Material — Part 3 Lincoln LS I facelift

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1. Remove the ignition pulse wheel.
2. Install the crankshaft damper bolt and washer.
3. Rotate the crankshaft clockwise to position the crankshaft keyway to the nine o'clock position.
4. Rotate the crankshaft clockwise to position the crankshaft keyway to the three o'clock position.
5. Verify that the front two intake camshaft lobes are pointing up.
6. Compress the timing chain tensioner. Release the racheting pawl. Compress the timing chain tensioner and install a stiff wire or paper clip.
7. Remove the bolts and the RH timing chain tensioner.
8. Remove the RH timing chain tensioner arm.
9. Remove the RH timing chain.
10. Remove the bolts and the RH variable camshaft timing (VCT) solenoid housing assembly.
11. Rotate the crankshaft counterclockwise to position the crankshaft keyway to the eleven o'clock position.
12. Compress the timing chain tensioner. Release the racheting pawl. Compress the timing chain tensioner and install a stiff wire or paper clip.
13. Remove the bolts and the LH timing chain tensioner.
14. Remove the LH timing chain tensioner arm.
15. Remove the LH timing chain.
16. Remove the LH VCT solenoid housing assembly.
17. Remove the crankshaft sprockets.

Items 110-114: RH Variable Camshaft Timing (VCT) Actuator, RH Exhaust Camshaft Sprocket and Bolts Disassembly Note

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1. 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.
2. 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.

Items 115-121: LH Variable Camshaft Timing (VCT) Actuator, LH Exhaust Camshaft Sprocket and Bolts, and Timing Chain Crankshaft Sprockets Disassembly Note

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1. 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.
2. 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.

Items 122 and 125: RH and LH Cylinder Head Bolts Disassembly Note

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1. Remove the bolts.
2. Using a soft-faced mallet, gently loosen and remove the camshaft journal thrust caps.
3. Remove the remaining camshaft journal cap bolts.
4. Using a soft-faced mallet, gently loosen and remove the remaining camshaft journal caps.
5. Carefully lift out the camshafts.
6. Remove the bolts and the coolant outlet pipe. Discard the O-ring seal.
7. Remove and discard the cylinder head bolts.
8. 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.
9. Remove the four oil pump bolts in the sequence shown. (Scheme 330) Remove the oil pump.

Item 128: Engine Assembly Disassembly Note

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1. Remove the bolts and the inlet tube.
2. Remove the bolt and the top-mounted knock sensor (KS).

Scheme 292

MATERIAL SPECIFICATION CHART

Scheme 293

1. Disassemble the components in the order indicated in the following illustration and table.
2. To assemble, reverse the disassembly procedure.
3. Repeat the procedure until all of the valves are removed.

Items 1, 2, 8, and 9: Tappet Shim and Tappet Disassembly Note

1. Remove the tappet and shim.

Items 3 and 10: Intake and Exhaust Valve Spring Retainer Keys Disassembly Note

Scheme 294

1. Using the special tool, compress the valve spring and remove the retainer keys.

Items 7 and 14: Intake and Exhaust Valves Disassembly Note

1. For component tests of the valve, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-207551) for basic mechanical concerns.
2. Lubricate the valve stem and the valve stem seal with clean engine oil prior to installation.

Item 15: Cylinder Head Disassembly Note

1. For component tests of the cylinder head, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-207551) for basic mechanical concerns.

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MATERIAL SPECIFICATION CHART

