2002 Ford Taurus major vacuum leak - Taurus Car Club of America : Ford Taurus Forum
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post #1 of 20 (permalink) Old 06-17-2019, 04:41 PM Thread Starter
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2002 Ford Taurus major vacuum leak

So i have a 2002 ford Taurus with OHV 3.0 Vulcan. I have been chasing what seems to be a vacuum leak according to obd2 (15 to 20 LTFT on both banks at idle). When starting engine at ambient temperature the idle is erratic up and down from 500 to 900 rpms. The obd is telling me the vacuum is as low as 9 to 15 at idle. Whenever I hit the throttle in the engine bay i get a woosh coming from the intake (yes woosh is a technical term lol) . Well....lol I have been writing this on and off for the last few hours so please excuse the brokeness of this post. I just got back inside from running a smoke test on the vac system anddddd it seems that i have a leak behind the upper intake where the EGR is connected to the plasticon the upper intake. I will post my results today or tommorrow once i do the repair so hopefully this will help some people if they run into this problem.
I just got done doing lower intake gaskets and oil pan gaskets so im pretty much ready to set this car on fire... O_o
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post #2 of 20 (permalink) Old 06-18-2019, 07:47 AM
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Use a small mirror to look at the EGR gasket to see if it slipped on installation. I thought I had mine right but I was wrong.
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post #3 of 20 (permalink) Old 06-18-2019, 05:29 PM Thread Starter
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So heres an update. I just installed the egr Oring seal. Turns out the replacement was a round o ring instead of the flat seal OEM style (correct me if im wrong please). Never the less it fit well. Thank you for mentioning checking on it to make sure it did not slip. I made sure to press the oring into the shaft before i tightened the two bolts down. Still having the same problem. Low vacuum on cold start. Still getting the wooshing sound when pressing the throttle. Im really starting to think my plastic upper intake has a hairline fracture that seals when it heats up maybe? It seems like i hear it from the bottom side of the upper intake. I tried spraying it with carb spray while "wooshing" it but i really cant get at it to spray it.
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post #4 of 20 (permalink) Old 06-18-2019, 06:27 PM Thread Starter
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Also just found a leak in the vacuum distribution box... this thing leaks more than the 91 f150... is there anything special about this box or can i re route everthing?
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post #5 of 20 (permalink) Old 06-18-2019, 08:53 PM Thread Starter
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So i took off the vacuum dist valve and used 2 part 3m polyurethane glue along the seals of what im guessing are check valves. Went for a test run and vacuum seems a little better but my LTFT for both banks are still around 15 percent at idle ( damn near 0 to 2 percent while cruising)
Ill have to wait until morning to try a true cold start and see if the erratic cold idle went away. Im still thinking hairline crack or something wrong with upper manifold (oh Ford WHY PLASTIC....lol). Let me know what you all think... even if you think im crazy 🙂
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post #6 of 20 (permalink) Old 06-18-2019, 08:56 PM Thread Starter
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Oh and kekaye56, i will be doing a smoke test tommorrow again so ill definitively know if i sealed that EGR tube correctly.
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post #7 of 20 (permalink) Old 06-18-2019, 11:50 PM
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Smoke test will show if its leaking.
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post #8 of 20 (permalink) Old 06-19-2019, 10:38 AM
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Check the intake just behind the throttle body and EGR. There were some reports of it melting there when there were EGR problems and/or clogged catalytic converters.

https://www.fordforums.com/f138/cata...nifold-171446/
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post #9 of 20 (permalink) Old 06-19-2019, 02:29 PM
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Thanks for the info Tollkeeper.
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post #10 of 20 (permalink) Old 06-19-2019, 02:53 PM Thread Starter
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Yes thank you for the info. I will be doing a smoke test in about an hour once the engine is cold. I will post results. 🙂
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