Engine Mount — Part 2 — Lincoln Zephyr US (2006-2006)

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With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/lincoln/zephyr/us-2006-2006/remont/hoistjack/#jacking-lifting) .
Release the fuel system pressure. For additional information, refer to «FUEL SYSTEM-GENERAL INFORMATION»(/lincoln/zephyr/us-2006-2006/remont/fuel-system/#fuel-system-general-information) .
Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/lincoln/zephyr/us-2006-2006/remont/body-electrical/#battery-mounting-and-cables) .
Recover the air conditioning system. For additional information, refer to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION AND DIAGNOSTICS»(/lincoln/zephyr/us-2006-2006/remont/automatic-hvac-system/#climate-control-system-general-information-and-diagnostics)
Place the steering wheel in the straight ahead position and the ignition key in the OFF position.
Remove the 2 nuts and the steering joint cover.
Remove the bolt and disconnect the steering column shaft from the steering gear.
Drain the cooling system. For additional information, refer to «ENGINE COOLING»(/lincoln/zephyr/us-2006-2006/remont/cooling-system-mechanical/#engine-cooling) .
If equipped, remove the 7 screws and the underbody cover.
Disconnect the power steering cooler tube and drain the power steering fluid into a suitable drain pan.
Remove the exhaust flexible pipe. For additional information, refer to «EXHAUST SYSTEM»(/lincoln/zephyr/us-2006-2006/remont/exhaust/#exhaust-system) .
Release the 4 clips and slide the steering gear-to-dash seal off of the steering gear and into the passenger compartment.
Remove the power steering pressure (PSP) hose bracket bolt.
Remove and discard the PSP hose banjo bolt and the 2 seals from the steering gear.
Remove the 2 bolts and the heat shield.
Remove the 2 bolts and the engine roll restrictor.
Remove the 4 screws and position the RH fender splash shield aside.
Remove the 6 pin-type retainers (4 shown) and the RH splash shield.
Remove the 4 screws and position the LH fender splash shield aside.
Remove the 6 pin-type retainers (4 shown) and the LH splash shield.
Remove the cotter pins and nuts from the tie-rod ends.
Using the special tool, separate the tie-rod ends from the steering knuckles.
Remove the nuts and separate the stabilizer bar links from the struts.
Remove the lower ball joint nuts.
Using the special tools, separate the lower ball joints from the lower control arms.
Remove the through bolts from the lower control arms.
Position the special tool under the subframe assembly.
Remove the subframe bracket-to-body bolts.
Remove the subframe nuts and the subframe brackets.
Remove the front subframe nuts.
Lower the subframe assembly from the vehicle.
Disconnect the transaxle cooler hoses.
Remove the drain plug and drain the engine oil. Install the drain plug and tighten to 27 Nm (20 lb-ft).
Remove and discard the engine oil filter.
Remove the engine air cleaner and air cleaner outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING - 2.3L»(ref-256206) .
Remove the battery tray. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/lincoln/zephyr/us-2006-2006/remont/body-electrical/#battery-mounting-and-cables) .
Remove the nut and disconnect the power feed wire from the battery terminal.
Disconnect the 2 engine wiring harness electrical connectors.
Remove the bolt and position aside the ground wire.
Disconnect the powertrain control module (PCM) electrical connector and the pin-type retainer.
Disconnect the fuel supply tube from the fuel rail. For additional information, refer to «FUEL SYSTEM-GENERAL INFORMATION»(/lincoln/zephyr/us-2006-2006/remont/fuel-system/#fuel-system-general-information) .
Disconnect the heater hose from the thermostat housing.