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1. Install the components in the order indicated in the following illustration and table. (Scheme 337)
2. Install the components in the order indicated in the following illustration and table. (Scheme 338)
3. Install the components in the order indicated in the following illustration and table. (Scheme 339)
4. Install the components in the order indicated in the following illustration and table. (Scheme 340)
5. Install the components in the order indicated in the following illustration and table. (Scheme 341)
6. Install the components in the order indicated in the following illustration and table. (Scheme 342)
7. Install the components in the order indicated in the following illustration and table. (Scheme 343)
8. Install the components in the order indicated in the following illustration and table. (Scheme 344)
9. Install the components in the order indicated in the following illustration and table. (Scheme 345)
10. Install the components in the order indicated in the following illustration and table. (Scheme 346)
11. Install the components in the order indicated in the following illustration and table. (Scheme 347)
12. Install the components in the order indicated in the following illustration and table. (Scheme 348)
13. Install the components in the order indicated in the following illustration and table. (Scheme 349)
14. Install the components in the order indicated in the following illustration and table. (Scheme 350)
15. Install the components in the order indicated in the following illustration and table. (Scheme 351)
16. Install the components in the order indicated in the following illustration and table. (Scheme 352)
17. Install the components in the order indicated in the following illustration and table. (Scheme 353)
18. Install the components in the order indicated in the following illustration and table. (Scheme 354)
19. Install the components in the order indicated in the following illustration and table. (Scheme 355)
20. Install the components in the order indicated in the following illustration and table. (Scheme 356)
21. Install the components in the order indicated in the following illustration and table. (Scheme 357)

Item 1: Engine Assembly Note

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1. Rotate the crankshaft to position the keyway at the nine o'clock position.
2. Position the oil pump and install the bolts.
3. Position the oil pan baffle and install the nuts. Tighten in two stages: Stage 1: Tighten to 5 N.m (44 lb-in). Stage 2: Tighten an additional 45 degrees.
4. Position the oil pump screen cover and tube and install the bolts. Use a new O-ring seal, if necessary.
5. Position the top-mounted knock sensor (KS) and install the bolt.
6. Using a new O-ring seal, position the coolant inlet tube and install the bolts.

Items 2-7: LH and RH Cylinder Head, Gaskets and Bolts Assembly Note

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1. Using a new cylinder head gasket, position the cylinder head, and install new bolts. Tighten the bolts in six stages: Stage 1: Tighten to 30 N.m (22 lb-ft). Stage 2: Tighten an additional 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: Tighten an additional 90 degrees. Stage 6: Tighten an additional 90 degrees.
2. Install the LH and RH spark plugs.
3. Lubricate camshafts with clean engine oil and carefully position the camshafts into the cylinder head.
4. Lubricate the bearing surfaces of the camshaft bearing caps with clean engine oil, install the bearing caps, and loosely install the bolts.
5. Lubricate the bearing surfaces of the camshaft bearing thrust caps with clean engine oil, install the caps, and loosely install the bolts.
6. Tighten the bolts in the sequence shown. (Scheme 369)
7. Lubricate the tappet shims and camshaft lobes with clean engine oil.
8. Rotate the camshafts to make sure they are not binding. If binding occurs, check to make sure that all bearing caps are in their original positions. Loosen all bearing cap bolts in reverse order and retighten.
9. Install the coolant outlet pipe, a new O-ring seal and the 2 bolts. Tighten to 25 N.m (18 lb-ft).

Items 8-19: Variable Camshaft Timing (VCT) Actuators, Exhaust Camshaft Sprockets, Bolts, Washers and Crankshaft Sprockets Assembly Note

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1. With the two keyways facing forward, install the crankshaft sprockets.
2. Install the LH exhaust camshaft sprocket and a new bolt hand tight. Using a wrench on the flats of the camshaft, hold the camshaft in position and tighten the bolt in two 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 LH variable camshaft timing (VCT) actuator and a new bolt hand tight. Using a wrench on the flats of the camshaft, hold the camshaft in position and tighten the bolt in two 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 a new bolt hand tight. Using a wrench on the flats of the camshaft, hold the camshaft in position and tighten the bolt in two stages. Stage 1: Tighten the exhaust camshaft sprocket bolt to 20 N.m (15 lb-ft). Stage 2: Tighten an additional 90 degrees.
5. Install the RH variable camshaft timing (VCT) actuator and a new bolt hand tight. Using a wrench on the flats of the camshaft, hold the camshaft in position and tighten the bolt in two stages. Stage 1: Tighten the VCT actuator bolt to 20 N.m (15 lb-ft). Stage 2: Tighten an additional 90 degrees.

