Engine - 3.0L (4V): Removal & Installation Lincoln LS I рестайлинг

Drive Belt - Incorrect Installation

Non-standard accessory drive belts can track differently or incorrectly. If an accessory drive belt tracks incorrectly, install a new accessory drive belt to avoid performance failure or loss of the drive belt.

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Drive Belt - Correct Installation

With the engine running, check accessory drive belt tracking on all pulleys. If the edge of the accessory drive belt rides beyond the edge of the pulleys, noise and premature wear will occur. Make sure the accessory drive belt rides correctly on the pulley. If an accessory drive belt tracking condition exists, proceed with the following

1. Visually check the accessory drive belt tensioner for damage, especially the mounting pad surface. If the accessory drive belt tensioner is not installed correctly, the mounting surface pad will be out of position. This will result in chirp and squeal noises.
2. With the engine running, visually observe the grooves in the pulleys (not the pulley flanges or the pulley forward faces) for excessive wobble. Install new components as necessary.
3. Check all accessories, mounting brackets and the accessory drive belt tensioner for any interference that would prevent the component from mounting correctly. Correct any interference condition and recheck the accessory drive belt tracking.
4. Tighten all accessories, mounting brackets and accessory drive belt tensioner retaining hardware to specification. Recheck the accessory drive belt tracking.

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Removal

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1. Remove the engine front cover. For additional information, refer to «ENGINE FRONT COVER»(ref-207552-S20877027482005113000000) in this section.
2. Remove the ignition pulse wheel.
3. Install the crankshaft damper bolt and washer.
4. Rotate the crankshaft clockwise to position the crankshaft keyway to the 9 o'clock position.
5. Rotate the crankshaft clockwise to position the crankshaft keyway to the 3 o'clock position.
6. Verify that the front 2 intake camshaft lobes are pointing up.
7. Compress the RH timing chain tensioner. Release the racheting pawl. Compress the timing chain tensioner and install a stiff wire or paper clip.
8. Remove the bolts and the RH timing chain tensioner.
9. Remove the RH timing chain tensioner arm.
10. Remove the RH timing chain.
11. Remove the bolts and the RH variable camshaft timing (VCT) solenoid housing assembly.
12. Rotate the crankshaft counterclockwise to position the crankshaft keyway to the 11 o'clock position.
13. Compress the LH timing chain tensioner. Release the racheting pawl. Compress the timing chain tensioner and install a stiff wire or paper clip.
14. Remove the bolts and the LH timing chain tensioner.
15. Remove the LH timing chain tensioner arm.
16. Remove the LH timing chain.
17. Remove the LH VCT solenoid housing assembly.
18. Using a wrench on the flats of the camshaft, hold the camshaft in position and remove the bolt and the RH VCT actuator. Discard the bolt.
19. Using a wrench on the flats of the camshaft, hold the camshaft in position and remove the bolt and the RH exhaust camshaft sprocket. Discard the bolt.
20. Using a wrench on the flats of the camshaft, hold the camshaft in position and remove the bolt and the LH VCT actuator. Discard the bolt.
21. Using a wrench on the flats of the camshaft, hold the camshaft in position and remove the bolt and the LH exhaust camshaft sprocket. Discard the bolt.
22. Remove the crankshaft sprockets.

