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Home >> Lincoln >> 2004 >> Town Car Protection Series >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> Engine >> In-Vehicle Repair >> Intake Manifold >> Removal

Intake Manifold: Removal

  1. Disconnect the fuel spring lock coupling. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION .
  2. Disconnect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  3. Drain the engine cooling system. For additional information, refer to ENGINE COOLING .
  4. Remove the air cleaner outlet pipe - resonator assembly. For additional information, refer to INTAKE AIR DISTRIBUTION & FILTERING .
  5. Remove the wiper mounting arm and pivot shaft. For additional information, refer to WIPERS AND WASHERS .
  6. Remove the RH cowl extension.
    1. Remove the pin-type retainers.
    2. Remove the nuts.
    3. Remove the bolts.
    4. Remove the extension.
    Fig 1: Removing RH Cowl Extension
    G03247846Courtesy of FORD MOTOR CO.
  7. Remove the LH cowl extension.
    1. Disconnect the electrical connector.
    2. Remove the bolts.
    3. Remove the extension.
    Fig 2: Removing LH Cowl Extension
    G03247847Courtesy of FORD MOTOR CO.
  8. Disconnect the fuel charging wiring electrical connectors from the eight ignition coils.
    Fig 3: Disconnecting Ignition Coils Electrical Connectors
    G03247848Courtesy of FORD MOTOR CO.
  9. Disconnect the fuel charging wiring electrical connectors from the eight fuel injectors.
    Fig 4: Disconnecting Fuel Injectors Electrical Connectors
    G03247849Courtesy of FORD MOTOR CO.
  10. Disconnect the accelerator cable, the speed control actuator cable, the throttle return spring and the cable retaining bolts.
    Fig 5: Disconnecting Accelerator Cable, Speed Control Actuator Cable
    G03247850Courtesy of FORD MOTOR CO.
  11. Remove the cables from the exhaust gas recirculation (EGR) system module tube heat shield and position out of the way.
    Fig 6: Removing Cables From Exhaust Gas Recirculation (EGR) System Module Tube Heat Shield
    G03247851Courtesy of FORD MOTOR CO.
  12. Remove the bolts and the EGR system module tube heat shield.
    Fig 7: Removing EGR System Module Tube Heat Shield
    G03247852Courtesy of FORD MOTOR CO.
  13. Disconnect the electrical connector and the vacuum hoses.
    Fig 8: Disconnecting Electrical Connector And Vacuum Hoses
    G03247853Courtesy of FORD MOTOR CO.
  14. Disconnect the EVAP canister purge valve vacuum hose.
    Fig 9: Disconnecting EVAP Canister Purge Valve Vacuum Hose
    G03247854Courtesy of FORD MOTOR CO.
  15. Disconnect the electrical connector and the harness location retainer.
    Fig 10: Disconnecting Electrical Connector And Harness Location Retainer
    G03247855Courtesy of FORD MOTOR CO.
  16. Remove the bolts and the generator mounting bracket.
    Fig 11: Removing Bolts And Generator Mounting Bracket
    G03247856Courtesy of FORD MOTOR CO.
  17. Disconnect the upper radiator hose.
    Fig 12: Disconnecting Upper Radiator Hose
    G03247857Courtesy of FORD MOTOR CO.
  18. Disconnect the idle air control (IAC) valve and the throttle position (TP) sensor electrical connectors.
    Fig 13: Disconnecting Idle Air Control (IAC) Valve And Throttle Position (TP) Sensor Electrical Connectors
    G03247858Courtesy of FORD MOTOR CO.
  19. Disconnect the heater hose.
    Fig 14: Disconnecting Heater Hose
    G03247859Courtesy of FORD MOTOR CO.
  20. Disconnect the EGR system module tube nut from the EGR system module.
    Fig 15: Disconnecting EGR System Module Tube Nut From EGR System Module
    G03247860Courtesy of FORD MOTOR CO.
  21. Remove the nut at the exhaust manifold and remove the EGR tube.
    Fig 16: Removing EGR Tube At Exhaust Manifold
    G03247861Courtesy of FORD MOTOR CO.
  22. Separate the fuel charging wiring pin-type retainer from the crash bracket.
    Fig 17: Removing Fuel Charging Wiring Pin-Type Retainer From Crash Bracket
    G03247862Courtesy of FORD MOTOR CO.
  23. Remove the cables from the crash bracket.
    Fig 18: Removing Cables From Crash Bracket
    G03247863Courtesy of FORD MOTOR CO.
  24. Remove the crash bracket bolt and prevent the bolt from contacting the cylinder head with a rubber band or tie strap.
    Fig 19: Removing/Securing Crash Bracket Bolt
    G03247864Courtesy of FORD MOTOR CO.
  25. Remove the stud.
    Fig 20: Removing Stud
    G03247865Courtesy of FORD MOTOR CO.
  26. Disconnect the fuel pressure sensor electrical connector and the vacuum hoses.
    Fig 21: Disconnecting Fuel Pressure Sensor Electrical Connector And Vacuum Hoses
    G03247866Courtesy of FORD MOTOR CO.
  27. Remove the generator harness position retainer from the LH front stud.
    Fig 22: Removing Generator Harness Position Retainer From LH Front Stud
    G03247867Courtesy of FORD MOTOR CO.
  28. Remove the fuel charging wiring pin-type retainer from the rear of the manifold.
    Fig 23: Removing Fuel Charging Wiring Pin-Type Retainer From Rear Of Manifold
    G03247868Courtesy of FORD MOTOR CO.
  29. Disconnect the ground wire connector from the RH rear stud.
    Fig 24: Disconnecting Ground Wire Connector From RH Rear Stud
    G03247869Courtesy of FORD MOTOR CO.
  30. Disconnect the coolant temperature sensor electrical connector.
    Fig 25: Disconnecting Coolant Temperature Sensor Electrical Connector
    G03247870Courtesy of FORD MOTOR CO.
  31. Remove the bolts and the eight ignition coils.
    Fig 26: Removing Ignition Coils
    G03247871Courtesy of FORD MOTOR CO.
  32. Remove the bolts and the coolant outlet adapter.
    Fig 27: Removing Bolts And Coolant Outlet Adapter
    G03247872Courtesy of FORD MOTOR CO.
  33. Remove the thermostat and discard the O-ring.
    Fig 28: Removing Thermostat
    G03247873Courtesy of FORD MOTOR CO.
  34. Remove the bolts and the intake manifold.
    Fig 29: Removing Intake Manifold
    G03247874Courtesy of FORD MOTOR CO.
  35. Remove and discard the intake manifold gaskets.
    Fig 30: Removing Intake Manifold Gaskets
    G03247875Courtesy of FORD MOTOR CO.
  36. Clean the sealing surfaces.
Fig 31: Cleaning Sealing Surfaces
G03247876Courtesy of FORD MOTOR CO.
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