Intake Manifold Replacement
Lincoln Town Car Maintenance & Repair
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One of the most important issues on the Lincoln Town Cars from mid 1995 through the 2001? model year is the plastic intake manifold. This was a redesign from the cast aluminum manifold used from 1991 to the mid 1995 model year. The redesign greatly reduced a tendency for clogged passages in the EGR and elsewhere after thousands of miles, but, unfortunately; there is a tendency for the plastic intake manifold to split close to the alternator mount. Replacement of the manifold with a newly redesigned reinforced one is the only solution. Below is information on doing so. FordPartsNetwork has the intake manifold kit for $465.00. The part number is: F8AZ-9424-AAA. Also it is a good idea to replace the under intake heater hose assembly, part number F6AZ 18B402-AC, $17.99. Instructions for removal and replacement of the intake are below if you desire to do it yourself. Dealer repair normally runs about $800-$900.00. Some fleet and commercial use vehicles are under warranty on this repair. Run a VIN check to see if your Lincoln Town Car qualifys for this recall warranty repair.
Cracked intake manifold, Lincoln Town Car illustrations Lincolntowncar.org
The following information is taken from the 1997 Service Manual CD
Removal

1. Note: When the battery has been disconnected or reconnected, volatile memory information will be lost. The affected systems will have to be programmed by the technician or customer. These systems include: radio station presets, clock settings, seat memory, mirror memory, window memory and customer input keyless, window memory and customer input keyless entry codes.

Disconnect the battery ground cable. For additional information, refer to «Section 14-01».

2. Drain the cooling system. For additional information, refer to «section 03-03».

3. Remove the engine cover (covering the throttle body).

4. Disconnect the crankcase ventilation tube and the idle air control valve inlet tube from the air cleaner outlet tube. Remove the air cleaner outlet tube.

5. WARNING: THE FUEL SUPPLY LINES ON VEHICLES EQUIPPED WITH FUEL INJECTED ENGINES REMAIN PRESSURIZED FOR LONG PERIODS AFTER ENGINE SHUT DOWN. THE FUEL SYSTEM PRESSURE MUST BE RELIEVED PRIOR TO FUEL SYSTEM SERVICE, TO PREVENT POSSIBLE INJURY.

(Here is a suggestion for releasing the fuel system pressure if the gauge is not available. Pull the cap off the fuel test point - rear passenger side - and with a rag over it, use a small screwdriver to press the valve stem.)

Connect the Multiport Fuel Injection (MFI) Fuel Pressure Gauge (T80L-9974-B) to the fuel pressure relief valve on the fuel supply manifold. Open the manual valve on the gauge to relieve the fuel system pressure. Once the pressure is relieved, close the valve and remove the gauge.

6. Remove the locking clip from the pressure and return fuel line spring lock couplings. Using the spring lock coupling disconnect tools (D87L-9280-A for 3/8-inch line, D87L-9280-B for 1/2-inch line) on the couplings. Push the tool into the cage opening to release the female fitting from the garter spring. Remove the tool and pull the male coupling and fitting apart. Install protective caps over the lines and the fuel rail.

7. Disconnect the upper radiator hose from the water outlet connection and position it out of the way.

8. Disconnect the accelerator cable and the speed control actuator cable from the throttle body and the locator. Remove the screws retaining the cables to the accelerator cable bracket and position the cables out of the way.



 

9. Disconnect the wiring connectors from the throttle position sensor (TP), idle air control valve (IAC) and the engine coolant temperature sensor (ECT). Disconnect the wiring connectors from the LH fuel injectors and the two wiring locators from the fuel rail. Position the harness out of the way.

10. CAUTION: Do not pull directly on the ignition wires, the wires could separate from the connectors inside the boots.

Disconnect the ignition wires from the LH spark plugs and position them out of the way. Refer to «Section 03-07».

11. Remove the bolts retaining the spark plug wiring harness bracket to the intake manifold and the generator. Disconnect the ignition wires from the locators and remove the bracket.

12. Remove the serpentine drive belt from the generator pulley. Refer to «Section 03-05».

13. Remove the generator retaining bolts and position it out of the way.

14. Remove the PCV valve and tube.

15. Disconnect the wiring connectors from the water temperature indicator sender unit and the EGR vacuum regulator solenoid. Disconnect the RH fuel injector connectors and harness locators from the fuel rail. Position the harness out of the way.

16. CAUTION: Do not pull directly on the ignition wires, the wires could separate from the connectors inside the boots.

Disconnect the ignition wires from the RH spark plugs and position them out of the way. For additional information, refer to «Section 03-07».

17. Disconnect the vacuum line from the fuel vapor storage canister purge valve. Disconnect the heater hose from the rear of the intake manifold.

18. Disconnect the main vacuum hose from the rear of the intake manifold. Disconnect the hose from the fuel vapor storage canister purge valve.

19. Disconnect the EGR tube nut from the EGR valve.

20. Disconnect the vacuum hose from the EGR valve. Remove the EGR valve and gasket.

21. Remvoe the water outlet connection housing.

22. Remove the intake manifold. Remove and discard the intake manifold gaskets.

Installation

1. Note: It is extremely important that the gasket surfaces are free from all dirt, oil and debris.

Clean the intake manifold and gasket surfaces.

