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Home >> Lincoln >> 2004 >> Town Car Protection Series >> 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
    G03247877Courtesy of FORD MOTOR CO.
  1. Install new intake manifold gaskets.
  2. Install the intake manifold and hand-tighten the bolts at the locations shown.
    Fig 2: Installing Intake Manifold
    G03247878Courtesy of FORD MOTOR CO.
  3. Install the ignition coils and tighten the bolts.
    Fig 3: Installing Ignition Coils
    G03247879Courtesy of FORD MOTOR CO.
  4. Install the crash bracket and loosely install the bolt and the stud.
    Fig 4: Installing Crash Bracket
    G03247880Courtesy of FORD MOTOR CO.
  5. Tighten the bolts in the sequence shown.
    Fig 5: Identifying Intake Manifold Bolts Tightening Sequence
    G03247881Courtesy of FORD MOTOR CO.
  6. Tighten the stud.
    Fig 6: Tightening Stud
    G03247882Courtesy of FORD MOTOR CO.
  7. Connect the EGR system module tube to the EGR system module.
    Fig 7: Connecting EGR System Module Tube To EGR System Module
    G03247883Courtesy of FORD MOTOR CO.
  8. Install the EGR tube and nut at the exhaust manifold.
    Fig 8: Installing EGR Tube At Exhaust Manifold
    G03247884Courtesy of FORD MOTOR CO.
  9. Position the EGR tube heat shield and install the bolts.
    Fig 9: Installing Bolts
    G03247885Courtesy of FORD MOTOR CO.
  10. Connect the IAC control valve and the TP sensor electrical connectors.
    Fig 10: Connecting IAC Control Valve And TP Sensor Electrical Connectors
    G03247886Courtesy of FORD MOTOR CO.
  11. Attach the cables to the crash bracket.
    Fig 11: Attaching Cables To Crash Bracket
    G03247887Courtesy of FORD MOTOR CO.
  12. Install the thermostat and a new O-ring.
    Fig 12: Installing Thermostat And O-Ring
    G03247888Courtesy of FORD MOTOR CO.
  13. Install the thermostat housing and the bolts.
    Fig 13: Installing Thermostat Housing
    G03247889Courtesy of FORD MOTOR CO.
    14. NOTE: Do not reuse hose clamps. Use appropriately sized worm-style clamps in place of the constant tension clamps.
    Fig 14: Connecting Upper Radiator Hose
    G03247890Courtesy of FORD MOTOR CO.
  14. Connect the upper radiator hose.
  15. Connect the heater hose.
    Fig 15: Connecting Heater Hose
    G03247891Courtesy of FORD MOTOR CO.
  16. Install the generator mounting bracket and the bolts.
    Fig 16: Installing Generator Mounting Bracket And Bolts
    G03247892Courtesy of FORD MOTOR CO.
  17. Connect the electrical connector and the harness location retainer.
    Fig 17: Connecting Electrical Connector And Harness Location Retainer
    G03247893Courtesy of FORD MOTOR CO.
  18. Position the vacuum harness and connect the vacuum hose to the EVAP canister purge valve.
    Fig 18: Connecting Vacuum Hose To EVAP Canister Purge Valve
    G03247894Courtesy of FORD MOTOR CO.
  19. Connect the electrical connector and the vacuum hoses.
    Fig 19: Connecting Electrical Connector And Vacuum Hoses
    G03247895Courtesy of FORD MOTOR CO.
  20. Connect the fuel pressure sensor electrical connector and the vacuum hoses.
    Fig 20: Connecting Fuel Pressure Sensor Electrical Connector And Vacuum Hoses
    G03247896Courtesy of FORD MOTOR CO.
  21. Position and attach the cables to the EGR system module tube heat shield.
    Fig 21: Attaching Cables To EGR System Module Tube Heat Shield
    G03247897Courtesy of FORD MOTOR CO.
  22. Connect the accelerator cable, the speed control actuator cable, the throttle return spring and the cable retaining bolts.
    Fig 22: Connecting Accelerator Cable, Speed Control Actuator Cable, Throttle Return Spring
    G03247898Courtesy of FORD MOTOR CO.
  23. Connect the fuel charging wiring electrical connectors to the eight fuel injectors.
    Fig 23: Connecting Fuel Injectors Electrical Connectors
    G03247899Courtesy of FORD MOTOR CO.
  24. Connect the fuel charging wiring electrical connectors to the eight ignition coils.
    Fig 24: Connecting Ignition Coils Electrical Connectors
    G03247900Courtesy of FORD MOTOR CO.
  25. Install the fuel charging wiring pin-type retainer to the rear of the manifold.
    Fig 25: Installing Fuel Charging Wiring Pin-Type Retainer To Rear Of Manifold
    G03247901Courtesy of FORD MOTOR CO.
  26. Install the generator harness position retainer to the LH front stud.
    Fig 26: Installing Generator Harness Position Retainer To LH Front Stud
    G03247902Courtesy of FORD MOTOR CO.
  27. Attach the fuel charging wiring pin-type retainer to the crash bracket.
    Fig 27: Attaching Fuel Charging Wiring Pin-Type Retainer To Crash Bracket
    G03247903Courtesy of FORD MOTOR CO.
  28. Connect the ground wire connector to the RH rear stud.
    Fig 28: Connecting Ground Wire Connector To RH Rear Stud
    G03247904Courtesy of FORD MOTOR CO.
  29. Connect the coolant temperature sensor electrical connector.
    Fig 29: Connecting Coolant Temperature Sensor Electrical Connector
    G03247905Courtesy of FORD MOTOR CO.
  30. Install the LH cowl extension.
    1. Install the extension.
    2. Install the bolts.
    3. Connect the electrical connectors.
    Fig 30: Installing LH Cowl Extension
    G03247906Courtesy of FORD MOTOR CO.
  31. Install the RH cowl extension.
    1. Install the extension.
    2. Install the pin-type retainers.
    3. Install the nuts and the bolts.
    Fig 31: Installing RH Cowl Extension
    G03247907Courtesy of FORD MOTOR CO.
  32. Install the wiper mounting arm and pivot shaft. For additional information, refer to WIPERS AND WASHERS .
  33. Connect the fuel spring lock coupling. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION .
  34. Install the air cleaner outlet pipe - resonator assembly. For additional information, refer to INTAKE AIR DISTRIBUTION & FILTERING .
  35. Connect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  36. Check the engine oil.
  37. Fill and bleed the engine cooling system. For additional information, refer to ENGINE COOLING .
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