7

Removal (1.8L & 1.9L)

1. Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE. Disconnect negative battery cable. Depress 2 clips securing front of rear seat cushion, and remove seat cushion. Disconnect wiring harness connectors from fuel pump assembly.
2. Remove fuel pump access cover. Remove any dirt from around fuel pump flange area. Disconnect fuel inlet and return lines from fuel pump. Remove fuel pump screws, and remove fuel pump/sender assembly.

1. Clean fuel pump mounting flange, fuel tank mounting surface and seal ring groove. To hold new seal ring in place during installation, apply a light coating of Long Life Lubricant (ESA-M1C75-B) on new seal ring.
2. Install seal ring in fuel ring groove. Install fuel pump/sender assembly. DO NOT damage nylon filter. Ensure locating keys are in keyways and seal ring remains in place.
3. Install and tighten fuel pump screws. To complete installation, reverse removal procedure. Fill fuel tank. Pressurize fuel system and check for leaks. To pressurize fuel system, turn ignition on for 3 seconds, then turn ignition off. Repeat ignition cycle 5 to 10 times.

Removal (4.6L Except Mark VIII)

1. Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE. Disconnect negative battery cable. Drain fuel from tank through filler neck until tank is about 1/4 full. Raise and support vehicle.
2. Remove any dirt around fuel pump flange area. Using Fuel Tank Sender Wrench (D84P-9257-A), remove fuel pump locking ring. Remove fuel pump/sender assembly. Remove and discard fuel pump seal ring.

1. Clean fuel pump mounting flange, fuel tank mounting surface and seal ring groove. To hold new seal ring in place during installation, apply a light coating of Long Life Lubricant (ESA-M1C75-B) on new seal ring.
2. Install seal ring in fuel ring groove. Install fuel pump/sender assembly. DO NOT damage nylon filter. Ensure locating keys are in keyways and seal ring remains in place.
3. Using Fuel Tank Sender Wrench (D84P-9257-A), tighten locking ring by rotating ring clockwise until ring stops against stops. To complete installation, reverse removal procedure. Fill fuel tank.
4. Pressurize fuel system and check for leaks. To pressurize fuel system, turn ignition on for 3 seconds, then turn ignition off. Repeat ignition cycle 5 to 10 times.

Removal (All Others)

1. Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE. Drain fuel from tank. Raise vehicle on hoist. Remove exhaust heat shield. Remove exhaust pipe (if necessary). Remove fuel inlet and return hoses.
2. Disconnect vapor crossover and filler hoses. Support fuel tank. Remove fuel tank strap bolts. Partially lower fuel tank. Disconnect fuel lines and electrical connector from fuel gauge sender. Remove fuel tank.
3. Remove any dirt from around fuel pump flange area. Using Fuel Tank Sender Wrench (D84P-9257-A), remove fuel pump locking ring. Remove fuel pump.

1. Clean fuel pump mounting flange, fuel tank mounting surface and seal ring groove. To hold new seal ring in place during installation, apply a light coating of Long Life Lubricant (C1AZ-19590-BA) on seal ring.
2. Install seal ring in fuel ring groove. Install fuel pump and sender assembly. DO NOT damage nylon filter. Ensure locating keys are in keyways and seal ring remains in place.
3. Using Fuel Tank Sender Wrench (D84P-9257-A), tighten locking ring by rotating ring clockwise until ring stops against stops. To complete installation, reverse removal procedure.
4. Pressurize fuel system and check for leaks. To pressurize fuel system, turn ignition on for 3 seconds, then turn ignition off. Repeat ignition cycle 5 to 10 times.

1. Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE. Disconnect fuel supply and return lines. See FUEL LINE CONNECTOR. Disconnect negative battery cable. Disconnect fuel injector connectors.
2. Remove PCV hose. Remove fuel rail bolts. Carefully disengage injectors from fuel rail. Disconnect vacuum line from fuel pressure regulator. Remove fuel rail assembly.

When installing fuel rail assembly, use new "O" rings. Push fuel rail down to ensure all injector "O" rings are fully seated in fuel rail cups and intake manifold. Install fuel rail bolts. Tighten to specifications. See TORQUE SPECIFICATIONS. To complete installation, reverse removal procedure.

