Engine - 3.9L V8 VIN a - Ls: Other Lincoln LS I

FUEL PRESSURE RELEASE & FUEL LINE CONNECTIONS

1. Disconnect battery ground cable. Remove fuel cap to release fuel tank pressure. Using EFI Pressure Gauge (T80L-9974-B), release fuel pressure from fuel-pressure relief valve on fuel rail.
2. To disconnect fuel lines, remove retaining clip from outside of fuel line coupling. Use Spring Lock Coupling Remover (D87L-9280-A) for 3/8" line or (D87L-9280-B) for 1/2" line. Install spring lock coupling remover on fuel line coupling so it enters cage opening.
3. Push spring lock coupling remover into cage opening to release female fitting from garter spring. Pull couplings apart. Remove spring lock coupling remover.
4. When installing fuel lines, install NEW "O" rings on fuel lines. Use only specified fuel resistant "O" rings (Black). Before installing, lightly coat "O" rings with clean engine oil. Clean fittings, and replace garter spring (if necessary). Fit female fitting to male fitting and push until garter spring snaps over flared end of female fitting.
5. Ensure lines are locked together and garter spring is over female fitting flared end. Install retaining clip. Ensure horseshoe portion of clip is over coupling. DO NOT install retaining clip over rubber fuel line.

FRONT COVER

Note. Use a clean container to reuse coolant. If coolant is contaminated, coolant must be recycled, or disposed of correctly.

CYLINDER HEAD

Note. When valve and/or valve seat are machined, valve clearance is reduced and may cause improper valve operation. Valve clearance must be checked. See VALVE CLEARANCE ADJUSTMENT under ADJUSTMENTS.

Check cylinder head warpage. Resurface cylinder head if warpage exceeds specification. See CYLINDER HEAD table under ENGINE SPECIFICATIONS.

Valve Springs

1. Inspect valve spring pressure. Replace valve spring if pressure is not within specification. See «VALVES & VALVE SPRINGS»(ref-97869-S30483478842001051200000) table under ENGINE SPECIFICATIONS.
2. Check springs for squareness, stand spring on table with closed end of spring downward. Hold square against spring and rotate spring. Measure space between spring and square. See «VALVES & VALVE SPRINGS»(ref-97869-S30483478842001051200000) table.
3. Measure valve spring installed height from cylinder head surface to underside of spring retainer. If installed height is not within specification, install shim between cylinder head and valve spring to obtain correct height. See «VALVES & VALVE SPRINGS»(ref-97869-S30483478842001051200000) table.

Note. Lubricate all valves, valve stems and valve guides with clean 5W/30 engine during installation.

Valve Stem Oil Seals

Different types of valve stem oil seals are used on intake and exhaust valves. Ensure oil seal bottoms on valve guide. Exhaust valve stem oil seal are Black, and intake valve stem oil seals are Gray.

Valve Guides

1. Valve guides may be reamed for oversize valves if stem-to-guide oil clearance exceeds specification. See «CYLINDER HEAD»(ref-97869-S32384036132001051200000) table under ENGINE SPECIFICATIONS. Valves are available in .015" (.38 mm) and .030" (.76 mm) oversizes.
2. Valve guides may also be bored and replaced with a service guide if oversize valves are not available, or if guide is damaged. Ream valve guides until proper stem-to-guide clearance exists.

Valve Seat

Ensure valve seat angle, seat width and seat runout are within specification. See CYLINDER HEAD table under ENGINE SPECIFICATIONS. Valve seats must be ground when valve guide is reamed or replaced. Replacement information is not available from manufacturer.

Valves

Ensure head diameter, valve face runout, stem diameter and valve margin are within specification. See VALVES & VALVE SPRINGS table under ENGINE SPECIFICATIONS.

Valve Seat Correction Angles

Use a 30-degree stone to lower seat, or a 75-degree stone to raise seat.

