How to Replace an Intake Manifold Gasket in a 3.0 Ford Engine

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Ford Motor Company manufactures and distributes several models of 3.0-liter engines. The Vulcan 3.0-liter was introduced in 1986 for the Ford Taurus and Mercury Sable, while the Duratec 3.0-liter was released to consumers a decade later. Both engines have similar designs, with slight improvement over the years. The intake manifold gasket is located between the manifold and the engine block, and prevents leaks between the two surfaces.

Things You'll Need

  • Wrench set
  • Screwdriver set
  • Ratchet and socket set
  • Intake manifold gasket
  • Sealant
  • Torque wrench
  • Clean shop rag
  • Work gloves

Removal

  • Disconnect the cable to the negative terminal of the battery using a wrench.

  • Remove all hardware and wiring that connects to the intake manifold. Make notes of where each part attaches.

  • Disconnect the throttle position sensor and the EGR valve, located adjacent to the intake manifold. Place these parts and connecting hardware to the side.

  • Remove the fuel lines from their respective connections to the fuel injectors. Plug the fuel lines to minimize fuel spilling. Disconnect the intake manifold runner control cable from the manifold.

  • Label the spark plug wires and pull from the boot to remove from their corresponding spark plugs. The spark plug wires must later be connected to the same plugs in order for the cylinders to fire in the correct order.

  • Remove the bolts that hold the intake manifold to the engine block, and remove the manifold. Pry the intake manifold gasket from the block with a flat-head screwdriver.

  • Clean the top mating edge of the engine block thoroughly. The surface where the new intake manifold gasket will rest must be smooth and free of debris.

Installation

  • Apply sealant to the gasket surfaces and place it on the mating edge of the engine block. Position the new intake manifold so that it aligns exactly with the cylinder flanges of the engine block.

  • Bolt the intake manifold to the engine block. Tighten the bolts to 22 foot-pounds with a torque wrench.

  • Reconnect the spark plug wires with their corresponding spark plugs. Pull the boots over the spark plugs.

  • Replace all removed parts in their original positions. Reattach all of the fuel lines to the fuel rails and fuel injectors. Reconnect all electrical wiring to its respective part.

  • Connect the cable to the negative terminal of the battery. Start the engine and let it idle for about ten minutes. Check for leaks around the new intake manifold gasket.

Tips & Warnings

  • Wear work gloves to protect your hands.

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