Ford 4.6L SOHC (2V) & 3.8L OHV Engine Service Manual

03-oo-1
GROUP
ENGINE 03
SECTIO N TITLE PAGE SECTION TITLE PAGE
DRIVE BELTS, ACCESSORY ................ .. .. ....... ... .... .... .03-G5- 1 FUEL CHARGING AND CONTROLS- 3.8L.. ....••.•••.••. 03-Q4A·1
ENGINE CONTROLS, ELECTRO NIC 03- 1 4-1
..•..•••••••••••••••••.•.... FUEL CHARGING AND CONTROLS- 4.6L
ENGINE COOLING 03.03-1
...........••..•••.••••.•••.••..•••••••......•...•••• (2V).........••.•.••............•••••••••••.•••....•••••••••••••••...•••• 03-Q4B-1
ENGINE EMISSION CO NTRO L 03-GB-1
••••..••.•••.••..•.................• IGNITION, ELECTRO NIC-3.8L •..••....•...•••••••••.•••••••• 03-G 7A-1
ENGINE, 3.8L 03-G 1A-1
••••.•••..••.••••••••••••••••••••.••••••••••.•.•...•..•..• IGNITIO N, ELECTRO NIC-4.6L (2V) .....•.•••••••••••••••.. 03.078-1
ENGINE, 4.6L (2V) 03-o 1 B-1
••••••••••••••••••••••..••........•.....••.•••••..• INTAKE AIR SYSTEM ••.•••••••••••.•••........••..••••••••••••••••••. 03· 1 2-1
ENGINE-SERVICE 03-Q0- 1
•••••••••••....•..••••••..••••••••••..•••••••••.•.. STARTING SYSTEM •••••.•...........•.••.••••.•••••••••••••.•••.••••• 03-o6-1
EVAPO RATIVE EMISSIO NS 03- 1 3-1
..••••••••••••••••••••••••••••.••••.....
SECTION 03-00 Engine-Service

SUBJECT PAGE SUBJECT PAGE
VEHICLE APPLICATION ••••..•••.••••..•••••••••••••.••••••••••••••• 03-Q0-2 SERVICE PROCEDURES (Cont'd.)
DESCRIPTION AND O PERATION Cyli nder Block ...............•••••..••••••••••••••.•.•.•.•••.•..••• oa-oo-11
Engine Identification •....•••.••••..••.••••••••••••••••..•........ 03-Go- 2 Cylinder Block Distortion •••••..••.••••••.••......•.•..•••..•• 03-Go-1&
Exhaust Em ission Control System .•..•••••••••.•••••••••••• 03-oo-3 Cylinder Heads •....•..•••......•....••••••••••.••••••••••••••••.•• 03-oo-30
Introduction .•••••••••••••.••...•.•.......••.••••••••••••..••.••••••.• 03-Go-2 4.6L Englne •••••••••.•.•..•...•.•••••••••••••••••••••••••••••• 03-Go-32
DIAGNOSIS AND TESTING 3.8L Engine .............•..•.•••••••.•••••...•...•.•.••••••••• 03-Go-32
Englne ••.••••••••...•..•...•.•.•••••.•••••••.•••••••••••••.••••.•........ 03-Q0- 3 Cylinder Leakage Detector ..•..••••••••••••••••••••....•••.••• 03-Go-8
Inspection and Verlflcatlon •.......•....•.....•••.•••••..••• 03-G0·3 Cylinder Walls, Reflnlshlng •••.........•......•••••••••••••••• 03-oo- 1 7
Sym ptom Chart ••.•••.••••••••••••...............••••..•...••..•• 03-G0-4 Cylinder Bore .••••••.•••••••••.•••.••••.•••••..•.••••••••••••••• 03-Go- 1 7
SERVICE PROCEDURES Cylinder Bore Diameter •...••....•••••.•••.•••••••••••••••• 03-oo- 18
Camshaft End Play •••••••....•.....•..••••.••..•••.•••.•••.•••••• 03-G0· 1 5 Cylinder Wall Honing ••••••••••••••...•...••.•••••••••••••••• 03-Go-18
Camshaft Lobe Lift .•••••••••••••••.•..•..••.....••.••••••••••••• 03-Go-13 Engine Block Plugs •.•••.•••••••••.•••••••••••••••....•••.••••••• 03-oo-19
Camshaft/Cylinder Head Journals •.....•.•............•. 03-Go-26 Engine Oil Consum ption, Excessive ••••••••••••••••••••• oa-oo- 1 0
t- Cam Lobe Lift
Cam Lobes
••••••••••••••••••••••••••••••••••••••.•••.••••••••
•••••••••••••••••••••••••••••••.••••.••••••••••••••••••
03-Go-27
03-Go- 27
Oi l Pressure Test
Engine Oil Leak s
••••••.•••..••••••.••••••••••.••••••••••••••••
...........•.•.•••••••.•••••••••••••••••...•••••••••
0 3-oo-12
03-00-8
r
:
Camshaft End Play
3.8L Engl ne
4.6L Englne
•...•.••••••••••.••.•••••••.•••.•••••••••••
•..............•..••••••.••..•••••••..••.••••••••••
••••..•••.••••••••••••••.•••••••••••••••••••••••.•.
03-Go-28
03-G0·28
03-oo- 28
Exhaust Manifold
Flywheel lnspection
•.••.•••.•••.•..••••......•..•.••••••••••••••••••
•••••••••••••••••••••••.•..•..••••.••••••••••
Hydraulic Valve Tappets or Hydraulic Roller

03-G0- 37
oa-oo-37
Camshaft Journal Diameters ••.••...•..••...••...••..... 03-G0- 27 Valve Tappets ••••.•••••••...•........•....•••••••••••••••••••••• oa-o0-28
Camshaft Journal 011 Clearance •.•.•••.••••••.•••.••.•• 03-oo- 27 Intak e Manifold •••••••••••••.•••.•••••••••••••••••••••••••.•••••••• oa-oo-37
4.6L Englne •................••••••••••.••..••••.••..•••••...•. 03-G0·27 Intake Manifold Vacuum Test .•••••••••••••••••••....•.•.••••• 0 3-oo-9
Camshaft Runout •••••••..•••••••.•••••••••.••.•••••.••••••.... 03-oo- 27 Leakage Polnts ••••••••.••••••••••••••••••••••••.•••••••••••••••••••• 03-00-8
Camshaft Sprocket •••.•••••••••••••••••••••.•••.•••••.•..••• 03-Go- 28 011 Leak and Valve Guide Seal Test ••••••••.••••.••••••••••• 03-o0-9
Cleaning •••••••••.••••.•••••••••.•••••••••.•.••••••••.•••••.•••••• 03.00-26 011 Pan ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• oa-oo -30
Inspection •••••.•••••••.•..•..•.......•.•.•••••.••••••••.••••••..• 03-G0-26 011 Pum p .••••......••..........••.••••••••..•.•••••••••••••••••••••••• 0 3-oo- 29
Compression Test •••••••••.•••••••••••••.•••••••••.•••.•.••••.•••• 03-oo-7 Pistons, Piston Pins and Piston Rings ••••.•••••••••••••• 03-Go- 22
Connecting Rod Side Clearance ••.•••••••••••.••••••••••.• 03-G0- 16 Piston Outer Diameter •••••••••••••••••••••••••••••••••••••• 03-oo- 25
Connecting Rods ••••••••••••.•••••••••••••••••••••••••••••••••••• 03-Go-26 Piston Pin Diameter •.•••••••••••••••••••••••••••••••••••••••• 03-oo- 28
Connecting Rod Bending Clearance •••••.••••••••••• 03-oo-26 Piston Pin Hole Diameter ..••.•.•.•.•.••.•.....•••••••••••• 03-oo- 25
Crank shaft ••••••••••••••••••.•.•..••••.•.•...•••••.•••••••••.••••••• 03-Go-2 1 Piston Pin-to-Piston Clearance ••••••••.•••••••••••••••• 03-oo- 25
Crank shaft End Play ••.•••.•••••••••.•••••••••••••.••.••••••• 03-oo-2 1 Piston Ring End Gap .........•••••••••••••••••••••••••••••••• 03-oo-25
Crank shaft Main Journal and Connecting Piston Ring-to-Groove Clearance •••••.•••••••••••••••• oa-oo-25
Rod Journals .•••••.....................••....•••••••••••.•••. 03-Go-22 Piston Rings •.••••••••••••••••••.....••••••••••.••••••••••••••.•• 03-oo- 25
Crankshaft Sprocket ..•...........•.••......••..•..••...•••• 03-Go-22 Positive Crankcase Ventilation (PCV) System ,
Crankshaft End Play •••••.••••••••••••••••••••••••••••••.••..••• 03-Go- 1 5 Closed·Type Oa-oo-6
•••••••••.••.•••••.•••.•..•.••••••••.•..•.••••.••.•••••
Crankshaft Main and Connecting Rod Pressure Regulator Valve Inspection ••••••••••••••••••••03-Go-30
Bearings ••.•••.••.....••....•..•..••••.•••.•••••••••••.••••••••••.03-oo-20 Push Rods ...•..••••••.••.•••••••••••••••••••••••••••••••••••••••••..03-G0- 38
Crank shaft Main or Connecting Rod Rocker Arm .•...•••••••••.•••••••••••••••••••••••••••••••••.••••.•••03-G0-38
Bearings- Fitting •••••.•••••••••••••••••••••••.••••••••••••..03-Go-20 Valve Train Analysls- Dynamlc •••••••.•••••••••••.••.••.••03-Go- 1 3
1997 Thunderbird, Cougar July 1996

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03-oo-2 Engine-Service 03-oo-2
SECTION 03-00 Engine-Service -

SERVICE PROCEDURES (Cont'd.) SERVICE PROCEDURES (Cont'd.)
Valve Train Analysis-Static (Engine Valve Seat Contact Width 03-oo- 34
•••••••••••••••.•••••••••••••••••
Off ) 03-oo- 1 2
.•••...•••••....••.••••••...•••••..••••••.•••.••••••••..•••••.•••• Valve Stem D iameter 03-oo- 3 5
••••••••••••••..••••••••••••••••••••••••
Valves, Inspection •••••••••••••••••••••••••.•••••••••••••••••••••03.00·33 SPECIFICATIONS 03-Go-37

•••••••••••••••••••••••••••••••••••••••.••••••••••••
Valve Guide Inner Diameter ••••••••••••••••••••••••••••.•03.00 -35 SPECIAL SERVICE TOOLS/EQUIPMENT 03-Go-37
••••••••••••••••••
VEHICLE APPLICATION • ignition system

Thunderbird, Cougar • emissions system
• exhaust system
When performing tests, adjustment or service to the
DESCRIPTION AND OPERATION engine fuel system or ignition system, it is essential to
follow the procedures and specifications in the
Introduction appropriate section in this manual and the Powertrain
Control / Emissions Diagnosis Manual. 1
WARNING: TO AVOID THE POSSIBILITY OF
PERSONAL INJURY OR DAMAGE TO THE Make sure that the following engine components are
VEHICLE, DO NOT OPERATE THE ENGINE WITH not serviceable before replacing damaged or worn
THE HOOD ( 166 1 2) OPEN UNTIL THE FAN BLADE engine components:
(8600) HAS FIRST BEEN EXAMINED FOR • crankshaft (6303)
POSSIBLE CRACKS AND SEPARATION.
• cylinder heads (6049)
This section covers the following information:
• valve guides
• service procedures
• intake valve (6507)
• diagnosis and testing
• exhaust valve (6505)
• cleaning I inspection procedures • camshafts (6250)
Refer to Section 03-Q1 A (3.8L) or Section 03-Q 1 8
• cylinder blocks (60 1 0)
(4.6L) for the following:
• removal
• disassembly
Engine Identification
• assembly
Vehicle Certification Label
• installation
The vehicle certification label, mounted on the LH front
• adjustment procedures
door lock face panel, provides the following
-
• specifications informstion:
These engines incorporate: • engine identification
• closed-type positive crankcase ventilation (PCV) • an engine code (letter or number) which can be
system. found in the engine identification chart to determine
• exhaust emission control system. the engine type and size
All engine I emission control systems are covered in An engine identification label is also attached to the
the Powertrain Control / Emissions Diagnosis Manual. 1 engine. The symbol code on the identification label
identifies each engine for determining parts usage; for
To maintain the required exhaust emission levels, the instance, engine displacement and model year.
following components must be kept in good operating
condition and meet recommended adjustment Engine label information is located in Section 03-Q 1 A
specifications: (3.8L) or Section 03-Q1 8 (4.6L).
• engine
• fuel system
1 Can be purchased as a separate item.

DESCRIPTION AND OPERATION (Continued)
Vehicle Certification Label Always refer to this label when:
I 1FABP43F9U3100001 I • replacement parts are required.

VEHICLE IDENTIFICATION NUMBER • checking engine calibrations.
MFD. BY FORD MOTOR CO. IN U.S.A.

DATE' 5/116 1111111' 5307 Ll- Z4ZS KG
F-T 1_, l114 ll REAR GAIIII' 2113 Ll
�� G
Exhaust Emission Control System
THII n•cLE co•- T8 ALL ""LICAILE FEDERAL MOTDI VE E SAFETY MD
IIIWEI nMDAIDit• EFFECT a• THE DATE DF MA•UFACTURE- A..VE.
HICL The Powertrain Control I Emissions Diagnosis Manual2
covers the following information of the exhaust
VEH.IDEIIT. •a. 1
TYl'£ PASSUGER
FAB�Pl43F9-U"3100001 1�11211
Rl1tt
emission control devices used on these engines:
• description and operation and
3H 412450
EXTiftiCNI MPIT COLO I
.,...
oaov I VII I "'/Dil. I INT.T� I AJC I • I s I AX I TR
• diagnosis and testing.
54IC VI JA" G8 ' " 2 8 8 XBIBB
Refer to Section 03-08 or Section 03- 14 for Removal
ENGINE corfE
(8th CHARACTER)
� DEL
YEAR
and Installation procedures.
AA0104-A
DIAGNOSIS AND TESTING
Engine parts often differ within a cubic inch
displacement family. Verification of identification
codes will ensure that the proper parts are obtained. Engine
The codes contain all pertinent information relating to
the following: Inspection and Verification
1. Verify the customer's concern by operating the
• dates engine to duplicate the condition.
• optional equipment 2. Inspect to determine if any of the following
• revisions mechanical concerns apply:
The Ford Master Parts Catalog contains a complete VISUAL INSPECTION CHART
listing of the codes and their application.
Mechanical
Emission Calibration Number Label • Engine coolant leaks
The emission calibration number label is located on the • Engine oil leaks
LH side door or LH door post pillar. It identifies the • Damaged and I or severely worn pads
following: • Loose mounting bolts, studs and nuts
• engine calibration number 3. If inspection reveals obvious concerns that can

be readily identified, service as required.
• revision level
4. If the concerns remain after the inspection,
These numbers are used to determine if parts are determine the symptoms and go to Symptom
unique to specific engines. Chart.
Emission Calibration Label
ETALONNAGE
,
CALl BRACI ON
7·25F-ROO ESAE -6E061- AAA
' I �
CALlBAATION
REVISION NUMBER
AA0227-A
2 Can be purchased as a separate 1tem.

03-oo-4 Engine-Service
DIAGNOSIS AND TESTING (Continued)
Symptom Chart
ENGINE DIAGNOSIS
Condition Possible Source Action
• Difficult Starting • Damaged starting system . • REFER to Section 03-06.
• Damaged charger system I • REFER to Section 14-00.
battery.
• Damaged fuel system. • REFER to the Powertrain
Control/ Emissions Diagnosis
Manual3•
• Damaged ignition system. • REFER to the Powertrain
Control / Emissions Diagnosis
Manual3•
• Burnt valve. • REPLACE valve .
• Worn piston. • REPLACE piston .
• Worn piston ring(s). • REPLACE piston ring(s) .
• Worn cylinder. • SERVICE or REPLACE cylinder
blocks.
• Damaged cylinder head gasket . • REPLACE cylinder head gasket.
• Poor Idling • Damaged fuel system. • REFER to the Powertrain
• Incorrect cam timing. Control / Emissions Diagnosis
Manual3•
Manual3•
• Damaged hydraulic valve tappet . • REPLACE hydraulic valve tappet.
• Worn valve stem guide . • REPLACE valve stem guide.
• Improper valve-to-valve seat • REPLACE valve and I or valve seat.
contact.
• Damaged cylinder head gasket. • REPLACE cylinder head gasket .
• Leaking intake manifold gasket . • REPLACE intake manifold gasket.
• Abnormal Combustion • Damaged fuel system. • REFER to the Powertrain
• Restricted, plugged induction Control/ Emissions Diagnosis
system. Manual3•
Manual3•
• Damaged hydraulic valve tappet. • REPLACE hydraulic valve tappet.
• Worn valve stem guide. • REPLACE valve stem guide.
• Burnt or sticking valve . • SERVICE or REPLACE valve.
• Weak or broken valve spring . • REPLACE valve spring.
• Carbon accumulation in • ELIMINATE carbon buildup.
combustion chamber.
• Leaking intake manifold gasket. • REPLACE intake manifold gasket.
• Excessive Oil Consumption • Leaking oil . • SERVICE oil leakage.
• Plugged or restricted air intake • SERVICE intake air system as
system. required.
• Worn piston ring groove. • REPLACE piston .
• Sticking piston ring(s). • SERVICE or REPLACE piston
ring(s).
• Worn piston or cylinder. • SERVICE or replace piston or
cylinder blocks.
• Worn valve stem seal. • REPLACE valve stem seal.
• Worn valve stem or valve guide. • REPLACE valve and guide .

03-oo-5 Engine-Service 03·00·5
ENGINE DIAGNOSIS (Continued)

• Engine Noise • Damaged cooling system. • REFER to Section 03-03.
• Damaged fuel system. • REFER to the Powertrain
Control I Emissions Diagnosis
Manual4•
• Leaking exhaust system. • REFER to Section 09-00.
• Improper drive belt tension. • REFER to Section 03-05.
• Damaged generator bearing. • REFER to Section 14-02 .
• Damaged water pump bearing. • REFER to Section 03-03.
• Damaged exhaust gas • REFER to the Powertrain
recirculation (EGR) system. Control I Emissions Diagnosis
Manual4•
• Excessive main bearing oil • REPLACE crankshaft main bearing
clearance. and I or crankshaft.
• Seized or heat damaged • REPLACE crankshaft main bearing
crankshaft main bearing. and I or crankshaft.
• Excessive crankshaft end play. • REPLACE crankshaft thrust
washer (if equipped), crankshaft
thrust main bearing and I or
crankshaft.
• Excessive connecting rod bearing • REPLACE connecting rod bearing,
oil clearance. connecting rod and I or crankshaft.
• Heat damaged connecting rod • REPLACE connecting rod bearing
bearing. and I or crankshaft.
• Worn cylinder. • SERVICE or REPLACE cylinder
blocks.
• REPLACE connecting rod bushing .
• Worn piston or piston pin. • REPLACE piston or piston pin .
• Damaged piston ring(s). • REPLACE piston ring(s) .
• Bent connecting rod. • REPLACE connecting rod .
• Damaged valve tappet. • REPLACE valve tappet.
• Excessive hydraulic valve tappet • ADJUST clearance or REPLACE
clearance. hydraulic valve tappet guide.
• Broken valve spring. • REPLACE valve spring .
• Excessive valve guide clearance . • SERVICE clearance or REPLACE
valve guide I stem.
• Loose timing chain. • REPLACE timing chain.
• Insufficient Power • Damaged fuel system. • REFER to the Powertrain
Manual4•
Manual4•
• Slipping transmission. • REFER to Section 07-01 .
• Dragging brakes . • REFER to Section 06-00.
• Incorrect tire size . • REFER to Section 04-04.
• Restricted exhaust system. • REFER to Section 09-00.
• Damaged hydraulic valve tappet. • REPLACE hydraulic valve tappet.
• Damaged hydraulic valve tappet • REPLACE hydraulic tappet guide.
guide.
• Compression leakage at valve • SERVICE or REPLACE valve, valve
seat. seat and I or cylinder head.
• Seized valve stem . • REPLACE valve stem.
• Weak or broken valve spring . • REPLACE valve spring.
• Damaged cylinder head gasket. • REPLACE cylinder head gasket.
• Cracked or distorted cylinder • REPLACE cylinder head.
head.
• Damaged, worn or sticking piston • SERVICE or REPLACE piston
ring(s). ring(s).
• Worn or damaged piston. • REPLACE piston.

03-0o-6 Engine-Service 03-oo-6
SERVICE PROCEDURES
Positive Crankcase Ventilation (PCV) 3. Run engine for 15 minutes. Stop engine and
System, Closed-Type inspect all seal and gasket areas for leaks using
Rotunda Oil Leak Detector 1 64-R0756 or
CAUTION: The removal of the positive crankcase equivalent. A clear bright yellow or orange area
ventilation (PCV) system from the engine will will identify leak. For extremely small leaks,
adversely affect the fuel economy and engine several hours may be required for the leak to
ventilation as well as shorten engine life. appear.
A malfunctioning closed positive crankcase ventilation 4. If necessary, pressurize main oil gallery system
system may be indicated by loping or rough engine to locate leaks due to improperly sealed, loose or
idle. Do not compensate for this condition by cocked plugs, If flywheel bolts leak oil, look for
disconnecting the crankcase ventilation system and sealer on threads.
making an idle speed adjustment. To determine
whether the loping or rough idle condition is caused by 5. Service all leaks as required.
a malfunctioning crankcase ventilation{PCV) system, Pressure Method
refer to the Powertrain Control I Emissions Diagnosis
Manual. 5 The crankcase can be pressurized to locate oil leaks.
The following materials are required to fabricate the
tool to be used:
• air supply and air hose
Engine Oil Leaks
• air pressure gauge that registers pressure in 4 kPa
NOTE: When diagnosing engine oil leaks, the source { 1 psi) increments
and location of the leak must be positively identified
• air line shut-off valve
prior to service.
• appropriate fittings to attach above parts to oil fill,
The following procedure is very effective and requires
PCV grommet hole and crankcase ventilation tube
only a minimum of equipment. Prior to using this
{6758)
procedure, clean the cylinder blocks{60 1 0), cylinder
heads (6049), valve covers{6582), oil pan{6675) and • appropriate plugs to seal any openings leading to
flywheel{6375) with a suitable solvent to remove all crankcase
traces of oil. • a solution of liquid detergent and water to be applied
Use Rotunda 12 Volt Master UV Diagnostic Kit with a suitable applicator such as a squirt bottle or
164-R0756 or equivalent to perform the following brush
procedure for oil leak diagnosis. Fabricate the air supply hose to include the air line
shutoff valve and the appropriate adapter to permit
the air to enter the engine through the crankcase
ventilation tube. Fabricate the air pressure gauge to a
suitable adapter for installation on the engine at the oil
filler opening.
Testing Procedure
12 VOLT MASTER 1. Open air supply valve until pressure gauge
UV DIAGNOSTIC KIT
164- R0756 maintains 34 kPa{5 psi).
2. Inspect sealed and I or gasketed areas for leaks
by performing Snoop leak detector or applying a
solution of liquid detergent and water over areas
for formation of bubbles which indicates leakage.
AA0873-A
Fluorescent Oil Additive Method Leakage Points
1. Clean engine with a suitable solvent to remove all Examine the following areas for oil leakage:
traces of oil.
Underhood
2. Drain engine oil crankcase and refill with
recommended oil, premixed with Rotunda • valve cover gaskets {6584)
Fluorescent Oil Additive 1 64-R3705 or equivalent
• intake manifold gaskets{946 1 )
meeting Ford specification ESE-M99C 103-A.
Use a minimum 1 4.8 ml {0.5 ounce) to a maximum • cylinder head gaskets{605 1)
29.6 ml{ 1 ounce) of fluorescent additive to all • oil bypass filter{67 1 4)
engines. If oil is not premixed, fluorescent additive
must first be added to crankcase. • oil filter adapter{688 1)
• engine front cover{60 1 9)
• oil pump and filter body{6603) {3.8L engine)

--- ...
SERVICE PROCEDURES (Continued)
• distributor 0-ring With Transmission and Flywheel Removed

• oil level indicator tube connection NOTE: Air leakage in area around a crankshaft rear oil
• oil pressure sensor (9278) seal does not necessarily indicate a crankshaft rear oil
seal leak. However, if no other cause can be found for
Under Engine-With Vehicle on Hoist oil leakage, assume that crankshaft rear oil seal is the
cause of the oil leak.
• oil pan gaskets (67 1 0) (4.6L engine)
NOTE: Light foaming equally around valve cover bolts
• oil pan sealer (3.8L engine) and crankshaft seals is not detrimental and no
• oil pan rear seal (6723) (3.8L engine) corrections are required.
• engine front cover gasket • crankshaft rear oil seal
• crankshaft front seal (6700) • rear main bearing cap parting line
• crankshaft rear oil seal (670 1) • rear main bearing cap and seals
• ·crankshaft main bearing cap side bolts • flywheel mounting bolt holes (with flywheel (6375)
• oil pump and filter body (3.8L engine) installed)
• camshaft rear bearing covers (6266) and or pipe
plugs at the end of oil passages
Oil leaks at crimped seams in sheet metal parts and
cracks in cast or stamped parts can be detected when
pressurizing the crankcase.
Compression Test 3. Install an auxiliary starter switch in starting

circuit. With ignition switch in the OFF position,
Compression Gauge Check and using auxiliary starter switch, crank engine a
1. Make sure oil in crankcase is of the correct minimum of five compression strokes and record
viscosity and at proper level and battery ( 1 0655) highest reading. Note the approximate number of
is properly charged. Operate vehicle until engine compression strokes required to obtain the
is at normal operating temperature. Turn ignition highest reading.
switch to the OFF position, then remove all spark 4. Repeat test on each cylinder, cranking the engine
plugs (1 2405). approximately the same number of compression
2. Install a compression gauge such as Rotunda strokes.
Compression Tester 0 1 4-Q0707 or equivalent in
No. 1 cylinder. Test Results
The indicated compression pressures are considered
within specification if the lowest reading cylinder is
within 75 percent of the highest reading. Refer to the
Compression Pressure Limit Chart.
COMP RESSION P RESSURE LIMIT CHART

Maximum Minimum Maximum Minimum Maximum Minimum Maximum Minimum
PSI PSI PSI PSI PSI PSI PSI PSI
924 kPa 696 kPa 1 1 3 1 kPa 848 kPa 1 338 kPa 1000 kPa 1 544 kPa 1 1 58 kPa
( 1 34 PSI) ( 1 0 1 PSI) ( 1 64 PSI) ( 1 2 3 PSI) ( 1 94 PSI) ( 1 46 PSI) (224 PSI) ( 168 PSI)
938 kPa 703 kPa 1 145 kPa 855 kPa 1 35 1 kPa 1 0 1 4 kPa 1558 kPa 1 165 kPa
( 1 36 PSI) ( 1 02 PSI) ( 1 66 PSI) ( 1 24 PSI) ( 1 96 PSI) ( 1 47 PSI) (226 PSI) ( 1 69 PSI)
952 kPa 7 1 7 kPa 1 158 kPa 869 kPa 1 365 kPa 1020 kPa 1 572 kPa 1 1 79 kPa
( 1 38 PSI) ( 1 04 PSI) ( 1 68 PSI) ( 1 26 PSI) ( 1 98 PSI) ( 1 48 PSI) (228 PSI) ( 1 7 1 PSI)
965 kPa 724kPa 1 172 kPa 876 kPa 1 379 kPa 1034kPa 1 586 kPa 1 186 kPa
( 1 40 PSI) ( 1 06 PSI) ( 1 70 PSI) ( 1 27 PSI) (200 PSI) ( 1 50 PSI) (230 PSI) ( 1 72 PSI)
979 kPa 738kPa 1 186 kPa 889 kPa 1 303 kPa 1041 kPa 1600kPa 1 200 kPa
( 1 42 PSI) ( 1 07 PSI) ( 1 72 PSI) ( 1 29 PSI) (202 PSI) ( 1 5 1 PSI) (232 PSI) ( 1 74 PSI)
933 kPa 745 kPa 1 200 kPa 903kPa 1 407 kPa 1055 kPa 1055 kPa 1 207 kPa
( 144 PSI) ( 1 09 PSI) ( 1 74 PSI) ( 1 3 1 PSI) (204 PSI) ( 1 53 PSI) ( 1 53 PSI) ( 1 75 PSI)
1007 kPa 758kPa 1 2 1 4 kPa 9 10 kPa 1 420 kPa 1 062 kPa 1627 kPa 1 220 kPa
( 1 46PSI) ( 1 1 0 PSI) ( 1 76 PSI) ( 1 32 PSI) (206 PSI) ( 1 54 PSI) ( 1 54 PSI) ( 1 7 7 PSI)
1020kPa 765 kPa 1227 kPa 9 1 7 kPa 1 434 kPa 1075 kPa 1641 kPa 1 227 kPa
( 1 48 PSI) ( 1 1 1 PSI) ( 1 78 PSI) ( 1 33 PSI) (208 PSI) ( 1 56 PSI) (238PSI) ( 1 78 PSI)
(Continued)
1997 Thunderbird, Cougar July 1 996

COMP RESSION P RESSURE LIMIT CHART (Cont'd)

Maximum Minimum Maximum Minimum Maximum Minimum Maximum Minimum
PSI PSI PSI PSI PSI PSI PSI PSI
1034 kPa 779 kPa 1241 kPa 931 kPa 1 448 kPa 1083 kPa 1 655 kPa 1 24 1 kPa
( 1 50 PSI) ( 1 1 3 PSI) ( 1 8 PSI) ( 1 35 PSI) (2 10 PSI) ( 1 57 PSI) (240 PSI) ( 1 80 PSI)
1048kPa 786 kPa 1255 kPa 936 kPa 1462 kPa 1 089 kPa 1669 kPa 1 248 kPa
( 1 52 PSI) ( 1 14 PSI) ( 1 82 PSI) ( 1 36 PSI) (2 1 2 PSI) ( 1 58 PSI) (242 PSI) ( 1 8 1 PSI)
1062 kPa 793 kPa 1 269 kPa 952 kPa 1476 kPa 1 103 kPa 1682 kPa 1262 kPa
( 1 54 PSI) ( 1 1 5 PSI) ( 1 84 PSI) ( 1 38 PSI) (2 1 4 PSI) ( 1 60 PSI) (244 PSI) ( 1 83 PSI)
1076 kPa 807 kPa 1282 kPa 965 kPa 1 489 kPa 1 1 1 1 kPa 1 696 kPa 1 269 kPa
( 1 56 PSI) ( 1 1 7 PSI) ( 1 86 PSI) ( 1 40 PSI) (2 1 6 PSI) ( 1 62 PSI) (246 PSI) ( 1 84 PSI)
1089 kPa 8 1 4 kPa 1296 kPa 972 kPa 1 503 kPa 1 124 kPa 1 7 1 0 kPa 1 282 kPa
( 1 58 PSI) ( 1 18 PSI) ( 1 88 PSI) ( 1 4 1 PSI) (2 1 8 PSI) ( 1 63 PSI) (248 PSI) ( 1 86 PSI)
1 103 kPa 827 kPa 1 31 0 kPa 75=982 kPa 1 5 1 7 kPa 11 38 kPa 1 724 kPa 1 293 kPa
( 160 PSI) ( 1 20 PSI) ( 1 90 PSI) ( 142 PSI) (220 PSI) ( 1 65 PSI) (250 PSI) ( 1 87 PSI)
1 1 10 kPa 834kPa 1 324 kPa 993 kPa 1 631 kPa 1 223.25 kPa
( 1 6 1 PSI) ( 1 2 1 PSI) ( 1 92 PSI) ( 1 44 PSI) (222 PSI) ( 1 66 PSI)
If one or more cylinders reads low, squirt Example Readings

approximately one tablespoon of clean engine oil If, after checking the compression pressures in all
meeting Ford specification WSS-M2C 1 53-F on top of cylinders, the highest reading obtained was 1 35 1 kPa
the pistons (6 1 08) in the low-reading cylinders. ( 1 96 psi) and the lowest pressure reading was 1 069
Repeat compression pressure check on these kPa ( 1 55 psi), the engine is within specification and
cylinders. the compression is satisfactory.
Compression Readings-Interpreting
1. If compression improves considerably, piston
rings are faulty.
Cylinder Leakage Detector
2. If compression does not improve, valves are
sticking or seating poorly. When a cylinder produces a low reading, the use of
Rotunda Pressurization Kit 0 1 4-Q0705 or equivalent
3. If two adjacent cylinders indicate low will be helpful in pinpointing the exact cause.
compression pressures and squirting oil on piston
does not increase compression, the head gasket The leakage detector is inserted in the spark plug
(605 1 ) may be leaking between cylinders. Engine hole, the piston (6 1 08) is brought up to dead center on
oil and I or coolant in cylinders cou!d result from the compression stroke and compressed air is
this condition. admitted.
Use the Compression Pressure Limit Chart when Once the combustion chamber is pressurized, a
checking cylinder compression so that the lowest special gauge will read the percentage of leakage.
reading number is 75 percent of the highest Leakage exceeding 20 percent is excessive.
reading.

03-oo-9 Engine-Service 03-00-9
While the air pressure is retained in the cylinder, listen 3. Using a solution of liquid soap and water, brush
for the hiss of escaping air. A leak by the intake valve the solution along the gasket sealing surfaces
{6507) will be heard in the throttle body{9E926). A and bearing seals. Look for bubbles or foam.
leak by the exhaust valve{6505) can be heard at the 4. Remove the spark plugs{ 1 2405) and rotate the
tailpipe. Leakage past the piston rings will be audible crankshaft{6303) slowly with a wrench. Check
at the positive crankcase ventilation{PCV) for large amounts of air escaping into the
connection. Hair is passing through a blown head cylinders as each intake valve{6507) and
gasket{605 1) to an adjacent cylinder, the noise will be exhaust valve{6505) opens.
evident at the spark plug hole of the cylinder into which
the air is leaking. Cracks in the cylinder blocks{60 1 0) 5. The spark plugs on the leaking cylinders will
or gasket leakage into the cooling system may be probably show deposits of burned oil.
detected by a stream of bubbles in the radiator
{8005).
Intake Manifold Vacuum Test

Bring the engine to normal operating temperature.
Connect Rotunda Vacuum I Pressure Tester
1 64-R0253 or equivalent to the intake manifold
{9424). Run the engine at the specified idle speed.
The vacuum gauge should read between 5 1 ·74 kPa
{ 1 5-22 in-Hg) depending upon the engine condition and
the altitude at which the test is performed. Subtract
4.0 1 93 kPa{ 1 in-Hg) from the specified reading for
every 304.8 m{ 1 ,000 feet) of elevation above sea
level.
The reading should be quite steady. Hnecessary,
adjust the gauge damper control {where used) if the
needle is fluttering rapidly. Adjust damper until needle
moves easily without excessive flutter.
Vacuum Gauge Readings-Interpretation
A careful study of the vacuum gauge reading while the
engine is idling will help pinpoint trouble areas. Always
conduct other appropriate tests before arriving at a
final diagnostic decision. Vacuum gauge readings,
although helpful, must be interpreted carefully.
ROTUNDA ENGINE CYLINDER LEAK Most vacuum gauges have a normal band indicated on
DETECTION/ AIR P RESS URIZ ATION KIT the gauge face.
014-00 705
A23313·B ROTUNDA VACUUM/PRESSURE TESTER
164-R0253
Oil Leak and Valve Guide Seal Test

The cylinder leakage detector tests for engine oil
leaks and checks the valve stem seals{657 1 ) for
leakage.
1. Plug all crankcase openings except the one used
for connecting the leakage detector.
2. Connect the detector to a crankcase opening{an
oil level indicator tube{6754) is convenient).
Adjust the air pressure to approximately 34 kPa AA0197-A
{5 psi).

03-oo- 10 Engine-Service 03-oo- 1 0
The following are potential gauge readings. Some are 8. WORN VALVE GUIDES: When the needle
normal; others should be investigated further. oscillates (swings back and forth), over about a
13 kPa (4 in-Hg) range at idle speed the valve
guides could be worn. As engine speed
increases, needle will become steady if guides
are responsible.
9. WEAK VALVE SPRINGS: When the needle
oscillation becomes more violent as engine rpm is
increased, weak valve springs (6513) are
2 3 4 indicated. The reading at idle could be relatively
steady.
10. LATE VALVE TIMING: A steady but low reading
could be caused by late valve timing.
11. IGNITION TIMING RETARDING: Retarded ignition
5 6 7 8 timing will produce a steady but somewhat low
reading.
12. INSUFFICIENT SPARK PLUG GAP: When spark
plugs (12405) are gapped too close, a regular,
small pulsation of the needle can occur.
9 10 12 13. INTAKE LEAK: A low, steady reading which can
be caused by an intake manifold or throttle body
gasket leak.
14. BLOWN HEAD GASKET: A regular drop of fair
magnitude can be caused by a blown head
gasket (6051) or warped cylinder
13 14 15 head-to-cylinder block surface.
15. RESTRICTED EXHAUST SYSTEM: When the
A23315-A engine is first started and is idled, the reading
may be normal but as the engine rpm is
1. NORMAL READING: Needle between 51-7 4 kPa increased, the back pressure caused by a
(15-22 in-Hg) and holding steady. clogged muffler, kinked tailpipe or other
2. NORMAL READING DURING RAPID concerns, will cause the needle to slowly drop to
ACCELERATION AND DECELERATION: When 0 kPa (0 in-Hg). The needle then may slowly rise.
engine is rapidly accelerated (dotted needle), Excessive exhaust clogging will cause the needle
needle will drop to a low (not to zero) reading. to drop to a low point even if the engine is only
When throttle is suddenly released, the needle idling.
will snap back up to a higher than normal figure. When vacuum leaks are indicated, search out and
3. NORMAL FOR HIGH-LIFT CAMSHAFT WITH correct the cause. Excess air leaking into the
LARGE OVERLAP: Needle will register as low as system will upset the fuel mixture and cause
51 kPa (15 in-Hg) but will be relatively steady. concerns such as rough idle, missing on
Some oscillation is normal. acceleration or burned valves. If the leak exists in
an accessory unit such as the power brake
4. WORN RINGS OR DILUTED OIL: When engine is booster (2005), the unit will not function correctly.
accelerated (dotted needle), needle drops to 0 ALWAYS FIX VACUUM LEAKS.
kPa (0 in-Hg). Upon deceleration, needle runs
slightly above 7 4 kPa (22 in-Hg).
5. STICKING VALVES: When the needle (dotted)
remains steady at a normal vacuum but Engine Oil Consumption, Excessive
occasionally flicks (sharp, fast movement) down
and back about 13 kPa (4 in-Hg), one or more The amount of oil an engine uses will vary with the way
valves may be sticking. the vehicle is driven in addition to normal
engine-to-engine variation. This is especially true
6. BURNED OR WARPED VALVES: A regular, during the first 16,100 km (10,000 miles) when a new
evenly-spaced, downscale flicking of the needle engine is being broken in or until certain internal engine
indicates one or more burned or warped valves. components become conditioned. Vehicles used in
Insufficient hydraulic valve tappet clearance will heavy-duty operation may use more oil. The following
also cause this reaction. are examples of heavy-duty operation:
7. POOR VALVE SEATING: A small but regular
• trailer towing applications
downscale flicking can mean one or more valves
are not seating. • severe loading applications
• sustained high speed operation

03-oo- 1 1 Engine-Service 03-oo-1 1
Engines need oil to lubricate the following internal 1. NOTE: Oil use is normally greater during the first
components: 16,100 km (10,000 miles) of service. As mileage
increases, oil use generally decreases. Vehicles
• cylinder block cylinder walls in normal service should get at least 1,450 km
• pistons (6108) and piston rings (900 miles) per liter (quart) after 16,100 km
(10,000 miles) of service. High speed driving,
• intake and exhaust valve stems
towing, high ambient temperature and other
• intake and exhaust valve guides factors may result in greater oil use.
• all internal engine components Define excessive oil consumption, such as the
When the pistons move downward, a thin film of oil is number of miles driven per liter (quart) of oil. Also
left on the cylinder walls. The thin film of oil is burned determine owner's driving habits, such as
away on the firing stroke during combustion. If an sustained high speed operation, towing,
engine burned a drop of oil during each firing stroke, oil extended idle and other considerations.
consumption would be about one liter (quart) for every 2. Verity engine has no external oil leak as
kilometer (mile) traveled. Fortunately, modern engines described under Engine Oil Leaks.
use much less oil than this example. However, even
3. Verity engine has correct oil level dipstick.
efficient engines will use some oil or they would quickly
wear out. As the vehicle is operated, some oil is also 4. Verity that the engine is NOT being run in an
drawn into the combustion chambers past the intake overfilled condition. Check the oil level at least
and exhaust valve stem seals (6571) and burned. five minutes after a hot shutdown with the vehicle
parked on a level surface. In no case should the
Many different conditions can affect oil consumption
level be above the top of cross-hatch area and
rates. The following is a partial list of these items:
"F" in FULL. If significantly overfilled, perform
• engine size steps 5a through 5d.
• operator driving habits 5. Perform an oil consumption test:
• ambient temperature a. Drain engine oil, remove oil bypass filter
(6714) and refill with one liter (quart) less
• quality and viscosity of the oil than the recommended amount.
Operation under varying conditions can frequently be b. Run the engine for three minutes (10 minutes
misleading. A vehicle that has been run for several if cold), and allow oil to drain for at least five
thousand miles on short trips or below-freezing minutes with vehicle on level surface.
ambient temperatures may have consumed a
"normal" amount of oil. However, when checking the c. Remove oil level dipstick and wipe clean. (Do
engine oil level, it may measure up to the full mark on not wipe with anything contaminated with
the oil level dipstick (6750) due to dilution silicone compounds.) Reinstall oil level
(condensation and fuel) in the engine crankcase. The dipstick being sure to seat the oil level
vehicle then might be driven at high speeds on the dipstick firmly in the oil level indicator tube
highway where the condensation and fuel boil off. The (6754). Remove the oil level dipstick and
next time the engine oil is checked, it may appear that draw a mark on the back (unmarked) surface
a liter (quart) of oil was used in about 160 km (100 at the indicated oil level. (This level should be
miles). This perceived 160 km (100 miles) per liter about the same as the ADD mark on the face
(quart) oil consumption rate causes customer concern of the oil level dipstick.)
even though the actual overall oil consumption rate is d. Add one liter (quart) of oil. Restart the engine
about 2400 km (1500 miles) per liter (quart). and allow to idle for at least two minutes.
Make sure the selected engine oil meets Ford Shut off the engine and allow oil to drain back
specification WSS-M2C153-F and the recommended for at least five minutes. Mark the oil level
API performance category "SG" and SAE viscosity dipstick, using the procedure above. (This
grade as shown in the vehicle Owner Guide. It is also level may range from slightly below the top of
important that the engine oil is changed at the intervals the cross-hatched area to slightly below the
specified for the typical operating conditions. Refer to letter "F" in FULL.)
Section OQ-03. e. Record vehicle's mileage.
Oil Consumption Test f. Instruct the owner to drive the vehicle as
The following diagnostic procedure is intended to be usual and:
used to determine the source of excessive internal oil (1) Check the oil level regularly at intervals
consumption: of 160 to 240 km (100-150 miles).
(2) Return to the service point when the oil
level drops below the lower (ADD)
mark on the oil level dipstick.
(3) Add only full liters (quarts) of the same
oil in an emergency. Note the mileage
at which the oil is added.

03-0G- 12 Engine-Service 03-0G- 1 2
g. Check the oil level under the same conditions 1. Disconnect and remove the oil pressure sensor
and at the same location as in Steps c and d. (9278} from the engine.
(1} Measure the distance from the oil level 2. Connect an Engine Oil Pressure Gauge
to the UPPER mark on the oil level T73L-660Q-A and Transmission Test Adapter
dipstick and record. D87C-77000-A or equivalent to the oil pressure
(2} Measure the distance between the two sensor oil galley port.
scribe marks and record. 3. Run the engine until normal operating temperature
(3} Divide the first measurement by the is reached.
second. 4. Run the engine at 3000 rpm and record the gauge
(4} Divide the distance driven during the oil reading.
test by the result. This quantity is the 5. The oil pressure should be within specifications
approximate oil consumption rate as described in Section 03-Q1A (3.8L} or Section
kilometers per liter or in miles per 03-D1B (4.6L}.
quart. 6. If the pressure is not within specification, check
h. If the oil consumption rate is unacceptable, the following possible sources:
go toStep 6.
• insufficient oil
6. Check the positive crankcase ventilation (PCV}
system. Make sure system is not plugged. • oil leakage
7. Check for plugged oil drain-back holes in cylinder • worn or damaged oil pump
heads (6049} and cylinder blocks (6010}. • oil pump screen cover and tube (6622}
8. H the condition still exists after performing the • excessive main bearing clearance
above tests, go to Step 9.
• excessive connecting rod bearing clearance
9. Perform a cylinder compression test as
described, and I or perform a cylinder leak
detection test with Rotunda Pressurization Kit
014-Q0705 or equivalent. This can help Valve Train Analysis-Static (Engine Off)
determine the source of oil consumption such as
valves, piston rings or other areas. Valve Cover Removed
10. NOTE: After determining if worn parts should be NOTE: Refer to Section 03-Q 1A (3.8L} or Section
replaced, make sure correct replacement parts 03-Q18 (4.6L} for the removal and installation of the
are used. valve covers (6582}.
Check valve guides for excessive guide Check for damaged and I or severely worn parts and
clearance. REPLACE all valve stem seals after correct assembly. Make sure correct parts are used
verifying valve guide clearance. with the static engine analysis as follows.
11. Worn or damaged internal engine components Rocker Arm
can cause excessive oil consumption. Small
deposits of oil on tip of spark plugs (12405} can • Check for loose mounting bolts, studs and nuts.
be a clue to internal oil consumption. If internal oil • Check for plugged oil feed in the rocker arms
consumption still persists, proceed as follows: (6564} or cylind�r head (6049}.
a. Remove engine from vehicle and place it on
an engine work stand. Remove intake
Rocker Arms/Hydraulic Valve
manifolds (9424}, cylinder heads, oil pan Tappets/Hydraulic Lash Adjusters, Overhead
(6675} and oil pump (6600}. Refer to Section Camshaft
03-Q1A (3.8L} or Section 03-D18 (4.6L}. • Check for loose mounting bolts, studs and nuts.
b. Check piston ring clearance, ring gap and • Check for plugged oil feed in the rocker arms or
ring orientation. Service as required. cylinder heads.
c. Check for excessive bearing clearance.
Service as required. Camshaft-Overhead Camshaft Engines
12. Perform oil consumption test as described to • Check for broken or damaged parts.
confirm oil consumption concern has been
resolved.
Push Rods
• Check for bent push rods (6565} and restricted oil
Oil Pressure Test
passage.
SP ECIAL SERVICE TOOL(S) REQUIRED Valve Springs
Description Tool Number • Check for broken or damaged parts.
Engine Oil Pressure Gauge T73L·6600-A

03-oo- 13 Engine-Service 03-oo- 1 3
SERVICE PROCEDURES (Continued}
Valve Spring Retainer and Valve Spring If insufficient oiling is suspected, check oil passages
Retainer Keys for blockage, then accelerate the engine to 1200 rpm
with the transmission in NEUTRAL and the engine at
• Check for proper seating of valve spring retainer normal operating temperature. Oil should spurt from
key (6518) on valve stem and in valve spring the rocker arm oil holes such that valve tips and
retainer (6514). rocker arms are well oiled. With the valve covers off,
Valves and Cylinder Head some oil splash may overshoot rocker arms.
• Check the head gasket (6051) for proper

installation.
• Check for plugged oil drain back holes. Camshaft Lobe Lift
• Check for worn or damaged valve tips. Check the lift of each lobe in consecutive order and
make a note of the readings.
• Check for missing or damaged guide-mounted valve
stem seal (6571). 1. Remove valve covers {6582).
• Check collapsed valve tappet gap (hydraulic valve 2. Remove rocker arm seat bolts, rocker arm seat
tappet applications). {6A528) and rocker arms {6564).
• Check installed valve spring height. 3. Make sure valve tappet {6500) is seated against
camshaft {6250). Install Dial Indicator with
• Check for missing or worn valve spring seats (if Bracketry TOOL-4201-c or equivalent so the ball
equipped). socket adapter of indicator is on top of valve
Static checks (engine off) are to be made on the tappet or Cup Shaped Adapter TOOL-6565-AB
engine prior to the dynamic procedure. or equivalent is on top of push rod {6565) and in
same plane as valve tappet push rod movement.
Typical Engine With Push Rods

Valve Train Analysis-Dynamic
• Start the engine and, while idling, check for proper
operation of all parts. Check the following:
Rocker Arm
• Check for plugged oil in rocker arms (6564) or
cylinder head (6049).
• Check for proper overhead valve train lubrication.
If insufficient oiling is suspected, accelerate the engine
to 1200 rpm ± 100 rpm with the transmission in
NEUTRAL and the engine at normal operating
temperature. Oil should spurt from the rocker arm oil
holes such that valve tips and rocker arms are well
oiled and I or, with the valve covers (6582) off, oil
splash may overshoot rocker arms. If oiling is
insufficient for this to occur, check oil passages for
blockage.
Push Rods
• Check for bent push rods {6565) and restriction in
oil passage.
Positive Rotator and Valve Spring Retainer 4. Remove spark plugs {12405).
Keys
5. Connect an auxiliary starter switch in starting
4.6L Engine circuit. Crank engine with ignition switch in OFF
position. Bump crankshaft {6303) over until valve
• Check for proper operation of positive rotator. tappet is on base circle of camshaft lobe. Zero
Valves and Cylinder Head the dial indicator. At this point, valve tappet will
be in its lowest position. If checking during engine
• Check for plugged oil drain back holes. assembly, turn crankshaft using a socket or
• Check for missing or damaged valve stem seals ratchet.
{6571) or guide mounted valve stem seals. 6. Continue to rotate crankshaft slowly until valve
• Check for plugged oil metering orifice in cylinder tappet is in fully-raised position {highest indicator
head oil reservoir {4.6L engine only). reading).