Removal (2.0L)

Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE. Disconnect negative battery cable. Disconnect fuel injector connectors. Disconnect fuel supply and return lines. Disconnect fuel pressure regulator vacuum hose. Remove fuel line bracket bolt. Remove fuel rail attaching bolts, spacers and insulators. Remove fuel rail with injectors and fuel pressure regulator attached.

Position grommets and new "O" rings onto fuel injectors. Lightly lubricate "O" rings with clean engine oil. To complete installation, reverse removal procedure. Ensure injectors are properly seated. Tighten fuel rail bolts to specification. See TORQUE SPECIFICATIONS.

Removal (2.3L)

1. Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE. Disconnect negative battery cable. Remove fuel supply and return lines. See FUEL LINE CONNECTOR. Remove wiring harness from injectors.
2. Remove upper intake manifold. See UPPER INTAKE MANIFOLD. Remove fuel rail bolts. Carefully disengage fuel rail from injectors. Disconnect vacuum line from fuel pressure regulator. Remove fuel rail assembly.

Position grommets and new "O" rings onto fuel injectors. Lightly lubricate "O" rings with clean engine oil. To complete installation, reverse removal procedure. Ensure injectors are properly seated. Tighten fuel rail bolts to specification. See TORQUE SPECIFICATIONS.

Removal (2.5L)

1. Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE. Remove air cleaner housing and air ducts. Disconnect negative battery cable. Disconnect fuel supply and return lines. Discard copper crush washer. Disconnect fuel injector connectors. Remove fuel pressure regulator.
2. Remove fuel rail bolts and fuel rails. Remove injector insulators. Remove screws attaching distribution harness to fuel rails. Remove and discard spacer from top of each fuel injector. Carefully rotate each injector back and forth, and remove injectors from fuel rails.

To install, reverse removal procedure. When installing fuel rails, use new "O" rings, spacers and crush washers. Tighten fuel rail bolts to specification. See TORQUE SPECIFICATIONS.

Removal (3.0L Flex Fuel)

1. Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE. Disconnect negative battery cable. Remove fuel supply and return lines. See FUEL LINE CONNECTOR. Remove negative battery cable. Remove wiring harness from injectors.
2. Remove throttle body. See THROTTLE BODY. Disconnect fuel pressure regulator vacuum hose. Remove 4 fuel rail bolts. Carefully disengage fuel rail from injectors. Remove fuel rail assembly.

When installing fuel rail assembly, use new "O" rings. Push fuel rail down to ensure all injector "O" rings are fully seated in fuel rail cups and intake manifold. Install fuel rail bolts and tighten to specification. See TORQUE SPECIFICATIONS. To complete installation, reverse removal procedure.

Removal (3.0L Sable, 3.0L SHO, 3.0L Taurus & 3.2L SHO)

1. Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE. Disconnect negative battery cable. Remove fuel supply and return lines. See FUEL LINE CONNECTOR. Remove wiring harness from injectors.
2. On 3.0L SHO and 3.2L SHO, remove upper intake manifold. See UPPER INTAKE MANIFOLD. On 3.0L, remove throttle body. See THROTTLE BODY. Mark distributor housing for installation reference. Remove distributor hold-down clamp. Lift distributor enough to allow fuel rail crossover tube to clear distributor housing and lower intake manifold.
3. On all models, remove fuel rail bolts. Carefully disengage fuel rail from injectors. Disconnect vacuum line from fuel pressure regulator. Remove fuel rail assembly.

When installing fuel rail assembly, use new "O" rings. Push fuel rail down to ensure all injector "O" rings are fully seated in fuel rail cups and intake manifold. Install fuel rail bolts and tighten to specification. See TORQUE SPECIFICATIONS. To complete installation, reverse removal procedure.

Removal (3.8L & 5.0L)

1. Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE. Disconnect negative battery cable. Remove fuel supply and return lines. See FUEL LINE CONNECTOR. Remove wiring harness from injectors.
2. Remove upper intake manifold. See UPPER INTAKE MANIFOLD. Disconnect vacuum line from fuel pressure regulator. Remove fuel rail bolts. Carefully disengage fuel rail from injectors. Remove fuel rail.

