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Ford And Mercury Intake Manifold Replacing procedure?

The procedure is same for Ford and mercury.Taurus and Sable car models.

The detail covers year 2008 and 2009.

Intake Manifold
REMOVAL & INSTALLATION

instructions are as follows :----

Lower Manifold
Specific to:
Ford Taurus 2008-2009
Mercury Sable 2008-2009

NOTE
During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces that enters the oil passages, coolant passages or the oil pan, may cause engine failure.

  1. Drain the cooling system.
  2. Remove the fuel rail.
  3. Remove the 3 thermostat housing-to-lower intake manifold bolts.
  4. Remove the 10 bolts and the lower intake manifold.
  5. Remove and discard the intake manifold and thermostat housing gaskets.
  6. Clean and inspect all sealing surfaces.
To install:

NOTE
If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions can result in engine damage.

  1. Using new intake manifold and thermostat housing gaskets, install the lower intake manifold and the 10 bolts. Tighten in the sequence shown to 89 inch lbs. (10 Nm).

    Click image to see an enlarged view
    Fig. Lower intake manifold tightening sequence
  2. Install the 3 thermostat housing-to-lower intake manifold bolts. Tighten to 89 inch lbs. (10 Nm).
  3. Install the fuel rail.
  4. Fill and bleed the cooling system.
Upper Manifold
Specific to:
Ford Taurus 2008-2009
Mercury Sable 2008-2009
  1. Remove the air cleaner outlet pipe.
  2. Disconnect the throttle body (TB) electrical connector.
  3. Disconnect the evaporative emissions (EVAP) tube from the intake manifold.
  4. Detach the EVAP tube pin-type retainer from the upper intake manifold.
  5. Disconnect the brake booster vacuum hose from the intake manifold.
  6. Disconnect the PCV tube from the PCV valve.
  7. On early build engines, disconnect the heated PCV electrical connector.
  8. Remove the upper intake manifold long support bracket bolt.
  9. On all engines, detach the wiring harness retainers from the upper intake manifold.
  10. Remove the upper intake manifold short support bracket bolt.
  11. Remove the fuel tube bracket bolt.
  12. Remove the 6 bolts and the upper intake manifold.
  13. Remove and discard the gaskets.
  14. Clean and inspect all of the sealing surfaces of the upper and lower intake manifold.
To install:

NOTE
If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions can result in engine damage.

  1. Using new gaskets, install the upper intake manifold and the 6 bolts. Tighten in the sequence shown to 89 inch lbs. (10 Nm).

    Click image to see an enlarged view
    Fig. Upper intake manifold tightening sequence
  2. Install the fuel tube bracket bolt. Tighten to 53 inch lbs. (6 Nm).
  3. Install the upper intake manifold short support bracket bolt. Tighten to 89 inch lbs. (10 Nm).
  4. Attach the wiring harness retainers to the upper intake manifold.
  5. On early build engines, install the upper intake manifold long support bracket bolt. Tighten to 89 inch lbs. (10 Nm).
  6. Connect the heated PCV electrical connector.
  7. On all engines, connect the PCV tube to the PCV valve.
  8. Connect the brake booster vacuum hose to the intake manifold.
  9. Connect the EVAP tube to the intake manifold.
  10. Attach the EVAP tube pin-type retainer to the upper intake manifold.
  11. Connect the TB electrical connector.
  12. Install the air cleaner outlet pipe.

This details will help.
Thanks.




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