03-oo-14 Engine-Service 03-0Q- 14
7. NOTE: If lift on any lobe is below specified service If the leakdown time is below the specified time for
limits, camshaft and valve tappet operating on used valve tappets, noisy operation may result. If no
worn lobes must be replaced, as well as any other cause for noisy valve tappets can be found, the
valve tappet showing roller wear or needle leakdown rate should be checked and any valve
bearing damage (3.8L). Refer to Service tappets outside the specification should be replaced.
Procedures. Assembled valve tappets can be tested with a
Compare total lift recorded on indicator with hydraulic tappet leakdown tester to check the
specifications. leakdown rate. The leakdown rate specification is the
8. To check accuracy of original indicator reading, time in seconds for the plunger to move a specified
continue to rotate crankshaft until indicator reads distance while under a 22.7 kg (50 lb) load. Test the
zero. valve tappets as follows.
9. Remove dial indicator, adapter and auxiliary Leakdown Testing

starter switch. 1. NOTE: Do not mix parts from different valve
10. CAUTION: After installing rocker arms, do tappets. Parts are select-fit and not
not rotate crankshaft until valve tappets interchangeable.
have had sufficient time to bleed down. To Disassemble and clean valve tappet to remove all
do otherwise may cause serious valve traces of engine oil.
damage. Manually bleeding-down valve
tappets will reduce waiting time. 2. NOTE: Valve tappets cannot be checked with
engine oil in them. Use only testing fluid.
Install rocker arm seats, rocker arms and rocker
arm seat bolts. Place valve tappet in tester with plunger facing
upward. Pour hydraulic tester fluid into cup to a
11. Install valve covers. level that will cover valve tappet. The fluid can be
12. Install spark plugs. purchased from the tester's manufacturer. Using
kerosene or any other fluid will not provide an
Hydraulic Valve Tappet accurate test.
Hydraulic valve tappet noise may be caused by any of 3. Place a 7.94 mm (0.312-inch) steel ball provided
the following: with tester in plunger cap.
• excessive collapsed valve tappet gap 4. Adjust length of ram so that pointer is 1.59 mm
(0.062 inch) below starting mark when ram
• sticking valve tappet plunger
contracts tappet plunger to facilitate timing as
• valve tappet check valve not functioning properly pointer passes Start Timing mark.
• air in lubrication system Use center mark on pointer scale as Stop Timing
• leakdown rate too rapid point instead of original Stop Timing mark at top
of scale.
• excessive valve guide wear
5. Work valve tappet plunger up and down until
Excessive collapsed valve tappet gap may be caused valve tappet fills with fluid and all traces of air
by loose rocker arm seat bolts I nuts, incorrect initial bubbles have disappeared.
adjustment or wear of valve tappet face, or worn roller
valve tappets, push rod, rocker arm, rocker arm seat 6. Allow ram and weight to force valve tappet
or valve tip. With valve tappet collapsed, check gap plunger downward. Measure exact time it takes
between valve tip and rocker arm to determine if any for pointer to travel from Start Timing to Stop
other valve train parts are damaged, worn or out of Timing marks of tester.
adjustment. 7. A satisfactory valve tappet must have a
A sticking valve tappet plunger may be caused by dirt, leakdown rate (time in seconds) within specified
chips or varnish inside the valve tappet. The sticking minimum and maximum limits as described under
can be corrected by disassembling the valve tappet Specifications in Section 03-01A (3.8L) or
and removing the dirt, chips or varnish that are Section 03-Q18 (4.6L).
causing the condition. 8. If valve tappet is not within specification, replace
A valve tappet check valve that is not functioning may it with a new valve tappet. Do not disassemble
be caused by an obstruction such as dirt or chips that and clean new valve tappets before testing
prevent it from closing when the camshaft lobe is lifting because oil contained in new valve tappets is test
the valve tappet. It may also be caused by a broken fluid.
check valve spring. 9. Remove fluid from cup and bleed fluid from valve
Air bubbles in the lubrication system will prevent the tappet by working plunger up and down. This step
valve tappet from supporting the valve spring load. will aid in depressing valve tappet plungers when
This may be caused by too high or too low an oil level checking valve clearance.
in the oil pan (6675) or by air being drawn into the
system through a hole, crack or leaking gasket on the
oil pump screen cover and tube (6622).
1 997 Thunderbird, Cougar July 1 996

03-oo- 15 Engine-Service 03-oo- 15
SERVICE PROCEDURES {Continued)
Camshaft End Play

CAUTION: Prying against the camshaft sprocket
(6256) with the valve train load on the camshaft
(6250) can break or damage the camshaft
sprocket. Therefore the rocker arm adjusting
nuts (if equipped) must be backed off, or the
rocker arm (6564) must be loosened enough to
free the camshaft. After checking the camshaft
end play, adjust the valve clearance.
3.8L engine
1. Push camshaft toward rear of engine. Install Dial
Indicator with Bracketry TOOL-4201-C or
equivalent so indicator point is on camshaft
sprocket bolt.
2. Zero the dial indicator. Pull camshaft forward and

release it. Compare dial indicator reading with
specifications. If end play is too tight, check for
binding or foreign material in camshaft thrust
plate. If end play is excessive, check for worn
camshaft thrust plate and replace cylinder head
as required.
3. Remove dial indicator.
Crankshaft End Play

1. Install crankshaft (6303) into cylinder blocks
(6010) as described in Section 03-01A (3.8L) or
A15376-C Section 03-Q1B (4.6L).
2. Zero the dial indicator. Pull camshaft forward and 2. Pry crankshaft toward rear of engine.
specifications. If end play is excessive, replace 3. Install Dial Indicator with Bracketry TOOL-4201-C
camshaft thrust plate (6269). or equivalent so contact point rests against
crankshaft flange and indicator axis is parallel to
3. Remove dial indicator. crankshaft axis.
4. After replacing camshaft thrust plate, check end
play again. If it is still out of specified range, PRYBAR
inspect camshaft and cylinder head (6049) I
cylinder blocks (6010) for excessive wear.
4.6L Engine
1. NOTE: Dial indicator may also be installed on rear
of engine with indicator point placed on flat area
of camshaft end.
Push camshaft toward rear of engine. Install Dial
Indicator with Bracketry TOOL-4201-C or
sprocket bolt.
NOTE: P RY CRANKSHAFT IN
DIRECTION OF ARROWS AND
NOTE TOTAL END P LAY AA1008-A

03-oo- 1 6 Engine-Service 03-oo- 1 6
4. Zero the dial indicator. Push crankshaft forward Check all machined surfaces for burrs, nicks,
and note reading on dial. scratches and scores. Remove minor imperfections
5. If the end play exceeds the wear limit listed in the with an oil stone.
specifications in Section 03-01A (3.8L) or Replace all plugs that show evidence of leakage.
Section 03-018 (4.6L), replace the lower Inspect the cylinder walls for scoring, roughness or
crankshaft thrust main bearing (6337). Inspect other signs of wear.
the crankshaft for damage to the thrust face
before installing the new crankshaft thrust main
bearing. If the end play is less than the minimum
limit, inspect the thrust bearing faces for Cylinder Block Distortion
scratches, burrs, nicks or dirt. If the thrust faces
are not damaged or dirty, they probably were not Check the cylinder blocks (6010) for flatness of the
aligned properly. Lubricate and install the lower head gasket surface following the procedure and
crankshaft thrust main bearing and crankshaft specifications recommended for the cylinder head
thrust washer (6334). Align the faces, following (6049). The cylinder blocks can be machined to bring
Main Bearing Replacement procedure in Section the head gasket surface within the flatness
03-Q1A (3.8L) or Section 03-018 (4.6L). specifications listed in Section 03-01A (3.8L) or
Section 03-Q1B (4.6L), but not to exceed 0.254 mm
(0.010 inch) stock removal from the original head
gasket surface.
Connecting Rod Side Clearance Sand Holes or Porous Engine
1. Install Dial Indicator with Bracketry TOOL-4201-C Castings-Service
or equivalent so that the contact point rests Cast Iron
against the connecting rod cap.
Porosity or sand holes, which will cause oil seepage or
2. Pull connecting rod cap toward front of engine leakage, can occur with modern casting processes.
and zero the dial indicator. Make a complete inspection of engine and
3. Push cap toward rear of engine and observe transmission. If the leak is attributed to the porous
amount of side clearance on dial indicator. condition of the cylinder blocks or sand holes, service
with an epoxy sealer meeting Ford specification
4. If side clearance exceeds specification, replace
M3D35-A (E). Do not service cracks with this
connecting rod (6200) and cap. Refer to material. Service with this metallic plastic must be
Specifications in Section 03-01A (3.8L) or confined to those cast-iron engine component
Section 03-018 (4.6L). surfaces where the inner wall surface is not exposed
If side clearance is less than specification, to engine coolant pressure or oil pressure. For
remove connecting rod and cap and inspect for example:
scratches, burrs, nicks or dirt between
crankshaft (6303) and connecting rod. Refer to • cylinder block surfaces extending along the length
Section 03-01A (3.8L) or Section 03-01B (4.6L) of the cylinder blocks, upward from the oil pan rail to
under Specifications. the cylinder water jacket but not including machined
areas.
• lower rear face of the cylinder blocks.
• CAUTION: Service is not recommended to the
Cylinder Block intake manifold exhaust crossover section,
Cleaning and Inspection since temperatures can exceed the
recommended temperature limit of 260"C
If the engine is disassembled, thoroughly clean the (500"F).
cylinder blocks (6010) with solvent. Remove old
gasket material from all machined surfaces. Remove • intake manifold (9424)
all pipe plugs that seal oil passages and clean out all • cylinder head along the valve cover gasket surface
the passages. Blow out all passages, then bolt holes
and other openings with compressed air. Make sure
threads in the cylinder head bolt holes are clean. Dirt
in the threads may cause binding and result in a false
torque reading. Use a tap to true-up threads and to
remove all deposits. Thoroughly clean the grooves in
the crankshaft bearings and bearing retainers.

03-oo- 1 7 Engine-Service 03-0G- 1 7
The following procedure should be used to service Cylinder Walls, Refinishing

porous areas or sand holes in cast iron:
Cleaning
1. CAUTION: If these procedures are not
TYPICAL FOR V-6 ENGINE followed, rusting of the cylinder bores may
occur.
After any cylinder bore service operation, such
as honing or deglazing, clean bores with soap or
detergent and water.
2. Thoroughly rinse the bores with clean water to
remove the soap or detergent, and wipe the
bores dry with a clean, lint-free cloth.
3. Wipe the bores with a clean cloth dipped in clean
FRONT AND LEFT SIDE engine oil Motorcraft meeting Ford specification
WSS-M2C153-F.
Inspection
After the cylinder blocks (6010) has been thoroughly
cleaned, check it for cracks. Invisible cracks may be
detected by coating the suspected area with a mixture
of 25 percent kerosene and 75 percent light engine oil.
Wipe the part dry and immediately apply a coating of
zinc oxide dissolved in wood alcohol. Do not use
REAR AND RIGHT SIDE rubbing alcohol as a substitute. If cracks are present,
A23530·A the coating will become discolored at the damaged
area. Replace the cylinder blocks if it is cracked.
1. Clean surface to be serviced by grinding or
rotary-filing to a clean, bright metal surface. Cylinder Bore
Chamfer or undercut hole or porosity to a greater
Measure the bore with a bore gauge following the
depth than rest of cleaned surface. Solid metal
� instructions of the manufacturer.
must surround hole. Openings larger than 6.35
mm (0.25 inch) should not be serviced using an Cylinder Bore Taper
epoxy sealer meeting Ford specification
Measure the cylinder bores at points A and C as
M3D35·A (E). Openings in excess of 6.35 mm
shown.
(0.25 inch) can be drilled, tapped and plugged
using common tools. Clean service area
thoroughly. An epoxy sealer meeting Ford CYLINDER
specification M3D35·A (E) will not stick to a dirty BORE TAPER
or oily surface.
2. Mix an epoxy sealer base meeting Ford
specification M3D35·A (E) and hardener as
directed on container. Stir thoroughly until
uniform.
3. Apply an epoxy sealer meeting Ford specification
M3035·A (E) with a suitable clean tool (such as
putty knife or wood spoon), forcing epoxy into
hole or porosity.
4. Allow service mixture to harden. Two methods
can be used. Heat-cure with a 250-watt lamp (as
per direction on container) placed 254 mm (10
inches) from serviced surface, or air-dry for
CYLINDER WALLS
10-12 hours at temperatures above 10 oc A14471·A
(50°F).
If the difference between measurements A and C
5. Sand or grind serviced area to blend with general
exceeds the maximum taper value as specified in
contour of surrounding surface.
Section 03-01A (3.8L) or Section 03-018 (4.6L),
6. Paint the surface to match the rest of the cylinder rebore the cylinder to oversize.
blocks.

03-Q0- 18 Engine-Service 03-oo- 1 8
Cylinder Out-of-Round NOTE: Only experienced technicians should perform

Measure the cylinder bores in the directions as shown: this work.
NOTE: Before any cylinder is refinished, all main
bearing caps must be in place and tightened to the
proper torque so that the crankshaft bearing bores will
not become distorted from the refinishing operation.
Cylinder walls that are severely marred and I or worn
beyond the specified limits should be refinished. Hone
only the cylinder or cylinders that require refinishing.
All pistons are the same weight, both standard and
oversize; therefore, various sizes of pistons can be
CYLINDER used without upsetting engine balance. Refinish the
BORE cylinder with the most wear first to determine the
maximum oversize. If the cylinder will not clean up
when refinished for the maximum oversize piston
recommended, replace the cylinder blocks.
Refinish the cylinder to within approximately 0.038
mm (0.0015 inch) of the required oversize diameter.
This will allow enough stock for the final step of honing
A23317-A to obtain the correct surface finish and pattern. For the
proper use of the refinishing equipment, follow the
If the difference between measurements exceeds the manufacturer's instructions.
maximum out-of-round value as specified in Section
03-01A (3.8L) or Section 03-018 (4.6L) under Use a motor-driven, spring pressure-type Engine
Specifications, rebore the cylinder to oversize. Cylinder Hone Set T73L-6011-A and hone at a speed
of 300-500 rpm. Hones of grit sizes 18Q-220 will
Cylinder Bore Diameter normally provide the desired bore surface finish of
Measure the diameter of each cylinder bore at 32 mm 18-38 AA.
(1.25 inch) down from head deck at 90 degrees to the CAUTION: After the final operation In either of the
piston pin centerline. two refinishing methods described and prior to
checking the piston fit, thoroughly clean with a
Cylinder Wall Honing detergent and water solution and then oil the
cylinder walls or rusting of cylinder bores may
SP ECIAL SERVICE TOOL(S) REQUIRED occur.
Description Tool Number When honing the cylinder bores, use a lubricant
Engine Cylinder Hone Set T73L·60 1 1 -A mixture of equal parts of kerosene and clean engine oil
meeting specification WSS-M2C153-F. Operate the
Honing is recommended for refinishing cylinder walls hone to produce a cross-hatch finish on the cylinder
only when no cross-hatch pattern is visible on cylinder bore. The cross-hatch pattern should be at an angle of
walls or for fitting pistons (6108) to the specified approximately 30 degrees to the cylinder bore. Mark
clearance. The grade of hone is determined by the the pistons to correspond to the appropriate cylinders.
amount of metal to be removed. Follow the instructions When the refinishing of all affected cylinders has been
of the hone manufacturer. H coarse stones are used to completed and all pistons are fitted, thoroughly clean
start the honing operation, leave enough material so the entire cylinder blocks and oil the cylinder walls.
that all hone marks can be removed with the finishing
hone which is used to obtain the proper piston
clearance. After honing, thoroughly clean cylinder
bores with a detergent and water solution.
1997 Thunderbird. Cougar July 1 996

03-oo- 19 Engine-Service 03-oo- 19
SERVICE PROCEDURES {Continued)
Refinish cylinders that are deeply scored, Oversize plugs are identified by the "OS" stamped in
out-of-round, and I or taper exceeds specification. If the flat located on the cup side of the plug.
the cylinder walls have minor surface imperfections, Coat the plug and I or bore lightly with an oil-resistant
but the out-of-round and taper are within limits, try to (oil galley) sealer such as Stud and Bearing Mount
remove the imperfections by honing the cylinder walls EOAZ-19554-BA or equivalent meeting Ford
and installing new service piston rings, providing the specification WSK-M2G349-A1, or Thread Lock 262
piston clearance is within specification. Refer to E2FZ-19554-B or equivalent meeting Ford
Section 03-01A (3.8L) or Section 03-Q1B (4.6L) under specification WSK-M2G351-A6. Install plug following
Specifications. the procedure for cup-type or expansion-type below:
Cup-Type
- CENTER LINE OF ENGINE - Cup-type core plugs are installed with the flanged
edge outward. The maximum diameter is located at
A the outer edge of the flange. The flange on cup-type
plugs flares outward with the largest diameter of the
A outer (sealing) edge.
AT RIGHT ANGLE
TO CAUTION: It is imperative to push or drive the
CENTER LINE OF plug into the machined bore by using a properly
ENGINE designed tool. Do not drive the plug into the bore
B using a tool that contacts the flange. This will
PARALLEL damage the sealing edge and result in leakage
TO CENTER LINE and/ or plug blowout.
OF ENGINE
NOTE: If the core plug replacing tool has a depth
seating surface, do not seat the tool against a
A non-machined (casting) surface.
When installed, the flanged (trailing) edge must be
1 . OUT-OF-ROUND = DIFFERENCE below the chamfered edge of the bore to effectively
BETWEEN A AND B seal the plugged bore.
6
2. TAPER = DIFFERENCE BETWEEN THE A
MEASUREMENT AT TOP OF CYLINDER
BORE AND THE A MEASUREMENT AT SEALING
BOTTOM OF CYLINDER BORE. A2905-C EDGE
BEFORE
INSTALLATION
Engine Block Plugs
SPECIAL SERVICE TOOL(S) REQUIRED 0

Description
Impact Slide Hammer
Tool Number
T59L- 1 00-B or
\
CUP TYPE CORE
T50T- 100-A PLUG REPLACER
CUP TYPE TOOL
Removal and Installation
PLUG A23318-A
To remove a large core plug, drill a 12.70 mm (0.5
Expansion-Type
inch) hole in the center of the plug and remove with an
Impact Slide Hammer T59L-1OQ-B or T50T-1OQ-A. On Expansion-type core plugs are installed with the flange
a small core plug, drill a 6.35 mm (0.25 inch) hole in edge inward. The maximum diameter of this plug is
the center of the plug and pry it out with a small pin located at the base of the flange with the flange flaring
punch. Clean and inspect the plug bore. inward.
Inspect the plug bore before installation for any
damage that would interfere with the proper sealing of
the plug. If the bore is damaged, true the surface by
boring for the next specified oversize plug.

03-oo-20 Engine-Service 03-0G-20
CAUTION: Push or drive the plug into the

machined bore using a properly designed tool. Do
not drive the plug using a tool that contacts the
crowned portion of the plug. This will expand the
plug prior to installation and may damage the
plug and/or plug bore.
NOTE: If the core plug replacing tool has a depth
seating surface, do not seat the tool against a
non-machined (casting) surface.
SURFACE CRACKS, BRIGHT (POLISHED)
CAUTION: Pull the plug into the machined bore by SECTIONS
using a properly designed tool. Under no
CRATERS OR POCKETS
circumstances is the plug to be driven into the FATIGUE FAILURE IMPROPER SEAnNG
bore using a tool that contacts the flange. This
will damage the sealing edge and will result in
leakage and/or plug blowout.
When installed, the trailing (maximum) diameter must
be below the chamfered edge of the bore to effectively
seal the plugged bore.
SURFACE TORN
DIRT IMBEDDED OR SMEARED
SEALING
D
INTO BEARING MATERIAL
EDGE SCRATCHED BY DIRT LACK OF OIL OR
BEFORE IMPROPER CLEARANCE
INSTALL.ATION
RADIUS RIDE.
EXPANSION TYPE CORE EDGE LOADING
PLUG REPLACER TOOL
EXPANSION TYPE PLUG A23319-A A8509-D
Crankshaft Main and Connecting Rod Crankshaft Main or Connecting Rod

Bearings Bearings-Fitting
CAUTION: Do not scrape gum or varnish deposits Plastigage Method
from the bearing shells or damage to bearings
1. Clean crankshaft journals. Inspect journals and
may occur.
thrust faces for nicks, burrs or roughness that
Cleaning would cause premature bearing wear.
Identify reusable bearings so they can be installed in 2. CAUTION: Do not position jack under
their original locations. crankshaft pulley (63 1 2). Crankshaft post
damage will result.
Clean the bearing and caps thoroughly in solvent and
dry them with compressed air. If fitting crankshaft main bearing (6333) in
vehicle, position a jack under counterweight
Inspection adjoining crankshaft main bearing which is being
Inspect each bearing carefully. Replace bearings that checked. Support crankshaft (6303) with jack so
have scored, chipped or worn surfaces. Typical its weight will not compress Plastigage
examples of unsatisfactory bearings and their causes 081L-6002-B or equivalent and provide an
are shown in the following illustration. The copper lead erroneous reading.
bearing base may be visible through the bearing
overlay. If the base showing is less than 20 percent of
the total area, the bearing is not excessively worn. It is
not necessary to replace the bearing if the bearing
clearance is within recommended limits. Check the
clearance of bearings that appear to be satisfactory
with Plastigage 081L-6002-8 or equivalent as
described.

03-oo-2 1 Engine-Service 03-oo-2 1
3. NOTE: Do not turn crankshaft while Plastigage is 8. Repeat procedure for remaining bearings that
in place. require replacement.
Place a piece of Plastigage D8 1 l-6002-B or
equivalent on bearing surface across full width of
bearing cup and about 6.35 mm (0.25 inch) off
center. Crankshaft
Place a piece of Plastigage D8 1 l-6002-B or Cleaning
equivalent on bearing surface across full width of
CAUTION: Handle the crankshaft (6303) carefully
bearing cup and about 6.35 mm (0.25 inch) off
to avoid damage to the finished surfaces.
center.
Clean the crankshaft with solvent; then blow out all oil
4. Install cap and tighten bolts to specification.
passages with compressed air.
5. Remove cap. Using Plastigage scale, check
width of Plastigage at widest point to get Inspection
minimum clearance. Check at narrowest point to Inspect the main and connecting rod journals for
get maximum clearance. Difference between cracks, scratches, grooves, scores or rough finish.
reading is taper of journals. Inspect the crankshaft rear oil seal surface for nicks,
sharp edges or burrs that might damage the oil seal
during installation or cause premature oil seal wear.
Crankshaft Runout
Set the crankshaft on V-blocks and use Dial Indicator
with Bracketry TOOL-420 1 -C or equivalent to
measure the crankshaft runout.
CRANKSHAFT DIAL INDICATOR

6303 WITH BRACKETRY
TOOL-4201-C
0.038 mm
(0.0015 1NCH)
PLACE PL.ASTIGAGE CLEARANCE
FULL WIDTH MEASURING
OF JOURNAL ABOUT PL.ASTIGAGE
6.35 mm (1/4 INCH)
INSTALLING
PL.ASTIGAGE A2868-D
6. H crankshaft journals are damaged or if bearing AA1 002·A
clearance exceeds the specified limits, refinish
the crank journals to 0.254 mm (0.0 1 0 inch) Maximum crankshaft runout is 0.03 mm (0.00 1 2 inch).
undersize, and use the appropriate undersize H the crankshaft runout exceeds specification, replace
bearings. the crankshaft.
7. After bearing has been fitted and cleaned, apply a Crankshaft End Play
light coat of clean engine oil meeting Ford
specification WSS-M2C 1 53-F to journal and 1. Install crankshaft into cylinder blocks (60 1 0) as
bearings. Install bearing cap. Tighten cap bolts to described in Section 03-Q 1 A (3.8l) or Section
specification. Refer to Section 03-Q 1 A (3.8l) or 03-Q 1 8 (4.6l).
Section 03-0 1 8 (4.6L) under Specifications.

...
I 03-0G-22 Engine-Service 03-0G-22
2. Pry against No. 2 main bearing cap and check If required, machine the journals to give the proper
crankshaft end play in both directions as shown. clearance with the next undersize bearing. If the
journals will not clean up to maximum undersize
bearing available, replace the crankshaft.
PRYBAR
Always reproduce the same journal shoulder radius
which existed originally. Too small a radius will result in
fatigue failure of the crankshaft. Too large a radius will
result in bearing failure due to radius ride of the
bearing.
After refinishing the journals, chamfer the oil holes.
Polish the journal with a No. 500 grit polishing cloth
and engine oil (crocus cloth may also be used) to
obtain a smooth finish. Remove all grinding dust from
oil passages with compressed air.
Crankshaft Sprocket
CAUTION: Handle crankshaft sprocket (6306)
NOTE: PRY CRANKSHAFT IN with care to avoid possible damage to the
DIRECTION OF ARROWS AND finished surfaces.
NOTE TOTAL END PLAY AA1008-A
Inspect crankshaft sprocket for nicks, burrs or
3. If end play exceeds the wear limit as described in roughness that would cause premature wear. If
Section 03-Q1A (3.8L) or 03-018 (4.6L) under crankshaft sprocket is worn or damaged, replace
Specifications, grind the crankshaft and install an crankshaft sprocket as described in Section 03-Q 1A
oversize crankshaft thrust main bearing (6337) (3.8L) or Section 03-018 (4.6L).
or replace crankshaft and crankshaft thrust main
bearing.
Crankshaft Main Journal and Connecting Rod Pistons, Piston Pins and Piston Rings
Journals
Cleaning
Inspect the main journal and connecting rod journal
diameters. Measure the diameter of each journal at CAUTION: Do not use a caustic cleaning solution
two different points in the directions as shown: or a wire brush to clean pistons (6 1 08) or damage
may occur.
Using a gasket scraper, remove deposits from the
JOURNAL piston surfaces. Clean gum or varnish from the piston
skirt, piston pins (6 1 35) and piston rings with solvent.
' '
t t A15056-A
Clean the piston ring grooves with Piston Ring Groove

Cleaner 081 L-6002-D or equivalent or a broken piston
A14474-A ring. Make sure oil ring slots (or holes) are clean.
If a main journal or connecting rod journal diameter is

less than the specifications as listed in Section 03-Q1A
(3.8L) or Section 03-Q18 (4.6L), grind the journal to
match an undersize bearing.
Journals, Refinishing
Dress minor imperfections such as scores, nicks or PISTON RING GROOVE
burrs with an oil stone. If the journals are severely CLEANER
marred or exceed the service limit, refinish to size for 081 L-6002-D
the next undersize bearing. A15059-C

Inspection Pistons-Fitting
Carefully inspect the pistons for fractures at the ring Coated Pistons
lands, skirts, oil ring slot corners, and pin bosses. Also
inspect for scuffed, rough or scored skirts. If the lower SPECIAL SERVICE TOOL(S) REQUIRED
inner portion of the piston ring grooves has a high step,
replace the piston I rod I pin assembly (the 3.8L engine Description Tool Number
uses powdered metal rods). The step will interfere Engine Cylinder Hone Set T73L-60 1 1 -A
with piston ring operation and cause excessive piston
ring side clearance. NOTE: Pistons are sized prior to coating. Actual size
Spongy, eroded areas near the edge of the top of the cannot be measured on a coated piston.
piston are usually caused by detonation or pre-ignition. Pistons are available for service in standard size and
A shiny surface on the thrust surface of the piston, oversize shown in Section 03-0 1 A (3.8L) or Section
offset from the centerline between the piston pin holes 03-0 1 8 (4.6L) under Specifications.
or a sideways wear pattern on the skirt, can be The standard-size pistons are color-coded red, blue or
caused by a bent connecting rod (6200). Replace
yellow on the dome.
pistons that show signs of excessive wear, wavy ring
lands or fractures or damage from detonation or Measure the cylinder bore diameter as described.
pre-ignition. Select the piston to ensure the proper clearance.
When the bore diameter is in the lower one-third of the
Check the piston-to-cylinder bore clearance by
specified range, use a red piston. When the bore
measuring the piston I rod I pin assembly (the 3.8L diameter is in the middle one-third, use a blue piston.
engine uses powdered metal rods) and bore When the bore diameter is in the upper one-third, use a
diameters. Refer to Specifications in Section 03-Q 1 A yellow piston.
(3.8L) or Section 03-Q 1 B (4.6L) for the proper
clearance. Refer to Cylinder Bore Diameter for the Piston-to-Cylinder Clearance
bore measurements procedure. Measure the outer NOTE: Cylinder bore must be clean and dry, and
diameter (OD) of the piston and check the piston ring cylinder blocks (60 1 0) must remain at room
side clearance following the procedure under Piston temperature (2 1 o C 70 o F) for eight hours before
Rings-Fitting. taking cylinder measurements.
Replace piston I rod I pin assembly (the 3.8L engine
uses powdered metal rods) showing signs of fracture,
etching or wear. Check the piston pin fit in the piston
and connecting rod as described.
Cylinder Bore Diameter Gauge
CENTRALIZING CENTRALIZING
PLUNGERS PLUNGERS
GAUGING PLUNGER
POSmVE CENTRALIZATION
CENTRALIZING PLUNGERS AUTOMAncALLY

LOCATE lltE GAUGING-CONTACTS CENTRALLY ON
lltE BORE DIAMETER EVEN WHEN lltE GAUGE IS
INSERTED AT AN ANGLE.
A23321-A

03-G0-24 Engine-Service 03-G0-24
Measure cylinder bore diameter in direction A and B at 1. NOTE: After any refinishing operation, allow
32 mm ( 1 .25 inch) below top of cylinder block deck. cylinder bore to cool. Make sure piston and bore
are clean and dry before piston fit is checked.
Calculate size of piston to be used by taking a
fl\
cylinder bore check. Follow procedures
described previously.
•----- .
· �1 . CENTERUNE OF
CRANKSHAFT
2. Select proper size piston to provide desired
clearance. Measure piston diameter in-line with
centerline of piston pin and at 90 degrees to
piston pin axis.
3. Make sure piston and cylinder blocks are at room
temperature, 2 1 oc (70° F).
A - AT RIGHT ANGLE TO CENTER LINE OF ENGINE Piston Rings-Fitting
B PARALLEL TO CENTER LINE OF ENGINE
•
1. NOTE: Always use a piston ring expanding tool to

install rings on a piston.
A23320.A
Select proper piston ring set for size of cylinder
The cylinder bore service limit equals the average of bore.
measurements A and B when measured at the center 2. CAUTION: Use care when installing piston
of the piston travel. ring to avoid possible damage to piston ring
The cylinder bore taper equals the difference between or cylinder bore.
measurements A at top and bottom of cylinder bore Position piston ring in corresponding cylinder
and A at top and bottom of cylinder bore. bore.
The cylinder bore out-of-round equals the difference 3. Insert piston ring into cylinder bore using a piston.
between measurements A and B when measured at Push piston ring slightly beyond bottom of ring
the center of the piston travel. travel, 1 1 5 mm (4.5 inches) from cylinder block
Refer to Specifications as described in Section deck face.
03-Q 1 A (3.8L) or Section 03-0 1 8 (4.6L). 4. Verify position of piston ring in bore is square with
On 3.8L engine, measure the piston outer diameter as cylinder wall and check piston ring end gap as
described to obtain the specific clearance. It may be described.
necessary periodically to use another piston (within
the same grade size) that is either slightly larger or
smaller to achieve the specified clearance.
On 4.6L (2V) engine, measure the piston outer
diameter as described to obtain the specific
clearance. Pistons are graded prior to skirt coating.
Exact clearance cannot be determined. Clearance is
calculated based on bore-piston dimensions.
Piston-to-bore clearance with coating is -0.01 2.0.026
mm (-0.00047.0.00 1024 inch).
If the taper, out-of-round and piston-to-cylinder bore
clearance conditions of the cylinder bore are within
specified limits, new piston rings will work well.
H installing new piston rings in a used cylinder that has
not been refinished, remove the cylinder wall glaze A15061-A
only using spring-loaded Engine Cylinder Hone Set
T73L-60 1 1-A. Remove only if there is no visible sign of
cross-hatch markings on the cylinder walls. (Refer to
Cylinder Block, Cylinder Walls, Refinishing.) Always
clean the cylinder bore thoroughly with detergent and
water solution.
1 997 Thunderbird. Cougar July 1 996

Piston Ring End Gap Piston Rings

1. Measure gap between ends of piston ring with CAUTION: Piston rings should not be transferred
Feeler Gauge 081 L-420 1-A or equivalent. If ring from one piston to another, regardless of mileage
gap is less than or greater than specified limits, or piston ring failure may occur.
try another piston ring set. For Specifications, Replace all piston rings that are scored, broken,
refer to Section 03-0 1 A (3.8L) or Section 03-0 1 8 chipped or cracked. Check the end gap and side
(4.6L). clearance as described.
If end gap is greater than service limit, replace
piston ring. If end gap exceeds service limit, even Piston Ring-to-Groove Clearance
with a new piston ring, rebore cylinder blocks. NOTE: If lower lands have high steps, piston should be
replaced.
Check piston ring side clearance of compression rings
with Feeler Gauge 081 L-420 1 -A or equivalent
inserted between piston ring and its lower land. Gauge
should slide freely around entire piston ring
circumference without binding. Any wear that occurs
will form a step at inner portion of lower land.
If clearance is greater than service limit, replace piston
ring. If clearance exceeds service limit, even with a
new piston ring, replace piston.
/ A15062-B
2. Piston rings should be staggered on the piston to
make sure the piston ring end gaps are not
aligned.
Piston Pin-to-Piston Clearance
Check the outside diameter of the piston pin and the CHECK PISTON RING SIDE
inner diameter (10) of the pin bore in the piston as CLEARANCE USING FEELER
described. Replace any piston pin or piston that is not GAUGE 081 L-4201 -A
within specifications. For Specifications, refer to
Section 03-D 1 A (3.8L) or Section 03-0 1 B (4.6L).
Piston Outer Diameter Piston Pin Hole Diameter
Measure the piston diameter using a micrometer. Measure each piston pin hole diameter at the four
Measure piston skirt diameter 90 degrees to piston pin points shown.
center axis, 42 mm ( 1 .65 inches) from piston dome.
It may be necessary periodically to use another piston
(within the same grade size) that is either slightly
larger or smaller to achieve the specified clearance.
A14483-B
Replace piston that is not within specifications. For
Specifications, refer to Section 03-Q 1 A (3.8L) or
Section 03-D 1 B (4.6L).

03-Q0-26 Engine-Service 03-oo-26
Piston Pin Diameter The connecting rod and related parts should be
Use a micrometer to inspect the piston pin diameter in carefully inspected and checked so they conform to
the X and Y directions at points A, B, C and D as specifications. For Specifications, refer to Section
shown. 03-Q 1 A (3.8L} or Section 03-0 1 8 (4.6L}. Various
forms of engine wear caused by these parts can be
readily identified.
MICROMETER A shiny surface on either pin boss inside of the piston
usually indicates that a connecting rod is bent.
Abnormal connecting rod bearing wear can be caused
by either a bent, worn or damaged crankpin or a
tapered connecting rod bore.
Twisted connecting rods can create an identifiable
piston skirt wear pattern, but badly twisted connecting
rods will disturb the action of the entire piston, piston
rings and may also cause excessive oil consumption.
Connecting Rod Bending Clearance
Check the connecting rods for bend or twist on a
A24230-A suitable alignment fixture. Follow the instructions of
the fixture manufacturer. If the bend and twist exceeds
Replace piston pin that is not within specifications. For specification, the connecting rod must be replaced.
Specifications, refer to Section 03-Q 1 A (3.8L} or
Section 03-0 1 8 (4.6L}.
Camshaft/Cylinder Head Journals

Connecting Rods Cleaning
Piston Pin Clearance-4.6L Engine Clean the camshaft (6250} in solvent and wipe it dry.
The interference between the connecting rod and the Remove light scuffs, scores or nicks from the
piston pin (6 1 35} should be within 0.0 1 5-Q.040 mm camshaft-machined surfaces with a smooth oil stone.
(0.0006-0.00 16 inch}. On 3.8L engines, the camshaft must be replaced if
camshaft journals are excessively worn or scored.
Cleaning Camshaft journals can be refinished to accommodate
CAUTION: Do not use a caustic cleaning solution 0.38 mm (0.0 1 5 inch} undersize camshaft bearings
or damage to connecting rods (6200) may occur. (626 1 }. If the journals do not ''clean up, ' ' replace the
Remove the connecting rod bearings (62 1 1} from the camshaft.
connecting rods and caps. Identify each connecting Inspection
rod bearing location if connecting rod bearings are to
be reused. Clean the connecting rod in solvent, Check camshaft bores for size, taper, roundness,
including the rod bore and the back of the connecting alignment and finish. If any of these exceed the limits
rod bearings. Blow out all passages with compressed given in Specifications, install new camshaft bearings,
air. rebore cylinder head (6049} to accept oversize
camshaft or replace cylinder head.
Inspection
CAUTION: It is not necessary to ream or hone the
pin bore in the connecting rod. Replace damaged
connecting rod nuts and bolts or engine damage
may occur.
Inspect the connecting rods for signs of fractures and
the bearing bores for out-of-round and taper. If the
bore exceeds the recommended limits and I or if the
connecting rod is fractured, replace it. Check the ID of
the connecting rod piston pin bore. If the pin bore in the
connecting rod is larger than specification, install a
0.025 mm (0.00 1 inch} oversize piston pin. Prefit the
oversize piston pin to the piston pin bore by reaming or
honing the piston (6 1 08} to provide 0.007-0.0 1 3 mm
(0.0003-0.0005 inch} clearance (light slip fit}.
Assemble the piston, piston pin and connecting rod as
described.

03-0G-27 Engine-Service 03-0G-27
Camshaft Runout
Inspect the camshaft runout by setting the No. 1 and
No. 4 journals on V-blocks and using Dial Indicator with 6.35 mm 6.35 mm NO PITTING
Bracketry TOOL-420 1 -c or equivalent. 0.25 INCH 0.25 INCH ALLOWED IN
THIS AREA
DIAL
INDICATOR WITH BRACKETRY
TOOL-4201-C DIMENSION A MINUS
DIMENSION B EQUALS
THE CAM LOBE LIFT
AA0874-A
If the maximum runout of the camshaft is not within A
specifications as described in Section 03-0 1 A (3.8L) A23322·B
or Section 0 3-Q 1 B (4.6L), replace the camshaft.
Camshaft Journal Oil Clearance
Cam Lobes
4.6L Engine
3.8L Englne
1. Remove all foreign material and oil from the
Inspect the camshaft lobes for scoring and signs of camshaft journals and cylinder head bearing
abnormal wear. Lobe pitting except in the general area surfaces.
of the lobe toe does not harm camshaft operation;
therefore, the camshaft should not be replaced unless 2. Set the camshaft into the cylinder head.
the lobe lift loss has exceeded specification or pitting 3. Position Plastigage material on top of the journals
has occurred in the lobe lift area. in the axial direction.
Cam Lobe Lift 4. Install cylinder head journal caps as described in
Section 03-Q 1 B.
The lift of the camshaft lobes can be checked with the
camshaft installed in the engine or on centers. 5. Loosen the cylinder head journal cap bolts as
described in Section 03-Q 1 B.
To measure the camshaft lobe lift, proceed as follows:
6. Remove cylinder head journal caps as described
1. Measure distance between major (A-A) and minor in Section 03-Q 1 B.
(B-B) diameters of each camshaft lobe with a
Vernier caliper and record readings. The 7. Measure the camshaft oil clearance. The
difference in readings on each camshaft diameter standard camshaft oil clearance should be
is lobe lift. 0.025-Q.076 mm (0.00 1 o-o.0029 inch).
Maximum service limit is 0. 1 2 1 mm (0.0048
2. If readings do not meet specification, replace inch).
camshaft. For Specifications, refer to Section
03-Q 1A. Camshaft Journal Diameters
Measure the journal diameters in the X and Y
directions at points A and B as shown.
y
JOURNAL
A16624·B
1 997 Thunderbird, Cougar July 1996

Replace the camshaft if not within specifications as

described. Refer to Specifications in Section 03-0 1 A
{3.8L) or Section 03-0 1 8 {4.6L).
Camshaft End Play
CAUTION: Prying against the camshaft sprocket
(6256} with the valve train load on the camshaft
can break or damage the camshaft sprocket.
Therefore the rocker arm adjusting nuts (if
equipped} must be backed off, or the rocker arm
(6564} must be loosened enough to free the
camshaft. After checking the camshaft end play,
adjust the valve clearance.
3.8L Engine
1. Push camshaft toward rear of engine. Install Dial
Indicator with Bracketry TOOL-420 1 -c or
sprocket retaining bolt.
2. Zero the dial indicator. Pull camshaft forward and

specifications. If end play is too tight, check for
binding or foreign material in camshaft thrust
plate. If end play is excessive, check for worn
camshaft thrust plate and replace cylinder head
as required.
3. Remove dial indicator.
Camshaft Sprocket
Inspect the camshaft sprocket for warping or
abnormal wear. Inspect the sprocket teeth for wear,
deformation, chipping, or other damage. If necessary,
replace the camshaft sprocket as described in
Section 03-0 1 A.
A15376-C
Hydraulic Valve Tappets or Hydraulic Roller
2. Zero the dial indicator. Pull camshaft forward and Valve Tappets
CAUTION: If any part of the valve tappet (6500}
specifications. If end play is excessive, replace
needs replacing, replace the entire valve tappet.
camshaft thrust plate {6269).
Internal tolerances for the valve tappets are very
3. Remove dial indicator. critical. Mixing components from different valve
4. After replacing camshaft thrust plate, check end tappets may upset these tolerances, resulting In
play again. If it is still out of specified range, improper valve tappet operation and possible
inspect camshaft and cylinder blocks {60 1 0) for engine damage.
excessive wear. The valve tappets should be kept in proper sequence
so that they can be installed in their original position.
4.6L Engine
Inspect and test each valve tappet sep>arately so as
1. NOTE: Dial indicator may also be installed on rear not to intermix. If a valve tappet is worn, it is
of engine with indicator point placed on flat area recommended that all valve tappets and camshaft
of camshaft end. {6250) or rocker arms {6564) be replaced.
Push camshaft toward rear of engine. Install Dial Cleaning
Indicator with Bracketry TOOL-420 1 -c or
equivalent so indicator point is on camshaft Thoroughly clean all the parts in clean solvent and
sprocket bolt. wipe them with a clean lint-free cloth.

Inspection 2. Check the inside of the oil pump and filter body
Inspect the parts and discard the entire valve tappet, if (6603) and the inner and outer gears for damage
any part shows pitting, scoring or excessive wear. or excessive wear.
Replace the entire valve tappet if the plunger is not 3. Check the mating surface of the oil pump and
free in the body. The plunger should drop to the bottom filter body for wear. Minor scuff marks are normal
of the body by its own weight when assembled dry. but if the engine front cover, gears or oil pump
Assemble the valve tappet and check for freeness of and filter body surfaces are excessively worn,
operation by pressing down on the plunger. The valve scored or grooved, replace. the engine front cover
tappets can also be checked with a hydraulic tester to or oil pump and filter body. Remove minor
test the leakdown rate. Follow the instructions of the imperfections with an oil stone.
test unit manufacturer or the Leakdown Testing 4. Inspect oil pump cover gasket surface on engine
procedure as described. front cover. Remove any gasket material, burrs
or nicks. Visually inspect Q-rings for any nicks
Valve, Roller-Tappet Wear and I or cuts and replace as necessary.
3.8L Engines 5. Measure thickness of gear using a micrometer.
Inspect roller valve tappets for flat spots or scoring. If Gear should be 30.480- 30.455 mm ( 1 . 2Q- 1 . 19
flat spot is found, check camshaft lobes for proper inches) thick.
height or wear. Replace as required. Refer to Section
• If gear is less than 30.455 mm ( 1 . 19 inches)
03-Q 1 A.
thick, replace gear.
• If gear thickness is within specification, it may
be necessary to replace the oil pump and filter
FLAT SPOT body.
• If thickness of gear is within specified limits, go
to Step 6.
6. Measure depth of the gear pocket in the oil pump
and filter body. Depth should be 30.49-30.54 mm
( 1 .200- 1 .202 inches).
• If depth is more than 30.54 mm ( 1 . 202 inches),
replace oil pump and filter body.
7. Measure side clearance by inserting Feeler
Gauge D81 L-420 1-A or equivalent between a
gear tooth and side wall of the gear pocket.
• Clearance should be a maximum of 0. 1 3 mm
A15295-B (0.005 inch) and gears should be free to turn.
• If clearance is greater than 0. 1 3 mm (0.005
inch), go to Step 8.
8. Measure diameter of gear using a micrometer.
Oil Pump Gear should be 38.252"38.332 mm ( 1 .505- 1 .509
inches).
Cleaning
Wash all parts in a solvent and dry them thoroughly • If gear is less than 38.252 mm ( 1 .505 inches)
wide, replace gear and measure clearance as
with compressed air. Use a brush to clean the inside of
the oil pump housing and the pressure relief valve described in Step 7.
chamber. Remove all dirt and metal particles. • If diameter of gear is within specified limits, go
to Step 9.
Inspection
9. Measure diameter of gear pocket in the oil pump
Refer to Specifications in Section 03-Q 1 A for and filter body. The diameter should be
clearances and service limits. 38.22-38.30 mm ( 1 .504-1 .507 inches).
3.8L Engine
• If diameter is less than 38.22 mm ( 1 .504
1. Place Straight Edge D83L-420 1 -A or equivalent inches), replace oil pump and filter body and
across mounting surface of engine front cover measure clearance as specified in Step 7.
(60 19) and measure for wear or warpage tJsing a
feeler gauge. If surface is out of flat by more than
0.04 mm (0.00 1 6 inch), replace engine front
cover.

Pressure Regulator Valve Inspection The following inspection procedures are for a cylinder
NOTE: Internal components are not serviced. If any head that is to be completely overhauled. For
component is out of specification, replace oil pump individual service operations, use only the pertinent
(6600). inspection procedure.
Check the relief valve piston for free operation in the Spark Plug Thread Service
bore. Inspect the relief valve spring to see if it is Damaged spark plug threads in the cylinder head can
collapsed or worn. Check the relief valve spring be serviced using Rotunda Sav-A-Thread Spark Plug
tension. If the spring tension is not within specification Kit 1 07-R092 1 or equivalent.
and I or the spring is worn or damaged, replace the oil
pump on 4.6L engine-equipped vehicles, or the oil The procedure involves cutting new threads in the
pump and filter body (6603) on 3.8L engine-equipped spark plug hole. After rethreading operation, tapered
vehicles. sleeve will be installed in the cylinder head. The sleeve
is threaded on the inside and outside. The outside
threads into the cylinder head while the inside
provides new threads for the spark plug ( 1 2405).
Oil Pan This service is permanent and will have no effect on
cylinder head or spark plug life.
Cleaning
CAUTION: The cylinder head must be removed
CAUTION: Do not damage the low oil level sensor from engine before installing a tapersert. The
(if equipped) when cleaning the oil pan (6675). service procedure includes a thread cutting
Scrape any dirt or metal particles from the inside of process which produces metal chips. Performing
the oil pan. Scrape all old gasket material from the this procedure while the cylinder head is on the
gasket surface. Wash the oil pan in a solvent and dry it cylinder blocks (60 1 0) will cause metal chips to
thoroughly. Make sure all foreign particles are fall into the cylinder. Once in the cylinder, these
removed. chips can damage the cylinder wall when the
engine is started.
Inspection
NOTE: The use of power or air-driven tools is not
Check the oil pan for cracks, holes or damaged drain approved for the installation of taperserts.
plug threads. Check the gasket surface for damage
caused by over-tightened bolts. Replace with a new oil
pan if service cannot be made. TAP MANDREL
Cylinder Heads
Replace the cylinder head (6049) if it is cracked. Do
not plane or grind more than 0.254 mm (0.010 inch)
from original cylinder head gasket surface. Remove all
burrs or scratches with an oil stone.
Cleaning
CAUTION: With the valves installed to protect the
valve seats, remove deposits from the
combustion chambers and valve heads with a
scraper and a wire brush. Be careful not to ROTUNDA SAY-A-THREAD SPARK PLUG KIT
damage the cylinder head gasket surface or 107-R0921 AA1009-A
possible leakage may occur upon reassembly.
After the valves are removed, clean the valve guide 1. Thoroughly clean spark plug counterbore, seat
bores. Use cleaning solvent to remove dirt, grease and and threads of all dirt or other foreign material.
other deposits from the valves with a fine wire brush or 2. Start tap into spark plug hole, being careful to
buffing wheel. keep it properly aligned. As tap begins cutting
new threads, apply aluminum cutting oil to tap.
Inspection
Continue cutting threads and applying oil until
Inspect the cylinder heads for cracks or excessively stop ring bottoms against spark plug seat.
burned areas in the exhaust outlet ports.
3. Remove tap. Remove all metal chips using
Check the cylinder head for cracks and inspect the compressed air.
gasket surface for burrs and nicks. Small
imperfections can be dressed down using an oil stone.
Replace the cylinder head if it is cracked.

