Engine - 3.0l (4v) Lincoln Zephyr US

GENERAL SPECIFICATIONS

GENERAL SPECIFICATIONS

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

The 3.0L Duratec is a 4-valve-per-cylinder, dual overhead camshaft engine. The engine uses a distributorless ignition system. The cylinder block is a 2-piece design with the upper portion housing the cylinders and a separate lower cylinder block containing the main bearing caps. Both sections are made of aluminum, with inserts for the bearing areas and caps. An aluminum oil pan bolts to the bottom of the lower cylinder block and to the transaxle to provide greater strength.

The camshafts are mounted in the cylinder heads and act against a roller follower to open and close the valves. A hydraulic lash adjuster is located on one side of the roller follower and the valve tip on the opposite end. The camshafts are driven off the front of each cylinder head by 2 chains (one each side). Both of the chains are driven by sprockets that are located on the crankshaft, just in front of the oil pump.

For basic engine mechanical concerns, refer to ENGINE SYSTEM-GENERAL INFORMATION . For driveability concerns, refer to the INTRODUCTION - GASOLINE article.

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Removal

1. Remove the air cleaner outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING - 3.0L (4V)»(/lincoln/zephyr/us-2006-2006/remont/removal-installation/#intake-air-distribution-filtering-30l-4v) .
2. Disconnect the throttle body electrical connector.
3. Remove the 4 bolts and position the throttle body aside. Discard the gasket.
4. Disconnect the evaporative emissions (EVAP) tube from the intake manifold.
5. Remove the vacuum tube clamp bolt.
6. Disconnect the vacuum tube from the intake manifold.
7. Disconnect the positive crankcase ventilation (PCV) tube from the intake manifold.
8. Disconnect the exhaust gas recirculation (EGR) valve electrical connector.
9. Loosen the EGR tube-to-EGR valve nut.
10. Disconnect the manifold absolute pressure (MAP) sensor electrical connector and the pin-type retainer.
11. Detach the wiring harness retainer from the front of the upper intake manifold.
12. Remove the 8 bolts and remove the upper intake manifold. Remove and discard the gaskets.

Scheme 3

1. Clean and inspect all of the sealing surfaces of the upper intake manifold.
2. Install the upper intake manifold, gaskets and the 8 bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
3. Attach the wiring harness retainer to the front of the upper intake manifold.
4. Connect the MAP sensor electrical connector and the pin-type retainer.
5. Install the EGR tube-to-EGR valve nut. Tighten to 40 Nm (30 lb-ft).
6. Connect the EGR valve electrical connector.
7. Connect the PCV tube to the intake manifold.
8. Connect the vacuum tube to the intake manifold.
9. Install the vacuum tube clamp bolt. Tighten to 10 Nm (89 lb-in).
10. Connect the EVAP tube to the intake manifold.
11. Tighten to 10 Nm (89 lb-in).
12. Connect the throttle body electrical connector.
13. Install the air cleaner outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING - 3.0L (4V)»(/lincoln/zephyr/us-2006-2006/remont/removal-installation/#intake-air-distribution-filtering-30l-4v) .

Scheme 4

1. 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) .
2. 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) .
3. Remove the upper intake manifold. For additional information, refer to «UPPER INTAKE MANIFOLD»(/lincoln/zephyr/us-2006-2006/remont/mechanical/#engine-30l-4v) .
4. Disconnect the fuel supply tube quick connect coupling 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) .
5. Detach the 2 wiring harness retainers from the LH valve cover stud bolts.
6. Detach the 3 pin-type retainers from the fuel rail.
7. Disconnect the 6 fuel injector electrical connectors.
8. Remove the 8 lower intake manifold bolts and the lower intake manifold. Remove and discard the gaskets.

Scheme 5

1. Position the lower intake manifold and install the 8 bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
2. Connect the 6 fuel injector electrical connectors.
3. Attach the 3 pin-type retainers to the fuel rail.
4. Attach the 2 wiring harness retainers to the LH valve cover stud bolts.
5. Connect the fuel supply tube quick connect coupling at the fuel rail. For additional information, refer to «FUEL SYSTEM-GENERAL INFORMATION»(/lincoln/zephyr/us-2006-2006/remont/fuel-system/#fuel-system-general-information) .
6. Install the upper intake manifold. For additional information, refer to «UPPER INTAKE MANIFOLD»(/lincoln/zephyr/us-2006-2006/remont/mechanical/#engine-30l-4v) .
7. Connect 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) .

Valve Cover - LH

MATERIAL

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1. Remove the LH ignition coil-on-plugs. For additional information, refer to «ENGINE IGNITION - 3.0L (4V)»(ref-256253) .
2. Remove the crankcase ventilation tube.
3. Disconnect the variable camshaft timing (VCT) solenoid electrical connector.
4. Disconnect the LH heated oxygen sensor (HO2S) electrical connector and pin type retainer.
5. Detach the power steering hose retainer from the valve cover stud bolt.
6. Remove the oil level indicator.
7. Remove the stud bolt and position the oil level indicator tube aside.
8. Detach the 6 wiring harness retainers from the valve cover stud bolts.
9. Detach the 2 pin-type retainers from the valve cover and position the wiring harness aside.
10. If equipped, remove the 2 nuts and the coolant pump drive pulley cover.
11. Remove the 4 bolts, 10 stud bolts and the valve cover. Discard the gaskets.

Scheme 8

1. Clean the valve cover, cylinder head and front cover sealing surfaces with metal surface cleaner and install new valve cover and spark plug cavity gaskets.
2. Apply an 8 mm (0.31 in) dot of silicone gasket sealant to the front cover-to-cylinder head joints and the camshaft seal retainer-to-cylinder head joints.
3. Position the valve cover and install the bolts and stud bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
4. If equipped, install the coolant pump drive pulley cover and the 2 nuts. Tighten to 6 Nm (53 lb-in).
5. Position the wiring harness and attach the 2 pin-type retainers to the valve cover.
6. Attach the 6 wiring harness retainers to the valve cover stud bolts.
7. Position the oil level indicator tube and install the stud bolt. Tighten to 9 Nm (80 lb-in).
8. Install the oil level indicator.
9. Attach the power steering tube retainer to the valve cover stud bolt.
10. Connect the LH HO2S electrical connector and pin type retainer.
11. Connect the VCT solenoid electrical connector.
12. Install the crankcase ventilation tube.
13. Install the LH ignition coil-on-plugs. For additional information, refer to «ENGINE IGNITION - 3.0L (4V)»(ref-256253) .

Valve Cover - RH

MATERIAL

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1. Remove the lower cowl panel. For additional information refer to «COWL PANEL GRILLE»(/lincoln/zephyr/us-2006-2006/remont/exterior-body-panels/#front-end-body-panels) .
2. Remove the RH ignition coil-on-plugs. For additional information, refer to «ENGINE IGNITION - 3.0L (4V)»(ref-256253) .
3. Remove the retaining bolt from the windshield washer bottle and A/C tube.
4. Remove the 2 A/C tube retaining bolts and position the A/C tubes aside.
5. Remove the positive crankcase ventilation (PCV) tube.
6. Disconnect the PCV valve electrical connector.
7. Disconnect the power steering hose from the reservoir.
8. Remove the 3 power steering reservoir nuts.
9. Remove the power steering pressure (PSP) tube bracket-to-reservoir bolt.
10. Remove the PSP tube bracket-to-cylinder head bolt.
11. Reposition the power steering reservoir and disconnect the reservoir-to-pump hose. Remove the power steering reservoir.
12. Remove the power steering pressure tube-to-power steering pump banjo bolt and position the power steering pressure tube aside. Discard the bolt and seals.
13. Disconnect the variable camshaft timing (VCT) solenoid electrical connector.
14. Detach the 3 wiring harness retainers from the valve cover stud bolts.
15. Remove the nut and the radio frequency interference capacitor from the valve cover stud bolt.
16. Detach the 2 pin-type retainers from the valve cover and position the wiring harness aside.
17. Remove the 10 bolts, 4 stud bolts and the valve cover. Discard the gaskets.

Scheme 13

1. Clean the valve cover, cylinder head and front cover sealing surfaces with metal surface cleaner and install a new valve cover and spark plug cavity gaskets.
2. Apply an 8 mm (0.31 in) dot of silicone gasket sealant to the front cover-to-cylinder head joints.
3. Position the valve cover and install the bolts and stud bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
4. Position the wiring harness and attach the 2 pin-type retainers to the valve cover.
5. Install the radio frequency interference capacitor and the nut. Tighten to 6 Nm (53 lb-in).
6. Attach the 3 wiring harness retainers to the stud bolts.
7. Connect the VCT solenoid electrical connector.
8. Position the power steering pressure tube-to-power steering pump and install the new seals and banjo bolt. Tighten to 35 Nm (26 lb-ft).
9. Position the power steering reservoir and connect the reservoir-to-pump hose.
10. Install the PSP tube bracket-to-cylinder head bolt. Tighten to 9 Nm (80 lb-in).
11. Install the PSP tube bracket-to-reservoir bolt. Tighten to 9 Nm (80 lb-in).
12. Install the 3 power steering reservoir nuts. Tighten to 9 Nm (80 lb-in).
13. Connect the power steering hose to the reservoir.
14. Connect the PCV valve electrical connector.
15. Install the PCV tube.
16. Position the A/C tubes and install the 2 A/C tube retaining bolts. Tighten to 8 Nm (71 lb-in).
17. Install the A/C tube and windshield washer bottle retaining bolt. Tighten to 7 Nm (62 lb-in).
18. Install the RH ignition coil-on-plugs. For additional information, refer to «ENGINE IGNITION - 3.0L (4V)»(ref-256253) .
19. Install the lower cowl panel. For additional information refer to the «COWL PANEL GRILLE»(/lincoln/zephyr/us-2006-2006/remont/exterior-body-panels/#front-end-body-panels) .
20. Fill the power steering system. For additional information, refer to «STEERING SYSTEM-GENERAL INFORMATION»(/lincoln/zephyr/us-2006-2006/remont/manual-power-steering/#steering-system-general-information) .

