Engine - 3.9L V8 VIN a - Ls: Removal & Installation Lincoln LS I

REMOVAL & INSTALLATION

Note. For reassembly reference, label all electrical connectors, vacuum hoses and fuel lines before removal. Place mating marks on engine hood and other major assemblies before removal.

Removal

1. Disconnect battery negative terminal. Remove air cleaner inlet. Drain engine coolant. Remove upper radiator sight shield. Remove 2 upper radiator support brackets. Discharge A/C system, using approved refrigerant recovery/recycling equipment. Disconnect A/C pressure switch electrical connector. Release power steering return line from pressure clip line.
2. Remove power steering pump reservoir retaining bolts, and secure reservoir to engine. Relieve fuel pressure and disconnect supply and return lines. See «FUEL PRESSURE RELEASE & FUEL LINE CONNECTIONS»(ref-97869-S22262939422001051200000) . Remove Vapor Management Valve (VMV) cover. Disconnect VMV canister purge hose, and vacuum hose. Disconnect main vacuum supply hose.
3. Remove cowl vent screens. Remove engine compartment brace. Disconnect degas (coolant recovery) bottle. Disconnect accelerator cable and cruise control cable. Disconnect ground strap. Remove fresh air filter. Remove fresh air filter housing. Disconnect powertrain bulkhead electrical connectors. Remove fresh air filter panel.
4. Disconnect heater hoses. Remove hydraulic cooling fan reservoir and secure onto engine. Disconnect water valve electrical connector, and unclip connector form radiator support and position aside. Raise and support vehicle.
5. Remove front wheels and tires. Remove inner splash shield pin-type retainers, and position left and right side inner splash panels aside. Disconnect left and right side anti-lock brake sensor electrical connectors. Unclip left and right side anti-lock brake harnesses from brake hoses. Remove left and right side brake calipers, and wire aside. DO NOT allow calipers to hang by brake hose.
6. Remove left and right side sway bar lower nuts. Remove left and right side ball joint nuts, and separate ball joints from spindles. Remove left and right side lower strut mount bolts. Remove left and right side splash shields. Remove center splash shield. Remove A/C high pressure line retaining nut and disconnect line. Disconnect low pressure A/C line.
7. Remove drive shaft. Disconnect shift cable from shifter. Unclip shift cable from bracket. Remove shift cable bracket. Release power steering lines from left side frame rail. Disconnect rack and pinion steering unit electrical connectors. Remove steering column pinch bolt, and separate steering shaft from steering gear.
8. Remove starter motor ground cable. Remove starter motor cover, and disconnect starter motor electrical connectors. Disconnect generator electrical connector.
9. Remove 6 lower transmission-to-engine bolts. Remove torque converter inspection cover. Remove 8 torque converter nuts. Remove inner air deflector. Remove engine block heater plug (if equipped). Support rear of vehicle with suitable safety stands. Support engine, transmission, front and center crossmembers, and cooling system with a powertrain lift and transmission support bracket.
10. Remove transmission crossmember bolts. Remove 4 front and 4 center crossmember bolts. Carefully lower entire assembly from vehicle. Disconnect block heater (if equipped).
11. Disconnect A/C manifold and tube. Disconnect power steering pump and hydraulic cooling fan pump return hoses. Remove lower radiator hose. Disconnect remaining radiator hoses. Disconnect knock sensor electrical connector. Disconnect heater hose. Remove transmission cooler line bracket. Disconnect transmission cooler lines. Disconnect power steering pressure line. Remove power steering line bracket.
12. Install Engine Lifting Brackets (303-050). Remove hydraulic fan pump bracket. Disconnect hydraulic fan pump line. Using engine lifting brackets and an engine hoist, support engine and transmission on front subframe. Remove left and right side engine mount nuts. remove engine and transmission from subframe and rest on floor or bench. Remove wiring harness retaining nuts and position wiring harness aside. Remove bolts and separate engine from transmission. Mount engine into suitable engine stand.

Installation

1. To install, reverse removal procedure. Tighten bolts and nuts to specification. See «TORQUE SPECIFICATIONS»(ref-97869-S19739856382001051200000) .
2. When installing fuel lines, install NEW "O" rings on fuel lines. Use only specified fuel resistant "O" rings (Black). Lightly coat "O" rings with clean engine oil before installing. Clean fittings, and replace garter spring (if necessary).
3. Adjust control cables and fluid levels. Refill cooling system. Evacuate and recharge A/C system. Check wheel alignment. See appropriate SPECIFICATIONS & PROCEDURES article in WHEEL ALIGNMENT.

