Material — Part 1 Lincoln LS I facelift

Material

MATERIAL SPECIFICATION

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1. Disconnect the battery ground cable.
2. Remove the air cleaner outlet tube. For additional information, refer to «INTAKE AIR, FUEL CHARGING, STARTING & ENGINE ELECTRONICS - 3.9L»(ref-207556) for additional information.
3. Drain the engine cooling system. For additional information, refer to «ENGINE COOLING»(ref-207554).
4. Remove the cowl vent screen. For additional information, refer to «INTERIOR TRIM»(ref-207570).
5. Remove the engine compartment brace.
6. Disconnect the fuel line. For additional information, refer to «FUEL SYSTEM»(ref-207559).
7. Illustration 1 of 4. Remove the components in the order indicated in the following illustration and table. (Scheme 450)
8. Illustration 2 of 4. Remove the components in the order indicated in the following illustration and table. (Scheme 451)
9. Illustration 3 of 4. Remove the components in the order indicated in the following illustration and table. (Scheme 452)
10. Illustration 4 of 4. Remove the components in the order indicated in the following illustration and table. (Scheme 453)
11. To install, reverse the removal procedure.

Items 11 and 13: Engine Appearance Cover Support Bracket Removal Note

1. Disconnect the engine wiring harness retainers from the engine appearance cover support bracket.

Items 14, 15, and 16: Intake Manifold Removal Note

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Scheme 452

1. Disconnect the fuel injector and RFI suppressor electrical connectors
2. Remove the nuts and the engine wiring harness retainer and position aside.
3. Remove the nut and the RFI suppressor.
4. Disconnect the throttle body heater hoses.
5. Remove the bolts and studs in the sequence shown.
6. Remove the intake manifold.
7. Clean the sealing surfaces.

Items 14, 15, and 16: Intake Manifold Installation Note

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Scheme 454

1. Install new intake manifold gaskets.
2. Install the intake manifold and tighten the bolts in the sequence shown.
3. Connect the throttle body heater hoses.
4. Install the RFI suppressor and the nut.
5. Install the engine wiring harness retainer and the nuts.
6. Connect the fuel injector and RFI suppressor electrical connectors

Item 7 and 9: Engine Appearance Cover Support Bracket Installation Note

1. Connect the engine wiring harness retainers to the engine appearance cover support bracket.

Scheme 455

MATERIAL SPECIFICATION

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1. Disconnect the battery ground cable.
2. Remove the air cleaner assembly. For additional information, refer to «INTAKE AIR, FUEL CHARGING, STARTING & ENGINE ELECTRONICS - 3.9L»(ref-207556) for additional information.
3. Remove the LH ignition coils. For additional information, refer to «INTAKE AIR, FUEL CHARGING, STARTING & ENGINE ELECTRONICS - 3.9L»(ref-207556) for additional information.
4. Remove the oil level indicator and tube. For additional information, refer to «OIL LEVEL INDICATOR AND TUBE»(ref-207553-S36345318972005113000000) in this section.
5. Release the fuel system pressure. For additional information, refer to «FUEL SYSTEM»(ref-207559).
6. Illustration 1 of 3. Remove the components in the order indicated in the following illustration and table. (Scheme 468)
7. Illustration 2 of 3. Remove the components in the order indicated in the following illustration and table. (Scheme 469)
8. Illustration 3 of 3. Remove the components in the order indicated in the following illustration and table. (Scheme 470)
9. To install, reverse the removal procedure.

Item 2: Spring Lock Coupling Removal Note

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Scheme 461

1. Install the special tool.
2. Press the special tool into the open end of the cage.
3. Separate the spring lock coupling.

Item 11: LH Valve Cover Removal Note

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1. Disconnect the crankcase ventilation tube.
2. Disconnect the evaporative emission (EVAP) canister purge valve hose.
3. Remove the fuel hose bracket bolt from the LH shock tower.
4. Loosen the bolts and position the power steering pump reservoir aside.
5. Remove the LH valve cover. Loosen the bolts in the sequence shown.
6. Clean the sealing surfaces.
7. Install new gaskets.

Item 11: LH Valve Cover Installation Note

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1. Apply two beads of silicone gasket and sealant as shown. (Scheme 480)
2. Install the LH valve cover. Position the valve cover and tighten the bolts in the sequence shown.
3. Install the power steering pump reservoir.
4. Install the fuel hose bracket bolt.
5. Connect the crankcase ventilation tube.