Scheme 14

1. For additional information, refer to the appropriate procedure.

Crankshaft Pulley

SPECIAL TOOL(S) Strap Wrench 303-D055 (D85L-6000-A) 3-Jaw Puller 303-D121 Replacer, Crankshaft Damper 303-102 (T74P-6316-B) Installer, Front Cover Seal 303-335 (T88T-6701-A)

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MATERIAL

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1. 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) .
2. Remove the accessory drive belt. For additional information, refer to «ACCESSORY DRIVE - 3.0L (4V)»(ref-256223) .
3. Use the special tool to hold the crankshaft pulley and remove the crankshaft pulley bolt and washer.
4. Using the special tool, remove the crankshaft pulley.

Scheme 21

1. Lubricate the crankshaft front seal inner lip with clean engine oil.
2. Apply silicone gasket and sealant to the end of the keyway slot.
3. Using the special tool, install the crankshaft pulley.
4. Install the bolt and washer. Using the special tool to hold the crankshaft pulley, tighten the bolt in 4 stages: Stage 1: Tighten to 120 Nm (89 lb-ft). Stage 2: Loosen one full turn. Stage 3: Tighten to 50 Nm (37 lb-ft). Stage 4: Tighten an additional 90 degrees.
5. Install the accessory drive belt. For additional information, refer to «ACCESSORY DRIVE - 3.0L (4V)»(ref-256223) .

Crankshaft Front Seal

SPECIAL TOOL(S) Remover, Oil Seal 303-409 (T92C-6700CH) Replacer, Crankshaft Damper 303-102 (T74P-6316-B) Installer, Front Cover Seal 303-335 (T88T-6701-A)

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MATERIAL

Scheme 24

1. 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) .
2. Remove the crankshaft pulley. For additional information, refer to «CRANKSHAFT PULLEY»(/lincoln/zephyr/us-2006-2006/remont/mechanical/#engine-30l-4v__crankshaft-pulley) .
3. Using the special tool, remove and discard the crankshaft front seal.

Scheme 25

1. Apply clean engine oil to the seal lip and seal bore before installing the seal.
2. Using the special tools, install a new crankshaft front seal.
3. Install the crankshaft pulley. For additional information, refer to «CRANKSHAFT PULLEY»(/lincoln/zephyr/us-2006-2006/remont/mechanical/#engine-30l-4v__crankshaft-pulley) .

Scheme 26

1. For additional information, refer to the appropriate procedure.

Removal and Installation

1. 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) .
2. Remove the transaxle. For additional information, refer to the appropriate automatic transmission article.
3. Remove the bolts and the flexplate. To install, tighten to 80 Nm (59 lb-ft).
4. To install, reverse the removal procedure.

Crankshaft Rear Seal

SPECIAL TOOL(S) Slide Hammer 307-005 (T59L-100-B) Remover, Crankshaft Rear Seal 303-519 (T95P-6701-DH) Installer, Crankshaft Rear Main Oil Seal 303-178 (T82L-6701-A) Installer Bolts, Crankshaft Rear Main Oil Seal 303-384 (T91P-6701-A)

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MATERIAL

Scheme 30

1. 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) .
2. Remove the flexplate. For additional information, refer to «FLEXPLATE»(/lincoln/zephyr/us-2006-2006/remont/mechanical/#engine-30l-4v) .
3. Using the special tools, remove and discard the crankshaft rear oil seal.

Installation

1. Using the special tools, install the crankshaft rear oil seal.
2. Install the flexplate. For additional information, refer to «FLEXPLATE»(/lincoln/zephyr/us-2006-2006/remont/mechanical/#engine-30l-4v) .

Engine Front Cover

MATERIAL

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1. 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) .
2. 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) .
3. 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) .
4. Remove the crankshaft front seal. For additional information, refer to «LOWER END COMPONENTS - EXPLODED VIEW, CRANKSHAFT PULLEY AND CRANKSHAFT FRONT SEAL»(/lincoln/zephyr/us-2006-2006/remont/mechanical/#engine-30l-4v) and «CRANKSHAFT FRONT SEAL»(/lincoln/zephyr/us-2006-2006/remont/mechanical/#engine-30l-4v__crankshaft-front-seal) .
5. If equipped, remove the 7 screws and the underbody cover.
6. Disconnect the crankshaft position (CKP) sensor and pin-type retainer.
7. Remove the accessory drive belt tensioner and 2 idler pulleys. For additional information, refer to «ACCESSORY DRIVE - 3.0L (4V)»(ref-256223) .
8. Remove the LH and RH valve covers. For additional information, refer to «VALVE COVER - LH»(/lincoln/zephyr/us-2006-2006/remont/mechanical/#engine-30l-4v__valve-cover-lh) and «VALVE COVER - RH»(/lincoln/zephyr/us-2006-2006/remont/mechanical/#engine-30l-4v__valve-cover-rh) .
9. Remove the 3 bolts and position the power steering pump aside.
10. Remove the engine mount and bracket. For additional information, refer to «ENGINE MOUNT»(/lincoln/zephyr/us-2006-2006/remont/mechanical/#engine-30l-4v__engine-mount) .
11. Remove the LH and RH camshaft position (CMP) sensors. For additional information, refer to «ELECTRONIC ENGINE CONTROLS - 3.0L (4V)»(/lincoln/zephyr/us-2006-2006/remont/removal-installation/#electronic-engine-controls-30l-4v) .
12. Disconnect the A/C compressor electrical connector and wiring harness retainer.
13. Disconnect the generator electrical connector.
14. Disconnect the oil pressure sender electrical connector and position the wiring harness aside.
15. Remove the stud bolt, the 2 bolts and position the generator aside.
16. Remove the 2 oil pan-to-front cover bolts.
17. Remove the 14 bolts, 2 stud bolts and the engine front cover. Remove and discard the gaskets.

Scheme 34

1. Use a plastic scraping tool to remove all traces of sealant. Clean all sealing surfaces with metal surface cleaner and install new gaskets.
2. Apply a 6 mm (0.23 in) diameter dot of silicone gasket and sealer to the cylinder block, lower cylinder block, cylinder head and oil pan mating surfaces.
3. Position the engine front cover and install the 14 bolts and the 2 stud bolts. Tighten in the sequence shown to 25 Nm (18 lb-ft).
4. Install the 2 oil pan-to-front cover bolts. Tighten to 25 Nm (18 lb-ft).
5. Remove the oil pan plug and drain the engine oil. Install the plug and tighten to 26 Nm (19 lb-ft).
6. Install the generator, 2 bolts and the stud bolt. Tighten to 48 Nm (35 lb-ft).
7. Connect the oil pressure sender electrical connector.
8. Connect the generator electrical connector.
9. Connect the A/C compressor electrical connector and wiring harness retainer.
10. Install the LH and RH CMP sensors. For additional information, refer to «ELECTRONIC ENGINE CONTROLS - 3.0L (4V)»(/lincoln/zephyr/us-2006-2006/remont/removal-installation/#electronic-engine-controls-30l-4v) .
11. Install the engine mount and bracket. For additional information, refer to «ENGINE MOUNT»(/lincoln/zephyr/us-2006-2006/remont/mechanical/#engine-30l-4v__engine-mount) .
12. Install the power steering pump and the 3 bolts. Tighten to 25 Nm (18 lb-ft).
13. Install the LH and RH valve covers. For additional information, refer to «VALVE COVER - LH»(/lincoln/zephyr/us-2006-2006/remont/mechanical/#engine-30l-4v__valve-cover-lh) and «VALVE COVER - RH»(/lincoln/zephyr/us-2006-2006/remont/mechanical/#engine-30l-4v__valve-cover-rh) .
14. Install the accessory drive belt tensioner and 2 idler pulleys. For additional information, refer to «ACCESSORY DRIVE - 3.0L (4V)»(ref-256223) .
15. Connect the CKP sensor electrical connector and pin-type retainer.
16. If equipped, install the underbody cover and 7 screws.
17. Install the crankshaft front seal. For additional information, refer to «LOWER END COMPONENTS - EXPLODED VIEW, CRANKSHAFT PULLEY AND CRANKSHAFT FRONT SEAL»(/lincoln/zephyr/us-2006-2006/remont/mechanical/#engine-30l-4v) and «CRANKSHAFT FRONT SEAL»(/lincoln/zephyr/us-2006-2006/remont/mechanical/#engine-30l-4v__crankshaft-front-seal) .
18. Fill the engine with clean engine oil.
19. Connect 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) .
20. Fill the power steering system. For additional information, refer to «STEERING SYSTEM-GENERAL INFORMATION»(/lincoln/zephyr/us-2006-2006/remont/manual-power-steering/#steering-system-general-information) .

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1. Remove the engine front cover. For additional information, refer to «ENGINE FRONT COVER»(/lincoln/zephyr/us-2006-2006/remont/mechanical/#engine-30l-4v__engine-front-cover) .
2. Remove the ignition pulse wheel.
3. Install the crankshaft pulley bolt and washer.
4. Remove the 6 spark plugs
5. 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.
6. Rotate the crankshaft clockwise 120 degrees to the 3 o'clock position to position the RH camshafts in the neutral position.
7. Verify that the RH camshafts are in the neutral position.
8. Remove the RH timing chain tensioner arm. Remove the 2 bolts. Remove the tensioner. Remove the tensioner arm.
9. Remove the RH timing chain.
10. Remove the 3 bolts and the RH VCT assembly.
11. Rotate the crankshaft clockwise 600 degrees (1-2/3 turns) to position the crankshaft keyway in the 11 o'clock position. This will position the LH camshafts in the neutral position.
12. Verify the LH camshafts are in the neutral position.
13. Remove the LH timing chain tensioner and tensioner arm. Remove the 2 bolts. Remove the tensioner. Remove the tensioner arm.
14. Remove the LH timing chain.
15. Remove the 4 bolts and the LH VCT assembly.
16. Remove the pulley bolt, washer and the crankshaft sprocket.