1. Drain engine cooling system. Remove left and right side valve covers. See «VALVE COVER»(ref-97869-S07762799622001051200000). Remove cooling fan assembly. Loosen water pump pulley bolts. Remove generator. Remove and discard water pump pulley bolts. Remove water pump pulley. Remove bracket in front of lower radiator hose. Remove lower radiator hose stud bolts. Disconnect lower radiator hose from thermostat hosing.
2. Disconnect heater hose. Remove accessory drive belt idler pulleys. Remove and discard crankshaft pulley bolt. Using Crankshaft Damper Remover (303-009), remove crankshaft pulley. Remove A/C compressor. Disconnect power steering reservoir hose, and drain reservoir into a suitable container.
3. Remove power steering pump retaining bolts and position pump aside. Remove power steering pump bracket.
4. Disconnect hydraulic cooling fan pump reservoir hose, and drain reservoir into a suitable container. Disconnect hydraulic cooling fan pump electrical connector. Remove hydraulic cooling fan pump reservoir line bracket. Remove hydraulic cooling fan pump. Remove hydraulic cooling fan pump bracket. Disconnect 5 wiring harness clips. Remove front engine cover bolts in sequence. (Scheme 188) Remove front cover.

Scheme 188

1. Clean sealing surfaces. Install NEW gaskets. Apply a.12" (3 mm) bead of Silicone Gasket and Sealant (F7AZ-19554-EA) or equivalent onto 8 sealing surfaces. (Scheme 189) Install front cover, and loosely install front cover retaining bolts. Tighten bolts in sequence in 2 stages. (Scheme 190) See «TORQUE SPECIFICATIONS»(ref-97869-S19739856382001051200000).
2. To complete installation, reverse removal procedure. Tighten all bolts and nuts to specification. See «TORQUE SPECIFICATIONS»(ref-97869-S19739856382001051200000).

Scheme 189

Scheme 190

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

1. Disconnect negative battery cable. Remove air cleaner outlet tube. Drain engine coolant. Remove cowl vent screen. Remove engine compartment brace. Disconnect accelerator and cruise control cables. Disconnect necessary vacuum hoses and lines. Disconnect EGR valve to exhaust manifold tube. Remove EGR valve and discard gasket. Disconnect camshaft position sensor electrical connector, and separate connector from fuel injection supply manifold.
2. Disconnect evaporative emission canister purge valve line. Disconnect fuel pressure sensor electrical connector. Disconnect fuel pressure sensor vacuum connector. Relieve fuel pressure and disconnect supply and return lines. See «FUEL PRESSURE RELEASE & FUEL LINE CONNECTIONS»(ref-97869-S22262939422001051200000). Remove left side knock sensor and cylinder head temperature sensor electrical connectors from bracket. Remove retaining nut and electrical connector bracket.
3. Disconnect left side fuel injector connectors. Disconnect Idle Air Control (IAC) valve, and Throttle Position (TP) sensor electrical connectors. Disconnect crankcase ventilation tube from right side valve cover. Disconnect hoses from throttle body. Disconnect right side fuel injectors. Remove delta PFE sensor. Remove intake manifold bolts and stud in sequence. (Scheme 191) Remove intake manifold. Clean all sealing surfaces.

Scheme 191

To install, reverse removal procedure. Tighten all nuts and bolts to specification. See TORQUE SPECIFICATIONS .

Removal (Left Side)

Disconnect negative battery cable. Remove power steering reservoir retaining bolts, and position power steering reservoir aside. Remove oil level tube retaining nut, and position oil level indicator tube aside. Raise and support vehicle. Disconnect three-way catalytic converter from exhaust manifold. Lower vehicle. Remove exhaust manifold nuts. Remove exhaust manifold and gaskets.

Removal (Right Side)

Disconnect negative battery cable. Disconnect 3-way catalytic converter from exhaust manifold. Disconnect EGR valve-to-exhaust manifold tube nut. Remove exhaust manifold nuts. Remove exhaust manifold and gaskets.

Installation (Left & Right Side)

Clean gasket mating surfaces. Install NEW gasket. Position exhaust manifold on cylinder head studs. Tighten nuts to specification. See TORQUE SPECIFICATIONS . To complete installation, reverse removal procedure.

1. Disconnect negative battery cable. Remove air cleaner outlet tube. Disconnect Mass Airflow (MAF) sensor electrical connector on air cleaner housing. Remove retaining bolt, and remove air cleaner housing.
2. Disconnect crankcase ventilation tube. Relieve fuel pressure and disconnect supply and return lines. See «FUEL PRESSURE RELEASE & FUEL LINE CONNECTIONS»(ref-97869-S22262939422001051200000). Disconnect evaporative emission canister purge valve hose. Remove Vapor Management Valve (VMV) cover. Disconnect VMV vacuum hose, and purge line. Remove retaining nut, and position valve aside. Remove Engine Vacuum Regulator (EVR) solenoid retaining bolts, and position solenoid aside.
3. Remove bracket. Position engine sensor control wiring harness aside. Remove ignition coil cover, and inspect gasket. Replace as necessary. Disconnect ignition coil electrical connectors. Remove ignition coils. Disconnect 4 wiring harness retainers. Remove fuel line bracket bolt from left side strut tower.
4. Remove power steering pump reservoir retaining bolts, and position power steering pump reservoir aside. Remove oil level indicator tube. Remove brake line bracket from left side frame rail. Loosen valve cover bolts in sequence, and remove valve cover. (Scheme 192) Clean sealing surfaces. Inspect and install new gaskets as necessary.

