Lincoln Aviator: Engine - 3.0L EcoBoost / Removal and Installation - Intake Manifold

Removal

NOTICE: During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces, that enters the oil passages, coolant passages or the oil pan, can cause engine failure.

NOTE: Removal steps in this procedure may contain installation details.

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

1. Remove the retainers and the RH side engine compartment cover.
   

1. Remove the retainers and the LH side engine compartment cover.
   

1. Remove the bolts and the suspension support bar.
   Torque: 22 lb.ft (30 Nm)

1. Remove the following items:
   1. Air cleaner.
      Refer to: Air Cleaner (303-12 Intake Air Distribution and Filtering - 3.0L EcoBoost/3.0L EcoBoost – Hybrid (BQ), Removal and Installation).
      
   2. CAC outlet pipe.
      Refer to: Charge Air Cooler (CAC) Outlet Pipe (303-12 Intake Air Distribution and Filtering - 3.0L EcoBoost/3.0L EcoBoost – Hybrid (BQ), Removal and Installation).
      

1. • Disconnect the crankcase vent tube quick release couplings.
     Refer to: Quick Release Coupling (310-00A Fuel System - General Information - 3.0L EcoBoost, General Procedures).
     
   • Remove the crankcase vent tube.
     

1. Remove the cowl panel.
   Refer to: Cowl Panel (501-02 Front End Body Panels, Removal and Installation).
   

1. • Remove the coolant pipe bracket retaining bolts.
     Torque: 97 lb.in (11 Nm)
   • Remove the intake manifold bracket retaining bolts.
     Torque: 97 lb.in (11 Nm)

1. 1. Detach the vacuum tube retainers.
      
   2. Disconnect the engine wiring harness electrical connectors.
      
   3. Detach the engine wiring harness retainers.
      

1. 1. Detach the wiring harness retainers.
      
   2. Detach the fuel tube retainer.
      

1. 1. Remove the bolt and position the vacuum pressure sensor aside.
      
   2. Disconnect the EVAP purge valve quick release coupling.
      Refer to: Quick Release Coupling (310-00A Fuel System - General Information - 3.0L EcoBoost, General Procedures).
      
   3. Slide the EVAP purge valve off of the bracket.
      

1. Remove the bolts and position the coolant pipe aside.
   Torque: 97 lb.in (11 Nm)

1. 1. Loosen the intake manifold bolts.
      

   2. NOTE: The coolant pipe may come out during removal of the intake manifold.

      Remove the intake manifold.
      

1. Remove the insulator.
   

1. • Remove and inspect the gaskets, replace as necessary.
     
   • Clean and inspect all sealing surfaces.
     

Installation

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 if found, install a new intake manifold. Failure to follow these instructions can result in engine damage.

1. To install, reverse the removal procedure.
   

1. Tighten the bolts in 2 stages.
   Torque:
     Stage 1:  Bolts 1 through 8 in sequence::   44 lb.in (5 Nm)
     Stage 2:  Bolts 8 through 1 in reverse sequence::   89 lb.in (10 Nm)

1. Inspect the O-ring seal and replace as necessary.