Engine 4.6l (2v) Ford Crown Victoria II

GENERAL SPECIFICATIONS

GENERAL SPECIFICATIONS

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

Engine Component View

The concept of modularity allows engine designs to share commonization between concepts and engine hardware. The illustration (modular engine-typical) represents the basic cross sectional view of a modular V8 engine. The four modules are the

1. Intake module
2. Cylinder head module (RH)
3. Cylinder head module (LH)
4. Lower engine module

The modular engine concept supports efficiencies during repairs by allowing the removal and installation of these modules. While not all in-vehicle repairs can take advantage of the modular concept, most out-of-vehicle repairs benefit in reduction of time and labor needed to repair the engine.

The basic engine components consist of

1. Single overhead camshafts
2. Two valves per cylinder
3. Sequential multiport fuel injection (SFI)
4. Aluminum cylinder heads
5. Cast iron, 90-degree V-cylinder block
6. Individual ignition coils for each spark plug
7. Composite-material lower intake manifold with noise insulator
8. Large-bore throttle body

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Refer to ENGINE SYSTEM-GENERAL INFORMATION for basic mechanical concerns or refer to the INTRODUCTION - CNG, FLEX-FUEL & GASOLINE article.

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1. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/crown-victoria/ii-1997-2011/remont/charging-system/#battery-mounting-and-cables) .
2. Drain the engine cooling system. For additional information, refer to «ENGINE COOLING»(/ford/crown-victoria/ii-1997-2011/remont/cooling-system-mechanical/#engine-cooling-system) .
3. Remove the air cleaner and outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(/ford/crown-victoria/ii-1997-2011/remont/removal-installation/#intake-air-distribution-filtering) .
4. Disconnect the fuel spring lock coupling. For additional information, refer to «FUEL SYSTEM-GENERAL INFORMATION»(/ford/crown-victoria/ii-1997-2011/remont/fuel-system/#fuel-system-general-information) .
5. Remove the wiper mounting arm and pivot shaft. For additional information, refer to «WIPERS AND WASHERS»(/ford/crown-victoria/ii-1997-2011/remont/wiperwasher-systems/#wiper-system-washer-system) .
6. Disconnect the fuel charging wiring electrical connectors from the eight ignition coils.
7. Disconnect the fuel charging wiring electrical connectors from the eight fuel injectors.
8. Disconnect the accelerator cable, the speed control actuator cable, the throttle return spring and the cable retaining bolts.
9. Remove the cables from the exhaust gas recirculation (EGR) tube heat shield and position out of the way.
10. Remove the bolts and the EGR tube heat shield.
11. Disconnect the electrical connector and the vacuum hoses.
12. Disconnect the EVAP canister purge valve vacuum hose.
13. Disconnect the electrical connector and the wiring harness location retainer.
14. Remove the bolts and the generator mounting bracket.
15. Disconnect the upper radiator hose.
16. Disconnect the idle air control (IAC) valve and the throttle position (TP) sensor electrical connectors.
17. Disconnect the heater hose.
18. Disconnect the EGR system module tube nut from the EGR system module.
19. Remove the nut at the exhaust manifold and remove the EGR tube.
20. Separate the fuel charging wiring pin-type retainer from the crash bracket.
21. Remove the cables from the crash bracket.
22. Remove the crash bracket bolt and prevent the bolt from contacting the cylinder head with a rubber band or tie strap.
23. Remove the stud.
24. Disconnect the fuel pressure sensor electrical connector and the vacuum hoses.
25. Remove the generator harness position retainer from the LH front stud.
26. Remove the fuel charging wiring pin-type retainer from the rear of the manifold.
27. Disconnect the ground wire connector from the RH rear stud.
28. Disconnect the coolant temperature sensor electrical connector.
29. Remove the bolts and the eight ignition coils.
30. Remove the bolts and the coolant outlet adapter.
31. Remove the thermostat and discard the O-ring.
32. Remove the bolts and the intake manifold.
33. Remove and discard the intake manifold gaskets.
34. Clean the sealing surfaces.

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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.
4. Install the crash bracket and loosely install the bolt and the stud.
5. Tighten the bolts in the sequence shown.
6. Tighten the stud.
7. Connect the EGR system module tube to the EGR system module.
8. Install the EGR tube nut at the exhaust manifold.
9. Position the EGR system module tube heat shield and install the bolts.
10. Connect the IAC control valve and the TP sensor electrical connectors.
11. Attach the cables to the crash bracket.
12. Install the upper radiator hose.
13. Install the generator mounting bracket and the bolts.
14. Connect the electrical connector and the wiring harness location retainer.
15. Position the vacuum harness and connect the vacuum hose to the EVAP canister purge valve.
16. Connect the electrical connector and the vacuum hoses.
17. Connect the fuel pressure sensor electrical connector and the vacuum hoses.
18. Position and attach the cables to the EGR tube heat shield.
19. Connect the accelerator cable, the speed control actuator cable, the throttle return spring and the cable retaining bolts.
20. Connect the fuel charging wiring electrical connectors to the eight fuel injectors.
21. Connect the fuel charging wiring electrical connectors to the eight ignition coils.
22. Install the fuel charging wiring pin-type retainer to the rear of the manifold.
23. Install the generator harness position retainer to the LH front stud.
24. Attach the fuel charging wiring pin-type retainer to the crash bracket.
25. Connect the ground wire connector to the RH rear stud.
26. Connect the coolant temperature sensor electrical connector.
27. Install the wiper mounting arm and pivot shaft. For additional information, refer to «WIPERS AND WASHERS»(/ford/crown-victoria/ii-1997-2011/remont/wiperwasher-systems/#wiper-system-washer-system) .
28. Connect the fuel spring lock coupling. For additional information, refer to «FUEL SYSTEM-GENERAL INFORMATION»(/ford/crown-victoria/ii-1997-2011/remont/fuel-system/#fuel-system-general-information) .
29. Install the air cleaner and outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(/ford/crown-victoria/ii-1997-2011/remont/removal-installation/#intake-air-distribution-filtering) .
30. Connect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/crown-victoria/ii-1997-2011/remont/charging-system/#battery-mounting-and-cables) .
31. Check the engine oil.
32. Fill and bleed the engine cooling system. For additional information, refer to «ENGINE COOLING»(/ford/crown-victoria/ii-1997-2011/remont/cooling-system-mechanical/#engine-cooling-system) .

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1. Remove the wiper arm and pivot shaft. For additional information, refer to «WIPERS AND WASHERS»(/ford/crown-victoria/ii-1997-2011/remont/wiperwasher-systems/#wiper-system-washer-system) .
2. Remove the air cleaner outlet tube. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(/ford/crown-victoria/ii-1997-2011/remont/removal-installation/#intake-air-distribution-filtering) .
3. Disconnect the fuel line. For additional information, refer to «FUEL SYSTEM-GENERAL INFORMATION-NATURAL GAS»(/ford/crown-victoria/ii-1997-2011/remont/fuel-system/#fuel-system-general-information-natural-gas) .
4. Disconnect the fuel charging wiring electrical connectors from the eight ignition coils and the eight fuel injectors.
5. Disconnect the fuel charging wiring electrical connector from the fuel pressure sensor.
6. Disconnect the fuel charging wiring electrical connector from the fuel temperature sensor.
7. Disconnect the fuel charging wiring electrical connector from the engine coolant temperature sensor.
8. Separate the isolation valve wiring lead from the upper generator support bracket and disconnect.
9. Disconnect the generator battery cable.
10. Remove the power distribution box access cover.
11. Remove the nut and the wiring.
12. Disconnect the fuel charging wiring electrical connectors at the inner fender splash shield.
13. Disconnect the fuel charging wiring electrical connector from the A/C pressure transducer.
14. Disconnect the fuel charging wiring electrical connector from the cylinder head temperature sensor jumper.
15. Disconnect the fuel charging wiring electrical connector from the camshaft position sensor.
16. Disconnect the fuel charging wiring electrical connector from the generator.
17. Disconnect the fuel charging wiring electrical connector from the throttle position sensor.
18. Disconnect the fuel charging wiring from the radio ignition interference capacitor.
19. Disconnect the fuel charging wiring from the exhaust gas recirculation (EGR) vacuum regulator solenoid.
20. Disconnect the differential pressure feedback exhaust gas recirculation (EGR) system electrical connector.
21. Disconnect the fuel charging wiring from the idle air control valve.
22. Disconnect the throttle cable and the speed control actuator cable from the throttle body.
23. Remove the bolts and position the cables and bracket out of the way.
24. Remove the bolts and position the fuel charging wiring out of the way.
25. Disconnect the hoses from the differential pressure feedback EGR system.
26. Disconnect the vacuum hose from the (EGR) valve.
27. Disconnect the main chassis vacuum supply hose from the throttle body adapter.
28. Disconnect the crankcase ventilation tube at two locations and remove from the vehicle.
29. Disconnect the vacuum hose from the throttle body adapter.
30. Disconnect the vacuum hoses from the EGR vacuum regulator solenoid.
31. Disconnect the EGR tube from the EGR valve.
32. Remove the bolts from the isolation valve.
33. Remove the four bolts.
34. Remove the fuel injection supply manifold and the fuel injectors as an assembly.
35. Disconnect the heater water hose from the intake manifold.
36. Disconnect the upper radiator hose from the water outlet adapter.
37. Remove the bolts and the eight ignition coils.
38. Remove the bolts and the generator support bracket.
39. Remove the bolts and the water outlet adapter.
40. Remove the water thermostat and the O-ring.
41. Remove the bolts.
42. Remove the intake manifold.
43. Remove the intake manifold gaskets.
44. Clean the sealing surfaces.

