Engine - 3.9L: Removal & Installation Ford Thunderbird XI

Removal

Note. The RH secondary timing chains are shown; the LH secondary timing chains are similar.

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1. Remove the primary timing chains. For additional information, refer to «TIMING DRIVE COMPONENTS - PRIMARY»(ref-204559-S09416534882005111300000) .
2. Remove the exhaust sprocket bolt.
3. Collapse the tensioners. Insert a thin wire into the check valve and apply hand pressure until the tensioners are fully collapsed. Install a wire in the side of the tensioner to retain it.
4. Remove the intake sprocket bolt.
5. Remove the sprockets and chain as an assembly.
6. Remove the secondary timing chain tensioner bolts.
7. Remove the tensioner.

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1. Position the tensioner.
2. Install the timing chain tensioner bolts.
3. Position the intake sprocket, chain and exhaust sprocket on the camshafts as an assembly.
4. Loosely install the intake and exhaust sprocket bolts.
5. Install the primary timing chains. For additional information, refer to «TIMING DRIVE COMPONENTS - PRIMARY»(ref-204559-S09416534882005111300000) .
6. Remove the wire retainer from the secondary chain tensioner.

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1. Remove the camshaft. For additional information, refer to «CAMSHAFT»(ref-204559-S13019775132005111300000) .
2. Position the piston at the top of the stroke on the appropriate cylinder.
3. Remove the spark plug and apply compressed air in the cylinder to hold both valves in position.
4. Remove the bucket tappet and shim from the valve.
5. Using the special tool, remove the retainer keys.
6. Remove the valve springs. Remove the spring retainers. Remove the valve springs.
7. Repeat the procedure until all of the valve springs are removed.

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1. Position the valve springs. Position the spring retainers. Position the valve springs.
2. Using the special tool, install the retainer keys.
3. Repeat the procedure until all of the valve springs are installed.
4. Install the camshaft. For additional information, refer to «CAMSHAFT»(ref-204559-S13019775132005111300000) .

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1. Remove the valve springs. For additional information, refer to «VALVE SPRINGS»(ref-204559-S40184163682005111300000) .
2. Remove the valve stem seals.

Installation

1. Install the valve stem seals over the valve stems.
2. Install the valve springs. For additional information, refer to «VALVE SPRINGS»(ref-204559-S40184163682005111300000) .

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1. To install, reverse the removal procedure. Install a new gasket and bolts.

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1. Raise and support the vehicle. For additional information, refer to «JACKING & HOISTING»(ref-232595-S06496072622006051700000) .
2. Remove the Three-Way Catalytic (TWC) converter. .
3. Remove the screws and the lower RH splash shield.
4. Disconnect the EGR valve to exhaust manifold tube nut at the exhaust manifold.
5. Remove the exhaust manifold. Remove the eight bolts and discard. Remove the exhaust manifold and discard the gasket.
6. Inspect the exhaust manifold. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-204558) .

1. To install, reverse the removal procedure. Install a new gasket and bolts.

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1. Remove the intake manifold. For additional information, refer to «INTAKE MANIFOLD»(ref-204559-S25252532282005111300000) .
2. Remove the engine sound insulator.
3. Remove the camshafts. For additional information, refer to «CAMSHAFT»(ref-204559-S13019775132005111300000) .
4. If necessary, remove the tappet bucket and shims.
5. Disconnect the clamp, remove the four bolts and the water outlet pipe.
6. Disconnect the Cylinder Head Temperature (CHT) sensor electrical connector.
7. Raise and support the vehicle. For additional information, refer to «JACKING & HOISTING»(ref-232595-S06496072622006051700000) .
8. Disconnect the Three-Way Catalytic (TWC) converter from the exhaust manifolds.
9. Disconnect the EGR valve to exhaust manifold tube.
10. Lower the vehicle.
11. Remove the bolts from the rear of the cylinder head.
12. Remove and discard the bolts.
13. Remove the RH bolts in the sequence shown. Discard the bolts.
14. Remove the RH cylinder head. Discard the gasket.
15. Clean the sealing surfaces.
16. Remove the stud bolts from the rear of the cylinder head.
17. Remove and discard the bolts.
18. Remove the bolts in the sequence shown. Discard the bolts.
19. Remove the LH cylinder head. Discard the gasket.
20. Clean the sealing surfaces.
21. Remove the RH exhaust manifold bolts. Discard the gasket and bolts.
22. Clean the sealing surfaces.
23. Remove the LH exhaust manifold bolts. Discard the gasket and bolts.
24. Clean the sealing surfaces.
25. Inspect the exhaust manifold. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-204558) .