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1. Install the LH variable camshaft timing (VCT) actuator and install a new bolt hand-tight. Use a wrench on the flats of the camshaft to hold it in position and tighten the bolt in 2 stages. Stage 1: Tighten the VCT actuator bolt to 20 N.m (15 lb-ft). Stage 2: Tighten an additional 90 degrees.
2. Install the LH exhaust camshaft sprocket and install a new bolt hand-tight. Using a wrench on the flats of the camshaft, hold the camshaft in position and tighten the bolt in 2 stages. Stage 1: Tighten the exhaust camshaft sprocket bolt to 20 N.m (15 lb-ft). Stage 2: Tighten an additional 90 degrees.
3. Install the RH variable camshaft timing (VCT) actuator and install a new bolt hand-tight. Using a wrench on the flats of the camshaft, hold the camshaft in position and tighten the bolt in 2 stages. Stage 1: Tighten the VCT actuator bolt to 20 N.m (15 lb-ft). Stage 2: Tighten an additional 90 degrees.
4. Install the RH exhaust camshaft sprocket and install a new bolt hand-tight. Using a wrench on the flats of the camshaft, hold the camshaft in position and tighten the bolt in 2 stages. Stage 1: Tighten the exhaust camshaft sprocket bolt to 20 N.m (15 lb-ft). Stage 2: Tighten an additional 90 degrees.
5. With the 2 keyways facing forward, install the crankshaft sprockets.
6. If timing marks in the timing chains are not evident, use a permanent-type marker to mark the crankshaft and camshaft timing marks on the LH and RH timing chains. Mark any link to use as the exhaust camshaft timing mark. Starting with the exhaust camshaft timing mark, count 16 links and mark the link as the intake camshaft sprocket timing mark. Starting with the intake camshaft timing mark, count 25 links and mark the link as the crankshaft sprocket timing mark.
7. Verify that the crankshaft keyway is in the 11 o'clock position.
8. Rotate the LH and RH intake and exhaust camshafts to locate them in their NEUTRAL positions.
9. Install the LH VCT solenoid housing assembly and hand-tighten the bolts. Tighten in the sequence shown to 25 N.m (18 lb-ft).
10. Install the LH timing chain, aligning the copper (or marked) link with the marks on the camshaft and crankshaft sprockets.
11. Install the LH timing chain tensioner arm.
12. Install the LH timing chain tensioner and bolts.
13. Remove the wire or paper clip from the tensioner.
14. Rotate the crankshaft clockwise and position the keyway at the 3 o'clock position for RH timing chain installation.
15. Verify that the copper (or marked) links on the LH timing chain are in alignment with the timing marks on the camshaft and crankshaft sprockets.
16. Install the RH VCT solenoid housing assembly and hand-tighten the bolts. Tighten in the sequence shown to 25 N.m (18 lb-ft).
17. Install the RH timing chain, aligning the copper or (marked) links with the marks on the camshaft and crankshaft sprockets.
18. Install the RH timing chain tensioner arm.
19. Install the RH timing chain tensioner and bolts.
20. Remove the wire or paper clip from the RH timing chain tensioner.
21. Rotate the crankshaft counterclockwise to position the crankshaft keyway to the 11 o'clock position.
22. Verify that the timing component alignment is correct. There should be 14 chain links between the exhaust and intake camshaft timing marks. There should be 23 chain links between the camshaft and crankshaft timing marks. There should be 28 chain links between the camshaft and crankshaft timing marks.
23. Remove the crankshaft damper bolt and washer.
24. Install the ignition pulse wheel using the orange marked keyway slot and the teeth facing forward.
25. If necessary, install new variable camshaft timing (VCT) system oil filters. For additional information, refer to «VARIABLE CAMSHAFT TIMING (VCT) SYSTEM OIL FILTER»(ref-207552-S29327139782005113000000) in this section.
26. Install the engine front cover. For additional information, refer to «ENGINE FRONT COVER»(ref-207552-S20877027482005113000000) in this section.

Removal and Installation

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1. Remove the timing drive components. For additional information, refer to «TIMING DRIVE COMPONENTS»(ref-207552-S16094195452005113000000) in this section.
2. Remove the components in the order indicated in the following illustration and table. To remove individual components, carry out only the listed steps. COMPONENT STEPS SPECIFICATION Component Steps Camshafts 1-5 Valve springs and valve seals 1-12
3. Illustration 1 of 2. Remove the components in the order indicated in the following illustration and table.
4. Illustration 2 of 2. Remove the components in the order indicated in the following illustration and table.

Item 1: Camshaft Journal Thrust Cap Bolts Removal Note

1. Remove the bolts.

Item 2: Camshaft Journal Thrust Cap Removal Note

1. Using a soft-faced mallet, gently loosen and remove the camshaft journal thrust caps.

Item 4: Camshaft Journal Caps Removal Note

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1. Using a soft-faced mallet, gently loosen and remove the remaining camshaft journal caps.

Items 5 and 6: Intake And Exhaust Camshafts Removal Note

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1. Use care when lifting out the camshafts.

Items 7 and 8: Tappet and Shim Removal Note

1. Remove the tappet and shim.

Items 9-12: Valve Spring Retainer Key, Retainer, Valve Spring and Valve Stem Seal Removal Note

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1. Remove the spark plug for the cylinder being serviced.
2. Position the piston for the cylinder being serviced at the top of its stroke and pressurize the cylinder with compressed air.
3. Using the special tool, compress the valve spring and remove the retainer keys.
4. Repeat the procedure for all of the cylinders to be serviced.
5. Remove the valve spring. Remove the retainer. Remove the valve spring.
6. Remove the valve stem seal.

Items 9-12: Valve Spring Retainer Key, Retainer, Valve Spring and Valve Stem Seal Installation Note

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1. Install the valve stem seal.
2. Install the valve spring and retainer.
3. Using the special tool, compress the valve spring and install the retainer keys.
4. Release the compressed air used to hold the valves closed.
5. Install the spark plug. For additional information, refer to «INTAKE AIR, FUEL CHARGING, STARTING & ENGINE ELECTRONICS - 3.0L (4V)»(ref-207555) .

Items 7 and 8: Tappet and Shim Installation Note

1. Install the tappet and shim.

Items 5 and 6: Exhaust and Intake Camshafts Installation Note

1. Lubricate camshafts with clean engine oil and carefully position the camshafts into the cylinder head.

Item 4: Camshaft Journal Caps Installation Note

1. Lubricate the bearing surfaces of the camshaft bearing caps with clean engine oil, install the bearing caps, and loosely install the bolts.