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1. Install the crankshaft sprockets with the timing marks out.
2. Position the chain tensioner in a soft-jawed vise.
3. Hold the chain tensioner ratchet lock mechanism away from the ratchet stem with a small pick.
4. Slowly compress the timing chain tensioner.
5. Retain the tensioner piston with a 1.5 mm (0.05 in) wire or paper clip.
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 crankshaft timing mark. Starting with the crankshaft timing mark, count counterclockwise 29 links and mark the link. Continue counting counterclockwise to link 42 and mark the link.
7. Verify that the LH camshafts are correctly positioned.
8. Install the variable camshaft timing (VCT) assembly and the 4 bolts. Tighten to 25 Nm (18 lb-ft).
9. Install the LH timing chain. Align the marks on the timing chain with the marks on the camshaft and crankshaft sprockets.
10. Install the LH timing chain tensioner arm and the LH timing chain tensioner. Install the tensioner arm. Position the tensioner. Install the 2 bolts. Tighten to 25 Nm (18 lb-ft).
11. Install the crankshaft pulley bolt and washer and rotate the crankshaft clockwise 120 degrees until the crankshaft key way is in the 3 o'clock position.
12. Verify that the RH camshafts are correctly positioned.
13. Install the RH VCT assembly and the 3 bolts. Tighten to 25 Nm (18 lb-ft).
14. Install the RH timing chain. Align the marks on the timing chain with the marks on the camshaft and crankshaft sprockets.
15. Install the RH timing chain tensioner and tensioner arm. Install the tensioner arm. Position the tensioner. Install the 2 bolts. Tighten to 25 Nm (18 lb-ft).
16. Remove the LH and RH timing chain tensioner piston retaining wires.
17. Rotate the crankshaft counterclockwise 120 degrees to top dead center (TDC).
18. Verify the timing with the following steps. There should be 12 chain links between the camshaft timing marks. There should be 27 chain links between the camshaft and the crankshaft timing marks. There should be 30 chain links between the camshaft and the crankshaft timing marks.
19. Remove the crankshaft pulley bolt and washer.
20. Install the ignition pulse wheel.
21. Install the 6 spark plugs. Tighten to 15 Nm (11 lb-ft).
22. Install the engine front cover. For additional information, refer to «ENGINE FRONT COVER»(/lincoln/zephyr/us-2006-2006/remont/mechanical/#engine-30l-4v__engine-front-cover) .

Camshafts - LH

SPECIAL TOOL(S) Service Set, Water Pump Pulley 303-S455 (T94P-6312-AH) Remover, Crankshaft Vibration Damper 303-009 (T58P-6316-D) Remover, Oil Seal 303-409 (T92C-6700-CH) Installer, Camshaft Oil Seal 303-464 (T94P-6256-BH) Protector, Camshaft Oil Seal 303-463 (T94P-6256-AH) Installer, Power Steering Pump Pulley 211-185 (T91P-3A733-A)

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MATERIAL

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1. Remove the timing drive components. For additional information, refer to «TIMING DRIVE COMPONENTS»(/lincoln/zephyr/us-2006-2006/remont/mechanical/#engine-30l-4v) .
2. Cut and discard the coolant pump belt.
3. Using the special tools, remove the coolant pump drive pulley from the camshaft.
4. Using the special tools, remove and discard the camshaft oil seal.
5. Remove the 2 bolts and the camshaft oil seal retainer. Discard the press-in-place gasket.
6. Verify the camshafts are in the neutral position.
7. Remove the bolt and the variable camshaft timing (VCT) actuator.
8. 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.

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1. Position the VCT actuator onto the intake camshaft. Install the bolt finger-tight.
2. Lubricate the camshafts with clean engine oil and carefully position the camshafts into the cylinder head. Align the camshafts in the neutral position as shown.
3. Install the camshaft bearing caps. Loosely install the bolts.
4. Install the camshaft bearing thrust caps. Loosely install the bolts.
5. Tighten the camshaft bearing cap bolts in the sequence shown to 10 Nm (89 lb-in).
6. Tighten the VCT actuator bolt to 40 Nm (30 lb-ft) plus an additional 90 degrees.
7. Install the camshaft oil seal retainer and the 2 bolts. Tighten to 10 Nm (89 lb-in).
8. Using the special tools, install a new camshaft oil seal.
9. Using the special tool, install the coolant pump drive pulley.
10. Install the timing drive components. For additional information, refer to «TIMING DRIVE COMPONENTS»(/lincoln/zephyr/us-2006-2006/remont/mechanical/#engine-30l-4v) .
11. Install the coolant pump belt. For additional information, refer to «ACCESSORY DRIVE - 3.0L (4V)»(ref-256223) .

Camshafts - RH

MATERIAL

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1. Remove the timing drive components. For additional information, refer to «TIMING DRIVE COMPONENTS»(/lincoln/zephyr/us-2006-2006/remont/mechanical/#engine-30l-4v) .
2. Verify the camshafts are in the neutral position.
3. Remove the bolt and the VCT actuator.
4. 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.

Scheme 82

Scheme 83

Scheme 84

Scheme 85

Scheme 86

1. Position the VCT actuator onto the intake camshaft. Install the bolt finger-tight.
2. Lubricate the camshafts with clean engine oil and carefully position the camshafts onto the cylinder head. Align the camshafts in the neutral position as shown.
3. Install the camshaft bearing caps. Loosely install the bolts.
4. Install the camshaft bearing thrust caps. Loosely install the bolts.
5. Tighten the camshaft bearing cap bolts in the sequence shown to 10 Nm (89 lb-in).
6. Tighten the VCT actuator bolt to 40 Nm (30 lb-ft) plus an additional 90 degrees.
7. Install the timing drive components. For additional information, refer to «TIMING DRIVE COMPONENTS»(/lincoln/zephyr/us-2006-2006/remont/mechanical/#engine-30l-4v) .

Valve Train Components - Exploded View

Note. LH shown, RH similar.

Scheme 87

1. For additional information, refer to the appropriate procedure.

Camshaft Roller Follower

SPECIAL TOOL(S) Compressor, Valve Spring 303-473 (T94P-6565-BH)

Scheme 88

MATERIAL

Scheme 89

Scheme 90

1. 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) .
2. Remove the LH and RH valve covers. For additional information, refer to «VALVE COVER - LH»(/lincoln/zephyr/us-2006-2006/remont/mechanical/#engine-30l-4v__valve-cover-lh) and «VALVE COVER - RH»(/lincoln/zephyr/us-2006-2006/remont/mechanical/#engine-30l-4v__valve-cover-rh) .
3. Remove the 6 spark plugs. To install, tighten to 15 Nm (11 lb-ft).
4. Remove the 4 screws and position the RH fender splash shield aside.
5. Remove the 6 pin-type retainers (4 shown) and the RH splash shield.
6. Rotate the crankshaft until the camshaft lobe is pointing directly away from the roller follower.
7. Using the special tool, remove the roller followers.
8. To install, reverse the removal procedure.

Hydraulic Lash Adjuster

MATERIAL

1. Remove the camshaft roller followers. For additional information, refer to «CAMSHAFT ROLLER FOLLOWER»(/lincoln/zephyr/us-2006-2006/remont/mechanical/#engine-30l-4v__camshaft-roller-follower) .
2. Remove the hydraulic lash adjusters.
3. To install, reverse the removal procedure. Lubricate the hydraulic lash adjusters with clean engine oil.

Valve Spring, Retainer, and Seal

SPECIAL TOOL(S) Compressor, Valve Spring 303-473 (T94P-6565-BH) Installer, Valve Stem Oil Seal 303-470 (T94P-6510-CH)

Scheme 91

MATERIAL

Scheme 92

1. Remove the camshaft roller followers. For additional information, refer to «CAMSHAFT ROLLER FOLLOWER»(/lincoln/zephyr/us-2006-2006/remont/mechanical/#engine-30l-4v__camshaft-roller-follower) .
2. Pressurize the cylinder using compressed air.
3. Using the special tool, remove the key, retainer and the valve spring.
4. Remove and discard the valve seal.

1. Using the special tool, install the new valve seal.
2. Using the special tool, install the valve spring, retainer and key.
3. Install the camshaft roller followers. For additional information, refer to «CAMSHAFT ROLLER FOLLOWER»(/lincoln/zephyr/us-2006-2006/remont/mechanical/#engine-30l-4v__camshaft-roller-follower) .

Cylinder Head - RH

MATERIAL

Scheme 93

Scheme 94

1. 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) .
2. Remove the RH camshafts. For additional information, refer to «CAMSHAFTS - RH»(/lincoln/zephyr/us-2006-2006/remont/mechanical/#engine-30l-4v__camshafts-rh) .
3. Remove the coolant bypass tube. For additional information, refer to «ENGINE COOLING»(/lincoln/zephyr/us-2006-2006/remont/cooling-system-mechanical/#engine-cooling) .
4. Remove the bolt and detach the power steering pressure (PSP) tube bracket from the back of the cylinder head.
5. Remove the RH catalytic converter. For additional information, refer to «EXHAUST SYSTEM»(/lincoln/zephyr/us-2006-2006/remont/exhaust/#exhaust-system) .
6. Remove the camshaft roller followers.
7. Loosen the 8 bolts in the sequence shown and remove the cylinder head. Discard the bolts and the gasket.
8. 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.
9. Support the cylinder head on a bench with the head gasket side up.
10. 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).