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1. Install the LH exhaust manifold. Install a new gasket and bolts.
2. Install the RH exhaust manifold. Install a new gasket and bolts.
3. Position the LH cylinder head. Install a new gasket.
4. Install and tighten the bolts in five stages in the sequence shown. Stage 1: Install finger-tight. Stage 2: Tighten to 20 N.m (15 lb-ft). Stage 3: Tighten to 35 N.m (26 lb-ft). Stage 4: Tighten to 45 N.m (33 lb-ft) and an additional 90 degrees. Stage 5: Tighten an additional 90 degrees.
5. Install the bolts on the rear of the cylinder head.
6. Install and tighten the bolts in two stages. Stage 1: Tighten to 20 N.m (15 lb-ft). Stage 2: Tighten an additional 90 degrees.
7. Position the RH cylinder head. Install a new gasket.
8. Install and tighten the bolts in five stages in the sequence shown. Stage 1: Install finger-tight. Stage 2: Tighten to 20 N.m (15 lb-ft). Stage 3: Tighten to 35 N.m (26 lb-ft). Stage 4: Tighten to 45 N.m (33 lb-ft) and an additional 90 degrees. Stage 5: Tighten an additional 90 degrees.
9. Install the stud bolts on the rear of the cylinder head.
10. Install and tighten the bolts in two stages. Stage 1: Tighten to 20 N.m (15 lb-ft). Stage 2: Tighten an additional 90 degrees.
11. Install the tappets and shims.
12. Raise the vehicle.
13. Connect the EGR valve to exhaust manifold tube.
14. Connect the TWC to the exhaust manifolds.
15. Lower the vehicle.
16. Connect the CHT sensor electrical connector.
17. Install the engine sound insulator.
18. Install the water crossover and tighten the four bolts and connect the hose.
19. Install the camshafts. For additional information, refer to «CAMSHAFT»(ref-204559-S13019775132005111300000) .
20. Install the intake manifold. For additional information, refer to «INTAKE MANIFOLD»(ref-204559-S25252532282005111300000) .

Note. Make sure all gasket sealing surfaces are clean and dry.

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1. Install the oil pan. Tighten the bolts in the sequence shown in two stages. Stage 1: Tighten to 5 N.m (44 lb-in). Stage 2: Tighten to 12 N.m (9 lb-ft).
2. Install the oil pan drain plug.
3. Install the front crossbrace and bolts.
4. Install the front valance panel. Install the bolts. Install the pin-type retainer.
5. Lower the vehicle.
6. Fill the crankcase to the specified level with clean engine oil.

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1. Remove the primary timing chains. For additional information, refer to «TIMING DRIVE COMPONENTS - PRIMARY»(ref-204559-S09416534882005111300000) .
2. Remove the oil pump screen and pickup tube. For additional information, refer to «OIL PUMP SCREEN AND PICKUP TUBE»(ref-204559-S11704921832005111300000) .
3. Remove the bolts and the oil pump. Discard the gasket.
4. Clean the sealing surfaces.

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1. Install a new gasket.
2. Install the oil pump and tighten the bolts in two stages. Stage 1: Tighten to 6 N.m (53 lb-in). Stage 2: Tighten an additional 90 degrees.
3. Install the oil pump screen and pick up tube. For additional information, refer to «OIL PUMP SCREEN AND PICKUP TUBE»(ref-204559-S11704921832005111300000) .
4. Install the primary timing chains. For additional information, refer to «TIMING DRIVE COMPONENTS - PRIMARY»(ref-204559-S09416534882005111300000) .

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1. Remove the oil pan. For additional information, refer to «OIL PAN»(ref-204559-S14945398542005111300000) .
2. Remove the bolts and the pump screen cover and tube. Inspect the O-ring seal and install a new one if necessary.
3. Verify the retaining washers are in place.