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1. Install new intake manifold gaskets.
2. Install the intake manifold.
3. Install the bolts and tighten in the sequence shown.
4. Install the water thermostat and a new O-ring.
5. Install the water outlet adapter and tighten the bolts.
6. Install the generator support bracket and tighten the bolts.
7. Install the eight ignition coils and tighten the bolts.
8. Connect the upper radiator hose to the water outlet adapter.
9. Connect the heater water hose to the intake manifold.
10. Install the fuel injectors and the fuel injection supply manifold as an assembly.
11. Install the four bolts.
12. Install the bolts in the isolation valve and tighten.
13. Connect the EGR tube to the EGR valve.
14. Connect the vacuum hoses to the EGR vacuum regulator solenoid.
15. Connect the vacuum hoses to the throttle body adapter.
16. Install the crankcase ventilation tube and connect at two locations.
17. Connect the main chassis vacuum supply hose to the throttle body adapter.
18. Connect the vacuum hose to the EGR valve.
19. Connect the hoses to the differential pressure feedback exhaust gas recirculation (EGR) system.
20. Connect the fuel lines. For additional information, refer to «FUEL SYSTEM-GENERAL INFORMATION-NATURAL GAS»(/ford/crown-victoria/ii-1997-2011/remont/fuel-system/#fuel-system-general-information-natural-gas) .
21. Position the fuel charging wiring and install the bolts.
22. Position the cables and the bracket and install the bolts.
23. Connect the throttle cable and the speed control actuator cable to the throttle body.
24. Connect the fuel charging wiring to the idle air control valve.
25. Connect the differential pressure feedback EGR system electrical connector.
26. Connect the fuel charging wiring to the EGR vacuum regulator solenoid.
27. Connect the fuel charging wiring to the radio ignition interference capacitor.
28. Connect the fuel charging wiring electrical connector to the throttle position sensor.
29. Connect the fuel charging wiring electrical connector to the generator.
30. Connect the fuel charging wiring electrical connector to the camshaft position sensor.
31. Connect the fuel charging wiring electrical connector to the cylinder head temperature sensor jumper.
32. Connect the fuel charging wiring electrical connector to the A/C pressure transducer.
33. Connect the fuel charging wiring electrical connectors at the inner fender splash shield.
34. Reposition the wiring on the stud and tighten the nut.
35. Install the power distribution box access cover.
36. Connect the generator battery cable and tighten the nut.
37. Connect the isolation valve jumper to the fuel charging wiring electrical connector.
38. Connect the fuel charging wiring electrical connector to the engine coolant temperature sensor.
39. Connect the fuel charging wiring electrical connector to the fuel temperature sensor.
40. Connect the fuel charging wiring electrical connector to the fuel pressure sensor.
41. Connect the fuel charging wiring electrical connectors to the eight ignitions coils and the eight fuel injectors.
42. Install the wiper arm and pivot shaft. For additional information, refer to «WIPERS AND WASHERS»(/ford/crown-victoria/ii-1997-2011/remont/wiperwasher-systems/#wiper-system-washer-system) .
43. Install the air cleaner outlet tube. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(/ford/crown-victoria/ii-1997-2011/remont/removal-installation/#intake-air-distribution-filtering) .

Valve Cover RH

MATERIAL SPECIFICATION

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1. Disconnect the fuel line spring lock coupling. For additional information, refer to «FUEL SYSTEM-GENERAL INFORMATION»(/ford/crown-victoria/ii-1997-2011/remont/fuel-system/#fuel-system-general-information) .
2. Remove LH engine mount. For additional information, refer to «ENGINE MOUNT LH»(/ford/crown-victoria/ii-1997-2011/remont/mechanical/#engine-46l-2v) .
3. Disconnect the crankshaft position (CKP) sensor electrical connector.
4. Disconnect the power steering pressure (PSP) switch electrical connector.
5. Disconnect the A/C compressor electrical connector.
6. Disconnect the engine wiring harness retainers.
7. Lower the vehicle.
8. Remove the power distribution center electrical connection cover.
9. Disconnect the power distribution center electrical connection.
10. Disconnect the ground wire.
11. Disconnect the electrical connectors.
12. Disconnect the A/C high pressure switch electrical connector.
13. Disconnect the evaporative emission (EVAP) canister purge valve hoses and the electrical connector.
14. Disconnect the vacuum hose.
15. Remove the nuts and the EVAP canister purge valve.
16. Disconnect the wiring harness and position aside.
17. Disconnect the positive crankcase ventilation (PCV) hose.
18. Disconnect the ignition coil electrical connectors.
19. Disconnect the harness from the valve cover and position out of the way.
20. Lower the engine.
21. Remove the studs, the bolts and the valve cover. Clean the gasket surfaces with a plastic scraping tool and metal surface cleaner.
22. To install, reverse the removal procedure. Apply sealant in the location shown.
23. Tighten the bolts in the sequence shown.

Valve Cover LH

MATERIAL SPECIFICATION

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1. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/crown-victoria/ii-1997-2011/remont/charging-system/#battery-mounting-and-cables) .
2. Remove the air cleaner and outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(/ford/crown-victoria/ii-1997-2011/remont/removal-installation/#intake-air-distribution-filtering) .
3. Disconnect the: 42-pin connector. 16-pin connector. Transmission electrical connector.
4. Disconnect the electrical connectors.
5. Disconnect the fuel charging wiring harness from the valve cover and position out of the way.
6. Remove the studs, the bolts and the valve cover. Clean the sealing surfaces with a plastic scraping tool and metal surface cleaner.
7. To install, reverse the removal procedure. Apply sealant in the locations shown.
8. Tighten the bolts and studs in the sequence shown.

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MATERIAL SPECIFICATION

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1. Remove the engine cooling fan and fan shroud. For additional information, refer to «ENGINE COOLING»(/ford/crown-victoria/ii-1997-2011/remont/cooling-system-mechanical/#engine-cooling-system) .
2. Remove the drive belt. For additional information, refer to «SPECIFICATIONS & DRIVE BELT ROUTING»(/ford/crown-victoria/ii-1997-2011/remont/accessory-drive-belts/#cooling-system-specifications-drive-belt-routing) .
3. Remove the crankshaft pulley bolt.
4. Use the special tool to remove the crankshaft pulley.

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1. Apply sealant to the woodruff key slot on the crankshaft pulley.
2. Use the special tool to install the crankshaft pulley.
3. Install the bolt and washer. Tighten the bolt in four steps. Step 1: Tighten to 90 Nm (66 lb-ft). Step 2: Loosen the bolt. Step 3: Tighten to 47-53 Nm (34-39 lb-ft). Step 4: Tighten an additional 85-90 degrees.
4. Install the drive belt. For additional information, refer to «SPECIFICATIONS & DRIVE BELT ROUTING»(/ford/crown-victoria/ii-1997-2011/remont/accessory-drive-belts/#cooling-system-specifications-drive-belt-routing) .
5. Install the engine cooling fan and the fan shroud. For additional information, refer to «ENGINE COOLING»(/ford/crown-victoria/ii-1997-2011/remont/cooling-system-mechanical/#engine-cooling-system) .

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MATERIAL SPECIFICATION

Removal

1. Remove the cranskhshaft pulley. For additional information, refer to «CRANKSHAFT PULLEY»(/ford/crown-victoria/ii-1997-2011/remont/mechanical/#engine-46l-2v) .
2. Use the special tool to remove the front cover seal.

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1. Lubricate the engine front cover and the front oil seal inner lip with clean engine oil.
2. Use the special tools to install the crankshaft front seal into the engine front cover.
3. Install the crankshaft pulley. For additional information, refer to «CRANKSHAFT PULLEY»(/ford/crown-victoria/ii-1997-2011/remont/mechanical/#engine-46l-2v) .

Engine Front Cover

MATERIAL SPECIFICATION

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1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/ford/crown-victoria/ii-1997-2011/remont/hoistjack/#jacking-lifting) .
2. Release the fuel system pressure. For additional information, refer to «FUEL SYSTEM-GENERAL INFORMATION»(/ford/crown-victoria/ii-1997-2011/remont/fuel-system/#fuel-system-general-information) .
3. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/crown-victoria/ii-1997-2011/remont/charging-system/#battery-mounting-and-cables) .
4. Remove both valve covers. For additional information, refer to «VALVE COVER RH»(/ford/crown-victoria/ii-1997-2011/remont/mechanical/#engine-46l-2v__valve-cover-rh) or «VALVE COVER LH»(/ford/crown-victoria/ii-1997-2011/remont/mechanical/#engine-46l-2v__valve-cover-lh) .
5. Remove the coolant pump. For additional information, refer to «ENGINE COOLING»(/ford/crown-victoria/ii-1997-2011/remont/cooling-system-mechanical/#engine-cooling-system) .
6. Remove the bolts and position the power steering pump aside.
7. Remove the oil pan drain plug and drain the engine oil.
8. Remove the four bolts.
9. Remove the crankshaft front oil seal. For additional information, refer to «CRANKSHAFT FRONT OIL SEAL»(/ford/crown-victoria/ii-1997-2011/remont/mechanical/#engine-46l-2v) .
10. Remove the bolt and the belt idler pulley.
11. Remove the bolts and the stud bolts in the sequence shown.
12. Remove the engine front cover from the front cover-to-cylinder block dowel. Clean the gasket surfaces with a plastic scraping tool and metal surface cleaner.