Scheme 95

1. Clean the cylinder head bolt holes in the cylinder block. Make sure all coolant, oil or other foreign material is removed.
2. Position a new gasket and the cylinder head on the engine.
3. Install the 8 bolts and tighten in 6 stages in the sequence shown. Stage 1: Tighten to 40 Nm (30 lb-ft). Stage 2: Tighten 90 degrees. Stage 3: Loosen one full turn. Stage 4: Tighten to 40 Nm (30 lb-ft). Stage 5: Tighten 90 degrees. Stage 6: Tighten 90 degrees.
4. Install the camshaft roller followers.
5. Install the RH catalytic converter. For additional information, refer to «EXHAUST SYSTEM»(/lincoln/zephyr/us-2006-2006/remont/exhaust/#exhaust-system) .
6. Position the PSP tube bracket onto the rear of the cylinder head and install the bolt. Tighten to 9 Nm (80 lb-in).
7. Install the coolant bypass tube. For additional information, refer to «ENGINE COOLING»(/lincoln/zephyr/us-2006-2006/remont/cooling-system-mechanical/#engine-cooling) .
8. Install the RH camshafts. For additional information, refer to «CAMSHAFTS - RH»(/lincoln/zephyr/us-2006-2006/remont/mechanical/#engine-30l-4v__camshafts-rh) .

Cylinder Head - LH

MATERIAL

Scheme 96

Scheme 97

Scheme 98

1. 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) .
2. Remove the LH camshafts. For additional information, refer to «CAMSHAFTS - LH»(/lincoln/zephyr/us-2006-2006/remont/mechanical/#engine-30l-4v__camshafts-lh) .
3. Remove the coolant bypass tube. For additional information, refer to «ENGINE COOLING»(/lincoln/zephyr/us-2006-2006/remont/cooling-system-mechanical/#engine-cooling) .
4. Remove the 3 bolts and position the coolant pump aside.
5. Remove the LH catalytic converter. For additional information, refer to «EXHAUST SYSTEM»(/lincoln/zephyr/us-2006-2006/remont/exhaust/#exhaust-system) .
6. Remove the camshaft roller followers.
7. Loosen the 8 bolts in the sequence shown and remove the cylinder head. Discard the bolts and the gasket.
8. 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.
9. Support the cylinder head on a bench with the head gasket side up.
10. 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).

Scheme 99

1. Clean the cylinder head bolt holes in the cylinder block. Make sure all coolant, oil or other foreign material is removed.
2. Position a new gasket and the cylinder head on the engine.
3. Install the 8 bolts and tighten in 6 stages in the sequence shown. Stage 1: Tighten to 40 Nm (30 lb-ft). Stage 2: Tighten 90 degrees. Stage 3: Loosen one full turn. Stage 4: Tighten to 40 Nm (30 lb-ft). Stage 5: Tighten 90 degrees. Stage 6: Tighten 90 degrees.
4. Install the camshaft roller followers.
5. Install the LH catalytic converter. For additional information, refer to «EXHAUST SYSTEM»(/lincoln/zephyr/us-2006-2006/remont/exhaust/#exhaust-system) .
6. Position the coolant pump and install the bolts. Tighten to 10 Nm (89 lb-in) then rotate 90 degrees.
7. Install the coolant bypass tube. For additional information, refer to «ENGINE COOLING»(/lincoln/zephyr/us-2006-2006/remont/cooling-system-mechanical/#engine-cooling) .
8. Install the LH camshafts. For additional information, refer to «CAMSHAFTS - LH»(/lincoln/zephyr/us-2006-2006/remont/mechanical/#engine-30l-4v__camshafts-lh) .

Scheme 100

Scheme 101

1. For additional information, refer to the appropriate procedure.

Oil Pan

MATERIAL

1. 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) .
2. Remove the LH catalytic converter. For additional information, refer to «EXHAUST SYSTEM»(/lincoln/zephyr/us-2006-2006/remont/exhaust/#exhaust-system) .
3. Drain the engine oil and install the drain plug. Tighten to 26 Nm (19 lb-ft).
4. Remove the 2 oil pan-to-transaxle bolts.
5. Remove the 10 bolts, 5 stud bolts and the oil pan. Discard the gasket.

Scheme 102

1. Clean all sealing surfaces with metal surface cleaner and install a new oil pan gasket.
2. Apply a 10 mm (0.39 in) diameter dot of silicone sealant to the areas indicated.
3. Position the oil pan and install the 10 bolts and 5 stud bolts finger tight.
4. Install the 2 oil pan-to-transaxle bolts. Tighten to 48 Nm (35 lb-ft).
5. Tighten the oil pan-to-engine bolts and stud bolts in the sequence shown to 25 Nm (18 lb-ft).
6. Install the LH catalytic converter. For additional information, refer to «EXHAUST SYSTEM»(/lincoln/zephyr/us-2006-2006/remont/exhaust/#exhaust-system) .
7. Fill the engine with clean engine oil.

Oil Pump Screen and Pickup Tube

MATERIAL

Scheme 103

1. 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) .
2. Remove the oil pan. For additional information, refer to «OIL PAN»(/lincoln/zephyr/us-2006-2006/remont/mechanical/#engine-30l-4v__oil-pan) .
3. Remove the 2 bolts and the oil pump screen and pickup tube. Remove and discard the O-ring seal.

Scheme 104

1. Install a new O-ring seal on the oil pump screen and pickup tube.
2. Install the oil pump screen and pickup tube and the 2 bolts. Tighten to 10 Nm (89 lb-in).
3. Install the oil pan. For additional information, refer to «OIL PAN»(/lincoln/zephyr/us-2006-2006/remont/mechanical/#engine-30l-4v__oil-pan) .

1. 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) .
2. Remove the oil pump screen and pickup tube. For additional information, refer to «OIL PUMP SCREEN AND PICKUP TUBE»(/lincoln/zephyr/us-2006-2006/remont/mechanical/#engine-30l-4v__oil-pump-screen-and-pickup-tube) .
3. Remove the 8 nuts and the oil pan baffle. To install tighten the oil pan baffle nuts in 2 stages. Stage 1: Tighten the 4 smaller nuts to 5 Nm (44 lb-in) and the larger nuts to 15 Nm (11 lb-ft). Stage 2: Tighten all 8 nuts an additional 45 degrees.
4. To install, reverse the removal procedure.

Scheme 105

1. 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) .
2. Remove the timing drive components. For additional information, refer to «TIMING DRIVE COMPONENTS»(/lincoln/zephyr/us-2006-2006/remont/mechanical/#engine-30l-4v) .
3. Remove the oil pump screen and pickup tube. For additional information, refer to «OIL PUMP SCREEN AND PICKUP TUBE»(/lincoln/zephyr/us-2006-2006/remont/mechanical/#engine-30l-4v__oil-pump-screen-and-pickup-tube) .
4. Remove the 4 bolts in the sequence shown.

Scheme 106

1. Position the oil pump and install the 4 bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
2. Install the oil pump screen and pickup tube. For additional information, refer to «OIL PUMP SCREEN AND PICKUP TUBE»(/lincoln/zephyr/us-2006-2006/remont/mechanical/#engine-30l-4v__oil-pump-screen-and-pickup-tube) .
3. Install the timing drive components. For additional information, refer to «TIMING DRIVE COMPONENTS»(/lincoln/zephyr/us-2006-2006/remont/mechanical/#engine-30l-4v) .

Oil Level Indicator and Tube

MATERIAL

Scheme 107

1. 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) .
2. Remove the oil level indicator.
3. Remove the oil pressure sender. For additional information, refer to «ENGINE OIL PRESSURE (EOP) SWITCH»(/lincoln/zephyr/us-2006-2006/remont/mechanical/#engine-30l-4v__engine-oil-pressure-eop-switch) .
4. If equipped, disconnect the block heater electrical connector and wiring harness retainers.
5. Remove the stud bolt and the oil level indicator tube. Discard the O-ring seal. To install, tighten to 9 Nm (80 lb-in).
6. To install, reverse the removal procedure.

Engine Oil Pressure (EOP) Switch

MATERIAL

Scheme 108

1. 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) .
2. If equipped, remove the 7 screws and the underbody cover.
3. Remove the engine oil filter. To install tighten to 5 Nm (44 lb-in) and then rotate an additional 180 degrees.
4. Disconnect the oil pressure sender electrical connector.
5. Remove the oil pressure sender. To install, tighten to 14 Nm (10 lb-ft).
6. To install, reverse the removal procedure. Apply pipe sealant with Teflon® to the oil pressure sender threads.

Engine Mount

SPECIAL TOOL(S) 3-Bar Engine Support Kit 303-F072 Lifting Brackets, Engine 303-050 (T70P-6000) Universal Adapter Brackets 014-0001

Scheme 109

Scheme 110

Scheme 111

Scheme 112

Scheme 113

Scheme 114

1. 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) .
2. 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) .
3. Remove the engine coolant degas bottle. For additional information, refer to «ENGINE COOLING»(/lincoln/zephyr/us-2006-2006/remont/cooling-system-mechanical/#engine-cooling) .
4. Remove the lower intake manifold. For additional information, refer to «LOWER INTAKE MANIFOLD»(/lincoln/zephyr/us-2006-2006/remont/mechanical/#engine-30l-4v) .
5. Remove the bolt and position aside the ground wire. To install, tighten to 10 Nm (89 lb-in).
6. Remove the bolt and damper. To install, tighten to 23 Nm (17 lb-ft).
7. Remove the engine mount bracket bolt. To install, tighten to 115 Nm (85 lb-ft).
8. Install the special tools. Position the 2 universal adapter brackets on top of the cylinder block. Install 2 M8 x 1.25 x 36 mm (1.41 in) bolts and tighten to 10 Nm (89 lb-in). Position the universal lifting bracket onto the 2 universal adapter brackets. Fasten the universal lifting bracket to the 2 universal adapter brackets with a suitable nut and bolt.
9. Install the special tool and raise the engine 25 mm (0.98 in).
10. Remove the 3 engine mount bracket nuts. To install, tighten to 63 Nm (46 lb-ft).
11. Remove the nut, 2 bolts and the engine mount. To install, tighten to 55 Nm (41 lb-ft).
12. Use the special tool to lower the engine 25 mm (0.98 in). Remove the engine mount bracket.
13. To install, reverse the removal procedure.