03-Q0-3 1 Engine-Service 03-Q0-31
4. Coat threads of mandrel with cutting oil. Thread Cylinder Head Flatness
tapersert onto mandrel until one thread of When a cylinder head is removed because of gasket
mandrel extends beyond tapersert. leaks, check the flatness of the cylinder head gasket
surface so it conforms to specification using Straight
Edge D83L-420 1 -A or equivalent and Feeler Gauge
08 1 L-420 1-A or equivalent. For Specifications, refer
to Section 03-Q 1 A. If necessary to refinish the cylinder
TAPERSERT head gasket surface, on the 3.8L plane or grind up to
0.254 mm (0.010 inch) from original cylinder head
gasket surface. Remove all burrs or scratches with an
oil stone. If surface has still not cleaned up after the
0.254 mm (0.0 1 0 inch) pass, replace the cylinder
head. On the 4.6L (2V) engine, replace the cylinder
head.
ONE THREAD
EXTENDING STRAIGHT EDGE D83L-4201-A
BEYOND
TAPERSERT A647G-D
5. NOTE: A properly installed tapersert will be flush

to 1 .0 mm (0.039 inch) below spark plug gasket
seat.
Thread tapersert into tapped spark plug hole
using a torque wrench. Continue tightening
mandrel until torque wrench
. indicates 6 1 N·m (45
lb-ft).
6. To loosen mandrel for removal, hold mandrel
stationary and turn mandrel body approximately
one-half turn. Remove mandrel. A23325-A
Valve Seat Runout

Check the valve seat runout with a Valve Seat Runout
Gauge as illustrated below. Follow the instructions of
the gauge manufacturer. If the runout exceeds the
wear limit, reface the valve and valve seat. For
Specifications, refer to Section 03-Q 1 A (3.8L) or
Section 03-Q 1 B (4.6L).
VALVE SEAT
RUNOUT GAUGE
A6658-C

03-oo-32 Engine-Service 03-0G-32
Valve Stem-to-Valve Guide Clearance 3.8L Engine

Check the valve stem-to-valve guide clearance of If the valve stem-to-valve guide clearance exceeds the
each valve in its respective valve guide with Dial service clearance, ream the valve guide for the next
Indicator with Bracketry TOOL-420 1-G and Valve oversize valve stem. Valves with oversize stem
Stem Clearance Tool TOOL-6505-E or equivalents. diameters of 0.38 mm and 0. 76 mm {0.0 1 5 inch and
Use a flat-end indicator point. 0.030 inch) are available in diameters of 0.4 1 mm and
Install the tool on the valve stem until it is fully seated 0.81 mm {0.0 1 6 inch and 0.032 inch) oversize.
and firmly tighten the knurled setscrew. Permit the Always reface the valve seat after the valve guide has
valve to drop away from its seat until the tool contacts been reamed. Refer to Valve Guides, Reaming under
the upper surface of the valve guide. Service Procedures, Cylinder Head.
Valve Guide Replacement
"' DIAL INDICATOR 4.6L Engine
WITH BRACKETRY
TOOL-4201-C If the valve stem-to-valve guide clearance exceeds the
� service clearance, replace the valve guide. Ream the
valve guide to the standard diameter of 7.02-7.04 mm
{0.276-Q.277 inch). Always reface the valve seat after
the valve guide has been replaced.
CAUTION: The interference angle of the valve
and seat should not be lapped out. Remove all
grooves or score marks from the end of the valve
stem and chamfer it as necessary. Do not remove
more than 0.254 mm (0.0 1 0 inch) from the end of
the valve stem.
If the valve face runout is excessive and I or to remove
pits and grooves, reface the valves to a true
45-degree angle. Remove only enough stock to
)
correct the runout or clean up the pits and grooves. If
the edge of the valve head is less than 0. 794 mm
{0.03 1 inch) thick after grinding, replace the valve
because the valve will run too hot in the engine.
If the valve and I or valve seat has been refaced, check
the clearance between the rocker arm pad and the
Position Dial Indicator with Bracketry TOOL-420 1 -C or valve stem with the valve train installed in the engine
equivalent with its flat tip against the center portion of and replace valve stem seal {657 1).
the tool's spherical section at approximately 90
degrees to the valve stem axis. Move the tool back
and forth in line with the indicator stem. Take a reading
on the dial indicator without removing the tool from the
valve guide upper surface. Divide the reading by two
which is the division factor for the tool. If valve
stem-to-valve guide clearance exceeds the wear limit,
ream the valve guide for the next oversize valve stem
as described under Valve Guides, Reaming.
Valves, Select Fitting
In the case of valve stem-to-valve guide clearance, the
service clearance is intended as an aid to diagnosing
engine noise only, and does not constitute a failure or
indicate need for service. However, when overhauling
or reconditioning a cylinder head, the service
clearance should be regarded as having a practical
working value, and used to determine installation of the
next oversize valve.

03-0G-33 Engine-Service 03-0G-33
Valve Guides, Reaming If the valve and I or valve seat has been refaced, check
the clearance between the rocker arm pad and the
3.8L Engines valve stem with the valve train installed in the engine.
CAUTION: Always reface the valve seat after the
valve guide has been reamed and use a suitable Valve Seats, Refacing
scraper to break the sharp corner (ID) at the top Measure the valve seat width. Reface the valve seats
of the valve guide. Failure to do so may result in if the width is not within specifications. Refer to
possible valve train wear and/ or damage. Section 03-Q 1 A (3.8L) or Section 03-Q 1 B (4.6L) for
If it becomes necessary to ream a valve guide to install Specifications.
a valve with an oversize stem, a hand-reaming kit is Refer to Engine Service Section in the Rotunda Tool
available which contains the following reamer and pilot catalog for a description of the various valve seat
combinations: a 0.38 mm (0.0 15 inch) OS reamer with grinders and cutters available.
a 0. 76 mm (0.03 inch) OS pilot, and a 0. 76 mm (0.03 Refacing the valve seat should be closely coordinated
inch) reamer with a 0.38 mm (0.0 1 5 inch) OS pilot. with the refacing of the valve face so that the finished
seat and valve face will be concentric and the
specified interference angle will be maintained. This is
important so that the valve and seat will have a
compression-tight fit. Make sure refacer grinding
wheels are properly dressed.
Grind the valve seats to a true 45-degree angle.
Remove only enough stock to clean up pits and
grooves or to correct the valve seat runout. After the
seat has been refaced measure valve seat contact
width as described.
The finished valve seat should contact the
approximate center of the valve face. Determine
where the valve seat contacts the face.
To do this, coat the seat with Prussian Blue and set the
valve in place. Rotate the valve with light pressure. If
the Prussian Blue is transferred to the center of the
valve face, the contact is satisfactory. lf the Prussian
is transferred to the top edge of the valve face, lower
the valve seat. If the Prussian Blue is transferred to the
bottom edge of the valve face, raise the valve seat.
Valves
The critical inspection points and tolerances of the
When replacing a standard size valve with an oversize valve are illustrated. Refer to Specifications in Section
valve, always use the reamer in sequence (smallest 03-0 1 A (3.8L) or Section 03-0 1 B (4.6L) for service
oversize first, and then next smallest and so forth) so limits.
reamers will not be overloaded.
NOTE: If oversize valve stems and oversize valve
stem seal are not available, press out original guide
and install service bushing. Ream ID for specified Valves, Inspection
clearance for standard-size valve. Reface valve seat Inspect the valve stem for bends and the end of the
as required. Install standard-size valve stem seal. stem for grooves or scoring.
CAUTION: The interference angle of the valve Inspect the valve face and the edge of the valve head
and seat should not be lapped out. Remove all for pits, grooves or scores. Inspect the stem for bends
grooves or score marks from the end of the valve and the end of the stem for grooves or scores. Check
stem and chamfer it as necessary. Do not remove the valve head for signs of burning, erosion, warpage
more than 0.254 mm (0.0 1 0 inch) from the end of and cracking. Minor pits, grooves and other abrasions
the valve stem or excessive valve clearance may may be removed. Discard severely damaged valves.
occur.
Inspect the valve spring (65 1 3), valve spring retainers
If the valve face runout is excessive and I or to remove (65 14), valve spring retainer keys (65 1 8) and discard
pits and grooves, reface the valves to a true any damaged parts.
45-degree angle. Remove only enough stock to
correct the runout or to clean up the pits and grooves.
If the edge of the valve head is less than 0. 794 mm
(0.03 1 inch) thick after grinding, replace the valve
because the valve will run too hot in the engine.

Valves, Refacing
CAUTION: Discard any excessively worn or
damaged valve train parts.
Minor pits or grooves may be removed. Discard valves
that are severely damaged. If the face runout cannot
be corrected by refinishing, or stem clearance
exceeds specification discard the valves. Refer to
Section 03-Q 1A (3.8L) or Section 03-Q 1 B (4.6L) for
Specifications.
Refer to Engine Service Section in the Rotunda Tool
catalog for a description of the various valve
resurfacing equipment.
The valve refacing operation should be closely
coordinated with the valve seat refacing operations so
0
that the finished angles of the valve face and valve
seat will meet specifications and provide a
compression-tight fit.
Make sure refacer grinding wheels are properly If the valve seat width exceeds the maximum limit,
dressed. Refer to the illustration for critical valve remove enough stock from the top edge and I or
dimensions. bottom edge of the seat to reduce the width to
specifications.
On the intake and exhaust seats, a 30-degree angle
VALVE TYPICAL, wheel is used to remove stock from the top of the
FOR DIMENSIONS REFER seats (lower the seats).
TO SPECIFICATIONS
CHECK FOR THIN (WORN) USE 30 DEGREE WHEEL ON

LANDS BETWEEN KEEPER ALL ENGINES TO REMOVE
GROOVES OR BURRS STOCK FROM TOP OF SEAT
(MULTIPLE BEAD VALVES) CHECK FOR
BENT STEM
VALVE THIS LINE

FACE PARALLEL WITH
ANGLE VALVE HEAD I
�
ON 4.6L ENGINE, TO REMOVE
STOCK FROM BOTTOM OF SEAT,
USE THE FOLLOWING WHEEL
INTAKE-n DEGREE
EXHAUST-70 DEGREE A20812-C
A23526-B
Valve Seat Contact Width
Use a seat width scale or a machinist scale to
measure the seat width. Narrow the seat, if
necessary, to bring it within specification. Refer to
Section 03-0 1A (3.8L) or Section 03-Q 1 8 (4.6L) for
Specifications.

03-0Q-35 Engine-Service 03-oo-35
Valve Guide Inner Diameter

Measure the inner diameter of the valve guides at the
points shown.
�tti��
(CROSS-SECTION) �
A1 4570-B
If a valve spring is not within specifications as
described in Section 03-o 1 A (3.8L) or Section 03-o 1 8
(4.6L), replace the valve spring.
Valve Spring Tension
Inspect the valve spring, valve spring retainers and
valve spring retainer keys for wear or damage.
A14465-B Discard any damaged parts.
If valve guide is not within specification as listed in NOTE: Make sure the valve springs are reassembled
Section 03-o 1 A (3.8L) or Section 03-o 1 8 (4.6L), ream to their OWN ORIGINAL DAMPERS by pushing
the valve guide as described and install a valve with an damper on the valve spring. DO NOT OPEN damper
oversize stem. with any kind of tool when reassembling.
Check the valve springs for proper pressure at the
Valve Stem Diameter
specified valve spring lengths using Valve Clutch
Measure the diameter of each valve at the points Spring Tester TOOL-65 13-DD or equivalent. Weak
shown. valve springs cause poor engine performance.
Replace any valve spring not within specification. For
Specifications, refer to Section 03-o 1 A (3.8L) or
Section 03-0 1 8 (4.6L). Manually rotating the valve
spring while installed in the engine will not determine
condition of valve springs.
APPLY TORQUE UNTIL

CLICK IS HEARD, READ
TORQUE WRENCH AND
MULTIPLY READING
BY TWO
A23529-A
If the stem diameter is not within specification as
described in Section 03-o 1 A (3.8L) or Section 03-0 1 8
(4.6L), replace the valve.
Valve Spring Length Inspection
Inspect each valve spring for cracks or damage and
replace as necessary. Measure the free length of each
valve spring as shown.
A8516-C

03-0G-36 Engine-Service 03-Q0-36
---1
Valve Spring Squareness
Check each valve spring for squareness using a steel
square and a flat surface. Stand the valve spring and ROCKER
ARM BOLT
square on end of the flat surface. Slide the valve spring 390385
up to the square. Revolve the valve spring slowly and
observe the space between the inner diameter of the I
�
top coil of the valve spring and the square. Refer to the
following illustration.
ROCKER ARM
I
SEAT 6A528
�
�
ROCKER
ARM
6564
A5859-G
CAUTION: Do not attempt to true surfaces by

grinding. Check the rocker arm pad, side ralls
and seat for excessive wear, cracks, nicks or
burrs. Check the rocker arm seat bolt for stripped
or broken threads. Replace components as
required or possible damage may occur.
Inspect the pad at the valve end of the rocker arm for
CLOSED COIL END DOWNWARD A8517·B indications of scuffing or abnormal wear. If the pad is
grooved, replace the rocker arm.
NOTE: Make sure the proper valve spring
(color-coded) is installed. 4.6L Engine
NOTE: Make sure the valve springs are reassembled Inspect the valve tappet rocker arm bore for nicks,
to their OWN ORIGINAL DAMPERS by pushing scratches, scores or scuffs. Replace any damaged
damper on the valve spring. DO NOT OPEN damper parts.
with any kind of tool when reassembling. Inspect the camshaft pad of the rocker arm for
Refer to Specifications in Section 03-Q 1 B. Follow the indications of scuffing or abnormal wear. If the pad is
same procedure for new valve springs before grooved, replace the rocker arm and inspect camshaft
installation. (6250). Refer to Camshaft I Cylinder Head Journals
Inspection Procedure as described.
Inspect the roller at the valve end of the rocker arm for
indications of scuffing or abnormal wear. If the roller is
Rocker Arm grooved, replace the rocker arm.
Cleaning
Clean all parts thoroughly. Make sure all oil passages
are open. Push Rods
Make sure oil passage in the push rod I valve tappet Cleaning
end of the rocker arm (6564) is open.
Clean the push rods (6565) in a suitable solvent. Blow
Inspection out the oil passage in the push rods with compressed
3.8L Engine air.
Inspect the push rod rocker arm bore for nicks, Inspection
scratches, scores or scuffs. Replace any damaged Check the ends of the push rods for nicks, grooves,
parts. roughness or excessive wear. Replace damaged push
rods.

The push rods can be checked for straightness while Inspect the exhaust manifolds for cracks, damaged
they are installed in the engine by rotating them with gasket surfaces or other damage that would make
the valve closed. They also can be checked with a Dial them unfit for further service. Warped or cracked
Indicator with Bracketry TOOL-420 1-c or equivalent. exhaust manifolds must be replaced.
DIAL INDICATOR
WITH BRACKETRY
TOOL-4201 -C Flywheel Inspection
Transmission, Automatic
Inspect the flywheel (6375) for cracks or other
damage that would make it unfit for further service.
Inspect the flywheel ring gear for worn, chipped or
cracked teeth. If the teeth are damaged, replace the
flywheel.
PUSH ROD SPECIFICATIONS

A15361-C
TORQUE SPECIFICATIONS
CAUTION: Do not attempt to straighten push
rods. Description N·m Lb-Ft
If the push rod is bent beyond specifications, replace Tapersert Mandrel-to-Cylinder 61 45
it. Head
LUBRICANTI ADHESIVE/CLEANER SPECIFICATIONS

Ford
Intake Man ifold Description Part Number Specification
,-.. Cleaning Rotunda 164-R3705 ESE-M99C 1 03-A

Fluorescent Oil
CAUTION: Remove all filings and foreign matter Additive
that may have entered the intake manifold (9424)
Engine Oil - WSS-M2C 153-F
as a result of service or damage to the engine
may occur. Epoxy Sealer M3035-A (E)
Remove all gasket material from the machined Stud and Bearing EOAZ- 1 9554-BA WSK-M2G349-A 1
surfaces of the intake manifold. Clean the intake Mount
manifold in a suitable solvent and dry it with Threadlock E2FZ-1 9554-B WSK-M2G35 1 -A6
compressed air.
Inspection
SPECIAL SERVICE TOOLS/ EQUIPMENT
CAUTION: Check the baffle plates on the
underside of the lower intake manifold if so
equipped. The baffles should be securely SPECIAL SERVICE TOOLS REQUIRED
fastened or damage to the engine may occur. Tool Number I
Inspect the intake manifold for cracks, damaged Description Illustration
gasket surfaces or other conditions that would make it T50T- 1 00-A
�
unfit for further service. Replace all studs that are Impact Slide Hammer
stripped or otherwise damaged. Clean the Exhaust
Gas Recirculation (EGR) passages. TIOT-1110-A
T59L- 100-B
�
Impact Slide Hammer
Exhaust Manifold na.-1ao.a
Cleaning (Continued)
Remove all gasket or foreign material from all inlet and

outlet sealing surfaces of the exhaust manifolds
(9430).
!""'""""' Inspection
Inspect the cylinder head joining flanges of the exhaust
manifolds for evidence of exhaust gas leaks.

SPECIAL SERVICE TOOLS/EQUIPMENT

(Continued)
SPECIAL SERVICE TOOLS REQUIRED (Cont'd) SPECIAL SERVICE TOOLS DESIRED (Cont'd)
Tool NumberI Tool Number Description
Description Illustration
D8 1 L-6002-D Piston Ring Groove Cleaner
T73L-60 1 1 -A
D83L-420 1 -A Straight Edge
'
Engine Cylinder Hone Set
D87C-77000-A Transmission Test Adapter
TOOL-420 1 -C Dial indicator with Bracketry
TOOL-6505-E Valve Stem Clearance Tool
TOOL-65 1 3-DD Valve I Clutch Spring Tester
T73L-41011-A
TOOL-6565-AB Cup Shaped Adapter
T73L-6600-A
Engine Oil Pressure Gauge
�o
ROTUNDA EQUIPMENT
� Model Description
T73L-IMIOO-A 0 1 4-00705 Pressurization Kit
0 1 4-R00707 Compression Tester
SPECIAL SERVICE TOOLS DESIRED 0 1 4-R1054 Vacuum I Pressure Tester
Tool Number Description 107-R092 1 Sav-A-Thread Spark Plug Kit
D81 L-420 1 -A Feeler Gauge 164-R0756 Oil Leak Detector
D81 L-6002-B Plastigage 164-R3705 Fluorescent Oil Additive
(Continued)

03·01A- 1 Engine, 3.8L 03·01A·1
r" SECTION 03·0 1 A Engine, 3.8L

VEHICLE APPLICATION ••••••••••••••••••••••••••••••••••••••••••• 03..0 1A-1 IN-VEHICLE SERVICE (Cont'd.)
DESCRIPTION AND OPERATION Oil Bypass Filter • . . • • . . • • . . • . . . . • • . • •••••• • . . • . . . •• . . . •• • . • • • . . • 03..0 1 A-4 1
Camshaft • • • . . . • • . . •••.•••••..••••••.•••.•••••• . . • • . . • • • . . • . . . •• • • • . • 03.0 1A·2 Oil Level Indicator Tube • • . . . • • • . • • . . . . . . •• • • . • . • . ••••••••.•• 03-o 1 A-41
Crankshaft ••••••••••••.••••••••••••••••••••••••••••••••••••••••••••• 03-o 1 A-2 011 Pan/Oil Pump Screen Cover and
Drive Belt System • . .••••••••••• . • • • • . . • • . ••••••••••..•••••••••••• 03..01 A-3 Tube • . • • . . • .•••••• . • • . . . • . . •••.•••..•••..••.•••.•• . . • . . . • • • . . . . . . • 03.01A·32
Emission Calibration Label ••••.•••..•. .•••••. ••••••••••• . . • . 03·0 1 A-2 Oil Pump .••.•..••.••..•••••••••••••• ..••.. .••••••.••.• ••••••••••••.. 03..01A·35
Engine • . ••••••••••••. . • . . • • • . . • • • . . • • . . • • . . • • . . • . . ••.•••••••.••..•••.•• 03..0 1 A-1 Pistons and Connecting Rods .•••••••..•••• •••••••••••••• 03..01A·37
Engine Code Information . . • . . ••••••.•••••••••.••••.••..•••••• 03·01A·2 Rocker Arm •••.....••.•••.....•..••.••..•.•....•..•..••..•••.•.•.• 03..01A·1 1
Engine Cooling System ••..••. ••••••••••••••••••••••.•• •••••••• 03.01A·3 Sensors •••••••••. • . . . • • . • • . . • . . • • . •••••••••••.••••..••.••••••••••••. 03..0 1 A-42
Engine Identification ••••••.••.•••..••••••••••••••••.•••.•••.••• 03.01A-1 Timing Chain, Sprockets, Tensioners and
Engine Lubrication System .••.••••••.••••••.•••.••..••..•••• 03·01A-3 Guides • . • . .••.•••••.••• . . • . . • • . • • . ••••••••••••..••.•••••••••••••. 03..01A·27
Exhaust Emission Control System 03.01 A·2
• • • • • • • • . • • • • • • • • • • • • • •• Valve Cover and Gasket • . . • . . •• • . . • • • . • • • . • • • . . • • • • • . • • . • • . • 03..01A·10
Induction System ..• ••••••• . . • • . • • • • • . . • • . . •• . •••••••••••.••••••. 03.01A·2 Valve Spring, Retainer and Valve Stem
Positive Crankcase Ventilation System • • . . ••.• •••••••. 03.01A·3 Seai••••••••••.••.••••••••.. •••••••••• . . . • . . • . ••••••••.•••••••••••• 03..01A·1 1
Valve Train •••••••••••..•••••••••••••• •••••••.••..••••••.. ••••••••••• 03.01A-3 Valve Tappet, Hydraulic • • • • • • • • • . . • . • . . • •• • • • • • • • • . • • . . • • . • • 03..01A·12
IN·VEHICLE SERVICE Water Pump ••.••••••••• •••••• . . • • • . . • . . • .•••••.••. . • • • . ••••••••••• 03..01 A·22
Camshaft ••••••••••••••••••• ••••••••••••••••••••••••••••.•.•••••••• 03..0 1 A·29 REMOVAL AND INSTALLATION
Camshaft Rear Bearing Cover • • • • • . • . . • • • . ••••••••••••••• 03.01A·40 Camshaft Bearings ••••••.•• • . • • . . • • . . • • ••••• . . . . . •• . . •• . . ••••• 03..0 1 A-44
Connecting Rod Bearings ••••••••••••••••••••.•••..•••••••• 03-o 1 A·39 Crankshaft • • . . • . . • . . • . . • . . • .• • • • . • . • . . • • . • . ••.•••••••••..•••.•••.• 03..01 A·46
Crankshaft Main Bearings ••••••.••.•••••••••.••.•••.••..••• 03-o 1 A-35 Engine• • • • • . . • . . . • • • • . • • . • . . •• • . • • • . . • • • • • . • . . • • . •• • • • . . . •••••••••... 03..01A·43
Crankshaft Pulley /Damper /Crankshaft Front DISASSEMBLY AND ASSEMBLY
Seai •••••••••••••••••• .••••••••••••••••••••.••.•••••••••••••••••••• 03·01 A·2 1 Englne•••••.••..••. ••.••••••••.••• . . • . . • . . • . • • • • . • • . • • . . . • . . •• . •••••• 03..01A·48
Crankshaft Rear Oil Seai . .••••••••••••••.••••••••.•••••••••• 03·01A-40 Subassemblies • . . • . • . . • • •••••••• . • • . • • . • • . . ••••••••••••••••••..• 03..0 1 A-55
Cylinder Heads ••••••••••••••••••.••••••••••••••••••••••••••••••• 03-0 1 A·19 Cylinder Head • . • • . . • • . • • . •• . . ••••• •••• . • • • . • • . . • • . . •••••••.•• 03..01A·55
Engine Components • • . . ••••••••••••• . • • • . . ••••••••••••••••••••• 03·01A·4 Pistons, Piston Pins and Rings •••••••••.••..•••..••••• 03..0 1 A-56
Engine Front Cover ••••..•• . ••••••••••••• • . . • • . . •••••••••••••• 03.01 A·24 ADJUSTMENTS
Exhaust Manifolds . . • • • • • • • . • . • • • . . • • . ••••••••••••• . • • . • • . ••••• 03..0 1 A·30 Valve Clearance •.••..••.•• •••••••• .•••.••.•...• •••••••• . . . • • . . • 03..0 1A·59
Flywheei ••••••••••• . • • • . . •••.•••••••••••• • . . • • . . •••••••••••.••.•••• 03·01A·39 SPECIFICATIONS ••••••.••••••••••••••••• • • • . . • . . • . . .••••••••••.••• 03..0 1 A·59
Intake Manifold •.••. .••••••.••.••••••• . . •• • . . • • • . . • • . • • • . • • • • . . • 03..01 A·13 SPECIAL SERVICE TOOLS/EQUIPMENT •••.•••••••••••. 03.01A·64
Upper ••••••.•••••.••••••• • • • . . • . . • • . . ••.• ••••••••..•••.••••••••••• 03.01A·13
VEHICLE APPLICATION
Thunderbird, Cougar
DESCRIPTION AND OPERATION
Engine
The 3.8L sequential multipart fuel injection (SFI) engine
has V·block construction with the following features:
• overhead valves
• lightweight, compact and similar to a V-8 engine in
construction and components
Engine codes and calibration number must be used
when ordering parts or making inquiries about the
engine.

..--
I
03·01A·2 Engine, 3.8L 03·01A·2
Engine Code Information Six solenoid-operated fuel injectors mounted in the

The engine code information label located on the valve cylinder heads (6049) meter fuel into the.air intake
cover (6582) contains the following: stream according to engine demand.
The six fuel injectors are:
• engine calibration number
• positioned so that their tips direct fuel just ahead of
• engine build date
the engine intake valves (6507).
• engine plant code
• connected in parallel with the fuel pressure
• engine code regulator (9C968).
Fuel:
Engine Code Information Label
• is supplied from the vehicle fuel tank (9002) by a
ENGINE BUILD DATE
��==�==�---�ECODE high-pressure electric fuel pump (9350) mounted in
the fuel tank.
• is filtered and sent to the fuel injection supply
manifold (9F792).
II I
A fuel pressure regulator on the fuel injection supply
manifold controls the fuel delivery pressure at a
/ PLANT INFORMATION constant 269 kPa (39 psi). Excess fuel supplied by the
PLANT INFORMATION A11468-B fuel pump, but not needed by the engine, is returned to
the fuel tank by a fuel return line.
The fuel induction system is mounted on an aluminum
intake manifold (9424) which, in turn, is bolted to
aluminum aHoy cylinder heads. The intake manifold
Emission Calibration Label
and cylinder head are cast from aluminum to aid in
NOTE: The calibration number must be used when removing weight from the engine.
ordering parts or making inquiries about the engine.
The emission calibration number label located on the
LH quarter latch pillar (281 60) identifies:
Crankshaft
• the engine calibration number.
The crankshaft (6303):
• engine code number.
• is supported on the bottom of the cylinder blocks
• revision level.
(60 1 0) by three steel-backed, over-plated
These numbers are used to determine if parts are copper-lead crankshaft main bearings (6333).
unique to specific engines.
• piston crankpins are positioned to provide a power
impulse every 1 20 degrees of crankshaft rotation,
providing smooth engine operation.
CALIBRAT ION
E TAL ONNAGE � • is connected to the camshaft (6250) by sprockets
and a timing chain (6268) with timing chain vibration
CAL l BRACI ON damper (6284) which provide a 2: 1 drive ratio.
r' 7-25F-ROO .......... .ABv
CALIBRATION
REVISION NUMBER A11644-E Camshaft
The camshaft (6250) is:
• installed in the cylinder blocks (60 1 0).
• supported on four babbit-lined camshaft bearings
Exhaust Emission Control System (626 1).
Operation and required maintenance of the exhaust • Thrust loads and end play are limited by a camshaft
emission control devices used on this engine are thrust plate (6269) installed at the front of the
covered in the Powertrain Control I Emissions camshaft.
1
Diagnosis Manual •
Immediately in front of the camshaft thrust plate are:
• a camshaft sprocket spacer (6265).
• the camshaft sprocket (6256).
Induction System
• the distributor drive gear (6255).
Sequential multiport fuel injection (SFI) provides the
fuel I air mixture needed for burning in the cylinder.

03-01 A-3 Engine, 3.8L 03-01A-3
Valve Train Oil Pan

The valve train consists of: The moulded aluminum oil pan (6675) is bolted to the
bottom of the cylinder blocks (60 1 0).
• hydraulic roller valve tappets (6500) which provide
automatic lash adjustment. While riding on camshaft The oil pan acts as a reservoir holding lubricating oil
lobes, their up-and-down motion is transferred to the that is pumped through the engine by the oil pump after
rocker arms (6564) through push rods (6565). start-up.
• six valve tappet guide plates (6K5 1 2) which are
held in place by a spring steel tappet guide plate
and retainer (6K564) preventing the roller valve
tappets from turning. Engine Cooling System
• pedestal-mounted rocker arms pivoting on rocker The engine cooling system consists of:
arm seats (6A528) which are bolted to the cylinder • radiator (8005).
heads (6049).
• water pump (850 1).
The valves are arranged alternately intake valve
(6507) I exhaust valve (6505). • cooling fan motor (8K62 1 ) and fan blade (8600)
which are activated by the constant control relay
module (CCRM).
• radiator coolant recovery reservoir (8A080) which
Positive Crankcase Ventilation System is located beside the radiator and aids in maintaining
the correct volume of engine coolant mixture in the
All engines are equipped with a positive closed-type cooling system.
crankcase ventilation system recycling the crankcase
vapors to the intake manifold (9424). The water pump is:
• of a conventional design.
• driven by the accessory drive belt (8620).
Engine Lubrication System
/"'""'- Oil Pump
The engine lubrication system is of the force-feed type Drive Belt System
in which oil is supplied from the oil pump (6600) under The 3.8L OHV engine is equipped with a serpentine
full pressure to the following: drive belt (8620). To ensure maximum life, always
• crankshaft (6303) replace the drive belt with the same type as originally
installed.
• connecting rod bearings (62 1 1 )
The drive belt system operates as follows:
• hydraulic valve tappets (6500)
• The accessories mounted on the front of the engine
• camshaft bearings (626 1 )
are belt-driven.
A controlled volume of oil through the valve tappets is
• A serpentine drive belt is routed over each
supplied to:
accessory pulley.
• push rods (6565). • The accessory pulleys are driven by the crankshaft
• rocker arms (6564). pulley (63 1 2) which is bolted to the crankshaft
(6303).
All other moving parts are lubricated by gravity flow or
splash. For service procedures, including tensioning, refer to
Section 03-05.
The rotary gear-type oil pump:
• develops the oil pressure.
• is located in the engine front cover (60 1 9).
• is rotated by the camshaft position sensor housing
shaft through an oil pump intermediate shaft
(6A6 1 8).
A full-flow oil bypass filter (67 14) is externally
mounted on the oil pump and filter body (6603).
Normally all engine oil passes through the oil bypass
filter element. However, if the oil bypass filter element
should become restricted, a spring-loaded bypass
valve will open which allows an uninterrupted flow of oil
to the engine's moving parts.

03·01A·4 Engine, 3.8L 03-01A·4
IN-VEHICLE SERVICE
Engine Components
3.8L Engine-Disassembled View

03-01 A-5 Engine, 3.8L 03-01 A-5
IN-VEHICLE SERVICE (Continued)
3.8L Engine- Disassembled View (Continued)

03·01A·6 Engine, 3.8L 03·01 A·6
3.8L Engine-Disassembled View (Continued)

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03·01A-8 Engine, 3.8L 03·01 A·8
Part P a rt
Item Number Description Item N umber Description
1 N807609 Nut 43 N805840 Stud Bolt
2 9J433 EGA Transducer 44 90930 Fuel Charging Wiring
3 N804178 Nut 45 W701 775 Bolt (4 Req'd)
4 N804278 Nut (3 Req'd) 46 N606689 Bolt
5 N8076 10 Stud Bolt 47 14A163 Wiring Harness Retainer
6 9E936 Throttle Body Gasket 48 9F792 Fuel Injector (6 Req'd)
7 N804834 Bolt 49 9F792 Fuel Injection Supply
8 N804268 Bolt (4 Req'd) Manifold
9 9E948 Vacuum Tube 50 N805424 Bolt
10 9E948 Vacuum Tube 51 N808250 Bolt
11 -
Not Used 52 2882 A I C Compressor Mounting
Bracket
12 90460 Bolt (2 Req'd) 53 N807488 Stud
13 90475 EGA Valve 54 N807442 Stud Bolt
14 9424 Intake Manifold 55 N807443 Bot (4 Req'd)
15 9H286 Intake Manifold Gasket 56 6A666 Positive Crankcase
Upper Ventilation Valve
16 8A574 Water Outlet Connection 57 6758 Crankcase Ventilation Tube
Metering Plug
17 8C309 Water Outlet Connection 58 381 188 Tube (2 Req'd)
Plug Gasket 59 9439 Intake Manifold Gasket, RH
18 10884 Water Temperature Indicator 60 1 2405 Spark Plug (3 Req'd)
Sender Unit 61 605 1 Head Gasket, LH
19 8548 Water Bypass Tube 62 9439 Intake Manifold Gasket, LH
20 W701588 Bolt (5 Req'd) 63 6049 Cylinder Head, LH
21 9424 Intake Manifold 64 6582 Valve Cover, LH
22 N390633 Bolt (4 Req'd) 65 6766 Oil Filler Cap
23 9A424 Intake Manifold Seal Rear 66 6853 Crankcase Ventilation Hose
24 9A424 Intake Manifold Seal Front 67 N807442 Stud Bolt (2 Req'd)
25 60 10 Cylinder Blocks 68 N807443 Bolt (3 Req'd)
26 6522 Push Rod Valley Baffle 69 1 2405 Spark Plug (3 Req'd)
27 W701607 Bolt (2 Req'd) 70 9448 Exhaust Manifold Gasket, LH
28 8594 Water Outlet Connection 71 9430 Exhaust Manifold, LH
29 8A570 Water Thermostat 72 N807002 Stud Bolt (3 Req'd)
30 W701589 Stud Bolt (2 Req'd) 73 1 7A084 Engine Lifting Eye
31 8597 Water Bypass Hose 74 N62 1939 Nut (2 Req'd)
32 18599 Fitting 75 N62 1939 Nut
33 12A648 Engine Coolant Temperature 76 6754 Oil Level Indicator Tube
Sensor
77 17A605 Windshield Washer Hose
34 N807609 Nut
78 N801647 Bolt (3 Req'd)
35 N804207 Bolt
79 6A008 Cylinder Head to Block
36 9J444 Intake Manifold Support Dowel (2 Req'd)
37 N605908 Bolt (2 Req'd) 80 605 1 Head Gasket, RH
38 9723 Accelerator Cable Bracket 81 9448 Exhaust Manifold Gasket,
39 9737 Accelerator Retracting RH
Spring 82 90447 Vacuum Tube to Intake
40 9P76 1 EGA Vacuum Control Valve Manifold Clip
Hose 83 N801647 Bolt (2 Req'd)
41 9P76 1 EGA Vacuum Control Valve 84 N62 1939 Nut (2 Req'd)
Hose
85 N62 1939 Nut (2 Req'd)
42 9E936 Throttle Body Gasket
(Continued)
(Continued)

03-0 1A-9 Engine, 3.8L 03-01A-9
Part Part
Item Number Description Item Number Description
86 17A084 Engine Lifting Eye 130 12270 Hold-Down Clamp
87 N805530 Bolt 131 6020 Engine Front Cover Gasket
88 9G297 Evaporative Emission Hose 132 N804853 Stud (3 Req'd)
89 N800419 Nut 133 38031 7 Pipe Plug
90 N805425 Bolt 134 N805757 Stud
91 6582 Valve Cover, RH 135 N804839 Bolt
92 9C968 Fuel Pressure Regulator, RH 136 N806 1 12 Stud Bolt (2 Req'd
93 9430 Exhaust Manifold, RH 137 N605908 Bolt (3 Req'd)
94 N807002 Stud Bolt (4 Req'd) 138 N804852 Stud Bolt
95 18472 Heater Water Hose 139 N8082 17 Bolt
96 12280 Ignition Wire and Bracket 140 6255 Distributor Drive Gear
97 12281 Spark Plug Wire Set 141 6256 Camshaft Sprocket
98 18663 Heater Water Outlet Tube 142 6268 Timing Chain I Belt
99 N606676 Bolt 143 6K305 Engine Balance Shaft Gear
100 N807609 Nut Spacer
101 12A1 12 Camshaft Position Sensor 144 N80462 1 Screw (2 Req'd)
102 12A362 Camshaft Synchronizer 145 6269 Camshaft Thrust Plate
103 37958 Cup Plugs (2 Req'd) 146 6265 Camshaft Sprocket Spacer
104 87744 Pipe Plug (2 Req'd) 147 N805256 Woodruff Key
105 6397 Flywheel Housing to Block 148 6250 Camshaft
Dowel (2 Req'd) 149 6K564 Tappet Guide Plate and
106 9278 Oil Pressure Sensor Retainer (2 Req'd)
107 N800299 Fitting 150 6500 Valve Tappet (12 Req'd)
108 87744 Pipe Plug 151 6565 Push Rod (6 Req'd)
109 670 1 Crankshaft Rear Oil Seal 152 6564 Rocker Arm (6 Req'd)
1 10 6C057 Engine Block Plug (2 Req'd) 153 6A528 Rocker Arm Seat (6 Req'd)
111 6397 Flywheel Housing to Block 154 N808305 Bolt (6 Req'd)
Dowel 155 65 14 Valve Spring Retainer (6
1 12 9F008 Oil Pump and Filter Body Req'd)
1 13 67 14 Oil Bypass Filter 156 657 1 Valve Stem Seal (6 Req'd)
1 14 N80484 1 Bolt 157 65 17 Valve Spring Retainer
Sleeve (6 Req'd)
1 15 6C315 Crankshaft Position Sensor 158 65 14 Valve Spring Retainer (6
1 16 N806976 Stud Bolt (2 Req'd) Req'd)
1 17 N620478 Nut (2 Req'd) 159 65 18 Valve Spring Retainer Key (6
1 18 6K342 Crankshaft Position Sensor Req'd)
Upper Shield 160 N807699 Bolt (4 Req'd)
1 19 6A328 Engine Balance Pin 161 N807324 Bolt (3 Req'd)
120 63 12 Crankshaft Pulley 162 6505 Exhaust Valve (3 Req'd)
121 N801539 Washer 163 6507 Intake Valve (3 Req'd)
122 N800069 Bolt 164 670 1 Crankshaft Rear Oil Seal
123 N62 1939 Nut (2 Req'd) 165 6303 Crankshaft
124 12A310 Radio Interference 166 6337 Crankshaft Thrust Main
Capacitor Bearing
125 N605906 Bolt 167 6325 Rear Main Bearing Cap
126 N804758 Nut (4 Req'd) 168 N8054 16 Bolt (7 Req'd)
127 8501 Water Pump 169 N8054 1 7 Stud Bolt
128 8507 Water Pump Housing Gasket 170 6622 Oil Pump Screen Cover and
129 6A618 Oil Pump Intermediate Shaft Tube
(Continued)
171 N801689 Bolt (2 Req'd)
(Continued)

03·01A·10 Engine, 3.8L 03·0 1 A· 1 0
Part Part
172 6626 Oil Pump Inlet Tube Gasket 187 6 16 1 Piston Ring (6 Req'd)
173 N62 1942 Nut 188 6 100 Piston and Connecting Rod
174 6329 Main Bearing Cap Assy (6 Req'd)
175 6334 Main Bearing Cap 189 6200 Connecting Rod Assy (6
Req'd)
176 6333 Crankshaft Main Bearing (3 190 62 10 Connecting Rod Cap (6
Req'd) Req'd)
177 388907 Woodruff Key 191 62 1 1 Connecting Rod Bearing (12
178 6337 Crankshaft Thrust Main Req'd)
Bearing 192 6205 Connecting Rod (6 Req'd)
179 6284 Timing Chain Vibration 193 6 135 Piston Pin (6 Req'd)
Damper
180 N605890 Bolt (3 Req'd) 194 6 108 Piston (6 Req'd)
181 6306 Crankshaft Sprocket 195 6 159 Piston Ring (6 Req'd)
182 N808319 Bolt 196 N805 18 Bolt (6 Req'd)
183 6333 Crankshaft Main Bearing (3 1 97 6375 Flywheel
Req'd) 198 7007 Engine Rear Plate
184 6327 Main Bearing Cap 199 N605892 Bolt (16 Req'd)
-
185 6152 Piston Ring (6 Req'd) 200 Gasket (Form in Place)
186 6150 Piston Ring (6 Req'd) 20 1 6675 Oil Pan
(Continued) 202 6723 Oil Pan Rear Seal
Valve Cover and Gasket 2. Position valve cover on the cylinder head and
install retaining bolts. Note location of ignition wire
Removal routing clip stud bolts. Tighten retaining bolts to
1. Disconnect ignition wires from spark plugs 8- 1 2 N·m (7 1 - 1 06 1b-in).
( 1 2405). Refer to Section 03-07A. 3. If LH valve cover is being installed, proceed with
2. Remove ignition wire routing clips from valve the following steps:
cover retaining bolt studs. a. Install oil filler cap.
3. If LH valve cover (6582) is being removed, b. Install crankcase ventilation tube (6758).
proceed with the following steps:
4. If RH valve cover is being installed, install positive
a. Remove oil filler cap (6766). crankcase ventilation valve.
b. Remove crankcase ventilation hose (6853). 5. Install ignition wire routing clips.
4. If RH valve cover is being removed, remove 6. Connect ignition wires to spark plugs. Refer to
positive crankcase ventilation valve (PCV Section 03-Q7A.
valve)(6A666).
7. Start engine and check for oil leaks.
5. Remove valve cover retaining screws, valve
cover and valve cover gasket (6584).
Installation
1. NOTE: Lightly oil bolt and stud threads before
installation. Using solvent, clean cylinder head
(6049) and valve cover sealing surfaces to
remove all gasket material and dirt.
Position and install a new valve cover gasket onto
valve cover.

03-01A- 1 1 Engine, 3.8L 03-01A- 1 1
IN-VEHICLE SERVICE (Continued}

�""'"'·
Valve Cover and Gasket- LH Side Shown, RH Side Valve Spring, Retainer and Valve Stem Seal
Similar
Removal
1. Remove valve covers (6582) and rocker arms
(6564) as described.
2. Remove spark plug ( 1 2405) from applicable
cylinder. Refer to Section 03-07A.
3. Position piston (6 1 08) at top of stroke with both
exhaust valve (6505) and intake valve (6507)
closed.
4. NOTE: Failure of air pressure to hold the exhaust
valve and intake valve closed while performing
the following steps is an indication of valve
and I or valve seat damage and requires removal
of cylinder head (6049).
Install an air line with an adapter in the spark plug
hole and turn air supply on.
A18907-B 5. Compress valve spring (65 1 3) using a suitable
valve spring compressor following tool
Part manufacturer's instructions.
Item Number Description 6. CAUTION: If air pressure has forced the
piston to the bottom of the cylinder, any loss
1 6582 Valve Cover of air pressure will allow the valve(s) to fall
2 N807442 Bolt (3 Req'd) into the cylinder. A rubber band, tape or
3 N807443 Stud (2 Req'd) string wrapped around the end of the valve
4 6049 Cylinder Head stem will prevent this from happening and
still allow enough travel to check the valve
5 6584 Valve Cover Gasket for binds and excessive guide-to-valve stem
�. A -
Tighten to 8- 12 N·m (7 1 - 1 06 clearance.
Lb-ln) Remove valve spring retainer keys (65 18), valve
spring retainer (65 14) and valve spring.
7. Using locking pliers, remove valve stem seal
Rocker Arm (657 1 ).
8. Repeat Steps 2 through 7 until all necessary
Removal valve stem seals are removed.
1. Remove valve covers (6582) as described.
Installation
2. Remove rocker arm seat retaining bolts from
cylinder heads (6049) and remove rocker arms 1. NOTE: Piston must be at top dead center (TDC)
(6564). of cylinder being serviced.
Remove air pressure from spark plug adapter.
Installation Inspect the valve stem for damage. Rotate the
1. Lubricate all rocker arms with Engine Assembly valve and check the valve stem tip for eccentric
Lubricant D9AZ- 1 9579-D or equivalent meeting movement during rotation. Move the valve up and
Ford specification ESR-M99C80-A. down through normal travel in the valve guide and
2. CAUTION: Rocker arm seats (6A528) must check the stem for binds.
be fully seated in cylinder head and push 2. CAUTION: If the valve has been damaged, it
rods (6565) must be seated In rocker arm will be necessary to remove the cylinder
sockets prior to final tightening or damage to head for service. Refer to Section 03-00.
engine may occur. If the condition of the valve is satisfactory, apply
For each valve, rotate crankshaft (6303) until clean engine oil to the valve stem and hold the
valve tappet (6500) rests onto heel (base circle) valve closed. Apply the air pressure within the
of camshaft lobe. Position rocker arms over push cylinder.
rods. Install rocker arm seats. Tighten rocker arm 3. Install new valve stem seal. Make sure valve stem
seat retaining bolts to 5 N·m (44 1b-in) MAX. seal is bottomed on guide.
3. Final-tighten rocker arm seat bolts to 30-40 N·m 4. Position valve spring and valve spring retainer
(22-29 1b-ft). For final tightening, the camshaft over valve stem.
(6250) may be in any position.
5. Compress valve spring using a suitable valve
4. Install valve covers as described. spring compressor and install valve spring
retainer keys.
l
03-01A- 12 Engine, 3.8L 03·01 A- 1 2
6. Remove valve spring compressor. Installation

7. Turn air supply off and remove adapter from 1. Using solvent, clean the cylinder head (6049) and
spark plug hole. valve sealing surfaces.
8. Install spark plug. Refer to Section 03-Q7A. 2. NOTE: Lightly oil all bolt and stud threads before
9. Install rocker arms and valve covers as installation, except those specifying special
described. sealant.
10. Start engine and check for leaks. Lubricate each valve tappet and bore with Engine
Assembly Lubricant D9AZ- 1 9579-D or equivalent
meeting Ford specification ESR-M99C80-A.
3. Install each valve tappet in bore from which it was
Valve Tappet, Hydraulic removed. If new valve tappets are being installed,
check for free fit in bore into which they are to be
NOTE: Before replacing a valve tappet (6500) for installed.
noisy operation, make sure the noise is not caused by
improper valve-to-rocker arm clearance or by worn 4. Align flats on side of valve tappets and install six
rocker arms (6564) or push rods (6565). valve tappet guide plates between adjacent valve
tappets (make sure the word "up" is showing).
SPECIAL SERVICE TOOL(S) REQUIRED Install two tappet guide plates and retainers and
tighten four captive bolts to 1 Q- 1 4 N·m (89- 1 23
Description Tool Number lb-in).
Spark Plug Wire Remover T74P-6666·A 5. Dip each push rod end in Engine Assembly
Lubricant D9AZ- 1 9579-D or equivalent meeting
Removal Ford specification ESR-M99C8Q-A. Install push
1. Disconnect ignition wires at the spark plugs rods in their original location.
(1 2405). To avoid damaging ignition wires use 6. Lubricate all rocker arms with Engine Assembly
Spark Plug Wire Remover T74P-6666·A. Refer to Lubricant D9AZ- 1 9579-D or equivalent meeting
Section 03-Q7A. Ford specification ESR-M99C8Q-A.
2. Remove ignition wire routing clips from studs on 7. CAUTION: Rocker arm seats (6A528) must
the valve cover retaining bolts. Lay ignition wires be fully seated in cylinder heads and push
with routing clips toward front of engine. rods must be seated in rocker arm sockets
3. Remove upper intake manifold (9424) as prior to final tightening or possible damage
described. to engine may occur.
4. Remove valve covers (6582) as described. For each valve, rotate crankshaft (6303) until
valve tappet rests onto heel (base circle) of
5. Remove lower intake manifold as described. camshaft lobe. Position rocker arms over push
6. Sufficiently loosen each rocker arm seat retaining rods. Install rocker arm seats. Initially tighten
bolt to allow rocker arm to be lifted off push rod rocker arm seat retaining bolts to 5 N·m (44 1b-in)
and rotated to one side. MAX.
7. Remove push rods. The location of each push rod Final-tighten rocker arm seat bolts to 30-40 N·m
should be identified. When engine is assembled, (22-29 lb-ft). For final tightening, the camshaft
each push rod should be installed in its original (6250) may be in any position.
position. 8. Install lower intake manifold as described.
8. Remove four bolts holding two tappet guide 9. Install rocker arms as described.
plates and retainers (6K564) in place (bolts are
held captive in retainers). Remove six valve 10. Install upper intake manifold as described.
tappet guide plates (6K5 1 2) from adjacent valve 1 1 . Install ignition wire routing clips and connect
tappets. ignition wires to the spark plugs. Refer to Section
9. Remove valve tappets using a magnet The 03-Q?A.
location of each valve tappet should be identified.
When engine is assembled, each valve tappet
should be installed in its origi�al position.
If valve tappets are stuck in bores due to
excessive varnish or gum deposits, it may be
necessary to use a claw-type tool to aid removal.
When using a remover tool, rotate valve tappet
back and forth to loosen it from gum or varnish
that may have formed on the valve tappet.