Items 20-33: Timing Drive Components Assembly Note

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1. 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.
2. Verify that the crankshaft keyway is in the eleven o'clock position.
3. Rotate the LH and RH intake and exhaust camshafts to locate them in their neutral positions.
4. Install the LH VCT solenoid housing assembly and hand-tighten the bolts. Tighten in the sequence shown to 25 N.m (18 lb-ft).
5. Install the LH timing chain, aligning the copper (or marked) link with the marks on the camshaft and crankshaft sprockets.
6. Install the LH timing chain tensioner arm.
7. Install the LH timing chain tensioner and bolts.
8. Remove the wire or paper clip from the tensioner.
9. Rotate the crankshaft clockwise and position the keyway at the three o'clock position for RH timing chain installation.
10. Verify that the copper (or marked) links on the LH timing chain are in alignment with the timing index marks on the camshaft and crankshaft sprockets.
11. Install the RH VCT solenoid housing assembly and hand-tighten the bolts. Tighten in the sequence shown to 25 N.m (18 lb-ft).
12. Install the RH timing chain, aligning the copper (or marked) links with the marks on the camshaft and crankshaft sprockets.
13. Install the RH timing chain tensioner arm.
14. Install the RH timing chain tensioner and bolts.
15. Remove the wire or paper clip from the RH timing chain tensioner.
16. Rotate the crankshaft counterclockwise to position the crankshaft keyway to the 11 o'clock position.
17. Verify that the timing component alignment is correct. There should be LH 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.
18. Remove the crankshaft damper bolt and washer.
19. Install the ignition pulse wheel using the orange marked keyway slot and the teeth facing forward.

Items 20 and 27: VCT System Oil Filters Assembly Note

Scheme 343

1. Remove the bolt and the variable camshaft timing (VCT) solenoid.
2. Remove the VCT system filter cap and replace the VCT system filter.
3. Repeat the previous steps for the RH VCT system filter.

Items 34 and 35: Engine Front Cover and Front Cover Gaskets Assembly Note

Scheme 344

1. Clean the engine front cover to cylinder block and cylinder head sealing surfaces, using a clean shop towel and metal surface cleaner to remove all residue.
2. Install new front cover seals into the front cover.
3. Apply a 6 mm (0.24 in) diameter dot of silicone gasket and sealant to the areas shown.
4. Install the engine front cover and the bolts. Tighten the bolts in the sequence shown.

Items 36-39: Oil Pan Gasket, Oil Pan, Oil Pan Stud and Bolts Assembly Note

Scheme 345

1. Rotate the engine upside down on the engine stand.
2. Clean the oil pan-to-cylinder block sealing surfaces on the oil pan and cylinder block with a clean shop towel and metal surface cleaner to remove all residue.
3. Apply a 10 mm (0.4 in) dot of silicone gasket and sealant onto the top of the new oil pan gasket at the two locations shown.
4. Install the oil pan. Using a straightedge, align the rear face of the oil pan with the rear face of the cylinder block.
5. Tighten the oil pan bolts in the sequence shown. (Scheme 402)

Items 40 and 41: RH Valve Cover and Gaskets Assembly Note

Scheme 346

1. Install a new gasket in the RH valve cover.
2. Apply an 8 mm (0.32 in) bead of silicone gasket and sealant to the cylinder half round surface and to the front cover gasket intersection places.
3. Position the RH valve cover and install the bolts in the sequence shown.

Items 44 and 45: LH Valve Cover and Gaskets Assembly Note

Scheme 347

1. Install a new gasket in the LH valve cover.
2. Apply an 8 mm (0.32 in) bead of silicone gasket and sealer to the cylinder half round surface and to the front cover gasket intersection places.
3. Position the LH valve cover and install the bolts in the sequence shown. (Scheme 406)

Items 47-49: Lower Intake Manifold Assembly, Gaskets and Bolts Assembly Note

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1. Inspect the lower intake manifold gaskets. Install new gaskets if necessary.
2. Position the lower intake manifold assembly and install the bolts in the sequence shown.

Items 57 and 58: RH Exhaust Manifold and Nuts Assembly Note

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1. Position the RH engine mount bracket and install the bolts.
2. Using a new gasket, position the RH exhaust manifold and install the nuts.

Items 68: Oil Filter Assembly Note

1. Using an oil filter strap wrench, install the oil filter until the seal makes contact. Tighten an additional 270 degrees.

Item 77: Crankshaft Front Oil Seal Assembly Note

Scheme 352