SPECIAL TOOL(S) Separator, Ball joint 205-592 Adapter for 204-592 204-592/1 Remover, Halfshaft 205-832 Slide Hammer 100-001 Remover, Halfshaft 205-243 Powertrain Lift 014-00765 Universal Adapter Brackets 014-0001 Lifting Bracket Set, Engine 303-D095 (D94L-6001-A) or equivalent Lifting Brackets, Engine 134-00243 or equivalent Engine Lifting Bracket Set 303-1140 Lifting Bracket, Engine 303-050 (T70P-6000) Heavy Duty Floor Crane 014-00071 or equivalent Spreader Bar 303-D089 (D93P-6001-A3) or equivalent Tie-Rod End Remover 211-105 (T85M-3395-A)

Scheme 115

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Scheme 199

1. 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) .
2. 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) .
3. 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) .
4. 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)
5. Place the steering wheel in the straight ahead position and the ignition key in the OFF position.
6. Remove the 2 nuts and the steering joint cover.
7. Remove the bolt and disconnect the steering column shaft from the steering gear.
8. Drain the cooling system. For additional information, refer to «ENGINE COOLING»(/lincoln/zephyr/us-2006-2006/remont/cooling-system-mechanical/#engine-cooling) .
9. If equipped, remove the 7 screws and the underbody cover.
10. Disconnect the power steering cooler tube and drain the power steering fluid into a suitable drain pan.
11. Remove the exhaust flexible pipe. For additional information, refer to «EXHAUST SYSTEM»(/lincoln/zephyr/us-2006-2006/remont/exhaust/#exhaust-system) .
12. Release the 4 clips and slide the steering gear-to-dash seal off of the steering gear and into the passenger compartment.
13. Remove the power steering pressure (PSP) hose bracket bolt.
14. Remove and discard the PSP hose banjo bolt and the 2 seals from the steering gear.
15. Remove the 2 bolts and the heat shield.
16. Remove the 2 bolts and the engine roll restrictor.
17. Remove the 4 screws and position the RH fender splash shield aside.
18. Remove the 6 pin-type retainers (4 shown) and the RH splash shield.
19. Remove the 4 screws and position the LH fender splash shield aside.
20. Remove the 6 pin-type retainers (4 shown) and the LH splash shield.
21. Remove the cotter pins and nuts from the tie-rod ends.
22. Using the special tool, separate the tie-rod ends from the steering knuckles.
23. Remove the nuts and separate the stabilizer bar links from the struts.
24. Remove the lower ball joint nuts.
25. Using the special tools, separate the lower ball joints from the lower control arms.
26. Remove the through bolts from the lower control arms.
27. Position the special tool under the subframe assembly.
28. Remove the subframe bracket-to-body bolts.
29. Remove the subframe nuts and the subframe brackets.
30. Remove the front subframe nuts.
31. Lower the subframe assembly from the vehicle.
32. Disconnect the transaxle cooler hoses.
33. Remove the drain plug and drain the engine oil. Install the drain plug and tighten to 27 Nm (20 lb-ft).
34. Remove and discard the engine oil filter.
35. Remove the engine air cleaner and air cleaner outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING - 2.3L»(ref-256206) .
36. 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) .
37. Remove the nut and disconnect the power feed wire from the battery terminal.
38. Disconnect the 2 engine wiring harness electrical connectors.
39. Remove the bolt and position aside the ground wire.
40. Disconnect the powertrain control module (PCM) electrical connector and the pin-type retainer.
41. 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) .
42. Disconnect the heater hose from the thermostat housing.
43. Disconnect the heater hose inline connection.
44. Disconnect the throttle body coolant hose.
45. Disconnect the evaporative emissions (EVAP) hose.
46. Disconnect the upper and lower radiator hoses from the thermostat housing.
47. Disconnect the transaxle control cable from the transaxle selector lever.
48. Remove the 3 transaxle control cable bracket bolts and position the cable aside.
49. Remove the bolt and position the ground wire aside.
50. Remove the vacuum tube bracket bolt.
51. Disconnect the vacuum hose from the intake manifold.
52. If equipped, detach the block heater cable retaining clips from the cooling fan shroud.
53. Disconnect the power steering hose from the power steering reservoir.
54. Detach the power steering hose retaining clip from the LH valve cover stud bolt and the engine wiring harness.
55. Disconnect the coolant hose from the degas bottle.
56. Detach the coolant hose retaining clip and position the coolant hose aside.
57. Remove the 2 A/C tube bracket bolts.
58. Remove the 2 nuts and disconnect the A/C tubes.
59. Remove the bolt and the ground wire from the engine mount bracket.
60. Remove the bolt and separate the A/C manifold from the A/C compressor.
61. Using the special tools, separate the LH halfshaft from the transaxle and support the halfshaft with a length of mechanic's wire.
62. Disconnect the crankshaft position (CKP) sensor electrical connector and pin-type retainer.
63. Disconnect the power steering pressure (PSP) switch electrical connector.
64. Disconnect the catalyst monitor sensor (CMS) electrical connector and pin-type retainer.
65. Remove the 2 RH halfshaft carrier bearing bracket bolts.
66. Separate the RH halfshaft from the transaxle and support the halfshaft with a length of mechanic's wire.
67. Remove the torque converter nut access plug.
68. Remove the 3 torque converter nuts.
69. Remove the 2 oil pan-to-transaxle bolts.
70. Install the special tools onto the engine. Raise the engine and transaxle 25.4 mm (1 in) to neutralize the engine and transaxle mounts.
71. Remove the 2 transaxle mount bolts.
72. Remove the bolt and damper.
73. Remove the bolt, 3 nuts and the engine mount bracket.
74. Lower the engine and transaxle from the vehicle.
75. Install the special tools.
76. Detach the wiring harness retainer from the PSP hose bracket.
77. Remove the bolt and detach the PSP hose bracket from the cylinder head.
78. Detach the heated oxygen sensor (HO2S) electrical connector from the PSP bracket.
79. Remove the bolt and detach the PSP hose bracket from the cylinder head.
80. Remove the bolt and detach the PSP hose bracket from the power steering reservoir.
81. Remove the banjo bolt and the PSP hose. Discard the banjo bolt and 2 seals.
82. Install the special tool.
83. Disconnect the exhaust gas recirculation (EGR) valve electrical connector.
84. Loosen the EGR tube-to-EGR valve nut.
85. Remove the 2 bolts and the EGR valve. Discard the gasket.
86. Loosen the EGR tube-to-catalytic converter nut and remove the EGR tube.
87. Remove the 2 bolts and the heat shield.
88. Remove the 2 bolts and the catalytic converter bracket.
89. Remove the 2 bolts and the catalytic converter bracket assembly.
90. Install the lower half of the special tool.
91. Install the upper half of the special tool.
92. Using the special tools and a suitable engine crane, remove the engine and transaxle from the lift table.
93. Remove the bolt and the ground wire.
94. Remove the bolt and the catalyst monitor sensor (CMS) electrical connector bracket.
95. Disconnect the transmission control module (TCM) electrical connector.
96. Detach the wiring harness pin-type retainer.
97. Remove the 2 nuts and the starter motor wiring.
98. Remove the 2 bolts and the starter motor.
99. Remove the engine-to-transaxle bolt.
100. Remove the 3 transaxle-to-engine bolts.
101. Detach the wiring harness retainer from the stud bolt.
102. Remove the transaxle-to-engine stud bolt, bolt and nut.
103. 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)