03-01A- 1 3 Engine, 3.8L 03-0 1 A- 1 3
12. Start engine and check for oil or coolant leaks. 9. Remove the nut and bolt retaining engine support
and wiring retainer bracket located at the LH
front of the intake manifold and set aside with
ignition wires.
10. Remove upper intake manifold retaining
bolts I studs.
1 1 . Remove upper intake manifold and intake
manifold upper gasket {9H486).
Part
Item Number Description
1 N605890-S2 Bolt (4 Req'd)
2 6K564 Tappet Guide Plate and
Retainer (2 Req'd)
3 6500 Valve Tappet (12 Req'd)
4 60 10 Cylinder Blocks
-
A Tighten to 10-14 N-m (7- 10
Lb-Ft)
e TIGHTEN IN SEQUENCE IN THREE STEPS

Intake Manifold
Upper
Removal 0 REFER TO CALLOUT TABLE AA1005-A
1. Remove air cleaner outlet tube {98659). Refer to
Section 03-12. Part
2. Disconnect accelerator cable {9A758) at throttle Item Number Description
body {9E926). Disconnect speed control
actuator cable {9A825) {if equipped).
1 N804268 Bolt (4 Req'd)
2 N805840 Stud Bolt
3. Remove retaining bolts from accelerator cable
and position cables aside. 3 9424 Intake Manifold, Lower
-
4. Disconnect vacuum lines at upper intake manifold 4 Locating Pins (2 Req'd)

{9424). 5 9H486 Intake Manifold Upper
Gasket
5. Disconnect necessary electrical connectors.
6 9424 Upper Intake Manifold
6. Disconnect crankcase ventilation tube {6758) at
the upper intake manifold and at positive 7 N804834 Bolt
-
crankcase ventilation valve {PCV valve){6A666). A Tighten in sequence in three
steps:
7. Remove throttle body if necessary. Refer to e 10 N·m (8 Lb-Ft)
Section 03-04A. e 20 N·m ( 15 Lb-Ft)
• 32 N·m (24 Lb-Ft)
8. Remove the EGR valve {EGR valve){9D475) from
the upper intake manifold. Refer to Section
03-QS.

03·01A-14 Engine, 3.8L 03·01A· 1 4
Installation
Part
1. NOTE: Use locating pins to secure position of
intake manifold upper gasket between upper
intake manifold and lower intake manifold. 3 9E936 Throttle Body Gasket
NOTE: When the upper intake manifold is 4 9E926 Throttle Body
removed, always use a new intake manifold 5 N8076 10 Stud Bolt
upper gasket upon reassembly. 6 N805328 Nut (3 Req'd)
Position new intake manifold upper gasket and -
A Tighten to 20-30 N-m ( 15-22
upper intake manifold on top of lower intake Lb-Ft)
manifold.
6. Connect crankcase ventilation tube to positive
2. NOTE: Apply a light coat of Pipe Sealant with
crankcase ventilation valve on the upper intake
Teflon® D8AZ- 1 9554-A or equivalent meeting
manifold.
Ford specification WSK-M2G350-A2 to retaining
bolts and stud bolt threads prior to installation. 7. Connect necessary fuel charging wiring
connectors.
Install bolts and stud bolts in original locations.
8. Connect necessary vacuum hoses.
lighten in sequence as shown under Removal
Step 18, in three steps: 9. Position accelerator cable bracket (9723). Install
and tighten retaining bolts to 1 4-20 N-m ( 1 1 - 1 4
• 1 0 N-m (8 lb-ft) lb-ft).
• 20 N-m ( 1 5 lb-ft) 1 0. Connect accelerator cable at throttle body.
• 32 N-m (24 lb-ft) Connect speed control actuator cable (if
equipped).
3. Install engine support and wiring bracket and
retaining nut and bolt to LH front of the upper 1 1 . Install air cleaner outlet tube. Refer to Section
intake manifold. lighten bolt to 2Q-30 N-m ( 1 5-22 03- 1 2.
lb-ft). lighten nut to 8-1 1 N-m (7 1 -97 lb-in). 1 2 . Check and adjust accelerator cable if necessary.
4. Install the EGR valve as described in Section Refer to Section 1 0-Q2.
03-Q8. 13. Check and, if necessary, adjust engine idle
5. Install throttle body if removed. Cross-tighten airflow. Refer to Powertrain Control / Emissions
retaining nuts to 20-30 N-m ( 1 5-22 1b-ft). Diagnosis Manual. 2
14. Check and adjust speed control actuator cable if
necessary. Refer to Section 1 0-Q3.
Lower
/ Removal
1. Drain engine cooling system as described in
Section 03-Q3.
2. Remove upper intake manifold as described.
3. Remove fuel injectors and fuel injection supply
manifold (9F792). Refer to Section 03-Q4A.
4. Remove heater water inlet hose.
A20849-C
Part
1 9424 Intake Manifold, Upper
-
2 Stud (Part of 9424)
(Continued)

03-01A- 1 5 Engine, 3.8L 03-01A- 1 5
Fuel Injection Supply Manifold
_...,
FRONT OF ENGINE
�
VIEW A
NOTE: LUBRICATE
FUEL INJECTOR
BORES OR 0-RINGS
WITH MOTOR OIL
PRIOR TO INSTALLATION
SIX PLACES
�
�
FRONT OF ENGINE
AA1006-A
Part Part
1 W701 775 Bolt (4 Req'd) 5 6049 Cylinder Head
-
2 9F792 Fuel Injection Supply A Tighten to 8- 1 1 N·m (7 1-97
Manifold Lb-ln)
-
3 9424 Intake Manifold B Tighten to 20-30 N·m (15-22
4 N606689 Bolt Lb-Ft)
(Continued)

03·01A·16 Engine, 3.8L 03·01 A· 1 6
Heater Water Inlet Hose Removal Heater Water Outlet Hose Removal
__..-
FRONT OF ENGINE
'
----- A24822·A
Part
1 18599 Hot Water Heater Elbow
Connection ----
-
FRONT OF ENGINE
2 Clamp ----
3 18472 Heater Water Hose
4 N62 1939 Nut (2 Req'd) NOTE: LUBRICATE HEATER WATER OUTLET
TUBE ASSY "0" RING OR BORE WITH
5 9430 Exhaust Manifold, RH ESE·M99B144-B SURFACTANT PRIOR TO
-
INSTALLATION
A Tighten to 2.5-3.5 N·m (23-30 A24823·A
Lb-ln)
B - Tighten to 20-30 N·m (15-22 Part
Lb-Ft) Item Number Description
1 N807609 Nut
2 18663 Heater Water Outlet Tube
3 - Lower Intake Manifold Stud
4 8A530 Water Bypass Tube
5 8501 Water Pump
6 - Clamp
7 N606676 Bolt
A - Tighten to 8- 1 1 N·m 7 1 -97
(Lb-ln)
5. Remove heater water outlet hose.
6. Remove lower intake manifold retaining
bolts / studs.
7. CAUTION: The lower intake manifold is
sealed at each end with silicone sealer. To
break the seal, it may be necessary to pry on
the front of the lower intake manifold with a
prybar. If it is necessary to pry on the lower
intake manifold, use care to prevent damage
to machined surfaces.
Remove lower intake manifold.

03·01A· 1 7 Engine, 3.8L 03·0 1 A· 1 7
8. Remove and discard water hose connections

{8592) and end seals. Part
9. If lower intake manifold is to be disassembled,
perform the following: 3 8575 Water Thermostat
4 9424 Intake Manifold, Lower
• Remove water hose connection and water
-
thermostat {8575). A Tighten to 8- 1 1 N·m (71·97
Lb·ln)
• Remove engine coolant temperature sensor
{ECT sensor){ 1 2A648). Installation
• Remove heater elbow. 1. NOTE: Lightly oil all retaining bolt and stud
threads before installation.
• Remove all vacuum and electrical fittings.
The lower intake manifold cylinder head and
Water Thermostat cylinder block mating surfaces should be clean
and free of old gasketing material. Use a suitable
solvent to clean these surfaces.
- FRONT OF
ENGINE 2. If lower intake manifold was disassembled:

a. Apply Pipe Sealant with Teflon®
D8AZ- 1 9554-A or equivalent meeting Ford
specification WSK-M2G350-A2 to the
threads of the engine coolant temperature
sensor, all vacuum fittings, heater elbows,
and electrical fittings {if equipped). Refer to
Specifications.
b. Install water hose connection {note direction)
and water thermostat. Install water hose
connection. Tighten retaining bolts to 8-1 1
N·m {7 1 -97 lb-in).
3. NOTE: Prior to applying sealer, clean sealing
surfaces of cylinder heads {6049) and lower
intake manifold with Metal Surface Cleaner
F4AZ- 1 9A536-RA or equivalent meeting Ford
specification WSE-M5B392-A to remove all
residues that may interfere with the sealer's
ability to adhere.
NOTE: When the lower intake manifold is
removed, always use new intake manifold
gaskets {9439) upon reassembly.
Apply a dab of Gasket and Trim Adhesive
07AZ- 1 98508-B or equivalent meeting Ford
specifications ESR-M 1 1 P 1 7-A and
ESE-M2G52-A to each cylinder head mating
surface. Press new intake manifold gasket into
place, using location pins as necessary to aid in
assembly.
4. NOTE: When using silicone sealer, assembly
NOTE: ALIGN TANG AND NOTCH ON must occur within 1 5 minutes after sealer
WATER THERMOSTAT O.RING WITH application. After this time, the sealer may start
CORRESPONDING NOTCHES IN WATER to set-up, and its sealing effectiveness may be
HOSE CONNECTION. reduced.
VIEW A
Apply a 3-4 mm {0. 1 25 inch) bead of Silicone
AA0863-A Rubber D6AZ- 19562-BA or AA or equivalent
meeting Ford specifications ES&M4G92-A or
Part ESE-M4G 1 95-A at each corner where the
Item Number Description cylinder head joins the cylinder blocks {60 1 0).
1 W701607 Bolt (2 Req'd) 5. Install new front and rear intake manifold end
2 8592 Water Hose Connection seals.
� (Continued)

03·01A·18 Engine, 3.8L 03-01A- 1 8
Intake Manifold Gaskets 7. Install bolts and stud bolt in their original
locations.
.......
FRONT OF
ENGINE
........-
PRIOR TO INSTALLATION OF SEAL,

FORCE A BEAD OF WSE-M4G323-A1
SEALER INTO CORNER JUNCTION
OF GASKETS 4 REO'D
INSTALL BOLTSISTUDS
AS SHOWN A20850-B
VIEW A
Part
A24824-A Item Number Description
1 W70 1589 Stud Bolt (2 Req'd)
Part
2 W701588 Bolt (10 Req'd)
3 9424 Intake Manifold, Lower
1 9439 Intake Manifold Gasket
4 9439 Intake Manifold Gasket
2 9A424 Intake Manifold Rear Seal -
5 End Seals (2 Places) (Part of
3 6049 Cylinder Head 9439)
4 6010 Cylinder Blocks
8. lighten bolts and stud bolt in numerical sequence
5 9A425 Intake Manifold Front Seal to the following specifications in two steps:
6 605 1 Head Gasket
a. 5 N·m (44 1b-in).
6. Carefully lower intake manifold into position on
cylinder blocks and cylinder head. Use locating
pins as necessary to guide intake manifold.

03-01A- 19 Engine, 3.8L 03-01 A-19
b. 8- 1 2 N·m {7 1 - 1 06 1b-in). b. Remove power steering pump front mounting

bracket retaining bolts.
c. Remove generator {GENX 1 0346) and belt
idler pulley {8678).
d. Remove power steering pump / generator
bracket retaining bolts.
Leaving hoses connected, place
pump I bracket assembly aside in a position
to prevent fluid from leaking out.
6. If RH cylinder head is being removed, perform the
following:
a. Remove drive belt.
b. If equipped with A I C, remove mounting
bracket retaining bolts. Leave hoses
connected and position A I C compressor
{ 1 9703) aside. If not equipped with A I C,
remove A I C belt idler pulley.
LOWER INTAKE
MANIFOLD 9424 c. Remove positive crankcase ventilation valve
TIGHTEN IN NUMERICAL SEQUENCE IN {PCV valveX6A666).
STEPS AS FOLLOWS: 7. Remove upper intake manifold {9424).
STEP 1 - 5 N·m (44 LB·IN)
STEP 2 - 8-12 N· m (71-106 LB-IN) A212S1-C 8. Remove valve cover {6582).
9. Remove fuel injection supply manifold {9F792).
9. Install front crankcase ventilation tube so that the Refer to Section 03-Q4A.
mounting bracket sits over the lower intake
manifold stud. Tighten nut on stud to 20-30 N·m 1 0. Remove lower intake manifold as described.
{ 1 5-22 1b-ft). 1 1 . Remove exhaust manifolds {9430) as described.
1 0. Install fuel injectors and fuel injection supply 1 2. Loosen rocker arm seat retaining bolts enough to
manifold. Tighten fuel injection supply manifold to allow rocker arm {6564) to be lifted off the push
lower intake manifold bolts to 8-1 1 N.m {7 1 -97 rod {6565) and rotate to one side.
lb-in). T�ghten fuel pressure bracket bolt to 20-30
N·m { 1 5-22 1b-ft). 1 3. Remove push rods. Identify position of each push
rod. Push rods should be installed in their original
1 1 . Install upper intake manifold as described. position during assembly.
12. CAUTION: This engine has aluminum cylinder 14. Remove cylinder head retaining bolts and
heads and requires a special corrosion discard.
inhibiting coolant to avoid cooling system
damage. Refer to Section 03-03 for the 1 5. Remove cylinder heads.
coolant specifications. 1 6. Remove and discard old head gaskets {605 1 ).
Fill engine cooling system as described in Section 1 7 . If disassembling cylinder heads, refer to Cylinder
03-03. Head, Disassembly.
13. Start engine and check for leaks. Installation
1. NOTE: RH and LH head gaskets are not
interchangeable.
Cylinder Heads NOTE: Lightly oil all bolts and stud bolt threads
before installation except those specifying
Removal special sealant.
1. Drain engine cooling system as described in Clean cylinder head, intake manifold, valve cover
Section 03-03. and head gasket surfaces. If cylinder head was
2. Disconnect battery ground cable { 1 430 1 ). Refer removed for head gasket replacement, check
to Section 14-Q 1 . flatness of cylinder head and cylinder block
gasket surfaces. Refer to Section 03-QO for
3. Remove air cleaner outlet tube {98659) from procedure.
throttle body {9E926). Refer to Section 03- 1 2 .
2. Position new cylinder heads onto cylinder blocks
4. Loosen drive belt tensioner {68209). Remove {60 1 0) using cylinder head to block dowels
drive belt {8620). Refer to Section 03-Q5. {6A008) for alignment.
5. If LH cylinder head {6049) is being removed,
perform the following:
a. Remove oil filler cap {6766).

03·01A·20 Engine, 3.8L 03·01 A·20
Head Gasket
CYLINDER HEAD TO
CYLINDER BLOCK BLOCK DOWEL
6010 6A008
NOTE: MUST BE BOTIOMED OUT
(FOR MANUAL OPERATIONS ONLY)
/
SEcnoN A
SECTION A
TYPICAL TWO PLACES
CYLINDER HEAD
TO BLOCK DOWEL
6A008
2 REQ'D AA0866-A
3. Position cylinder heads onto cylinder blocks. d. CAUTION: Do not loosen all of the bolts
4. CAUTION: Always use new cylinder head at the same time; only work on one bolt
bolts to ensure a leak-tight assembly. Torque at a time or damage to engine or leakage
retention with used bolts can vary, which may occur.
may result in coolant or compression Loosen retaining bolts one at a time two to
leakage at the cylinder head mating surface three revolutions and retighten as follows:
area. Long bolts:
NOTE: When cylinder head retaining bolts have
been tightened using the following procedure, it is • Tighten to 4Q-50 N·m (3Q-37 1b-ft).
not necessary to retighten bolts after extended • Rotate an additional 1 75- 1 85 degrees.
engine operation. However, bolts can be checked
• Go to next bolt in sequence.
for tightness if desired.
Short bolts:
Tighten cylinder head retaining bolts in numerical
sequence in three steps as follows: • Tighten to 2Q-30 N·m ( 1 5-22 1b-ft).
a. 20 N·m ( 1 5 1b-ft). • Rotate an additional 1 75- 1 85 degrees.
b. 40 N·m (30 lb-ft). • Go to next bolt in sequence.
c. 50 N·m (37 lb-ft).

03-01A-2 1 Engine, 3.8L 03-01 A-21

r"'.
Cylinder Head and Retaining Bolts- Installation 8. Install exhaust manifolds as described.
Sequence
9. Install lower intake manifold as described.
10. Install fuel injection supply manifold. Refer to
Section 03-Q4A.
1 1 . Position rocker arm and new valve cover on
cylinder head and install retaining bolts. Note
location of ignition wire routing clip stud bolts.
Tighten retaining bolts to 8-1 2 N·m (7 1-106 1b-in).
1 2 . Install upper intake manifold.
13. Install spark plugs ( 1 2405), if removed. Refer to
Section 03-Q7A.
14. Connect ignition wires to the spark plugs. Refer to
Section 03-Q7 A.
15. If LH cylinder head is being installed, perform the
following:
a. Install oil filler cap.
b. Install generator I power steering pump
mounting bracket.
c. Install generator.
d. Install accessory drive belt tensioner.
e. Install power steering pump (3A674).
f. Install power steering pump support bracket.
Tighten bolts to specification. Refer to
Section 1 1 -02.
/
1 6. If RH cylinder head is being installed, perform the
following:
FRONT OF ENGINE
a. Install positive crankcase ventilation valve.
/ b. If equipped with A I C, install A I C compressor
mounting and supporting brackets. Install
A TIGHTEN BOLTS A I C compressor.
W IN SEQUENCE A21 253-B
1 7 . Install drive belt. Refer to Section 03-Q5.
Part 18. Connect battery ground cable.
Item Number Description 1 9. Install air cleaner outlet tube as described in
1 6010 Cylinder Blocks Section 03- 12.
2 -
Locating Pin (2 Req'd) 20. CAUTION: This engine has aluminum cylinder
heads and requires a special corrosion
3 N81 1496 Cylinder Head Bolt (4 Req'd inhibited coolant formulation to avoid cooling
Each Side)
system damage. Refer to Section 03-03 for
4 6049 Cylinder Head the coolant specifications.
5 N81 1497 Cylinder Head Bolt (4 Req'd Fill engine cooling system with specified coolant. ·
Each Side)
6 6A008 Cylinder Head to Block 2 1 . Start engine and check for coolant, fuel and oil
Dowel leaks.
5. NOTE: If original valve train components are

being installed, a valve clearance check is not
required. If a component has been replaced, Crankshaft Pulley/Damper/Crankshaft
perform a valve clearance check. Refer to Front Seal
Section 03-00.
Dip each push rod end in Engine Assembly SPECIAL SERVICE TOOL(S) REQUIRED
Lubricant D9AZ- 19579-D or equivalent meeting
Ford specification ESR-M99C8Q-A and install Description Tool Number
push rods in their original positions. Crankshaft Damper Remover T58P-63 16-D
6. Lubricate all rocker arms with Engine Assembly Front Cover Seal Replacer T70P-6B070-B
Lubricant D9AZ- 1 9579-D or equivalent meeting Damper 1 Front Cover Seal Replacer T82L-63 16-A
Ford specification ESR-M99C8Q-A.
Vibration Damper Remover Adapter T82L -63 1 6-B
7. Install rocker arms as described.

03·01A·22 Engine, 3.8L 03·01 A·22
Removal Installation
1. Disconnect cooling fan motor and remove cooling 1. Inspect engine front cover and crankshaft pulley
fan motor, fan blade (8600) and fan shroud and vibration damper for damage, nicks, burrs or
(81 46) assembly from vehicle. Refer to Section other roughness which may cause the crankshaft
03-Q3. front seal to fail. Service or replace components
2. Remove drive belt (8620) as described in Section as necessary.
03-Q5. 2. Lubricate the crankshaft front seal lip with clean
3. Raise vehicle on hoist. Refer to Section OO-Q2. engine oil and install the crankshaft front seal
using Damper I Front Cover Seal Replacer
T82L-63 16-A and Front Cover Seal Replacer
T70P-68070-8.
" 3. Lubricate crankshaft front seal surface on the
FRONT OF crankshaft pulley and vibration damper with clean
ENGINE engine oil. Install crankshaft pulley and vibration
"' damper using Damper I Front Cover Seal
Replacer T82L-63 1 6-A.
4. Install crankshaft pulley and vibration damper
retaining bolt and washer. Tighten bolt to
14Q- 1 80 N·m ( 1 04- 132 1b-ft).
5. Lower vehicle.
6. Install drive belt as described in Section 03-Q5.
7. Install fan shroud, fan blade and cooling fan motor
assembly as described in Section 03-Q3.
8. Start engine and check for oil leaks.
Water Pump
A21254-B Removal
1. Drain engine cooling system. Refer to Section
Part 03-Q3.
Item Number Description 2. Remove cooling fan motor , fan blade (8600) and
1 6303 Crankshaft fan shroud (81 46) assembly as described in
2 6B32 1 Crankshaft Pulley and Section 03-03.
Vibration Damper Assembly 3. Rotate drive belt tensioner (68209). Remove
3 N80 1539 Washer drive belt (8620). Refer to Section 03-Q5.
4 N808089 Bolt 4. Remove retaining bolts and water pump pulley
5 6A328 Engine Balance Pin (8509).
A - Tighten to 140- 180 N-m 5. Remove power steering pump pulley (3A733) and
(104- 132 Lb-Ft) remove water pump-to-power steering pump
brace.
4. Remove crankshaft pulley and vibration damper 6. Remove heater water outlet tube retaining bolts
using Crankshaft Damper Remover T58P-63 1 6-D and clutch pressure plate (7563) from water
and Vibration Damper Remover Adapter pump (850 1 ).
T82L-63 1 6-8 and Front Cover Seal Replacer
T70P-6807Q-8. 7. Disconnect lower radiator hose (8286) from
water pump.
5. CAUTION: Use care to prevent damage to
engine front cover (601 9)and crankshaft
(6303) or engine oil leakage may occur.
Remove crankshaft front seal (6700) from the
engine front cover using a hammer and punch.

03·01A-23 Engine, 3.8L 03·01A-23
8. CAUTION: If using a prying device to assist in 2. NOTE: Gasket and Trim Adhesive
water pump removal, be careful not to 07AZ-1 98508-B or equivalent meeting Ford
damage the mating surfaces. specifications ESR-M 1 1 P 1 7-A and
Remove water pump retaining bolts, stud bolts ESE-M2G52-A is recommended to hold the water
and nuts. Remove water pump. Discard old water pump housing gasket in position.
pump housing gasket (8507). Position a new water pump housing gasket on
water pump sealing surface.
A TIGHTEN BOLTS 3. NOTE: The threads of the No. 1 water pump
W IN SEQUENCE retaining bolt must be coated with Pipe Sealant
with Teflon® D8AZ- 1 9554-A or equivalent
meeting Ford specifications WSK-M2G35D-A2
before installing.
Position water pump on the engine front cover.
Install retaining bolts, stud bolts and nuts.
Tighten retaining bolts and studs to 2D-30 N·m
( 1 5-22 lb-ft). Tighten retaining nuts to 8- 1 2 N·m
(7 1 - 1 06 1b-in).
4. Inspect 0-ring (replace as necessary) and install
heater water outlet tube ( 1 8663) to water pump.
Tighten retaining bolts to 8- 1 2 N·m (7 1 - 106 1b-in).
5. Install lower radiator hose to water pump. Tighten
clamps securely.
6. Install water pump-to-power steering pump brace
and install water pump pulley.
7. Install water pump pulley and retaining bolts.
Tighten retaining bolts to 2 1 -29 N·m ( 1 6-2 1 lb-ft).
A24825-A 8. Position drive belt over pulleys. Rotate drive belt
tensioner and install drive belt. Refer to Section
Part 03-Q5.
Item Number Description 9. CAUTION: This engine has aluminum cylinder
1 N804853 Stud (4 Req'd) heads (6049) and requires a special
corrosion Inhibiting coolant formula to avoid
2 8507 Water Pump Housing Gasket cooling system damage. Refer to Section
3 850 1 Water Pump 03-03 for the coolant specifications.
4 N804758 Nut (4 Req'd) Fill engine cooling system with specified coolant.
5 N605908 Bolt (3 Req'd) 1 0. Start engine and check for coolant leaks.
6 N8082 1 7 Bolt
7 N804852 Stud Bolt
Installation
1. NOTE: Lightly oil all bolt and stud threads before
installation except those specifying special
sealant.
Clean gasket surfaces on water pump and engine
front cover (60 19).

03-01A-24 Engine, 3.8L 03-01A-24
Engine Front Cover and Water Pump
- TIGHTEN IN SEQUENCE
SHOWN TO 20-30 N·m
0
(15-22 LB-FT)
REFER TO LEGEND
A24826-A
Part Part
1 60 1 9 Engine Front Cover 4 850 1 Water Pump
2 N605908 Bolt (3 Req'd) 5 N8082 1 7 Bolt
3 N804758 Nut (4 Req'd) 6 N804852 Stud Bolt
(Continued) 7 60 10 Cylinder Blocks
Engine Front Cover 6. Remove power steering pump bracket retaining

bolts. Refer to Section 1 1 -02 _
SPECIAL SERVICE TOOL(S) REQUIRED Leaving hoses connected, place power steering
Description Tool Number pump (3A674) and bracket aside in a position to
prevent fluid from leaking out.
Crankshaft Damper Remover T58P-6316-D
7_ If equipped with air conditioning, remove A I C
Damper I Front Cover Seal Replacer T82L-63 16-A
compressor front support bracket. Leave A I C
Vibration Damper Remover Adapter T82L-63 1 6-B compressor ( 1 9703) in place_
8. Remove heater water outlet tube retaining bolts,
Removal
heater water outlet tube ( 1 8663) and 0-ring from
1. Drain engine cooling system as described in water pump (850 1 )_
Section 03-03.
9. Disconnect upper radiator hose (8260) at water
2. Disconnect battery ground cable ( 1 430 1). Refer hose connection (8592).
to Section 1 4-0 1 .
10- Disconnect fuel charging wiring (9D930) from
3_ Remove engine air cleaner (ACL)(9600) and air camshaft position sensor (CMP sensor)( 1 2 1 26).
cleaner outlet tube (98659). Refer to Section
1 1 . Remove hold-down clamp ( 1 2270) and lift
03- 1 2.
camshaft position sensor and housing out of the
4. Remove cooling fan motor, fan blade (8600) and engine front cover (60 1 9).
fan shroud (81 46) assembly. Refer to Section
1 2. Raise vehicle on hoist. Refer to Section OO-Q2.
03-Q3_
5. Remove drive belt (8620) and water pump pulley
(8509).

03-01A-25 Engine, 3.8L 03-01A-25
13. NOTE: If the crankshaft vibration damper and 1 8. CAUTION: Do not overlook the engine front
pulley have to be separated, mark the damper cover retaining bolt located behind the oil
and pulley so that they may be reassembled in pump and filter body (6603). The engine
the same relative position. This is important, front cover will break if pried upon and all
because the damper and pulley are initially retaining bolts are not removed.
balanced as a unit. Remove engine front cover retaining bolts. It is not
NOTE: If the vibration damper is being replaced, necessary to remove water pump.
check if the original vibration damper has balance 19. Remove engine front cover and water pump as an
pins installed. If so, new balance pins assembly.
(EOSZ-6A328-A or equivalent) must be installed
on the new vibration damper in the same position 20. If necessary, remove engine front cover gasket
as the original vibration damper. The pulley (new {6020) and discard.
or original) must also be installed in the same 2 1 . If necessary, remove crankshaft position sensor
relative position as originally installed. shield and crankshaft position sensor (CKP
Remove crankshaft pulley and vibration damper sensor)(6C3 1 5).
using Crankshaft Damper Remover T58P-63 1 6-D 22. If necessary, remove oil pump and filter body.
and Vibration Damper Remover Adapter
T82L-63 1 6-8. Installation
14. Remove oil bypass filter (67 1 4). 1. NOTE: Lightly oil all bolt and stud threads before
sealant.
OIL BYPASS FILTER Clean gasket surfaces on the engine front cover
/ 6714 TIGHTEN
1/2 TURN AFTER
and cylinder blocks (60 1 0).
FRONT OF ENGINE
GASKET CONTACT If reusing engine front cover, replace crankshaft
/ - OPTIONAL front seal (6700).
TIGHTEN TO
10-15 N·m 2. If a new engine front cover is to be installed:
(7-1 1 LB-FT) a. Install oil pump and filter body.
b. Install crankshaft position sensor and shield.
lighten crankshaft position sensor stud bolts
to 8- 1 2 N·m (7 1 - 1 06 1b-in). lighten
crankshaft position sensor shield nuts to 2-4
N·m ( 1 8-35 1b-in).
c. Clean water pump gasket surface. Position a
new water pump housing gasket (8507) on
the engine front cover and install water pump.
Install water pump retaining bolts, stud bolts
and nuts. lighten bolts and stud bolts to
20-30 N-m ( 1 5-22 lb-ft). lighten retaining
nuts to 8- 1 2 N·m (7 1 - 1 06 1b-in).
3. Lubricate crankshaft front seal with clean engine
\ oil.
*THOROUGHLY COAT GASKET 4. NOTE: Gasket and Trim Adhesive
SEALING SURFACE WITH CLEAN
ENGINE OIL MEETING FORD D7AZ- 1 98508-8 or equivalent meeting Ford
SPECIFICATION WS8-M2C153-F specifications ESR-M 1 1 P 1 7-A and
PRIOR TO FILTER INSTALLATION AA0867-B ESE-M2G52-A is recommended to hold the
engine front cover gasket in position while the
1 5. Disconnect lower radiator hose (8286) at water engine front cover is installed.
pump.
Position a new engine front cover gasket on the
16. CAUTION: The engine front cover cannot be cylinder blocks and install the engine front cover
removed without lowering the oil pan (6675} and water pump as an assembly using dowels for
or possible damage to the engine may occur. proper alignment.
Remove oil pan as described. 5. Install the engine front cover retaining bolts.
1 7. Lower vehicle. lighten to 20-30 N·m ( 1 5-22 1b-ft).

03·01A·26 Engine, 3.8L 03·01A·26
IN-VEHICLE SERVICE {Continued)
Engine Front Cover and Water Pump
e TIGHTEN IN SEQUENCE
SHOWN TO 20-30 N·m
(15-22 LB-FT)
0 REFER TO LEGEND
A24827·A
Part Part
1 60 1 9 Engine Front Cover 6 N8082 1 7 Bolt
2 M805 1 1 2 Stud Bolt (2 Req'd) 7 N804852 Stud Bolt
3 N605908 Bolt (3 Req'd) 8 N804839 Bolt
4 N804758 Nut (4 Req'd) 9 6049 Cylinder Head
5 850 1 Water Pump 10 N80484 1 Socket Head Cap Bolt
(Continued)
6. Raise vehicle. 1 1 . NOTE: Prior to applying sealer, clean sealing

7. Install oil pan as described. surfaces with Metal Surface cleaner
8. Connect lower radiator hose. lighten clamp specification WSE-M5B392-A, to remove all
securely. residues that may interfere with the sealer's
9. Install oil bypass filter. Refer to illustration ability to adhere.
following Removal, Step 14. NOTE: When using silicone sealer, assembly
10. Coat crankshaft pulley and vibration damper must occur within 1 5 minutes after sealer
sealing surface with clean engine oil. application. After this time, the sealer may start
to set-up and its sealing effectiveness may be
reduced.
Apply a small amount of Silicone Gasket and
Sealant F6AZ- 1 9562-AA or equivalent meeting
Ford specification WSE-M4G323-A6 to
crankshaft keyway.
1 2. Position crankshaft key in the crankshaft
keyway.
13. Install the crankshaft pulley and vibration damper
using Damper Front Cover Seal Replacer
T82L-63 1 6-A.

03·01A-27 Engine, 3.8L 03·01 A·27
� 14. Install crankshaft pulley retaining washer and 2. Remove camshaft sprocket retainer bolt and
bolt. Tighten bolt to 1 4Q- 1 80 N·m ( 1 04- 1 32 1b-ft}. washer from end of the camshaft (6250}.
15. Install crankshaft pulley to vibration damper if 3. Remove distributor drive gear (6255}.
removed. Tighten retaining bolts to 26-38 N·m 4. NOTE: If crankshaft sprocket (6306} is difficult to
(20-28 1b-ft}. remove, loosen crankshaft sprocket by prying,
1 6. Lower vehicle. using a pair of large prybars positioned on both
1 7 . Inspect heater water outlet tube 0-ring (replace sides of the crankshaft sprocket.
as necessary}. Install heater water outlet tube Remove camshaft sprocket (6256}, crankshaft
and 0-ring into water pump. Install and tighten sprocket and timing chain at the same time.
retaining bolts to 8- 1 2 N·m (7 1- 106 1b-in}.
18. Install camshaft position sensor (CMP
sensor}(68288}. Refer to Section 03- 14.
19. Connect upper radiator hose at water hose
connection. Tighten clamp securely.
20. If vehicle is equipped with air conditioning, install
A I C compressor and mounting brackets. Tighten
retaining bolts to 2 1 -29 N·m ( 1 6-2 1 lb-ft}.
2 1 . Install power steering pump and mounting
bracket. Tighten retaining bolts to 40-55 N·m
(30-4 1 1b-ft}. Refer to Section 1 1-02.
22. Position drive belt over the pulleys.
23. Install water pump pulley to water pump.
Cross-tighten the retaining bolts to 2 1 -29 N·m
( 1 6-2 1 1b-ft}.
24. Install cooling fan motor, fan blade and fan shroud
assembly. Tighten retaining screws. Connect
wiring to cooling fan motor. Refer to Section
�
03-03. PRY DOWNWARD
TO REMOVE
25. Install drive belt. Refer to Section 03-Q5. SPROCKET
26. Connect battery ground cable.
27. Fill crankcase to proper level with engine oil 5. Remove timing chain vibration damper (6284}
(three bolts} from front of cylinder blocks (6010}.
meeting Ford specification WSS-M2C 1 53-F.
(This requires pulling back on ratcheting
28. CAUTION: The engine has aluminum cylinder mechanism and then installing pin through hole in
heads (6049) and requires a special bracket to relieve tension.}
corrosion-inhibited coolant formulation to
avoid cooling system damage. Refer to
Section 03-03 for coolant specifications.
Fill engine cooling system with specified coolant.
Refer to Section 03-Q3.
29. Install engine air cleaner and air cleaner outlet
tube as described in Section 03- 1 2.
30. Start engine and check for coolant, oil or fuel
leaks.
Timing Chain, Sprockets, Tensioners and

Guides
Removal
1. NOTE: The engine front cover (60 19) contains
the oil pump gears and water pump (850 1 }. If a
new engine front cover is to be installed, remove
the water pump and oil pump gears from the old
!""""'"' engine front cover. Refer to Engine Front Cover.
Remove engine front cover as described.

03·01A·28 Engine, 3.8L 03·01A-28
Timing Chain and Sprocket
/
FRONT OF ENGINE
/ 1:::\ NOTE: MUST BE

� INSTALLED PRIOR
TO KEY
NOTE: THOROUGHLY COAT

ALL GEAR TEETH WITH
ENGINE OIL SAE 50
MEETING FORD SPECIFICATION
WSS-M2C153-F
Part Part
1 N808319 Camshaft Sprocket 7 6303 Crankshaft
Retaining Bolt and Washer 8 388907 Crankshaft Key
2 6255 Distributor Drive Gear 9 6284 Timing Chain Vibration
3 6256 Camshaft Sprocket Damper
4 6306 Crankshaft Sprocket 10 N805256-S Camshaft Sprocket Key
5 6268 Timing Chain /Belt 11 6250 Camshaft
6 6K305 Engine Balance Shaft Gear 12 6265 Camshaft Sprocket Spacer
Spacer A -
Tighten to 40-50 N·m (30-36
(Continued) Lb-Ft)

03-01 A-29 Engine, 3.8L 03-01 A-29
IN-VEHICLE SERVICE (Continued}
Installation 7. Install engine front cover as described.

1. With the timing chain vibration damper in the
compressed position, install the timing chain
vibration damper and retaining bolts to front of
cylinder blocks. lighten retaining bolts to 8- 14 Camshaft
N·m (7 1 - 1 23 1b-in).
Removal
1. Remove radiator (8005). Refer to Section 03-Q3.
2. If vehicle is equipped with air conditioning,
remove A I C condenser core ( 1 97 1 2). Refer to
Section 1 2-Q3A.
3. Remove radiator grille (8200). Refer to Section
BOLT 0 1 -Q2.
N605890
3 REQ'D 4. Remove camshaft position sensor (CMP
TIGHTEN TO sensor)( 1 2 1 26) and housing as described in
8-1 4 N·m Section 03- 1 4.
(71 -124 LB-IN)
5. Remove upper intake manifold (9424) and lower
intake manifold as described.
6. Remove valve tappet (6500), valve tappet guide
plate (6K5 1 2) and tappet guide plate and retainer
(6K564) as described.
7. Remove engine front cover (60 1 9), timing chain
and camshaft sprocket spacer (6265) as
described.
/ 8. Remove oil pan (6675) as described.
FRONT OF ENGINE
9. Remove camshaft thrust plate (6269).
/ A24828-A
10. Remove camshaft (6250) through the front of the
2. Rotate crankshaft (6303) as necessary to engine, being careful not to damage camshaft
position No. 1 piston (6 1 08) at top dead center bearing surfaces and lobes.
(TDC) and keyway at the 1 2 o'clock position.
Installation
3. Lubricate timing chain with clean engine oil 1. NOTE: Lightly oil retaining bolt and stud threads
meeting Ford specification WSS-M2C 1 53-F. before installation except those specifying
Install camshaft sprocket, crankshaft sprocket special sealant.
and timing chain at the same time. Make sure NOTE: Inspect camshaft rear bearing cover
timing marks line up across from each other. (6266) for damage or leakage. Replace or reseal
if necessary (engine removed).
Lubricate the camshaft lobes and bearing
surfaces with Engine Assembly Lubricant
D9AZ- 1 9579-D or equivalent meeting Ford
specification ESR-M99C8Q-A.
CAMSHAFT 2. Install camshaft. Be careful not to damage
SPROCKET bearing surfaces and lobes while sliding into
6256
position.
3. Install camshaft thrust plate. lighten bolts to 8- 14
N·m (7 1 - 1 23 1b-in).
4. Install camshaft sprocket spacer, timing chain
and engine front cover as described.
POSITIONING OF TIMING MARKS AND 5. Install oil pan as described.
KEYWAYS IN CAMSHAFT AND CRANKSHAFT 6. Install valve tappet, valve tappet guide plate and
SPROCKETS MUST BE IN LINE AS SHOWN
WITH NO. 1 PISTON AT TOP DEAD CENTER tappet guide plate and retainer as described.
FIRING A12694-B 7. Install lower intake manifold and upper intake
4. Install distributor drive gear. manifold as described.
5. Install retaining bolt and washer at end of 8. Install camshaft position sensor and housing as
camshaft. lighten to 4Q-50 N·m (30-36 lb-ft). described in Section 03- 1 4.
6. Remove timing chain vibration damper retaining 9. Install radiator grille. Refer to Section 0 1 -02.
pin.
1 997 Thunderbird. Cougar July 1996

03·01A·30 Engine, 3.8L 03·01 A·30
10. If vehicle is equipped with air conditioning, install 1 1 . Install radiator. Refer to Section 03-Q3.
A I C condenser core. Refer to Section 1 2-Q3A.
Camshaft

THRUST PLATE
WITH MOTOR OIL
PRIOR TO COLD TEST
0 THOROUGHLY COAT CAM

BEARINGS IN BLOCK WITH
MOTOR OIL PRIOR TO
INSTALLATION
--
FRONT OF ENGINE
---
NOTE: APPLY
WSK·M2G349-A 10
SEALER PRIOR TO
SECTION A INSTALLATION A24829-A
Part Part
1 6010 Cylinder Blocks 4 6269 Camshaft Thrust Plate
2 6250 Camshaft 5 N80462 1 Bolt
3 6265 Camshaft Sprocket Spacer 6 N805256 Woodruff Key
(Continued) 7 376958 Cap Plug
Exhaust Manifolds 3. Loosen retaining nut and remove heater inlet tube
and heater water hose ( 1 8472).
RH
4. Raise vehicle on hoist. Refer to Section OO-Q2.
Removal
5. Remove exhaust manifold-to-dual converter
1. Disconnect ignition wire from ignition coil ( 1 2029) Y-pipe retaining nuts.
and ignition wires from spark plugs ( 1 2405).
Refer to Section 03-Q7A. 6. Lower vehicle.
2. Disconnect EGR valve to exhaust manifold tube
(9D477)from exhaust manifold (9430).

03-01 A-3 1 Engine, 3.8L 03-01 A-3 1
7. Remove exhaust manifold retaining bolts.

Remove exhaust manifold and exhaust manifold
gasket (9448).
8. If a new RH exhaust manifold is being installed,
remove EGR valve tube to manifold connector
(9F485). Refer to Section 03-08.
Installation
sealant.
Clean mating surfaces on exhaust manifold,
cylinder head (6049) and dual converter Y pipe
(5F250).
2. If removed, install EGR valve tube to manifold
connector into exhaust manifold. Tighten to 46·65
N·m (34-47 1b-ft). Refer to Section 03-08.
3. Position exhaust manifold gasket and exhaust
manifold on cylinder head. Install two new
retaining bolts loosely.
4. NOTE: A slight warpage in the exhaust manifold
may cause a misalignment between the bolt holes
in the cylinder head and exhaust manifold.
Elongate the holes in the exhaust manifold as
necessary to correct the misalignment. Do not
elongate the pilot hole (lower rear bolt hole on No.
2 cylinder).
Start remaining exhaust manifold retaining bolts
r, loosely.
5. Connect EGR valve to exhaust manifold tube
loosely.
6. Tighten exhaust manifold retaining bolts and
studs to 30-36 N·m (22-27 lb-ft).
7. Raise vehicle. Refer to Section OQ.02.
� 8. NOTE: If a new exhaust manifold is being installed TIGHTEN IN SEQUENCE
:
or a new dual converter Y-pipe to exhaust
A2483G-A
manifold retaining stud is required, install stud
until seated securely on exhaust manifold.
Part
Connect dual converter Y pipe to exhaust Item Number Description
manifold. Tighten retaining nuts to 2 1 -32 N·m
( 1 6·23 1b-ft). 1 6049 Cylinder Head
9. Lower vehicle.
2 N80 1648-S Stud (4 Req'd)
3 N801647-S Bolt (2 Req'd)
1 0. Install heater inlet tube and heater water hose.
Tighten retaining nut to 20.30 N·m ( 1 5-22 1b-ft). 4 9430 Exhaust Manifold
1 1 . Tighten EGR valve to exhaust manifold tube nut to 5 9448 Exhaust Manifold Gasket
34-47 N·m (25-34 1b-ft). 6 90477 EGR Valve to Exhaust
Manifold Tube
1 2. Connect ignition wires to spark plugs. Refer to
Section 03-Q7A. 7 90475 EGR Valve
-
13. Connect ignition wire to ignition coil. A Tighten to 30-36 N· m (23-26

Lb-Ft)
14. Start engine and check for exhaust leaks. B -
Lb-Ft)
LH
Removal
1. Loosen retaining nut and remove oil level indicator
tube support bracket.
2. Disconnect ignition wires from spark plugs. Refer
to Section 03-Q7A.

03·01A-32 Engine, 3.8L 03·01A·32
3. Raise vehicle on hoist. Refer to Section OO-Q2.

4. Remove exhaust manifold-to-converter Y pipe
retaining nuts.
5. Lower vehicle.
6. Remove exhaust manifold retaining bolts and LH
exhaust manifold and exhaust manifold gasket.
Installation
FRONT OF
installation except those specifying special .-- ENGINE
sealant.
Clean mating surfaces on the LH exhaust
manifold, cylinder head and dual converter Y
pipe.
2. Position exhaust manifold and exhaust manifold
gasket on the cylinder head. Install new pilot bolt
(lower front bolt hole on No. 5 cylinder) loosely.
3. NOTE: A slight warpage in the exhaust manifold
may cause a misalignment between the bolt holes
in the cylinder head and the exhaust manifold.
Elongate the holes in the exhaust manifold as _ FRONT OF
necessary to correct the misalignment. Do not ENGINE
elongate the pilot hole (lower front bolt on No. 5
VIEW A
cylinder).
A24300-A
Start new remaining exhaust manifold retaining
bolts. Tighten new exhaust manifold retaining
bolts to 3Q-36 N-m (23-26 lb-ft) in the sequence Part
shown in the illustration. Item Number Description
4. Raise vehicle. 1 6049 Cylinder Head
5. Connect dual converter Y pipe to exhaust
2 9448 Exhaust Manifold Gasket
manifold. Tighten retaining nuts to 2 1 -32 N·m 3 9430 Exhaust Manifold, LH
(16-23 1b-ft). 4 N80 1648 Stud (3 Req'd)
6. Lower vehicle. 5 N801647 Bolt (3 Req'd)
-
7. Connect ignition wires to spark plugs. Refer to A Tighten to 30-36 N·m (23-26
Section 03-07 A. Lb·Ft)
8. Install oil level indicator tube support bracket
retaining nut. Tighten to 20-30 N·m ( 1 5-22 lb-ft).
9. Start engine and check for exhaust leaks. Oil Pan/Oil Pump Screen Cover and Tube
Removal
1. Disconnect battery ground cable ( 1 430 1 ).
2. Remove air cleaner outlet tube (9B659). Refer to
Section 03- 1 2 .
3. Remove two bolts retaining radiator upper sight
shield (8C29 1 ) and position radiator upper sight
shield aside.
4. Remove hood weather seal.
5. Remove windshield wipers.
6. Remove LH cowl vent screen and wiper module.
7. Install Rotunda 3.8L Engine Lifting Brackets
0 1 4-Q0792 and Three Bar Engine Support
D88L-600Q-A or equivalent.
8. Raise vehicle on a hoist. Refer to Section OO-Q2.
9. Remove front engine support insulator
through-bolts.
10. Partially lower vehicle.

