OEM 2004 Lincoln Navigator Intake Manifold

2004 Lincoln Navigator Intake Manifold Parts Questions & Experts Answers

• Q: How to service and repair the upper intake manifold on 2004 Lincoln Navigator?

  A: You must start the upper intake manifold service and repair operation through cowl grille removal and battery ground cable disconnection. Proceed to remove first the bolts before taking away the five clips and then disconnecting the wiring harness shield and engine appearance cover. The engine cooling requires partial drainage before the technicians remove the air cleaner outlet tube and air cleaner assembly components. First disconnect the accelerator cable, speed control cable and return spring before removing the bolts to place all components out of the work area. You should disconnect the Evaporative Emission (EVAP) return hose and Positive Crankcase Ventilation (PCV) tube in addition to the coolant hoses. To clean the surfaces use a plastic scraping tool instead of metal scrapers or abrasive tools when removing the bolts, studs and balance tube. Also discard the gaskets during this process. Detach the Throttle Position (TP) sensor and Idle Air Control (IAC) valve cable connectors while also removing their vacuum hoses in addition to disconnecting the Exhaust Gas Recirculation (EGR) vacuum regulator solenoid electrical connector and differential pressure feedback EGR system. First remove the nut along with the bolts from the power steering reservoir bracket before setting it aside to take out the stud and oil fill tube from its position. You must eliminate all vacuum lines that connect between the EGR valve and the intake manifold as well as the brake booster vacuum hose. After discarding the EGR adapter gasket remove its bolts then remove the upper intake manifold by discarding its retaining bolts. Inspection of sealing surfaces must be followed by new intake gasket installation when required. Place new upper intake manifold gasket in position followed by upper intake manifold installation and add new bolts at first tightening stage to 10 Nm (89 inch lbs.) and then a second tightening step to 90°. Fits the EGR adapter by using a fresh gasket while properly connecting vacuum tubes to EGR valve and intake manifold before joining the vacuum hose to the brake booster. Fits the oil fill tube as well as installs the stud before carefully replacing the power steering reservoir bracket and its bolts. Reinstall the nut and join all vacuum hoses and electrical connectors both to the differential pressure feedback EGR system and EGR vacuum regulator solenoid alongside reconnecting the IAC valve and TP sensor electrical connectors. You should begin by preparing the balance tube gaskets followed by installing the balance tube and bolts along with the stud before you complete your work by uniting the PCV heater coolant hoses with the PCV valve tube. Proceed by reconnecting the EVAP return hose before installing the cables along with the bracket and bolting them into place. First install the engine air cleaner along with outlet tube and finally the engine appearance cover. Afterward connect the accelerator cable followed by speed control cable and the return spring. The final procedures include placing the cowl grille followed by reconnecting the battery ground cable and filling the engine cooling system. Additionally, re-installation of the wiring harness shield and its bolts along with securing the five clips completes the process.