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1. Apply sealant along the cylinder head-to-block surface and the oil pan-to-cylinder block surface.
2. Install the engine front cover on the front cover-to-cylinder block dowel and loosely install the bolts.
3. Tighten the front cover bolts and stud bolts in sequence in two stages. ITEM DESCRIPTION Item Part Number Description 1 N806177 Bolt, hex flange head pilot, M8 x 1.25 x 53 2 N806177 Bolt, hex flange head pilot, M8 x 1.25 x 53 3 N806177 Bolt, hex flange head pilot, M8 x 1.25 x 53 4 N806177 Bolt, hex flange head pilot, M8 x 1.25 x 53 5 N806177 Bolt, hex flange head pilot, M8 x 1.25 x 53 6 N806177 Bolt, hex-head pilot, M10 x 1.5 x 1.5 x 103.1 7 N808529 Stud, hex-head pilot, M10 x 1.5 x 1.5 x 103.1 8 N808142 Screw and washer, hex-pilot, M10 x 1.5 x 57.5 9 N808142 Screw and washer, hex pilot, M10 x 1.5 x 57.5 10 N808142 Screw and washer, hex pilot, M10 x 1.5 x 57.5 11 N808140 Stud and washer, hex-head pilot, M10 x 1.5 x M8 x 1.25 x 109.6 12 N808140 Stud and washer, hex-head pilot, M10 x 1.5 x M8 x 1.25 x 109.6 13 N808140 Stud and washer, hex-head pilot, M10 x 1.5 x M8 x 1.25 x 109.6 14 N808140 Stud and washer, hex-head pilot, M10 x 1.5 x M8 x 1.25 x 109.6 15 N808140 Stud and washer, hex-head pilot, M10 x 1.5 x M8 x 1.25 x 109.6 Stage 1: Tighten fasteners 1 through 7 to 25 Nm (18 lb-ft). Stage 2: Tighten fasteners 6 through 15 to 48 Nm (35 lb-ft).
4. Position the belt idler pulley and install the bolt.
5. Install a new crankshaft front oil seal. For additional information, refer to «CRANKSHAFT FRONT OIL SEAL»(/ford/crown-victoria/ii-1997-2011/remont/mechanical/#engine-46l-2v) .
6. Loosely install the front oil pan bolts.
7. Tighten the bolts in two stages. Stage 1: Tighten to 20 Nm (15 lb-ft). Stage 2: Tighten an additional 60 degrees.
8. Position the power steering pump and install the bolts.
9. Install the oil pan drain plug.
10. Install the valve covers. For additional information, refer to «VALVE COVER RH»(/ford/crown-victoria/ii-1997-2011/remont/mechanical/#engine-46l-2v__valve-cover-rh) or «VALVE COVER LH»(/ford/crown-victoria/ii-1997-2011/remont/mechanical/#engine-46l-2v__valve-cover-lh) .
11. Install the coolant pump. For additional information, refer to «ENGINE COOLING»(/ford/crown-victoria/ii-1997-2011/remont/cooling-system-mechanical/#engine-cooling-system) .
12. Connect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/crown-victoria/ii-1997-2011/remont/charging-system/#battery-mounting-and-cables) .
13. Fill the engine with oil.

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MATERIAL SPECIFICATION

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1. Remove the engine front cover. For additional information, refer to «ENGINE FRONT COVER»(/ford/crown-victoria/ii-1997-2011/remont/mechanical/#engine-46l-2v__engine-front-cover) .
2. Remove the crankshaft sensor ring from the crankshaft.
3. Disconnect the eight ignition coil electrical connectors.
4. Remove the bolts and the eight ignition coils.
5. Remove the spark plugs.
6. Position the lobe of the camshaft up.
7. Install the special tool between the valve spring coils to prevent valve stem seal damage.
8. Use the special tool to compress the valve spring and remove the camshaft roller followers.
9. Position the crankshaft with the keyway at the 12 o'clock position.
10. Remove the timing chain tensioning system from both timing chains. Remove the bolts. Remove the timing chain tensioners. Remove the timing chain tensioner arms.
11. Remove the LH and RH timing chains and the crankshaft sprocket. Remove the RH timing chain from the camshaft sprocket. Remove the RH timing chain from the crankshaft sprocket. Repeat for the LH timing chain and crankshaft sprocket.
12. Remove the timing chain guides. Remove the bolts. Remove the LH timing chain guide. Remove the bolts. Remove the RH timing chain guide.
13. Install the special tool.
14. Remove the bolt and the camshaft gear.

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1. Compress each tensioner plunger, using an edge of a vise.
2. Using a small screwdriver or pick, push back and hold the ratchet mechanism.
3. While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing.
4. Install a paper clip into the hole of each tensioner housing to hold the ratchet assembly and plunger in during installation. Remove the tensioner from the vise.
5. Inspect the RH and LH timing chain tensioners. Install new tensioners as necessary.
6. Compress each tensioner plunger, using a vise.
7. Install a retaining clip on each tensioner to hold the plunger in during installation.
8. If the copper links are not visible, mark one link on one end and one link on the other end, and use as timing marks.
9. Install the camshaft sprockets and new bolts. Tighten the bolts in two stages. Stage 1: Tighten the bolt to 40 Nm (30 lb-ft). Stage 2: Tighten the bolt an additional 90 degrees (1/4 turn).
10. Using the special tool, position the crankshaft so the number one cylinder is at top dead center (TDC).
11. Install the crankshaft sprocket, making sure the flange faces forward.
12. Install the timing chain guide. Position the LH timing chain guide. Install and tighten the LH bolts. Position the RH timing chain guide. Install and tighten the RH bolts.
13. Rotate the RH camshaft sprocket until the timing mark is approximately at the 11 o'clock position. Rotate the LH camshaft sprocket until the timing mark is approximately at the 12 o'clock position.
14. Position the LH (inner) timing chain on the crankshaft sprocket, aligning the copper (marked) link with the timing mark on the sprocket.
15. Install the LH timing chain on the sprocket, aligning the copper (marked) link with the timing marks on the sprocket.
16. Position the LH timing chain tensioner arm on the dowel pin and install the LH timing chain tensioner.
17. Remove the retaining clip from the LH timing chain tensioner.
18. Remove the retaining clip from the LH timing chain tensioner.
19. Position the RH (outer) timing chain on the crankshaft sprocket, aligning the copper (marked) link with the timing mark on the sprocket.
20. Install the RH timing chain on the camshaft sprocket, aligning the copper (marked) link with the timing marks on the sprocket.
21. Position the RH timing chain tensioner arm on the dowel pin and install the RH timing chain tensioner.
22. Remove the retaining clip from the RH timing chain tensioner.
23. Remove the retaining clip from the RH timing chain tensioner.
24. Make sure that the copper (marked) chain links are lined up with the dots on the crankshaft sprocket and the camshaft sprockets.
25. Rotate the camshaft until the lobe is in the up position.
26. Install the special tool between the valve spring coils to prevent valve stem seal damage.
27. Install the camshaft roller followers. Install the special tool. Compress the valve spring. Install the camshaft roller followers in their original locations.
28. Install the eight spark plugs.
29. Install the eight ignition coils and bolts.
30. Connect the eight ignition coil electrical connectors.
31. Install the crankshaft sensor ring on the crankshaft.
32. Install the engine front cover. For additional information, refer to «ENGINE FRONT COVER»(/ford/crown-victoria/ii-1997-2011/remont/mechanical/#engine-46l-2v__engine-front-cover) .

Scheme 310

1. Remove the roller followers. For additional information, refer to «ROLLER FOLLOWER»(/ford/crown-victoria/ii-1997-2011/remont/mechanical/#engine-46l-2v) .
2. Position the piston at the top of the stroke.
3. Remove the spark plug and install compressed air in the cylinder to hold both valves in position.
4. Use the special tool to compress the valve springs.
5. Remove the valve spring retainer keys, the valve spring retainers, and the valve spring.

Scheme 311

Scheme 312

Scheme 313

Scheme 314

1. Position the valve spring and the valve spring retainers.
2. Install the special tool between the valve spring coils to prevent valve stem seal damage.
3. Use the special tool to compress the valve spring. Install the valve spring retainer keys.
4. Remove the special tools.
5. Install the roller followers. For additional information, refer to «ROLLER FOLLOWER»(/ford/crown-victoria/ii-1997-2011/remont/mechanical/#engine-46l-2v) .

Scheme 315

1. Remove the valve springs. For additional information, refer to «VALVE SPRINGS»(/ford/crown-victoria/ii-1997-2011/remont/mechanical/#engine-46l-2v) .
2. Remove the valve stem seals.

Scheme 316

Installation

1. Use the special tool to install the valve stem seals.
2. Install the valve springs. For additional information, refer to «VALVE SPRINGS»(/ford/crown-victoria/ii-1997-2011/remont/mechanical/#engine-46l-2v) .

Scheme 317

1. Remove the roller followers. For additional information, refer to «ROLLER FOLLOWER»(/ford/crown-victoria/ii-1997-2011/remont/mechanical/#engine-46l-2v) .
2. Remove the valve tappets.
3. To install, reverse the removal procedure.

Scheme 318

Scheme 319

1. Remove the valve cover. For additional information, refer to «VALVE COVER RH»(/ford/crown-victoria/ii-1997-2011/remont/mechanical/#engine-46l-2v__valve-cover-rh) or «VALVE COVER LH»(/ford/crown-victoria/ii-1997-2011/remont/mechanical/#engine-46l-2v__valve-cover-lh) .
2. Position the piston of the cylinder being repaired at the bottom of the stroke.
3. Install the special tool between the valve spring coils to prevent valve stem seal damage.
4. Use the special tool to compress the valve springs and remove the cam roller followers.

Scheme 320

Scheme 321

1. Use the special tool to compress the valve spring and install the camshaft roller followers.
2. Remove the special tools.
3. Install the valve cover. For additional information, refer to «VALVE COVER RH»(/ford/crown-victoria/ii-1997-2011/remont/mechanical/#engine-46l-2v__valve-cover-rh) or «VALVE COVER LH»(/ford/crown-victoria/ii-1997-2011/remont/mechanical/#engine-46l-2v__valve-cover-lh) .

Camshaft

MATERIAL SPECIFICATION

Scheme 322

Scheme 323

Scheme 324

1. Remove the camshaft roller followers. For additional information, refer to «ROLLER FOLLOWER»(/ford/crown-victoria/ii-1997-2011/remont/mechanical/#engine-46l-2v) .
2. Remove the timing chain. For additional information, refer to «TIMING DRIVE COMPONENTS»(/ford/crown-victoria/ii-1997-2011/remont/mechanical/#engine-46l-2v) .
3. Remove the camshaft sprocket and spacer. Remove the bolt. Remove the camshaft sprocket and spacer.
4. Remove the 13 camshaft bearing cap bolts.
5. Remove the camshaft bearing cap ladders.
6. Remove the camshaft from the cylinder head.

