OEM 2002 Lincoln Navigator Intake Manifold

2002 Lincoln Navigator Intake Manifold Parts Questions & Experts Answers

• Q: How to service and repair the upper intake manifold on 2002 Lincoln Navigator?

  A: You must start service and repairs on the upper intake manifold by taking out the air cleaner outlet tube while draining part of the engine cooling system. The procedure starts with fastening the engine appearance cover with three bolts before disconnecting the accelerator cable and speed control cable and return spring. The cables and bracket must be set aside after removing all bolts. The technician should disconnect and plug the evaporative emission return line and positive crankcase ventilation tube and coolant lines. Loosen the connector at the intake tuning valve and remove all bolts and five clips of the wiring harness shield. Take out the balance tube bolts and stud then discard the gaskets while cleaning the sealing surfaces. The technician disconnects throttle position (TP) sensor connections along with idle air control (IAC) motor connections and vacuum lines together with EGR vacuum regulator (EVR) electrical connector. Remove the differential pressure feedback EGR sensor nut by disconnecting its electrical connector and two hoses. You should remove the power steering reservoir bracket bolts while setting the bracket aside and set the oil fill tube stud to the side. Prepare the EGR valve by removing its brake booster vacuum line and other vacuum lines followed by EGR adapter and upper intake manifold bolts removal. Clean the sealing surfaces before visual inspection. Position the upper intake manifold then install all bolts before securing them to 10 Nm (89 inch lbs.) and further tightening by 90 degrees according to specified order. Position the EGR adapter equipped with a new gasket before installing its bolts. The vacuum lines must be reconnected between the EGR valve and the brake booster vacuum line as well as the oil fill tube with its stud. Connect the power steering reservoir bracket while tightening the EGR valve at its place on the exhaust manifold. Install the locking nut after reconnecting the differential feedback EGR sensor hoses together with its electrical connector followed by connecting vacuum lines and electrical connector to the EVR. Fasten the balance tube using its bolts and stud. Reinstall both the IAC valve along with the TP sensor. Use bolts and five clips to reattach the wiring harness shield while you connect the electrical connector to the intake manifold tuning valve then place the tube assembly with its fitting heater coolant hoses and the PCV valve tube. Once the EVAP return line is reconnected users must install the bolts to position cables and bracket before final installation of accelerator cable and speed control cable and return spring. End the work by putting the three bolts on the engine appearance cover followed by refilling the engine cooling system then reinstalling both the engine air cleaner and outlet tube.