1998 Town Car Workshop Manual

SECTION 303-01: Engine

IN-VEHICLE REPAIR

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1998 Town Car Workshop Manual

Intake Manifold
Removal
1. Disconnect the battery ground cable (14301).
2. Drain the cooling system; refer to Section 303-03 .
3. NOTE: With the retaining nut removed, lift the cover off the stud and slide it toward the front of the
vehicle.
Remove the engine appearance cover.

4. Remove the air cleaner outlet tube (9B659); refer to Section 303-12 .
5. Relieve the fuel pressure; refer to Section 310-00 .
6. Disconnect the fuel line; refer to Section 310-00 .

7. Remove the mounting arm and pivot shaft; refer to Section 501-16 .
8. Remove the five bolts and two nuts and remove the right-hand wet cowl.

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9. Disconnect the electrical connector.

10. Remove the three bolts and remove the left-hand wet cowl.

11. Remove the drive belt (8620); refer to Section 303-05 .

12. Raise the vehicle on a hoist; refer to Section 100-02 .
13. Disconnect the EGR valve to exhaust manifold tube (9D477).

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14. Lower the vehicle.

15. Disconnect the two EGR transducer hoses.

16. Disconnect the electrical connectors from the eight ignition coils (12029).

17. Disconnect the fuel charging wiring (9D930) from the eight fuel injectors.

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18. Disconnect the accelerator cable (9A758) and the speed control actuator cable (9A825).

19. Remove the bolts and the bracket.

20. Disconnect the vacuum lines for the evaporative emission canister purge valve (EVAP canister purge
valve) (9C915), the main chassis line and the exhaust gas recirculation valve (EGR valve) (9D460).

21. Disconnect the crankcase ventilation tube (6758).

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22. Disconnect the electrical connector from the EGR solenoid.

23. Disconnect the vacuum line from the evaporative emission canister purge valve.

24. Disconnect the generator cable.

25. Remove the generator mounting bracket (10153).

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Remove the bolts.

Remove the bracket.

26. Remove the upper radiator hose (8260).

Position the two clamps out of the way.
Remove the hose.

27. Disconnect the electrical connector from the idle air control valve (IAC valve) (9F715) and the throttle
position sensor (TP sensor) (9B989).

28. Disconnect the electrical connector from the generator (GEN) (10346).

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29. Position the hold down clamp out of the way and remove the hose.

30. Disconnect the EGR valve to exhaust manifold tube.

31. Remove the bolt and nut; remove the bracket.

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32. Remove the four bolts and the throttle body (9E926).

33. Remove the bolt and the stud. Remove the crash bracket.

34. Remove the studs and the fuel injection supply manifold (9F792) and remove the fuel injectors as an
assembly.

35. Remove the bolts and the ignition coils.

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36. Remove the bolts and the water hose connection (8592).

37. Remove the water thermostat (8575).

38. Remove the bolts and the intake manifold (9424).

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39. Remove the intake manifold gaskets (9439).

40. Clean the sealing surfaces.

Installation

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1. Install new intake manifold gaskets.

2. Install the intake manifold and hand-tighten the bolts at the locations shown.

3. Install the ignition coils and tighten the bolts.

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4. Install the fuel injection supply manifold and tighten the studs.

5. Install the crash bracket and loosely install the bolt and the stud.

6. Install the water thermostat.

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7. Install the water hose connection and loosely install the bolts.

8. Tighten the bolts in sequence.

9. Tighten the stud.

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10. Tighten the bolts.

11. Install the throttle body and tighten the bolts.

12. Install the transmission harness support bracket.

Position the bracket.
Install the nut and the bolt.

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13. Connect the EGR valve to exhaust manifold tube.

14. Connect the hold-down clamp (12270).

15. Connect the electrical connector to the generator.

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16. Connect the electrical connector to the:

idle air control valve
throttle position sensor

17. Install the upper radiator hose:

Position the hose and clamp.

18. Install the generator mounting bracket:

Position the generator mounting bracket.
Install the bolts.

19. Connect the generator cable.

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20. Connect the vacuum line to the evaporative emission canister purge valve.

21. Connect the electrical connector to the EGR solenoid.

22. Connect the crankcase ventilation tube.

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23. Connect the vacuum lines for the evaporative emission canister purge valve, the main chassis line
and the exhaust gas recirculation valve.

24. Position the bracket and install the bolts.

25. Connect the accelerator cable and the speed control actuator cable.
Install the bolts.
Connect the cables.

26. Connect the fuel charging wiring to the eight fuel injectors.

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27. Connect the electrical connectors to the eight ignition coils.

28. Connect the two EGR transducer hoses.

29. Raise the vehicle; refer to Section 100-02 .

30. Connect the EGR valve to exhaust manifold tube at the exhaust manifold (9430).

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31. Lower the vehicle.

32. Install the drive belt; refer to Section 303-05 .
33. Install the right-hand wet cowl, five bolts and two nuts.

34. Connect the electrical connector.

35. Install the left-hand wet cowl and bolts.

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36. Install the mounting arm and pivot shaft; refer to Section 501-16 .
37. Connect the fuel line; refer to Section 310-01 .

38. Install the air cleaner outlet tube; refer to Section 303-12 .
39. NOTE: Be sure to slide the cover over the retaining pegs before securing it.
Install the engine appearance cover.

40. Connect the battery ground cable.

41. Fill the cooling system; refer to Section 303-03 .

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