Note. It may be easier to remove fuel rail and injectors as an assembly.

When installing fuel rail assembly, use new "O" rings. Push fuel rail down to ensure all injector "O" rings are fully seated in fuel rail cups and intake manifold. Install fuel rail bolts and tighten to specification. See TORQUE SPECIFICATIONS. To complete installation, reverse removal procedure.

1. Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE. Disconnect negative battery cable. Remove throttle body. See THROTTLE BODY. Remove charge air cooler tubes. See CHARGE AIR COOLER INLET TUBE and CHARGE AIR COOLER OUTLET TUBE. Remove charge air cooler. See CHARGE AIR COOLER.
2. Remove cowl vent screens. Disconnect electrical connections and vacuum lines from intake elbow. Loosen clamp at idle air control valve inlet hose. Remove 3 elbow-to-manifold bolts.
3. Remove intake elbow. Remove fuel supply and return lines at fuel rail assembly. See FUEL LINE CONNECTOR. Remove wiring harness from fuel injectors. Remove fuel pressure regulator bolt. Remove fuel rail.

1. When installing fuel rail assembly, use new "O" rings. Push fuel rail down to ensure all injector "O" rings are fully seated in fuel rail cups and intake manifold.
2. Install fuel rail bolts. Tighten to specification. See TORQUE SPECIFICATIONS. To complete installation, reverse removal procedure. When installing intake elbow, align paint stripe on hose with rib on elbow assembly.

Removal (4.6L)

On Mark VIII, remove engine cover and air inlet tube assembly. On all models, release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE. Disconnect negative battery cable. Disconnect fuel inlet and return lines. See FUEL LINE CONNECTOR. Disconnect wiring harness connectors from injectors. Disconnect vacuum line at fuel pressure regulator and brake booster (Mark VIII). Remove fuel rail bolts. Remove fuel rails and injectors as an assembly.

Position new "O" rings onto fuel injectors. Lightly lubricate "O" rings with clean engine oil. To complete installation, reverse removal procedure. Ensure injectors are properly seated. Tighten fuel rail bolts to specification. See TORQUE SPECIFICATIONS.

1. If removing fuel pressure regulator while fuel rail assembly is still installed on engine, release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE.
2. Remove vacuum line at pressure regulator. Remove 3 Allen screws from regulator housing. Remove pressure regulator assembly, gasket and "O" ring.
3. To install, ensure gasket surfaces are clean. Lubricate new "O" ring with clean engine oil. Install new "O" ring and gasket on regulator. Install fuel pressure regulator on fuel rail assembly, and tighten screws.

Injectors may be removed after fuel rail has been removed from intake manifold. See FUEL RAILS. Lubricate new "O" rings with clean engine oil. Install new "O" rings on injectors. Inspect injector "plastic hat" (covering the injector pintle) and washer for deterioration. Replace as necessary.

1. Disconnect air cleaner outlet tube from throttle body. Disconnect throttle position sensor and idle air control valve connectors. Mark and disconnect vacuum lines from upper intake manifold. Disconnect EGR tube at intake manifold.
2. Remove throttle cables and speed control cable (if equipped). Remove top bolt from manifold upper support bracket. Remove fuel supply manifold shield. Remove 4 bolts and one stud from upper intake manifold. Remove upper intake manifold and throttle body as an assembly.

Clean all gasket surfaces. Install new gasket on intake manifold. Mount upper intake manifold to intake manifold. Install manifold bolts and tighten to specification. See TORQUE SPECIFICATIONS. Reconnect EGR tube and tighten to specification. To complete installation, reverse removal procedure.

1. Remove intake air boot from throttle body and mass airflow sensor. Disconnect throttle cables. Disconnect electrical connectors from throttle position sensor, idle air control valve, vacuum switching valve and ignition control module.
2. Disconnect coolant by-pass hoses. Disconnect and mark all vacuum lines from upper intake manifold and throttle body. Disconnect EGR pipe from EGR valve.
3. Remove 8 bolts from upper intake manifold support brackets, and remove brackets. Remove coolant hose bracket bolt. Remove remaining 12 upper intake manifold bolts. Remove upper intake manifold and throttle body as an assembly.