MATERIAL SPECIFICATION

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Scheme 471

1. Remove the air cleaner outlet tube. For additional information, refer to «INTAKE AIR, FUEL CHARGING, STARTING & ENGINE ELECTRONICS - 3.9L»(ref-207556) for additional information.
2. Remove the RH ignition coils. For additional information, refer to «INTAKE AIR, FUEL CHARGING, STARTING & ENGINE ELECTRONICS - 3.9L»(ref-207556) for additional information.
3. Illustration 1 of 2. Remove the components in the order indicated in the following illustration and table. (Scheme 485)
4. Illustration 2 of 2. Remove the components in the order indicated in the following illustration and table. (Scheme 486)
5. To install, reverse the removal procedure.

Item 8: RH Valve Cover removal Note

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Scheme 473

1. Remove the RH valve cover. Loosen the bolts in the sequence shown.
2. Clean the sealing surfaces.
3. Inspect and install new gaskets as necessary.

Item 8: RH Valve Cover Installation Note

Scheme 474

1. Apply two beads of silicone gasket and sealant as shown. (Scheme 490)
2. Install the RH valve cover. Tighten the bolts in the sequence shown. (Scheme 491)

Scheme 475

MATERIAL SPECIFICATION

Scheme 476

1. Remove the cooling fan assembly. For additional information, refer to «ENGINE COOLING»(ref-207554) .
2. Remove the accessory drive belt. For additional information, refer to «ACCESSORY DRIVE BELT, TENSIONER AND PULLEY»(ref-207553-S28737290532005113000000) in this section.
3. Remove the oil cooler. For additional information, refer to «OIL COOLER»(ref-207553-S29036104372005113000000) in this section.
4. Remove the components in the order indicated in the following illustration and table. To remove individual components, only carry out the listed steps. CRANKSHAFT PULLEY AND CRANKSHAFT SEAL COMPONENT STEPS Component Steps Crankshaft pulley 1-2 Front crankshaft seal 1-3
5. To install, reverse the removal procedure.

Items 1-3: Crankshaft Pulley, Bolt and Washer Removal Note

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Scheme 478

1. Remove and discard the bolt.
2. Using the special tool, remove the crankshaft pulley.

Item 4: Front Crankshaft Seal Removal Note

Scheme 479

1. Using the special tool, remove the front crankshaft seal. Discard the seal.

Item 4: Front Crankshaft Seal Installation Note

Scheme 480

1. Using the special tool, install a new front crankshaft seal.

Items 1-3: Crankshaft Pulley, Bolt and Washer Installation Note

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1. Apply a bead of silicone gasket and sealant to the keyway.
2. Using the special tool, install the crankshaft pulley.
3. Install a new bolt and tighten in four stages. Stage 1: Tighten to 80 N.m (59 lb-ft). Stage 2: Loosen the bolt two complete turns. Stage 3: Tighten to 50 N.m (37 lb-ft). Stage 4: Tighten an additional 90 degrees.

MATERIAL SPECIFICATION

Scheme 483

1. Drain the engine cooling system. For additional information, refer to «ENGINE COOLING»(ref-207554) .
2. Drain the engine oil.
3. Remove the LH valve cover. For additional information, refer to «VALVE COVER LH»(ref-207553-S41300758332005113000000) in this section.
4. Remove the RH valve cover. For additional information, refer to «VALVE COVER RH»(ref-207553-S01213765582005113000000) in this section.
5. Remove the engine cooling fan assembly. For additional information, refer to «ENGINE COOLING»(ref-207554) .
6. Remove the crankshaft pulley and crankshaft seal. For additional information, refer to «CRANKSHAFT PULLEY AND CRANKSHAFT SEAL»(ref-207553-S18031230982005113000000) in this section.
7. Remove the A/C compressor. For additional information, refer to «ENGINE COOLING»(ref-207554) .
8. Remove the components in the order indicated in the following illustration and table.
9. To install, reverse the removal procedure.

Items 1, 2 and 3: Engine Front Cover Removal Note

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Scheme 490

1. Disconnect the lower radiator-to-thermostat housing hose.
2. Disconnect the heater hose.
3. Remove the stud bolt.
4. Remove the bolts and position the power steering pump aside.
5. Remove the coolant pump pulley bolts and the pulley.
6. Remove the power steering pump bracket.
7. Disconnect the five wiring harness clips.
8. Remove the engine front cover. Remove the bolts in the sequence shown. (Scheme 509) Remove the engine front cover.
9. Clean the sealing surfaces with metal surface cleaner.

