OEM 2009 Lincoln Navigator Intake Manifold

2009 Lincoln Navigator Intake Manifold Parts Questions & Experts Answers

• Q: How to remove and replace the intake manifold on 2009 Lincoln Navigator?

  A: The first step for intake manifold replacement requires avoiding open flames or smoking near fuel components because flammable mixtures exist in this area. Draining the cooling system should be the first step before moving forward with generator removal. Start by disconnecting quick connect couplings from the crankcase vent tube while turning loose the clamp for easy removal of the air intake resonator assembly. The removal procedure starts with bolt detachments from the throttle body (TB)-to-air cleaner (ACL) outlet pipe adapter and then quick connect couplings need to be unplugged from the PCV tube. The EVAP canister purge valve requires removal of its fuel supply tube quick connect coupling together with the evaporative emission (EVAP) electrical connector and EVAP tube quick connect coupling. Disconnect both the upper radiator hose from the thermostat housing as well as the heater coolant hose from the coolant crossover manifold assembly. You should disconnect eight fuel injector electrical connectors along with throttle position (TP) sensor, electronic throttle control (ETC) electrical connectors and heated PCV element electrical connector. The technicians will disconnect four left-hand (LH) ignition coil electrical connectors as well as LH variable camshaft timing (VCT) solenoid connectors and separate engine wiring harness retainers from their LH valve cover stud locations. Disconnect the intake manifold vacuum tube from brake booster vacuum hose by removing it as one unit while also unfastening it from the LH valve cover stud bolt and the support bracket located at the rear of the LH cylinder head. Extract the ten bolts securing the intake manifold combined with the coolant crossover manifold assembly while discarding its gaskets. Clean the sealing areas with silicone gasket remover and metal surface prep while skipping the use of metal scrapers or abrasive tools. The installation process requires a check of the intake manifold for debris in cases where the engine has history of upper engine damage or replacement. Installed debris warrants replacing the intake manifold. Secure the intake manifold with new gaskets before you join the CHT sensor jumper harness electrical connector retainer and fasten its two engine wiring harness retainers at the intake manifold rear. The installer should begin by tightening three new bolts on the coolant crossover manifold assembly to 10 Nm (89 lb-in) torque setting before proceeding to tighten ten intake manifold bolts twice: first phase at 2 Nm (18 lb-in) and second phase at 10 Nm (89 lb-in). The intake manifold vacuum tube must be reconnected to the support bracket attached to the valve cover stud and then followed by reattaching the brake booster vacuum hose. Rejoin electrical wires for LH ignition coil and LH VCT solenoid along with the heated PCV element and TP sensor and ETC sensors and eight fuel injector electrical connectors. The worker reconnects the heater coolant hose onto the coolant crossover manifold assembly while attaching the upper radiator hose to the thermostat housing and the EVAP canister purge valve electrical connector together with the EVAP tube quick connect coupling. Complete the procedure by connecting the fuel supply tube quick connect coupling then position the PCV tube and attach all quick connect couplings. After tightening three bolts on the TB-to-ACL outlet pipe adapter to 10 Nm (89 lb-in), install the air intake resonator assembly while securing its bolt and clamp to 10 Nm (89 lb-in), reconnect the crankcase vent tube then reinstall the generator and complete engine cooling system fill and bleeding procedures.