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Home › Lincoln › 2003 › Town Car Protection Series › Repair and Diagnosis › Engine Mechanical › Mechanical › Engine - 4.6L › In-Vehicle Repair › Intake Manifold › Installation

Intake Manifold: Installation

    NOTE: Align the gasket locator tabs with the slots in the cylinder head.
    Fig 1: Locating Intake Manifold Gasket
    G01338729Courtesy 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: Locating Intake Manifold Bolts
    G01338730Courtesy of FORD MOTOR CO.
  3. Install the ignition coils and tighten the bolts.
    Fig 3: Locating Ignition Coils
    G01338731Courtesy of FORD MOTOR CO.
  4. Install the crash bracket and loosely install the bolt and the stud.
    Fig 4: Locating Crash Bracket Bolt & Stud
    G01338732Courtesy of FORD MOTOR CO.
  5. Install a new O-ring and the water thermostat.
    Fig 5: Locating Thermostat
    G01338733Courtesy of FORD MOTOR CO.
  6. Install the water outlet adapter and loosely install the bolts.
    Fig 6: Locating Water Outlet Adapter Bolts
    G01338734Courtesy of FORD MOTOR CO.
  7. Tighten the bolts in the sequence shown.
    Fig 7: Intake Manifold Tightening Sequence
    G01338735Courtesy of FORD MOTOR CO.
  8. Tighten the stud.
    Fig 8: Locating Crash Bracket Stud
    G01338736Courtesy of FORD MOTOR CO.
  9. Tighten the bolts.
    Fig 9: Locating Water Outlet Adapter Bolts
    G01338737Courtesy of FORD MOTOR CO.
  10. Connect the EGR system module tube to the EGR system module.
    Fig 10: Locating EGR System Module Tube Nut
    G01338738Courtesy of FORD MOTOR CO.
  11. Position the EGR tube heat shield and install the bolts.
    Fig 11: Locating EGR System Module Tube Heat Shield Bolts
    G01338739Courtesy of FORD MOTOR CO.
    12. NOTE: Do not reuse hose clamps. Use appropriately sized worm-style clamps in place of the constant tension clamps.
    Fig 12: Locating Heater Hose
    G01338740Courtesy of FORD MOTOR CO.
  12. Connect the heater water hose and position the clamp.
  13. Connect the IAC control valve and the TP sensor electrical connectors.
    Fig 13: Locating IAC Valve & TP Sensor Electrical Connectors
    G01338741Courtesy of FORD MOTOR CO.
  14. Attach the cables to the crash bracket.
    Fig 14: Locating Cables At Crash Bracket
    G01338742Courtesy of FORD MOTOR CO.
    15. NOTE: Do not reuse hose clamps. Use appropriately sized worm-style clamps in place of the constant tension clamps.
    Fig 15: Locating Upper Radiator Hose
    G01338743Courtesy of FORD MOTOR CO.
  15. Connect the upper radiator hose.
  16. Install the generator mounting bracket and the bolts.
    Fig 16: Locating Generator Mounting Bracket Bolts
    G01338744Courtesy of FORD MOTOR CO.
  17. Connect the electrical connector, the generator cable and the harness location retainer.
    Fig 17: Locating Generator Electrical Connectors
    G01338745Courtesy of FORD MOTOR CO.
  18. Position the vacuum harness and connect the vacuum hose to the EVAP canister purge valve.
    Fig 18: Locating EVAP Canister Purge Valve Vacuum Hose
    G01338746Courtesy of FORD MOTOR CO.
  19. Connect the vacuum hoses and the electrical connector.
    Fig 19: Locating Electrical Connector & Vacuum Hoses
    G01338747Courtesy of FORD MOTOR CO.
  20. Position and attach the cables to the EGR system module tube heat shield.
    Fig 20: Removing Cable From EGR System Module Tube Heat Shield
    G01338748Courtesy of FORD MOTOR CO.
  21. Connect the accelerator cable, the speed control actuator cable, the throttle return spring and the cable retaining bolts.
    Fig 21: Removing Accelerator Cable & Speed Control Actuator Cable
    G01338749Courtesy of FORD MOTOR CO.
  22. Connect the fuel charging wiring electrical connectors to the eight fuel injectors.
    Fig 22: Locating Fuel Injector Connectors
    G01338750Courtesy of FORD MOTOR CO.
  23. Connect the fuel charging wiring electrical connectors to the eight ignition coils.
    Fig 23: Locating Ignition Coil Connectors
    G01338751Courtesy of FORD MOTOR CO.
  24. Connect the coolant temperature sensor electrical connector.
    Fig 24: Locating Coolant Temperature Sensor Electrical Connector
    G01338752Courtesy of FORD MOTOR CO.
  25. Raise the vehicle.
  26. Connect the power steering electrical connector.
    Fig 25: Locating Power Steering Electrical Connector
    G01338753Courtesy of FORD MOTOR CO.
  27. Connect the oil pressure sensor electrical connector.
    Fig 26: Locating Oil Pressure Sensor Electrical Connector
    G01338754Courtesy of FORD MOTOR CO.
  28. Connect the A/C compressor clutch electrical connector.
    Fig 27: Locating A/C Compressor Clutch Electrical Connector
    G01338755Courtesy of FORD MOTOR CO.
  29. Connect the PSP electrical connector.
    Fig 28: Locating PSP Switch Connector
    G01338756Courtesy of FORD MOTOR CO.
  30. Connect the CKP sensor electrical connector.
    • Connect the pin-type retainers to the A/C compressor bracket.
    Fig 29: Locating CKP Sensor Connector
    G01338757Courtesy of FORD MOTOR CO.
  31. Lower the vehicle.
  32. Install the accessory drive belt.
  33. Install the wiper mounting arm and pivot shaft. See WIPERS & WASHERS .
  34. Connect the fuel spring lock coupling. For additional information, see SPRING LOCK COUPLINGS .
  35. Install the air cleaner and outlet pipe. For additional information, see INTAKE AIR DISTRIBUTION & FILTERING .
  36. Connect the battery ground cable. For additional information, see BATTERY, MOUNTING & CABLES .
  37. Check the engine oil.
  38. Fill and bleed the engine cooling system.
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