03-01A-33 Engine, 3.8L 03-01 A-33

�
1 1 . Raise engine and support with Three Bar Engine
Support D88L-6000-A or equivalent.
1 2. Raise vehicle.
13. Remove starter motor ( 1 1 002).
1 4. Position drain pan.
1 5. Drain engine oil.
16. Remove oil bypass filter (67 14).
1 7 . Remove starter motor wire, ground strap and
automatic transmission oil cooler lines.
18. Remove oil pan-to-bell housing bolts and bolts at
crankshaft position sensor lower shield.
1 9. Remove remaining oil pan retaining bolts.
20. Remove steering shaft pinch bolt and separate
steering shaft.
2 1 . Position transmission jack under front sub-frame
(5C 145).
22. Remove six rearward bolts on front sub-frame. --
Loosen two forward front sub-frame bolts. FRONT OF ENGINE
---- A24831-A
23. Remove lower shock absorber-to-front
suspension lower arm bolts and nuts (both sides).
Part
24. Lower front sub-frame. Item Number Description
25. Remove oil pan (6675). 1 6622 Oil Pump Screen Cover and
26. Empty any residual oil from oil pan. Tube
27. Remove oil pump screen cover and tube retainer 2 N8 1 1 1 1 5 Nut
/"'"' bolts and support bracket nut. Remove oil pump 3 N8 1 146 1 Stud Bolt
screen cover and tube (6622) and discard oil 4 60 10 Cylinder Blocks
pump inlet tube gasket (6626).
5 6626 Oil Pump Inlet Tube Gasket
Installation 6 N80 1689 Bolt
1. Install oil pump screen cover and tube using a new -
A Tighten to 40-55 N·m (30-40
oil pump inlet tube gasket. Tighten retainer bolts Lb-Ft)
to 20-30 N·m ( 1 5-22 1b-ft) and support bracket B -
Tighten to 20-30 N·m ( 15-22
nut to 4Q-55 N·m (30-40 lb-ft). Lb-Ft)
2. Clean mating surfaces of oil pan and cylinder
blocks (60 1 0).
3. Trial fit oil pan to cylinder blocks. Make sure
enough clearance has been provided to allow oil
pan to be installed without sealant being scraped
off under cylinder blocks.
surfaces of cylinder blocks and oil pan with Metal
Surface Cleaner F4AZ- 1 9A536-RH or equivalent
meeting Ford specification WSE-M5B392-A, to
remove all residues that may interfere with the
sealer's ability to adhere.
NOTE: When using silicone sealer, assembly
must occur within 1 5 minutes after sealer
application. After this time, the sealer may start
to set-up and its sealing effectiveness may be
reduced.
Apply Silicone Gasket and Sealant
F6AZ- 19562-AA or equivalent meeting Ford
� specification WSE-M4G323-A6 to oil pan.

03-01A-34 Engine, 3.8L 03-01A-34
011 Pan
FRONT OF/
ENGINE
�
SEALER MUST
FILL SEAL
GROOVE (AS
SHOWN)
TWO PLACES
� VIEW A
NOTE:
APPLY A ZIG-ZAG BEAD OR
EXTRA SEALER ON JOINT OF
FRONT COVER AND CYLINDER
BLOCK TWO PLACES A20805-B
Part Part
1 6675 Oil Pan 6 N605892 Bolt (16 Req'd)
-
2 6723 Oil Pan Rear Seal 7 Rear Crankshaft Main
3 F1AZ-19652-A Silicone Gasket and Sealant Bearing Cap (Part of 60 1 0)
4 6019 Engine Front Cover 8 60 10 Cylinder Blocks
-
5 -
Guide Pin (2 Req'd) A Tighten to 9- 12 N·m (80-106
Lb-ln)
(Continued)
5. Install oil pan retaining bolts at cylinder blocks

and bell housing. Install crankshaft position
sensor lower shield. lighten in two steps; in
sequence to 4-5 N·m (36-44 lb-in) then in
sequence to 9- 1 2 N·m (8Q- 106 1b-in).

03-01A-35 Engine, 3.8L 03-01 A-35

�·.
Installation Sequence 24. Connect battery ground cable.
25. Refill crankcase to proper level with engine oil
meeting Ford specification WSS-M2C1 53-F.
26. Start engine and check for leaks.
Oil Pump
Removal
1. If necessary, remove oil bypass filter (67 14).
2. Remove oil pump and filter body to engine front
cover retaining bolts and remove oil pump and
filter body (6603) from engine front cover (60 19).
3. Inspect Q-ring for distortion and wear. Replace if
necessary.
Installation
1. Position oil pump and filter bod y on engine front
cover and install retaining bolts.
--
FRONT OF ENGINE 2. Tighten four large engine front cover retaining
---- A24831 -A bolts to 23-32 N·m ( 1 7-23 1b-in). Tighten two
small retaining bolts to 8- 1 1 N·m (7 1 -97 1b-in).
6. Raise front sub-frame into position.
3. If removed, reinstall oil bypass filter as described.
7. Install lower shock absorber-to-front suspension
lower arm bolts. Tighten to 140- 195 N·m
( 1 04-143 1b-ft).
8. Install two forward front sub-frame bolts and six Crankshaft Main Bearings
r· bolts at rear of front sub-frame. Refer to Section The crankshaft main bearings (6333) are precision
02-o 1 for specifications, tightening sequence and select-fit. To check the bearing clearance or to
alignment procedures. select-fit a new crankshaft main bearing, refer to
9. Connect steering shaft and install pinch bolt. Section 03-QO.
Tighten to 4 1 -57 N·m (3 1 -42 1b-ft).
Removal
10. Install transmission cooler lines (if equipped),
starter wire harness and ground strap. 1. Remove intake manifold (9424), lower as
described.
1 1 . Install oil bypass filter as described.
2. Remove cylinder heads (6049) as described.
1 2. Install starter motor. Refer to Section 03-Q6.
3. Remove oil pan (6675) as described.
13. Partially lower vehicle.
4. Remove oil pump screen cover and tube (6622).
14. NOTE: Seat LH side locating pin before RH side.
5. Replace one crankshaft main bearing at a time,
Lower engine and support with Three Bar Engine leaving the other crankshaft main bearings
Support D88L-6000-A or equivalent. securely fastened.
15. Partially raise vehicle. Remove crankshaft main bearing cap to which
16. Install front engine support insulator new crankshaft main bearings are to be installed.
through-bolts. Tighten to 47-68 N·m (35-50 lb-ft). 6. Insert Main Bearing Insert Tool, TOOL-633 1 -E or
1 7. Lower vehicle. equivalent in the oil hole in the crankshaft (6303).
18. Remove Three Bar Engine Support D88L-6000-A 7. Rotate crankshaft in the direction of engine
or equivalent. rotation to force crankshaft main bearing out of
the cylinder blocks (60 1 0).
19. Install wiper module and LH cowl vent screen.
Refer to Section 0 1 - 1 6. 8. Clean crankshaft journals. Inspect journals and
thrust faces (crankshaft thrust main bearing
20. Install windshield wipers. (6337)) for nicks, burrs or bearing pick-up that
2 1 . Install hood weather seal. would cause premature crankshaft main bearing
22. Install radiator upper sight shield and two wear.
retaining bolts.
23. Install air cleaner outlet tube. Refer to Section
03- 1 2.

03-01A-36 Engine, 3.8L 03-01A-36
9. If the crankshaft rear oil seal {670 1 ) is to be

replaced, refer to Crankshaft Rear Oil Seal, Part
In-Vehicle Service. Item Number Description
6 6337 Crankshaft Thrust Main
NOTE: ASSEMBLE CAPS NOTE: THE REAR
Bearing, Upper
WITH ARROWS POINTING CRANKSHAFT MAIN 7 6010 Cylinder Blocks
FORWARD. CAPS ARE BEARING CAP MUST
IDENTIFIED 1, 2 AND 3 BE INSTALLED SO THAT 8 6303 Crankshaft
FRONT TO REAR THE CAP IS FLUSH TO 9 6333 Crankshaft Main Bearing,
0.5mm (0.02 INCH) Lower (3 Req'd)
FORWARD OF THE
-
FACE OF BLOCK. 10 Front Main Bearing Cap (Part
of 6010)
-
11 Front Intermediate Main
Bearing Cap (Part of 60 10)
12 N8 1 1537 Bolt (7 Req'd)
-
A Tighten in two steps: Tighten
to 50 N·m (37 Lb-Ft), Tighten
an additional 1 15-125
degrees
Installation
installation.
Lubricate and position the upper crankshaft main
bearing on crankshaft journal with plain end
started into the side of cylinder blocks with
locking tang slot. Line up crankshaft main bearing
tang with slot in cylinder blocks.
2. Install Main Bearing Insert Tool TOOL-633 1 -E or
equivalent, in crankshaft journal oil hole.
3. With crankshaft main bearing and tool in position,
rotate crankshaft so that the tool catches the
edge of the crankshaft main bearing and pushes
crankshaft main bearing into position in cylinder
blocks. Remove tool.
4. Install crankshaft main bearing in crankshaft main
bearing cap.
5. If crankshaft main bearing clearance is to be
checked, refer to Section 03-00.
6. If No. 1 or No. 2 crankshaft main bearing was
AA0869-A removed, lubricate bearing surface with Engine
Part meeting Ford specificationESR-M99C8Q-A and
Description install crankshaft main bearing cap.
Item Number
1 Stud Bolt lighten retaining bolts in two steps in sequence
N81 146 1 shown.
-
2 Rear Main Bearing Cap (Part
of 60 10) a. lighten to 50 N·m {37 lb-ft).
- b. lighten an additional 1 1 5- 1 25 degrees.
3 Rear Intermediate Main
Bearing Cap (Part of 60 10) 7. If rear crankshaft main bearing was removed,
4 6337 Crankshaft Thrust Main perform the following:
Bearing, Lower
a. Remove all traces of sealant from main
5 6333 Crankshaft Main Bearing, bearing cap to cylinder block parting line.
Upper (3 Req'd)
(Continued)

03-01A-37 Engine, 3.8L 03-01A-37

�.
b. NOTE: Prior to applying sealer, clean sealing Removal
surfaces with Metal Surface Cleaner 1. Drain engine cooling system. Refer to Section
F4AZ- 1 9A536-RA or equivalent meeting 03-Q3.
Ford specification WSE-M58392-A, to
remove all residues that may interfere with 2. Remove upper intake manifold (9424) and lower
the sealer's ability to adhere. intake manifold as described.
NOTE: The crankshaft main bearing cap 3. Remove cylinder heads (6049) as described.
must be installed within 1 5 minutes after the 4. Remove oil pan (6675) as described.
silicone sealer application. After this time, the
5. Before removing piston (6 1 08), inspect top of
sealer may start to set-up and its sealing
each cylinder bore. If a ridge has formed at the
effectiveness may be reduced.
top of the cylinder, it must be removed before
Apply a 3 mm (0. 1 25 inch) bead of Silicone piston removal. Remove ridge as follows:
Rubber D6AZ- 1 9562-BA or AA or equivalent
a. Turn crankshaft (6303) until piston to be
meeting Ford specifications ESB-M4G92-A
removed is at bottom of cylinder bore.
and ESE-M4G 1 95-A to main bearing
cap-to-cylinder block parting line. b. Place a clean shop cloth over piston head to
lubricate bearing surfaces with Engine collect cuttings.
c.
Assembly lubricant D9AZ- 1 9579-D or c. Remove ridge using Cylinder Ridge Reamer
equivalent meeting Ford specification T64l-601 1-EA. Never cut into ring travel
ESR-M99C80-A and install crankshaft main area more than 0.8 mm (0.03 1 inch) when
bearing cap. lighten retaining bolts in two removing ridge.
steps in sequence shown: tighten to 50 N·m 6. Turn crankshaft until piston to be removed is at
(37 lb-ft), tighten an additional 1 1 5- 1 25 the low point of its travel.
degrees.
If more than one piston is being removed, identify
8. If crankshaft thrust main bearing was removed, the piston and connecting rod caps by numbering
perform the following: 1 through 3 from front to rear on RH bank and 4
a. lubricate bearing surface with Engine through 6 from front to rear on lH bank. This will
Assembly lubricant D9AZ- 1 9579-D or make sure each component is installed in its
equivalent meeting Ford specification original position during assembly.
r'
ESR-M99C8Q-A. Install crankshaft main 7. Remove connecting rod cap retaining nuts and
bearing cap with bolt and finger-tighten. cap.
b. Pry crankshaft forward against thrust 8. Install ignition wire spark plug boots over
surface on upper crankshaft thrust main connecting rod cap studs and push piston out
bearing, while holding bearing cap to the rear. through the top of the cylinder blocks (60 1 0).
This aligns thrust rear surfaces on both Use care to prevent damage to bearing surfaces.
halves of the crankshaft thrust main bearing.
9. Install connecting rod cap and hold in position with
c. While holding crankshaft forward, tighten cap retaining nuts.
crankshaft main bearing cap retaining bolts
to 1 1 Q- 1 20 N·m (82-88 1b-ft). 1 0. If piston is to be disassembled, refer to
Subassemblies.
9. Install oil pump screen cover and tube with a new
oil pump inlet tube gasket (6626). 1 1 . Inspect cylinder bore. If new piston rings are to be
installed on the piston, a cross-hatch pattern
lighten oil pump screen cover and tube retaining should be obvious on the cylinder bore wall.
bolts to 2Q-30 N·m ( 1 5-22 1b-ft).
If honing is required, remove glaze from cylinder
lighten oil pump screen cover and tube support bore wall using spring-loaded hone. Follow
bracket retaining nut to 4Q-55 N·m (30-40 lb-ft). manufacturer's instructions when using this type
10. Install oil pan as described. of equipment.
1 1 . Install cylinder heads as described. After honing, thoroughly clean cylinder bore using
a detergent and water solution.
1 2. Install lower intake manifold as described.
Installation
1. NOTE: lightly oil all retaining bolt and stud
threads before installation except those
Pistons and Connecting Rods specifying special sealant.
lubricate cylinder bore wall and piston with
SPECIAL SERVICE TOOL(S) REQUIRED
Engine Assembly lubricant D9AZ- 19579-D or
Description Tool Number equivalent I'TlE!eting Ford specification
ESR-M99C80-A.
Cylinder Ridge Reamer T64L-60 1 1 -EA
2. Install ignition wire spark plug boots or suitable
protection on connecting rod (6200).

03·01A-38 Engine, 3.8L 03·01A·38
3. CAUTION: As piston is tapped into bore with 6. Make sure connecting rod is seated on
a hammer handle, guide connecting rod onto crankshaft journal. Install connecting rod cap and
crankshaft journal to avoid damage to tighten retaining bolts as follows:
bearing surfaces.
• Tighten to 20·25 N·m ( 1 5- 1 8 1b-ft).
NOTE: Install pistons in the same cylinders from
which they were removed or to which they were • Tighten to 40·45 N·m (3Q-33 1b-ft).
fitted. If a connecting rod is transposed from one • Rotate an additionai 9Q- 1 20 degrees.
cylinder blocks or cylinder to another, new
7. If necessary, check connecting rod side
connecting rod bearings (62 1 1) should be fitted
clearance as described in Section 03-oo.
and connecting rod should be numbered to
correspond with new cylinder number. 8. Install oil pump screen cover and tube (6622) with
a new oil pump inlet tube gasket (6626) and
Install piston with notch in piston dome facing the
tighten retainers as follows:
front of engine, using Piston Ring Compressor
08 1 L-6002·C or equivalent. • Tighten oil pump screen cover and tube
4. Check connecting rod bearing clearances. Refer cylinder block bolts to 2Q-30 N·m ( 1 5·22 1b-ft).
to Section 03..()(). • Tighten oil pump screen cover and tube
5. Lubricate bearing surfaces with Engine Assembly support bracket retaining nut to 4Q-55 N·m
Lubricant 09AZ· 1 9579-D or equivalent meeting (3Q-40 lb-ft).
Ford specification ESR-M99C8Q-A. 9. Install oil pan as described.
10. Check piston deck clearance and bore clearance
as shown.
Piston and Connecting Rod
NOTE: PISTON TO DECK CLEARANCE NOTE: LETTERS FOR

PISTON CYLINDER BLOCK TO BE 0.27 mm (0.01 1 INCH) BELOW CAP ORIENTATION
6108 6010 DECK TO 0.25 mm (0.010 INCH) ABOVE IN THIS AREA
DECK WHEN MEASURED AT PISTON T.D.C.
PARALLEL TO CRANKSHAFT ON
TRUE CENTERLINE OF PISTON.
(AVERAGE OF TWO READINGS)
�at- DISTORTION
MIN.
NOTE: ARROW TOWARDS FRONT 1 .5 mm (O.G59 1NCH)
OF ENGINE (AS SHOWN) NO
m;; OF PARTING
SURFACE
PERMITTED
-1 1-
CONNEcnNG ROD TO
CRANKSHAFT SIDE
CLEARANCE 0.11..0.29 mm
(0.0047-G.01 14 1NCH)
NOTE: PISTON TO BORE CLEARANCE. VIEW A

PISTON AND LOCATION SPECIFIED ON
CYLINDER BLOCK - 0.018-0.044 mm VIEW A
(0.00071-0.00173 INCH)
N
CONNECTING ROD BEARING 8211
NOTE: TO PREVENT DAMAGE TO VERTICAL ASSEMBI.ED CLEARANCE TO
PISTONS AFTER ASSEMBLY, POSITION BE 0.022..0.069 mm (0.0009-0.0027 1 CH)
CRANKSHAFT KEYWAY SO ALL
PISTONS ARE BELOW DECK AA1007·A
1 1 . Install cylinder heads as described. 14. Fill cooling system with the specified engine
12. Install lower intake manifold and upper intake coolant. Refer to Section 03.03.
manifold as described. 1 5. Start engine and check for oil and coolant leaks.
13. Fill crankcase with the correct amount of clean
engine oil meeting Ford specification
WSS-M2C 1 53-F.

03·01A·39 Engine, 3.8L 03-01 A-39
Connecting Rod Bearings

The connecting rod bearings (62 1 1 ) are a selective fit
to provide the necessary clearance. Refer to Section
03-QO to measure clearance and select the proper
connecting rod bearings.
Removal
1. Remove spark plugs ( 1 2405) as described in
Section 03-07A.
2. Remove oil pan (6675) as described.
3. Turn crankshaft (6303) until connecting rod
(6200) from which the connecting rod bearings
are to be removed is at the lowest point of travel.
4. Remove connecting rod cap and connecting rod
bearing.
5. CAUTION: Tape or place old ignition wire
spark plug boots over connecting rod bolts
to avoid damage to crankshaft journal during
service.
Remove upper connecting rod bearing. Push
piston (6 1 08) up into cylinder block bore slightly
to provide clearance for removal.
FRONT OF
/
ENGINE
/
Installation
1. CAUTION: Contaminants allowed to remain
on the connecting rod, cap or connecting rod AA087G-A
bearings can distort connecting rod bearings
or damage crankshaft journals. Part
NOTE: Lightly oil bolt and stud threads before Item Number Description
installation. 1 62 14 Connecting Rod Bolt ( 1 2
Thoroughly clean connecting rod bearings,
Req'd)
connecting rod cap and connecting rod. 2 0 1 4-00290 Piston Ring Compressor
2. Clean crankshaft journal and lubricate with Engine 3 6200 Connecting Rod (6 Req'd)
Assembly Lubricant D9AZ-1 9579-D or equivalent 4 6 108 Piston (6 Req'd)
meeting Ford specification ESR-M99C8Q-A. 5 62 1 1 Connecting Rod Bearing (6
3. Install upper connecting rod bearing in the Req'd)
connecting rod and pull connecting rod down until -
6 Connecting Rod Cap (Part of
connecting rod seats on crankshaft. 6200, 6 Req'd)
When installing connecting rod bearings, make
sure tab on connecting rod bearings engages slot
in connecting rod and that connecting rod bearing
is fully seated in connecting rod. Flywheel
4. Install lower connecting rod bearing in connecting Removal
rod cap and lubricate bearing surface with Engine
1. Remove transmission. Refer to Section 07-o 1 .
Assembly Lubricant 09AZ- 1 9579-D or equivalent
meeting Ford specification ESR-M99C8Q-A. 2. Remove flywheel retaining bolts and flywheel
(6375).
5. Install connecting rod cap and retaining bolts as
follows: 3. The engine rear plate (7007) can be removed if
necessary.
• lighten bolts to 20-25 N·m ( 1 5- 1 8 1b-ft).
Installation
• lighten bolts to 40-45 N·m (3Q-33 lb-ft).
1. NOTE: If flywheel is to be replaced, check if
• Rotate an additional 9Q- 1 20 degrees. original flywheel has balance pins or rivets
6. Install oil pan as described. installed. If so, new balance rivets E2DZ-6A32-A
7. Install spark plugs as described inSection or equivalent must be installed on new flywheel in
03-07A. same position as on original flywheel.
Coat threads of flywheel retaining bolts with Pipe
Sealant with Teflon® DBAZ- 1 9554-A or
equivalent meeting Ford specification
WSK-M2G35Q-A2.

03·01 A·40 Engine, 3.8L 03·01 A·40
IN-VEHICLE SERVICE {Continued)
2. Install engine rear plate if removed. Removal

3. Position flywheel on crankshaft (6303) and install 1. Remove transmission. Refer to Section 07-o 1 .
retaining bolts. lighten retaining bolts to 73-87 2. CAUTION: Avoid scratching or damaging oil
N·m (54-64 lb-ft) using standard cross-tightening seal surface or possible engine oil leakage
sequence. may occur.
4. Install transmission. Refer to Section 07-Q 1 . Using a sharp awl, punch one hole into the
crankshaft rear oil seal metal surface between lip
NOTE: MARK FLYWHEEL WITH AN ORANGE and cylinder blocks (60 1 0).
STRIPE AT THE CONVERTER MOUNTING 3.
BOLT HOLE NEAREST TO LOCATION OF Screw in the threaded end of Jet Plug Remover
LIGHT POINT OF THE FLYWHEEL AFTER T77L-9533-B. Use the jet plug remover to
BALANCING. PAINT STRIPE MUST EXTEND remove crankshaft rear oil seal.
TO OUTER EDGE AND PERIPHERY OF THE
RING GEAR. Installation
1. Position crankshaft rear oil seal on Rear Main
Seal Replacer T82L-670 1 -A. Position tool and
/
crankshaft rear oil seal to rear of cylinder blocks.
2. Alternate bolt tightening to seat crankshaft rear
FRONT OF ENGINE oil seal properly. (Two bolts are supplied with
/
Rear Main Seal Replacer T82L-670 1 -A. Engine
flywheel bolts may be used if necessary.)
LUBRICATE SEAL AND SEAL CYLINDER BLOCK

MATING SURFACE WITH CLEAN 6010
ENGINE OIL MEETING FORD
SPECIFICATION WSS-M2C153-F ./-
NOTE: APPLY ENGINE BALANCE RIVETS

TO FRONT FACE OF FLYWHEEL AS
REQUIRED TO BALANCE ENGINE AT
FLYWHEEL PLANE. A1 1 487·D
Part
1 7007 Engine Rear Plate
FRONT OF ENGINE
./"' CRANKSHAFT REAR OIL SEAL
2 6397 Flywheel Housing to Block 6701 (INSTALL WITH SPRING SIDE
Dowel (2 Req'd) � TOWARD ENGINE)
3 6303 Crankshaft NOTE: REAR FACE OF SEAL MUST BE
WITHIN 0.508 mm (0.020 mm INCH) OF THE REAR
4 66430 Balance Rivet FACE OF THE BLOCK AA0871-B
5 N8050 18 Bolt (6 Req'd) (Automatic
Transmission) 3. Install transmission. Refer to Section 07-0 1 .
-
A Tighten to 73-87 N-m (54-64
Lb·Ft)
Camshaft Rear Bearing Cover
Crankshaft Rear Oil Seal SPECIAL SERVICE TOOL(S) REQUIRED

NOTE: A one-piece crankshaft rear oil seal (670 1 ) is Description Tool Number
used for replacement on all engines. If replacement is
Impact Slide Hammer T50T- 1 00-A
necessary, this type of crankshaft rear oil seal MUST
BE used. The complete crankshaft rear oil seal can be Impact Slide Hammer T59L-100-B
replaced without removing the crankshaft (6303).
Removal
SPECIAL SERVICE TOOL(S) REQUIRED 1. Remove transmission. Refer to Section 0 7-o 1 .
Description Tool Number 2. Remove flywheel (6375) as described.
Jet Plug Remover T77L-9533-B 3. Remove engine rear plate (7007).
Rear Main Seal Replacer T82L-670 1-A

03-01A-4 1 Engine, 3.8L 03-01 A-41
4. Using a sharp chisel or punch and hammer, cut a 2. lubricate oil bypass filter gasket with Engine
hole in center of camshaft rear bearing cover Assembly lubricant D9AZ- 1 9579-D or equivalent
{6266). meeting Ford specification ESR-M99C80.
5. Remove camshaft rear bearing cover using 3. Thread oil bypass filter onto adapter until gasket
Impact Slide Hammer T59L- 1 0Q-B or contacts cylinder blocks {60 10) and then
T50T- 1 0Q-A. The camshaft rear bearing cover advance oil bypass filter an additional one-half
can also be pried from bore using a large punch. turn.
Use care to prevent damage to camshaft rear 4. lower vehicle.
bearing cover bore.
5. Refill crankcase to proper level with clean engine
Installation oil meeting Ford specification WS8-M2C 1 53-F.
1. NOTE: Prior to installing a camshaft rear bearing 6. Start engine and check for leaks.
cover, the camshaft rear bearing cover bore
should be inspected for any damage that would
interfere with proper sealing of the camshaft rear
bearing cover. If the bore is damaged, it will be Oil Level Indicator Tube
necessary to true the surface by boring for the
next specified oversize camshaft rear bearing Removal
cover. Oversize camshaft rear bearing covers 1. Remove oil level dipstick {6750) from oil level
are identified by the OS stamped in the flat indicator tube {6754).
located on cup side of camshaft rear bearing
cover. 2. Remove oil level indicator tube retaining nut from
lH exhaust manifold stud.
NOTE: Apply a light coating of Perfect-Seal
Sealing Compound B5A- 1 9554-A or equivalent 3. Remove oil level indicator tube from cylinder
meeting Ford specifications ESR-M 1 8P2-A and blocks {601 0).
ESE-M4G 1 1 5-A to seal camshaft rear bearing Installation
cover before installation.
1. NOTE: Prior to applying sealer, clean oil level
Install camshaft rear bearing cover using suitable indicator tube and cylinder block sealing surfaces
driver. with Metal Surface Cleaner F4AZ- 1 9A536-RA or
2. Install engine rear plate. equivalent meeting Ford specification
3. Install flywheel as described. WSE-M58392-A to remove all residues that may
interfere with the sealer's ability to adhere.
4. Install transmission. Refer to Section 07-o 1 .
Apply a 3 mm {0. 1 25 inch) bead of Silicone
Rubber D6AZ-1 9562-BA or AA or equivalent
meeting Ford specifications ESB-M4G92-A and
ESE-M4G 1 95-A to oil level indicator tube where
Oil Bypass Filter oil level indicator tube mates with cylinder blocks.
Removal 2. Install oil level indicator tube into cylinder blocks.
1. Raise vehicle on hoist. Refer to Section OO-Q2. 3. Install oil level indicator tube bracket onto lH
2. Position drain pan beneath engine oil pan {6675). intake manifold stud. Install and tighten oil level
indicator tube retaining nut to 2Q-30 N·m { 1 5-22
3. Remove oil pan drain plug and drain. lb-ft).
4. Remove oil bypass filter {67 1 4).
Installation
1. Install oil pan drain plug. lighten to 20-34
N·m{1 5-25 1b-ft).
1 997 Thunderbird. Cougar July 1 996

03·01 A·42 Engine, 3.8L 03·01 A-42
4. Install oil level dipstick into oil level indicator tube. 2. Remove oil pressure sensor from the oil pressure
fitting.
Installation
1. Follow removal procedure in reverse order.
2. Tighten to 1 1-16 N·m (98- 1 4 1 1b-in).
--
FRONT OF ENGINE
----
--
FRONT OF ENGINE
--
NOTE: ADVANCE CLOCKWISE

TO POSmON SHOWN IN VIEW A
(NOT MORE THAN ONE FULL
TURN) NO BACK-UP ALLOWED VIEW A
--- FRONT OF ENGINE ---
NOTE: LUBRICATE "0" RING WITH

MOTOR OIL PRIOR TO INSTALLATION
SECTION A
A24832·A
Part 40 DEGREES -
50 DEGREES
VIEW A
1 6750 Oil Level Dipstick
A24834-A
2 6754 Oil Level Indicator Tube
3 N62 1939 Nut Part
4 60 10 Cylinder Blocks Item Number Description
5 N80 1648 Stud Bolt 1 60 1 0 Cylinder Blocks
-
6 0-Ring 2 N800299 Fitting
-
A Tighten to 20-30 N·m ( 1 5-22 3 9278 Oil Pressure Sensor
Lb-Ft) A -
Tighten to 1 1-24 N·m (98-2 1 2
Lb-ln)
-
B Tighten to 1 1 - 1 6 N·m (98- 1 4 1
Lb-ln)
Sensors
Oil Pressure Sensor
Removal
1. Disconnect wiring connector from oil pressure
sensor (9278).

03·01A-43 Engine, 3.8L 03-01 A·43
REMOVAL AND INSTALLATION
Engine 28. Disconnect fuel return hose as described in

Section 1 o-o 1 .
Removal
29. Disconnect fuel charging wiring from engine
1. Drain engine cooling system. Refer to Section control sensor wiring ( 1 2A58 1) at 4Q-pin
03-03. connector.
2. Disconnect battery ground cable ( 1 430 1). Refer 30. Disconnect main vacuum source hose.
to Section 14-0 1 .
3 1 . Disconnect evaporative emission hose.
3. Disconnect underhood lamp wiring connector.
32. Remove A I C compressor mounting bracket
4. Mark position of hood hinge ( 1 6796) and remove (2882) with drive belt tensioner attached.
hood ( 1 66 1 2).
33. Raise vehicle on hoist. Refer to Section oo-o2.
5. Disconnect generator-to-voltage regulator wiring
assembly. 34. Position drain pan beneath engine oil pan (6675).
6. Remove radiator upper sight shield (8C29 1). 35. Drain engine oil.
7. R�lease drive belt tensioner (68209) and remove 36. Remove oil bypass filter (67 1 4)
dnve belt (8620) as described in Section 03-05.
8. Remove air cleaner outlet tube (98659). Refer to
OIL BYPASS FILTER
Section 03- 1 2 .
/
FRONT OF ENGINE
6714 TIGHTEN
1/2 TURN AFTER
9. Disconnect cooling fan motor wiring.
GASKET CONTACT
10. Disconnect constant control relay module at / - OPTIONAL
wiring connector and remove radiator coolant TIGHTEN TO
recovery reservoir (8A080). Refer to Section 10-15 N·m
03-03.
(7-1 1 LB-FT)
1 1 . Remove cooling fan motor, fan blade (8600) and
fan shroud (8 1 46) assembly. Refer to Section
03-03.
1 2. Remove upper radiator hose (8260).
13. Disconnect transmission oil cooler inlet and outlet
tubes.
14. Disconnect heater inlet and heater return tube
hoses.
15. Disconnect lower radiator hose (8286) at water
pump (850 1).
16. Remove radiator retaining bolts and radiator
(8005). Refer to Section 03-03.
17. Disconnect power steering pressure hose
\
*THOROUGHLY COAT GASKET
(3A7 1 9). SEALING SURFACE WITH CLEAN
18. Remove power steering pump (3A674) and ENGINE OIL MEETING FORD
SPECIFICATION WS8-M2C153-F
power steering pump bracket and move aside. PRIOR TO FILTER INSTALLATION AA0867-B
19. Di�connect power steering pressure switch (PSP
37. Move drain pan away from vehicle.
sw•tch)(3N824) at wiring connector.
38. Disconnect heated oxygen sensors
20. Disconnect A I C clutch (2884) from fuel charging
(H02S)(9F472).
wiring (9D930).
39. Remove dual converter Y pipe (5F250). Refer to
2 1 . Recover A I C system. Refer to Section 1 2-QO.
Section 09-QO.
22. Disco�nect A I C compressor lines. Cap or plug
40. Remove inspection plug from engine rear plate
open lines.
(7007) and remove torque converter bolts.
23. Remove A I C compressor retaining bolts and
4 1 . Remove engine-to-transmission bolts.
remove A I C compressor ( 1 9703).
42. Remove transmission oil cooler line retainers from
24. Remove wiring shield.
RH front engine support insulator (6038).
25. Disconnect accelerator cable (9A758) and speed
43. Remove through bolts retaining front engine
control actuator cable (9A825) from throttle body
support insulator to front sub-frame (5C 1 45).
(9E926).
44. Remove starter motor ( 1 1 002). Refer to Section
26. Remove accelerator cable bracket (9723) and
03-Q6.
move aside with cables.
45. Remove ground cable. Remove starter motor
27. Release fuel system pressure and disconnect fuel
wire harness retainers (LH and RH sides).
supply hose as described in Section 10-0 1 .

03-01A-44 Engine, 3.8L 03-01 A-44
REMOVAL AND INSTALLATION (Continued)

�------�
\�------�
46. Partially lower vehicle. 25. Install A I C compressor and retaining bolts.
47. Position floor jack under transmission. Tighten to 2 1 -29 N-m ( 1 6-2 1 1b-ft).
48. Install Rotunda Engine Lifting Brackets (3.8L) 26. Remove caps or plugs on A I C compressor lines
0 1 4-00792 and Separator Bar 0 1 4-Q0793 or and connect lines to A I C compressor.
equivalent. 27. Connect A I C clutch to fuel charging wiring.
49. Position engine-lifting equipment. 28. Connect power steering pressure switch at wiring
50. Remove engine assembly from vehicle. connector.
5 1 . Place engine on a workstand. 29. Install power steering pump and bracket.
30. Connect power steering hoses.
Installation
3 1 . Install radiator as described in Section 03-Q3.
installation except those specifying special 32. Connect lower radiator hose to water pump.
sealant. 33. Install heater inlet and heater return tube hoses.
Install engine-lifting equipment and remove engine 34. Install transmission cooler lines.
assembly from work stand.
35. Install upper radiator hose.
2. Position engine assembly in vehicle.
36. Install cooling fan motor, fan blade and fan shroud
3. Install two engine-to-transmission bolts. assembly. Refer to Section 03-Q3.
4. NOTE: Seat LH side front engine support 37. Connect engine control sensor wiring to cooling
insulator locating pin before RH side front engine fan motor.
support insulator.
38. Install radiator coolant recovery reservoir and
Lower engine onto front engine support insulators connect constant control relay module at wiring
and remove lifting equipment, Rotunda Engine connector. Refer to Section 03-03.
Lifting Brackets (3.8L) 0 1 4-Q0792 and Separator
Bar 0 1 4-Q0793 or equivalent. 39. Install drive belt. Refer to Section 03-Q5.
5. Remove floor jack from under transmission. 40. Install radiator upper sight shield.
6. Tighten two engine-to-transmission bolts. 4 1 . Install air cleaner outlet tube to throttle body as
described in Section 03- 1 2.
7. Raise vehicle.
42. Install hood to previously marked position.
8. Install remaining engine-to-transmission bolts.
Tighten all bolts to 34-46 N-m (25-33 lb-ft). 43. Connect underhood lamp wiring.
9. Install torque converter bolts and tighten to 27-46 44. Connect battery ground cable.
N-m (2Q-33 lb-ft). Install inspection plug to engine 45. Refill crankcase to proper level with clean engine
rear plate. oil meeting Ford specification WSS-M2C 1 53-F.
10. Install and tighten front engine support insulator 46. Refill engine cooling system. Refer to Section
through bolts. Tighten through bolts to 47-68 N-m 03-03.
(35-50 lb-ft). Refer to Section 02-Q3. 4 7. Evacuate and recharge A I C system. Refer to
1 1 . Install starter motor. Refer to Section 03-o6. Section 1 2-oo.
12. Install transmission oil cooler line bracket. 48. Start engine and check for leaks.
13. Install dual converter Y pipe. Refer to Section
09-QO.
14. Connect heated oxygen sensor.
Camshaft Bearings
15. Install oil bypass filter as described.
16. Lower vehicle. SPECIAL SERVICE TOOL(S) REQUIRED
17. Install A I C compressor mounting bracket with Description Tool Number
drive belt tensioner attached. Camshaft Bearing Set T65L-6250-A
18. Connect evaporative emission hose.
19. Connect main vacuum source hose. Removal
20. Connect fuel charging wiring to engine control 1. Remove engine from vehicle as described.
sensor wiring at 42-pin connector. 2. Remove flywheel (6375) and engine rear plate
2 1 . Remove plugs from fuel supply and return lines (7007).
and connect lines as described in Section 1 o-o 1 . 3. Remove camshaft (6250) as described. Loosen
22. Install accelerator cable bracket. lower intake manifold bolts.
23. Connect accelerator cable and speed control 4. Remove crankshaft (6303) as described, and
actuator cable to throttle body. push pistons (6 1 08) to top of cylinder bore.
24. Install wiring shield.

03·01A-45 Engine, 3.8L 03·01 A-45
5. Remove camshaft rear bearing cover (6266) Installation

from rear of cylinder blocks (60 1 0). 1. CAUTION: Failure to use correct expanding
6. Select proper size expanding collet and back-up collet can cause severe camshaft bearing
nut and assemble on expanding mandrel from damage. Make sure front camshaft bearing is
Camshaft Bearing Set T65L-625Q-A. With installed at specified distance below front
expanding collet collapsed, install collet face of cylinder blocks.
assembly in camshaft bearing (626 1). Tighten NOTE: Camshaft bearings are available
back-up nut on expanding mandrel until collet fits refinished to size for standard and 0.38 mm
camshaft bearing. (0.0 1 5 inch) undersize journal diameters. The
7. Assemble puller screw and extension if camshaft bearings are not interchangeable from
necessary, and install on expanding mandrel. one bore to another.
Wrap a cloth around threads of puller screw to Position new camshaft bearings at bearing bores
protect front bearing or journal. Tighten pulling nut with oil holes aligned with holes in cylinder blocks.
against thrust bearing and pulling plate to remove Press camshaft bearings in place using Camshaft
camshaft bearing. Hold a wrench on end of puller Bearing Set T65L-625Q-A. Center pulling plate
screw to prevent it from turning. and puller screw to avoid damage to camshaft
8. Repeat this procedure for each camshaft bearing.
bearing. To remove front camshaft bearing, install 2. Install camshaft rear bearing cover as described.
puller screw from rear of cylinder blocks.
3. Install crankshaft as described.
4. Retighten lower intake manifold bolts as
described.
5. Install camshaft as described.
6. Install engine rear plate and flywheel as
described.
7. Install engine in vehicle as described.
Camshaft Bearing Set T65L-6250·A
CAMSHAFT BEARING SET

T&SL-6250-A
Part Part
- -
1 Expanding Collet (Part of 4 Pulling Plate (Part of
T65L-6250-A) T65L-6250-A)
- -
2 Back-Up Nut (Part of 5 Puller Screw (Part of
T65L-6250-A) T65L -6250-A)
-
3 626 1 Camshaft Bearing 6 Pulling Nut (Part of
T65L-6250-A)
(Continued)
(Continued)

03·01A·46 Engine, 3.8L 03·01A·46
Part Part
7 - Thrust Bearing (Part of 8 - Puller Screw Extension (Part
T65L-6250-A) of T65L-6250-A)
(Continued) 9 - Expanding Collet (Part of
T65L-6250-A)
Crankshaft
NOTE: ASSEMBLE CAPS NOTE: THE REAR
Removal WITH ARROWS POINTING CRANKSHAFT MAIN
FORWARD. CAPS ARE BEARING CAP MUST
1. Remove engine from vehicle as described. IDENTIFIED 1, 2 AND 3 BE INSTALLED SO THAT
FRONT TO REAR THE CAP IS FLUSH TO
2. Mount engine in a suitable work stand. Drain 0.5mm (0.02 1NCH)
crankcase and cylinder block cooling jackets. FORWARD OF THE
3. Disconnect ignition wire from the spark plugs OF BLOCK.
( 1 2405). Refer to Section 03-Q7A.
4. Remove spark plugs. Refer to Section 03-Q7A.
5. Remove oil pan (6675) and oil pump screen cover
and tube (6622).
6. Remove engine front cover (60 1 9) and water
pump (850 1 ) as an assembly.
7. Remove camshaft position sensor drive gear.
8. Remove crankshaft sprocket (6306), camshaft
sprocket (6256) and timing chain.
9. Remove flywheel (6375) and engine rear plate
(7007) as described.
10. Remove connecting rod caps. Turn crankshaft
(6303) as necessary to position connecting rod
(6200) in the low point of travel before removing
connecting rod cap.
Push piston (6 1 08) up into cylinder block bore
after removing connecting rod cap. Make sure
crankshaft journals are not damaged.
Each connecting rod cap should be identified so it
can be installed in its original position during
assembly.
1 1 . Remove crankshaft main bearing caps.
1 2. NOTE: Handle crankshaft with care to prevent
possible damage to finished bearing surfaces.
Carefully lift crankshaft out of cylinder blocks
(60 10) to prevent damage to bearing surfaces.
1 3. Remove crankshaft rear oil seal (670 1) and 0 REFER TO LEGEND
AA0869-A
discard.
1 4. CAUTION: Because the crankshaft Part
incorporates deep rolling of the main journal Item Number Description
fillets, journal refinishing is limited to 0.25
mm (0.01 0 Inch) undersize standard journal
1 N8 1 146 1 Stud Bolt
dimensions. Further crankshaft main journal 2 - Rear Main Bearing Cap (Part
refinishing may result In fatigue failure of the of 6010)
crankshaft. 3 - Rear Intermediate Main
Refer to Section 03-QO for crankshaft cleaning, 4 6337 Crankshaft Thrust Main
inspection and refinishing. Bearing -Lower
5 6333 Crankshaft Main
Bearing -Upper (3 Req'd)
(Continued)

·
03·01A-47 � 3.8L 03·01 A·47

Part surfaces with Metal Parts Cleaner
Item Number Description F4AZ- 1 9A536-RA or equivalent meeting Ford
6 6337 Crankshaft Thrust Main specification WSE-M5B392-A, to remove all
Bearing-Upper residues that may interfere with the sealers
7 6010 Cylinder Blocks ability to adhere.
8 6303 Crankshaft NOTE: When using silicone sealer, assembly
must occur within 1 5 minutes after sealer
9 6333 Crankshaft Main application. After this time, the sealer may start
Bearing-Lower (3 Req'd) to set-up and its sealing effectiveness may be
-
10 Front Main Bearing Cap (Part reduced.
of 6010)
-
Apply a 3 mm (0. 1 25 inch) bead of Silicone
11 Front Intermediate Main Rubber D6AZ- 1 9562-AA or equivalent meeting
Bearing Cap (Part of 60 1 0) Ford specifications ESB-M4G92-A and
12 N8 1 1537 Bolt (7 Req'd) ESE-M4G 1 95-A to rear main bearing
- cap-to-cylinder block parting line.
A Tighten in two steps: Tighten
to 50 N·m (37 lb·ft), tighten 7. Lubricate bearing surfaces with Engine Assembly
an additional 1 15-125 Lubricant D9AZ- 1 9579-D or equivalent meeting
degrees.
Ford specification ESR-M99C8Q-A. Install main
Installation bearing caps and retaining bolts.
1. CAUTION: Contaminants on a bearing 8. lighten main bearing cap retaining bolts as
surface will cause damage to the crankshaft follows:
journals. a. Wedge a prybar between cylinder block web
NOTE: Lightly oil all bolts and stud threads before and crankshaft cheek in front of the No. 3
installation. crankshaft main bearing.
Make sure all crankshaft bearing surfaces and Do not jam the prybar into position. Carefully
crankshaft main bearings (6333) are clean. tap on the prybar until it holds crankshaft
2. H crankshaft main bearing journals have been toward front of engine.
I"""' refinished to definite undersize, remove b. lighten main bearing cap retaining bolts in
crankshaft main bearings from cylinder blocks two steps in sequence shown: tighten to 50
and main bearing caps. N·m (37 lb-ft), tighten an additional 1 1 5- 1 25
Loosen the lower intake manifold retaining bolts degrees.
and support brackets prior to installing c. Remove prybar.
crankshaft main bearings or measuring bearing 9. Check crankshaft end play as described in
clearances. Section 03-QO.
Install new crankshaft main bearings. Make sure 10. Install crankshaft rear oil seal as described.
tabs on crankshaft main bearings engage slots in
the main cap and cylinder blocks. 1 1 . If crankshaft connecting rod journals have been
refinished to a definite undersize, remove
3. Make sure crankshaft rear oil seal groove in connecting rod bearings (62 1 1 ) from connecting
cylinder blocks is clean. rods and connecting rod caps.
4. Carefully lower crankshaft into position in cylinder Install new connecting rod bearings. Make sure
blocks. Be careful not to damage crankshaft tabs on connecting rod bearings securely engage
thrust main bearing (6337). the slots in connecting rod and cap.
5. Make sure crankshaft rear oil seal groove in rear 1 2 . Rotate cylinder blocks as necessary to bring
main bearing cap is clean. each crankshaft throw to lowest point of travel.
Pull piston downward until connecting rod bearing
seats on crankshaft and install connecting rod
caps.
1 3. Check connecting rod clearance. Refer to
Section 03-QO.
As each clearance check is completed, lubricate
bearing surfaces with Engine Assembly Lubricant
specification ESR-M99C8Q-A before installing
connecting rod cap.
I"""' lighten retaining bolts in three steps:
a. lighten to 2Q-25 N·m ( 1 5- 1 8 1b-ft).
b. lighten to 4Q-45 N·m (3Q-33 lb-ft).

03-01 A-48 ( Engine, 3.8L 03-01A-48
'-
c. Tighten an additional 9Q- 1 20 degrees. 6. NOTE: When removing an ignition wire from a
14. Install timing chain and engine front cover with spark plug ( 1 2405), use Spark Plug Wire
water pump as described. Remover T74P-6666-A. Grasp and twist boot
back and forth on spark plug insulator to free
15. Install camshaft position sensor (CMP boot. Use tool to pull boot from spark plug. Do not
sensor)(6B288) as described in Section 03- 1 4. pull on ignition wire directly or it may become
16. Install oil pan as described. separated from connector inside boot.
17. Install engine rear plate and flywheel as Disconnect ignition wires from spark plugs. Refer
described. to Section 03-07A.
18. Install spark plugs. Refer to Section 03-07A. 7. Remove the following components:
19. Connect ignition wires to spark plugs. Refer to • throttle body (9E926) and throttle body gasket
Section 03-07A. (TB gasket)(9E936)
20. Install engine in the vehicle as described. • EGR valve (EGR valve)(9D475)
• upper intake manifold and intake manifold
upper gasket (9H486)
DISASSEMBLY AND ASSEMBLY
• fuel injectors (9F593) and fuel injection supply
manifold (9F792)
Engine 8. NOTE: If the crankshaft pulley and vibration
damper have to be separated, mark the damper
SPECIAL SERVICE TOOL(S) REQUIRED and pulley so that they may be reassembled in
Description Tool Number the same relative position. This is important as
the damper and pulley are initially balanced as an
assembly.
Front Cover Seal Replacer T70P-6B070-B
NOTE: If the crankshaft damper is being
Spark Plug Wire Remover T74P-6666-A replaced, check if the original damper has
Damper I Front Cover Seal Replacer T82L-631 6-A balance pins installed. If so, new balance pins
Vibration Damper Remover Adapter T82L-631 6-B
(EOSZ-6A328-A or equivalent) must be installed
on the new damper in the same position as the
Cylinder Ridge Reamer T64L-601 1 -EA original damper. The crankshaft pulley (new or
original) must also be installed in the same
Disassembly relative position as originally installed.
Before starting disassembly, remove accessories and Remove crankshaft pulley and vibration damper.
any emission control equipment which is not directly Use Crankshaft Damper Remover T58P-63 1 6-D
attached to the engine. and Vibration Damper Remover Adapter
1. Remove flywheel (6375) and engine rear plate T82L-63 1 6-B to remove vibration damper.
(7007). 9. Remove hold-down clamp ( 1 2270) and camshaft
2. Remove intake manifolds (9424). position sensor (CMP sensor)(6B288) and
housing.
3. NOTE: When LH exhaust manifold (9430) is
removed, note location of oil level indicator tube 10. Remove valve covers (6582).
support bracket. 1 1 . CAUTION: Do not damage machined sealing
Remove LH and RH exhaust manifolds. surfaces or possible leakage may occur.
4. Disconnect front evaporative emission hose and NOTE: Before attempting to remove lower intake
remove the following positive crankcase manifold, break seal between lower intake
ventilation system components: manifold and cylinder blocks (60 1 0). Wedge a
large prybar between lower intake manifold and
• Front and rear crankcase ventilation tube cylinder blocks. Pry downward on prybar using
(6758). lug on water pump as a leverage point.
• Positive crankcase ventilation valve (PCV Remove lower intake manifold and intake
valve)(6A666). manifold gasket (9439). Discard intake intake
5. Disconnect water bypass tube (8548) and water manifold gasket and end seals.
bypass hose (8597) at lower intake manifold. 1 2. Remove spark plugs.
Remove heater water outlet tube retaining bolts
and heater water outlet tube ( 1 8663) from water 1 3. Remove rocker arms (6564) and push rods
pump (850 1). (6565). The location of each rocker arm, push
rod and rocker arm seat (6A528) should be
noted. When engine is assembled, each
component should be installed in its original
position.