Scheme 200

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MATERIAL

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

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1. Remove the 8 bolts and the flexplate.
2. Remove the engine-to-transaxle separator plate.
3. Using the special tools, remove and discard the crankshaft rear oil seal.
4. Mount the engine on a suitable stand.
5. Disconnect the manifold actual pressure (MAP) sensor electrical connector and the pin-type retainer.
6. Detach the wiring harness pin-type retainer from the upper intake manifold.
7. Disconnect the crankcase vent hose from the upper intake manifold.
8. Disconnect the electronic throttle body electrical connector.
9. Disconnect the throttle body coolant hose.
10. Remove the 8 bolts and the upper intake manifold. Discard the gaskets.
11. Disconnect the A/C compressor electrical connector.
12. If equipped, disconnect the block heater electrical connector.
13. If equipped, detach the block heater wiring harness retainers from the oil level indicator tube and remove the harness.
14. Disconnect the oil pressure sender electrical connector.
15. Remove the nut and disconnect the generator B+ cable and electrical connector.
16. 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.
17. Disconnect the LH heated oxygen sensor (HO2S) electrical connector and pin-type retainer.
18. Detach the 3 wiring harness retainers from the valve cover stud bolts.
19. Disconnect the 3 LH coil-on-plug electrical connectors. Detach the 2 wiring harness pin-type retainers from the valve cover.
20. Detach the wiring harness retainer from the LH valve cover stud bolt.
21. Disconnect the 6 (3 shown) fuel injector electrical connectors.
22. Detach the 3 wiring harness retainers from the fuel rail.
23. Disconnect the 3 RH coil-on-plug electrical connectors. Detach the 2 wiring harness pin-type retainers from the valve cover.
24. Disconnect the RH VCT solenoid and LH CMP sensor electrical connectors. Detach the 2 wiring harness retainers from the valve cover stud bolts.
25. Remove the nut and the radio frequency interference capacitor.
26. Detach the wiring harness retainer from the power steering stud bolt.
27. Disconnect the RH HO2S electrical connector.
28. Disconnect the positive crankcase ventilation (PCV) valve electrical connector.
29. Disconnect the knock sensor (KS) electrical connector.
30. Disconnect the electronic coolant temperature (ECT) sensor electrical connector.
31. Detach the wiring harness retainer from the coolant bypass stud bolt.
32. Disconnect the LH catalyst monitor sensor (CMS) electrical connector. Remove the wiring harness from the engine.
33. Rotate the accessory drive belt tensioner counterclockwise and remove the accessory drive belt.
34. Remove the 3 bolts and the generator.
35. Remove the 3 bolts and the A/C compressor.
36. Remove the 3 bolts and the A/C compressor bracket.
37. Remove the 3 power steering reservoir nuts.
38. Remove the 3 bolts and the power steering pump and reservoir assembly.
39. Remove the 6 nuts and the RH catalytic converter. Discard the gasket.
40. Remove and discard the 6 RH catalytic converter studs.
41. Remove the 4 bolts and the heat shield.
42. Remove the 2 bolts from the LH catalytic converter bracket.
43. Remove the 6 nuts and the LH catalytic converter. Discard the gasket.
44. Remove and discard the 6 LH catalytic converter studs.
45. Remove the 2 bolts and the LH catalytic converter bracket.
46. Remove the bolt and the oil level indicator tube. Remove and discard the O-ring seal.
47. Remove the 8 bolts and the lower intake manifold. Discard the gaskets.
48. If equipped, remove the 2 nuts and the coolant pump drive pulley cover.
49. Cut and discard the coolant pump belt.
50. Release the 2 clamps and remove the thermostat housing.
51. Remove the bolt, stud bolt and the coolant bypass. Remove and discard the O-ring seals.
52. Disconnect the coolant pump hose from the cylinder block outlet.
53. Using the special tools, remove the coolant pump drive pulley from the camshaft.
54. Remove the 3 bolts and the coolant pump.
55. Remove the bolt and the KS.
56. Remove the oil pressure sender.
57. If equipped, remove the block heater.
58. Remove the 3 bolts and the 3 LH coil-on-plug assemblies.
59. Remove the 4 bolts, 10 stud bolts and the LH valve cover. Discard the gaskets.
60. Remove the 3 bolts and the 3 RH coil-on-plug assemblies.
61. Remove the 6 bolts, 8 stud bolts and the RH valve cover. Discard the gaskets.
62. Remove the 10 bolts, 5 stud bolts and the oil pan. Discard the gasket.
63. Remove the 2 bolts and the oil pump screen and pickup tube. Remove and discard the O-ring seal.
64. Remove the 8 nuts and the oil pan baffle.
65. Remove the accessory drive belt tensioner and the 2 idler pulleys.
66. Using the special tool, remove the crankshaft pulley bolt.
67. Using the special tool, remove the crankshaft pulley.
68. Using the special tool, remove and discard the crankshaft front seal.
69. Remove the 16 bolts and the engine front cover. Discard the gaskets.
70. Remove the ignition pulse wheel.
71. Install the crankshaft pulley bolt and washer.
72. Remove the 6 spark plugs
73. 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.
74. Rotate the crankshaft clockwise 120 degrees to the 3 o'clock position to position the RH camshafts in the neutral position.
75. Verify that the RH camshafts are in the neutral position.
76. Remove the RH timing chain tensioner arm. Remove the bolts. Remove the tensioner. Remove the tensioner arm.
77. Remove the RH timing chain.
78. Remove the 3 bolts and the RH VCT assembly.
79. 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.
80. Verify the LH camshafts are in the NEUTRAL position.
81. Remove the LH timing chain tensioner and tensioner arm. Remove the bolts. Remove the tensioner. Remove the tensioner arm.
82. Remove the LH timing chain.
83. Remove the 4 bolts and the LH VCT assembly.
84. Remove the pulley bolt, washer and the crankshaft sprocket.
85. Remove the 4 bolts in the sequence shown. Remove the oil pump.
86. Remove the crankshaft key.
87. Using the special tools, remove the camshaft oil seal and discard.
88. Remove the 2 bolts and the camshaft oil seal retainer Discard the press-in-place gasket.
89. Verify the camshafts are in the neutral position.
90. Remove the bolt and the VCT actuator.
91. 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.
92. Verify the camshafts are in the neutral position.
93. Remove the bolt and the VCT actuator.
94. 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.
95. Remove the LH and RH camshaft roller followers.
96. Loosen the 8 bolts in the indicated sequence and remove the LH and RH cylinder heads. Discard the bolts and the gaskets.
97. 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.
98. Support the cylinder head on a bench with the head gasket side up.
99. 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).
100. Remove the bolts and the oil separator cover. Discard the gasket.

Cylinder Head

SPECIAL TOOL(S) Compressor, Valve Spring 303-300 (T87C-6565-A) Compressor, Valve Spring 303-350 (T89P-6565-A) Installer, Valve Stem Oil Seal 303-470 (T94P-6510-CH)

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MATERIAL

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Disassembly

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1. Remove the hydraulic lash adjusters.
2. Using the special tool, remove the keys, retainer and spring.
3. Remove the valve from the cylinder head.
4. Remove the valve stem seal.

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1. Using the special tool, install the valve stem seal.
2. Install the valve.
3. Using the special tool, install the valve spring, retainer and key.
4. Install the hydraulic lash adjusters. Lubricate the hydraulic lash adjusters with clean engine oil.

SPECIAL TOOL(S) Installer, Crankshaft Vibration Damper 303-102 (T74P-6316-B) Installer, Front Cover Oil Seal 303-335 (T88T-6701-A) Installer, Crankshaft Rear Main Oil Seal 303-178 (T82L-6701-A) Installer Bolts, Crankshaft Rear Main Oil Seal 303-384 (T91P-6701-A) Service Set, Water Pump Pulley 303-S455 (T94P-6312-AH) Protector, Camshaft Oil Seal 303-463 (T91P-6256-AH) Installer, Camshaft Oil Seal 303-464 (T94P-6256-BH) Installer, Power Steering Pump Pulley 211-185 (T91P-3A733-A) Lifting Brackets, Engine 303-050 (T70P-6000) Lifting Brackets, Engine 134-00243 or equivalent Engine Lifting Bracket Set 303-1140 Spreader Bar 303-D089 (D93P-6001-A3) or equivalent Strap Wrench 303-D055 (D85L-6000-A)

