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Home >> Lincoln >> 2005 >> Town Car Signature Limited >> 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
    G03881839Courtesy 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 Bolts
    G04001857Courtesy of FORD MOTOR CO.
  3. Install the ignition coils and tighten the bolts.
    Fig 3: Ignition Coil Bolts Torque Specification
    G04001862Courtesy of FORD MOTOR CO.
  4. Install the crash bracket and loosely install the bolt and the stud.
    Fig 4: Installing Crash Bracket Bolt & Stud
    G03881486Courtesy of FORD MOTOR CO.
  5. Tighten the bolts in the sequence shown.
    Fig 5: Tightening Sequence & Torque Specification Of Intake Manifold Bolts
    G04001864Courtesy of FORD MOTOR CO.
  6. Install the stud.
    Fig 6: Stud Torque Specification
    G04001865Courtesy 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
    G04001866Courtesy of FORD MOTOR CO.
  8. Install the EGR tube nut at the exhaust manifold.
    Fig 8: EGR Tube Nut Torque Specification
    G04001867Courtesy of FORD MOTOR CO.
  9. Position the EGR system module tube heat shield and install the bolts.
    Fig 9: EGR System Module Tube Heat Shield Bolts Torque Specifications
    G03881491Courtesy of FORD MOTOR CO.
  10. Connect the throttle control and the TP sensor electrical connectors.
    Fig 10: Locating Electrical Connectors
    G03881492Courtesy of FORD MOTOR CO.
  11. Install the thermostat and O-ring.
    Fig 11: Installing Thermostat
    G04002392Courtesy of FORD MOTOR CO.
  12. Install the thermostat housing and the bolts.
    Fig 12: Thermostat Housing Bolts Torque Specification
    G04001871Courtesy of FORD MOTOR CO.
    13. NOTE: Do not reuse hose clamps. Use appropriately sized worm-style clamps in place of the constant tension clamps.
    Fig 13: Installing Upper Radiator Hose
    G04001841Courtesy of FORD MOTOR CO.
  13. Install the upper radiator hose.
  14. Connect the heater hose.
    Fig 14: Connecting Heater Hose
    G04001843Courtesy of FORD MOTOR CO.
  15. Install the generator mounting bracket and the bolts.
    Fig 15: Generator Mounting Bracket Bolts Torque Specification
    G04002498Courtesy of FORD MOTOR CO.
  16. Connect the electrical connector.
    Fig 16: Connecting Electrical Connector
    G04001875Courtesy of FORD MOTOR CO.
  17. Connect the emission tubes to the EVAP canister purge valve.
    Fig 17: Connecting Emission Tubes To EVAP Canister Purge Valve
    G04001838Courtesy of FORD MOTOR CO.
  18. Connect the electrical connector and the vacuum hoses.
    Fig 18: Connecting Electrical Connector And Vacuum Hoses
    G04001837Courtesy of FORD MOTOR CO.
  19. Connect the fuel pressure and temperature sensor electrical connector and the vacuum hoses.
    Fig 19: Connecting Fuel Pressure, Temperature Sensor Electrical Connector And Vacuum Hoses
    G04001849Courtesy of FORD MOTOR CO.
  20. Connect the fuel charging wiring electrical connectors to the eight fuel injectors.
    Fig 20: Connecting Fuel Charging Wiring Electrical Connectors To Fuel Injectors
    G04001879Courtesy of FORD MOTOR CO.
  21. Connect the fuel charging wiring electrical connectors to the eight ignition coils.
    Fig 21: Connecting Fuel Charging Wiring Electrical Connectors To Ignition Coils
    G04001880Courtesy of FORD MOTOR CO.
  22. Install the fuel charging wiring pin-type retainer to the rear of the manifold.
    Fig 22: Installing Fuel Charging Wiring Pin-Type Retainer To Rear Of Manifold
    G04001851Courtesy of FORD MOTOR CO.
  23. Install the generator harness position retainer to the LH front stud.
    Fig 23: Installing Generator Harness Position Retainer To LH Front Stud
    G04001850Courtesy of FORD MOTOR CO.
  24. Attach the fuel charging wiring pin-type retainer to the crash bracket.
    Fig 24: Attaching Fuel Charging Wiring Pin-Type Retainer To Crash Bracket
    G04001846Courtesy of FORD MOTOR CO.
  25. Connect the ground wire connector to the RH rear stud.
    Fig 25: Connecting Ground Wire Connector To RH Rear Stud
    G04001852Courtesy of FORD MOTOR CO.
  26. Connect the coolant temperature sensor electrical connector.
    Fig 26: Connecting Coolant Temperature Sensor Electrical Connector
    G04001885Courtesy of FORD MOTOR CO.
  27. Install the LH cowl extension.
    1. Install the extension.
    2. Install the bolts.
    3. Connect the electrical connectors.
    Fig 27: Installing LH Cowl Extension
    G04001886Courtesy of FORD MOTOR CO.
  28. Install the RH cowl extension.
    1. Install the extension.
    2. Install the pin-type retainers.
    3. Install the nuts and the bolts.
    Fig 28: Installing RH Cowl Extension
    G04001887Courtesy of FORD MOTOR CO.
  29. Install the wiper mounting arm and pivot shaft. For additional information, refer to WIPERS AND WASHERS .
  30. Connect the fuel tube spring lock coupling. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION .
  31. Install the air cleaner outlet pipe resonator assembly. For additional information, refer to INTAKE AIR DISTRIBUTION AND FILTERING .
  32. Connect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  33. Fill and bleed the engine cooling system. For additional information, refer to ENGINE COOLING .
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