Note. Metal intake manifold gaskets can be reused if undamaged.

Clean all mounting surfaces. Position gaskets and upper intake manifold assembly. Install bolts and tighten to specification. See TORQUE SPECIFICATIONS. To complete installation, reverse removal procedure. Check and top-off cooling system.

1. Disconnect wiring harness connectors as necessary. Disconnect throttle and transmission linkages from throttle body. Remove cable bracket with cables attached, and position bracket aside.
2. Mark and disconnect all vacuum lines to throttle body and upper intake manifold. Disconnect PCV system from fitting at rear of upper intake manifold. On 5.0L, disconnect EGR coolant lines from fittings on EGR spacer.
3. On 3.8L models, remove EGR valve and EGR transducer. Remove nut retaining alternator bracket to upper intake manifold. Remove 2 bolts retaining alternator bracket to water pump and alternator. On all models, remove bolts holding upper intake manifold to lower intake manifold. Remove upper intake manifold and throttle body as an assembly.

Clean and inspect gasket mounting surfaces. Position new gasket, and install upper intake manifold with throttle body onto intake manifold. On 5.0L, tighten bolts to specification. See TORQUE SPECIFICATIONS. On 3.8L, tighten upper intake manifold bolts in sequence to specification. (Scheme 8) On all models, to complete installation, reverse removal procedure.

Scheme 8

Disconnect negative battery cable. Remove throttle body air duct. Disconnect throttle cables. Disconnect electrical connectors as necessary. Disconnect idle air control valve hoses. Remove throttle body bolts/nuts. Remove throttle body and gasket.

Clean and inspect gasket mating surfaces. Install new throttle body gasket. To complete installation, reverse removal procedure. Tighten bolts to specification. See TORQUE SPECIFICATIONS. Check and top-off cooling system.

Removal & Installation (2.3L, 3.8L SC & 5.0L)

1. Disconnect air cleaner outlet tube from throttle body. Disconnect throttle position sensor and idle air control valve connectors. Disconnect throttle cables and speed control cable (if equipped). Remove throttle body bolts. Remove throttle body and gasket.
2. Clean and inspect gasket mating surfaces. Install new throttle body gasket. To complete installation, reverse removal procedure. Tighten bolts to specification. See TORQUE SPECIFICATIONS.

Removal (3.0L)

1. Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE. Disconnect negative battery cable. Remove air cleaner duct and plastic shield from throttle body. Remove EGR supply tube. Mark and disconnect vacuum hoses from throttle body.
2. Disconnect wiring harness connectors from throttle body as necessary. Disconnect throttle and kickdown (A/T only) cables from throttle lever. Remove fuel rail bracket from throttle body. Remove throttle body bolts. Remove throttle body and gasket.

Clean gasket mating surfaces. Install new throttle body gasket. Install throttle body. Lightly oil throttle body bolt threads. Install bolts and tighten in sequence to specification. (Scheme 9) See TORQUE SPECIFICATIONS. To complete installation, reverse removal procedure.

Scheme 9

Remove intake air boot from throttle body and mass airflow sensor. Disconnect throttle cables. Disconnect electrical connectors from throttle position sensor and idle air control valve. Disconnect coolant by-pass hoses. Disconnect PCV hoses. Remove throttle body bolts/nuts. Remove throttle body and gasket.

Clean and inspect gasket mating surfaces. Install new throttle body gasket. To complete installation, reverse removal procedure. Tighten bolts to specification. See TORQUE SPECIFICATIONS. Check and top-off cooling system.

Disconnect inlet and outlet tubes at charge air cooler. (Scheme 10) Loosen inlet tube at alternator/power steering pump bracket. Remove charge air cooler nuts and washers. Push downward on charge air cooler to disengage retaining clips. Remove charge air cooler.