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1. Install the oil separator cover, a new gasket and the bolts. Tighten to 10 Nm (89 lb-in).
2. Position the new gaskets and the LH and RH cylinder heads. Install new bolts and tighten in the sequence shown in 6 stages: Stage 1: Tighten to 40 Nm (30 lb-ft). Stage 2: Tighten to 90 Nm (66 lb-ft). Stage 3: Loosen one full turn. Stage 4: Tighten to 40 Nm (30 lb-ft). Stage 5: Tighten 90 degrees. Stage 6: Tighten 90 degrees.
3. Position the oil pump and install the 4 bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
4. If removed, install the crankshaft key into the keyway on the crankshaft.
5. Install the crankshaft pulley bolt and washer and rotate the crankshaft keyway to the 11 o'clock position to locate top dead center (TDC).
6. Apply clean engine oil to the LH and RH camshaft roller followers.
7. Install the LH and RH camshaft roller followers.
8. Position the variable camshaft timing (VCT) actuators onto the intake camshafts. Install the bolts finger-tight.
9. Lubricate the RH camshafts with clean engine oil and carefully position the camshafts onto the cylinder head. Align the RH camshafts as shown.
10. Install the RH camshaft bearing caps. Loosely install the bolts.
11. Install the RH camshaft bearing thrust caps. Loosely install the bolts.
12. Tighten the RH camshaft bearing cap bolts in the sequence shown to 10 Nm (89 lb-in).
13. Tighten the RH VCT actuator bolt to 40 Nm (30 lb-ft) plus an additional 90 degrees.
14. Lubricate the LH camshafts with clean engine oil and carefully position the camshafts into the cylinder head. Align the LH camshafts as shown.
15. Install the LH camshaft bearing caps. Loosely install the bolts.
16. Install the LH camshaft bearing thrust caps. Loosely install the bolts.
17. Tighten the LH camshaft bearing cap bolts in the sequence shown to 10 Nm (89 lb-in).
18. Tighten the LH VCT actuator bolt to 40 Nm (30 lb-ft) plus an additional 90 degrees.
19. Install the camshaft oil seal retainer and the 2 bolts. Tighten to 10 Nm (89 lb-in).
20. Using the special tools, install a new camshaft oil seal.
21. Remove the crankshaft pulley bolt and washer.
22. Install the crankshaft sprockets with the timing marks out.
23. Position the chain tensioner in a soft-jawed vise.
24. Hold the chain tensioner ratchet lock mechanism away from the ratchet stem with a small pick.
25. Slowly compress the timing chain tensioner.
26. Retain the tensioner piston with a 1.5 mm (0.05 in) wire or paper clip.
27. 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 crankshaft timing mark. Starting with the crankshaft timing mark, count counterclockwise 29 links and mark the link. Continue counting counterclockwise to link 42 and mark the link.
28. Verify that the LH camshafts are correctly positioned.
29. Install the variable camshaft timing (VCT) assembly and the 4 bolts. Tighten to 25 Nm (18 lb-ft).
30. Install the LH timing chain. Align the marks on the timing chain with the marks on the camshaft and crankshaft sprockets.
31. Install the LH timing chain tensioner arm and the LH timing chain tensioner. Install the tensioner arm. Position the tensioner. Install the 2 bolts. Tighten to 25 Nm (18 lb-ft).
32. Install the crankshaft pulley bolt and washer and rotate the crankshaft clockwise 120 degrees until the crankshaft key way is in the 3 o'clock position.
33. Verify that the RH camshafts are correctly positioned.
34. Install the RH VCT assembly and the 3 bolts. Tighten to 25 Nm (18 lb-ft).
35. Install the RH timing chain. Align the marks on the timing chain with the marks on the camshaft and crankshaft sprockets.
36. Install the RH timing chain tensioner and tensioner arm. Install the tensioner arm. Position the tensioner. Install the 2 bolts. Tighten to 25 Nm (18 lb-ft).
37. Remove the LH and RH timing chain tensioner piston retaining wires.
38. Rotate the crankshaft counterclockwise 120 degrees to top dead center (TDC).
39. Verify the timing with the following steps. There should be 12 chain links between the camshaft timing marks. There should be 27 chain links between the camshaft and the crankshaft timing marks. There should be 30 chain links between the camshaft and the crankshaft timing marks.
40. Remove the crankshaft pulley bolt and washer.
41. Install the ignition pulse wheel.
42. Install 3 new gaskets in the front cover.
43. Apply a 6 mm (0.23 in) dot of silicone gasket and sealant to the cylinder block to lower cylinder block and cylinder head mating surfaces.
44. Position the engine front cover and install the 14 bolts and 2 stud bolts. Tighten in the sequence shown to 25 Nm (18 lb-ft).
45. Apply clean engine oil to the seal lip and seal bore before installing the seal.
46. Using the special tools, install a new crankshaft front seal.
47. Apply silicone gasket and sealant to the end of the keyway slot.
48. Using the special tool, install the crankshaft pulley.
49. Install the bolt and washer. Using the special tool to hold the crankshaft pulley, tighten the bolt in 4 stages: Stage 1: Tighten to 120 Nm (89 lb-ft). Stage 2: Loosen one full turn. Stage 3: Tighten to 50 Nm (37 lb-ft). Stage 4: Tighten an additional 90 degrees.
50. Install the accessory drive belt tensioner and the 2 idler pulleys. Tighten the tensioner bolt to 45 Nm (33 lb-ft). Tighten the idler pulley bolts to 25 Nm (18 lb-ft).
51. Instal the oil pan baffle and the 8 nuts. Tighten the oil pan baffle nuts in 2 stages. Stage 1: Tighten the 4 smaller nuts to 5 Nm (44 lb-in) and the larger nuts to 15 Nm (11 lb-ft). Stage 2: Tighten all 8 nuts an additional 45 degrees.
52. Install a new O-ring seal on the oil pump screen and pickup tube. Lubricate with clean engine oil.
53. Install the oil pump screen and pickup tube and the 2 bolts. Tighten to 10 Nm (89 lb-in).
54. Install the LH and RH spark plugs. Tighten to 15 Nm (11 lb-ft).
55. Apply a an 8 mm (0.31 in) dot of silicone gasket sealant to the front cover-to-cylinder head joints and the cam seal retainer-to-cylinder head joints.
56. Position the LH valve cover and install the bolts and stud bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
57. Install the 3 LH coil-on-plug assemblies and the 3 bolts. Tighten to 7 Nm (62 lb-in).
58. Apply an 8 mm (0.31 in) dot of silicone gasket sealant to the front cover-to-cylinder head joints.
59. Position the RH valve cover and install the bolts and stud bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
60. Install the 3 RH coil-on-plug assemblies and the 3 bolts. Tighten to 7 Nm (62 lb-in).
61. If equipped, install the block heater. Tighten to 41 Nm (30 lb-ft).
62. Install the oil pressure sender. Tighten to 14 Nm (10 lb-ft).
63. Install the knock sensor (KS) and the bolt. Tighten to 20 Nm (15 lb-ft).
64. Install the coolant pump and the 3 bolts. Tighten to 10 Nm (89 lb-in) then rotate 90 degrees.
65. Using the special tool, install the coolant pump drive pulley.
66. Install the coolant pump belt on the coolant pump pulley and position it on the coolant pump drive pulley.
67. Rotate the crankshaft clockwise to seat the coolant pump belt on the coolant pump drive belt pulley.
68. If equipped, install the coolant pump drive pulley cover and the 2 nuts. Tighten to 6 Nm (53 lb-in).
69. Connect the coolant pump hose to the cylinder block outlet.
70. Install new O-ring seals, the bypass tube, bolt and stud bolt. Tighten to 10 Nm (89 lb-in).
71. Install the thermostat housing.
72. Position the lower intake manifold and install the 8 bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
73. Install a new O-ring on the oil level indicator tube. Apply clean engine oil to the O-ring.
74. Position the oil level indicator and tube and install the stud bolt. Tighten to 9 Nm (80 lb-in).
75. Install the LH catalytic converter bracket and the 2 bolts. Tighten to 35 Nm (26 lb-ft).
76. Install 6 new RH catalytic converter studs. Tighten to 12 Nm (9 lb-ft).
77. Install a new gasket, the RH catalytic converter and 6 new nuts. Tighten to 20 Nm (15 lb-ft) in the sequence shown.
78. Position the power steering pump and reservoir assembly onto the engine and install the 3 bolts. Tighten to 25 Nm (18 lb-ft).
79. Install the 3 power steering reservoir nuts. Tighten to 9 Nm (80 lb-in).
80. Install the A/C compressor bracket and the 3 bolts. Tighten to 25 Nm (18 lb-ft).
81. Install the A/C compressor and the 3 bolts. Tighten to 25 Nm (18 lb-ft).
82. Install the generator and the 3 bolts. Tighten to 48 Nm (35 lb-ft).
83. Rotate the accessory drive belt tensioner counterclockwise and install the accessory drive belt.
84. Attach the wiring harness retainer to the coolant bypass stud bolt.
85. Position the wiring harness onto the engine and connect the engine coolant temperature (ECT) sensor electrical connector.
86. Connect the KS electrical connector.
87. Connect the positive crankcase ventilation (PCV) valve electrical connector.
88. Connect the RH heated oxygen sensor (HO2S) electrical connector.
89. Attach the wiring harness retainer to the power steering stud bolt.
90. Install the radio frequency interference capacitor and the nut. Tighten to 6 Nm (53 lb-in).
91. Connect the RH VCT solenoid and LH camshaft position (CMP) sensor electrical connectors. Attach the 2 wiring harness retainers to the valve cover stud bolts.
92. Connect the 3 RH coil-on-plug electrical connectors. Attach the 2 wiring harness pin-type retainers to the valve cover.
93. Attach the 2 wiring harness retainers to the fuel rail.
94. Connect the 6 (3 shown) fuel injector electrical connectors.
95. Attach the wiring harness retainer to the LH valve cover stud bolt.
96. Connect the 3 LH coil-on-plug electrical connectors. Attach the 2 wiring harness pin-type retainers to the valve cover.
97. Attach the 3 wiring harness retainers to the valve cover stud bolts.
98. Connect the LH VCT solenoid and LH CMP sensor electrical connectors. Attach the 2 wiring harness retainers to the valve cover stud bolts.
99. Connect the generator B+ cable and electrical connector and install the nut. Tighten to 6 Nm (53 lb-in).
100. Connect the oil pressure sender electrical connector.
101. If equipped, attach the block heater wiring harness retainers to the oil level indicator tube and remove the harness.
102. If equipped, connect the block heater electrical connector.
103. Connect the A/C compressor electrical connector.
104. Position the upper intake manifold and install the 8 bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
105. Connect the throttle body coolant hose.
106. Connect the electronic throttle body electrical connector.
107. Connect the crankcase vent hose to the upper intake manifold.
108. Attach the wiring harness pin-type retainer to the upper intake manifold.
109. Connect the manifold actual pressure (MAP) sensor electrical connector and the pin-type retainer.
110. Install the lower half of the special tool.
111. Install the upper half of the special tool.
112. Install the special tool.
113. Install the special tools.
114. Using the special tools and a suitable engine crane, remove the engine from the engine stand.
115. Using the special tools, install the crankshaft rear seal.
116. Install the engine-to-transaxle separator plate.
117. Position the flexplate and install the 8 bolts. Tighten to 80 Nm (59 lb-ft).

SPECIAL TOOL(S) Powertrain Lift 014-00765 Universal Adapter Brackets 014-0001 Lifting Bracket Set, Engine 303-D095 (D94L-6001-A) or equivalent Lifting Brackets, Engine 134-00243 or equivalent Engine Lifting Bracket Set 303-1140 Lifting Bracket, Engine 303-050 (T70P-6000) Heavy Duty Floor Crane 014-00071 or equivalent Spreader Bar 303-D089 (D93P-6001-A3) or equivalent

