Removal (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.
- Disconnect negative battery cable. Remove air cleaner outlet tube. Drain engine cooling system. See COOLING SYSTEM DRAINING under COOLING SYSTEM. Remove 2 wiper pivot arm nut covers and 2 nuts and remove wiper pivot arms. Remove left and right side cowl vent screen extension panels. Disconnect windshield washer nozzle hoses from engine main wiring harness at lower right side of engine compartment.
- Remove 9 pin-type retainers and remove cowl vent screen. Remove 7 bolts and remove strut support brace. See Figure. Disconnect accelerator and speed control cables. Disconnect vacuum hoses from intake manifold. Disconnect vacuum hose from Exhaust Gas Recirculation (EGR) valve. Remove exhaust manifold-to-EGR valve tube. See EXHAUST MANIFOLD-TO-EXHAUST GAS RECIRCULATION VALVE TUBE .
- Remove 2 EGR valve bolts and remove valve and discard gasket. Disconnect Camshaft Position (CMP) sensor harness connector and separate connector from fuel injection supply manifold. Disconnect evaporative emission canister purge valve hose. See REMOVAL & INSTALLATION (VAPOR TUBE FITTING) under FUEL LINE CONNECTOR.
- Disconnect Fuel Rail Pressure (FRP) sensor harness connector and vacuum connector. Disconnect fuel line. See FUEL LINE CONNECTOR . Disconnect left side Knock Sensor (KS) and Cylinder Head Temperature (CHT) sensor harness connectors. See Fig 1. Remove nut and bracket for left side Knock Sensor (KS) and Cylinder Head Temperature (CHT) sensor harness connectors.
- Remove engine wiring harness, hose, nuts and bracket. See Fig 2. Raise engine wiring harness and disconnect left side fuel injector connectors. Disconnect Idle Air Control (IAC) valve and Throttle Position (TP) sensor harness connectors.
- Disconnect Positive Crankcase Ventilation (PCV) tube from right side valve cover. Disconnect hoses from throttle body. Raise engine wiring harness and disconnect right side fuel injectors. Disconnect Differential Pressure Feedback EGR (DPFEGR) sensor harness connector and vacuum hoses. Remove bolts and DPFEGR sensor.
- Remove bolts and stud in sequence shown. See Fig 3. Position throttle body heater return hose aside before removing intake manifold. Remove intake manifold. Clean sealing surfaces. Inspect gaskets and install new gaskets if necessary.
CAUTION:
Coolant drain procedure must be followed exactly or damage to engine may occur.
NOTE:
Cowl vent screen must be removed to access intake manifold.
NOTE:
Cowl vent screen pin-type retainers are reusable.
CAUTION:
DO NOT use metal scrapers, wire brushes, power abrasive discs, or other abrasive means to clean sealing surfaces. These tools cause scratches and gouges, which make leak paths. Use a plastic scraping tool to clean surfaces.
NOTE:
Throttle body, adapter, and EGR valve are shown removed for clarity. It is not necessary to remove throttle body and adapter to remove intake manifold.