1. Disconnect negative battery cable. Remove air cleaner outlet tube. Remove hydraulic cooling fan reservoir retaining bolts, and position hydraulic cooling fan reservoir aside. Disconnect crankcase ventilation hose. Remove right side strut tower wiring harness bracket retaining bolts, and position wiring harness bracket aside.
2. Remove ignition coil cover, and inspect gasket. Replace as necessary. Disconnect ignition coil electrical connectors. Remove ignition coils. Disconnect 4 wiring harness retainers. Remove right side ignition coils.
3. Loosen valve cover bolts in sequence, and remove valve cover. (Scheme 192)

Scheme 192

Clean sealing surfaces. Inspect and install new gaskets as necessary. Apply 2 beads of Silicone Gasket and Sealant (F7AZ-19554-EA) or equivalent onto indicated areas. Ensure Silicone bead is at least.118" (3 mm) in thickness. (Scheme 193) Tighten bolts to specification. See TORQUE SPECIFICATIONS. To complete installation, reverse removal procedure.

Scheme 193

1. Remove intake manifold. See «INTAKE MANIFOLD»(ref-97869-S41162088012001051200000). Remove engine sound insulator. Remove valve covers. See «VALVE COVER»(ref-97869-S07762799622001051200000). Remove camshafts. See «CAMSHAFTS»(ref-97869-S16858226732001051200000). Remove tappet bucket and shims, if necessary. Remove water outlet pipe. Disconnect Cylinder Head Temperature (CHT) sensor electrical connector.
2. Raise and support vehicle. Disconnect three-way catalytic converter from exhaust manifold. Disconnect EGR valve to exhaust manifold tube. Lower vehicle. Remove 2 bolts at rear of cylinder head. Remove 2 bolts at front of cylinder head. Remove remaining cylinder head bolts in sequence. (Scheme 194) Remove cylinder head, and discard gasket. Remove exhaust manifold, and discard gasket.

1. Clean sealing surfaces. Install exhaust manifold with NEW gasket. Install NEW cylinder head gasket. Install cylinder head and tighten bolts in sequence to specification. (Scheme 194) See «TORQUE SPECIFICATIONS»(ref-97869-S19739856382001051200000).
2. Install 2 stud bolts onto rear cylinder head. Install 2 front cylinder head bolts. Install 2 rear stud bolts into right side cylinder head. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-97869-S19739856382001051200000). To complete installation reverse removal procedure.

Scheme 194

Remove generator. Disconnect hydraulic cooling fan hose coupling, and allow to drain. Disconnect hydraulic cooling fan assembly electrical connector. Remove high pressure line bracket retaining bolt and bracket. Disconnect high pressure line. Remove hydraulic cooling fan assembly. Remove accessory drive belt. Remove and discard crankshaft pulley bolt. Using Crankshaft Damper Remover (303-009), remove crankshaft pulley. Using Seal Remover (303-409), remove and discard crankshaft front oil seal.

Lubricate NEW front crankshaft oil seal with clean 5W/30 engine oil. Using Front Crankshaft Seal Installer (303-646), install front cover oil seal. To complete installation, reverse removal procedure. Tighten all nuts and bolts to specification. See TORQUE SPECIFICATIONS .

1. Remove front engine cover. See «FRONT COVER»(ref-97869-S09095883922001051200000). Raise and support vehicle. Remove Crankshaft Position (CKP) sensor and torque converter cover.
2. Rotate crankshaft to 45 degrees ATDC. Crankshaft keyway should be in 6 o'clock position. Install crankshaft position keeper. (Scheme 195)
3. Lower vehicle. Remove valve covers. See «VALVE COVER»(ref-97869-S07762799622001051200000). Ensure flat lobes on camshafts (behind front camshaft bearing cap) are facing upward. If camshaft flat lobes are not facing upward, repeat step 2).
4. Install Camshaft Setter/Locker (303-530) onto right side cylinder head camshafts. Loosen exhaust camshaft sprocket bolt. Loosen intake camshaft sprocket bolt, and slide camshaft sprockets forward on bolts.
5. Remove right side timing chain tensioner and blanking plate. Remove tensioner arm. Remove timing chain guide. Remove right side timing chain and crankshaft sprocket as an assembly. Remove Camshaft Setter/Locker from right side cylinder head. Repeat steps 4) and 5) for left side cylinder head.
6. Remove exhaust camshaft sprocket bolt. Remove intake camshaft sprocket bolt, and slide sprockets, camshaft damper, and secondary timing chain off camshaft. Remove secondary timing chain tensioner bolts, and remove tensioner. (Scheme 196)

