OEM 2006 Lincoln Zephyr Intake Manifold

2006 Lincoln Zephyr Intake Manifold Parts Q&A

• Q: How to service the upper intake manifold on 2006 Lincoln Zephyr?

  A: One must disconnect the battery ground cable before working on the upper intake manifold. Detach the air cleaner outlet pipe from its position after disconnecting the throttle body electrical connector. The throttle body requires removal of its four securing bolts which should remain for later use but discard the gasket warms. Serviceable procedures on the evaporative emissions system involves disconnecting tubes followed by vacuum tube clamp bolt removal to release the tube and PCV tube from the intake manifold. Follow this procedure to disconnect the exhaust gas recirculation (EGR) valve electrical connector followed by EGR tube-to-EGR nut loosening and disconnecting the manifold absolute pressure (MAP) sensor electrical connector and its pin-type retainer. The wiring harness retainer must be detached from the front of the upper intake manifold before removing the eight bolts to detach the upper intake manifold for disposal of its gaskets. All sealing surfaces must be cleaned before new gaskets are installed onto the upper intake manifold which should be bolted into place using the specified sequence and tightened to 10 Nm (89 inch lbs.). Reinstall the wiring harness retainer followed by connecting the MAP sensor electrical connector via pin-type retainer. Then fasten the EGR tube-to-EGR valve nut to 40 Nm (30 ft. lbs.). Open the EGR valve electrical connector followed by connecting the PCV tube and vacuum tube then install the vacuum tube clamp bolt before tightening it to 10 Nm (89 inch lbs.). The EVAP tube must be connected after securing the throttle body with four bolts at 10 Nm (89 inch lbs.). To complete the installation connect the throttle body electrical connector, reinstall the air cleaner outlet pipe along with reattaching the battery ground cable.