How to replace Exhaust Manifold on 2000 to 2005 Ford Taurus?

The details to Replace Exhaust Manifold are as follows :---

Exhaust Manifold
REMOVAL & INSTALLATION details are as follows : ------

3.0L Engine
VIN S Engine

1. Before servicing the vehicle, refer to the precautions section.
2. Remove or disconnect the following:
   
   
   Negative battery cable
   

   Upper intake manifold
   

   Right exhaust manifold heat shield
   

   Ignition coil
   

   Exhaust Gas Recirculation (EGR) tube
   

   Heated Oxygen (HO ₂ S) sensors
   

   Secondary air injection tube
   

   Dual converter Y-pipe
   

   Exhaust manifolds
   

To install:

1. Install or connect the following:
   
   
   Exhaust manifolds. Use new gaskets and tighten the bolts in sequence to 13-16 ft. lbs. (18-22 Nm).
   
   

   

   

   Fig. Right side exhaust manifold mounting bolt tightening sequence-2001-04 3.0L (VIN S) engine

   
   
   

   

   

   Fig. Left side exhaust manifold mounting bolt tightening sequence-2001-04 3.0L (VIN S) engine

   Dual converter Y-pipe
   

   Secondary air injection tube
   

   HO ₂ S sensors
   

   EGR tube
   

   Ignition coil
   

   Right exhaust manifold heat shield
   

   Upper intake manifold
   

   Negative battery cable
   
2. Run the engine and check for exhaust leaks and proper operation.

1. Before servicing the vehicle, refer to the precautions at the beginning of this section.
2. Remove or disconnect the following:
   
   
   Negative battery cable
   

   Upper intake manifold
   

   Right exhaust manifold heat shield
   

   Ignition coil
   

   Exhaust Gas Recirculation (EGR) tube
   

   Heated Oxygen (HO ₂ S) sensors
   

   Secondary air injection tube
   

   Dual converter Y-pipe
   

   Exhaust manifolds
   

To install:

1. Install or connect the following:
   
   
   Exhaust manifolds. Use new gaskets and tighten the bolts in sequence to 13-16 ft. lbs. (18-22 Nm).

   
   Dual converter Y-pipe

   Secondary air injection tube

   HO ₂ S sensors

   EGR tube

   Ignition coil

   Right exhaust manifold heat shield

   Upper intake manifold

   Negative battery cable
2. Run the engine and check for exhaust leaks and proper operation.

Left Side

1. Before servicing the vehicle, refer to the precautions section.
2. Remove the coolant tube bracket bolt.
3. Disconnect and unclip the Heated Oxygen (HO ₂ S) sensor electrical connector from the coolant tube.
4. Remove the dual converter Y-pipe.
5. Remove the front splash shield.
6. Remove the coolant tube lower bracket bolt.
7. Remove the nuts and the exhaust manifold.
8. Discard the gasket.

To install:

1. Installation is the reverse of removal. Tighten the manifold bolts in the sequence illustrated to 15 ft. lbs. (20 Nm).
   
   
   

   

   Fig. Left exhaust manifold tightening sequence-2005 3.0L (VIN S) engine

Right Side

1. Before servicing the vehicle, refer to the precautions section.
2. Disconnect the negative battery cable.
3. Remove the wiper mounting arm and pivot shaft.
4. Remove the air cleaner outlet pipe.
5. Remove the three retaining screws and the right hand cowl top inner panel.
6. Remove the two retaining nuts and position the vacuum outlet manifold assembly aside.
7. Unseat the windshield wiper motor wiring harness grommet. Pull the wiring harness through the grommet.
8. Disconnect the cowl drain tube, remove the three retaining screws and the left hand cowl top inner panel.
9. Disconnect the differential pressure feedback Exhaust Gas Recirculation (EGR) sensor and the Heated Oxygen (HO ₂ S) sensor electrical connectors.
10. Remove the differential pressure feedback EGR sensor tube and bracket as follows:
    1. Detach the electrical connector pin-type retainer.
    2. Remove the bolts from the differential pressure feedback EGR bracket.
    3. Disconnect and remove the differential pressure feedback EGR and bracket from the vacuum tubes.
11. Remove the rear support brace.
12. Remove the steering gear heat shield.
13. Remove the EGR tube.
14. Remove the dual converter Y-pipe.
15. Remove the nuts in the sequence shown and remove the exhaust manifold.
16. Discard the gasket.
    