Scheme 325

Scheme 326

Scheme 327

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Scheme 331

1. Lubricate the camshaft journals with clean engine oil.
2. Install the camshaft onto the cylinder head.
3. Lubricate the camshaft bearing cap ladders with clean engine oil.
4. Install the camshaft bearing caps and loosely install the bolts.
5. Tighten the bolts in the sequence shown.
6. Install the camshaft sprocket spacer. Position the camshaft sprocket and sprocket spacer. Install the bolt.
7. Install the timing chains. For additional information, refer to «TIMING DRIVE COMPONENTS»(/ford/crown-victoria/ii-1997-2011/remont/mechanical/#engine-46l-2v) .
8. Install the roller follower. For additional information, refer to «ROLLER FOLLOWER»(/ford/crown-victoria/ii-1997-2011/remont/mechanical/#engine-46l-2v) .

Scheme 332

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Scheme 338

1. Disconnect the negative battery cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/crown-victoria/ii-1997-2011/remont/charging-system/#battery-mounting-and-cables) .
2. Rotate the drive belt tensioner clockwise and remove the drive belt.
3. Disconnect the crankshaft position (CKP) sensor electrical connector.
4. Disconnect the A/C compressor electrical connector.
5. Remove the bolt and position aside the transmission cooler tube bracket.
6. Remove the bolts and position aside the A/C compressor.
7. Disconnect the exhaust pipe from the exhaust manifold.
8. Remove the eight nuts, the exhaust manifold and the gasket.
9. To install, reverse the removal procedure.

Scheme 339

Scheme 340

Scheme 341

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/ford/crown-victoria/ii-1997-2011/remont/hoistjack/#jacking-lifting) .
2. Disconnect the negative battery cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/crown-victoria/ii-1997-2011/remont/charging-system/#battery-mounting-and-cables) .
3. Remove the exhaust manifold heat shield.
4. Disconnect the exhaust pipe from the exhaust manifold.
5. Disconnect the exhaust gas recirculation (EGR) system module tube from the exhaust manifold.
6. Disconnect and remove the heated oxygen sensor (HO2S). For additional information, refer to «ELECTRONIC ENGINE CONTROLS»(/ford/crown-victoria/ii-1997-2011/remont/removal-installation/#electronic-engine-control-system) .
7. Remove the eight nuts, the exhaust manifold and the gasket.
8. To install, reverse the removal procedure.

Oil Filter Adapter

MATERIAL SPECIFICATION

Scheme 342

Scheme 343

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/ford/crown-victoria/ii-1997-2011/remont/hoistjack/#jacking-lifting) .
2. Drain the cooling system. For additional information, refer to «ENGINE COOLING»(/ford/crown-victoria/ii-1997-2011/remont/cooling-system-mechanical/#engine-cooling-system) .
3. Disconnect the lower radiator hose from the oil filter adapter.
4. Drain the engine oil. Install the drain plug when finished.
5. Remove the oil filter.
6. Disconnect the oil pressure sensor electrical connector.
7. Remove the oil filter adapter. Remove the bolts. Remove the oil filter adapter.

Scheme 344

Scheme 345

Scheme 346

1. Clean the sealing surfaces.
2. Install a new gasket.
3. Install the oil filter adapter and tighten the bolts in the sequence shown. Attach the wiring harness.
4. Connect the oil pressure sensor electrical connector.
5. Install the oil filter.
6. Fill the crankcase with clean engine oil.
7. Connect the lower radiator hose.
8. Fill and bleed the cooling system. For additional information, refer to «ENGINE COOLING»(/ford/crown-victoria/ii-1997-2011/remont/cooling-system-mechanical/#engine-cooling-system) .

Scheme 347

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/ford/crown-victoria/ii-1997-2011/remont/hoistjack/#jacking-lifting) .
2. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/crown-victoria/ii-1997-2011/remont/charging-system/#battery-mounting-and-cables) .
3. Remove the oil pressure sensor electrical connector and remove the oil pressure sensor. To install, tighten to 14 Nm (10 lb-ft), then tighten an additional 180 degrees.
4. To install, reverse the removal procedure.

Scheme 348

Scheme 349

1. Remove the exhaust manifold. For additional information, refer to «EXHAUST MANIFOLD LH»(/ford/crown-victoria/ii-1997-2011/remont/mechanical/#engine-46l-2v) .
2. Remove the bolt and the oil level indicator tube.
3. Inspect the O-ring; install a new O-ring if necessary.
4. To install, reverse the removal procedure.

Oil Pan

MATERIAL SPECIFICATION

Scheme 350

Scheme 351

Scheme 352

1. Remove the front crossmember.
2. Remove the bolt and the nut. Position the transmission cooler tubes aside.
3. Drain the engine oil. Install the drain plug when finished.
4. Remove the oil pan bolts in the sequence shown.
5. Remove the oil pan and the gasket.

Scheme 353

Scheme 354

1. Clean and inspect the mating surfaces.
2. Apply silicone gasket and sealant at the rear oil seal retainer-to-cylinder block sealing surface.
3. Apply silicone gasket and sealant at the engine front cover-to-cylinder block mating surface.
4. Position the oil pan gasket and the oil pan.
5. Tighten the bolts in two stages, in the sequence shown. Stage 1: Tighten to 20 Nm (15 lb-ft). Stage 2: Rotate an additional 60 degrees.
6. Position the transmission cooler tubes and install the bolt and the nut.
7. Install the front crossmember.
8. Fill the engine with clean engine oil.
9. Start the engine and check for leaks.

1. Remove the transmission. For additional information, refer to «AUTOMATIC TRANSAXLE/TRANSMISSION»(/ford/crown-victoria/ii-1997-2011/remont/automatic-trans/#automatic-transmission) .
2. Remove the bolts and the flexplate.

Scheme 355

Scheme 356

1. Position the flexplate and loosely install the bolts. Tighten the bolts in the sequence shown.
2. Install the transmission. For additional information, refer to «AUTOMATIC TRANSAXLE/TRANSMISSION»(/ford/crown-victoria/ii-1997-2011/remont/automatic-trans/#automatic-transmission) .

Scheme 357

MATERIAL SPECIFICATION

Scheme 358

Scheme 359

1. Remove the flexplate. For additional information, refer to «FLEXPLATE»(/ford/crown-victoria/ii-1997-2011/remont/mechanical/#engine-46l-2v) .
2. Use the special tools to remove the rear oil seal slinger.
3. Use the special tools to remove the rear main seal.
4. If the oil dye leak test reveals a leak behind the retainer, remove the eight bolts and the crankcase rear oil seal retainer.

Scheme 360

Scheme 361

Scheme 362

Scheme 363

1. Clean and inspect the mating surface.
2. Apply sealant around the rear oil seal retainer sealing surface.
3. Install the rear oil seal retainer and loosely install the eight bolts.
4. Tighten the rear oil seal retainer bolts in the sequence shown and install the two oil pan bolts.
5. Use the special tools to install the rear main seal.
6. Use the special tools to install the rear main seal slinger.
7. Install the flexplate. For additional information, refer to «FLEXPLATE»(/ford/crown-victoria/ii-1997-2011/remont/mechanical/#engine-46l-2v) .

Scheme 364

Scheme 365

Scheme 366

Scheme 367

Scheme 368

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/ford/crown-victoria/ii-1997-2011/remont/hoistjack/#jacking-lifting) .
2. Remove the generator. For additional information, refer to «GENERATORS & REGULATORS»(/ford/crown-victoria/ii-1997-2011/remont/charging-system/#charging-system-generators-regulators) .
3. Install the special tools.
4. Remove the nut.
5. Using the special tools, raise the engine.
6. Remove the three bolts.
7. Remove the RH engine mount.
8. To install, reverse the removal procedure.

Scheme 369

Scheme 370

Scheme 371

Scheme 372

Scheme 373

1. With the vehicle in neutral, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/ford/crown-victoria/ii-1997-2011/remont/hoistjack/#jacking-lifting) .
2. Remove the generator. For additional information, refer to «GENERATORS & REGULATORS»(/ford/crown-victoria/ii-1997-2011/remont/charging-system/#charging-system-generators-regulators) .
3. Install the special tools.
4. Remove the oil filter.
5. Remove the nut.
6. Using the special tools, raise the engine.
7. Remove the three bolts.
8. Remove the LH engine mount.
9. To install, reverse the removal procedure.

