The intake manifold was replaced on my 2000 Lincoln Towncar signature series and got new spark plugs... and now it won't crank. Anyone got any guesses as to why it won't crank? The battery was tested and is fine.
When you turn the ignition switch to on does the PATS red light at the top of the dash go out or flash quickly or stay solid red? If red or flashing then the PATS is not allowing the starter relay to be closed to crank the engine. We have a tech article in our Lincoln Tech forum here: http://www.lincolnforums.com/forums/threads/10468-Town-Car-no-start-or-no-crank-with-PATS-light-on that may help you with that.
When you turn the key to start can you hear a clunk or click? That would indicate the ign has closed the starter relay and provided power to the starter motor solenoid. The clunk is the starter motor solenoid driving the starter gear into contact with the flywheel teeth and making a circuit for the heavy battery cable to power the starter motor.
If you hear the clunk then the problem is likely with the battery (but that tested good) or starter motor, or the cables and connections. Also the ground connection from the starter motor to the starter motor body. You can use a large screwdriver to cross the positive and negative connections on the starter motor and that should make the starter crank. If the starter does not crank then use a heavy ground to the starter motor neg terminal (to bypass the internal grounding wire to the starter body) and try again. If still does not crank then use a jumper cable from battery positive terminal to the starter motor positive terminal and if the screwdriver across the terminals doe not cause the starter to crank the engine then replace the starter.
If you don't hear the clunk then check the small connection to the starter motor. When the switch is in the start position there should be battery voltage at that wire connection. If the wire and connecting tang have power then replace the starter motor or the solenoid if detachable. If the wire does not have power then the wire may be broken or the starter relay (or its fuse) may be problematic. I will get you the starter relay location and the fuse # with the wiring colours since I cannot readily see the relay in the owner's manual.
The starter motor has three bolts/nuts and one bolt in particular is hard to reach so I would spend the time to check before replacing the starter or solenoid.