1. Install the oil pump screen cover and tube.
2. Install the oil pan. For additional information, refer to «OIL PAN»(ref-204559-S14945398542005111300000) .

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1. Remove the transmission. For additional information, refer to «REMOVAL & INSTALLATION - A/T»(ref-155872) .
2. Remove the flexplate. Remove the bolts in the sequence shown. Remove the flexplate.

Note. The crankshaft dowel must be positioned below the outer face of the flexplate.

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1. Install the flexplate with the elongated hole over the crankshaft dowel.
2. Install the flexplate bolts and tighten in two stages in the sequence shown. Stage 1: Tighten to 15 N.m (11 lb-ft). Stage 2: Tighten to 110 N.m (81 lb-ft).
3. Install the transmission. For additional information, refer to «REMOVAL & INSTALLATION - A/T»(ref-155872) .

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For LH & RH

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1. Disconnect the battery ground cable (14301). For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-204581) .
2. Remove the air cleaner outlet tube.
3. Remove the upper radiator sight shield.
4. Install the special tools and support the engine.
5. Raise and support the vehicle. For additional information, refer to «JACKING & HOISTING»(ref-232595-S06496072622006051700000) .
6. Remove the LH and the RH lower splash shield. For RH
7. Remove the nut and disconnect the starter motor ground cable.
8. Remove the nut and disconnect the wiring harness support bracket from the engine mount bracket. For LH & RH
9. Remove the two nuts from the top and bottom of the engine mounts.
10. Remove the four bolts, the engine mounts and the brackets.
11. To install, reverse the removal procedure.

