Installation (3.9L)

WARNING: This page is about a different car, the 2002 Lincoln LS. However, it is still accessible from the selected car via links, so may be relevant.

NOTE: Ensure throttle body heater return hose is positioned between heat shield and intake manifold.

Install intake manifold gaskets, if removed or replaced. Install intake manifold and tighten bolts to specification in sequence shown. See Figure. See TORQUE SPECIFICATIONS . Install DPFEGR sensor and tighten bolts to specification. Connect harness connector and hoses to DPFEGR sensor. Connect right side fuel injector connectors, and position engine wiring harness. Connect hoses to throttle body and position clamps.
Connect PCV tube. Connect IAC valve and TPS harness connectors. Connect left side fuel injector connectors and position engine wiring harness. Install engine wiring harness, hose, nuts and bracket. See Figure. Install nut and bracket for left side KS and CHT sensor harness connectors. Connect KS and CHT sensor harness connectors. Install electrical connectors on bracket. Connect fuel line. Connect vacuum connector and harness connector to fuel rail pressure sensor.
Connect evaporative emission canister purge valve hose. Connect CMP sensor harness connector, and position connector on fuel injection supply manifold. Connect exhaust manifold-to-EGR valve tube. Install a NEW EGR valve gasket, EGR valve and install 2 bolts. Tighten exhaust manifold-to-EGR valve tube. Connect EGR valve vacuum hose. Connect intake manifold vacuum hoses. Connect accelerator and speed control cables.

CAUTION: Cooling system filling and bleeding procedure must be followed exactly or damage to engine may occur.

Install strut support brace. Tighten bolts to specification. See TORQUE SPECIFICATIONS . Install cowl vent screen. To complete installation, reverse removal procedure. Fill and bleed engine cooling system. See COOLING SYSTEM FILLING & BLEEDING under COOLING SYSTEM.