1. Install Teflon tape to circumference of seat surfaces of CAC inlet and outlet tubes. Keep tape close to inner diameter, and overlap ends by 1/4".
2. Install charge air cooler retaining clips. Install retaining nuts and washers. Ensure air boot fits on charge air cooler and no gaps exist. Install inlet and outlet tubes on charge air cooler.
3. Tighten inlet and outlet tube nuts to specification. See TORQUE SPECIFICATIONS. Ensure clamping connectors on inlet and outlet tubes at charge air cooler are parallel to charge air cooler surface. Tighten nut attaching inlet tube to alternator/power steering bracket to specification. Start engine and check for leaks.

Scheme 10

1. Using Spanner (T89P-6634-A), disconnect inlet tube from supercharger. (Scheme 10) Disconnect outlet tube at charge air cooler. Remove nuts attaching inlet tube to charge air cooler.
2. Remove nuts attaching inlet tube to alternator/power steering pump bracket. Remove stud from alternator/power steering pump bracket during inlet tube removal (if necessary). Carefully remove inlet tube to avoid damaging sealing surfaces.

1. Ensure all sealing surfaces are clean. Install Teflon tape to circumference of sealing surfaces of charge air cooler inlet tube. Apply tape 1/8" from inner diameter, and overlap ends by 1/4". Apply Anti-Seize Compound (ESE-M12A-4A) to sealing surface and threads of supercharger outlet adapter collar. CAUTION: DO NOT stretch Teflon tape during installation.
2. Install inlet tube. (Scheme 10) Install stud into alternator/power steering pump bracket. DO NOT damage sealing surfaces of inlet tube. Install push-on nut on stud enough to hold inlet tube. Ensure inlet tube is free to move for alignment of sealing surfaces.
3. Hand tighten supercharger outlet adapter collar on inlet tube. Install and slightly tighten nuts attaching inlet and outlet tubes to charge air cooler. Ensure tubes are free to move at sealing areas. Using adapter, tighten supercharger outlet adapter collar to specification. See TORQUE SPECIFICATIONS. Wait at least 10 minutes, and retighten adapter collar to specification. CAUTION: Supercharger outlet adapter collar must be retightened after 10 minutes, as Teflon tape will form to sealing surfaces.
4. Tighten nuts attaching inlet and outlet tubes to charge air cooler to specification. Ensure clamping connectors on inlet and outlet tubes at charge air cooler are parallel to charge air cooler surface. Tighten nut attaching inlet tube to alternator/power steering bracket to specification. Start engine and check for leaks.

1. Remove nuts attaching outlet tube to intake elbow assembly. Raise and support vehicle. Remove bolt attaching outlet tube to cylinder block front upper support bracket.
2. Loosen, but DO NOT remove, support bracket at front of cylinder block. Bracket must remain close to cylinder block so bracket can pivot during installation of outlet tube.
3. Remove nut and push-on nut attaching outlet tube to alternator/power steering pump bracket. Remove inlet tube stud from alternator/power steering pump bracket. Remove power steering pump belt.
4. Disconnect spark plug wires at ignition coil. Remove nuts attaching power steering pump bracket brace to water pump. Remove bolts and stud nut attaching power steering pump bracket to cylinder head.
5. Install a long bolt in top hole of power steering pump bracket to retain pump bracket in position. Remove power steering pump filler cap. Slide power steering pump bracket outward on long bolt.
6. Remove outlet tube by moving tube underneath power steering pump bracket and up into engine compartment. DO NOT damage sealing surfaces of outlet tube during removal.

1. Install Teflon tape to circumference of sealing surfaces of outlet tube. Keep tape close to inner diameter, and overlap ends by 1/4". DO NOT stretch tape during installation, or a leak at sealing surface may develop.
2. Install outlet tube underneath power steering pump bracket assembly. (Scheme 10) Install power steering bracket and stud retaining nut. Tighten nut to specification. See TORQUE SPECIFICATIONS. CAUTION: Carefully install outlet tube to avoid damaging sealing surfaces.
3. Remove bolt installed in step 5) during removal. Install power steering pump bracket-to-cylinder head bolts, and tighten to specification.
4. Install power steering pump bracket brace-to-water pump retaining studs. Tighten nuts to specification. Install outlet tube on lower stud on alternator/power steering pump bracket.
5. Install push-on nut to hold outlet tube on pump bracket. Ensure outlet tube is free to move for alignment of sealing surfaces. Install outlet tube clamping connector over intake elbow assembly studs.
6. Install and tighten nuts to specification. Ensure clamping connectors on outlet tube-to-intake elbow are parallel to intake elbow surface. Install nut on stud of alternator/power steering pump bracket and tighten nut to specification.
7. Install outlet tube-to-cylinder block support bracket. Tighten bolt to specification. Tighten support bracket-to-front of cylinder block retaining nut and bolt to specification.