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1. Disconnect the battery ground cable (14301). For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-204581) .
2. Remove the air cleaner assembly and outlet pipe.
3. Drain the engine coolant. For additional information, refer to «ENGINE COOLING»(ref-204560) .
4. Remove the upper radiator sight shield.
5. Remove the two upper radiator support brackets.
6. Discharge the A/C system. For additional information, refer to «AIR CONDITIONING»(ref-204570) .
7. Disconnect the A/C pressure switch electrical connector.
8. Release the power steering return line from the pressure line clip.
9. Remove the power steering pump reservoir bolts, disconnect the power steering hoses and remove the power steering reservoir.
10. Disconnect the fuel line. For additional information, refer to «FUEL SYSTEM»(ref-142371-S41650265912002073100000) .
11. Remove the Vapor Management Valve (VMV) cover.
12. Disconnect the VMV. Canister purge hose. Vacuum hose.
13. Disconnect the main vacuum supply hose.
14. Remove the cowl vent screens. For additional information, refer to «FRONT END BODY PANELS»(ref-204605) .
15. Unclip the hose and position aside.
16. Remove the bracket. Remove the seven bolts and one nut. Remove the windshield washer hose. Remove the bracket.
17. Disconnect the degas bottle.
18. Disconnect the accelerator cable and the speed control cable.
19. Disconnect the ground strap.
20. Remove the fresh air filter.
21. Remove the fresh air filter housing.
22. Disconnect the powertrain bulkhead electrical connectors.
23. Remove the fresh air filter panel. Remove the pin-type retainer. Remove the nuts. Remove the panel.
24. Disconnect the connectors.
25. Remove the hydraulic cooling fan reservoir bolts, disconnect the cooling fan hoses and remove the reservoir.
26. Disconnect the heater hoses from the water control valve.
27. Disconnect the water valve electrical connector, unclip from the radiator support and position the harness aside.
28. Remove the front wheels and tires. .
29. Remove the LH and the RH inner splash shields.
30. Disconnect the LH and the RH anti-lock brake sensor electrical connectors.
31. Unclip the LH and the RH anti-lock brake harness from the brake hoses.
32. Remove the LH and the RH brake calipers and position the calipers aside.
33. Remove the LH and the RH sway bar lower nuts.
34. Remove the LH and the RH nuts and separate the ball joints from the spindles.
35. Remove the LH and the RH lower strut mount bolts.
36. Remove the LH and the RH splash shields.
37. Remove the center splash shield.
38. Remove the nut and disconnect the A/C high pressure hose.
39. Disconnect the low pressure A/C hose.
40. Remove the driveshaft. For additional information, refer to «DRIVE SHAFTS»(ref-154077) .
41. Disconnect the shift cable from the shifter.
42. Unclip the shift cable from the bracket.
43. Remove the shift cable bracket.
44. Release the hydraulic cooling fan return hose from the RH frame rail.
45. Remove the retaining bolt for the high pressure power steering hose bracket.
46. Disconnect the rack and pinion steering unit electrical connectors and remove the tie-strap.
47. Remove the steering shaft bolt.
48. Disconnect the steering coupling. Remove the bolt. Disconnect the coupling.
49. Remove the starter motor ground cable.
50. Remove the cover.
51. Disconnect the starter motor electrical connectors.
52. Disconnect the generator electrical cable.
53. Remove the Three-Way Catalytic (TWC) converter. .
54. Remove the six lower transmission-to-engine bolts.
55. Remove the cover.
56. Remove the eight torque converter nuts.
57. Remove the inner air deflector.
58. Remove the engine block heater plug, if equipped.
59. Support the rear of the vehicle with suitable safety stands.
60. Remove the engine crossmember.
61. Support the engine, transmission, front and center crossmembers, and the cooling system with a powertrain lift and a transmission support bracket.
62. Remove the transmission crossmember bolts.
63. Remove the four front and the four center crossmember bolts.
64. Carefully lower the entire assembly from the vehicle.
65. Disconnect the block heater, if equipped.
66. Disconnect the A/C manifold and tube.
67. Remove the bracket.
68. Remove the lower radiator hose.
69. Disconnect the radiator hoses.
70. Disconnect the Knock Sensor (KS) electrical connector.
71. Disconnect the heater hose.
72. Remove the transmission cooler line bracket.
73. Disconnect the transmission cooler lines.
74. Remove the power steering line bracket bolt and disconnect the high pressure power steering line.
75. Install the special tool.
76. Install the special tool.
77. Remove the hydraulic fan pump bracket bolt and disconnect the hydraulic fan high pressure line.
78. Using the special tool and an engine crane, support the engine and transmission in the front subframe.
79. Remove the LH and the RH upper engine mount nuts.
80. Using the special tool and an engine crane, move the engine and transmission from the subframe to rest on the floor or on a bench.
81. Remove the nuts and position the transmission wiring harness aside.
82. Remove the bolts and separate the engine from the transmission.
83. Mount the engine on an engine stand.
84. Remove the engine lifting equipment.