03-01A-49 Engine, 3.8L 03-01 A-49
DISASSEMBLY AND ASSEMBLY (Continued)
1 4. Remove cylinder heads (6049). Discard cylinder 22. Remove camshaft thrust plate (6269).
head retaining bolts. Remove and discard head 23. CAUTION: Do not damage camshaft bearing
gaskets (605 1).
surfaces or engine damage may occur.
1 5. Remove tappet guide plates and retainers Remove camshaft.
(6K564) and valve tappets (6500).
24. If necessary, remove camshaft rear bearing
The locati ach valve tappet should be cover (6266) from back of engine.
identifi . When ine is assembled, each valve
tappet should be ins ailed in its original position. If 25. CAUTION: Never cut into ring travel area in
valve tappets are stuck in bores due to excessive excess of 0. 794 mm {0.0325 inch) or
varnish or gum deposits, it may be necessary to damage to piston rings or cylinder blocks
use a magnet or a claw-type tool to aid removal. may occur.
When using a remover tool, rotate valve tappet NOTE: Before removing pistons (6 1 08), inspect
back and forth to loosen it from any gum or top of cylinder bores. If necessary, remove ridge
varnish that may have formed on valve tappet. and I or carbon deposits from each cylinder using
16. Remove oil bypass filter (67 1 4). Rotunda Cylinder Ridge Reamer 0 1 4..()()292 or
equivalent. Before ridge or deposits are removed,
1 7 . Remove oil pan (6675). turn crankshaft until piston is at bottom of its
1 8. Remove oil pump screen cover and tube (6622) . stroke. Cover piston with a clean shop towel to
Discard oil pump inlet tube gasket (6626). collect cuttings. After cutting operation, turn
19. Remove water pump and engine front cover crankshaft until piston is at top of its stroke and
(60 1 9) as an assembly. Remove and discard remove shop towel with cuttings.
engine front cover gasket. Remove connecting rod caps and pistons.
After removing engine front cover, remove
camshaft sprocket retaining bolt and washer from
end of camshaft (6250).
20. CAUTION: Do not damage finished areas on "-"-- PISTON
crankshaft {6303) and crankshaft sprocket 6108
{6306).
NOTE: If crankshaft sprocket is difficult to
remove, it can be loosened by prying using two
large prybars.
Remove distributor drive gear (6255). Remove
camshaft sprocket (6256), crankshaft sprocket
CONNECTING ROD
BEARING (UPPER)
and timing chain at the same time. 621 1
rv/
IF NECESS RY PRY
SPROCKET OFF
CRANKSHAFT
CONNECTING ROD
Flfoo-- BEARING
621 1
(LOWER)
PRY DOWNWARD
TO REMOVE A6673-E
SPROCKET A6677·E The location of each piston, connecting rod
bearings (62 1 1 ) and connecting rod cap should
2 1 . Remove timing chain vibration damper (6284) be noted. When engine is assembled, each
from front of cylinder blocks. (This requires pulling component should be installed in its original
back on ratcheting mechanism and then installing position.
pin through hole in bracket to relieve tension.)

03·01A·50 Engine, 3.8L 03·01A·50
26. Remove main bearing caps and crankshaft. The

location of crankshaft main bearings (6333) Part
should be identified. When engine is assembled, Item Number Description
each crankshaft main bearing should be installed 7 60 10 Cylinder Blocks
in its original position .
8 6303 Crankshaft
27. For cleaning purposes, oil gallery and cooling 9 6333 Crankshaft Main Bearing,
-
jacket plugs can be removed. Lower (3 Req'd)
10 Front Main Bearing Cap (Part
NOTE: ASSEMBLE CAPS
WITH ARROWS POINTING
NOTE: THE REAR
CRANKSHAFT MAIN - / ot 6010)
(
FORWARD. CAPS ARE BEARING CAP MUST 11 Front Intermediate Main
IDENTIFIED 1, 2 AND 3 BE INSTALLED SO THAT Bearing Cap (Part of 6010)
- -
FRONT TO REAR THE CAP IS FLUSH TO 12 N8 1 15_37 Bolt (7 Req'd)
O.Smm (0.02 INCH) A '
Tighten in two steps: tighten
FORWARD OF THE
OF BLOCK. to 50 N·m (37 lb-ft), tighten
an additional 1 15- 125
degrees.
Assembly
1. NOTE: During engine assembly, silicone sealer
will be applied to many components before
installation. When the sealant is applied, the
component should be installed within 1 5 minutes.
After this time, the sealant begins to set-up and
its sealing effectiveness can be reduced.
NOTE: lightly oil all retaining bolt and stud
threads before installation except those
specifying special sealant.
If removed, install oil gallery and cooling jacket
plugs. Tighten plugs to specification.
Before installation, coat plug threads with Pipe
Sealant with Teflon® DBAZ- 1 9554-A or
WSK-M2G350-A2.
To provide clearance for camshaft sprocket, oil
gallery plugs on front of engine must be threaded
below machined surface.
2. Install crankshaft as follows:
a. Install crankshaft main bearings in cylinder
blocks. Note that third crankshaft main
bearing from front is the crankshaft thrust
main bearing (6337).
b. Lubricate crankshaft main bearings with
Engine Assembly Lubricant D9AZ-1 9579-D
or equivalent meeting Ford specification
AA0869-A
ESR-M99C8Q-A and carefully lower
crankshaft into place. Use care to prevent
Part
damage to bearing surfaces.
c. NOTE: Prior to applying sealer, clean sealing
1
2 -
N8 1 146 1 Stud Bolt
Rear Main Bearing Cap (Part
surfaces with Metal Surface Cleaner
F4AZ- 1 9A536-RA or equivalent meeting
3 - of 6010)
Rear Intermediate Main
Ford specification WSE-M58392-A, to
remove all residues that may interfere with
the sealers ability to adhere.
4 6337 Crankshaft Thrust Main Apply a 3 mm (0. 1 25 inch) bead of Silicone
Bearing, Lower Rubber D6AZ- 1 9562-BA or AA or equivalent
5 6333 Crankshaft Main Bearing, meeting Ford specifications ESB-M4G92-A
Upper (3 Req'd) and ESE-M4G 1 95-A to cylinder block rear
6 6337 Crankshaft Thrust Main main bearing cap parting line.
Bearing, Upper
(Continued)

03-01A-5 1 Engine, 3.8L 03-01 A-5 1

!"'""
d. Install crankshaft main bearings in main
bearing caps and install caps. Note that caps
are numbered with triangles. Cap No. 1 is (
located at the front of engine with triangle
facing front of engine.
I
e. Install main bearing cap retaining bolts.
f. CAUTION: Do not jam prybar into place.
Tap into position only enough to hold
crankshaft forward while cap bolts are
tightened.
Before tightening main bearing cap retaining
bolts, wedge a large prybar between cylinder
block web and crankshaft cheek located in
front of No. 3 crankshaft main bearing.
g. Tighten main bearing cap retaining bolts in
two steps: tighten to 50 N·m (37 lb-ft), tighten AA0192-B
an additional 1 1 5- 1 25 degrees.
3. Check crankshaft end play. Refer to Section
03-QO.
4. Install pistons as follows:
a. Install connecting rod bearings in connecting
rods (6200) and connecting rod caps.
b. NOTE: Lubricate piston and cylinder walls
with Engine Assembly Lubricant
specification ESR-M99C8Q-A before
installation.
r NOTE: Scratching of crankshaft journal can
be prevented by covering connecting rod
bolts with ignition wire spark plug boots or
flexible hose.
Install pistons using Piston Ring Compressor
081 L-6002-C or equivalent. The notch in
piston dome must face the front of engine.

/
03·01 A·52 Engine, 3.8L 03·01A·52
Camshaft Removal

THRUST PLATE
WITH MOTOR OIL
PRIOR TO COLD TEST
0 THOROUGHLY COAT CAM

BEARINGS IN BLOCK WITH
MOTOR OIL PRIOR TO
INSTALLATION
--
FRONT OF ENGINE
--
NOTE: APPLY
WSK-M2G349-A 10
SEALER PRIOR TO
SECTION A INSTALLATION A24829-A
Part Part
Item Number Description Item N umber Description
1 6010 Cylinder Blocks 4 6269 Camshaft Thrust Plate
2 6250 Camshaft 5 N80462 1 Bolt
3 6265 Camshaft Sprocket Spacer 6 N805256 Woodruff Key
(Continued) 7 376958 Cup Plug
c. Install connecting rod caps and retaining bolts 6. NOTE: Coat sealing edge of camshaft rear
as follows: bearing cover with Perfect-Seal Sealing
Compound B5A- 1 9554-A or equivalent meeting
• tighten to 20-25 N·m ( 1 5- 1 8 1b-ft). Ford specification ESE-M4G 1 1 5-A before
• tighten retaining nuts to 40-45 N·m (30-33 installation.
lb-ft). Install camshaft rear bearing cover using a
• rotate nuts an additional 9Q- 1 20 degrees. suitable driver.
5. Check connecting rod side clearance as 7. Coat camshaft lobes and camshaft bearings
described in Section 03-QO. (626 1 ) with Engine Assembly Lubricant
specification ESR-M99C8Q-A.

.
I
03-01A-53 Engine, 3.8L 03-01 A-53
8. Install camshaft, camshaft sprocket spacer and 20. Install oil pan as follows:
'
J
key. a. NOTE: Prior to applying sealer, clean oil pan
9. Install camshaft thrust plate and tighten retaining and cylinder block sealing surfaces with
bolts to 8- 1 4 N·m (7 1 - 1 23 1b-in).
10. With the timing chain vibration damper in the,/
/ Metal Surface Cleaner F4AZ- 19A536-RH or
WSE-M5B392-A, to remove all residues that
compressed position, install the timing chain
vibration damper and retaining bolts. lighten may interfere with the sealers ability to
retaining bolts to 8- 1 4 N·m (7 1 - 1 23 1b-in). adhere.
1 1 . Lubricate timing chain with clean engine oil Using a small-blade screwdriver, remove any
meeting Ford specification WS5-M2C 1 53-F. sealer which may have been squeezed into
seal groove when rear main bearing cap was
1 2. Rotate crankshaft, as necessary, to position installed. Place a 6.35 mm (0.25 inch) bead
crankshaft sprocket keyway in 1 2 o'clock of Silicone Rubber D6AZ- 19562-AA or BA or
position. equivalent meeting Ford specifications
1 3. Install camshaft sprocket, crankshaft sprocket ESB-M4G92-A and ESE-M4G 1 95-A into seal
and timing chain at the same time. groove where main bearing cap meets
cylinder blocks.
Make sure crankshaft keyway, camshaft
sprocket timing mark and crankshaft sprocket b. Apply a 3 mm (0. 1 25 inch) bead of Silicone
timing mark are properly aligned after installation. Rubber D6AZ- 1 9562-AA or BA or equivalent
meeting Ford specifications ESB-M4G92-A
and ESE-M4G 1 95-A to seams where engine
front cover mates with cylinder blocks and to
each end of oil pan end seal.
c. Apply silicone rubber in a zig-zag pattern on
cylinder blocks.
CAMSHAFT
SPROCKET d. Install oil pan. lighten in sequence in two
6256 steps:
- 4-5 N·m (36-44 lb-in)
- 9- 1 2 N·m (8Q- 1 06 1b-in).
2 1 . Lubricate oil bypass filter gasket with Engine
meeting Ford specification ESR-M99C8Q-A.
POSITIONING OF TIMING MARKS AND
KEYWAYS IN CAMSHAFT AND CRANKSHAFT Thread oil bypass filter onto adapter until gasket
SPROCKETS MUST BE IN LINE AS SHOWN contacts cylinder blocks and then advance oil
WITH N0. 1 PISTON AT TOP DEAD CENTER bypass filter an additional one-half turn.
FIRING A12694-B
22. Lubricate valve tappets with Engine Assembly
1 4. Install distributor drive gear. Lubricant D9AZ- 19579-D or equivalent meeting
15. Install camshaft sprocket retaining bolt and Ford specification ESR-M99C80-A and install.
washer. lighten bolt to 4Q-50 N·m (3Q-36 lb-ft). 23. Install six valve tappet guide plates (6K5 1 2) and
16. Remove timing chain vibration damper retaining two tappet guide plates and retainers. lighten
pin. tappet guide plate and retainer retaining bolts to
1 Q- 1 4 N·m (89- 1 23 1b-in).
1 7. If water pump was removed from engine front
cover during engine disassembly, position a new 24. NOTE: RH and LH head gaskets are not
water pump housing gasket (8507) on engine interchangeable.
front cover and install water pump. Install new head gaskets using cylinder head to
lighten water pump retaining bolts to 2Q-30 N·m block dowels (6A008) to align head gasket.
( 1 5-22 1b-ft). lighten water pump retaining nuts to
8- 1 2 N·m (7 1 - 1 06 1b-in).
1 8. Position a new engine front cover gasket on
engine. Install engine front cover. lighten
retaining bolts to 2Q-30 N·m ( 1 5-22 lb-ft).
19. Install oil pump screen cover and tube using a new
oil pump inlet tube gasket.
lighten retaining bolts to 2Q-30 N·m ( 1 5-22 lb-ft)
� and support bracket retaining nut to 4Q-55 N·m
(3Q-40 lb-ft).

�-
--
03-01A-54 Engine, 3.8L 03-01 A-54
Head Gasket
CYLINDER HEAD TO
CYLINDER BLOCK BLOCK DOWEL
6010 6A008
NOTE: MUST BE BOTTOMED OUT
(FOR MANUAL OPERATIONS ONLY)
/
,
_......
FRONT OF ENGINE
�
SECTION A
TYPICAL TWO PLACES
CYLINDER HEAD
TO BLOCK DOWEL
6A008
2 REQ'D AA0866-A
25. Install cylinder head as described under In-Vehicle 32. Install lower intake manifold as described.
Service, Cylinder Head.
26. Install push rods, rocker arms, rocker arm seats
and retaining bolts. Lubricate push rod ends and
rocker arm seats with Engine Assembly Lubricant
D9AZ- 19579-D or equivalent meeting Ford
specification ESR-M99C8Q-A before installation.
For each valve, rotate crankshaft until valve
tappet rests on heel (base circle) of camshaft
lobe. Tighten rocker arm seat retaining bolt to 5
N·m (44 1b-in) MAX. Final-tighten rocker arm seat
retaining bolts to 3Q-40 N·m (22-30 lb-ft). For
final-tightening, camshaft may be in any position.
27. Install lower intake manifold as described.
28. Install spark plugs. Tighten to 9-20 N·m (80- 1 77
lb-in). Refer to Section 03-Q7A.
29. NOTE: Using solvent, clean valve cover and
cylinder head sealing surfaces to remove all LOWER INTAKE
gasket material and dirt. MANIFOLD 9424
Install valve covers as follows: TIGHTEN IN NUMERICAL SEQUENCE IN
STEPS AS FOLLOWS:
a. Install a new valve cover gasket (6584) onto STEP 1 5 N·m (44 LB-IN)
-
cylinder head. STEP 2 - 8-12 N·m (71-106 LB-IN) A21 251-C

b. Install valve cover and retaining bolts. Note 33. Install fuel injectors and fuel injection supply
location of stud I bolts. manifold.-Tighten retaining bolts for fuel injection
c. Tighten retaining bolts to 8- 1 2 N·m (7 1 - 1 06 supply manifold bracket to 8-1 1 N·m (7 1 -97 1b-in).
Ib-in). 34. Connect the front evaporative emissions tube and
30. Install camshaft position sensor, housing and install the following positive crankcase ventilation
hold-down clamp as described in Section 03- 1 4. system components:
3 1 . Install crankshaft pulley and vibration damper • Front and rear crankcase ventilation tube.
using Damper / Front Cover Seal Replacer
• Positive crankcase ventilation valve.
T82L-631 6-A and Front Cover Seal Replacer
T70P-68070-A. Tighten retaining bolt to 1 4Q-180
N·m (103-132 1b-ft).

03·01 A·55 Engine, 3.8L 03-01A·55
35. NOTE: Apply a light coat of Pipe Sealant with

Teflon ® DBAZ- 1 9554-A or equivalent meeting
Ford specification WSK-M2G35Q-A2 to retaining Item
� art
N mber Description
bolts and stud bolt threads prior to installation. 3 9430 ) Exhaust Manifold, LH
Install upper intake manifold. lighten bolts and 4 N80 1tr48 Stud (3 Req'd)
studs in numerical sequence in three steps: 5 N8o1647 Bolt (3 Req'd)
-
a. 1 0 N·m (8 1b-ft). A Tighten to 30-36 N·m (23-26
b. 20 N·m ( 1 5 lb-ft).
Lb-Ft)
c. 32 N·m (24 1b-ft). 4 1 . NOTE: Apply a thin coat of Pipe Sealant with
Teflon ® DBAZ- 1 9554-A or equivalent meeting
36. Install EGR valve. lighten bolts to 20-30 N·m
Ford specification WSK-M2G35Q-A2 to flywheel
( 1 5·22 lb-ft).
retaining bolt threads before installation.
37. Connect ignition wires to spark plugs. Refer to
Install engine rear plate and flywheel.
Section 03-Q7A.
lighten flywheel retaining bolts to 73-87 N-m
38. Inspect heater water outlet tube Q-ring (replace
(54-64 1b-ft) in a standard cross-tightening
as necessary) and install heater water outlet
sequence.
tube. Install and tighten retaining bolts to 8- 1 2
N·m (7 1 - 1 06 1b-in).
39. Install water bypass tube to intake manifold.
lighten hose clamp securely. Subassemblies
40. Install exhaust manifolds. Note location of oil level
indicator tube support bracket. lighten exhaust Cylinder Head
manifold retaining bolts in sequence to 3Q-36 N·m
(23-36 lb-ft). SPECIAL SERVICE TOOL(S) REQUIRED
Description Tool Number
Exhaust Manifold LH Shown RH Similar
Valve Spring Compressor T81 P-651 3-A
Disassembly
1. Remove rocker arm seat retaining bolts, rocker
arm seats (6A528) and rocker arms (6564).
2. Remove exhaust manifolds (9430) if required,
and spark plugs ( 1 2405).
3. Clean carbon out of cylinder head combustion
chambers before removing valves.
FRONT OF 4. Compress valve spring (65 1 3) using Valve Spring
-- ENGINE Compressor T8 1 P-65 1 3-A. Remove valve spring
retainer keys (65 1 8) and release valve springs.
_ FRONT OF_
ENGINE
VIEW A
A24300-A
Part
It em N umber Description
1 6049 Cylinder Head
2 9448 Exhaust Manifold Gasket
(Continued)

03·01 A·56 Engine, 3.8L 03-01 A-56
5. Remove valve spring retainer (65 1 4), val�e stem 2. NOTE: Due to different leakage rates between
seal (657 1) and valve. Discard valve stem seals intake and exhaust valve stems, valve stem seals
and identify all valve parts from the disassembled must not be interchanged.
cylinder and note whether they are intake or Install exhaust valve stem seal. Make sure valve
exhaust. stem seal is bottomed on guide.
3. Install intake valve stem seal. Valve stem seal
must be bottomed on guide.
4. Install lower valve spring retainer.
5. Install valve spring over valve and then install
upper valve spring retainer. Compress valve
spring and install valve spring retainer keys.
6. CAUTION: Do not install the spacers unless
necessary. Use of spacers in excess of
recommendations will result in
over-stressing valve springs and overloading
camshaft lobes which could lead to valve
spring breakage and/ or worn camshaft
lobes.
Measure assembled height of valve spring from
top of lower valve spring retainer to underside of
upper valve spring retainer with dividers. Check
dividers against a scale. If assembled height is
greater than specificati n, install necessary 0. 79
mm (0.030 inch) thick s cer(s) between
cylinder head spring pad nd lower valve spring
retainer to bring assem ed height to
A6719-E recommended speci!i tion.
7. CAUTION: Do not tighten bolts. The bolts
Part
must be loose enough to allow rocker arm to
Item Number Description be rotated to side.
1 6507 Intake Valve Position rocker arms and rocker arm seats on
2 6505 Exhaust Valve cylinder heads and install rocker arm seat
3 69536 Lower Valve Spring Retainer retaining bolts.
4 657 1 Valve Stem Seal 8. Install exhaust manifold, if removed, and spark
5 65 13 Valve Spring plugs.
6 6514 Upper Valve Spring Retainer Pistons, Piston Pins and Rings
7 65 18 Valve Spring Retainer Key
6. Clean, inspect and service cylinder head (6049)
Piston Pin Remover I Replacer T68P·6 135-A
as required or prepare to transfer all usable parts
to a new cylinder head.
Disassembly
Assembly 1. Remove connecting rod bearings (62 1 1) from
All valves, valve stem seals and valve guides are to be connecting rod (6290) and cap.
lubricated with Engine Assembly Lubricant 2. Remove piston rings using a suitable piston ring
D9AZ- 19579-D or equivalent meeting Ford expander.
specification ESR-M99C80-A. Apply Multi-Purpose
Grease DOAZ- 1 9584-AA or equivalent meeting Ford 3. Mark piston (6 1 08) to ensure assembly with
specification ESB-M 1 C93-A and ESR-M 1 C 1 59-A to same connecting rod and installation in same
valve tips before installation. cylinders from which they were removed.
1. Install each valve in port from which it was
removed or to which it was fitted.

03·01A·57 Engine, 3.8L 03-01 A·57
4. Using an arbor press and Piston �in Remover and 4. Check piston ring side clearance of compression
Replacer T68P-6 1 35-A, press piston pin (6 1 35) rings with Feeler Gauge 08 1 L-420 1-A or
from piston and connecting rod. equivalent by inserting it between piston ring and
its lower land. This gauge should slide freely
around entire piston ring circumference without
binding. Any wear that occurs will form a step at
inner portion of lower land. If lower lands have
REMOVAL high steps, piston should be replaced.
5. Make sure connecting rod bearings and bearing
bore in connecting rod and cap are clean. Foreign
material under connecting rod bearings will distort
connecting rod bearings and cause a failure.
Install connecting rod bearings in connecting rod
and cap with tangs fitting in slots provided.
Oil Pump
Disassembly
1. If necessary, remove oil bypass filter (67 1 4).
PRESS 2. Remove oil pump and filter body (6603) to engine
PLATES A8121-C front cover retaining bolts and remove oil pump
and filter bod from engine front cover (60 1 9).
Assembly 3. Lift pump gear out of pocket in oil pump and filter
Check the fit of a new piston in the cylinder bore body.
before assembling piston and piston pin to connecting 4. Remove oil pump body seal (6C639) and discard.
rod. Refer to Section 03-QO. 5. Clean sealing surfaces of engine front cover and
The piston pin bore of a connecting rod and diameter oil pump and filter body.
of piston pin must be within specification. Refer to 6. Using a straightedge and feeler gauge, measure
Specifications as described. across mounting surface of engine front cover for
1. Apply light coat of clean engine oil to all parts. wear or warpage. .
2. Start piston pin in piston and connecting rod (this 7. If surface i s out of flat by more than 0.04 mm
may require a very light tap with a mallet). Using (0.00 1 6 inch), replace the engine front cover as
an Arbor Press and Piston Pin Remover and described.
Replacer T68P-6 1 35-A, press piston pin through
Assembly
piston until the piston pin is centered.
1. CAUTION: Failure to properly coat the oil
pump gears may result in failure of the pump
MAKE CERTAIN to prime when engine is started. Do not use
'PISTON FLOATS chassis lubricants.
DURING
INSTALLATION Lightly pack gear pocket with petroleum jelly or
OPERATION coat all gear surfaces with Engine Assembly
Lubricant D9AZ- 1 9579-D or equivalent meeting
Ford specification ESR-M99C80-A.
2. Install gears in oil pump and filter body pocket.
Make sure petroleum jelly fills all voids between
gears and pockets.
3. Position oil pump body seal. Install oil pump and
filter body to engine front cover using alignment
dowels on engine front cover.
A8122-C
4. lighten oil pump and filter body retaining bolts to
3. Check end gaps of all piston rings. It must be 23-32 N·m ( 1 7-23 lb-ft) for M8 bolts and 8- 1 1 N·m
within specification. Follow instructions (7 1-97 1b-in) for M6 bolts.
contained on piston ring package and install
Oil Pressure Relief Valve
piston rings. Refer to Section 03-00.
Removal
1. After drilling a hole through valve plug, remove
plug with a slide hammer or by prying.
2. Remove spring and pressure relief valve from
bore.

03-01 A-58 Engine, 3.8L 03-01A-58
Inspection 2. Remove the cylinder head to block dowels

1. Thoroughly clean pressure relief valve bore and (6A008) and the cylinder block drain plugs.
pressure relief valve to remove any metal chips 3. Remove the used cylinder blocks from the
which may have entered bore as a result of workstand.
drilling operation.
Assembly
2. Inspect pressure relief valve and valve bore for
wear, scoring or galling. If inspection determines 1. Clean the gasket and seal surtaces of all
part(s) to be unserviceable, replace pressure serviceable parts and assemblies.
relief valve and I or oil pump and filter body. 2. Position the new cylinder blocks in a work stand
3. Check clearance between pressure relief valve and install the cylinder head to block dowels and
and bore. The valve should slip into bore without cylinder block drain plugs.
side play or binding. 3. Transfer all serviceable parts removed from the
4. Check spring for signs of fatigue or collapse. used cylinder blocks.
4. Check all assembly clearances and correct as
Installation necessary.
1. Lubricate pressure relief valve with clean engine
oil and install in bore. The end with smaller Cylinder Block, Bare
diameter goes in first. Before replacing a cylinder blocks, determine if it is
2. Position spring in bore. serviceable. If so, make the necessary service. Refer
to Section 03-00.
3. Install a new plug. The plug can be tapped into
bore using a plastic-tipped hammer. Make sure Disassembly
plug is Q-0.25 mm (O-Q.0 1 0 inch) below machined
· 1. Completely disassemble the used engine
surtace. following the procedures in Removal and
Oil Pump Intermediate Shaft Installation.
2. Remember to ridge ream the cylinder bores
Removal before removing pistons.
1. Remove camshaft position sensor (CMP 3. Remove the cylinder head to block dowels and
sensor)( 1 2 1 26) and camshaft position sensor the cylinder block drain plugs.
housing as described in Section 03- 1 4.
2. Separate oil pump intermediate shaft (6A6 1 8) Assembly
from camshaft position sensor housing shaft. 1. Clean the gasket and seal surtaces of all
serviceable parts and assemblies.
Installation
2. Position the new cylinder blocks in a work stand
1. Push lock ring end of oil pump intermediate shaft and install the cylinder head to block dowels and
into camshaft position sensor housing shaft. the cylinder block drain plugs.
2. NOTE: Install camshaft position sensor housing 3. Transfer all serviceable parts removed from the
and oil pump intermediate shaft as an assembly, used cylinder blocks following the procedures in
making sure that end of oil pump intermediate Removal and Installation.
shaft is seated in oil pump drive gear.
Install oil pump intermediate shaft and camshaft necessary.
position sensor as described in Section 03- 1 4.
3. Install hold-down clamp ( 1 2270). lighten to
20-30 N·m ( 1 5-22 lb-ft).
Cylinder Block Assembly
Disassembly
1. Mount the engine in a workstand and remove all
parts not furnished with the new cylinder blocks
(60 1 0) following the procedures in Removal and
Installation.

03-01 A-59 Engine, 3.8L 03-01 A-59
ADJUSTMENTS
Valve Clearance
ROCKER ARM SEAT
1. With No. 1 piston (6 1 08) on the top dead center AND BOLT MUST BE
(TDC) at the end of compression stroke (Position FULLY SEATED AFTER
No. 1 in the illustration), and check the following FINAL TORQUE
·
valves:
A13129-C
SPECIFICATIONS
SPECIFICATIONS
POSITION 1 Description Specification
NO. 1 AT TDC. AT
END OF COMPRESSION GENERAL SPECIFICATIONS
STROKE Displacement 3.8L
POSITION 2 Number of Cylinders 6

ROTATE CRANKSHAFT Bore 96.8 mm (3.81 in)
ONE REVOLUTION - 360
_/
DEGREES A13128-B Stroke 86.0 mm (3.39 in)
."-.._ Firing Order 1 -4-2-5-3-6
Set Gap of Valves Noted 011 Pressure (HOT 2500 RPM) 40-60 psi
Crankshaft Position CYLINDER HEAD AND VALVE TRAIN
Cyi. No. 1 2 Combustion Chamber Volume 59.7-62.7
1 lnt -Exh No.ne (CC)
2 Exh lnt Valve Guide Bore Diameter

• Intake and Exhaust 8. 745-8.720 mm
3 lnt Exh
(0.3443-0.3433 in)
4 Exh lnt
Valve Seats
5 None lnt -Exh • Width -Intake & Exhaust 1 .5-2.0 mm (0.06-0.08 in)
6 lnt Exh • Angle 44.47 degrees
• Runout (T.I.R.) 0.076 mm (0.003 in)
2. When compressing valve spring (65 1 3) to
remove push rods (6565), make sure piston in Bore Diameter (Bearing
Counterbore Diameter)
individual cylinder is below TDC to avoid contact
between valve and piston. To replace a push rod, • Intake 47.097 mm ( 1 .8542 in)
MAX
it will be necessary to loosen the rocker arm seat 47.072 mm ( 1 .8532 in) MIN
retaining bolt and rotate rocker arm (6564) to the
• Exhaust 39.739 mm ( 1 .5645 in)
side. After replacement of a push rod, rocker arm MAX
or hydraulic valve tappet (6500), the engine
should not be cranked or rotated until valve Gasket Surface Flatness 0.0 1 8 mm (0.007 in)
tappets have an opportunity to leak down to their Valve Stem to Guide Clearance
normal operating position. The leak-down rate • Intake 0.026-0.07 1 mm
can be accelerated by using a valve tappet (0.00 1 -0.0028 in)
bleed-down wrench on rocker arm and applying • Exhaust 0.038·0.083 mm
pressure in a direction to collapse valve tappet. (0.00 1 5-0.0033 in)
Valve Head Diameter
• Intake 45.3 mm ( 1 .78 in)
• Exhaust 37. 1 mm ( 1 .46 in)
(Continued)

03·01A·60 Engine, 3.8L 03·01 A·60
SPECIFICATIONS (Continued)
SPECIFICATIONS (Cont'd) SPECIFICATIONS (Cont'd)

Description Specification Description Specification
Valve Face Runout Limit 0.05 mm (0.002 in) CAMSHAFT
Valve Face Angle 45.8 degrees Lobe lift
Valve Stem Diameter (STD) • Intake 6.22 (0.245 in)
• Intake 8.1194·8.674 mm • Exhaust 6.57 (0.259 in)
(0.3423·0.3415 in) • Allowable Lobe Lift Loss 0. 127 mm (0.005 in)
• Exhaust 8.682·8.662 mm Theoretical Valve Lift @ Zero
(0.34 18·0.34 1 0 in) Lash
Oversize • Intake 10.76 mm (0.424 in)
• Intake 9.075·9.055 mm • Exhaust 1 1 .37 mm (0.447 in)
(0.3573-0.3565 in)
End Play
• Exhaust 9.063·9.043 mm
• Service Limit 0.025·0. 150 mm
(0.3568·0.3560 in)
(0.001 ·0.006 in)
Oversize
Journal to Bearing
• Intake 9.456·9.436 mm
• Clearance 0.025·0.076 mm
(0.3723·0.37 15 in)
(0.001 ·0.003 in)
• Exhaust 9.444·9.424 mm
(0.37 1 8·0.3710 in) Journal Diameter
• All 52. 1 08-52.082 mm
Valve Springs
(2.0515·2.0505 in)
Compression Pressure (N [Lb]
@ Spec Length) Cam Bearing I. D. 52. 1S8·52. 133 mm
(2.0535·2.0525 in)
• Valve Open (Without 979 N (220 lbs) @ 30.0 mm
Damper) ( 1 . 1 8 in) • Runout Limit 0.05 mm (0.002 in)
Runout of #2 or #3 relative
• Valve Closed (Without 375 N (85 1bs) @ 4 1 .9 mm
to # 1 and #4
Damper) (1 .65 in)
• Out-of-Round Limit 0.025 mm (0.001 in)
• Free Length
(Approximate) CAMSHAFT DRIVE
• Service Limit 10% Force Loss @ Assembled Gear Face Runout
Specified Height • Crankshaft 0. 10 mm (0.004 in)
Rocker Arm • Camshaft 0.25 mm (0.0 1 0 in)
• Ratio 1 .73 • Timing Chain Deflection 12.7 mm (0.5 in)
Valve Tappet, Hydraulic CYLINDER BLOCK
• Diameter (Std) 22.200·22.2 1 2 mm Head Gasket Surface Flatness 0.08 mm (0.003 in) in 152.0
(0.8740-8745 in) mm (6.00 in)
• Clearance to Bore 0.01 8·0.068 mm
Head Gasket Surface Finish 2.0 @ 0.8
(0.0007·0.0027 in)
. � � 127 mm (0.005 in)
(RMS) 5.5 @ 2.5
• Service Limit
- Cylinder Bore
• Hydraulic Leakdown Rate (a}-_
• Collapsed Tappet Gap \ • Diameter 96.80 mm (3.81 in)
(Nominal) • Surface Finish (RMS) 0.45·0.96
• Intake 2.25·4. 79 mm (0.089·0. 189 • Out-of-Round Limit 0.025 mm (0.001 in)
in) • Out-of-Round Service 0.050 mm (0.002 in)
• Exhaust 2.25·4.79 mm (0.089·0. 1 89 Limit
in) • Taper Service Limit 0.050 mm (0.002 in)
Distributor Shaft Bearing Bore Main Bearing Bore Diameter 68.905 mm (2. 7 1 3 in)
Diameter 68.885 mm (2. 7 1 2 in)
• Tappet Bore Diameter 22.268·22.230 mm CRANKSHAFT AND FLYWHEEL
(0.8767·0.8752 in)
Main Bearing Journal
Camshaft Bore Inside Diameter
• Diameter 1, 2, 3 63.983·64.003 mm
• No. 1 55.689·55.664 mm (2.5190·2.5198 in)
(2. 192·2. 1 9 1 in)
• No. 2 55.308·55.283 mm MAX in 45 degrees, 0.01 5
(2. 1 77·2. 1 76 in) m m (0.006 in) TOTAL
• No. 3 55.308·55.283 mm • Taper Limit 0.008 mm (0.0003 in) per
(2. 1 77·2. 1 76 in) 25 mm ( 1 in)
• No. 4 55.684·55.664 mm • Journal Runout Limit 0.05 mm (0.002 in) (2)
(2. 192·2. 1 9 1 in) 0.05 mm (0.002 in) (3)
(Continued) • Surface Finish (RMS) 0.3 micrometers ( 1 1 . 8
micro in)
(Continued)

03·01A·6 1 Engine, 3.8L 03-01 A·61
SPECIFICATIONS (Cont'd) SPECIFICATIONS (Cont'd)

Description Specification Description SpecHication
Thrust Bearing Journal Side Clearance (Assembled to
• Length 29.725-29.775 mm . Crank)
( 1 .703- 1 .722 in) • Standard 0. 1 1 -0.29 mm
Connecting Rod Journal (0.0047-0.0 1 1 4 in)
• Diameter 58.682-58.702 mm • Service Limit 0.36 mm MAX (0.0 1 4 in
(2.31 03-2.31 1 1 in) MAX)
• Out-of-Round Limit 0.008 mm (0.0003 in) MAX PISTON
in 45 degrees, 0.0 1 5 mm
Diameter
(0.0006 in) TOTAL
• Coded Red 96.76 1 -96.777 mm
• Taper Limit 0.008 mm per 25 mm
(3.8095-3.8 1 0 1 in)
(0.0003 in per in)
• Coded Blue 96.791 -96.807 mm
• Surface Limit (RMS) 0.3 micrometers ( 1 1 .8
(3.8 1 07-3.81 13 in)
micro in)
• Coded Yellow 96.82 1 -96.837 mm
Main Bearing Thrust Face (3.81 1 9-3.8125 in)
• Surface Finish (RMS) 0.9 micrometers (0.354
Piston-to-Bore Clearance
micro in) FRONT;
0.6 micrometers (0.236 • 0.036-0.056 mm
micro in) REAR (0.001 4-0.0022 in)
• Runout Limit 0.025 mm (0.00 1 in) Service Piston Selection I.D. Code of Service
• Piston Bore Diameter Piston Required
Flywheel Ring Gear Lateral
Runout (T.I.R.) • 96.799-96.830 mm Red
• Automatic Transmission 1 . 778 mm (0.07 in) (3.8 1 1 0-3.8 1 22 in)
• 96.830-96.860 mm Blue
Crankshaft End Play 0 . 1 0-0.20 mm (0.004-0.008
(3.81 22-3.8 1 34 in)
in)
• 96.860-96.891 mm Yellow
Connecting Rod Bearings (3.8 1 34-3.8 1 46 in)
Clearance to Crankshaft When replacing pistons,
• Desired 0.025-0.035 mm measure the cylinder bore as
(0.00 1 -0.00 1 4 in) outlined in Section 03-oo.
• Allowable 0.022-0.069 Install the service piston
(0.00086-0.0027 in) matched to the piston bore
diameter above.
Bearing Wall Thickness (Std) 1 .453- 1 .466 mm
(0.0572-0.0577 in) Pin Bore Diameter 23. 1 70-23. 185 mm
(0.9 1 22-0.9128 in)
Main Bearings
-- Ring Groove Width
""' Clearance to Crankshaft • Compression (Top) 1 .550- 1 .530 mm
• Desired 0.025-0.035 mm
I\
(0.06 10-0.0602 in)
(0.00 1 -0.00 1 4 in)
• Compression (Bottom) 1 .550-1 .530 mm
• Allowable 0.0 1 3-0.058 mm (0.06 1 0-0.0602 in)
(0.0005-0.0023 in)
• Oil 4.030-4.055 mm
Bearing Wall Thickness 2.435-2.451 mm (0. 1 587-0. 1596 in)
(0.0959-0.0965 in)
Piston Pin
CONNECTING ROD, PISTON AND RINGS • Length 76.5-77.2 mm (3.01 2-3.039
Connecting Rod in)
• Piston Pin Bore Diameter 23. 1 05-23. 1 45 mm • Diameter 23. 162-23. 1 75 mm
(0.9096-0.9 1 1 2 in) (0.91 1 9-0.9124 in)
• Crankshaft Bearing Bore 6 1 .635-6 1 .655 mm Pin to Piston Clearance 0.005-0.0 1 2 mm
Diameter (2.4266-2.4274 in) (0.0002-0.0005 in)
• Out-of-Round 0.008 mm (0.0003 in) Pin to Rod Clearance Press Fit 8 Kilonewtons
Limit-Piston Pin Bore greater to 0.025 mm (0.00 1 ( 1 800 lbs)
in) ( 1 )
Piston Rings
• Taper Limit Piston Bore 0.033 per 25 mm (0.0 1 3
per in) • Ring Width
• Length 1 50. 165- 1 50.240 mm • Compression (Top) 1 .463- 1 .490 mm
(Center-to-Center) (5. 9 1 2-5. 9 1 5 in) (0.0576-0.0587 in)
• Compression (Bottom) 1 .463- 1 . 490 mm
Alignment (Bore-To-Bore Max.
(0.0576-0.0587 in)
Diff.)
• Oii Ring Side Seal -Snug Fit
• Twist 0.075 per 25 mm (0.003
per in) • Service Limit Side Clearance 0. 1 5 mm
MAX (0.0006 in MAX)
• Bend 0.04 per 25 mm (0.00 1 6
per in) (Continued)
(Continued)

03-01A-62 Engine, 3.8L 03-01A-62
SPECIFICATIONS (Cont'd) LUBRICANTI ADHESIVE/CLEANER SPECIFICATIONS

Description Specification Ford
Description Part Number Specification
Ring Gap
• Compression (Top) (In 0.29-0.55 mm (0.0 1 1 -0.0 1 2 Engine Assembly D9AZ- 1 9579-D ESR-M99C80-A
Gage) in) Lubricant
• Compression (Bottom) (In 0.24-0.5 1 mm (0.009-0.020 Pipe Sealant with DBAZ- 1 9544-A WSK-M2G350-A2
Gage) in) Teflon®
• Oil Ring (Steel Rail) (In 0.38- 1 .40 (0.0 1 5-0.0583 Metal Surface F4AZ·1 9A536-RH WSE·M5392-A
Gage) in) Cleaner
Side Clearance Gasket and Trim D7AZ-1 9B508-B ESR-M 1 1 P 1 7-A
• 1 st Ring 0.040-0.087 mm Adhesive
(0.00 16-0.0034 in)
Gasket and Trim D7AZ· 1 9B508-B ESE-M2G52-A
• 2nd Ring 0.040-0.087 mm Adhesive
(0.00 16-0.0034 in)
Silicone Rubber D6AZ-1 9562-AA or ESE-M4G92-A and
(a) 20-200 seconds to -BA ESE-M4G 1 95-A
leakdown 3. 18 mm (0. 125 in)
with 225 Newtons (50 pounds) Silicone Gasket F6AZ- 1 9562-AA WSE-M4G323-A6
load and tappet filled with and Sealant
leak-down fluid. Engine Oil - WSS-M2C 1 53-F
( 1) Smaller than pin bore Perfect-Seal B5A- 1 9554-A ESE-M4G 1 1 5-A
measured along center to Sealing Compound
center axis.
Multi-Purpose DOAZ- 1 9584-AA ESB·M 1 C93-A and
(2) Runout of journals No.2 and Grease ESR-M 1 C 1 59-A
No.3 to journals No. 1 and No.4.
(3) Runout of adjacent journals TORQUE SPECIFICATIONS
to each other.
Description N·m Lb-Ft Lb-ln
LUBRICATION SYSTEM
Camshaft Sprocket to 40-50 30-36 -
Oil Pump
Camshaft -Bolt
• Relief Valve Spring 76.2-67.6 N ( 1 7. 1 - 1 5.2 1bs)
Camshaft Thrust Plate -Bolt 8- 1 4 - 7 1 - 1 23
Tension @ 30.5 mm ( 1 .20 in)
(Force @ Length) Connecting Rod -Nut - (7) -
• Relief Valve to Bore 0.073-0.043 mm -
Water Temperature Indicator 1 4- 1 9 1 1- 1 4
Clearance (0.0029-0.00 1 7 in)
Sender Unit
e Oil p Gear Backlash 0.02-0.03 mm (0.008-0.0 1 2
Crankshaft Pulley to 1 40- 1 80 104-132 -
in)
Crankshaft -Bolt
• Oil Pump ear Radial 0. 1 25-0.050 mm
Clearance (0.0055-0.002 in) Crankshaft Pulley to 26-38 20-28 -
(Idler and rive) Damper -Bolt
• Oil Pump Gear End Height 0. 1 40-0.050 mm Crankshaft Position Sensor 8- 1 2 - 7 1 - 106
(Extends Beyond (0.0055·0.0005 in) Stud Bolt
Housing) -
Crankshaft Position Sensor 2-4 1 8-35
• Idler Shaft to Idler Gear 0.044-0.0 10 mm Shield Nuts
Clearance (0.00 1 7-0.0005 in)
Cylinder Head Bolt - (2), (3) -
• Driver Shaft to Housing 0.076-0.038 mm
Clearance (0.0030-0.00 1 5 in) Hold-Down Clamp 20-30 1 5-22 -
Oil Capacity 4 quart + 1 quart with filter ECT Sensor 1 4- 1 9 11 - 1 4 -

change. -
EGR Valve to Intake Manifold 20-30 1 5-22
TA1 2697H EGR Valve to Manifold Tube 46-65 34-47 -
Connector
DRIVE BELT TENSION Exhaust Manifold -Bolts 30-36 23-26 -
Allowable -
Dual Converter Y -pipe to 2 1 -32 1 6-23
Specifications Limits Exhaust Manifold Nuts
Used Cold Flywheel to Crankshaft -Bolt 73-87 54-64 -
New Bel.. Beltb Beltb, c -
Engine Front Cover to Cylinder 20-30 1 5-22
Installation Reset Audit
Block -Bolt
3.8L Englne Tension Tension Check
Fuel Injection Supply Manifold 8- 1 1 - 7 1 -97
6 Rib (V-6 Serpentine) 160- 1 90 1 30- 1 60 90- 1 80
Fuel Pressure Regulator 20-30 1 5-22 -
a New belt installed and tensioned; engine not rotated.
b Used belt is any belt that has been rotated on an engine. Bracket Bolt
c Cold belt (i.e., 3-hour soak; 0 warm up.) Heater Water Hose Retaining 20-30 15-22 -
Nut
(Continued)

03-01 A-63 Engine, 3.8L 03·01 A-63
TORQUE SPECIFICATIONS (Cont'd) 3. CAUTION: Do not loosen all of the bolts at

the same time; only work on one bolt at a
time or damage to the engine may occur.
Upper Intake Manifold Support 20-30 15-22 -
Bolt Back off all bolts one at a time two to three
-
revolutions and retighten as follows:
Oil Pan Drain Plug 20-34 1 5-25
- Long bolts:
Oil Pressure Sensor 1 1- 1 6 98- 1 4 1
Crankshaft Main Bearing Cap (9) (9) - a. Tighten to 4Q-50 N·m (3Q-36 1b-ft).
Bolt or Stud
b. Rotate an additional 1 75- 1 85 degrees.
-
Timing Chain Vibration Damper 8- 1 4 7 1 - 1 23
to Cylinder Block -Bolts
c. Go to next bolt in sequence.
Lower Intake Bolts - (5) - Short bolts:
Upper Intake Bolts - (6) - a. Tighten to 2Q-30 N·m ( 1 5-22 1b-ft).
- 40-6 1
CMP Sensor 4.5-7.0 b. Rotate an additional 1 75- 1 85 degrees.
-
Oil Pump and Filter Body to 23-32 1 7-23 c. Go to next bolt in sequence.
Front Cover-M8 Bolt
- 4. Tighten in two steps:
Oil Pump and Filter Body to 8- 1 1 7 1 -97
Front Cover -M6 Bolt a. 5 N·m (44 1b-in) MAX.
Oil Bypass Filter to Oil Pump 10-15 - 89- 132 b. 3Q-40 N·m (22-30 lb-ft).
and Filter Body ( 1)
5. Tighten in two steps:
Oil Inlet Tube to Cylinder 20-30 1 5-22 -
Block -Bolt a. 5 N·m (45 1b-in).
Oil Inlet Tube to Main Bearing 40-55 30-40 - b. 8- 1 2 N·m (7 1 - 1 06 1b-in).
Cap -Nut
6. Tighten in numerical sequence in three steps:
-
Oil Pan to Cylinder (8) (8)
Block -Bolt
a. 1 0 N·m (8 1b-ft).
Valve Cover to Cylinder 8- 1 2 -
7 1 - 106 b. 20 N·m ( 1 5 1b-ft).
Head -Bolts I Studs c. 32 N-m (24 lb-ft).
- -
Rocker Arm Seat to Cylinder (4) 7. Tighten i n two steps:
Head -Bolt
-
a. Tighten to 40 N·m (30 lb-ft).
Spark Plug to Cylinder Head 9-20 80- 1 77
Tappet Guide Plate -Bolt 1 0- 1 4 - 89- 1 23
b. Rotate an additionai 9Q- 1 20 degrees.
Water Outlet Connection to 8- 1 1 - 7 1 -97 8. Tighten in sequence in two steps:
Intake Manifold -Bolt a. 4-5 N·m (36-44 lb-in)
Throttle Body Retainers 20-30 1 5-22 -
b. 9- 1 2 N·m (8Q- 1 06 1b-in)
-
Vacuum Fitting to Intake 1 7-25 1 3- 1 8
9. Tighten in sequence in two steps:
Manifold
Water Pump to Front Cover 20-30 15-22 - a. Tighten to 50 N·m (37 lb-ft).
-Bolts and Stud Bolts b. Tighten an additional 1 1 5- 1 25 degrees.
Water Pump to Front 8- 1 2 - 7 1 - 106
Cover-Nuts ENGINE ACCESSORIES
Water Pump Pulley Bolts 2 1 ·29 1 6-2 1 -
Description N·m Lb-Ft
-
Heater Water Outlet Tube-to 8- 1 2 7 1 - 1 06
Power Steering Brace Bolt (2 40-62 30-45
Water Pump Bolt
Places)
Oil Level Indicator Tube 20-30 1 5-22 -
Power Steering Front Bracket Bolt 40-62 30-45
Support Bracket -Retainer
(2 Places)
Accelerator Cable Bracket 1 4-20 1 1-14 -
Power Steering Front Bracket Bolt 40-62 30-45
-Retainers
(3 Piaces)
EGR Valve to Exhaust Manifold 34-47 25-34 -
A I C Compressor Retaining Bolts 2 1 -29 16-2 1
Tube -Nuts
Front Engine Support 59-8 1 44-59
Heater Hose Clamps 2.5-3.5 - 23·30
Insulator-to-Cylinder Block
-Bolt I Stud Bolt
1. Advance half-turn after gasket contacts sealing
surface. Front Engine Support Insulator to 97-133 72-98
Front Sub-Frame Nut
2. Tighten in sequence as follows:
Shock Absorber to Control 1 40- 195 1 04- 1 43
a. 20 N·m ( 1 5 1b-ft). Arm -Bolt
b. 40 N·m (30 lb-ft). (Continued)
c. 50 N·m (37 lb-ft).