    
    

    

    Fig. Right exhaust manifold loosening sequence-2005 3.0L (VIN S) engine

To install:

1. Position a new gasket and install the exhaust manifold nuts in the sequence shown. Tighten to 15 ft. lbs. (20 Nm).
   
   
   

   

   Fig. Right exhaust manifold tightening sequence-2005 3.0L (VIN S) engine
2. Install the dual converter Y-pipe.
3. Install the EGR tube.
4. Install the steering gear heat shield.
5. Install the rear support brace. Position the rear support brace and tighten the retainers to 35 ft. lbs. (47 Nm).
6. Install the differential pressure feedback EGR valve sensor and bracket.
7. Attach the HO ₂ S electrical connector.
8. Connect the differential pressure feedback EGR sensor and the HO ₂ S electrical connectors
9. Connect the negative battery cable.

VIN U & 2 Engines
Left Side

1. Before servicing the vehicle, refer to the precautions section.
2. Remove or disconnect the following:
   
   
   Negative battery cable
   

   Heated Oxygen (HO ₂ S) sensor connector
   

   Oil dipstick tube
   

   Power steering pressure line
   

   Secondary air injection tube, if equipped
   

   Dual converter Y-pipe
   

   Exhaust manifold
   
   

   

   

   Fig. Left side Heated Oxygen (HO2S) sensor connector-3.0L (VIN U, 2) Engines

To install:

Fig. Left exhaust manifold torque sequence-3.0L (VIN U, 2) Engines

1. Install the exhaust manifold with a new gasket. Tighten the bolts in sequence as follows:
   1. Step 1: 89 inch lbs. (10 Nm)
   2. Step 2: 16 ft. lbs. (22 Nm)
2. Install or connect the following:
   
   
   Dual converter Y-pipe and tighten the bolts to 30 ft. lbs. (40 Nm)
   

   Secondary air injection tube, if equipped
   

   Power steering pressure line
   

   Oil dipstick tube
   

   HO ₂ S sensor connector
   

   Negative battery cable
   
3. Start the engine and check for leaks.

Right Side

1. Before servicing the vehicle, refer to the precautions section.
2. Remove or disconnect the following:
   
   
   Negative battery cable
   

   Cowl vent screen and extension
   

   Heated Oxygen (HO ₂ S) sensor connector
   

   Exhaust Gas Recirculation (EGR) tube
   

   Exhaust manifold heat shield
   

   Catalytic converter
   

   Exhaust manifold
   
   

   

   

   Fig. Right side Heated Oxygen (HO2S) sensor connector-3.0L (VIN U, 2) Engines

To install:

Fig. Right exhaust manifold torque sequence-3.0L (VIN U, 2) Engines

1. Install the exhaust manifold with a new gasket. Tighten the bolts in sequence as follows:
   1. Step 1: 89 inch lbs. (10 Nm)
   2. Step 2: 16 ft. lbs. (22 Nm)
2. Install or connect the following:
   
   
   Catalytic converter and tighten the bolts to 30 ft. lbs. (40 Nm)
   

   Exhaust manifold heat shield and tighten the bolts to 89 inch lbs. (10 Nm)
   

   EGR tube
   

   HO ₂ S sensor connector
   

   Cowl vent screen and extension
   

   Negative battery cable
   
3. Start the engine and check for leaks.

VIN U Engine
Left Side

1. Before servicing the vehicle, refer to the precautions section.
2. Remove or disconnect the following:
   
   
   Negative battery cable
   

   Heated Oxygen (HO ₂ S) sensor connector
   

   Oil dipstick tube
   

   Power steering pressure line
   

   Secondary air injection tube, if equipped
   

   Dual converter Y-pipe
   

   Exhaust manifold
   
   

   

   

   Fig. Left side Heated Oxygen (HO2S) sensor connector-3.0L (VIN U) engine

To install:

Fig. Left exhaust manifold torque sequence-3.0L (VIN U) engine

1. Install the exhaust manifold with a new gasket. Tighten the bolts in sequence as follows:
   1. Step 1: 89 inch lbs. (10 Nm)
   2. Step 2: 16 ft. lbs. (22 Nm)
2. Install or connect the following:
   
   
   Dual converter Y-pipe and tighten the bolts to 30 ft. lbs. (40 Nm)
   

   Secondary air injection tube, if equipped
   

   Power steering pressure line
   

   Oil dipstick tube
   

   HO ₂ S sensor connector
   

   Negative battery cable
   
3. Start the engine and check for leaks.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
2. Remove or disconnect the following:
   
   
   Negative battery cable
   

   Heated Oxygen (HO ₂ S) sensor connector
   

   Oil dipstick tube
   

   Power steering pressure line
   

   Secondary air injection tube, if equipped
   

   Dual converter Y-pipe
   

   Exhaust manifold
   
   