Scheme 195

Scheme 196

1. Install secondary timing chain tensioner. Install intake sprocket, camshaft damper, secondary timing chain, and exhaust sprocket onto intake camshaft. Loosely install intake and exhaust sprocket bolts.
2. Position timing chain over left side intake camshaft sprocket. Position crankshaft gear into timing chain. Install timing chain and crankshaft gear over crankshaft as an assembly. Install left side timing chain guide and tensioner arm.
3. Reset timing chain tensioners. Install left side timing chain, and crankshaft gear. Install left side timing chain guide. Install left side timing chain tensioner arm. Install left side timing chain tensioner. (Scheme 198)
4. Install a tie strap to take up slack in timing chain. Using Timing Chain Tensioner (303-532) apply tension to left side exhaust camshaft sprocket and tighten camshaft sprocket bolts in 2 steps to specification. (Scheme 199) See «TORQUE SPECIFICATIONS»(ref-97869-S19739856382001051200000).
5. Remove camshaft setter/locker from left side camshafts. Remove tie strap. Install camshaft setter/locker onto right side camshafts. Repeat installation procedure for right side primary timing chain. Tighten all bolts and nuts to specification. See «TORQUE SPECIFICATIONS»(ref-97869-S19739856382001051200000).
6. Raise vehicle, and remove crankshaft position keeper. Install CKP sensor, and torque converter cover. Lower vehicle. Install front engine cover. See «FRONT COVER»(ref-97869-S09095883922001051200000). Install valve covers. See «VALVE COVER»(ref-97869-S07762799622001051200000). To complete installation, reverse removal procedure. Tighten all bolts and nuts to specification. See «TORQUE SPECIFICATIONS»(ref-97869-S19739856382001051200000). Refill cooling system. See COOLING SYSTEM SPECIFICATIONS.

Scheme 197

Scheme 198

Scheme 199

Remove valve cover. See VALVE COVER . Install Camshaft Setting/Locking device (303-530). Remove primary and secondary timing chains. See TIMING CHAINS . Remove camshaft setting/locking device. Remove bearing cap retaining bolts. Remove bearing caps. Remove camshafts.

Note. Apply Super Premium SAE 5W-30 Motor Oil X0-5W30-QSP or equivalent onto camshaft journals, bearing caps and camshaft lobes, prior to installation.

Install camshafts into camshaft journals. Install bearing caps into their original locations, and tighten bolts in sequence to specification. (Scheme 200) See TORQUE SPECIFICATIONS. To complete installation reveres removal procedure.

Scheme 200

Remove transmission. See TRANSMISSION REMOVAL & INSTALLATION article in TRANSMISSION SERVICING. Remove flexplate retaining bolts in sequence. (Scheme 201) Remove flexplate. Using Rear Crankshaft Seal Remover/Installer (303-647) and Screw (204-208), remove crankshaft rear oil seal. Discard seal.

Lubricate outer lips and inner seal on crankshaft rear oil seal clean 5W/30 engine oil. Using crankshaft seal remover/installer, install rear oil seal. Install flexplate, and tighten bolts in sequence, and in 2 steps to specification. (Scheme 201) See TORQUE SPECIFICATIONS. To complete installation, reverse removal procedure. Tighten nuts and bolts to specification. See TORQUE SPECIFICATIONS.

Scheme 201

Drain cooling system. Loosen water pump pulley bolts. Remove accessory drive belt. Remove water pump pulley bolts, and water pump pulley. Remove water pump retaining bolts, and remove water pump.

Lubricate "O" ring, using Premium Engine Coolant E2FZ-19549-AA or equivalent. Install water pump and tighten bolts in 2 steps to specification. Install water pump pulley, and tighten in 2 steps. To complete installation, reverse removal procedure. Tighten all nut and bolts to specification. See TORQUE SPECIFICATIONS .

Raise and support vehicle. Drain oil from engine. Remove oil pan retaining bolts. Remove oil pan. To install, reverse removal procedure. Tighten bolts in sequence to specification. (Scheme 202) See TORQUE SPECIFICATIONS.

Scheme 202

Remove left and right side valve covers. See VALVE COVER . Remove front engine cover. See FRONT COVER . Remove primary timing chains. See TIMING CHAINS . Remove oil pump retaining bolts, and remove oil pump. Discard gasket.

Clean and inspect sealing surfaces. Install NEW gasket. Install oil pump, and tighten bolts in 2 steps to specification. See TORQUE SPECIFICATIONS . To complete installation, reverse removal procedure, and tighten all fasteners to specification. See TORQUE SPECIFICATIONS .