Items 1, 2 and 3: Engine Front Cover Installation Note

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Scheme 497

1. Install new gaskets.
2. Apply silicone gasket and sealant in the eight places shown. (Scheme 512)
3. Install the engine front cover. Position the engine front cover on the cylinder block. Loosely install the bolts. Tighten the bolts in two stages in the sequence shown. (Scheme 513) Stage 1: Tighten to 5 N.m (44 lb-in). Stage 2: Tighten to 10 N.m (89 lb-in).
4. Connect the five wiring harness clips.
5. Install the power steering pump bracket.
6. Install the coolant pump pulley and bolts and tighten in 2 stages: Stage 1: Tighten to 10 N.m (89 lb-in). Stage 2: Tighten an additional 45 degrees.
7. Position the power steering pump and install the bolts.
8. Connect the heater hose.
9. Connect the lower radiator hose to the thermostat housing.
10. Install the stud bolt.

Scheme 498

MATERIAL SPECIFICATION

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1. Remove the engine front cover. For additional information, refer to «ENGINE FRONT COVER»(ref-207553-S08841931702005113000000) in this section.
2. Remove the components in the order indicated in the following illustration and table. To remove individual components, only carry out the listed steps. TIMING DRIVE COMPONENTS STEPS Component Steps Timing gears, chain and tensioners 1-20 Variable camshaft timing (VCT) bush carriers 1-9 VCT units, exhaust camshaft sprockets, secondary timing chains and tensioners, and crankshaft sprocket 1-37
3. Illustration 1 of 4. Remove the components in the order indicated in the following illustration and table. (Scheme 522)
4. Illustration 2 of 4. Remove the components in the order indicated in the following illustration and table. (Scheme 523)
5. Illustration 3 of 4. Remove the components in the order indicated in the following illustration and table. (Scheme 524)
6. Illustration 4 of 4. Remove the components in the order indicated in the following illustration and table. (Scheme 525)and (Scheme 526).
7. To install, reverse the removal procedure.

Items 7-20: Timing Drive Components Removal Note

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1. Remove the crankshaft position (CKP) sensor and the torque converter cover.
2. Install the special tool. Turn the crankshaft to 45 degrees ATDC. The crankshaft keyway will be in the 6 o'clock position. Install the special tool.
3. Make sure the flats of the camshaft are facing upward. If not, repeat Step 2 .
4. Install the special tool on the RH cylinder head.
5. Remove and discard the RH exhaust camshaft sprocket bolt.
6. Remove and discard the RH VCT unit bolt.
7. Remove the RH timing chain tensioner. Push the lever down and install a drill rod to lock the piston. Remove the bolts and the tensioner.
8. Remove the RH tensioner arm.
9. Remove the RH timing chain guide.
10. Remove the RH primary timing chain.
11. Remove the special tool from the RH cylinder head.
12. Install the special tool on the LH head.
13. Remove and discard the LH VCT unit bolt and the exhaust camshaft sprocket bolt.
14. Remove the LH timing chain tensioner. Push the lever down and install a drill rod to lock the piston. Remove the bolts and the tensioner.
15. Remove the LH tensioner arm.
16. Remove the LH timing chain guide.
17. Remove the LH primary timing chain.

Items 21-25, and 27: RH Variable Camshaft Timing (VCT) Unit, Exhaust Camshaft Sprocket and Secondary Timing Chain Removal Note

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Scheme 516

1. Collapse the RH secondary timing chain tensioner and install a pin to lock the piston.
2. Remove the RH VCT unit, exhaust camshaft sprocket and timing chain as an assembly.

Items 28-32, and 34: LH Variable Camshaft Timing (VCT) Unit, Exhaust Camshaft Sprocket and Secondary Timing Chain Removal Note

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Scheme 518

1. Collapse the LH secondary timing chain tensioner and install a pin to lock the piston.
2. Remove the LH VCT unit, exhaust camshaft sprocket and timing chain as an assembly.

Items 28-32, and 34: LH Variable Camshaft Timing (VCT) Unit, Exhaust Camshaft Sprocket and Secondary Timing Chain Installation Note

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Scheme 521

1. Install the LH VCT unit, exhaust camshaft sprocket and timing chain as an assembly.
2. Using new bolts, install the LH VCT unit and exhaust camshaft sprocket bolts finger-tight.
3. Remove the locking pin from the LH secondary timing chain tensioner.

Items 21-25, and 27: RH Variable Camshaft Timing (VCT) Unit, Exhaust Camshaft Sprocket and Secondary Timing Chain Installation Note

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Scheme 524

1. Install the RH VCT unit, exhaust camshaft sprocket and timing chain as an assembly.
2. Using new bolts, install the RH VCT unit and exhaust camshaft sprocket bolts finger-tight.
3. Remove the locking pin from the RH secondary timing chain tensioner.

Items 7-20: Timing Drive Components Installation Note

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