The oxygen sensor is equipped with a permanent pigtail, which must be protected when sensor is removed. Ensure sensor is free of contaminants, and avoid using cleaning solvents of any type. Sensor may be difficult to remove when engine temperature is less than 120°F (48°C). Always use anti-seize compound on threads prior to installation. Tighten sensor to 30 ft. lbs. (41 N.m).

SUPERCHARGER

Note. Disassembly of supercharger unit may void warranty. Supercharger cannot be overhauled. Supercharger is serviced by replacement ONLY.

Removal & Installation (3.8L SC)

1. Clean areas surrounding supercharger. Disconnect negative battery cable. Remove throttle body air inlet tubes. Remove cowl vent screens. Partially drain cooling system.
2. Remove right side spark plug wires at ignition coil. Remove all vacuum and electrical connectors from upper intake manifold and throttle body. Remove throttle linkage and bracket. Remove supercharger drive belt.
3. Disconnect speed control (if equipped). Remove supercharger drive belt. Remove charge air cooler inlet and outlet tubes. See CHARGE AIR COOLER INLET TUBE and CHARGE AIR COOLER OUTLET TUBE.
4. Remove 3 intake elbow bolts. Remove 3 supercharger retaining bolts. Lift supercharger and intake assembly from vehicle as a unit. (Scheme 10) To install, reverse removal procedure. Tighten bolts to specification. See TORQUE SPECIFICATIONS.

1. Remove distributor cap, if necessary. Disconnect TP sensor from wiring harness. Mark throttle body and TP sensor for reassembly reference. Remove mounting screws and TP sensor. To install, slide rotary tangs of TP sensor into position over throttle shaft blade with wires pointing down. Rotate TP sensor clockwise to installed position.
2. Failure to install TP sensor in this manner may result in excessive idle speeds. Align marks on throttle body and TP sensor. Secure TP sensor to throttle assembly with retaining screws. Reconnect wiring.

Removal (Crown Victoria, Grand Marquis & Town Car)

1. Remove air cleaner outlet tube. Raise vehicle on hoist. Hold EGR valve tube to manifold connector with a wrench while disconnecting EGR valve to exhaust manifold tube. Use care not to damage EGR valve tube to manifold connector. Disconnect EGR valve to exhaust manifold tube from EGR valve and EGR valve tube to manifold connector. Lower vehicle.
2. Disconnect EGR pressure sensor hoses from EGR valve to exhaust manifold tube. Disconnect vacuum hose from EGR valve. Remove two EGR valve retaining bolts. Remove EGR valve, EGR valve gasket and EGR valve to exhaust manifold tube from vehicle.

1. Clean intake manifold sealing surface with a plastic-tipped scraper to remove any residual EGR valve gasket material. Position EGR valve to exhaust manifold tube into EGR valve and loosely connect EGR valve to exhaust manifold tube nut to EGR valve. Do not tighten EGR valve to exhaust manifold tube nut on EGR valve at this time.
2. Position EGR valve gasket, EGR valve and EGR valve to exhaust manifold tube into vehicle. Install two bolts retaining EGR valve to intake manifold. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(/ford/taurus/ii-1991-1995/remont/removal-installation/#engine-controls-removeinstalloverhaul__torque-specifications) . Connect vacuum hose to EGR valve. Connect EGR pressure sensor hoses to EGR valve to exhaust manifold tube.
3. Raise vehicle. Connect EGR valve to exhaust manifold tube to EGR valve tube to manifold connector. Hold EGR valve tube to manifold connector with a wrench while tightening EGR valve to exhaust manifold tube nut. Tighten EGR valve to exhaust manifold tube nuts to specification. Lower vehicle. Install air cleaner outlet tube.

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

See also:
• TORQUE SPECIFICATIONS