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

Intake Manifold: Removal

  1. Disconnect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  2. Drain the engine cooling system. For additional information, refer to ENGINE COOLING .
  3. Remove the air cleaner resonator and outlet tube.
  4. Disconnect the fuel line.
  5. Remove the wiper mounting arm and pivot shaft. For additional information, refer to WIPERS AND WASHERS .
  6. Remove the drive belt.
  7. Raise the vehicle on a hoist.
  8. Disconnect the electrical connector at the crankshaft position (CKP) sensor.
    • Disconnect the pin-type retainer from the A/C compressor bracket.
    Fig 1: Disconnecting Crankshaft Position Sensor Electrical Connector
    G02211610Courtesy of FORD MOTOR CO.
  9. Disconnect the electrical connector from the A/C compressor.
    Fig 2: Disconnecting Electrical Connector From A/C Compressor
    G02211611Courtesy of FORD MOTOR CO.
  10. Remove the oil bypass filter.
    Fig 3: Removing Oil Bypass Filter
    G02211612Courtesy of FORD MOTOR CO.
  11. Disconnect the oil pressure sensor electrical connector, the power steering pressure (PSP) switch electrical connector, and detach the harness position retainer.
    Fig 4: Disconnecting Oil Pressure Sensor Electrical Connector And Power Steering Pressure Switch Electrical Connector
    G02211613Courtesy of FORD MOTOR CO.
  12. Remove the RH catalytic converter assembly.
  13. Disconnect the exhaust gas recirculation (EGR) tube from the exhaust manifold.
    Fig 5: Disconnecting Exhaust Gas Recirculation Tube From Exhaust Manifold
    G02211614Courtesy of FORD MOTOR CO.
  14. Lower the vehicle.
  15. Disconnect the differential pressure feedback EGR system electrical connector.
    Fig 6: Disconnecting Differential Pressure Feedback EGR System Electrical Connector
    G02211615Courtesy of FORD MOTOR CO.
  16. Disconnect the fuel charging wiring electrical connectors from the eight ignition coils.
    Fig 7: Disconnecting Fuel Charging Wiring Electrical Connectors
    G02211616Courtesy of FORD MOTOR CO.
  17. Disconnect the fuel charging wiring electrical connectors from the eight fuel injectors.
    Fig 8: Disconnecting Fuel Charging Wiring Electrical Connectors
    G02211617Courtesy of FORD MOTOR CO.
  18. Disconnect the accelerator cable, the speed control actuator cable and the throttle return spring.
    Fig 9: Disconnecting Accelerator Cable, Speed Control Actuator Cable And Throttle Return Spring
    G02211618Courtesy of FORD MOTOR CO.
  19. Remove the cables from the EGR tube heat shield and position out of the way.
    Fig 10: Removing Cables From EGR Tube Heat Shield
    G02211619Courtesy of FORD MOTOR CO.
  20. Remove the bolts and the EGR tube heat shield.
    Fig 11: Removing EGR Tube Heat Shield
    G02211620Courtesy of FORD MOTOR CO.
  21. Disconnect the evaporative emissions (EVAP) return tube, the main chassis vacuum supply hose, and the EGR valve vacuum supply.
    Fig 12: Disconnecting Evaporative Emissions (EVAP) Return Tube, Main Chassis Vacuum Supply Hose And EGR Valve Vacuum Supply
    G02211621Courtesy of FORD MOTOR CO.
  22. Disconnect the positive crankcase ventilation (PCV) tube assembly at two locations and remove.
    Fig 13: Disconnecting Positive Crankcase Ventilation Tube Assembly
    G02211622Courtesy of FORD MOTOR CO.
  23. Disconnect the electrical connector from the EGR vacuum regulator solenoid.
    Fig 14: Disconnecting Electrical Connector From EGR Vacuum Regulator Solenoid
    G02211623Courtesy of FORD MOTOR CO.
  24. Disconnect the vacuum hose from the EVAP canister purge valve.
    Fig 15: Disconnecting Vacuum Hose From EVAP Canister Purge Valve
    G02211624Courtesy of FORD MOTOR CO.
  25. Disconnect the generator cable, the electrical connector and the harness location retainer.
    Fig 16: Disconnecting Generator Cable, Electrical Connector And Harness Location Retainer
    G02211625Courtesy of FORD MOTOR CO.
