OEM Lincoln Navigator Intake Manifold

Lincoln Navigator Intake Manifold Parts and Q&A

• Intake Manifold
  2L1Z-9424-AA
  Q: How to service and repair the lower intake manifold on Lincoln Navigator?

  A:

  The lower intake manifold service requires starting with upper intake manifold removal. Disconnect the sequence of parts starting with the fuel hose spring lock couplings, engine water bypass hose, water temperature indicator sender electrical connector, upper radiator hose, heater water inlet hose, and heated Positive Crankcase Ventilation (PCV) water heated fitting inlet hose. Remove the four bolts which hold the generator upper support bracket before disconnecting the eight Fuel Injectors and fuel injector pressure regulator vacuum hose that leads out of the working area. Start by disconnecting the wire harness pin-type retainer before unscrewing the bolts for lower intake manifold removal and then discard the bolts. Check gaskets for the radio ignition interference capacitors while removing their bolts and install new gaskets when needed but avoid using metal scrapers to clean sealing surfaces instead use a plastic scraping tool. Install the lower intake gaskets together with radio ignition interference capacitors through new bolts while mounting the lower intake manifold loosely. The technician should perform a two-step process when tightening the retaining bolts by starting at 10 Nm (89 inch lbs.) then continuing to 90° according to the specified sequence. Reconnect the wire harness pin-type retainer which includes the water temperature indicator sensor electrical connector and the vacuum line to the fuel injector pressure regulator. The eight fuel injector electrical connectors must be installed before reinstalling the upper generator support bracket with its four bolts and connecting the heater water inlet hose with the upper radiator hose and water heated fitting inlet hose. Before placing back the upper intake manifold you must connect both the engine water bypass return hose and the fuel hose spring lock couplings.
• Intake Manifold
  9L3Z-9424-H
  Q: How to remove and replace the intake manifold on 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.