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1. Disconnect the vacuum harness.
2. Disconnect the vacuum hose.
3. Remove the exhaust manifold to Exhaust Gas Recirculation (EGR) valve tube. Disconnect the upper fitting. Disconnect the hoses. Disconnect the lower fitting.
4. Disconnect the Camshaft Position (CMP) sensor electrical connector and separate the connector from the fuel injection supply manifold.
5. Disconnect the EGR Vacuum Regulator (EVR) electrical connector and the vacuum hose.
6. Disconnect the air assist tube.
7. Disconnect the fuel pressure sensor electrical connector.
8. Remove the electrical connectors from the bracket. LH Knock Sensor (KS). Cylinder Head Temperature (CHT) sensor.
9. Remove the nut and the bracket.
10. Disconnect the RH KS and remove the electrical connector from the bracket.
11. Remove the four bolts. Disconnect the hoses and remove the coolant outlet pipe.
12. Remove the two nuts and the bracket.
13. Raise the engine wiring harness and disconnect the LH fuel injector connectors.
14. Disconnect the Idle Air Control (IAC) valve and the Throttle Position Sensor (TPS) electrical connectors.
15. Disconnect the PCV tube.
16. Disconnect the hoses (1) from the throttle body and the clip (2).
17. Remove the throttle body.
18. Raise the engine wiring harness and disconnect the RH fuel injectors.
19. Remove the nuts and position the wiring harness aside.
20. Remove the nine bolts and one stud (2) in the sequence shown.
21. Remove the intake manifold.
22. Remove the four bolts and the thermostat housing.
23. Disconnect the crankcase ventilation tube.
24. Remove the nut and the oil level indicator and tube.
25. Remove the RH and LH coil covers.
26. Disconnect the RH and LH ignition coil connectors.
27. Remove the RH and LH ignition coils.
28. Disconnect the wiring harness retainers from the LH valve cover.
29. Remove the bolts in the sequence shown and remove the LH valve cover.
30. Remove the bracket.
31. Disconnect the three wiring harness retainers from the RH valve cover.
32. Remove the bolts in the sequence shown and remove the RH valve cover.
33. Loosen the water pump pulley bolts.
34. Remove the drive belt and tensioner. For additional information, refer to «SPECIFICATIONS & DRIVE BELT ROUTING»(ref-139103) .
35. Remove the water pump pulley. Remove and discard the bolts. Remove the pulley.
36. Remove the water pump. Remove the bolts. Remove the water pump. Discard the gasket. Clean and inspect the O-ring seal. Install a new seal if necessary.
37. Remove the two idler pulleys.
38. Disconnect the electrical connector at the rear of the generator.
39. Remove the bolt.
40. Remove the generator. Remove the upper bolt. Remove the lower bolt.
41. Disconnect the electrical connector.
42. Remove the hydraulic cooling fan pump.
43. Remove the hydraulic pump bracket.
44. Disconnect the A/C electrical connector and the retaining clip.
45. Remove the two power steering hose brackets.
46. Remove the A/C compressor (19703).
47. Disconnect the Power Steering Pressure (PSP) switch.
48. Remove the power steering pump.
49. Remove the power steering pump bracket.
50. Disconnect the two pin-type retainers.
51. Remove the wiring harness from the front cover.
52. Remove the wiring harness from the front cover.
53. Disconnect the Crankshaft Position (CKP) sensor electrical connector.
54. Remove the exhaust gas Oxygen Sensor (HO2S) connectors from the brackets.
55. Remove the starter motor.
56. Remove the RH and LH exhaust manifolds. Discard the bolts and gaskets.
57. Inspect the exhaust manifolds. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-204558) .
58. Remove the bolt and washer. Discard the bolt.
59. Using the special tool, remove the crankshaft damper.
60. Remove the bolts and remove the front cover.
61. Remove and discard the oil filter.
62. Remove the oil filter adapter. Discard the seal.
63. Turn the crankshaft to 45 degrees ATDC. The crankshaft keyway will be in the 6 o'clock position.
64. Remove the RH primary chain tensioner.
65. Remove the RH lower primary chain tensioner arm.
66. Remove the RH upper primary chain tensioner guide.
67. Remove the RH intake camshaft bolt.
68. Remove the RH primary timing chain (6268).
69. Remove the exhaust camshaft sprocket bolt.
70. Remove the secondary timing chain tensioner bolts.
71. Remove the RH camshaft chain, tensioner and sprockets as an assembly.
72. Remove the bolts and the LH primary chain tensioner.
73. Remove the LH upper primary chain tensioner arm.
74. Remove the LH lower primary chain tensioner guide.
75. Remove the exhaust camshaft sprocket bolt.
76. Remove the secondary timing chain tensioner bolts.
77. Remove the intake sprocket bolt.
78. Remove the LH camshaft chain, tensioner sprockets, primary chain and crankshaft sprocket as an assembly.
79. Remove the camshafts from the RH and LH cylinder heads. Remove the bolts. Remove the caps. Remove the camshafts.
80. Remove and discard the bolts from the RH and LH cylinder heads.
81. Remove the bolts in the sequence shown from both cylinder heads. Discard the bolts.
82. Remove the cylinder heads. Discard the gaskets.
83. Clean the sealing surfaces.
84. Remove the knock sensors.
85. Remove the throttle body heater return hose.
86. Remove the bolts and the oil pan.
87. Remove the oil pump screen cover and tube, and the seal.
88. Remove the four bolts and the oil pump. Discard the gasket.
89. Remove the flexplate. Remove the bolts in the sequence shown. Remove the flexplate.
90. Using the special tool, remove the rear main seal. Discard the seal.
91. Remove the bolts in the sequence shown and remove the sump body.

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