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Removal Lincoln Zephyr US

Engine - 3.0l (4v) 3 illustrations ~489 words

Removal

  1. Remove the air cleaner outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING - 3.0L (4V)»(/lincoln/zephyr/us-2006-2006/remont/removal-installation/#intake-air-distribution-filtering-30l-4v) .
  2. Disconnect the throttle body electrical connector.
  3. Remove the 4 bolts and position the throttle body aside. Discard the gasket.
  4. Disconnect the evaporative emissions (EVAP) tube from the intake manifold.
  5. Remove the vacuum tube clamp bolt.
  6. Disconnect the vacuum tube from the intake manifold.
  7. Disconnect the positive crankcase ventilation (PCV) tube from the intake manifold.
  8. Disconnect the exhaust gas recirculation (EGR) valve electrical connector.
  9. Loosen the EGR tube-to-EGR valve nut.
  10. Disconnect the manifold absolute pressure (MAP) sensor electrical connector and the pin-type retainer.
  11. Detach the wiring harness retainer from the front of the upper intake manifold.
  12. Remove the 8 bolts and remove the upper intake manifold. Remove and discard the gaskets.

Scheme 3

Scheme 3: Installation
Scheme 3: Installation
  1. Clean and inspect all of the sealing surfaces of the upper intake manifold.
  2. Install the upper intake manifold, gaskets and the 8 bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
  3. Attach the wiring harness retainer to the front of the upper intake manifold.
  4. Connect the MAP sensor electrical connector and the pin-type retainer.
  5. Install the EGR tube-to-EGR valve nut. Tighten to 40 Nm (30 lb-ft).
  6. Connect the EGR valve electrical connector.
  7. Connect the PCV tube to the intake manifold.
  8. Connect the vacuum tube to the intake manifold.
  9. Install the vacuum tube clamp bolt. Tighten to 10 Nm (89 lb-in).
  10. Connect the EVAP tube to the intake manifold.
  11. Tighten to 10 Nm (89 lb-in).
  12. Connect the throttle body electrical connector.
  13. Install the air cleaner outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING - 3.0L (4V)»(/lincoln/zephyr/us-2006-2006/remont/removal-installation/#intake-air-distribution-filtering-30l-4v) .

Scheme 4

Scheme 4: Lower Intake Manifold
Scheme 4: Lower Intake Manifold
WARNINGDo not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited, resulting in possible personal injury.
WARNINGFuel in the fuel system remains under high pressure even when the engine is not running. Before repairing or disconnecting any of the fuel system components, the fuel system pressure must be relieved to prevent accidental spraying of fuel, causing personal injury or a fire hazard.
  1. Release the fuel system pressure. For additional information refer to «FUEL SYSTEM-GENERAL INFORMATION»(/lincoln/zephyr/us-2006-2006/remont/fuel-system/#fuel-system-general-information) .
  2. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/lincoln/zephyr/us-2006-2006/remont/body-electrical/#battery-mounting-and-cables) .
  3. Remove the upper intake manifold. For additional information, refer to «UPPER INTAKE MANIFOLD»(/lincoln/zephyr/us-2006-2006/remont/mechanical/#engine-30l-4v) .
  4. Disconnect the fuel supply tube quick connect coupling from the fuel rail. For additional information, refer to «FUEL SYSTEM-GENERAL INFORMATION»(/lincoln/zephyr/us-2006-2006/remont/fuel-system/#fuel-system-general-information) .
  5. Detach the 2 wiring harness retainers from the LH valve cover stud bolts.
  6. Detach the 3 pin-type retainers from the fuel rail.
  7. Disconnect the 6 fuel injector electrical connectors.
  8. Remove the 8 lower intake manifold bolts and the lower intake manifold. Remove and discard the gaskets.

Scheme 5

Scheme 5: Installation
Scheme 5: Installation
  1. Position the lower intake manifold and install the 8 bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
  2. Connect the 6 fuel injector electrical connectors.
  3. Attach the 3 pin-type retainers to the fuel rail.
  4. Attach the 2 wiring harness retainers to the LH valve cover stud bolts.
  5. Connect the fuel supply tube quick connect coupling at the fuel rail. For additional information, refer to «FUEL SYSTEM-GENERAL INFORMATION»(/lincoln/zephyr/us-2006-2006/remont/fuel-system/#fuel-system-general-information) .
  6. Install the upper intake manifold. For additional information, refer to «UPPER INTAKE MANIFOLD»(/lincoln/zephyr/us-2006-2006/remont/mechanical/#engine-30l-4v) .
  7. Connect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/lincoln/zephyr/us-2006-2006/remont/body-electrical/#battery-mounting-and-cables) .