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Home >> Lincoln >> 2002 >> Town Car Base >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> Engine >> In-Vehicle Repair >> Intake Manifold >> Installation

Intake Manifold: Installation

    NOTE: Align the gasket locator tabs with the slots in the cylinder head.
    Fig 1: Installing Intake Manifold Gaskets
    G02211648Courtesy of FORD MOTOR CO.
  1. Install the new intake manifold gaskets.
  2. Install the intake manifold and hand-tighten the bolts at the locations shown.
    Fig 2: Installing Intake Manifold Bolts
    G02211649Courtesy of FORD MOTOR CO.
  3. Install the ignition coils and tighten the bolts.
    Fig 3: Installing Ignition Coils Bolts
    G02211650Courtesy of FORD MOTOR CO.
  4. Install the fuel injection supply manifold and tighten the studs.
    Fig 4: Installing Fuel Injection Supply Manifold Bolts
    G02211651Courtesy of FORD MOTOR CO.
  5. Install the crash bracket and loosely install the bolt and the stud.
    Fig 5: Installing Crash Bracket
    G02211652Courtesy of FORD MOTOR CO.
  6. Install the water thermostat.
    Fig 6: Installing Water Thermostat
    G02211653Courtesy of FORD MOTOR CO.
  7. Install the water outlet adapter and loosely install the bolts.
    Fig 7: Installing Water Outlet Adapter
    G02211654Courtesy of FORD MOTOR CO.
  8. Tighten the bolts in the sequence shown.
    Fig 8: Identifying Intake Manifold Bolts Tightening Sequence
    G02211655Courtesy of FORD MOTOR CO.
  9. Tighten the stud.
    Fig 9: Tightening Crash Bracket Stud
    G02211656Courtesy of FORD MOTOR CO.
  10. Tighten the bolts.
    Fig 10: Tightening Water Outlet Adapter Bolts
    G02211657Courtesy of FORD MOTOR CO.
  11. Install the throttle body and tighten the bolts.
    Fig 11: Installing Throttle Body
    G02211658Courtesy of FORD MOTOR CO.
  12. Install the wiring bracket.
    • Position the bracket.
    • Install the nut and the bolt.
    • Attach the wiring connectors to the wiring bracket.
    • Connect the LH heated oxygen sensor electrical connector.
    • Reattach the fuel charging wiring harness position retainer to the crash bracket.
    Fig 12: Installing Wiring Bracket
    G02211659Courtesy of FORD MOTOR CO.
  13. Connect the EGR tube to the EGR valve.
    Fig 13: Connecting EGR Tube To EGR Valve
    G02211660Courtesy of FORD MOTOR CO.
  14. Position the EGR tube heat shield and install the bolts.
    Fig 14: Installing EGR Tube Heat Shield
    G02211661Courtesy of FORD MOTOR CO.
  15. Connect the heater water hose and position the clamp.
    Fig 15: Connecting Heater Water Hose
    G02211662Courtesy of FORD MOTOR CO.
  16. Connect the electrical connector to the IAC control valve and the TP sensor.
    Fig 16: Connecting IAC Control Valve And TP Sensor Electrical Connector
    G02211663Courtesy of FORD MOTOR CO.
  17. Attach the cables to the crash bracket.
    Fig 17: Attaching Cables To Crash Bracket
    G02211664Courtesy of FORD MOTOR CO.
  18. Install the upper radiator hose.
    • Install the upper radiator hose.
    • Position the clamps.
    Fig 18: Installing Upper Radiator Hose
    G02211665Courtesy of FORD MOTOR CO.
  19. Install the generator mounting bracket.
    • Position the generator mounting bracket.
    • Install the bolts.
    Fig 19: Installing Generator Mounting Bracket
    G02211666Courtesy of FORD MOTOR CO.
  20. Connect the generator electrical connector, the battery lead and the harness pin-type retainer.
    Fig 20: Connecting Generator Electrical Connector, Battery Lead And Harness Pin-Type Retainer
    G02211667Courtesy of FORD MOTOR CO.
  21. Position the vacuum harness and connect the vacuum hose to the EVAP canister purge valve.
    Fig 21: Connecting Vacuum Hose To EVAP Canister Purge Valve
    G02211668Courtesy of FORD MOTOR CO.
  22. Connect the electrical connector and the vacuum hoses to the EGR vacuum regulator solenoid.
    Fig 22: Connecting Electrical Connector And Vacuum Hoses To EGR Vacuum Regulator Solenoid
    G02211669Courtesy of FORD MOTOR CO.
  23. Install and connect the PCV tube.
    Fig 23: Installing PCV Tube
    G02211670Courtesy of FORD MOTOR CO.
  24. Connect the vacuum hoses for the EVAP canister purge valve, the main chassis vacuum supply hose and the EGR valve.
    Fig 24: Connecting EVAP Canister Purge Valve, Main Chassis Vacuum Supply Hose And EGR Valve Vacuum Hoses
    G02211671Courtesy of FORD MOTOR CO.
  25. Position and attach the cables to the EGR tube heat shield.
    Fig 25: Attaching Cables To EGR Tube Heat Shield
    G02211672Courtesy of FORD MOTOR CO.
  26. Connect the accelerator cable, the speed control actuator cable and the throttle return spring.
    Fig 26: Connecting Accelerator Cable, Speed Control Actuator Cable And Throttle Return Spring
    G02211673Courtesy of FORD MOTOR CO.
  27. Connect the fuel charging wiring electrical connectors to the eight fuel injectors.
    Fig 27: Connecting Fuel Charging Wiring Electrical Connectors To Fuel Injectors
    G02211674Courtesy of FORD MOTOR CO.
  28. Connect the fuel charging wiring electrical connectors to the eight ignition coils.
    Fig 28: Connecting Fuel Charging Wiring Electrical Connectors To Ignition Coils
    G02211675Courtesy of FORD MOTOR CO.
  29. Connect the differential pressure feedback EGR system electrical connector.
    Fig 29: Connecting Differential Pressure Feedback EGR System Electrical Connector
    G02211676Courtesy of FORD MOTOR CO.
  30. Raise the vehicle.
  31. Connect the EGR tube to the exhaust manifold connector.
    Fig 30: Connecting EGR Tube To Exhaust Manifold Connector
    G02211677Courtesy of FORD MOTOR CO.
  32. Connect the electrical connector to the oil pressure sensor and the PSP switch and attach the harness position retainer.
    Fig 31: Connecting Oil Pressure Sensor And PSP Switch Electrical Connector
    G02211678Courtesy of FORD MOTOR CO.
  33. Reinstall the RH catalytic converter assembly.
  34. Install the oil bypass filter.
    Fig 32: Installing Oil Bypass Filter
    G02211679Courtesy of FORD MOTOR CO.
  35. Connect the electrical connector to the A/C compressor.
    Fig 33: Connecting Electrical Connector To A/C Compressor
    G02211680Courtesy of FORD MOTOR CO.
  36. Connect the electrical connector to the CKP sensor.
    • Connect the pin-type retainer to the A/C compressor bracket.
    Fig 34: Connecting Electrical Connector To CKP Sensor
    G02211681Courtesy of FORD MOTOR CO.
  37. Lower the vehicle.
  38. Install the drive belt. For additional information, refer to SPECIFICATIONS & DRIVE BELT ROUTING .
  39. Install the wiper mounting arm and pivot shaft. For additional information, refer to WIPERS AND WASHERS .
  40. Connect the fuel line.
  41. Install the air cleaner resonator and outlet tube.
  42. Connect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  43. Check the engine oil.
  44. Fill the engine cooling system. For additional information, refer to ENGINE COOLING .
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