03-01A-64 Engine, 3.8L 03-01A-64
ENGINE ACCESSORIES {Cont'd) SPECIAL SERVICE TOOLS REQUIRED (Cont'd)

Description N-m Lb-Ft Tool Number I
Front Engine Support Insulator 47-68 35-50
Through Bolts T65L-6250-A
}
Camshaft Bearing Set
Steering Shaft-Pinch Bolt 4 1 -57 3 1 -42
Automatic Transmission to 34-36 25-26
I :::=:J
•
c::=
eec:>=: �
Engine-Bolt
Torque Converter to 27-46 20-33 ··�
Flywheel -Bolt
TilL-aliCI-A
T68P-6 1 35-A
0�
GENERAL SPECIFICATIONS
Piston Pin Remover and
Torque Specifications -Unless Otherwise Noted Values for Replacer
Parts as Supplied
Torque Torque
Cast Iron Cast Iron -A1 -A7 -A2 -AI -M -AI -A4
and and TIII41 3S-A

Thread Size Aluminum Thread Size Aluminum
T70P-6B070-B
( 1 /4- 18) Pipe 24 N-m M6 1 4 N·m
Front Cover Seal Replacer
u
( 1 8 Lb-Ft) ( 1 1 Lb-Ft)
(3/8-18) Pipe 38 N-m M8 28 N·m
(28 Lb-Ft) (2 1 Lb-Ft)
�11070-11
M10 53 N-m
(39 Lb-Ft)
�
T74P-6666-A
M12 96 N-m Spark Plug Wire Remover
(7 1 Lb-Ft)
M14 1 58 N-m
( 1 1 7 Lb-Ft)
T7-A
T77L-9533-B
SPECIAL SERVICE TOOLS/EQUIPMENT Jet Plug Remover
� T77L-t533-ll
SPECIAL SERVICE TOOLS REQUIRED
T81 P-651 3-A
Tool Number I
�
Valve Spring Compressor
T50T- 100-A
�
Impact Slide Hammer
TI11451U
TSOT-10G-A
T82L-6316-A
T58P-63 16-D Damper I Front Cover Seal
�
Crankshaft Damper Remover Replacer
4f T58P-e31&-D
TI2L-631&-A
T82L-63 16-B
Au
T59L- 100-B Vibration Damper Remover
�
Impact Slide Hammer Adapter
T51L-1GO-I
T1121.-e31&-l
T64L-60 1 1 -EA
Cylinder Ridge Reamer T82L-670 1 - A
• ®
Rear Main Seal Replacer
��
T1121.-17D1-A
TML-4101 1-EA
(Continued)

03·01A·65 Engine, 3.8L 03-01 A·65

(Continued)
SPECIAL SERVICE TOOLS DESIRED ROTUNDA EQUIPMENT

Tool Number Description Model Description
D81 L-600-A Lb-ln Torque Wrench 0 14-00792 Engine Lifting Brackets (3.8L)
D81 L-600-B Lb-Ft Torque Wrench 0 1 4-00793 Separator Bar
D81 L-420 1-A Feeler Gauge
TOOL-633 1 -E Main Bearing Insert Tool

03-01B-1 Engine, 4.6L (2V) 03-018-1
SECTION 03-0 1 8 Engine, 4.6L (2V)

VEHICLE APPLICATION •••••.•••..•••..................•••.•••.•••
03-0 1 B-1 IN-VEHICLE SERVICE (Cont'd.)
DESCRIPTION AND OPERATION Oil Bypass FilterI Adapter ••••••...•.••••••••••••••••••••••• 03-o 1 B-61
Camshaft .....•••••••.•••••••••••••.••••••••.•..................•..••
03.0 1 B-3 Oil Level Indicator Tube ••••••.....••••••••••••..•••••••••••• 03-o 1 B-8 1
Crankshaft .....••••...••••••••••••.••••••••.•••.•...............••••
03.01 B-3 Oil Pan/Oil Pump Screen Cover and
Drive Belt System ••••••••••.•••••••••.•••...•..•.................
03-o 1 B-6 Tube ••••••••••••••...••••••••••••.•....•••••••••••••...••••••••••• 03-o1B-50
Emission Calibration Label .••••.•••.••••••.•••••••.•......•.
03-o 1 B-2 Oil Pump •••••••••••.....•..•••••••••..•.....•••••••••••.....•••••••• 03-o1 B-54
Engine .•..............•...•••••••••••..••••••.•.•.••....•..............
03.0 1 B-1 Pistons and Connecting Rods ..•••••••••••••...•••••••••• 03-o1 B-55
Engine Code Information •••.••••••••••.......................
03.0 1 B-2 Rocker Arm •••....•...•••.•••.•••..•..•••••••••••••••.••••••••••.. 03-o 1 B-14
Engine Cooling System ........•.••••••••••••••••••••.•.•......
03.0 1 B-5 Sensors .•...•.••.••••........•••••••••••••••..•.•••••••••••••••••••• 03-o1 B-62
Engine Identification •••••••••.•.••••••••••••.••••.•............
o3-o 1 B- 1 Timing Sprockets ...•••.••.••••.....••••••••••••..•••••••••••.. 03-o1 B-26
Engine Lubrication System •.•.•••••••.•.•••.••..............
03.01 B-3 Valve Cover and Gasket .••••••.•..•..•••••••••..•••••••••••• 03-o 1 B- 1 3
Oil Pan ...............••.••••••.•••.••••.....................•.•••••
o3-o1 B-5 R H Side ..........••••••••.•.......•••••••••••..•••••••••••••••••• 03-o 1 B· 1 3
Oil Pump .............................•••••..•••.•••••..•..•....•..
03.0 1 B-5 Valve Spring, Retainer and Valve Stem
Exhaust Emission Control System •••••••••••.•...•.••••••
03-o 1 B-2 Seai ••••••••••.•...•••••••••••.••....••••••••••••.••••••••••••••••• 03-o 1B-15
Induction System ................................................ 03.0 1 8-3 Valve Tappet, Hydraulic .••.......•••••••••....•.•••••••••••• 03-o 1B-1 5
Positive Crankcase Ventilation System ...•••••••••••••
03-o 1 B-3 Water Pump ...•••••••••••••...•••••••••••••..•.••••••••••••.•••••• 03-o 1 B-46
Valve Train •..•..............•..••.•••••••••••••.•.................••
03.0 1 B-3 REMOVAL AND INSTALLATION
IN-VEHICLE SERVICE Crankshaft •••••..••••••••••••.•••••••••••••••••••••••••••••••••••• 03-o1 B-66
Camshaft Timing Chains and Crankshaft Main Bearings ••..•.•••••••••••.....•••••••••••• 03-o1B-80
Tensioners ...•...••••..••••••.••••••••••••......•.....•••••.•••
03-o 1 B-22 Engine ••••..•....••••••••••.••.•.••.••••••••••••..•.•••.•••••••.••••• 03-o1 B-62
Camshafts .........••.••..•••••••••.•••••.••.................••••••
03-o 1 B-27 DISASSEMBLY AND ASSEMBLY
Connecting Rod Bearings •••••••.••••••••.•.......•••••••••
03-o 1 B-58 Englne •••••••••••••••••••••••••••••••••••••••••••••••••.•••••••••••••
03-o1 B-80
Crankshaft Pulley /Crankshaft Front Oil Subassemblies •••••••••.....••••••••••••..•.••••••••••••••••••••
03-o1 B-98
Seai ............................................................... 03-0 1 B- 1 7 Cylinder Block Assembly •••....•••••••••••••....••••••03-o 1 B-101
Crankshaft Rear Oil Seal ..........••••••.•••.•••.•..........
03-o 1 B-60 Cylinder Block, Bare •••••••........••••••••••••...•••••••03-o 1 B-101
Cylinder Heads .••••••.••••...................•.•••••••.••••.•...
03-o 1 B-35 Cylinder Head .........•.•••••••••••..•.••••••••••••.•••••••••
03-o 1 B-98
Engine Components .................••••.••••••.••••.•••.••.•..
03-o 1 B-7 Hydraulic Valve Tappet ••••••.•...•••••••••••••...••••••03.01 B·101
Engine Front Cover .........•.•.•••••••••••..•••••..........•.
03.0 1 8- 1 8 Piston Rings .......•••••••••••.......•••••••••••...••••••••••03-o1 B-100
Exhaust Manifold ...........••••••••••••••••••.............•.•••
03-o 1 B-49 Pistons and Piston Pins .•...•••••••••••..•...••••••••••03-o1 B-100
Flywheel •••••..................•.•••••••••••.....................•.
03-o 1 B-59 SPECIFICATIONS •...•••••••••••••...•...••••••••••••••••••••••••03.0 1 B-102
Intake Manifold ...•.•.••••••••••.•••••••••....•.....•...••••••••
03-o 1 B-46 SPECIAL SERVICE TOOLS/EQUIPMENT ••••••••••••••03-o 1 B-105
VEHICLE APPLICATION
Thunderbird, Cougar
Engine • sequential multiport fuel injection (SFI).

WARNING: DO NOT OPERATE THE ENGINE WITH • composite intake manifold (9424).
THE HOOD OPEN UNTIL THE FAN HAS BEEN • aluminum cylinder heads (6049).
FIRST EXAMINED FOR POSSIBLE CRACKS AND
SEPARATION. • a cast-iron, 90-degree V cylinder blocks (6010).
The 4.6L (2V) (28 1 CID) is a V-8 engine with the The electronic ignition system has two ignition coils
following: ( 1 2029). This high energy ignition system is required
for fast-burn combustion.
• single overhead camshafts (6250) (OHC).
• two valves per cylinder.
It is imperative that the engine codes and the
calibration number be used when ordering parts or
making inquiries about the engine.

03-01 8-2 Engine, 4.6L (2V) 03-01 8-2
Engine Code Information

The engine code information label, located on the front Emission Calibration Label- California
of the engine, contains the following information:
�I
• engine build date FOIII IIOTOII COII'NIY
• engine plant code VEtiCLE EMISSION eotmiOL IIFORIIA110N
,... vaa.a . ...... WRM ILIC'I'IIOIIIC ,_., ....., _.... ,__ ....
• engine code ......_ _. _ ..... __________
_..._
PLANT
_________ftC ___
NO.\
Engine Code Information Label ··------AT ____,_
--010'.
- - · - - -11C - - IILI - · IIOT -UU.

·--------
AUI'O.TMI&·-- ---
ii
ENGINE
CODES ... ... .... .. ... __. - -- ,
··--L
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:
..... _. _ IO U.
:
� ... .... -..,_

!
_TO ___
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1·---.-:.-:'_
·- 1!!1
"GoA'J CATALYST
.... .... --..c ... ...
:ott" DCI ftiCI_I_I_ A
A14872-H A14874-D
Emission Calibration Label Exhaust Emission Control System

The vehicle emission control information (VECI) label, Operation and required maintenance of the exhaust
located on the upper radiator sight shield, identifies emission control devices used on this engine are
the following: covered in the Powertrain Control / Emissions
• engine calibration number Diagnosis Manual. 1 •
• engine code number and revision level
These numbers are used to determine if parts are
unique to specific engines.
Emission Calibration Label -49 States
�I
FOIII IIOtOR COII'NIY
VEHICLE E111SS10N CONrROL INFORMA110N
,.. _. . _ Willi � - - -- -
-- - -- - -- - - -- - --
- - ----
_ __ _ _ IIUICK _._ _ _TIC __

- - · · - -AI.L- WIIII - AT
_IIAL ____ ...., ___
TIII - · - WITII -TIC - ---

-- - CCIIfTIICIL .. - · -
---- · -
--
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- ----
- - · - --
- - -- "" -
· · - - 1.
,_...,.... _ 10 u.& PA
Ll�
_,_ AM.ICMU TO I.. -
---- =-.�
- · --
A
"ocvl CATALYST
1 :=..- - -- -
....1'11C
... I HOal ... l _.
A14873-D

03-018-3 Engine, 4.6L (2V) 03-01 8-3
Induction System Camshaft

Sequential multipart fuel injection (SFI) provides the The camshafts (6250) are individually chain-driven.
fuel I air mixture needed. There is an automatic hydraulic timing chain tensioner
Eight solenoid-operated fuel injectors, mounted in the (6L266) on each timing chain.
intake manifold (9424), meter fuel into the air intake
stream in accordance with engine demand.
The eight fuel injectors are:
Valve Train
• positioned so that their tips direct fuel just ahead of The configuration of the valve train consists of a
the engine intake valves (6507). hydraulic valve tappet (6500) providing automatic lash
• connected in parallel with the fuel pressure adjustment.
regulator. The camshaft lobe transfers its up-and-down motion to
Fuel: the rocker arms (6564).
The camshafts (6250) are seated in journal bores on
• is supplied from the fuel tank (9002) by a
top of the cylinder head (6049).
high-pressure electric fuel pump (9350), mounted in
the fuel tank. The.valves are arranged alternately: intake valve
(6507) I exhaust valve (6505).
• is filtered and sent to the fuel injection supply
manifold (9F792).
A fuel pressure regulator (9C968) on this fuel injection
supply manifold controls the fuel delivery pressure at a Positive Crankcase Ventilation System
constant 269 kPa (39 psi).
All engines are equipped with a positive closed-type
Excess fuel supplied by the fuel pump, but not needed crankcase ventilation system recycling the crankcase
by the engine, is returned to the fuel tank via a fuel vapors to the intake manifold (9424).
return line.

Crankshaft
The lubrication system of the 4.6L (2V) engine is
The crankshaft (6303): designed to provide optimum oil flow to critical
• is supported on the bottom of the cylinder blocks components of the engine throughout its entire
(60 10) by five steel-backed, over-plated aluminum operating range.
crankshaft main bearings (6333).
• connects with the camshafts (6250) by two
sprockets and two timing chains.
The crankshaft thrust main bearing (6337) and
crankshaft thrust washer (6334) limits crankshaft end
play and absorbs thrust loads applied to the
crankshaft ends.

/
03-01 8-4 Engine, 4.6L (2V) 03-01 8-4
METERED OIL TRAVELS

THROUGH VALVE TAPPET
AND ROCKER ARM AND
IS SPLASHED ONTO CAM LOBE,
ROLLER BEARINGS IN ROLLER
FOLLOWER, AND VALVE TIP.
VALVE STEM IS LUBRICATED
BY METERED LEAKAGE PAST
LIP OF VALVE STEM SEAL.
A14937-D
Part Part
- -
1 Valve Tappet Vent Gallery 9 Oil Drain to Sump (Part of
(Open to Crankcase, Part of 6049)
6049) 10 -
To Hydraulic Timing Chain
- Tensioner (6L260)
2 Valve Tappet and Camshaft
Bearing Feed Gallery 11 -
From Left Bank Cylinder
(Reduced Pressure, Part of Block (Part of 6010)
6049)
-
12 67 14 Oil Bypass Filter
3 Orifice and Strainer (Part of
6049) 13 9278 Oil Pressure Sensor
4 -
RH Head Gallery Oil 14 688 1 Oil Filter Adapter
Reservoir (Part of 6049) 15 -
Oil Pump Integral Relief
5 -
Primary Main Gallery Valve (Part of 6010)
Pressure (Not Restricted, 16 -
Bypass (Part of 60 1 0)
Part of 6010)
-
17 6600 Oil Pump
6 LH Head Gallery Oil -
Reservoir (Part of 6049) 18 To LH Cylinder Head (Part of
-
6049)
7 Orifice and Strainer (Part of -
6049) 19 Oil Drain to Sump (Part of
60 10)
(Continued)
• Oil is drawn into the oil pump (6600) through the oil From the crankshaft main journals, the oil is routed
pump screen cover and tube (6622) in the sump. through cross-drilled passages in the crankshaft
• Oil is pumped through the oil bypass filter (67 1 4) on (6303) to the crankpins for connecting rod bearing
the left front side of the cylinder blocks (60 1 0). lubrication.
• Oil enters the main oil gallery where it is distributed

to the crankshaft main journals, and to both cylinder
heads (6049).

03·018·5 Engine, 4.6L (2V) 03·01 8·5
Controlled leakage through the crankshaft main • Oil pump displacement has been selected to provide
bearings (6333) and connecting rod bearings (62 1 1 ) adequate volume to ensure proper oil pressure both
i s distributed radially outward to cool and lubricate the at hot idle and maximum speed.
cylinder walls as well as the entire connecting rod • Relief valve calibration protects the system from
(6200), piston (6 1 08) and piston ring assemblies. excessive pressure during high viscosity conditions,
The left cylinder head is fed from a drilling into the yet is designed to provide adequate lubrication
lateral supply passage feeding the main gallery at the under high temperature and high speed conditions.
front of the cylinder blocks.
Oil Pan
The right cylinder head is fed from a drilling into the
rear of the main gallery. The oil pan (6675):
Main gallery pressure is reduced as it enters the • is a stamped steel component which is fastened to
cylinder head galleries through the use of fixed the bottom of the cylinder blocks.
serviceable orifices located at the upper part of the • acts as a reservoir holding lubrication that is
feed passages. pumped through the engine by the oil pump after
This reduced pressure in the cylinder head galleries start up.
feeds the following:
• camshaft journals
• valve tappets (6500) Engine Cooling System
• hydraulic timing chain tensioners (6L266) The engine coolant:
The cam lobes and rocker arms (6564) are lubricated • flows through the radiator tubes, cooled by air
by splash created through valve train operation.
passing over the cooling fins (assisted by the
Oil Pump cooling fan as necessary).
The oil pump has the following characteristics: • is then circulated from the radiator outlet tank
(8054) through the radiator coolant recovery
• It is a positive displacement, internal gear pump reservoir (8A080) which is pressurized to
using top seal rotors. continuously separate the air from the cooling
• It is mounted on the front face of the cylinder blocks. system.
• The inner rotor is piloted on the crankshaft post and • flows from the radiator coolant recovery reservoir
is driven through flats on the crankshaft. through the engine, heater core ( 1 84 76) and water
pump (850 1 ), then returns to the radiator (8005)
• System pressure is limited by an integral, internally through the water hose connection (8592).
vented relief valve which directs the bypass oil back
to the inlet side of the oil pump.

03-01 8-6 Engine, 4.6L (2V) 03-01 8-6
Engine Cooling System
13 J----I�
w-------� 7
COOLANT FLOW DIRECTION Q3012.C
Part Part
1 8A080 Radiator Coolant Recovery 7 6881 Oil Filter Adapter
Reservoir 8 8260 Upper Radiator Hose
2 8100 Pressure Relief Cap 9 8005 Radiator
3 18476 Heater Core 10 8501 Water Pump
4 18472 Heater Water Hose 11 8592 Water Hose Connection
5 6010 Cylinder Blocks 12 8286 Lower Radiator Hose
6 6049 Cylinder Head 13 8C289 Coolant Return Hose
(Continued)
Drive Belt System • a loose drive belt may result in operational

The 4.6L (2V) OHC engine is equipped with a problems, such as the generator not delivering
serpentine drive belt (8620) to ensure maximum life. proper charge, etc.
When replacing the drive belt, it should be of the same Refer to Section 03-Q5 for service procedures.
type as originally installed.
• Engines are equipped with an automatic drive belt
tensioner (68209) that will not require any drive belt
tension adjustment for the life of the drive belt.
• A loose drive belt will result in slippage which may
cause a noise complaint or improper accessory
operation.
1997 Thunderbird. Cougar July 1996

03-018-7 Engine, 4.6L (2V} 03-01 8-7
IN-VEHICLE SERVICE
Engine Components
Disassembled View
A24843-A

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03-018-9 Engine, 4.6L (2V) 03-G1B·9
Disassembled View (Continued)

03-01 8- 1 0 Engine, 4.6L (2V) 03-01 8-10
Disassembled View (Continued)
A24848-A
Part Part
1 90930 Fuel Charging Wiring 13 9F792 Fuel Injection Supply
2 9E498 Main Emission Vacuum Manifold
Control Connector 14 9F593 Fuel Injector (8 Req'd)
3 9E926 Throttle Body 15 12A648 Engine Coolant Temperature
4 9E936 Throttle Body Gasket Sensor
5 9A589 Throttle Body Adapter 16 8575 Water Thermostat
6 N806 154 Bolt (5 Req'd) 17 9424 Intake Manifold
7 90476 EGR Valve Gasket 18 9439 Intake Manifold Gasket (2
Req'd)
8 90475 EGR Valve 19 60 10 Cylinder Blocks
9 90477 EGR Valve to Exhaust 20 6345 Crankshaft Main Bearing
Manifold Tube Cap Stud (10 Req'd)
10 9L437 Intake Manifold Water 21 6C070 Torque Converter Inspection
Connection Gasket Hole Cover
11 N806 156 Bolt (2 Req'd) 22 N806807 0-Ring
12 N81 1017 Stud Bolt (4 Req'd) (Continued)
(Continued)

03-018- 1 1 Engine, 4.6L (2V) 03-o1B-1 1
Part Part
23 N808130 Bolt (9 Req'd) 66 6564 Rocker Arm (16 Req'd)
24 10884 Water Temperature Indicator 67 6065 Cylinder Head Stud (20
Sender Unit Req'd)
25 8594 Water Outlet Connection 68 65 18 Valve Spring Retainer Key
26 N81 101 1 Bolt (2 Req'd) (32 Req'd)
27 10153 Generator Mounting Bracket 69 65 14 Valve Spring Retainer (16
Req'd)
28 N80707 1 Screw I Washer 70 65 13 Valve Spring (16 Req'd)
29 N807 131 Screw /Washer (2 Req'd) 71 657 1 Valve Stem Seal (16 Req'd)
30 9H308 Idle Air Control Valve Inlet 72 6049 Cylinder Head LH
Tube
31 9F670 Idle Air Control Gasket 73 W70168 1 Stud (8 Req'd)
32 N806 155 Bolt (2 Req'd) 74 9448 Exhaust Manifold Gasket LH
33 9F7 15 Idle Air Control Valve 75 9430 Exhaust Manifold LH
34 N806 154 Bolt (4 Req'd) 76 W701706 Nut (8 Req'd)
35 12280 Ignition Wire and Bracket 77 18198A Engine Lifting Eyes
36 6C324 Crankcase Vent Connector 78 2741 6 1 Bolt (2 Req'd)
and Hose 79 6051 Head Gasket RH
37 6582 Valve Cover RH 80 W701 68 1 Stud (8 Req'd)
38 6B280 Camshaft Bearing Cap 81 9F485 EGA Valve Tube to Manifold
39 6250 Camshaft RH Connector
40 12405 Spark Plug (8 Req'd) 82 W701 706 Nut (8 Req'd)
41 18472 Heater Water Hose 83 274 1 6 1 Bolt (2 Req'd)
42 N808801 Stud Bolt 84 18198A Engine Lifting Eye
43 9J434 EGA Backpressure 85 9430 Exhaust Manifold RH
Transducer 86 9448 Exhaust Manifold Gasket RH
44 N807959 Bolt 87 6049 Cylinder Head RH
45 N805320 Nut 88 N806 139 Bolt
46 6051 Head Gasket LH 89 N8061 64 Washer
47 6505 Exhaust Valve (8 Req'd) 90 6256 Camshaft Sprocket
48 6507 Intake Valve (8 Req'd) 91 6265 Camshaft Sprocket Spacer
49 87838 Pipe Plug (8 Req'd) 92 N806282 Bolt (4 Req'd)
50 6F087 Cylinder Head Oil Reservoir 93 N8071 73 Bolt (2 Req'd)
Restrictor 94 N808102 Bolt
51 N806 139 Bolt 95 8678 Belt Idler Pulley
52 N806 164 Washer 96 10300 Generator
53 6256 Camshaft Sprocket LH 97 N805320 Nut
54 6265 Camshaft Sprocket Spacer 98 9S429 Evaporative Emissions Valve
LH
55 N807352 Bolt (4 Req'd) 99 N8065 13 Bolt
56 6582 Valve Cover LH 100 1 2043 Ignition Coil Mounting Strap
57 6758 Crankcase Ventilation Tube 10 1 1 2029 Ignition Coil (2 Req'd)
58 6766 Oil Filler Cap 102 N807959 Bolt (8 Req'd)
59 N806356 Stud Bolt 103 18801 Radio Ignition Interference
Capacitor (2 Req'd)
60 N80744 1 Stud Bolt 104 N806 1 55 Bolt
61 N806 183 Bolt (16 Req'd) 105 6C315 Crankshaft Position Sensor
62 N806070 Bolt (24 Req'd) 106 N806300 Stud Bolt (5 Reefd)
63 6B280 Camshaft Bearing Cap 107 601 9 Engine Front Cover
64 6A247 Camshaft LH 108 N606543 Bolt (4 Req'd)
65 6500 Valve Tappet (16 Req'd) 109 6L266 Timing Chain Tensioner
(Continued)
(Continued)

03-0 18- 1 2 Engine, 4.6L {2V) 03-0 1 8- 1 2
Part Part
1 10 6268 Timing Chain I Belt 1 50 N808801 Stud Bolt
111 6K297 Timing Chain Guide 151 N8041 78 Nut
1 12 6M269 Timing Chain Tensioner 1 52 8509 Water Pump Pulley
1 13 6L253 Timing Chain Tensioner Arm 1 53 631 2 Crankshaft Pulley
1 14 N806 184 Bolt (3 Req'd) 1 54 N806 1 65 Washer
1 15 19703 A I C Compressor 155 8620 Drive Belt
1 16 N806 177 Bolt (4 Req'd) 1 56 N806 139 Bolt
1 17 8501 Water Pump 1 57 6 1 50 Piston Ring (8 Req'd)
-
1 18 6334 Crankshaft Thrust Washer 158 6 100 Piston and Connecting Rod
1 19 6303 Crankshaft Assy (8 Req'd)
120 6337 Crankshaft Thrust Main 159 6 1 52 Piston Ring (8 Req'd)
Bearing 160 6161 Piston ring (8 Req'd)
121 6325 Rear Main Crankshaft 161 6200 Connecting Rod Assy (8
Bearing Cap Req'd)
122 6345 Crankshaft Main Bearing 162 62 14 Connecting Rod Bolt (16
Cap Stud Req'd)
123 N806180 Spacer 163 62 1 1 Connecting Rod Bearing (16
124 6622 Oil Pump Screen Cover and Req'd)
Tube 1 64 6 1 35 Piston Pin (8 Req'd)
125 N806459 Bolt 1 65 6 108 Piston (8 Req'd)
126 67 10 Oil Pan Gasket 1 66 6 1 59 Piston Ring (8 Req'd)
127 6675 Oil Pan 1 67 6 1 59 Piston Ring (8 Req'd)
128 W701 240 Bolt (16 Req'd) 1 68 N806007 Dowel
129 N8061 55 Bolt (2 Req'd) 169 N87836 Dowel (2 Req'd)
130 6345 Crankshaft Main Bearing 170 N806435 Pipe Plug
Cap Stud (9 Req'd) 171 6K30 1 Crankshaft Rear Oil Seal and
131 6C360 Crankshaft Main Bearing Retainer
Cap Adjusting Screw (10 172 N806 1 55 Bolt
Req'd)
Crankshaft Main Bearing (4 173 670 1 Crankshaft Rear Oil Seal
132 6333
Req'd) 174 6310 Crankshaft Oil Slinger
133 N80620 1 Woodruff Key 175 6375 Flywheel
134 6333 Crankshaft Main Bearing (5 176 N8061 68 Bolt (6 Req'd)
Req'd) 177 N8071 98 Dowel (2 Req'd)
135 N806 183 Bolt (4 Req'd) 178 N806459 Dowel (4 Req'd)
136 6600 Oil Pump 179 W701 706 Nut
137 N804958 Bolt (4 Req'd) 180 6750 Oil Level Dipstick
138 6K297 Timing Chain Guide 181 6754 Oil Level Indicator Tube
139 6268 Timing Chain I Belt 182 87838 Pipe Plug
140 6306 Crankshaft Sprocket (2 183 67 14 Oil Bypass Filter
Req'd)
1 84 N806 1 56 Bolt (4 Req'd)
141 12A227 Crankshaft Ignition Pulse
Sprocket 1 85 N806 176 Bolt (4 Req'd)
142 N806177 Bolt (6 Req'd) 1 86 3C5 10 Power Steering Hose
Bracket
143 N808586 Stud Bolt (4 Req'd)
187 3A733 Power Steering Pump Pulley
144 6700 Crankshaft Front Seal
188 3A674 Power Steering Pump
145 6B288 Camshaft Position Sensor
189 9278 Oil Pressure Sensor
146 N806155 Bolt
190 6881 Oil Filter Adapter
147 12043 Ignition Coil Mounting Strap
191 6840 Oil Filter Adapter Gasket
148 N804178 Nut (3 Req'd)
1 92 N806007 Dowel (2 Req'd)
149 N806177 Bolt
(Continued)
(Continued)

03-018- 1 3 Engine, 4.6L (2V) 03-0 1 8- 1 3
Part Part
I tem Number Description Item Number Description
193 N806040 Dowel (2 Req'd) 1 95 N64641 9 Dowel (2 Req'd)
194 N623454 Washer (2 Req'd) 1 96 8555 Water Bypass Tube
(Continued)
Valve Cover and Gasket 2. NOTE: Remove all traces of dirt, oil or previously
applied sealant from the sealing surfaces. Clean
RH Side all sealing surfaces with Metal Surface Cleaner
Removal F4AZ- 1 9A536-RA or equivalent meeting Ford
specification WSE-MSB392-A. Sealing surfaces
1. Disconnect negative battery ground cable
must be clean and dry before applying sealant.
( 1 430 1). Refer to Section 1 4.0 1 .
NOTE: Install valve covers and retainers no more
2. Remove air cleaner outlet tube (98659).
than four minutes after applying sealer.
3. Disconnect 42-pin connector and 8-pin connector
Apply Silicone Gasket and Sealer
leading to the mass air flow sensor (MAF
F6AZ- 1 9562-AA or equivalent meeting Ford
sensorX 1 28579) and intake air temperature
specification WSE-M4G323-A6 in both places
sensor (IAT sensorX 1 2A697).
where engine front cover (60 1 9) meets cylinder
4. Remove nut retaining A / C line to the RH front head.
fender apron ( 1 6054).
3. Install valve cover gaskets, valve covers, bolts
5. Lift A I C line and feed the 42-pin connector under and stud bolts. lighten stud bolts and bolts to
the line. Position 42-pin connector out of the way. 8- 1 2 N-m (7 1 - 1 06 lb-in) no more than four minutes
Relieve fuel system pressure and disconnect fuel after applying sealer.
6.
lines. Refer to. Section 1 o-o 1 . 4. Install positive crankcase ventilation valve into
7. CAUTION: Do not pull o n the ignition wires, crankcase ventilation grommet.
as Ignition wire may separate from the 5. Install ignition wire separators on studs and
connector in the ignition wire boot. connect ignition wires to spark plugs. Refer to
Disconnect ignition wires from spark plugs Section 03-o78.
( 1 2405). Refer to Section 03-o78. 6. Connect fuel lines. Refer to Section 1Q-O 1 .
8. Remove ignition wires and ignition wire 7. Position and connect 42-pin connector and 8-pin
separators ( 1 2297) from vawe cover studs and connector.
position ignition wires out of the way.
8. Position A / C line and install retaining nut.
9. Remove positive crankcase ventilation valve
(PCV valveX6A666) from crankcase ventilation
grommet (6A892) and position out of the way. 1 0. Start engine and check for leaks.
10. Remove bolts and stud bolts retaining valve cover LH Side
(6582) to cylinder head (6049). Remove valve
cover.
Removal
1. Remove air cleaner outlet tube.
Installation
2. Disconnect battery ground cable. Refer to
1. Position and glue new valve cover gasket (6584)
Section 1 4-o 1 .
into valve cover. Use Gasket and Trim Adhesive
D7 AZ- 1 98508-8 or equivalent meeting Ford 3. Disconnect speed control actuator cable
specifications ESR-M 1 1 P 1 7-A and (9A825) from throttle body (9E926). Position
ESE-M2G52-A. speed control actuator cable out of the way.
4. Disconnect fuel charging wiring (9D930) from the
electronic variable orifice sensor and oil pressure
sensor (9278). Position fuel charging wiring out of
way.
5. CAUTION: Do not pull on the ignition wire as
Ignition wire may separate from the
connector in the ignition wire boot.
Disconnect ignition wires from spark plugs. Refer
to Section 03-o78.
6. Remove ignition wires and ignition wire
separators from studs and position ignition wires
out of the way.

03-018-14 Engine, 4.6L (2V) 03-01 8-14
7. Remove bolts and stud bolts retaining valve cover 2. Position and glue new valve cover gasket onto
to cylinder head. Remove valve cover. valve cover. Use Gasket and Trim Adhesive
D7AZ- 1 98508-B meeting Ford specifications
ESR-M 1 1 P 1 7-A and ESE-M2G52-A.
specification WSE-M5B392-A, to remove all
ability to adhere.
NOTE: Install valve cover and retainers no more
Apply Silicone Gasket and Sealer
specification WSE-M4G323-A6 in both places
where engine front cover meets cylinder head.
4. Install valve cover gaskets, valve covers, bolts
and studs bolts. Tighten stud bolts and bolts to
8- 1 2 N-m (7 1 - 1 06 lb-in) no later than four minutes
after applying sealer.
5. Install ignition wire separators on studs and
connect ignition wires to spark plugs. Refer to
Section 03-Q7B.
6. Position and connect fuel charging wiring to the
electronic variable orifice sensor and oil pressure
sensor.
/
FRONT OF
7. Position and connect speed control actuator
cable.
ENGINE 8. Connect battery ground cable.
/ 9. Start engine and check for leaks.
LH SIDE SHOWN
RH SIDE SIMILAR
AA0636-A Rocker Arm
Part SPECIAL SERVICE TOOL(S) REQUIRED

Item Number Description Description Tool Number
1 6582 Valve Cover (RH) Valve Spring Spacer T91P-6565-AH
2 6584 Valve Cover Gasket Valve Spring Compressor T91 P-6565-A
3 N806356-S2 Stud (LH 4 Req'd, RH 2
Req'd) Removal
4 6766 Oil Filler Cap 1. Remove valve covers (6582) as described.
5 N806183-S2 Bolt (LH 7 Req'd, RH 9 2. Position piston (6 1 08) of cylinder being serviced
Req'd) at the bottom of its stroke and camshaft lobe at
6 6582 Valve Cover (LH) base circle.
7 6049 Cylinder Head (LH) 3. CAUTION: If Valve Spring Spacer
8 N807441 Stud Bolt T9 1 P-6565-AH is not used, valve spring
-
retainer (651 4) will hit valve stem seal (657 1 )
A Tighten to 8- 12 N-m (71- 106 resulting I n damage to the valve stem seal.
Lb-ln)
Install Valve Spring Spacer T9 1 P-6565-AH
Installation between valve spring coils to prevent valve stem
1. Remove all traces of dirt, oil or previously applied seal damage.
sealants from the engine front cover and cylinder
head sealing surfaces. Sealing surfaces must be
clean and dry before applying sealant.

03-018- 1 5 Engine, 4.6L (2V) 03-0 1 8· 1 5
4. Install Valve Spring Compressor T9 1 P-6565-A Valve Tappet, Hydraulic

under camshaft (6250) and on top of valve spring
retainer. Removal
1. Remove rocker arms (6564) as described.
2. Remove valve tappets (6500) from cylinder
heads (6049).
3. Clean and inspect valve tappets as described in
Section 03-0Q.
Installation
1. Apply clean engine oil to valve stem and tip,
rocker arm roller contact surfaces and valve
tappets and cylinder head valve tappet bore.
2. NOTE: Valve tappets must have no more than 1 .5
mm (0.059 inch) of plunger travel prior to
installation.
Install valve tappets into cylinder heads.
3. Install rocker arms as described.
�
Valve Spring, Retainer and Valve Stem Seal
� VALVE SPRING SPACER
T91 P-6565-AH SPECIAL SERVICE TOOL(S) REQUIRED
VIEW A Valve Spring Spacer T9 1 P-6565-AH

Valve Spring Compressor T91 P-6565-A
A15052-C Valve Stem Seal Replacer T91P-657 1-A
5. Compress valve spring (65 1 3) and remove Removal

rocker arm (6564).
1. Remove valve covers (6582) and rocker arms
6. Remove Valve Spring Compressor T9 1 P-6565-A (6564) as described.
and Valve Spring Spacer T9 1 P-6565-AH.
2. Remove spark plug ( 1 2405) from applicable
7. Repeat Steps 2 through 6 until all necessary cylinder. Refer to Section 03-078.
rocker arms are removed.
3. Position piston (6108) at top of stroke with both
Installation exhaust valve (6505) and intake valve (6507)
1. Apply clean engine oil to valve stem and tip, closed.
rocker arm contact surfaces and valve tappet. 4. NOTE: Failure of air pressure to hold the exhaust
2. Install Valve Spring Spacer T9 1 P-6565-AH valve and intake valve closed while performing
between valve spring coils. the following steps is an indication of valve
and I or valve seat damage and requires removal
3. NOTE: Piston must be at the bottom of its stroke of cylinder head (6049).
and camshaft at base circle.
Install an air line with an adapter in the spark plug
Compress valve spring using Valve Spring hole and turn air supply on.
Compressor T9 1 P-6565-A and install rocker arm.
5. Install Valve Spring Spacer T9 1 P-6565-AH
4. Remove valve spring compressor and spacer. between valve spring coils.
5. Repeat Steps 1 through 4 until all rocker arms are
installed.
6. Install valve cover, as described.

03-0 1 8- 1 6 Engine, 4.6L (2V) 03-0 1 8- 1 6
6. Compress valve spring (65 1 3) using Valve Spring

Compressor T9 1 P-6565-A.
VALVE STEM
NOTE: RH CYUNDER HEAD SHOWN
SEAL 6571
LH CYLINDER HEAD SIMILAR A136»8
Installation
1. NOTE: Piston must be at top dead center (TDC)
of cylinder being serviced.
�
T91 P-6565-AH
Remove air pressure from spark plug adapter.
Inspect the valve stem for damage. Rotate the
valve and check the valve stem tip for eccentric
movement during rotation. Move the valve up and
down through normal travel in the valve guide and
VIEW A check the stem for binds.
2. CAUTION: If the valve has been damaged, It
A15052-C will be necessary to remove the cylinder
head for service. Refer to Section 03-00.
7. CAUTION: If air pressure has forced the
piston to the bottom of the cylinder, any loss If the condition of the valve is satisfactory, apply
of air pressure will allow the valve(s) to fall clean engine oil to the valve stem and hold the
Into the cylinder. A rubber band, tape or valve closed. Apply the air pressure within the
string wrapped around the end of the valve cylinder.
stem will prevent this from happening and 3. Install new valve stem seal using Valve Stem Seal
still allow enough travel to check the valve Replacer T9 1 P-657 1 -A.
for binds and excessive guide-to-valve stem
clearance.
Remove valve spring retainer keys (65 1 8), valve
spring retainer (65 1 4) and valve spring.
8. Using locking pliers remove valve stem seal
(657 1).
9. Repeat Steps 2 through 8 until all necessary
valve stem seals are removed.
VALVE STEM
SEAL REPLACER
T91 P-6571-A
A24777-A
4. Position valve spring and valve spring retainer

over valve stem.
between valve spring coils.
6. Compress valve spring using Valve Spring
Compressor T9 1 P-6565-A and install valve
spring retainer key.
7. Remove valve spring compressor and spacer.

03-018- 1 7 Engine, 4.6L (2V) 03-0 1 8- 1 7
8. Turn air supply OFF and remove adapter from

spark plug hole. CRANKSHAFT SEAL
REPLACER/COVER ALIGNER
9. Install spark plug. TBST-6701-A
10. Install rocker arms and valve covers as
described.
1 1 . Start engine and check for leaks.
A14815-E
Crankshaft Pulley I Crankshaft Front Oil Seal 3. Using Crankshaft Damper Replacer
T74P-63 1 6-B, install crankshaft pulley.
Description Tool Number surfaces with Metal Surface Cleaner
Front Cover Seal Remover T74P-6700-A residues that may interfere with the sealer's
Crankshaft Seal Replacer I Cover TSST-670 1-A ability to adhere.
Aligner
Crankshaft Damper Replacer T74P-6316-B F6AZ- 1 9562-AA or equivalent meeting Ford
specification WSE-M4G323-A6 to end of keyway
Removal of crankshaft pulley as shown.
1. Disconnect battery ground cable ( 1 4301 ). Refer
to Section 1 4-Q 1 .
2. Release drive belt tensioner (68209) and remove
drive belt (8620). Refer to Section 03-Q5.
3. Raise vehicle on hoist.
4. Remove crankshaft pulley bolt (6A340) and
crankshaft pulley retaining washer (6378) from
crankshaft (6303).
5. Install Crankshaft Damper Remover .
T58P-63 1 6-D on crankshaft pulley (63 1 2) and
pull crankshaft pulley from crankshaft.
A13668-B
6. Using Front Cover Seal Remover T74P-670Q-A,
/
remove crankshaft front seal (6700).
Installation CRANKSHAFT
PULLEY 6312
1. Lubricate seal bore in engine front cover (60 1 9)
and seal lip with clean engine oil.
2. Using Crankshaft Seal Replacer /Cover Aligner
TBBT-670 1 -A, install crankshaft front seal. SEALER
KEYWAY
VIEW A
A18921-B

03-01 8- 1 8 Engine, 4.6L (2V) 03-o1 B-18
5. NOTE: Make sure key on crankshaft aligns with 6. NOTE: The front lower bolt on the power steering
keyway of crankshaft pulley. pump (3A67 4) will not come all the way out.
Install crankshaft pulley bolt and crankshaft Remove bolts retaining power steering pump to
pulley retaining washer. Tighten in four steps: cylinder blocks (601 0) and engine front cover.
a. Tighten to 90 N-m (67 lb-ft). 7. Wire power steering pump out of way.
b. Loosen bolt one full turn. 8. Remove oil pan and oil pan gasket as described.
c. Tighten bolt to 50 N·m (37 lb-ft). 9. Remove crankshaft pulley bolt (6A340) and
d. Tighten an additional 90 degrees. crankshaft pulley retaining washer (6378) from
crankshaft (6303).
10. Install Crankshaft Damper Remover
TSSP-63 1 6-0 on crankshaft pulley (63 1 2) and
pull crankshaft pulley from crankshaft.
CRANKSHAFT
DAMPER REPLACER
T74P-6316-B
6. Lower vehicle.
7. Install drive belt. Refer to Section 03-QS. A13668-B
9. Start engine and check for leaks. 1 1 . Lower vehicle.
1 2 . Remove bolts retaining power steering oil
reservoir (3A697) to the LH coil bracket and
position power steering oil reservoir out of the
Engine Front Cover way.
1 3. Remove both RH and LH valve covers as
SPECIAL SERVICE TOOL(S) REQUIRED described.
Description Tool Number 14. Disconnect the fuel charging wiring (9D930) from
both ignition coils ( 1 2029) and camshaft position
sensor (CMP sensorX6B288).
Crankshaft Damper Replacer T74P-63 16-B
1 5. Remove three bolts retaining RH ignition coil
Removal bracket to engine front cover.
1. CAUTION: The valve covers (6582), oil pan 1 6. Remove LH ignition coil from bracket and lay on
(6675) and oil pan gasket (67 1 0) must be top of engine.
removed prior to the engine front cover 1 7. Remove three nuts retaining LH ignition coil
(601 9) or possible engine damage and/or bracket to engine front cover.
leakage may occur upon reassembly.
1 8. Slide RH ignition coil bracket and ignition wires off
Remove cooling fan motor /fan blade (8600) and mounting studs and lay assembly on top of
fan shroud (8 1 46) assembly. Refer to SeCtion engine. Remove bolts and retaining belt idler
03-Q3. pulley, then remove pulley.
2. Loosen water pump pulley bolts. 1 9. Disconnect fuel charging wiring from crankshaft
3. Remove drive belt (8620). Refer to Section position sensor (CKP sensorX6C3 1 5).
03-QS. 20. Remove eight stud bolts and seven bolts retaining
4. Remove water pump pulley (8509). engine front cover to engine.

03-018-19 Engine, 4.6L (2V) 03-01 8-19
Engine Front Cover
Part Part
Ite m Number Description Item Number Description
1 N808586 Stud Bolt (3 Req'd) 3 N806300 Stud Bolt (5 Req'd)
2 N806 1 77 Bolt (7 Req'd) 4 601 9 Engine Front Cover
(Continued)
2 1 . Remove engine front cover. 3. NOTE: Prior to applying sealer, clean sealing
Installation F4AZ- 1 9A536-RA or equivalent meeting Ford
1. Remove all traces of dirt, oil or previously applied specification WSE-M5B392-A to remove all
sealant from the engine front cover, cylinder residues that may interfere with the sealer's
heads and cylinder block sealing surfaces. ability to adhere.
Sealing surfaces must be clean and dry before NOTE: Install engine front cover and retainers in
applying sealant. no more than four minutes after applying sealer.
2. Replace crankshaft front seal (6700) and engine Apply an 8- 1 2 mm (0.32-Q.47 inch) bead of
front cover gasket (three each). Silicone Gasket Sealant F6AZ- 1 9562-AA or
WSE-M4G323-A6 in locations shown:

03-01 8-20 Engine, 4.6L (2V) 03-01 8-20
Engine Front Cover Installation
----
FRONT OF ENGINE
---
VIEW A VIEW B
TYPICAL FOUR PLACES TYPICAL TWO PLACES
A25166-A
Part Part
1 601 9 Engine Front Cover 5 12A227 Crankshaft Position Sensor
2 6049 Cylinder Head Pulse Wheel
3 N806040-S Dowel (2 Req'd) 6 60081 Engine Front Cover Gasket
4 6303 Crankshaft 7 6010 Cylinder Blocks
(Continued)
8 67 10 Oil Pan Gasket
4. Install engine front cover on engine no more than 5. Install studs and bolts retaining engine front cover
four minutes after applying sealant. to engine in location as shown in illustration.
lighten to 2Q-30 N·m ( 1 5-22 lb-ft) in no more than
four minutes after applying sealant.

03-018-2 1 Engine, 4.6L (2V) 03-01 8-2 1
Retainer Locations
0
lllllillll!bllll llll ll l
REFER TO LEGEND
�
1
A nGHTEN IN SEQUENCE 2
W SHOWN
Part Part
2 N806177 Bolt (7 Req'd) 4 601 9 Engine Front Cover
(Continued)
6. Connect fuel charging wiring to the crankshaft 10. Position and install power steering oil reservoir.
position sensor. 1 1 . Connect fuel charging wiring to both ignition coils
7. Install RH ignition coil bracket and ignition wires and camshaft position sensors.
as an assembly. Tighten nuts to 2Q-30 N·m 1 2. Install valve covers as described.
( 1 5-22 1b-ft).
1 3. Raise vehicle.
8. Install LH ignition coil bracket. Tighten nuts to
2Q-30 N·m ( 1 5-22 1b-ft).
9. Install LH ignition coil and ignition wires as an
assembly.

03-018-22 Engine, 4.6L (2V) 03-01 8-22

ability to adhere.
Apply Silicone Gasket and Sealant CRANKSHAFT
F6AZ- 1 9562-AA or equivalent meeting Ford DAMPER REPLACER
specification WSE-M4G323-A6 to end of the T74P-6316-B
keyway and crankshaft pulley.
1 7. Install crankshaft pulley bolt and crankshaft pulley
retaining washer. Tighten in four steps:
b. Loosen one full turn.
c. Tighten to 50 N·m (37 lb-ft).
d. Tighten an additional 90 degrees.
1 8. Install oil pan and oil pan gasket as described.
19. Position power steering pump on engine and
install four retaining bolts. Tighten to 2D-30 N·m
( 1 5-22 1b-ft).
20. Lower vehicle.
2 1 . Install water pump pulley with four bolts. Tighten
to 2Q-30 N·m ( 1 5-22 1b-ft).
22. Install drive belt. Refer to Section 03-05.
23. Install cooling fan motor /fan blade and fan shroud
assembly. Refer to Section 03-03.
Camshaft Timing Chains and Tensioners

CRANKSHAFT SPECIAL SERVICE TOOL(S) REQUIRED
PULLEY 6312
Cam Positioning Tool T91P-6256·A
Cam Positioning Tool Adapters T92P-6256·A
SEALER
Crankshaft Holding Tool T93P-6303·A
KEYWAY
Removal
1. CAUTION: At no time, when the timing
chain(s) are removed and the cylinder heads
VIEW A (6049) are installed, may the crankshaft
(6303) and/ or camshafts (6250) be rotated.
A18921-B
Failure to follow these directions will result In
valve and/ or piston damage.
15. Position crankshaft pulley on crankshaft. Make
sure crankshaft key and keyway are aligned. NOTE: Because this is not a free-wheeling
engine, if it has "jumped time," there will be
16. Using Crankshaft Damper Replacer
damage to the valves and I or pistons (6 108) and
T74P-631 6-B, install crankshaft pulley.
will require the removal of the cylinder heads. The
camshaft sprockets (6256) should only be
disassembled from the camshafts when one of
the components is to be replaced.
Remove valve covers (6582), oil pan (6675) and
engine front cover (60 1 9) as described.
2. Remove crankshaft position sensor pulse wheel .