2. Note: Make sure the alignment tabs on the intake manifold gaskets are aligned with holes in cylinder heads.

Install new intake manifold gaskets. Carefully lower the intake manifold into position and install the nine retaining bolts. Tighten the bolts to 25 N-m (18 lb-ft) in the sequence shown.


3. Replace the O-ring seal on the water outlet connection and lube. Install the water outlet connection. Tighten the bolts to 25 N-m (18 lb-ft).

4. Clean the EGR valve sealing surface. Install a new gasket and the EGR valve. Tighten the bolts to 20 N-m (14 lb-ft). Connect the vacuum hose to the EGR valve.

5. Connect the exhaust manifold tube to the EGR valve. Tighten the tube nut to 40 N-m (30 lb-ft).

6. Connect the main vacuum hose to the rear of the intake manifold. Connect the emission hose to the fuel vapor storage canister purge valve.

7. Connect the heater hose at the rear of the intake manifold.

8. Connect the ignition wires to the RH spark plugs.

9. Connect the wiring connectors at the water temperature indicator sender unit and the EGR vacuum regulator solenoid. Connect the RH fuel injector connectors and the harness locators at the fuel rail.

10. Install the PCV valve and tube.

11. Install the generator. Tighten the bolts to 25 N-m (18 lb-ft).

12. Install the serpentine drive belt. Refer to «Section 03-05».

13. Install the ignition wire harness bracket to the intake manifold and generator. Tighten the bolts to 10 N-m (89 lb-in). Connect the ignition wires to the locators.

14. Connect the ignition wires to the LH spark plugs.

15. Position the engine harness and connect the wiring connectors at the throttle position (TP) sensor, idle air control valve (IAC) and the engine coolant temperature sensor (ECT). Connect the wiring connectors to the LH fuel injectors and the two wiring locators at the fuel rail.

16. Remove the protective caps from the fuel lines. Inspect and replace the fuel line O-rings as necessary. Lubricate the O-rings. Connect the fuel pressure and return line couplings. Pull on the fittings to verify proper coupling engagement and install the safety clips.

17. Connect the accelerator cable and speed control actuator cable to the throttle body and locator. Install the screws retaining the cables to the accelerator cable bracket. Tighten the screws to 10 N-m (89 lb-in).

18. Connect the upper radiator hose to the water outlet connection.

19. Install the air cleaner outlet tube and tighten the clamps securely. Connect the crankcase ventilation tube and idle air control valve inlet tube to the air cleaner outlet tube.

20. Install the engine cover (covering the throttle body). Tighten the nut to 4 N-m (36 lb-in).

21. Note: When the battery has been disconnected or reconnected, some abnormal drive symptoms may occur while the powertrain control module (PCM)(12A650) relearns its fuel trim. The vehicle may need to be driven 18 km (10 miles) or more to relearn the fuel trim.

Connect the battery ground cable.

22. Fill the cooling system. Refer to «Section 03-03».

23. Start the engine and check for leaks.


(Quoted from the www.crownvic.net message board, by member "dcooley".)

"Hi Eric,
Not ignorance...
Pretty simple swap.
1/2" breaker bar and lift from the pass side towards the center of the car to loosen the belt... once you have the tension off, pop it off the alternator pulley and let the bar slowly back down... have to remove the plug on the side of the pass. side ignition coil/module to make room for the breaker bar...
Once that's done, remove the plastic cover on the top... 1 10mm nut holds it down on the pass. side... drivers side snaps into the side of the air duct...
disconnect the battery. then disconnect the wires to the alternator... big one with a 10mm nut, then 2 plug ins.
2 10mm bolts on the bottom of the alt, and the bracket on the top rear of the alt comes off with 3 8mm bolts.
Drain the radiator.
on the pass. side rear of the manifold, there is a heat shield that is a bracket holding the throttle and cruise cables on... 2 8mm bolts hold it on... remove them and the bracket. disconnect the trhottle and cruise cable from the throttle body, and remove the throttle return spring... remove the 2 bolts holding the throttle cable bracket to the TB... move them out of the way.
disconnect the 2 hoses on the rear of the TB, the 2 on the front, and the 5 bolts holding the TB to the manifold (8mm)... Disconnect the TPS and IAC and remove the air intake tube.
Loosen the EGR tube to EGR valve nut, and remove the vacuum harness that goes to the Fuel Press. Reg, EGR etc...

Ned a 1/2 and 5/8 quick disconnect tools for the fuel lines on the drivers side...
remove the 11 bolts holding the manifold and thermostat housing on (10mm) and remove the heater hose on the rear pass. corner.
Disconnect the Fuel injector connectors, and the 2 temp senders. move the wiring harness out of the way.
Lift the manifold up and forward to clear the EGR tube and out it comes. Clean everything up on the engine...
To get the Injectors out, undo the 4 studs that hold the fuel rail to the manifold... Lift up (may have to use a foot on the manifold and tug hard while rocking back and forth a little) and the injectors will pull out of the manifold. Be careful with them, as the tips can break... you can turn them upside down and pull them out of the fuel rail. Put new O-Rings on the top and bottom... put a thin coat of oil on the O-Rings and push the injectors back into the fuel rail.

Put the new manifold on, and after it's in place and torqued to 18 lb/ft, put the injectors back on, and reassemble everything."


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96 TownCar
97 Dodge Ram 1500 Club Cab
92 Harley Lowrider Convertible 95.4 RWHP!!!!!

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