Disconnect the heater hose inline connection.
Disconnect the throttle body coolant hose.
Disconnect the evaporative emissions (EVAP) hose.
Disconnect the upper and lower radiator hoses from the thermostat housing.
Disconnect the transaxle control cable from the transaxle selector lever.
Remove the 3 transaxle control cable bracket bolts and position the cable aside.
Remove the bolt and position the ground wire aside.
Remove the vacuum tube bracket bolt.
Disconnect the vacuum hose from the intake manifold.
If equipped, detach the block heater cable retaining clips from the cooling fan shroud.
Disconnect the power steering hose from the power steering reservoir.
Detach the power steering hose retaining clip from the LH valve cover stud bolt and the engine wiring harness.
Disconnect the coolant hose from the degas bottle.
Detach the coolant hose retaining clip and position the coolant hose aside.
Remove the 2 A/C tube bracket bolts.
Remove the 2 nuts and disconnect the A/C tubes.
Remove the bolt and the ground wire from the engine mount bracket.
Remove the bolt and separate the A/C manifold from the A/C compressor.
Using the special tools, separate the LH halfshaft from the transaxle and support the halfshaft with a length of mechanic's wire.
Disconnect the crankshaft position (CKP) sensor electrical connector and pin-type retainer.
Disconnect the power steering pressure (PSP) switch electrical connector.
Disconnect the catalyst monitor sensor (CMS) electrical connector and pin-type retainer.
Remove the 2 RH halfshaft carrier bearing bracket bolts.
Separate the RH halfshaft from the transaxle and support the halfshaft with a length of mechanic's wire.
Remove the torque converter nut access plug.
Remove the 3 torque converter nuts.
Remove the 2 oil pan-to-transaxle bolts.
Install the special tools onto the engine. Raise the engine and transaxle 25.4 mm (1 in) to neutralize the engine and transaxle mounts.
Remove the 2 transaxle mount bolts.
Remove the bolt and damper.
Remove the bolt, 3 nuts and the engine mount bracket.
Lower the engine and transaxle from the vehicle.
Install the special tools.
Detach the wiring harness retainer from the PSP hose bracket.
Remove the bolt and detach the PSP hose bracket from the cylinder head.
Detach the heated oxygen sensor (HO2S) electrical connector from the PSP bracket.
Remove the bolt and detach the PSP hose bracket from the cylinder head.
Remove the bolt and detach the PSP hose bracket from the power steering reservoir.
Remove the banjo bolt and the PSP hose. Discard the banjo bolt and 2 seals.
Install the special tool.
Disconnect the exhaust gas recirculation (EGR) valve electrical connector.
Loosen the EGR tube-to-EGR valve nut.
Remove the 2 bolts and the EGR valve. Discard the gasket.
Loosen the EGR tube-to-catalytic converter nut and remove the EGR tube.
Remove the 2 bolts and the heat shield.
Remove the 2 bolts and the catalytic converter bracket.
Remove the 2 bolts and the catalytic converter bracket assembly.
Install the lower half of the special tool.
Install the upper half of the special tool.
Using the special tools and a suitable engine crane, remove the engine and transaxle from the lift table.
Remove the bolt and the ground wire.
Remove the bolt and the catalyst monitor sensor (CMS) electrical connector bracket.
Disconnect the transmission control module (TCM) electrical connector.
Detach the wiring harness pin-type retainer.
Remove the 2 nuts and the starter motor wiring.
Remove the 2 bolts and the starter motor.
Remove the engine-to-transaxle bolt.
Remove the 3 transaxle-to-engine bolts.
Detach the wiring harness retainer from the stud bolt.
Remove the transaxle-to-engine stud bolt, bolt and nut.
Using the special tools and a suitable engine crane, separate the engine and transaxle.