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1. Using the special tools and a suitable engine crane, align the engine to the transaxle.
2. Install the transaxle-to-engine stud bolt, bolt and nut. Tighten to 48 Nm (35 lb-ft).
3. Attach the wiring harness retainer to the stud bolt.
4. Install the 3 transaxle-to-engine bolts. Tighten to 48 Nm (35 lb-ft).
5. Install the engine-to-transaxle bolt. Tighten to 48 Nm (35 lb-ft).
6. Use a plastic scraping tool to remove all traces of the oil pan gasket. Clean all sealing surfaces with metal surface cleaner and install a new oil pan gasket.
7. Apply a 10 mm (0.39 in) diameter dot of silicone sealant to the areas indicated.
8. Position the oil pan and install the 10 bolts and 5 stud bolts finger tight.
9. Install the 2 oil pan-to-transaxle bolts. Tighten to 48 Nm (35 lb-ft).
10. Tighten the 15 oil pan-to-engine bolts and stud bolts in the sequence shown to 25 Nm (18 lb-ft).
11. Install 6 new LH catalytic converter studs. Tighten to 12 Nm (9 lb-ft).
12. Install a new gasket, the LH catalytic converter and 6 new nuts. Tighten to 20 Nm (15 lb-ft) in the sequence shown.
13. Install the LH catalytic converter bracket and the 2 bolts. Tighten to 20 Nm (15 lb-ft).
14. Install the heat shield and the 4 bolts. Tighten to 11 Nm (8 lb-ft).
15. Connect the LH heated oxygen sensor (HO2S) electrical connector and pin-type retainer.
16. Connect the LH catalyst monitor sensor (CMS) electrical connector.
17. Install the starter motor and the 2 bolts. Tighten to 27 Nm (20 lb-ft).
18. Connect the starter motor wiring and install the 2 nuts. Tighten the large nut to 12 Nm (9 lb-ft). Tighten the small nut to 5 Nm (44 lb-in).
19. Attach the wiring harness pin-type retainer.
20. Connect the transmission control module (TCM) electrical connector.
21. Install the CMS bracket and the bolt. Tighten to 12 Nm (9 lb-ft).
22. Install the ground wire and the bolt. Tighten to 12 Nm (9 lb-ft).
23. Using the special tools and a suitable engine crane, position the engine and transaxle onto the lift table.
24. Install the special tools.
25. Install the catalytic converter bracket assembly and the 2 bolts. Tighten to 35 Nm (26 lb-ft).
26. Install the catalytic converter bracket and the 2 bolts. Tighten to 20 Nm (15 lb-ft).
27. Install the heat shield and the 2 bolts. Tighten to 11 Nm (8 lb-ft).
28. Using a new gasket, install the EGR valve and the 2 bolts. Tighten to 25 Nm (18 lb-ft).
29. Install the EGR tube. Tighten both EGR tube nuts to 40 Nm (30 lb-ft).
30. Connect the EGR valve electrical connector.
31. Position the power steering pressure (PSP) hose on the engine and install the PSP hose bracket-to-power steering reservoir bolt. Tighten to 9 Nm (80 lb-in).
32. Using a new banjo bolt and 2 seals, connect the PSP hose to the power steering pump, Tighten to 35 Nm (26 lb-ft).
33. Attach the PSP hose bracket to the cylinder head and install the bolt. Tighten to 9 Nm (80 lb-in).
34. Attach the HO2S electrical connector to the PSP bracket.
35. Attach the PSP hose bracket to the cylinder head and install the bolt. Tighten to 9 Nm (80 lb-in).
36. Attach the wiring harness retainer to the PSP hose bracket.
37. Raise the engine and transaxle up into the vehicle.
38. Install the engine mount bracket, 3 nuts and the bolt. Tighten the nuts to 63 Nm (46 lb-ft). Tighten the bolt to 115 Nm (85 lb-ft).
39. Install the damper and bolt. Tighten to 23 Nm (17 lb-ft).
40. Install the 2 transaxle mount bolts. Tighten to 90 Nm (66 lb-ft).
41. Install the 3 torque converter nuts. Tighten to 36 Nm (27 lb-ft).
42. Install the torque converter nut access plug.
43. Install the RH halfshaft into the transaxle.
44. Install the 2 RH halfshaft carrier bearing bracket bolts. Tighten to 55 Nm (41 lb-ft).
45. Connect the CMS electrical connector and pin-type retainer.
46. Connect the PSP switch electrical connector.
47. Connect the crankshaft position (CKP) sensor electrical connector and pin-type retainer.
48. Install a new circlip in the groove on the LH halfshaft.
49. Install the LH halfshaft into the transaxle.
50. Position the A/C manifold onto the A/C compressor and install the bolt. Tighten to 15 Nm (11 lb-ft).
51. Install the ground wire and bolt to the engine mount bracket. Tighten to 10 Nm (89 lb-in).
52. Connect the A/C tubes and install the 2 nuts. Tighten to 8 Nm (71 lb-in).
53. Install the 2 A/C tube bracket bolts. Tighten to 10 Nm (89 lb-in).
54. Attach the coolant hose retaining clip.
55. Connect the coolant hose to the degas bottle.
56. Attach the power steering hose retaining clip to the engine wiring harness and the LH valve cover stud bolt.
57. Connect the power steering hose to the power steering reservoir.
58. If equipped, attach the block heater cable retaining clips to the cooling fan shroud.
59. Connect the vacuum hose to the intake manifold.
60. Install the vacuum tube bracket bolt. Tighten to 10 Nm (89 lb-in).
61. Install the ground wire and bolt. Tighten to 12 Nm (9 lb-ft).
62. Install the transaxle control cable bracket and the 3 bolts. Tighten to 8 Nm (71 lb-in).
63. Connect the transaxle control cable to the transaxle selector lever.
64. Connect the upper and lower radiator hoses to the thermostat housing.
65. Connect the evaporative emissions (EVAP) hose.
66. Connect the throttle body coolant hose.
67. Connect the heater hose inline connection.
68. Connect the heater hose to the thermostat housing.
69. Connect the fuel supply tube to the fuel rail. For additional information, refer to «FUEL SYSTEM-GENERAL INFORMATION»(/lincoln/zephyr/us-2006-2006/remont/fuel-system/#fuel-system-general-information) .
70. Connect the powertrain control module (PCM) electrical connector and the pin-type retainer.
71. Install the ground wire and bolt. Tighten to 10 Nm (89 lb-in).
72. Connect the 2 engine wiring harness electrical connectors.
73. Connect the power feed to the battery terminal and install the nut. Tighten to 6 Nm (53 lb-in).
74. Install the battery tray. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/lincoln/zephyr/us-2006-2006/remont/body-electrical/#battery-mounting-and-cables) .
75. Install the engine air cleaner and air cleaner outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING - 2.3L»(ref-256206) .
76. Install a new engine oil filter. Tighten to 5 Nm (44 lb-in) and then rotate an additional 180 degrees.
77. Connect the transaxle cooler hoses.
78. Place the subframe assembly on the special tool and raise the subframe into the installed position.
79. Install the front subframe nuts. Tighten to 150 Nm (111 lb-ft).
80. Position the subframe brackets and install the bolts finger-tight.
81. Install the subframe nuts. Tighten to 150 Nm (111 lb-ft).
82. Tighten the subframe bracket-to-body bolts to 103 Nm (76 lb-ft).
83. Install the through bolts into the lower control arms. Tighten to 103 Nm (76 lb-ft).
84. Install the lower ball joint nuts. Tighten to 200 Nm (148 lb-ft).
85. Install the stabilizer bar links and nuts to the struts. Tighten to 40 Nm (30 lb-ft).
86. Connect the power steering cooler tube.
87. Install tie-rod ends and nuts. Tighten to 48 Nm (35 lb-ft). Install the cotter pin.
88. Install the LH splash shield and the 6 pin-type retainers (4 shown).
89. Position the LH fender splash shield and install the 4 screws.
90. Install the RH splash shield and the 6 pin-type retainers (4 shown).
91. Position the RH fender splash shield and install the 4 screws.
92. Install the engine roll restrictor and the 2 bolts. Tighten to 90 Nm (66 lb-ft).
93. Install the heat shield and the 2 bolts.
94. Using a new banjo bolt and 2 seals, connect the PSP hose to the power steering gear. Tighten to 35 Nm (26 lb-ft).
95. Position the PSP hose onto the steering gear and install the PSP hose bracket bolt. Tighten to 9 Nm (80 lb-in).
96. Slide the steering gear-to-dash seal onto the steering gear and engage the 4 retaining clips into the body. From under the vehicle, verify that the seal is properly installed on the steering gear and the retaining clips are fully engaged into the body.
97. Install the exhaust flexible pipe. For additional information, refer to «EXHAUST SYSTEM»(/lincoln/zephyr/us-2006-2006/remont/exhaust/#exhaust-system) .
98. If equipped, install the underbody cover and 7 screws.
99. Install the steering intermediate shaft onto the steering gear and install the bolt. Tighten to 23 Nm (17 lb-ft).
100. Install the steering joint cover and the 2 nuts.
101. Fill the engine with clean engine oil.
102. Connect 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) .
103. Fill and bleed the cooling system. For additional information, refer to «ENGINE COOLING»(/lincoln/zephyr/us-2006-2006/remont/cooling-system-mechanical/#engine-cooling) .
104. Fill the power steering system. For additional information, refer to «STEERING SYSTEM-GENERAL INFORMATION»(/lincoln/zephyr/us-2006-2006/remont/manual-power-steering/#steering-system-general-information) .
105. Check the transaxle fluid and add fluid if necessary. For additional information, refer to the «TRANSMISSION FLUID DRAIN AND REFILL»(/lincoln/zephyr/us-2006-2006/remont/automatic-trans/#automatic-transmission-6-speed__transmission-fluid-drain-and-refill) procedure in .
106. Recharge 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) .

See also:
• ENGINE SYSTEM-GENERAL INFORMATION
• INTAKE AIR DISTRIBUTION & FILTERING - 3.0L (4V)
• FUEL SYSTEM-GENERAL INFORMATION
• BATTERY, MOUNTING AND CABLES
• COWL PANEL GRILLE
• STEERING SYSTEM-GENERAL INFORMATION
• JACKING & LIFTING
• ELECTRONIC ENGINE CONTROLS - 3.0L (4V)
• ENGINE COOLING
• EXHAUST SYSTEM
• CLIMATE CONTROL SYSTEM-GENERAL INFORMATION AND DIAGNOSTICS
• SUPPLEMENTAL RESTRAINT SYSTEM
• TRANSMISSION FLUID DRAIN AND REFILL
• UPPER INTAKE MANIFOLD
• CRANKSHAFT PULLEY
• CRANKSHAFT FRONT SEAL
• VALVE COVER - LH
• VALVE COVER - RH
• ENGINE MOUNT
• ENGINE FRONT COVER
• CAMSHAFT ROLLER FOLLOWER
• CYLINDER HEAD - RH
• CYLINDER HEAD - LH
• CAMSHAFTS - RH
• CAMSHAFTS - LH
• OIL PAN
• OIL PUMP SCREEN AND PICKUP TUBE
• ENGINE OIL PRESSURE (EOP) SWITCH