Scheme 374

MATERIAL SPECIFICATION

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Scheme 428

1. Remove the engine. For additional information, refer to «ENGINE»(/ford/crown-victoria/ii-1997-2011/remont/mechanical/#engine-46l-2v) .
2. Remove the bolts and the flexplate.
3. Remove the engine/transmission spacer plate.
4. Mount the engine on a suitable engine stand.
5. Remove the LH and the RH lifting brackets.
6. Remove the bolts and the RH engine mount.
7. Remove the drain plugs from the engine block. Allow the coolant to completely drain. Install the drain plugs when finished.
8. Remove the bolt and the battery cables from the engine.
9. Disconnect the exhaust gas recirculation (EGR) tube from the exhaust manifold.
10. Disconnect the differential pressure feedback EGR system electrical connector.
11. Disconnect the eight ignition coil electrical connectors.
12. Disconnect the eight fuel injector electrical connectors.
13. Remove the bolts and the EGR tube heat shield.
14. Remove the crankcase ventilation tube.
15. Remove the generator mounting bracket. Remove the bolts. Remove the bracket.
16. Disconnect the idle air control (IAC) and the throttle position (TP) sensor electrical connectors.
17. Disconnect the generator electrical connector.
18. Disconnect the cylinder head temperature (CHT) sensor electrical connector.
19. Remove the generator wiring harness anchor from the LH front stud.
20. Disconnect the ground wire from the RH rear stud.
21. Disconnect the engine coolant temperature (ECT) sensor electrical connector.
22. Disconnect the camshaft position (CMP) sensor electrical connector.
23. Disconnect the radio ignition interference capacitor and remove the engine control sensor wiring.
24. Disconnect the fuel charging wiring from the crash bracket and the wiring support bracket and remove the harness from the engine.
25. Disconnect the EGR tube nut from the EGR valve.
26. Remove the generator. Remove the bolts. Remove the generator.
27. Remove the throttle return spring.
28. Remove the four bolts and the throttle body.
29. Remove the bolt and the stud. Remove the crash bracket.
30. Remove the eight bolts and the eight ignition coils.
31. Remove the bolts and the coolant outlet adapter.
32. Remove the thermostat.
33. Remove the bolts and the intake manifold.
34. Remove the intake manifold gaskets.
35. Clean the sealing surfaces.
36. Remove the coolant bypass tube. Remove the retaining nut. Remove the ground strap. Remove the water bypass tube.
37. Remove the studs and bolts, and remove the valve cover. Clean the mating surface, and if necessary, install new gaskets.
38. Remove the studs and bolts and remove the right valve cover. Clean the mating surface, and if necessary, install new gaskets.
39. Remove the spark plugs.
40. Position the lobe of the camshaft up.
41. Install the special tool between the valve spring coils to prevent valve stem seal damage.
42. Use the special tool to compress the valve springs and remove the camshaft roller followers.
43. Remove the bolt and the belt idler pulley.
44. Remove the coolant pump pulley.
45. Remove the crankshaft pulley bolt.
46. Using the special tool, remove the crankshaft pulley.
47. Using the special tool, remove the crankshaft front oil seal.
48. Remove the front four oil pan bolts.
49. Remove the fasteners.
50. Remove the engine front cover from the cylinder block. Clean the sealing surfaces and discard the gaskets.
51. Remove the crankshaft sensor ring.
52. Position the crankshaft with the keyway at the 12 o'clock position.
53. Remove the timing chain tensioning system from both timing chains. Remove the bolts. Remove the timing chain tensioners. Remove the timing chain tensioner arms.
54. Remove the LH and RH timing chains and the crankshaft sprocket. Remove the RH timing chain from the camshaft sprocket. Remove the RH timing chain from the crankshaft sprocket. Repeat for the LH timing chain and crankshaft sprocket.
55. Remove both timing chain guides. Remove the bolts. Remove the LH timing chain guide. Remove the bolts. Remove the RH timing chain guide.
56. Remove the RH exhaust manifold. Remove the nuts. Remove the RH exhaust manifold. Remove and discard the RH exhaust manifold gasket.
57. Remove the LH exhaust manifold. Remove the nuts. Remove the LH exhaust manifold. Remove and discard the LH exhaust manifold gaskets.
58. Remove the bolt and the oil level indicator tube.
59. Clean and inspect the exhaust manifolds. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(/ford/crown-victoria/ii-1997-2011/remont/mechanical/#engine-system-general-information) .
60. Install the special tool on both ends of the cylinder head.
61. Remove the hydraulic lash adjusters.
62. Remove the bolts and the RH cylinder head. Discard the cylinder head gasket. Discard the cylinder head bolts.
63. Remove the bolts and the LH cylinder head. Discard the cylinder head gasket. Discard the cylinder head bolts.
64. Clean the cylinder head-to-cylinder block mating surfaces of both the cylinder head and the cylinder block. Remove any large deposits of silicone or gasket material with a plastic scraper. Apply silicone gasket remover, following package directions, and allow to set for several minutes. Remove the silicone gasket remover with a plastic scraper. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain. Apply metal surface prep, following package directions, to remove any remaining traces of oil or coolant, and to prepare the surfaces to bond with the new gasket. Do not attempt to make the metal shiny. Some staining of the metal surfaces is normal.
65. Support the cylinder head on a bench with the head gasket side up. Inspect all areas of the deck face with a straightedge, paying particular attention to the oil pressure feed area. The cylinder head must not have depressions deeper than 0.0254 mm (0.001 in) across a 38.1 mm (1.5 in) square area, or scratches more than 0.0254 mm (0.001 in).

Scheme 429

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Scheme 470

1. Remove the hood.
2. Disconnect both battery cables. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/crown-victoria/ii-1997-2011/remont/charging-system/#battery-mounting-and-cables) .
3. Remove the air cleaner and outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(/ford/crown-victoria/ii-1997-2011/remont/removal-installation/#intake-air-distribution-filtering) .
4. Remove the wiper mounting arm and pivot shaft. For additional information, refer to «WIPERS AND WASHERS»(/ford/crown-victoria/ii-1997-2011/remont/wiperwasher-systems/#wiper-system-washer-system) .
5. Remove the support bracket.
6. Remove the accessory drive belt. For additional information, refer to «SPECIFICATIONS & DRIVE BELT ROUTING»(/ford/crown-victoria/ii-1997-2011/remont/accessory-drive-belts/#cooling-system-specifications-drive-belt-routing) .
7. Drain the engine cooling system. For additional information, refer to «ENGINE COOLING»(/ford/crown-victoria/ii-1997-2011/remont/cooling-system-mechanical/#engine-cooling-system) .
8. Disconnect the vacuum hose.
9. Remove the evaporative emission (EVAP) canister purge valve. Disconnect the three hoses. Disconnect the electrical connector.
10. Disconnect the accelerator cable and the speed control actuator cable. Remove the bolts. Disconnect the cables.
11. Remove the accelerator cable and the speed control actuator cable from the clips and position out of the way.
12. Disconnect the fuel spring lock connector. For additional information, refer to «FUEL SYSTEM-GENERAL INFORMATION»(/ford/crown-victoria/ii-1997-2011/remont/fuel-system/#fuel-system-general-information) .
13. Disconnect the electrical connectors.
14. Remove the electrical connection cover.
15. Disconnect the power distribution power supply electrical connector.
16. Disconnect the ground wire.
17. Disconnect the A/C electrical connector.
18. Disconnect the A/C low charge protection switch electrical connector.
19. Disconnect the heater hoses.
20. Remove the ground strap.
21. Disconnect the engine bulkhead connectors.
22. Remove the bolt and position the power steering pump reservoir aside.
23. Disconnect the upper radiator hose from the hose connection. Secure the hose to the radiator assembly.
24. Disconnect the lower radiator hose from the oil filter adapter.
25. Remove the cooling fan. For additional information, refer to «ENGINE COOLING»(/ford/crown-victoria/ii-1997-2011/remont/cooling-system-mechanical/#engine-cooling-system) .
26. Raise and support the vehicle. For additional information, refer to «JACKING & LIFTING»(/ford/crown-victoria/ii-1997-2011/remont/hoistjack/#jacking-lifting) .
27. Drain the engine oil. Install the drain plug when finished.
28. Disconnect the power steering electrical connector.
29. Disconnect the electrical connector.
30. Disconnect the power steering pressure (PSP) switch electrical connector.
31. Remove the nut and the transmission cooler tube support bracket.
32. Remove the bolt.
33. Disconnect the crankshaft position (CKP) sensor electrical connector.
34. Position the power steering line bracket aside.
35. Disconnect the engine wiring harness retainers from the A/C compressor.
36. Disconnect the A/C compressor electrical connector.
37. Remove the four bolts and position the A/C compressor aside.
38. Remove the bolts and position the power steering pump aside.
39. Remove the starter motor. Remove the starter motor solenoid cover. Disconnect the electrical connections. Remove the bolts. Remove the starter motor.
40. Disconnect the transmission electrical connectors and the RH heated oxygen sensor electrical connectors.
41. Disconnect the LH heated oxygen sensor electrical connector.
42. Using the special tool, remove the LH heated oxygen sensor.
43. Support the exhaust and remove the four nuts.
44. Remove the bolts and the inspection cover.
45. Remove the torque converter nut access plug. Remove the four nuts.
46. Remove the four bolts and one stud.
47. Remove the engine support insulator nuts.
48. Lower the vehicle.
49. Install the special tool to the RH cylinder head.
50. Install the special tool to the LH cylinder head.
51. Install the special tools.
52. Support the transmission.
53. Remove the bolts.
54. Remove the engine assembly from the vehicle.