SPECIAL TOOL(S) Slide Hammer 07-005 (T59L-100-B) Remover, Crankshaft Rear Oil Seal 303-519 (T95P-6701-EH) Strap Wrench 303-D055 (D85L-6000-A) Remover, Oil Seal 303-409 (T92C-6700CH) 3-Jaw Puller 303-D121 Remover, Crankshaft Vibration Damper 303-009 (T58P-6316-D) Service Set, Water Pump Pulley 303-S455 (T94P-6312-AH)

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Item	Specification
Motorcraft Metal Surface Prep ZC-31
Silicone Gasket Remover ZC-30

MATERIAL

CAUTION

During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces that enters the oil passages, coolant passages or the oil pan, can cause engine failure.

Note. For additional information, refer to the appropriate exploded view under the ASSEMBLY procedure.

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Remove the 8 bolts and the flexplate.
Remove the engine-to-transaxle separator plate.
Using the special tools, remove and discard the crankshaft rear oil seal.
Mount the engine on a suitable stand.
Disconnect the manifold actual pressure (MAP) sensor electrical connector and the pin-type retainer.
Detach the wiring harness pin-type retainer from the upper intake manifold.
Disconnect the crankcase vent hose from the upper intake manifold.
Disconnect the electronic throttle body electrical connector.
Disconnect the throttle body coolant hose.
Remove the 8 bolts and the upper intake manifold. Discard the gaskets.
Disconnect the A/C compressor electrical connector.
If equipped, disconnect the block heater electrical connector.
If equipped, detach the block heater wiring harness retainers from the oil level indicator tube and remove the harness.
Disconnect the oil pressure sender electrical connector.
Remove the nut and disconnect the generator B+ cable and electrical connector.
Disconnect the LH variable camshaft timing (VCT) solenoid and LH camshaft position (CMP) sensor electrical connectors. Detach the 2 wiring harness retainers from the valve cover stud bolts.
Disconnect the LH heated oxygen sensor (HO2S) electrical connector and pin-type retainer.
Detach the 3 wiring harness retainers from the valve cover stud bolts.
Disconnect the 3 LH coil-on-plug electrical connectors. Detach the 2 wiring harness pin-type retainers from the valve cover.
Detach the wiring harness retainer from the LH valve cover stud bolt.
Disconnect the 6 (3 shown) fuel injector electrical connectors.
Detach the 3 wiring harness retainers from the fuel rail.
Disconnect the 3 RH coil-on-plug electrical connectors. Detach the 2 wiring harness pin-type retainers from the valve cover.
Disconnect the RH VCT solenoid and LH CMP sensor electrical connectors. Detach the 2 wiring harness retainers from the valve cover stud bolts.
Remove the nut and the radio frequency interference capacitor.
Detach the wiring harness retainer from the power steering stud bolt.
Disconnect the RH HO2S electrical connector.
Disconnect the positive crankcase ventilation (PCV) valve electrical connector.
Disconnect the knock sensor (KS) electrical connector.
Disconnect the electronic coolant temperature (ECT) sensor electrical connector.
Detach the wiring harness retainer from the coolant bypass stud bolt.
Disconnect the LH catalyst monitor sensor (CMS) electrical connector. Remove the wiring harness from the engine.
Rotate the accessory drive belt tensioner counterclockwise and remove the accessory drive belt.
Remove the 3 bolts and the generator.
Remove the 3 bolts and the A/C compressor.
Remove the 3 bolts and the A/C compressor bracket.
Remove the 3 power steering reservoir nuts.
Remove the 3 bolts and the power steering pump and reservoir assembly.
Remove the 6 nuts and the RH catalytic converter. Discard the gasket.
Remove and discard the 6 RH catalytic converter studs.
Remove the 4 bolts and the heat shield.
Remove the 2 bolts from the LH catalytic converter bracket.
Remove the 6 nuts and the LH catalytic converter. Discard the gasket.
Remove and discard the 6 LH catalytic converter studs.
Remove the 2 bolts and the LH catalytic converter bracket.
Remove the bolt and the oil level indicator tube. Remove and discard the O-ring seal.
Remove the 8 bolts and the lower intake manifold. Discard the gaskets.
If equipped, remove the 2 nuts and the coolant pump drive pulley cover.
Cut and discard the coolant pump belt.