Fitting Pistons

1. Standard selective fit pistons are color-coded Red (grade 1), Blue (grade 2) and Yellow (grade 3) on piston dome. Measure piston skirt diameter at 90-degree angle to piston pin. Replace piston if not within specification. See «PISTONS, PINS & RINGS»(ref-97869-S35036292262001051200000) table under ENGINE SPECIFICATIONS.
2. Measure cylinder bore 1/2" below top of cylinder bore and 1/2" above bottom of piston travel.
3. Using bore diameter, determine color-coded piston to be used. Ensure piston-to-bore clearance is within specification. See «PISTONS, PINS & RINGS»(ref-97869-S35036292262001051200000) table.

Piston Rings

Ensure ring end gap and side clearance are within specification. See PISTONS, PINS & RINGS table under ENGINE SPECIFICATIONS. Ensure ring gaps are NOT aligned.

Rod Bearings

1. Coat rod bearings with 5W/30 engine oil. Coat connecting rod bolts with oil before installing nuts. Ensure piston and connecting rod are installed so dome or notch on top of piston and button on connecting rod are toward front of engine. see scheme 16
2. Use plastigage method to check bearing oil clearance. DO NOT turn crankshaft while using plastigage. See «CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS»(ref-97869-S39992478882001051200000) and CONNECTING RODS tables under ENGINE SPECIFICATIONS. CAUTION: Do not grind more than.010" (.25 mm) from crankshaft journal surfaces. Further grinding may cause crankshaft failure.
3. If any bearing clearance is not within specifications, grind crankshaft and use undersize bearings. Ensure journal shoulder radius is reproduced when grinding journals.
4. Upon reassembling, apply Engine Assembly Lubricant (D9AZ-19579-D) to bearing faces. Ensure backside of bearing insert is free of grease. Tighten connecting rod bearing cap nuts to specification. See «TORQUE SPECIFICATIONS»(ref-97869-S19739856382001051200000).

Scheme 204

1. Ensure main bearing oil clearance and crankshaft end play is within specification. See «CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS»(ref-97869-S39992478882001051200000) table under ENGINE SPECIFICATIONS. Replace thrust bearing if end play is not within specification.
2. If oil clearance exceeds specification, try using a different combination of main bearings. See «SELECTIVE MAIN BEARINGS»(ref-97869-S20490958142001051200000) table. (Scheme 204) Use only bearing combinations listed in table. CAUTION: Do not grind more than.010" (.25 mm) from crankshaft journal surfaces. Further grinding may cause crankshaft failure.
3. If any bearing cannot be adjusted to standard oil clearance specification, grind crankshaft and use oversize bearings. Oversize main bearings are available in.010" (.25 mm). Tighten lower cylinder block bolts to specification. SELECTIVE MAIN BEARINGS Crankshaft Code Cylinder Block Code Bearing Grade 0 1 1 1 1 2 2 1 3 3 1 4 0 2 2 1 2 3 2 2 4 3 2 5 0 3 3 1 3 4 2 3 5 3 3 6
4. Install bolts finger tight. Pry crankshaft forward, and tighten lower cylinder block bolts to specification. See «TORQUE SPECIFICATIONS»(ref-97869-S19739856382001051200000).

Thrust Bearing

Thrust bearing is located on No. 3 main bearing. Replace bearing if crankshaft end play is not within specification. See CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS table under ENGINE SPECIFICATIONS.

Cylinder Block

1. Using a straightedge and feeler gauge, check cylinder block head surface warpage. Machine cylinder block if warpage exceeds specification. See «CYLINDER BLOCK»(ref-97869-S28289879602001051200000) table under ENGINE SPECIFICATIONS. CAUTION: Do not machine more than .010" (.25 mm) of material from original cylinder block deck surface.
2. Check cylinder bore diameter, out-of-round and taper. Cylinder bore is measured 1/2" below top of cylinder block deck and 1/2" above piston when at bottom of cylinder bore. Cylinder block must be bored if measurement is not within specification. See «CYLINDER BLOCK»(ref-97869-S28289879602001051200000) table under ENGINE SPECIFICATIONS.

Oil Pressure

Note. Information unavailable at time of publication from manufacturer.