OEM 2003 Lincoln Navigator Intake Manifold

2003 Lincoln Navigator Intake Manifold Parts Questions & Experts Answers

• Q: How to service the upper intake manifold on 2003 Lincoln Navigator?

  A: Start the servicing process of the upper intake manifold by disconnecting the battery ground cable. Secure the initial steps by removing the cowl grille followed by taking out bolts and five clips and the wiring harness shield. Start by removing the air cleaner outlet tube together with the air cleaner assembly before draining a portion of the engine cooling system. Start by removing the engine appearance cover followed by cutting the accelerator cable and speed control cable and return spring loose before removing the securing bolts and securing cables and bracket in a proper location. For the maintenance procedure disconnect the Evaporative Emission (EVAP) return hose and Positive Crankcase Ventilation (PCV) tube as well as the coolant hoses. First remove the balance tube accompanying the intake tuning valve electrical connector before you take out the bolts and studs. For cleaning sealing surfaces avoid using metal scrapers alongside abrasive tools since you should employ a plastic scraper to remove old sealant before disposing of the gaskets. The service requires disconnecting both the Throttle Position (TP) sensor electrical connector and Idle Air Control (IAC) valve electrical connector along with the vacuum hoses and electrical connector from the EGR vacuum regulator solenoid and differential pressure feedback EGR system. Remove the nut and bolts attached to the power steering reservoir bracket before placing it aside and remove the stud while setting the oil fill tube to the side. The procedure requires removing every brake booster vacuum hose and all other vacuum hoses which include the one connected to the EGR valve and the one located at the right rear of the intake manifold. First uninstall EGR nuts and bolts while disposing of the gasket and then uninstall the upper intake manifold bolts and its supporting bolts for disposal. After inspecting the sealing surfaces check for necessity to install a new intake gasket. Before assembly begin by setting the upper intake manifold gasket on its place and install the upper intake manifold while inserting new bolts. Follow a two-stage process by tightening the bolts to 10 Nm (89 inch lbs.) and afterward an additional 90-degree turn. Electrically connect the vacuum hoses between the EGR valve and right rear of the intake manifold following the installation of an adapter with a new gasket. Lastly, install the brake booster vacuum hose. Screw in the oil fill tube stud before you position the power steering reservoir bracket along with installing its bolts. Install the differential pressure feedback EGR system nut before connecting both vacuum hoses and electrical connector and then do the same with the EGR vacuum regulator solenoid vacuum hoses and electrical connector. Reinstall both IAC valve and TP sensor electrical connectors after positioning balance tube gaskets and installing balance tube components along with bolts and stud. Joint the electrical connector between the intake manifold tuning valve and the PCV heater coolant hoses as well as the PCV valve tube. The EVAP return hose needs reattachment while the cables must be positioned into their brackets before securing the bolts. Connect the accelerator cable followed by the speed control cable and return spring before you install the engine appearance cover and both the engine air cleaner and outlet tube. To complete the procedure install the wiring harness shield and its bolts and five clips then put back the cowl grille while connecting the battery ground cable and filling the engine cooling system.