Release the 2 clamps and remove the thermostat housing.
Remove the bolt, stud bolt and the coolant bypass. Remove and discard the O-ring seals.
Disconnect the coolant pump hose from the cylinder block outlet.
Using the special tools, remove the coolant pump drive pulley from the camshaft.
Remove the 3 bolts and the coolant pump.
Remove the bolt and the KS.
Remove the oil pressure sender.
If equipped, remove the block heater.
Remove the 3 bolts and the 3 LH coil-on-plug assemblies.
Remove the 4 bolts, 10 stud bolts and the LH valve cover. Discard the gaskets.
Remove the 3 bolts and the 3 RH coil-on-plug assemblies.
Remove the 6 bolts, 8 stud bolts and the RH valve cover. Discard the gaskets.
Remove the 10 bolts, 5 stud bolts and the oil pan. Discard the gasket.
Remove the 2 bolts and the oil pump screen and pickup tube. Remove and discard the O-ring seal.
Remove the 8 nuts and the oil pan baffle.
Remove the accessory drive belt tensioner and the 2 idler pulleys.
Using the special tool, remove the crankshaft pulley bolt.
Using the special tool, remove the crankshaft pulley.
Using the special tool, remove and discard the crankshaft front seal.
Remove the 16 bolts and the engine front cover. Discard the gaskets.
Remove the ignition pulse wheel.
Install the crankshaft pulley bolt and washer.
Remove the 6 spark plugs
Rotate the crankshaft clockwise to position the crankshaft keyway in the 11 o'clock position and position the camshafts in the correct position. This will position the No. 1 cylinder at top dead center (TDC). Verify that the camshafts are correctly located. If not, rotate the crankshaft one additional turn and recheck.
Rotate the crankshaft clockwise 120 degrees to the 3 o'clock position to position the RH camshafts in the neutral position.
Verify that the RH camshafts are in the neutral position.
Remove the RH timing chain tensioner arm. Remove the bolts. Remove the tensioner. Remove the tensioner arm.
Remove the RH timing chain.
Remove the 3 bolts and the RH VCT assembly.
Rotate the crankcase clockwise 600 degrees (1-2/3 turns) to position the crankcase keyway in the 11 o'clock position. This will position the LH camshafts in the neutral position.
Verify the LH camshafts are in the NEUTRAL position.
Remove the LH timing chain tensioner and tensioner arm. Remove the bolts. Remove the tensioner. Remove the tensioner arm.
Remove the LH timing chain.
Remove the 4 bolts and the LH VCT assembly.
Remove the pulley bolt, washer and the crankshaft sprocket.
Remove the 4 bolts in the sequence shown. Remove the oil pump.
Remove the crankshaft key.
Using the special tools, remove the camshaft oil seal and discard.
Remove the 2 bolts and the camshaft oil seal retainer Discard the press-in-place gasket.
Verify the camshafts are in the neutral position.
Remove the bolt and the VCT actuator.
Loosen the bolts evenly in the sequence shown. Remove the camshaft bearing thrust caps (1L and 6L). Remove the remaining camshaft bearing caps. Remove the camshafts from the cylinder head.
Verify the camshafts are in the neutral position.
Remove the bolt and the VCT actuator.
Loosen the bolts evenly in the sequence shown. Remove the camshaft bearing thrust caps (5R and 1R). Remove the remaining camshaft bearing caps. Remove the camshafts from the cylinder head.
Remove the LH and RH camshaft roller followers.
Loosen the 8 bolts in the indicated sequence and remove the LH and RH cylinder heads. Discard the bolts and the gaskets.
Clean the cylinder head-to-cylinder block mating surface of both the cylinder head and the cylinder block. Remove any large deposits of silicone or gasket material with a plastic scraper. Apply silicone gasket remover, following package directions, and allow to set for several minutes. Remove the silicone gasket remover with a plastic scraper. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain. Apply metal surface prep, following package directions, to remove any traces of oil or coolant, and to prepare the surfaces to bond with the new gasket. Do not attempt to make the metal shiny. Some staining of the metal surfaces is normal.
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).
Remove the bolts and the oil separator cover. Discard the gasket.

Engine Mount — Part 2 Lincoln Zephyr US