Scheme 471

Scheme 472

MATERIAL SPECIFICATION

Disassembly

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Scheme 534

1. Remove the bolts and the flexplate.
2. Remove the engine/transmission spacer plate.
3. Using the special tools, remove the rear oil seal slinger.
4. Using the special tools, remove the rear main seal.
5. Remove the eight bolts and the crankcase rear oil seal retainer.
6. Mount the engine on a suitable engine stand.
7. Remove the LH and the RH engine mount.
8. Remove the drain plugs from the engine block. Allow the coolant to completely drain. Install the drain plugs when finished.
9. Remove the bolt and the battery cables from the engine.
10. Disconnect the exhaust gas recirculation (EGR) tube from the exhaust manifold.
11. Disconnect the eight ignition coil electrical connectors.
12. Disconnect the eight fuel injector electrical connectors.
13. Remove the bolts and the EGR tube heat shield.
14. Disconnect and remove the crankcase ventilation tube.
15. Remove the generator mounting bracket. Remove the bolts. Remove the bracket.
16. Disconnect the idle air control (IAC) and the throttle position (TP) sensor electrical connectors.
17. Disconnect the generator electrical connector.
18. Disconnect the cylinder head temperature (CHT) sensor electrical connector.
19. Remove the generator wiring harness anchor from the LH front stud.
20. Disconnect the ground wire from the RH rear stud.
21. Disconnect the engine coolant temperature (ECT) sensor electrical connector.
22. Disconnect the camshaft position (CMP) sensor electrical connector.
23. Disconnect the radio ignition interference capacitor and remove the engine control sensor wiring.
24. Disconnect the knock sensor (KS) electrical connector and the wiring harness pin-type retainer.
25. Disconnect the vacuum hoses and the electrical connector.
26. Disconnect the fuel charging wiring from the crash bracket and remove the harness from the engine assembly.
27. Disconnect the EGR tube nut from the EGR valve.
28. Remove the generator. Remove the bolts. Remove the generator.
29. Remove the throttle return spring.
30. Remove the four bolts and the throttle body.
31. Remove the bolt and the stud. Remove the crash bracket.
32. Remove the eight bolts and the eight ignition coils.
33. Remove the bolts and the water outlet adapter.
34. Remove the thermostat.
35. Remove the bolts and the intake manifold.
36. Remove the intake manifold gaskets.
37. Clean the sealing surfaces.
38. Remove the coolant bypass tube. Remove the retaining nut. Remove the ground strap. Remove the water bypass tube.
39. Remove the knock sensor.
40. Remove the studs and bolts, and remove the valve cover. Clean the mating surface and, if necessary, install new gaskets.
41. Remove the studs and bolts, and remove the right valve cover. Clean the mating surface and, if necessary, install new gaskets.
42. Remove the spark plugs.
43. Position the lobe of the camshaft up.
44. Install the special tool between the valve spring coils to prevent valve stem seal damage.
45. Use the special tool to compress the valve springs and remove the camshaft roller followers.
46. Remove the bolt and the belt idler pulley.
47. Remove the bolts and the coolant pump pulley.
48. Remove the bolts and the coolant pump.
49. Remove the crankshaft pulley bolt.
50. Remove the crankshaft pulley bolt. Use the special tool to remove the crankshaft pulley.
51. Use the special tool to remove the crankshaft front seal.
52. Remove the bolts, and the oil pan and gasket.
53. Remove the bolts, and the oil pump screen cover and tube.
54. Remove the oil pump screen cover and tube spacer.
55. Remove the fasteners in the sequence shown.
56. Remove the engine front cover from the cylinder block.
57. Remove the crankshaft sensor ring from the crankshaft.
58. Position the crankshaft with the keyway at the 12 o'clock position.
59. Remove the timing chain tensioning system from both timing chains. Remove the bolts. Remove the timing chain tensioners. Remove the timing chain tensioner arms.
60. Remove the LH and RH timing chains and the crankshaft sprocket. Remove the RH timing chain from the camshaft sprocket. Remove the RH timing chain from the crankshaft sprocket. Repeat for the LH timing chain and crankshaft sprocket.
61. Remove both timing chain guides. Remove the bolts. Remove the LH timing chain guide. Remove the bolts. Remove the RH timing chain guide.
62. Remove the RH exhaust manifold. Remove the nuts. Remove the RH exhaust manifold. Remove the RH exhaust manifold gasket.
63. Remove the LH exhaust manifold. Remove the nuts. Remove the LH exhaust manifold. Remove the LH exhaust manifold gaskets.
64. Remove the bolt and the oil level indicator tube.
65. Clean and inspect the exhaust manifolds. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(/ford/crown-victoria/ii-1997-2011/remont/mechanical/#engine-system-general-information) .
66. Install the special tool on both ends of the cylinder head.
67. Remove the hydraulic lash adjusters.
68. Remove the bolts and the RH cylinder head. Discard the cylinder head gasket. Discard the cylinder head bolts.
69. Remove the bolts and the LH cylinder head. Discard the cylinder head gasket. Discard the cylinder head bolts.
70. Clean the cylinder head-to-cylinder block mating surfaces of both the cylinder head and the cylinder block. Remove any large deposits of silicone or gasket material with a plastic scraper. Apply silicone gasket remover, following package directions, and allow to set for several minutes. Remove the silicone gasket remover with a plastic scraper. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain. Apply metal surface prep, following package directions, to remove any remaining traces of oil or coolant, and to prepare the surfaces to bond with the new gasket. Do not attempt to make the metal shiny. Some staining of the metal surfaces is normal.
71. Support the cylinder head on a bench with the head gasket side up. Inspect all areas of the deck face with a straightedge, paying particular attention to the oil pressure feed area. The cylinder head must not have depressions deeper than 0.0254 mm (0.001 in) across a 38.1 mm (1.5 in) square area, or scratches more than 0.0254 mm (0.001 in).
72. Remove the bolts and the oil filter adapter and oil gasket.
73. Remove the oil pump. Remove the bolts. Remove the oil pump.
74. Before removing the pistons, inspect the top of the cylinder bores. If necessary, remove the ridge or carbon deposits from each cylinder using a cylinder ridge reamer, following the manufacturer's instructions.
75. Remove the bolts and the connecting rod cap. Discard the bolts.
76. Use the special tool to push the piston through the top of the cylinder block.
77. Remove the crankshaft bearing cap fasteners. Remove and discard the cross-mounted main cap bolts. Loosen the jack screws. Remove and discard the main cap bolts.
78. Remove the five main bearing caps and the lower crankshaft main bearings.
79. Remove the crankshaft and the upper crankshaft main bearings from the cylinder block.

Scheme 535

Scheme 536

MATERIAL SPECIFICATION

Scheme 537

Scheme 538

1. Install the special tool between the valve spring coils to prevent valve stem seal damage.
2. Use the special tool to compress the valve springs, and remove the roller followers.
3. Remove the hydraulic lash adjusters.
4. Use the special tool to compress the valve springs.
5. Remove the valve spring retainer keys, the valve spring retainers, the valve springs, and the valves.
6. Remove the valve stem seals.
7. Remove the bolts, the bearing caps and the camshaft.

Scheme 539

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Scheme 548

Scheme 549

1. Use a plastic scraper and metal surface cleaner to clean the cylinder head.
2. Lubricate the camshaft journals with clean engine oil.
3. Install the camshaft and the camshaft bearing caps. Lubricate with clean engine oil and position the camshaft bearing caps. Install the bolts loosely.
4. Tighten the bolts in the sequence shown.
5. Install the valves in the valve guides located in the cylinder head.
6. Use the special tool to install the valve stem seals.
7. Install the valve springs and the valve spring retainers onto the valves.
8. Install the special tool between the valve spring coils to prevent valve stem seal damage.
9. Use the special tool to compress the valve springs, and install the valve spring retainer keys.
10. Install the hydraulic lash adjusters in their original locations.
11. Using the special tool, install the roller followers in their original locations.
12. Remove the special tool.

Scheme 550

Piston - Pin Connecting Rod Assembly, Press Fit

MATERIAL SPECIFICATION

Scheme 551

Scheme 552

1. Use an appropriate piston pin tool to press the piston pin out from the connecting rod and piston assembly.
2. Remove the connecting rod from the piston.
3. Clean and inspect the connecting rod and piston. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(/ford/crown-victoria/ii-1997-2011/remont/mechanical/#engine-system-general-information) .

Scheme 553

1. Lubricate the piston pin and piston pin bore with clean engine oil.
2. Position the piston pin in the bore aligned with the connecting rod bore.
3. Use the piston pin tool to press the piston pin into the piston and rod assembly.

Scheme 554

Piston - Pin Connecting Rod Assembly, Floating Pin

MATERIAL SPECIFICATION

Scheme 555

Scheme 556

Scheme 557

1. Remove the clips.
2. Remove the piston pin from the piston and connecting rod assembly.
3. Remove the connecting rod from the piston.
4. Clean and inspect the piston and connecting rod. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(/ford/crown-victoria/ii-1997-2011/remont/mechanical/#engine-system-general-information) .

Scheme 558

Scheme 559

1. Position the connecting rod in the piston.
2. Lubricate the piston pin and pin bore with clean engine oil.
3. Install the piston pin in the piston and connecting rod assembly.
4. Install the piston pin retaining clips in the piston.