Item 2: Camshaft Journal Thrust Cap Installation Note

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1. Lubricate the bearing surfaces of the camshaft journal thrust caps with clean engine oil, install the caps, and loosely install the bolts.
2. Tighten the bolts in the sequence shown.
3. Using a feeler gauge, confirm that the tappet and shim clearances are within specification. For additional information, refer to «VALVE CLEARANCE CHECK»(ref-207552-S27244323302005113000000) in this section.
4. If tappet and shim clearances are not within specifications, adjust the clearance. For additional information, refer to «VALVE CLEARANCE ADJUSTMENT»(ref-207552-S40657616862005113000000) in this section. CAUTION: Verify that the crankshaft is in the nine o'clock position before rotating the camshafts, or damage to the valve train can result.
5. Rotate the camshafts to be sure they are not binding. If binding occurs, check to make sure that all bearing caps are in the original positions. Loosen all bearing cap bolts in reverse order and then tighten again.
6. Install the timing drive components. For additional information, refer to «TIMING DRIVE COMPONENTS»(ref-207552-S16094195452005113000000) in this section.

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1. With the vehicle in NEUTRAL, position on a hoist.
2. Remove the RH lower splash shield.
3. Remove the components in the order indicated in the following illustration and table.
4. To install, reverse the removal procedure.

Item 6: RH Exhaust Manifold Nuts Installation Note

1. Tighten the exhaust manifold nuts in the sequence shown in two stages: Stage 1: Tighten to 20 N.m (15 lb-ft). Stage 2: Tighten to 20 N.m (15 lb-ft).

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1. With the vehicle in NEUTRAL, position on a hoist.
2. Remove the LH lower splash shield.
3. Remove the components in the order indicated in the following illustration and table.
4. To install, reverse the removal procedure.

Item 5: LH Exhaust Manifold Nuts Installation Note

1. Using a new gasket, install the exhaust manifold. Tighten the nuts in two stages. Stage 1: Tighten to 20 N.m (15 lb-ft). Stage 2: Tighten to 20 N.m (15 lb-ft).

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1. Remove the LH camshafts. For additional information, refer to «CAMSHAFT, VALVE SPRINGS AND VALVE SEALS»(ref-207552-S21649349762005113000000) in this section.
2. Remove the LH exhaust manifold. For additional information, refer to «EXHAUST MANIFOLD - LH»(ref-207552-S00336559012005113000000) in this section.
3. Remove the lower intake manifold. For additional information, refer to «LOWER INTAKE MANIFOLD»(ref-207552-S34175828282005113000000) in this section.
4. Remove the components in the order indicated in the following illustration and table.
5. To install, reverse the removal procedure.

Items 9,10 and 11: Cylinder Head Gasket, Cylinder Head and Cylinder Head Bolts Removal Note

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1. Remove the ground strap.
2. Install the four crossmember bolts.
3. Remove the special tool.
4. Support the cylinder head on a bench with the head gasket side up. Inspect all areas of the deck face with a straightedge and feeler gauge. 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) deep.

Items 9,10 and 11: Cylinder Head Bolts, Cylinder Head, and Cylinder Head Gasket Installation Note

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1. Using a new cylinder head gasket and bolts, install the LH cylinder head and loosely install the bolts.
2. Tighten the bolts in six stages in the sequence shown. see scheme 128 Stage 1: Tighten to 30 N.m (22 lb-ft). Stage 2: Rotate 90 degrees. Stage 3: Back out a minimum of one full turn (360 degrees). Stage 4: Tighten to 30 N.m (22 lb-ft). Stage 5: Rotate 90 degrees. Stage 6: Rotate all bolts an additional 90 degrees.
3. Install the special tool.
4. Remove the four crossmember bolts.
5. Install the ground strap.

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1. Remove the RH camshafts. For additional information, refer to «CAMSHAFT, VALVE SPRINGS AND VALVE SEALS»(ref-207552-S21649349762005113000000) in this section.
2. Remove the RH exhaust manifold. For additional information, refer to «EXHAUST MANIFOLD - RH»(ref-207552-S23063060272005113000000) in this section.
3. Remove the lower intake manifold. For additional information, refer to «LOWER INTAKE MANIFOLD»(ref-207552-S34175828282005113000000) in this section.
4. Remove the components in the order indicated in the following illustration and table.
5. To install, reverse the removal procedure.

Item 6: Cylinder Head Bolts Removal Note

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1. Remove the ground strap.
2. Install the four crossmember bolts.
3. Remove the special tool.
4. Support the cylinder head on a bench with the head gasket side up. Inspect all areas of the deck face with a straightedge and feeler gauge. 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) deep.

Items 6, 7 and 8: Cylinder Head Bolts, Cylinder Head, and Cylinder Head Gasket Installation Note

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1. Using a new cylinder head gasket and bolts, install the RH cylinder head and loosely install the bolts.
2. Tighten the bolts in six stages in the sequence shown. see scheme 137 Stage 1: Tighten to 30 N.m (22 lb-ft). Stage 2: Rotate 90 degrees. Stage 3: Back out a minimum of one full turn (360 degrees). Stage 4: Tighten to 30 N.m (22 lb-ft). Stage 5: Rotate 90 degrees. Stage 6: Rotate all bolts an additional 90 degrees.
3. Install the special tool.
4. Remove the four crossmember bolts.
5. Install the ground strap.