   

   

   Fig. Left side Heated Oxygen (HO2S) sensor connector-3.0L (VIN U) engine

To install:

Fig. Left exhaust manifold torque sequence-3.0L (VIN U) engine

1. Install the exhaust manifold with a new gasket. Tighten the bolts in sequence as follows:
   1. Step 1: 89 inch lbs. (10 Nm)
   2. Step 2: 16 ft. lbs. (22 Nm)
2. Install or connect the following:
   
   
   Dual converter Y-pipe and tighten the bolts to 30 ft. lbs. (40 Nm)
   

   Secondary air injection tube, if equipped
   

   Power steering pressure line
   

   Oil dipstick tube
   

   HO ₂ S sensor connector
   

   Negative battery cable
   
3. Start the engine and check for leaks.

Right Side

1. Before servicing the vehicle, refer to the precautions section.
2. Remove or disconnect the following:
   
   
   Negative battery cable
   

   Cowl vent screen and extension
   

   Heated Oxygen (HO ₂ S) sensor connector
   

   Exhaust Gas Recirculation (EGR) tube
   

   Exhaust manifold heat shield
   

   Catalytic converter
   

   Exhaust manifold
   
   

   

   

   Fig. Right side Heated Oxygen (HO2S) sensor connector-3.0L (VIN U) engine

To install:

Fig. Right exhaust manifold torque sequence-3.0L (VIN U) engine

1. Install the exhaust manifold with a new gasket. Tighten the bolts in sequence as follows:
   1. Step 1: 89 inch lbs. (10 Nm)
   2. Step 2: 16 ft. lbs. (22 Nm)
2. Install or connect the following:
   
   
   Catalytic converter and tighten the bolts to 30 ft. lbs. (40 Nm)
   

   Exhaust manifold heat shield and tighten the bolts to 89 inch lbs. (10 Nm)
   

   EGR tube
   

   HO ₂ S sensor connector
   

   Cowl vent screen and extension
   

   Negative battery cable
   
3. Start the engine and check for leaks.

1. Before servicing the vehicle, refer to the precautions at the beginning of this section.
2. Remove or disconnect the following:
   
   
   Negative battery cable
   

   Cowl vent screen and extension
   

   Heated Oxygen (HO ₂ S) sensor connector
   

   Exhaust Gas Recirculation (EGR) tube
   

   Exhaust manifold heat shield
   

   Catalytic converter
   

   Exhaust manifold
   
   

   

   

   Fig. Right side Heated Oxygen (HO2S) sensor connector-3.0L (VIN U) engine

To install:

Fig. Right exhaust manifold torque sequence-3.0L (VIN U) engine

1. Install the exhaust manifold with a new gasket. Tighten the bolts in sequence as follows:
   1. Step 1: 89 inch lbs. (10 Nm)
   2. Step 2: 16 ft. lbs. (22 Nm)
2. Install or connect the following:
   
   
   Catalytic converter and tighten the bolts to 30 ft. lbs. (40 Nm)
   

   Exhaust manifold heat shield and tighten the bolts to 89 inch lbs. (10 Nm)
   

   EGR tube
   

   HO ₂ S sensor connector
   

   Cowl vent screen and extension
   

   Negative battery cable
   
3. Start the engine and check for leaks.

3.4L (VIN N) Engine

Fig. Left exhaust manifold and related components-3.4L (VIN N) engine

Fig. Right exhaust manifold and related components-3.4L (VIN N) engine

1. Before servicing the vehicle, refer to the precautions at the beginning of this section.
2. Remove or disconnect the following:
   
   
   Negative battery cable
   

   Secondary air injection tube
   

   Oil dipstick tube
   

   Dual converter Y-pipe
   

   Exhaust Gas Recirculation (EGR) tube
   

   Exhaust manifold heat shields
   

   Exhaust manifolds
   

To install:

1. Install the exhaust manifolds. Use new gaskets and tighten the nuts to 30-44 ft. lbs. (40-60 Nm).
2. Install or connect the following:
   
   
   Exhaust manifold heat shields
   

   EGR tube
   

   Dual converter Y-pipe
   

   Oil dipstick tube
   

   Secondary air injection tube
   

   Negative battery cable
   
3. Run the engine and check for exhaust leaks and proper operation.

This details will help.

Thanks.

The instructions are similar for 2000 to 2005 Ford Taurus.

                     

FOR MORE HELP GO TO: ---

Car repair guide?

http://technoanswers.blogspot.in/2012/03/car-repair-guide.html