Scheme 560

Scheme 561

Scheme 562

MATERIAL SPECIFICATION

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1. Record the main bearing code found on the front of the engine block.
2. Record the main bearing code found on the back of the crankshaft.
3. Using the data recorded earlier and the Bearing Select Fit Chart, Standard Bearings Chart determine the required bearing grade for each main bearing. Read the first letter of the engine block main bearing code and the first letter of the crankshaft main bearing code. Read down the column below the engine main bearing code letter, and across the row next to the crankshaft main bearing code letter, until the two intersect. This is the required bearing grade for the number one crankshaft main bearing. As an example, if the engine block code letter is "F" and the crankshaft code letter is "D," the correct bearing grade for this main bearing is "2." Repeat this process for the remaining four main bearings.
4. If oversize bearings are being used, use the procedure in the previous step and the Bearing Select Fit Chart, Oversize Bearing Chart to determine the required grade for each main bearing.
5. Lubricate with clean engine oil and install the crankshaft upper main bearings into the cylinder block.
6. Install the crankshaft onto the upper crankshaft thrust bearing and main bearings.
7. Install the rear main bearing cap.
8. Install the crankshaft lower main bearings, thrust bearing and thrust washer into the main bearing caps. Locate the main bearing cap on the cylinder block and tap into place using a plastic or dead-blow hammer.
9. Back out the jack screws against the cylinder block in two stages, in the sequence shown. Stage 1: Tighten to 5 Nm (44 lb-in). Stage 2: Tighten to 10 Nm (89 lb-in).
10. Install the bolts and tighten in two stages, in the sequence shown. Stage 1: Tighten to 10 Nm (89 lb-in). Stage 2: Tighten to 21 Nm (15 lb-ft).
11. Tighten the bolts in two stages, in the sequence shown. Stage 1: Tighten to 40 Nm (30 lb-ft). Stage 2: Tighten an additional 90 degrees.
12. Check piston-to-cylinder block and ring clearances. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(/ford/crown-victoria/ii-1997-2011/remont/mechanical/#engine-system-general-information) .
13. Use the special tools to install the piston and connecting rod assemblies. Lubricate the piston and ring with clean engine oil. Lubricate the rod bearings with clean engine oil. Rotate the crankshaft as necessary.
14. Once the connecting rod is seated on the crankshaft journal, remove the special tools.
15. Position the lower bearing and connecting rod cap, and install the new bolts loosely.
16. Tighten the bolts in two stages, in the sequence shown. Stage 1: Tighten to 43 Nm (32 lb-ft). Stage 2: Rotate an additional 90-120 degrees.
17. Position the oil pump and install the bolts loosely. Tighten the bolts in the sequence shown.
18. Install the head gasket over the dowel pins.
19. Install the cylinder head on the dowels and the head gasket. Loosely install new bolts.
20. Tighten the cylinder head bolts in six stages, in the sequence shown. Stage 1: Tighten to 40 Nm (30 lb-ft). Stage 2: Tighten an additional 90 degrees (1/4 turn). Stage 3: Loosen the bolts a minimum of one full turn (360 degrees). Stage 4: Tighten to 40 Nm (30 lb-ft). Stage 5: Tighten an additional 90 degrees (1/4 turn). Stage 6: Tighten an additional 90 degrees (1/4 turn).
21. Remove the special tools from both ends of the cylinder head.
22. Install the hydraulic lash adjusters in their original locations.
23. Install the oil lever indicator tube. Install a new O-ring seal on the oil level indicator tube.
24. Install the LH exhaust manifold. Install a new LH exhaust manifold gasket. Install the LH exhaust manifold. Tighten the nuts in the sequence shown.
25. Install the RH exhaust manifold. Install a new RH exhaust manifold gasket. Install the RH exhaust manifold. Tighten the nuts in the sequence shown.
26. Compress each tensioner plunger, using an edge or a vise.
27. Using a small screwdriver or pick, push back and hold the ratchet mechanism.
28. While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing.
29. Install a paper clip into the hole of each tensioner housing to hold the ratchet assembly and plunger in during installation. Remove the tensioner from the vise.
30. Compress each tensioner plunger, using a vise.
31. Install a retaining clip on the tensioner to hold the plunger in during installation.
32. If the copper links are not visible, mark one link on one end and one link on the other end, and use as timing marks.
33. Using the special tool, position the crankshaft. Remove the special tool after crankshaft positioning.
34. Install the crankshaft sprocket, making sure the flange faces forward.
35. Install the timing chain guides. Position the LH timing chain guide. Install and tighten the LH bolts. Position the RH timing chain guide. Install and tighten the RH bolts.
36. Rotate the RH camshaft sprocket until the timing mark is approximately at the 11 o'clock position. Rotate the LH camshaft sprocket until the timing mark is approximately at the 12 o'clock position.
37. Position the LH (inner) timing chain on the crankshaft sprocket, aligning the copper (marked) link with the timing mark on the sprocket.
38. Install the LH timing chain on the camshaft sprocket, aligning the copper (marked) link with the timing marks on the sprocket.
39. Position the LH timing chain tensioner on the dowel pin and install the LH timing chain tensioner.
40. Remove the retaining clip from the LH timing chain tensioner.
41. Remove the retaining clip from the LH timing chain tensioner.
42. Position the RH (outer) timing chain on the crankshaft sprocket, aligning the copper (marked) link with the timing mark on the sprocket.
43. Install the RH timing chain on the camshaft sprocket, aligning the copper (marked) link with the timing marks on the sprocket.
44. Position the RH timing chain tensioner arm on the dowel pin and install the RH timing chain tensioner.
45. Remove the retaining clip from the RH timing chain tensioner.
46. Remove the retaining clip from the RH timing chain tensioner.
47. Make sure that the copper (marked) chain links are lined up with the dots on the crankshaft sprockets and the camshaft sprocket.
48. Rotate and camshaft until the lobe is in the up position.
49. Install the special tool between the valve spring coil to prevent valve stem seal damage.
50. Install the camshaft roller followers. Install the special tool. Compress the valve spring. Install the camshaft roller followers in their original locations.
51. Remove the special tool.
52. Install all eight spark plugs.
53. Install the crankshaft sensor ring.
54. Apply a bead of sealant along the head-to-block surface and the oil pan-to-block surface as specified.
55. Install a new engine front cover gasket on the engine front cover. Position the engine front cover. Install the fasteners finger-tight.
56. Tighten the front cover fasteners in the sequence shown to 25 Nm (18 lb-ft).
57. Install the RH and LH engine mounts.
58. Lubricate the engine front cover and the front oil seal inner lip with clean engine oil.
59. Using the special tools, install the front oil seal.
60. Apply sealant to the Woodruff key slot on the crankshaft pulley.
61. Using the special tool, install the crankshaft pulley.
62. Tighten the crankshaft pulley bolt in four stages. Stage 1: Tighten to 90 Nm (66 lb-ft). Stage 2: Loosen 360 degrees. Stage 3: Tighten to 50 Nm (37 lb-ft). Stage 4: Rotate an additional 90 degrees (1/4 turn).
63. Apply a 4 mm (0.16 in) bead of silicone gasket and sealant around the rear oil seal retainer sealing surface.
64. Install the rear oil seal retainer and loosely install the six bolts.
65. Tighten the bolts in the sequence shown.
66. Install the oil pump screen cover and tube spacer.
67. Position the oil pump screen cover and tube, and install the bolts.
68. Apply the sealant at the rear oil seal retainer to cylinder block sealing surface.
69. Apply sealant at the front cover-to-cylinder block sealing surface.
70. Position the oil pan gasket, the oil pan and the bolts on the engine.
71. Tighten the bolts in two stages, in the sequence shown. Stage 1: Tighten to 20 Nm (15 lb-ft). Stage 2: Rotate an additional 60 degrees.
72. Install the oil filter adapter.
73. Install the coolant pump. Lubricate the new O-ring seal using engine coolant. Position the coolant pump into the engine block. Install the bolts.
74. Position the coolant pump pulley on the coolant pump and install the bolts.
75. Position the belt idler pulley and install the bolt.
76. Apply sealant in two places where the engine front cover meets the cylinder head.
77. Install the gasket into the valve cover and position on the cylinder head. Tighten the bolts in the sequence shown.
78. Apply sealant in two places where the engine front cover meet the cylinder head.
79. Install the gasket into the valve cover and position on the cylinder head. Tighten the bolts in the sequence shown.
80. Install the knock sensor (KS) and the bolts.
81. Inspect the O-rings seals. Install new seals if necessary.
82. Install the coolant bypass tube.
83. Install the ground strap on the rear of the RH cylinder head. Install the stud bolt. Install the ground strap. Install the retaining nut.
84. Install new intake manifold gaskets.
85. Install the intake manifold and hand-tighten the bolts at the locations shown.
86. Install the eight ignition coils and tighten the eight bolts.
87. Install the crash bracket and loosely install the bolt and the stud.
88. Install the thermostat.
89. Install the coolant outlet adapter and loosely install the bolts.
90. Tighten the bolts in the sequence shown.
91. Tighten the stud.
92. Tighten the bolts.
93. Install the throttle body and tighten the bolts.
94. Install the throttle return spring.
95. Connect the exhaust gas recirculation (EGR) tube to the EGR valve.
96. Connect the EGR tube to the exhaust manifold connector.
97. Position the fuel charging wiring at two locations at the back of the intake manifold.
98. Install the generator.
99. Connect the electrical connector to the idle air control (IAC) valve and the throttle position (TP) sensor.
100. Install the generator mounting bracket.
101. Connect the generator electrical connector, generator cable and harness pin-type retainer.
102. Position the vacuum harness and connect the vacuum hoses for the evaporative emission (EVAP) canister purge valve, the main chassis hose and the EGR valve.
103. Install the generator wiring harness anchor to the LH front stud.
104. Connect the engine coolant temperature (ECT) sensor electrical connector.
105. Connect the crankcase ventilation tube.
106. Install the EGR tube heat shield.
107. Connect the eight fuel injector electrical connectors.
108. Connect the eight ignition coil electrical connectors.
109. Connect the camshaft position (CMP) sensor electrical connector.
110. Connect the radio interference capacitor electrical connector.
111. Connect the KS electrical connector and install the harness retainer to the intake manifold.
112. Connect the cylinder head temperature (CHT) sensor electrical connector.
113. Connect the ground wire to the right rear fuel rail stud.
114. Install the battery cables and the bolt.
115. Install the RH and LH lighting brackets.
116. Remove the engine from the engine stand.
117. Using the special tool, install the crankshaft rear oil seal.
118. Using the special tools, install the crankshaft oil slinger.
119. Install the engine/transmission spacer plate.
120. Position the flexplate and install the bolts in the sequence shown.