  26. Remove the bolts and the generator mounting bracket.
    Fig 17: Removing Generator Mounting Bracket
    G02211626Courtesy of FORD MOTOR CO.
  27. Remove the upper radiator hose.
    Fig 18: Removing Upper Radiator Hose
    G02211627Courtesy of FORD MOTOR CO.
  28. Disconnect the electrical connector from the idle air control (IAC) valve and the throttle position (TP) sensor.
    Fig 19: Removing Idle Air Control Valve And Throttle Position Sensor Electrical Connector
    G02211628Courtesy of FORD MOTOR CO.
  29. Disconnect the heater water hose.
    Fig 20: Disconnecting Heater Water Hose
    G02211629Courtesy of FORD MOTOR CO.
  30. Disconnect the EGR tube nut from the EGR valve.
    Fig 21: Disconnecting EGR Tube Nut From EGR Valve
    G02211630Courtesy of FORD MOTOR CO.
    31. NOTE: The LH heated oxygen sensor and the transmission electrical connectors are attached to the wiring bracket and must be separated from the bracket.
    Fig 22: Removing Wiring Bracket
    G02211631Courtesy of FORD MOTOR CO.
  31. Remove the wiring bracket.
    • Disconnect the wiring connectors.
    • Separate the transmission harness from the stud.
    • Remove the nut and the bolt and remove the bracket.
  32. Remove the bolts and the throttle body.
    Fig 23: Removing Throttle Body
    G02211632Courtesy of FORD MOTOR CO.
  33. Separate the fuel charging wiring pin-type retainer from the crash bracket.
    Fig 24: Separating Fuel Charging Wiring Pin-Type Retainer From Crash Bracket
    G02211633Courtesy of FORD MOTOR CO.
  34. Remove the cables from the crash bracket.
    Fig 25: Removing Cables From Crash Bracket
    G02211634Courtesy of FORD MOTOR CO.
  35. Remove the bolt and the stud and remove the crash bracket.
    Fig 26: Removing Crash Bracket
    G02211635Courtesy of FORD MOTOR CO.
  36. Disconnect the vacuum hoses and remove the vacuum harness.
    Fig 27: Removing Vacuum Harness And Hoses
    G02211636Courtesy of FORD MOTOR CO.
  37. Remove the generator harness position retainer from the LH front stud.
    Fig 28: Removing Generator Harness Position Retainer
    G02211637Courtesy of FORD MOTOR CO.
  38. Remove the fuel charging wiring pin-type retainer from the rear of the manifold.
    Fig 29: Removing Fuel Charging Wiring Pin-Type Retainer
    G02211638Courtesy of FORD MOTOR CO.
  39. Disconnect the ground wire connector from the RH rear stud.
    Fig 30: Disconnecting Ground Wire Connector From RH Rear Stud
    G02211639Courtesy of FORD MOTOR CO.
  40. Disconnect the coolant temperature sensor connector.
    Fig 31: Disconnecting Coolant Temperature Sensor Connector
    G02211640Courtesy of FORD MOTOR CO.
  41. Remove the four studs and the fuel injection supply manifold and fuel injectors as an assembly.
    Fig 32: Removing Fuel Injection Supply Manifold And Fuel Injectors
    G02211641Courtesy of FORD MOTOR CO.
  42. Remove the bolts and the eight ignition coils.
    Fig 33: Removing Ignition Coils
    G02211642Courtesy of FORD MOTOR CO.
  43. Remove the bolts and the water outlet adapter.
    Fig 34: Removing Water Outlet Adapter
    G02211643Courtesy of FORD MOTOR CO.
  44. Remove the water thermostat.
    Fig 35: Removing Water Thermostat
    G02211644Courtesy of FORD MOTOR CO.
  45. Remove the bolts and the intake manifold.
    Fig 36: Removing Intake Manifold
    G02211645Courtesy of FORD MOTOR CO.
  46. Remove the intake manifold gaskets.
    Fig 37: Removing Intake Manifold Gaskets
    G02211646Courtesy of FORD MOTOR CO.
  47. Clean the sealing surfaces.
    Fig 38: Cleaning Sealing Surfaces
    G02211647Courtesy of FORD MOTOR CO.
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