How to remove Exhaust Manifold on ford Taurus?

REMOVAL & INSTALLATION

3.0L OHV Engine
Left Side

See Figures 1 through 8

1. Disconnect the negative battery cable.
2. Unfasten the oil level indicator tube support bracket retaining nut. Remove the oil level indicator tube and move engine control sensor wiring aside.
3. Raise and safely support the vehicle using jackstands.
4. Remove the exhaust manifold-to-exhaust pipe retaining nuts.
5. Lower the vehicle.

Mark the location of the manifold stud bolts prior to removal.

6. Unfasten the exhaust manifold retaining bolts and exhaust manifold stud bolts. Remove the exhaust manifold and gasket from the vehicle.

To install:

7. Clean all mating surfaces and lightly oil all bolt and stud threads prior to installation.
8. Place the exhaust manifold into position on the cylinder head using a new gasket. Tighten the four exhaust manifold retaining bolts and two stud bolts to 15-18 ft. lbs. (20-25 Nm).
9. Install the exhaust pipe to the exhaust manifold and tighten the exhaust pipe attaching nuts to 25-34 ft. lbs. (34-47 Nm).
10. Install the oil level indicator tube. Tighten the bracket nut to 12-15 ft. lbs. (16-20 Nm). Reposition the engine control sensor wiring.
11. Connect negative battery cable.
12. Run the engine and check for exhaust leaks and proper operation.

Fig. Fig. 1: Exploded view of the left hand exhaust manifold mounting-3.0L OHV gasoline engines

Fig. Fig. 2: Exploded view of the left hand exhaust manifold mounting-3.0L OHV flexible fuel engines (California only)

Fig. Fig. 3: Remove oil level indicator tube

Fig. Fig. 4: From underneath the vehicle, remove the two exhaust manifold-to-exhaust pipe retaining nuts

Fig. Fig. 5: While underneath the vehicle, remove the two lower exhaust manifold retaining bolts

Fig. Fig. 6: Remove the upper retaining bolts and remove the exhaust manifold from the vehicle

Fig. Fig. 7: The exhaust manifold-removed from the vehicle

Fig. Fig. 8: Thoroughly clean the manifold and cylinder head mating surfaces

Right Side

See Figure 9

1. Disconnect the negative battery cable.
2. Remove the EGR backpressure transducer hoses from the EGR valve-to-exhaust manifold tube.
3. Remove the EGR valve-to-exhaust manifold from the exhaust manifold. Use a back-up wrench on the EGR valve tube-to-manifold connector.
4. Unfasten the three retaining bolts from the exhaust manifold heat shield and remove the shield.
5. Raise and safely support the vehicle with jackstands.
6. Unfasten the exhaust manifold-to-exhaust pipe retaining nuts and separate the exhaust pipe from the exhaust manifold.
7. Lower the vehicle.
8. Unfasten the exhaust manifold retaining bolts and remove the exhaust manifold and gasket from the vehicle.

To install:

Fig. Fig. 9: Right hand exhaust manifold mounting-gasoline engines and flexible fuel engines-3.0L DOHC engines

9. Clean all mating surfaces and lightly oil all bolt threads prior to installation.
10. Install a new gasket.
11. Place the exhaust manifold into position on the cylinder head. Tighten the six exhaust manifold retaining bolts to 15-18 ft. lbs. (20-25 Nm).
12. Raise and safely support the vehicle with jackstands.
13. Position the exhaust pipe and install the retaining nuts. Tighten the retaining nuts to 25-34 ft. lbs. (34-47 Nm).
14. Install the exhaust manifold heat shield and install the retaining bolts. Tighten the retaining bolts to 71-106 inch lbs. (8-12 Nm).
15. Lower the vehicle.
16. Install the EGR tube to the exhaust manifold. Tighten the tube nut to 26-47 ft. lbs. (35-65 Nm). Connect the EGR valve hoses.
17. Connect the negative battery cable.
18. Run the engine and check for exhaust leaks and proper operation.

3.0L DOHC Engine
right side

See Figure 10

1. Disconnect the negative battery cable.
2. Remove the upper intake manifold assembly.
3. Remove the ignition coil assembly.
4. Loosen the EGR valve-to-exhaust manifold tube nuts and remove the tube from the right hand manifold.
5. Raise and safely support the vehicle with jackstands.
6. Remove the dual converter Y-pipe.
7. Remove the lower exhaust manifold retaining nuts from the cylinder head studs and lower the vehicle.
8. Remove the upper exhaust manifold retaining nuts from the cylinder head studs.
9. Remove the exhaust manifold and gasket from the engine.
10. Clean all gasket mating surfaces.

To install:

11. Install the exhaust manifold with a new exhaust manifold gasket.
12. Install the exhaust manifold retaining studs and tighten to 13-16 ft. lbs. (18-22 Nm) in the sequence illustrated.

Fig. Fig. 10: Right side exhaust manifold mounting bolt tightening sequence-3.0L DOHC engine

13. Raise and safely support the vehicle.
14. Position the Y-pipe assembly using a new flange gasket and install all the retaining nuts and bolts loosely.
15. Starting at the front of the system tighten the Y-pipe to exhaust manifold nuts to 26-34 ft. lbs. (34-46 Nm).

