Lincoln Navigator: Engine - 3.5L EcoBoost (272kW/370PS) / Intake Manifold. Removal and Installation

Removal

1. Disconnect the battery ground cable.
   Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures).
   

1. Remove the EGR cooler.
   Refer to: Exhaust Gas Recirculation (EGR) Cooler (303-08 Engine Emission Control - 3.5L EcoBoost (272kW/370PS), Removal and Installation).
   

1. Disconnect the cabin heater coolant pump heater hose.
   

1. Disconnect the heater hose from the intake manifold and position aside.
   

1. • Detach the pin-type retainer.
     
   • Disconnect the electrical connector.
     
   • Follow directions to release the quick release coupling type 5.
     Refer to: Quick Release Coupling (310-00 Fuel System - General Information - 3.5L EcoBoost (272kW/370PS), General Procedures).
     
   • Remove the fuel vapor purge valve.
     

1. This step is only necessary if installing new intake manifold.
   Disconnect the electrical connector, remove the retainer and the differential pressure feedback EGR sensor.
   

1. Disconnect the throttle body electrical connector and wiring harness retainers.
   

1. Loosen the clamp and position the throttle body intake pipe aside.
   

1. Follow directions to release the quick release coupling type 3. Remove the PCV tube.
   Refer to: Quick Release Coupling (310-00 Fuel System - General Information - 3.5L EcoBoost (272kW/370PS), General Procedures).
   

1. Disconnect the wire harness retainers.
   

1. Disconnect the wire harness retainers from the intake manifold.
   

1. Disconnect the electrical connects and remove the wire harness retainers from the intake manifold.
   

1. This step is only necessary if installing new intake manifold.
   Detach the heater hose clamps from the intake manifold.
   

1. Remove the bolts and the intake manifold.
   

1. Inspect the gaskets for nicks, cuts and abrasions. If these conditions are not present, the gasket may be re-used.
   

1. NOTE: This step only necessary if there are any nicks, cuts or abrasions present.

   • Discard the gaskets.
     
   • Clean and inspect all of the sealing surfaces of the cylinder heads and the intake manifold.
     

Installation

1. If gaskets were discarded install new intake manifold gaskets.
   

1. NOTICE: If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions can result in engine damage.

   Install the intake manifold and the bolts.
   Torque:
     Stage 1:  89 lb.in (10 Nm)
     Stage 2:  45°

1. This step is only necessary if installing new intake manifold.
   Attach the heater hose clamps to the intake manifold.
   

1. Install the wire harness retainers to the intake manifold and connect the electrical connectors.
   

1. Attach the wire harness retainers to the intake manifold.
   

1. Attach the wire harness retainers.
   

1. Follow directions to install quick release coupling type 3. Install the PCV tube.
   Refer to: Quick Release Coupling (310-00 Fuel System - General Information - 3.5L EcoBoost (272kW/370PS), General Procedures).
   

1. Attach the wiring harness retainers and connect the throttle body electrical connector.
   

1. Position back the throttle body intake pipe and tighten the clamp.
   Torque: 44 lb.in (5 Nm)

1. This step is only necessary if installing new intake manifold.
   Install the differential pressure feedback EGR sensor and bolt. Connect the electrical connector.
   Torque: 89 lb.in (10 Nm)

1. • Install the fuel vapor purge valve.
     
   • Follow directions to connect the quick release couplings type 5.
     Refer to: Quick Release Coupling (310-00 Fuel System - General Information - 3.5L EcoBoost (272kW/370PS), General Procedures).
     
   • Attach the pin-type retainer.
     
   • Connect the electrical connector.
     

1. Connect the heater hose to the intake manifold.
   

1. Connect the cabin heater coolant pump heater hose.
   

1. Install the EGR cooler.
   Refer to: Exhaust Gas Recirculation (EGR) Cooler (303-08 Engine Emission Control - 3.5L EcoBoost (272kW/370PS), Removal and Installation).
   

1. Connect the battery ground cable.
   Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures).
   

1. Road test the vehicle.