Scheme 654

MATERIAL SPECIFICATION

Scheme 655

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Scheme 723

1. Install the head gasket over the dowel pins.
2. Install the cylinder head on the dowels and the head gasket. Loosely install new bolts.
3. Tighten the cylinder head bolts in six stages, in the sequence shown. Stage 1: Tighten bolts to 40 Nm (30 lb-ft). Stage 2: Tighten bolt an additional 90 degrees (1/4 turn). Stage 3: Loosen the bolts a minimum of one full turn (360 degrees). Stage 4: Tighten bolts to 40 Nm (30 lb-ft). Stage 5: Tighten bolts an additional 90 degrees (1/4 turn). Stage 6: Tighten bolts an additional 90 degrees (1/4 turn).
4. Remove the special tools from both ends of the cylinder head.
5. Install the hydraulic lash adjusters in their original locations.
6. Install the oil level indicator tube. Install a new O-ring seal on the oil level indicator tube.
7. Install the LH exhaust manifold. Install a new LH exhaust manifold gasket. Install the LH exhaust manifold. Tighten the nuts in the sequence shown.
8. Install the RH exhaust manifold. Install a new RH exhaust manifold gasket. Install the RH exhaust manifold. Tighten the nuts in the sequence shown.
9. Compress each tensioner plunger, using a vise.
10. Install a retaining clip on each tensioner to hold the plunger in during installation.
11. If the copper links are not visible, mark one link on one end and one link on the other end, and use as timing marks.
12. Using the special tool, position the crankshaft. Remove the special tool after crankshaft positioning.
13. Install the crankshaft sprocket, making sure the flange faces forward.
14. Install the timing chain guides. Position the LH timing chain guide. Install and tighten the LH bolts. Position the RH timing chain guide. Install and tighten the RH bolts.
15. Rotate the RH camshaft sprocket until the timing mark is approximately at the 11 o'clock position. Rotate the LH camshaft sprocket until the timing mark is approximately at the 12 o'clock position.
16. Position the LH (inner) timing chain on the crankshaft sprocket, aligning the copper (marked) link with the timing mark on the sprocket.
17. Install the LH timing chain on the camshaft sprocket, aligning the copper (marked) link with the timing marks on the sprocket.
18. Position the LH timing chain tensioner arm on the dowel pin and install the LH timing chain tensioner.
19. Remove the retaining clip from the LH timing chain tensioner.
20. Position the RH (outer) timing chain on the crankshaft sprocket, aligning the copper (marked) link with the timing mark on the sprocket.
21. Install the RH timing chain on the camshaft sprocket, aligning the copper (marked) link with the timing marks on the sprocket.
22. Position the RH timing chain tensioner arm on the dowel pin and install the RH timing chain tensioner.
23. Remove the retaining clip from the RH timing chain tensioner.
24. Make sure that the copper (marked) chain links are lined up with the dots on the crankshaft sprockets and the camshaft sprocket.
25. Rotate the camshaft until the lobe is in the up position.
26. Install the special tool between the valve spring coils to prevent valve stem seal damage.
27. Install the camshaft roller follower. Install the special tool. Compress the valve spring. Install the camshaft roller followers in their original location.
28. Remove the special tool.
29. Install all eight spark plugs.
30. Install the crankshaft sensor ring.
31. Apply a bead of sealant along the head-to-block surface and the oil pan-to-block surface as specified.
32. Install a new engine front cover gasket on the engine front cover. Position the engine front cover. Install the fasteners finger-tight.
33. Tighten the front cover fasteners in the sequence shown to 25 Nm (18 lb-ft).
34. Loosely install the bolts, then tighten in two stages in the sequence shown. Stage 1: Tighten to 20 Nm (15 lb-ft). Stage 2: Tighten an additional 90 degrees.
35. Install the RH engine mount.
36. Lubricate the engine front cover and the front oil seal inner lip with clean engine oil.
37. Using the special tools, install the front oil seal.
38. Apply sealant to the Woodruff key slot on the crankshaft pulley.
39. Using the special tool, install the crankshaft pulley.
40. Tighten the crankshaft pulley bolt in four stages. Stage 1: Tighten to 90 Nm (66 lb-ft). Stage 2: Loosen 360 degrees. Stage 3: Tighten to 50 Nm (37 lb-ft). Stage 4: Rotate an additional 90 degrees (1/4 turn).
41. Position the coolant pump pulley on the water pump and install the bolts.
42. Install the accessory drive belt idler pulley.
43. Apply sealant in two places where the engine front cover meets the cylinder head.
44. Install the gasket into the valve cover and position on the cylinder head. Tighten the bolts in the sequence shown.
45. Apply sealant in two places where the engine front cover meets the cylinder head.
46. Install the gasket into the valve cover and position on the cylinder head. Tighten the bolts in the sequence shown.
47. Inspect the O-ring seals. Install new seals if necessary.
48. Install the coolant bypass tube.
49. Install the ground strap on the rear of the RH cylinder head. Install the stud bolt. Install the ground strap. Install the retaining nut.
50. Install new intake manifold gaskets.
51. Install the intake manifold and hand-tighten the bolts at the locations shown.
52. Install the eight ignition coils and tighten the eight bolts.
53. Install the crash bracket and loosely install the bolt and the stud.
54. Install the thermostat.
55. Install the coolant outlet adapter and loosely install the bolts.
56. Tighten the bolts in the sequence shown.
57. Tighten the stud.
58. Tighten the bolts.
59. Install the throttle body and tighten the bolts.
60. Install the throttle return spring.
61. Connect the exhaust gas recirculation (EGR) tube to the EGR valve.
62. Connect the EGR tube to the exhaust manifold connector.
63. Position the fuel charging wiring at two locations at the back of the intake manifold.
64. Install the generator.
65. Connect the electrical connector to the idle air control (IAC) valve and the throttle position (TP) sensor.
66. Install the generator mounting bracket.
67. Connect the generator electrical connector, generator cable and harness pin-type retainer.
68. Connect the electrical connector to the EGR vacuum regulator solenoid.
69. Install the generator wiring harness anchor to the LH front stud.
70. Connect the engine coolant temperature (ECT) sensor electrical connector.
71. Connect the crankcase ventilation tube.
72. Install the EGR tube heat shield.
73. Connect the eight fuel injector electrical connectors.
74. Connect the eight ignition coil electrical connectors.
75. Connect the differential pressure feedback EGR system electrical connector.
76. Connect the camshaft position (CMP) sensor electrical connector.
77. Connect the radio interference capacitor electrical connector.
78. Connect the cylinder head temperature (CHT) sensor electrical connector.
79. Connect the ground wire to the right rear fuel rail stud.
80. Install the battery cables and the bolt.
81. Install the RH and LH lifting brackets.
82. Remove the engine from the engine stand.
83. Install the engine/transmission spacer plate.
84. Position the flexplate and install the bolts in the sequence shown.
85. Install the engine. For additional information, refer to «ENGINE»(/ford/crown-victoria/ii-1997-2011/remont/mechanical/#engine-46l-2v) .

Scheme 724

MATERIAL SPECIFICATION

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1. Using the special tool, install the engine assembly in the vehicle.
2. Remove the special tools.
3. Raise the vehicle. For additional information, refer to «JACKING & LIFTING»(/ford/crown-victoria/ii-1997-2011/remont/hoistjack/#jacking-lifting) .
4. Install the four bolts and one stud.
5. Connect the electrical connectors.
6. Using the special tool, install the LH heated oxygen sensor.
7. Connect the LH heated oxygen sensor electrical connector.
8. Install the engine insulator mount nuts.
9. Install the four torque converter nuts. Rotate the crankshaft to access the nuts.
10. Install the rubber access plug.
11. Install the inspection cover and the bolts.
12. Install the starter motor and the bolts.
13. Connect the starter electrical connections and install the nuts. Install the solenoid terminal cover.
14. Position the exhaust, install the four nuts and remove the support.
15. Install the power steering pump and the bolts.
16. Install the A/C compressor and the bolts.
17. Connect the A/C compressor electrical connector.
18. Connect the engine wiring harness retainers to the A/C compressor.
19. Connect the crankshaft position (CKP) sensor electrical connector.
20. Position the transmission oil cooler tubes and install the bolt.
21. Install the transmission cooler tube support bracket.
22. Install the power steering line bracket.
23. Connect the power steering pressure (PSP) switch electrical connector.
24. Connect the power steering electrical connector.
25. Connect the electrical connector.
26. Lower the vehicle.
27. Install the bolts.
28. Install the cooling fan. For additional information, refer to «ENGINE COOLING»(/ford/crown-victoria/ii-1997-2011/remont/cooling-system-mechanical/#engine-cooling-system) .
29. Connect the lower radiator hose.
30. Connect the upper radiator hose to the hose connection.
31. Install the power steering reservoir.
32. Connect the engine bulkhead connectors.
33. Position the ground strap and install the bolt.
34. Connect the heater hoses.
35. Connect the A/C low charge protection switch electrical connector.
36. Connect the A/C electrical connector.
37. Connect the power distribution power supply electrical connector.
38. Install the electrical connection cover.
39. Connect the electrical connectors.
40. Install the ground strap.
41. Connect the fuel line spring lock coupling. For additional information, refer to «FUEL SYSTEM-GENERAL INFORMATION»(/ford/crown-victoria/ii-1997-2011/remont/fuel-system/#fuel-system-general-information) .
42. Install the accelerator cable and the speed control actuator cable to the clips.
43. Connect the accelerator cable and the speed control actuator cable. Install the bolts. Connect the cables.
44. Connect the three hoses and the canister purge valve electrical connection.
45. Connect the vacuum hose.
46. Install the air cleaner and outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(/ford/crown-victoria/ii-1997-2011/remont/removal-installation/#intake-air-distribution-filtering) .
47. Install the accessory drive belt. For additional information, refer to «SPECIFICATIONS & DRIVE BELT ROUTING»(/ford/crown-victoria/ii-1997-2011/remont/accessory-drive-belts/#cooling-system-specifications-drive-belt-routing) .
48. Install the support bracket.
49. Install the wiper mounting arm and pivot shaft. For additional information, refer to «WIPERS AND WASHERS»(/ford/crown-victoria/ii-1997-2011/remont/wiperwasher-systems/#wiper-system-washer-system) .
50. Fill the crankcase with clean engine oil.
51. Connect both battery cables.
52. Fill and bleed the cooling system. For additional information, refer to «ENGINE COOLING»(/ford/crown-victoria/ii-1997-2011/remont/cooling-system-mechanical/#engine-cooling-system) .
53. Install the hood.

See also:
• ENGINE SYSTEM-GENERAL INFORMATION
• INTRODUCTION - CNG, FLEX-FUEL & GASOLINE
• BATTERY, MOUNTING AND CABLES
• ENGINE COOLING
• INTAKE AIR DISTRIBUTION & FILTERING
• FUEL SYSTEM-GENERAL INFORMATION
• WIPERS AND WASHERS
• FUEL SYSTEM-GENERAL INFORMATION-NATURAL GAS
• SPECIFICATIONS & DRIVE BELT ROUTING
• JACKING & LIFTING
• ELECTRONIC ENGINE CONTROLS
• AUTOMATIC TRANSAXLE/TRANSMISSION
• GENERATORS & REGULATORS
• ENGINE MOUNT LH
• VALVE COVER RH
• VALVE COVER LH
• ENGINE FRONT COVER