Tighten the converter to transaxle nut and bolt to 30 ft. lbs. (40.3 Nm). Tighten the converter outlet bolts to 26-34 ft. lbs. (34-46 Nm).

16. Lower the vehicle.
17. Install the oxygen sensor and tighten to 26-34 ft. lbs. (35-46 Nm). Attach the electrical connector.
18. Install the EGR valve to exhaust manifold tube and tighten the nuts to 26-33 ft. lbs. (35-45 Nm).
19. Install the ignition coil assembly.
20. Install the upper intake manifold assembly.
21. Connect the negative battery cable.
22. Run the engine and check for exhaust leaks and proper operation.

left side

See Figure 11

1. Disconnect the negative battery cable.
2. Raise and safely support the vehicle with jackstands.
3. Remove the dual converter Y-pipe.
4. Remove the exhaust manifold retaining nuts from the cylinder head studs.
5. Remove the exhaust manifold and gasket from the engine.
6. Clean all gasket mating surfaces.

To install:

7. Install the exhaust manifold with a new exhaust manifold gasket.
8. Install the exhaust manifold retaining studs and tighten to 13-16 ft. lbs. (18-22 Nm) in the sequence illustrated.

Fig. Fig. 11: Left side exhaust manifold mounting bolt tightening sequence-3.0L DOHC engine

9. Position the Y-pipe assembly using a new flange gasket and install all the retaining nuts and bolts loosely.
10. Starting at the front of the system tighten the Y-pipe to exhaust manifold nuts to 26-34 ft. lbs. (34-46 Nm).

Tighten the converter to transaxle nut and bolt to 30 ft. lbs. (40.3 Nm). Tighten the converter outlet bolts to 26-34 ft. lbs. (34-46 Nm).

11. Lower the vehicle.
12. Install the oxygen sensor and tighten to 26-34 ft. lbs. (35-46 Nm). Attach the electrical connector.
13. Connect the negative battery cable.
14. Run the engine and check for exhaust leaks and proper operation.

3.4L DOHC Engine
Left Side

1. Disconnect the negative battery cable.
2. Raise and safely support the vehicle with jackstands.
3. Remove the dual converter Y-pipe.
4. Remove the lower exhaust manifold retaining nuts.
5. Lower the vehicle.
6. Remove the secondary air injection manifold tube from the exhaust manifold.
7. Remove the bolts and exhaust manifold shield from the exhaust manifold.
8. Remove the oil level indicator tube retaining bolt.
9. Remove the upper exhaust manifold retaining nuts.
10. Remove the left side exhaust manifold and gasket.

To install:

11. Clean the gasket mating surfaces.
12. Position the exhaust manifold to the engine, using a new gasket.
13. Install the upper exhaust manifold retaining nuts and tighten to 30-44 ft. lbs. (40-60 Nm).
14. Install the oil level indicator tube retaining bolt.
15. Install the bolts and exhaust manifold shield to the exhaust manifold and tighten to 12-16 ft. lbs. (16-23 Nm).
16. Install the secondary air injection manifold tube to the exhaust manifold and tighten the nut to 29-33 ft. lbs. (40-45 Nm).
17. Raise and safely support the vehicle.
18. Install the lower exhaust manifold retaining nuts and tighten to 30-44 ft. lbs. (40-60 Nm).
19. Install the dual converter Y-pipe.
20. Lower the vehicle.
21. Connect the negative battery cable.

Right Side

1. Disconnect the negative battery cable.
2. Remove the secondary air injection manifold tube from the exhaust manifold.
3. Remove the three bolts from the exhaust manifold shield.
4. Raise and safely support the vehicle with jackstands.
5. Remove the EGR valve-to-exhaust manifold tube from the exhaust manifold.
6. Disconnect the EGR valve to exhaust manifold tube from the EGR transducer.
7. Remove the dual converter Y-pipe.
8. Remove the two lower exhaust manifold retaining nuts.
9. Lower the vehicle.
10. Remove the exhaust manifold shield.
11. Remove the four upper exhaust manifold retaining nuts.
12. Raise and safely support the vehicle with jackstands.
13. Remove the right side exhaust manifold and gasket.

To install:

14. Clean the exhaust manifold gasket mating surfaces./
15. Position the exhaust manifold to the engine, using a new gasket.
16. Install the four upper exhaust manifold retaining nuts and tighten to 30-44 ft. lbs. (40-60 Nm).
17. Raise and safely support the vehicle with jackstands.
18. Install the two lower exhaust manifold retaining nuts and tighten to 30-44 ft. lbs. (40-60 Nm).
19. Install the dual converter Y-pipe.
20. Connect the EGR valve to exhaust manifold tube to the EGR transducer.
21. Install the EGR valve to exhaust manifold tube to the exhaust manifold.
22. Lower the vehicle.
23. Install the three bolts that attach the exhaust manifold shield to the exhaust manifold and tighten to 12-16 ft. lbs. (16-23 Nm).
24. Install the secondary air injection manifold tube to the exhaust manifold.
25. Connect the negative battery cable.

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