03-018-23 Engine, 4.6L (2V) 03-01 8-23
3. Rotate engine to No. 1 top dead center (TDC). 6. Remove RH timing chain tensioner arm (6L253).
7. Remove two bolts retaining RH timing chain guide
(6K297) to cylinder head and remove timing
90 DEGREES 90 DEGREES chain guide.
�
"-� / RH TIMING
CHAIN
8. Remove RH timing chain from camshaft sprocket
and crankshaft sprockets (6306).
9. NOTE: Cam Positioning Tool Adapters
T92P-6256-A and Cam Positioning Tool
T9 1 P-6256-A must be installed on camshaft to
prevent camshaft from rotating.
Remove two bolts retaining LH timing chain
tensioner to cylinder head and remove timing
chain tensioner.
10. Remove LH timing chain tensioner arm.
1 1 . Remove two bolts retaining LH timing chain guide
to cylinder head and remove timing chain guide.
A14820-B 1 2. Remove LH timing chain from camshaft sprocket
and crankshaft sprocket.
4. NOTE: This will prevent accidental rotation of the
camshafts. 13. If necessary, remove camshaft sprockets and
crankshaft sprockets as described.
NOTE: Cam Positioning Tool Adapters
T92P-6256-A and Cam Positioning Tool 14. CAUTION: Do not rotate crankshaft and/ or
T91 P-6256-A must be installed on camshaft to camshafts. Engine damage may occur.
prevent camshaft from rotating. Inspect the plastic running face on timing chain
Install Cam Positioning Tool Adapters tensioner arms and timing chain guides. If worn or
T92P-6256-A and Cam Positioning Tool damaged, remove and clean oil pan and oil pump
T91 P-6256-A on flats of camshafts. screen cover and tube (6622).
Installation
1. NOTE: If engine has "jumped time," make sure
CAM that all repairs to engine components and I or
POSITIONING valve train have been made. Then rotate engine
TOOL counterclockwise 45 degrees. This will position
T91 P-6256-A all pistons below top of deck face. Install cylinder
heads as described.
NOTE: Cam Positioning Tool Adapters
T9 1 P-6256-A must be installed on camshafts to
prevent camshafts from rotating.
Install timing chain guides (both sides). Install
timing chain guide retaining bolts. lighten to 8- 1 2
N·m (7 1 - 1 06 lb-in).
CAM POSITIONING TOOL 2. If removed, position LH camshaft sprocket
ADAPTERS spacer (6265) and sprocket on camshaft.
T92P-6256-A AA0628-A
3. Install washer and camshaft sprocket retaining
5. Remove two bolts retaining RH timing chain bolt. Do not tighten at this time.
tensioner (6L266) to cylinder head and remove 4. If removed, position RH camshaft sprocket
timing chain tensioner. spacer and sprocket on camshaft.

03·01 8-24 Engine, 4.6L (2V) 03-018-24
.fr
5. Install washer and camshaft sprocket retaining
bolt. Do not tighten at this time. viEW A
NOTE: ASSEMBLE
CRANKSHAFT
GEARS WITH HUBS
CORRECT
INCORRECT INCORRECT INSTALLATION
7. NOTE: If copper links of timing chain are not

A14821-c visible, split both timing chains in half and mark
the two opposing links as shown.
Part Install LH timing chain on camshaft sprocket.
Item Number Description Make sure copper link of timing chain lines up with
timing mark of camshaft sprocket.
1 6250 Camshaft
2 6303 Crankshaft
3 6K297 Timing Chain Guide (LH)
4 6306 Crankshaft Sprocket (2
Req'd)
5 N804958-S2 Bolt (2 Req'd Each Side)
6 6K297 Timing Chain Guide (RH) NOTE: WITH EITHER CHAIN POSmONED
7 N806139-S Bolt ( 1 Req'd Each Side) AS SHOWN, MARK EACH END AND USE
MARKS AS TIMING MARKS
8 N806 164-S Washer (1 Req'd Each Side) A14870-B
9 6268 Timing Chain (RH)
8. Install LH timing chain on crankshaft sprocket.
10 6256 Camshaft Sprocket (RH) Make sure copper link of timing chain lines up with
11 6265 Camshaft Sprocket Spacer timing mark of crankshaft sprocket.
(1 Req'd Each Side) 9. NOTE: Make sure tapered part of crankshaft
-
A Tighten to 8- 12 N·m (7 1 - 1 06 sprocket faces toward cylinder blocks.
Lb-ln)
-
If removed, install RH crankshaft sprocket.
B Tighten to 1 10- 130 N·m
(82-95 Lb-Ft) 10. Install RH timing chain on camshaft sprocket.
Make sure copper link of timing chain lines up with
6. NOTE: crankshaft sprockets are identical. They timing mark of camshaft sprocket.
may only be installed one way. Refer to the
following illustration for proper crankshaft
sprocket installation.
NOTE: Make sure tapered part of crankshaft
sprocket faces away from cylinder blocks
(60 10).
If removed, install LH crankshaft sprocket.

03-018-25 Engine, 4.6L (2V) 03-018-25
1 1 . Install RH timing chain on crankshaft sprocket.

Make sure copper link of timing chain lines up with NOTE: DO NOT REMOVE
TENSIONER LOCK PINS
timing mark of crankshaft sprocket.
./ UNTIL CHAIN GUIDES
HAVE BEEN INSTALLED
FRONT OF
ENGINE NOTE: LUBRICATE TENSIONER
/ ARM CONTACT SURFACES WITH
ENGINE OIL PRIOR TO ASSY
A14823-C
A14822..C
12. Install RH and LH timing chain tensioner and
secure with two bolts on each. lighten bolts to
2Q-30 N·m ( 15·22 1b-ft). Part
13. Install Crankshaft Holding Tool T93P-6303-A over
crankshaft and engine front cover alignment
·
1 6049 Cylinder Head (RH)
dowel, to position crankshaft. 2 6049 Cylinder Head (LH)
3 N806040-S Dowel (2 Req'd)
INSTALL TOOL
g��g�1
CRANKSHAFT HOLDING 4 6L253 Timing Chain Tensioner Arm
MENT TOOL T93P-6303-A (LH)
DOWEL 5 6L266 Timing Chain Tensioner (LH)
�
6 N606543-S2 Bolt (2 Req'd Each Side)
7 - Lock Pin (Part of 6L266)
/ 8 6L266 Timing Chain Tensioner (RH)
9 6L253 Timing Chain Tensioner Arm
(RH)
A - Tighten to 20-30 N·m (15-22
Lb-Ft)
1 5. With a suitable G-clamp around the timing chain
tensioner arm and timing chain guide, remove all
NOTE: ALIGN CRANKSHAFT slack from timing chain. Use caution not to bend
WOODRUFF KEY WITH
KEYWAY ON TOOL A16254-B the timing chain guide.
1 4. Lubricate timing chain tensioner arm contact

surfaces with clean engine oil and install RH and
LH timing chain tensioner arms on their dowels.

03-01 8-26 Engine, 4.6L (2V) 03-01 8-26
16. Remove lock pins from timing chain tensioners 2. Remove crankshaft sprockets (6306) from
and make sure all timing marks are aligned. crankshaft (6303).
NOTE: USE C-CLAMP TO REMOVE SLACK T92P-6256-A and Cam Positioning Tool
FROM CAMSHAFT TIMING CHAIN T9 1 P-6256-A must be installed on camshafts
(6250) to prevent camshafts from rotating.
Remove camshaft sprocket retaining bolts,
washers, camshaft sprockets (6256) and
camshaft sprocket spacers (6265).
4. CAUTION: Do not rotate crankshaft or
camshafts as possible damage to engine
may occur.
Inspect crankshafts and camshaft sprockets for
wear or damage and replace as required.
Installation
T9 1 -P6256-A must be installed on camshafts to
prevent camshafts from rotating.
Position camshaft sprocket spacers and
camshaft sprockets on camshafts.
2. Install washers and camshaft sprocket retaining
1 7. Using Cam Positioning Tool Adapters bolts. Do not tighten at this time.
T92P-6256-A and Cam Positioning Tool 3. NOTE: Crankshaft sprockets are identical. They
T9 1 P-6256-A, align camshaft, tighten camshaft may only be installed one way.
sprocket bolt to 1 1 Q- 1 30 N-m (8 1 -95 lb-ft).
Install crankshaft sprockets onto crankshaft.
18. NOTE: If not at maximum lift, loosen camshaft Refer to the following illustration for proper
sprocket bolt and repeat Steps 1 2- 1 5. crankshaft sprocket installation.
Install Rotunda Dial Indicator with Bracketry
0 1 4-Q0282 or equivalent in cylinder No. 1 spark
plug hole. Check that camshaft is at maximum lift
for the intake valve (6507) at 1 1 4 degrees after
� VIEW A
top dead center (TDC).
1 9. Remove Cam Positioning Tool Adapters
T9 1 P-6256-A and Crankshaft Holding Tool
T93P-6303-A.
20. Install engine front cover, oil pan and valve covers
as described. CORRECT
INCORRECT INCORRECT INSTAllATION
2 1 . Start engine and check for leaks and proper
operation.
liming Sprockets

Cam Positioning Tool T91 P·6256·A
Cam Positioning Tool Adapters T92P·6256·A
4. Install camshaft timing chains and timing chain
tensioners as described.
Removal
1. Remove camshaft timing chains and timing chain
tensioners (6L266) as described.

03-018-27 Engine, 4.6L (2V) 03-018-27
Camshafts 1 6. Disconnect fuel charging wiring at the 42-pin

engine harness connector and 8-pin connector
SPECIAL SERVICE TOOL(S) REQUIRED leading to the mass air flow sensor (MAF
sensor)( 1 28579).
1 7 . Remove nut retaining A I C line to the RH front
Crankshaft Damper Remover T58P-6316-D fender apron ( 1 6054).
18. Lift A / C line and feed the 42-pin connector under
Valve Spring Spacer T91 P-6565-AH the line. Position 42-pin connector out of the way.
Cam Positioning Tool Adapters T92P-6256-A 1 9. Disconnect fuel charging wiring from the
Cam Positioning Tool T91 P-6256-A crankshaft position sensor (CKP
sensor)(6C3 1 5), A / C clutch (2884) and
evaporative emission canister purge valves
Removal (EVAP canister purge valve)(9C9 1 5).
1. Disconnect battery ground cable ( 1 430 1 ). Refer 20. Raise vehicle on hoist.
to Section 14-Q 1 . 2 1 . NOTE: The front lower bolt on the power steering
2. Remove cooling fan motor /fan blade (8600) and pump (3A674) will not come all the way out.
fan shroud (8 146) assembly. Refer to Section Remove bolts retaining power steering pump to
03-Q3. cylinder blocks (601 0) and engine front cover.
3. Relieve fuel system pressure and disconnect fuel 22. Wire the power steering pump out of the way.
lines. Refer to Section 1 0-Q 1 . 23. Remove oil pan (6675) and oil pan gasket (67 1 0)
4. Remove air cleaner outlet tube (98659). Refer to as described.
Section 03- 1 2. 24. Remove crankshaft pulley bolt (6A340) and
5. Release drive belt tensioner (68209) and remove crankshaft pulley retaining washer (6378) from
drive belt (8620). Refer to Section 03-Q5. crankshaft (6303).
6. CAUTION: Do not pull on Ignition wire as 25. Install Crankshaft Damper Remover
wires may separate from the connector In T58P-63 1 6-D on crankshaft pulley (63 1 2) and
the ignition wire boot. pull crankshaft pulley from crankshaft.
Disconnect ignition wires from spark plugs
( 1 2405). Refer to Section 03-Q78.
7. Disconnect ignition wire and brackets ( 1 2280)
from valve cover studs.
8. Remove two bolts retaining ignition wire
separator ( 1 2297) to ignition coil brackets.
9. Disconnect fuel charging wiring (9D930) from
sensor (CMP sensor)(68288). A13668-B
10. Remove three nuts retaining RH ignition coil

bracket to engine front cover (60 1 9). Remove 26. Position drain pan under oil bypass filter (67 1 4)
ignition coil bracket, ignition coil and ignition wires and remove oil bypass filter.
from vehicle as an assembly. 27. Disconnect fuel charging wiring from the
1 1 . Remove bolts retaining power steering oil electronic variable orifice sensor and oil pressure
reservoir (3A697) to the LH ignition coil bracket sensor (9278).
and position power steering oil reservoir out of 28. Remove oil filter adapter (688 1 ) and position fuel
the way. charging wiring out of the way.
12. Remove LH ignition coil from bracket and remove 29. Lower vehicle.
from vehicle as an assembly, with the ignition 30. Remove nine bolts and two stud bolts retaining
wires. RH valve cover to cylinder head (6049) and
13. Remove three nuts retaining LH ignition coil remove valve cover.
bracket to engine front cover and remove.
14. Remove water pump pulley (8509).
15. Remove positive crankcase ventilation valve
(PCV valve)(6A666) from valve cover (6582) and
position out of the way.

03-018-28 Engine, 4.6L {2V) 03-01 8-28
3 1 . Remove seven bolts and four stud bolts retaining

LH valve cover to cylinder head and remove valve Part
cover. Item Number Description
3 N806356-S309 Stud (LH 4 Req'd, RH 2
Req'd)
4 6766 Oil Filler Cap
5 N806 183-S309 Bolt (LH 7 Req'd, RH 9
Req'd)
6 6582 Valve Cover (LH)
7 6049 Cylinder Head (LH)
8 N807441 Stud Bolt
-
A Tighten to 8- 12 N·m (7 1-1 06
Lb-ln)
32. Remove engine front cover as described.
FRONT OF
/
ENGINE
/
APPLY SILICONE LH SIDE SHOWN
GASKET SEALER RH SIDE SIMILAR
AA0636·A
Part
1 6582 Valve Cover (RH)
2 6584 Valve Cover Gasket
(Continued)

03-018-29 Engine, 4.6L (2V) 03-01 8-29
Engine Front Cover
Part Part
(Continued)
33. Remove timing chains as described. 35. NOTE: This ensures that all pistons (6 1 08) are
34. CAUTION: Crankshaft must be in this below the top of the cylinder block deck face.
position prior to rotating camshafts (6250) or Install Valve Spring Compressor T9 1 P-6565-A
damage to pistons and/ or valve train will under camshaft and on top of valve spring
result. retainer (65 1 4).
Rotate crankshaft counterclockwise 45 degrees
from toe.
CRANKSHAFT
KEYWAY A13655-B

03-018-30 Engine, 4.6L (2V) 03-01 8-30
36. NOTE: Valve Spring Spacer T9 1 P-6565-AH must

be installed between valve spring coils. Camshaft
must be at base circle before compressing valve
spring (65 1 3}. Rotate camshaft as required until
all rocker arms (6564} are removed.
Compress valve spring far enough to remove
rocker arm.
NOTE: VALVE TAPPET MUST

BE PUMPED UP BEFORE
INSTALLATION
NOTE: LH SHOWN
RH SIMILAR
A14818-C
�
T91 P-6565-AH Part
1 6B280 Front Camshaft Bearing Cap
VIEW A 2 N807352 Bolt (2 Req'd)
A15052-C
3 6B280 Rear Camshaft Bearing Cap
4 6250 Camshaft (LH)
37. Repeat above two steps until all rocker arms are 5 6564 Rocker Arm (8 Req'd)
removed. 6 6500 Valve Tappet (8 Req'd)
38. Remove 1 4 bolts retaining camshaft bearing caps 7 6049 Cylinder Head (LH)
(68280} to cylinder head.
8 N806070 Bolt ( 1 2 Req'd)
-
CAMSHAFT BEARING A Tighten to 8-1 2 N·m (7 1-106

CAP 68280 Lb-ln)
4 1 . If both camshafts are being serviced, repeat
Steps 35 through 40 to remove the other
camshaft.
Installation
1. Clean and inspect valve cover, engine front cover
and cylinder head sealing surfaces.
2. NOTE: Steps 2 through 1 1 will install only one
camshaft. If both camshafts are being serviced,
repeat Steps 2 through 1 1 to install the other
CYLINDER HEAD 6049 camshaft.
A1 4849-B
Position camshaft on cylinder head. Apply oil to
39. Tap upward on camshaft bearing caps at position journals and lobes of camshaft.
shown and gradually lift camshaft bearing caps 3. Install and seat camshaft bearing caps.
from cylinder head. Hand-start 1 4 bolts.
40. Remove camshaft straight upward to avoid 4. NOTE: Each camshaft bearing cap is tightened
bearing damage. individually.
lighten camshaft bearing cap retaining bolts in
sequence to 8- 1 2 N-m (7 1 - 1 06 lb-in}.

03-018-3 1 Engine, 4.6L (2V) 03-01 8-3 1
Installation Sequence 1 0. Compress valve spring far enough to install

rocker arm.
1 1 . Repeat Steps 8 through 1 0 until all rocker arms
are installed. Remove Valve Spring Spacer from
valve spring.
1 2 . CAUTION: Crankshaft must only be rotated in
the clockwise direction and only as far as top
dead center (TDC).
NOTE: This will position crankshaft at top dead
center (TDC).
Rotate crankshaft clockwise 45 degrees.
- FRONT OF __ __ FRONT OF _
ENGINE ENGINE
LH CYLINDER RH CYLINDER
HEAD HEAD
A14817-D
5. Loosen 14 camshaft bearing cap retaining bolts

approximately two turns or until head of bolt is
free. A13658-8
6. NOTE: Camshaft should turn freely with a slight
drag. 1 3. CAUTION: Timing chain procedures must be
followed exactly or damage to valves or
Retighten all bolts in sequence to 8- 1 2 N·m pistons will result.
(7 1-106 1b-in).
Install timing chains as described.
7. Check camshaft end play using Rotunda Dial
Indicator with Bracketry 0 1 4-Q0282 or 14. Inspect and replace crankshaft front seal (6700)
equivalent. and engine front cover as necessary.
8. If necessary, install Cam Positioning Tool 1 5. NOTE: Prior to applying sealer, clean sealing
Adapters T92P-6256-A and Cam Positioning Tool surfaces with Metal Surface Cleaner
T91 P-6256-A on flats of camshaft and install F4AZ- 1 9A536-RA or equivalent meeting Ford
camshaft sprocket spacer (6265) and camshaft specification WSE-M5B392-A, to remove all
sprocket (6256). Install bolt and washer and residues that may interfere with the sealer's
tighten to 1 1 Q- 1 30 N·m (82-95 1b-ft). ability to adhere.
9. NOTE: Valve Spring Spacer T9 1 P-6565-AH must Apply a 8-1 2 mm (0.32-Q.47 inch) bead of
be installed between valve spring coils and the Silicone Gasket and Sealant F6AZ- 1 9562-AA or
camshaft MUST be at base circle prior to equivalent meeting Ford specification
compressing valve spring. Rotate camshaft as WSE-M4G323-A6 in locations shown.
necessary until all rocker arms are installed.
Install Valve Spring Compressor T9 1 P-6565-A
under camshaft and on top of valve spring
retainer. Install valve tappet (6500).

03-01 8-32 Engine, 4.6L (2V) 03-01 8-32
--
FRONT OF ENGINE
---
VIEW A VIEW B
A25166-A
Part Part
1 601 9 Engine Front Cover 5 1 2A227 Crankshaft Position Sensor
4 6303 Crankshaft 7 6010 Cylinder Blocks
(Continued)

03·018·33 Engine, 4.6L (2V) 03-018-33
16. Install engine front cover as described.

Retainer Locations
0 REFER TO LEGEND
�
11111111111[)111 1111 11 1
1
A TIGHTEN IN SEQUENCE 2
- SHOWN
Part Part
2 N806177 Bolt (7 Req'd) 4 6019 Engine Front Cover
(Continued)
17. Position and, using Silicone Gasket and Sealant 1 9. Install RH valve cover, bolts and stud bolts.
F6AZ- 1 9562-AA or equivalent meeting Ford lighten to 8- 1 2 N·m (7 1 - 1 06 lb-in) in no more than
specification WSE-M4G323-A6, secure gaskets four minutes after applying sealer.
into valve covers.
specification WSE-M58392-A to remove all
ability to adhere.
NOTE: Install valve covers and retainers no more
FBAZ- 1 9562-AA or equivalent meeting Ford
specification WSE-M4G323-A6 at both places
engine front cover meets cylinder head.

03-018-34 Engine, 4.6L (2V) 03-o1 B-34
20. Install LH valve cover, bolts and stud bolts. 22. Connect the fuel charging wiring to the electronic
lighten to 8- 1 2 N·m (7 1 - 1 06 Ib-in) in no more than variable orifice sensor and oil pressure sensor.
four minutes after applying sealer. 23. NOTE: Prior to applying sealer, clean sealing
ability to adhere.
FSAZ- 1 9562-AA or equivalent meeting Ford
specification WSE-M4G323-A6 in keyway of
crankshaft pulley as shown.
FRONT OF
/
ENGINE
/
APPLY SILICONE LH SIDE SHOWN
GASKET SEALER AH SIDE SIMILAR
AA0636-A
Item
Part
Number Description
/ CRANKSHAFT
PULLEY 6312

SEALER
3 N806356-S Stud (LH 4 Req'd, RH 2
Req'd) KEYWAY
5 N806183-S Bolt (LH 7 Req'd, RH 9
Req'd)
6 6582 Valve Cover (LH) VIEW A
7 6049 Cylinder Head (LH) A18921-B
8 N807441 Stud Bolt
-
A Tighten to 8-1 2 N·m (71 - 1 06 sure crankshaft key and keyway are aligned.
Lb-ln)
2 1 . Raise vehicle.

03-018-35 Engine, 4.6L (2V) 03-018-35
25. Using Crankshaft Damper Replacer 45. Install cooling fan motor /fan blade and fan shroud
T74P-63 16-8, install crankshaft pulley. assembly. Fill cooling system. Refer to Section
03-Q3.
03- 1 2.
49. Check and add oil as needed.
CRANKSHAFT
DAMPER REPLACER
T74P-6316-B
Cylinder Heads
26. Install crankshaft pulley bolt and crankshaft pulley
retaining washer. Tighten in four steps: SPECIAL SERVICE TOOL(S) REQUIRED
c. Tighten to 50 N·m (37 lb-ft).
Crankshaft Damper Replacer T74P-6316-B
d. Tighten an additional 90 degrees. Cam Positioning Tool T91 P-6256-A
27. Install oil pan with new oil pan gasket as Cam Positioning Tool Adapters T92P-6256-A
described.
28. Position power steering pump on engine and Removal
install four retaining bolts. Tighten to 20-30 N·m 1. Disconnect battery ground cable ( 1 430 1 ). Refer
(15-22 1b-ft). to Section 1 4-Q 1 .
29. Lower vehicle. 2. Drain cooling system and remove fan blade
30. Connect fuel charging wiring to the A I C clutch, (8600) and fan shroud (8 1 46). Refer to Section
crankshaft position sensor and evaporative 03-Q3.
emission canister purge valves. 3. Relieve fuel system pressure and disconnect fuel
3 1 . Position and connect 42-pin engine harness lines. Refer to Section 1 0-Q 1 .
connector and 8-pin connector. 4. Remove air cleaner outlet tube (98659). Refer to
32. Position A/C line and install retaining nut. Section 03- 1 2.
33. Install positive crankcase ventilation valve in RH 5. Remove windshield wiper governor (1 7C476).
valve cover. Refer to Section 0 1 - 16.
34. Connect vent hose to evaporative emission 6. Release drive belt tensioner (68209) and remove
canister purge valve. drive belt (8620). Refer to Section 03-D5.
35. Install water pump pulley and tighten bolts to 7. CAUTION: Do not pull on ignition wire as
2Q-30 N·m ( 15-22 lb-ft). wires may separate from the connector In
the ignition wire boot.
36. Position RH ignition coil bracket, ignition wires
and ignition wire separators onto mounting studs. Disconnect ignition wires from spark plugs
( 1 2405). Refer to Section 03-Q78.
37. Install three nuts retaining ignition coil bracket to
engine front cover. Tighten to 2Q-30 N·m ( 1 5-22 8. Disconnect ignition wires and ignition wire
lb-ft). separators ( 1 2297) from valve cover stud bolts.
38. Install LH ignition coil bracket. Tighten nuts to 9. Disconnect fuel charging wiring (9D930) from
2Q-30 N·m ( 1 5-22 1b-ft). both ignition coils ( 1 2029) and camshaft position
sensor (CMP sensor)(68288).
39. Install LH ignition coil and ignition wires as an
assembly. 10. Remove bolts retaining power steering oil
reservoir (3A697) to the LH ignition coil bracket
40. Position and install power steering oil reservoir.
and position out of the way.
4 1 . Connect both ignition coils and camshaft position
1 1 . Remove three nuts retaining RH ignition coil
sensor.
bracket to engine front cover (60 1 9).
42. Connect ignition wires to spark plugs and install
1 2 . Remove LH ignition coil and ignition wires as an
brackets onto valve cover studs. Refer to Section
assembly.
03-078.
1 3. Remove four nuts retaining LH ignition coil
43. Install drive belt. Refer to Section 03-Q5.
bracket to engine front cover.
44. Connect fuel lines. Refer to Section 1 o-o 1 .
14. Slide ignition coil brackets and ignition wire and
bracket ( 1 2280) assembly off mounting studs
and remove from vehicle.

03-01 8-36 Engine, 4.6L (2V) 03-01 8-36
,....., 15. Remove water pump pulley (8509). 33. Disconnect three way catalytjc converter
(TWCX5E2 1 2) from RH and LH exhaust
16. Disconnect generator wiring harness from
junction block, front fender apron ( 1 6054) and manifolds.
generator (GENX 1 0346). 34. Lower exhaust system and secure to
crossmember in positions shown with wire.
1 7. Remove two bolts retaining generator mounting
bracket ( 1 0 1 53) to intake manifold (9424).
18. Remove two bolts retaining generator to cylinder NO. 3 CROSSMEMBER
blocks (60 1 0) and remove generator
(GEN)( 1 0300).
19. Disconnect and remove positive crankcase
ventilation valve (PCV valveX6A666) from valve
cover (6582).
20. Disconnect 42-pin engine harness connector and
&pin connector leading to the mass air flow
sensor (MAF sensor)( 1 28579).
2 1 . Remove nut retaining A I C line to the RH front
fender apron.
22. Lift A I C line and feed the fuel charging wiring
42-pin connector under the A / C line. Position fuel
charging wiring out of the way.
23. Disconnect the fuel charging wiring from the
crankshaft position sensor (CKP
sensorX6C3 15), A I C clutch (2884) and
evaporative emission canister purge valves
(EVAP canister purge valve)(9C9 1 5). NOTE: WIRE BOTH RH AND LH
PIPE TO NO. 3 CROSSMEMBER
24. Raise vehicle on hoist. A13631-B
25. NOTE: The front lower bolt on the power steering 35. Remove bolt retaining starter wiring harness to
r pump (3A674) will not come all the way out. rear of RH cylinder head (6049).
Remove bolts retaining power steering pump to 36. Lower vehicle.
cylinder blocks and engine front cover. 37. Remove bolts and stud bolts retaining RH valve
26. Secure the power steering pump out of the way. cover to cylinder head and remove valve cover.
27. Remove oil pan (6675) and oil pan gasket (67 1 0) 38. Disconnect accelerator cable (9A758) and speed
as described. control actuator cable (9A825).
28. Remove crankshaft pulley bolt (6A340) and 39. Remove accelerator cable bracket (9723) from
crankshaft pulley retaining washer (6378) from intake manifold and position out of the way.
crankshaft (6303). 40. Remove bolts and stud bolts retaining LH valve
29. Install Crankshaft Damper Remover cover to cylinder head and remove valve cover.
T58P-63 1 6-D on crankshaft pulley (63 1 2) and 4 1 . Disconnect vacuum hose from throttle body
pull crankshaft pulley from crankshaft. adapter vacuum port.
42. Disconnect fuel charging wiring from heated
oxygen sensors (H02SX9F472).
43. Disconnect heater water hose ( 1 8472).
44. NOTE: Two water outlet connection retaining
bolts also retain intake manifold.
Remove two bolts retaining water hose
connection (8592) to intake manifold and position
A13668-B upper radiator hose (8260) and water hose
connection out of the way.
30. Disconnect the fuel charging wiring from the 45. Remove the remaining nine bolts retaining intake
electronic variable orifice sensor and oil pressure manifold to cylinder heads and remove intake
sensor (9278). manifold.
3 1 . Position fuel charging wiring out of the way.
(9D477) from RH exhaust manifold (9430).

- - ---
--
03·018-37 Engine, 4.6L (2V) 03·018-37
Intake Manifold
---
FRONT OF ENGINE
---
0 REFER TO LEGEND
e REMOVE BOLTS IN SEQUENCE A24999-A
Part Part
1 N808130-S309 Bolt (8 Req'd) 4 9424 Intake Manifold
2 8592 Water Hose Connection 5 6049 Cylinder Head, LH
3 N81 10 1 1 -S309 Bolt (2 Req'd) 6 6049 Cylinder Head, RH
(Continued)
46. Remove intake manifold gaskets (946 1 ). 47. Remove eight stud bolts and seven bolts retaining
engine front cover to engine. Remove engine front
cover.

03-01 8-38 Engine, 4.6L (2V) 03-01 8-38
!""""' Engine Front Cover
Part Part
(Continued)
48. Remove timing chains as described.

49. NOTE: The lower rear bolt cannot be removed
due to interference with the power brake booster
(2005). Use a rubber band or similar item to hold
bolt away from cylinder blocks as shown in the
following illustration.
Remove 1 0 bolts retaining LH cylinder head to
cylinder blocks.
A1383&-a
50. NOTE: Cylinder head must not be set on head

face. If valves are open damage may occur.
Remove LH cylinder head.

03-018-39 Engine, 4.6L (2V) 03-01 8-39
5 1 . Remove stud bolts retaining heater water hose to

RH cylinder head. LOWER REAR
HEAD BOLT
/"'
FRONT OF ENGINE
../
A13835-B
53. Remove RH cylinder head.

54. If cylinder heads are to be replaced or serviced,
refer to Cylinder Head Disassembly and
Assembly in this Section.
Installation
1. Clean cylinder head, intake manifold, valve cover
and cylinder block sealing surfaces as described
PERPENDICULAR under Disassembly and Assembly. lf necessary,
TO CENTER LINE OF check cylinder head and cylinder block flatness.
ENGINE Refer to Section 03-00.
2. NOTE: This step makes sure that all pistons
NOTE: POSITION HOSE (6 108) are below top of cylinder block deck face.
CLAMP AS SHOWN Rotate crankshaft counterclockwise 45 degrees.
VIEW A
A24302-A
Part
1 N807381 Stud Bolt (2 Req'd)
4 6049 Cylinder Head, RH
-
A Tighten to 20-30 N·m ( 1 5-22 CRANKSHAFT
Lb-Ft) KEYWAY A13655-B
52. NOTE: The lower rear bolt cannot be removed
due to interference with the A I C evaporator 3. Inspect cylinder head face surface for scratches
housing ( 19850). Use a rubber band or similar near coolant passage and combustion chambers.
item to hold bolt away from cylinder blocks as 4. Rotate crankshaft to a stable position where
shown in the following illustration. valves do not extend below cylinder head face.
Remove 10 bolts retaining RH cylinder head to 5. Position new head gasket (605 1 ) on cylinder
cylinder blocks. blocks.
6. CAUTION: Cylinder head bolts must be
replaced with new bolts. They are
torque-to-yield designed and cannot be
reused.
Install lower rear cylinder head bolts and retain in
position with rubber bands or similar items as
described.

03-01 8-40 Engine, 4.6L (2V) 03-018-40
7. NOTE: Take care not to score the surface of the e. Rotate head bolts in sequence 85-95
cylinder head face. degrees.
Position LH cylinder head on cylinder head to f. Rotate head bolts in sequence an additional
block dowels (6A008). 85-95 degrees.
8. Apply clean engine oil meeting Ford specification 1 5. Position heater water hose on cylinder head and
WSS-M2C 153-F to all head bolt spot-faces. install two bolts. Tighten retaining bolts to 2Q-30
9. Remove rubber band from lower rear bolt and N-m ( 1 5-22 1b-ft).
install nine remaining bolts. Hand tighten. 16. Rotate camshafts (6250) using flats matched at
10. Tighten LH cylinder head bolts as follows: center of camshaft until both are in time. Install
Cam Positioning Tool Adapters T92P-6256-A and
a. Tighten head bolts in sequence to 37-43 N-m Cam Positioning Tool T91 P-6256-A on flats of
(28-3 1 lb-ft). camshafts. This will prevent the camshafts from
b. Rotate head bolts in sequence, 85-95 rotating.
degrees. 1 7. CAUTION: Cran.kshaft must only be rotated In
c. Loosen head bolts a minimum of one full turn the clockwise direction and only as far as
(360 degrees). TDC.
d. Retighten head bolts in sequence to 37-43 NOTE: This will position crankshaft at TDC No 1 .
N-m (28-3 1 lb-ft). Rotate crankshaft clockwise 45 degrees.
e. Rotate head bolts in sequence 85-95
degrees.
f. Rotate head bolts in sequence an additional
85-95 degrees.
RH CYLINDER LH CYLINDER
HEAD 6049 HEAD 6049
A13858-8
CYLINDER HEAD TIGHTENING SEQUENCE
I 1 8. CAUTION: Timing chain procedures must be
FRONT OF followed exactly or damage to valves or
ENGINE
pistons will result.
' A13857.C
Install timing chains as described.
1 1 . Position RH cylinder head on cylinder head to 1 9. Inspect and replace crankshaft front seal (6700)
block dowels. and engine front cover gasket (6020) as
1 2. Apply clean engine oil meeting Ford specification necessary.
WSS·M2C 153-F to all head bolt spot-faces. 20. NOTE: Prior to applying sealer, clean sealing
13. Remove rubber band from lower rear bolt and surfaces with Metal Surface Cleaner
install the nine remaining bolts. Hand-tighten. F4AZ- 1 9A536-RA or equivalent meeting Ford
specification WSE-M58392-A to remove all
14. Tighten RH cylinder head bolts as follows: residues that may interfere with the sealer's
a. Tighten head bolts in sequence to 37-43 N-m ability to adhere.
(28-3 1 lb-ft). Refer to illustration. Apply a 8- 1 2 mm (0.32-Q.47 inch) bead of
b. Rotate head bolts in sequence, 85-95 Silicone Gasket and Sealant FSAZ- 1 9562-AA or
degrees. equivalent meeting Ford specification
c. Loosen head bolts a minimum of one full turn WSE-M4G323-A6, in locations shown.
(360 degrees).
d. Retighten head bolts in sequence to 37-43
N-m (28-3 1 lb-ft).

03-018-41 Engine, 4.6L (2V) 03-01 8-41
--
FRONT OF ENGINE
---
VIEW A VIEW B
A25166-A
Part Part
1 6019 Engine Front Cover 5 1 2A227 Crankshaft Position Sensor
4 6303 Crankshaft 7 60 10 Cylinder Blocks
(Continued)

03·01 8-42 Engine, 4.6L (2V) 03·018·42
2 1 . Install engine front cover on engine.

Retainer Locations
QIUIIIIII(JIIIII!II!I �
0 REFER TO LEGEND
1
A nGHTEN IN SEQUENCE 2
W SHOWN
Part Part
1 NB08586 Stud Bolt (3 Req'd) 3 N806300 Stud Bolt (5 Req'd)
2 NB06 177 Bolt (7 Req'd) 4 60 19 Engine Front Cover
(Continued)
22. Install stud bolts and bolts retaining engine front 24. Position intake manifold on cylinder heads.
cover to engine. Tighten to 2Q-30 N·m ( 15-22 25. Install and tighten intake manifold retaining bolts
lb-ft). one through nine in sequence shown in the
23. NOTE: Before installation, inspect intake manifold following illustration to 2Q-30 N·m ( 1 5-22 1b-ft).
for nicks and cuts. Replace intake manifold as 26. Install water thermostat (8575) and new Q-ring,
required. then position water hose connection and upper
NOTE: Make sure alignment tabs on intake radiator hose and install two bolts. Tighten to
manifold gaskets are aligned with holes in 2Q-30 N·m ( 1 5-22 1b-ft).
cylinder heads.
Position new intake manifold gaskets on cylinder
heads.

03-01 8-43 Engine, 4.6L (2V) 03-G1B-43
Intake Manifold
�
�
FRONT OF ENGINE
O REFER TO LEGEND
- TIGHTEN BOLTS IN SEQUENCE A24301·A
Part Part
1 N808130-S309 Bolt (8 Req'd) 5 6049 Cylinder Head, LH
2
3
8592
N81 101 1 -S309
Water Hose Connection
Bolt (2 Req'd)
6
A -
6049 Cylinder Head, RH
Tighten to 20-30 N-m (15-22
Lb•Ft)
4 9424 Intake Manifold
(Continued)
27. Connect heater water hose. 29. Connect vacuum hose to throttle body adapter
28. Connect fuel charging wiring to heated oxygen vacuum port.
sensors.

03-01 8-44 Engine, 4.6L (2V) 03-01 8-44

F4AZ-1 9A536-RA or equivalent meeting Ford
specification WSE-M5B392-A to remove all
ability to adhere.
specification WSE-M4G323-A6 at both places
engine front cover meets cylinder head.
3 1 . Position and, using Gasket and Trim Adhesive
07 AZ-1 98508-B or equivalent meeting Ford
specifications ESR-M 1 1 P 1 7A and
ESE-M2G52-A, secure new valve cover gaskets
(6584) into valve covers and install valve covers
onto cylinder heads.
32. Install bolts and stud bolts into RH valve cover.
lighten all bolts and stud bolts to 8- 1 2 N-m
(7 1-106 1b-in).
33. Install bolts and stud bolts into LH valve cover.
lighten all bolts and stud bolts to 8- 1 2 N-m
(7 1-106 1b-in).
FRONT OF
/
ENGINE
/
APPL SILICONE LH SIDE SHOWN
AA0636·A
Part
Req'd)
5 N806 183-S2 Bolt (LH 7 Req'd, RH 9
Req'd)
8 N80744 1 Stud Bolt
-
A Tighten to 8-12 N-m (7 1-106
Lb-ln)
34. Install accelerator cable bracket on intake
manifold and connect accelerator cable and
speed control actuator cables to throttle body
(9E926).
35. Raise vehicle.
36. Position starter wiring harness to RH cylinder
head and install retaining bolt.
37. Remove wire and position three way catalytic
converter to RH and LH exhaust manifolds.

03-018-45 Engine, 4.6L (2V) 03-018-45
38. NOTE: Make sure exhaust system clears No. 3 43. Using Crankshaft Damper Replacer
crossmember. Adjust as necessary. T74P-63 1 6-B, · install crankshaft pulley.
Install four nuts and tighten to 27-4 1 N-m (2Q-30
lb-ft).
39. Connect EGR valve to exhaust manifold tube to
RH exhaust manifold and tighten nut to 35-45 N·m
(26-33 1b-ft).
40. Connect fuel charging wiring to the electronic
variable orifice sensor and oil pressure sensor. CRANKSHAFT
4 1 . NOTE: Prior to applying sealer, clean sealing DAMPER REPLACER
T74P-6316-B
specification WSE-M58392-A to remove all 44. Install crankshaft pulley bolt and crankshaft pulley
residues that may interfere with the sealer's retaining washer. Tighten in four steps:
ability to adhere. a. Tighten to 90 N·m (67 1b-ft).
Apply Silicone Gasket and Sealant b. Loosen one full turn.
specification WSE-M4G323-A6 in keyway of c. Tighten to 50 N-m (37 lb-ft).
crankshaft pulley as shown. d. Tighten an additional 90 degrees.
45. Install oil pan with new oil pan gasket as
described .
46. Position power steering pump on engine and
install four retaining bolts. Tighten to 2Q-30 N·m
( 1 5-22 1b-ft).
47. Lower vehicle.
48. Connect fuel charging wiring to the A / C clutch,
crankshaft position sensor and evaporative
emission canister purge valve.
49. Position and connect 42-pin engine harness
connector and 8-pin connector.
50. Position A / C line and install retaining nut.
5 1 . Install positive crankcase ventilation valve in RH
valve cover.
52. Connect front evaporative emission hose to
evaporative emission canister purge valve.
53. Position generator and install two retaining bolts.
Tighten to 2Q-30 N·m ( 1 5-22 lb-ft).
54. Install two bolts retaining generator rear mounting
bracket to intake manifold and tighten to 8- 1 2
N·m (7 1 - 1 06 1b-in).
55. Install water pump pulley and tighten bolts to
CRANKSHAFT 2Q-30 N·m ( 1 5-22 1b-ft).
PULLEY 6312 56. Position ignition coil brackets, ignition wires and
ignition wire separator onto mounting stud bolts.
57. Install nuts retaining ignition coil brackets to
engine front cover. Tighten to 2Q-30 N·m ( 1 5-22
SEALER lb-ft).
KEYWAY 58. Install LH ignition coil and ignition wire assembly.
59. Connect fuel charging wiring to both ignition coils
and camshaft position sensor.
60. Position and install power steering oil reservoir.
VIEW A
6 1 . Connect ignition wires to spark plugs and install
A18921-B ignition wire separators onto valve cover studs.
Refer to Section 03-078.
sure crankshaft key and keyway are aligned. 62. Install drive belt. Refer to Section 03-05.

03-01 8-46 Engine, 4.6L (2V) 03-01 8-46

�
63. Install windshield wiper governor. Refer to 5. Install drive belt. Refer to Section 03-Q5.
Section 0 1 · 16. 6. Install cooling fan motor /fan blade, fan shroud
64. Connect fuel lines. Refer to Section 1 o-o 1 . assembly and fill engine cooling system. Refer to
65. Install cooling fan motor /fan blade and fan shroud Section 03-Q3.
assembly. Fill engine cooling system. Refer to 7. Check tor leaks.
Section 03-03.
03· 12.
Intake Manifold
68. Check and add engine oil as needed. Removal
69. Start engine and check tor leaks. 1. Disconnect battery ground cable ( 1 430 1 ). Refer
2. Drain engine cooling system.
3. Relieve fuel system pressure and disconnect fuel
Water Pump lines. Refer to Section 1 0-Q 1 .
Removal 4. Remove air cleaner outlet tube (98659). Refer to
1. Drain engine cooling system, remove cooling fan Section 03- 1 2 .
motor I tan blade (8600) and fan shroud (81 46) 5. Release drive belt tensioner (68209) and remove
assembly. Refer to Section 03-Q3. drive belt (8620). Refer to Section 03-Q5.
2. Release drive belt tensioner (68209) and remove 6. CAUTION: Do not pull on Ignition wire as wire
drive belt (8620). Refer to Section 03-05. may separate from the connector in the
3. Remove four bolts retaining water pump pulley Ignition wire boot.
(8509) to water pump (850 1) and remove water Disconnect all ignition wires from spark plugs
pump pulley. ( 1 2405). Refer to Section 03-Q78.
4. Remove tour bolts retaining water pump to engine 7. Disconnect ignition wires and ignition wire
(6007} and remove water pump. separators ( 1 2297) from valve cover stud bolts.
sensor (CMP sensor)(68288).
9. Remove four bolts retaining ignition coil to ignition
coil brackets.
10. Disconnect generator wiring harness from
junction block at front fender apron ( 1 6054) and
from generator (GEN)( 10300).
1 1 . Remove four bolts retaining generator mounting
bracket ( 1 0 1 53) to intake manifold (9424).
1 2. Remove bolts retaining generator to cylinder
blocks (60 10) and remove generator.
BOLT 1 3. Raise vehicle on a hoist.
4 REQ"D
TIGHTEN TO WATER PUMP 1 4. Disconnect fuel charging wiring from the oil
20-30 N·m 8501 pressure sensor (9278) and electronic variable
(1 5-22 LB-FT) A1481CW> orifice sensor and position fuel charging wiring out
ot the way.
Installation 1 5. Disconnect EGR valve to exhaust manifold tube
1. Replace 0-ring type water pump housing gasket (9D477) from RH exhaust manifold (9430).
(8507) and clean sealing surface of cylinder 16. Lower vehicle.
blocks (60 1 0).
1 7. Disconnect accelerator cable (9A758) and speed
2. Lubricate water pump housing gasket with Ford control actuator cable (9A825) from throttle body
Premium Cooling System Fluid E2FZ- 19549-AA (9E926).
(in Canada, Motorcraft CXG-8-8) or equivalent
meeting Ford specification ESE-M97844·A. 1 8. Remove accelerator cable bracket (9723) from
intake manifold and position out of the way.
3. Position water pump on engine and install four
retaining bolts. lighten to 2Q-30 N·m ( 1 5-22 1b-ft). 1 9. Disconnect vacuum hose from throttle body
adapter vacuum port.
4. Position water pump pulley on water pump and
install four retaining bolts. lighten bolts to 2Q-30 20. Disconnect heater water hose ( 1 8472).
N·m ( 1 5-22 1b-ft).

03-01 8-47 Engine, 4.6L (2V) 03-01 8-47
2 1 . NOTE: Two water outlet connection retaining 22. Remove the remaining nine bolts retaining intake
bolts also retain intake manifold. manifold to cylinder heads {6049) and remove
Remove two bolts retaining water hose intake manifold.
connection {8592) to intake manifold and position
upper radiator hose {8260) and water hose
connection out of the way.
Intake Manifold
e
'�
--
FRONT OF ENGINE
---
I I
0 REFER TO LEGEND
e REMOVE BOLTS IN SEQUENCE A24999-A
Part Part
1 N808130-S309 Bolt (8 Req'd) 4 9424 Intake Manifold
3 N81 101 1 -S309 Bolt (2 Req'd) 6 6049 Cylinder Head, RH
(Continued)
23. Remove intake manifold gaskets {946 1 ).

r
I·
03-01 8-48 Engine, 4.6L (2V) 03-01 8-48
Installation 4. NOTE: Make sure alignment tabs on intake

1. NOTE: If a new intake manifold is being installed, manifold gasket are aligned with holes in cylinder
transfer all necessary components onto new heads.
intake manifold. Install and tighten intake manifold retaining bolts
Clean sealing surfaces of intake manifold and one through nine in sequence shown to 2Q-30 N·m
cylinder heads. ( 1 5-22 1b-ft).
2. Position new intake manifold gaskets on cylinder 5. Replace D-ring seal on water hose connection.
heads. Position water hose connection and upper
radiator hose and install two bolts and tighten to
3. Position intake manifold on cylinder heads. 2Q-30 N·m ( 1 5-22 1b-ft).
Installation Sequence
�
• �
FRONT OF ENGINE
O REFER TO LEGEND
- TIGHTEN BOLTS IN SEQUENCE A24301-A
Part Part
1 N808130·S309 Bolt (8 Req'd) 4 9424 Intake Manifold
3 N81 101 1 -S309 Bolt (2 Req'd) 6 6049 Cylinder Head, RH
(Continued) (Continued)

03-018-49 Engine, 4.6L (2V) 03-018-49
Part
A Tighten to 20-30 N·m ( 1 5-22
Lb-Ft)
6. Connect heater water hose. Exhaust Manifold

7. Connect vacuum hose to throttle body adapter Removal
vacuum port.
1. Disconnect battery ground cable ( 1 430 1 ). Refer
8. Install accelerator cable bracket on intake to Section 1 4-Q 1 .
manifold and connect accelerator cable and
speed control actuator cables to throttle body. 2. On LH exhaust manifold (9430), remove bolt
retaining oil level indicator tube (6754).
9. Raise vehicle.
10. Connect EGR valve to exhaust manifold tube to
RH exhaust manifold and tighten nut to 35-45 N·m 4. Disconnect fuel charging wiring (9D930) from
(26-33 1b-ft). heated oxygen sensors (H02S)(9F472).
1 1 . Connect the fuel charging wiring to the electronic. 5. Remove EGR valve to exhaust manifold tube line
variable orifice sensor and oil pressure sensor. nut from RH exhaust manifold and remove EGR
valve to exhaust manifold tube (9D477).
12. Lower vehicle.
6. Disconnect three way catalytic converter
13. Position generator and install two retaining bolts. (TWC)(5E2 1 2) from RH and LH exhaust
Tighten to 2Q-30 N·m ( 1 5-22 1b-ft). manifold. Refer to Section 09-QO.
14. Install two bolts retaining generator rear mounting 7. Lower three way catalytic converter and secure
bracket to intake manifold and tighten to 8- 1 2 to crossmember with wire in positions shown.
N·m (7 1-106 1b-in).
15. Connect generator wiring harness to generator,
RH front fender apron and junction block. NO. 3 CROSSMEMBER
16. Position ignition wires and ignition wire separators
on engine and install bolts retaining ignition coil to
ignition coil brackets. Tighten bolts to 8- 1 2 N·m
(7 1-106 1b-in).
1 7. Connect all ignition wires to spark plugs. Refer to
Section 03-078.
18. Connect ignition wire separators on valve cover
studs.
19. Connect the fuel charging wiring to both ignition
coils and camshaft position sensor.
20. Install drive belt. Refer to Section 03-Q5.
2 1 . Install air cleaner outlet tube. Refer to Section
03- 1 2.
22. Connect fuel lines. Refer to Section 1 0-Q 1 .
24. Fill and bleed engine cooling system. Refer to NOTE: WIRE BOTH RH AND LH
PIPE TO NO. 3 CROSSMEMBER
Section 03-Q3. A13631·B
25. Check and fill crankcase to specified level with 8. For LH exhaust manifold, disconnect the steering
engine oil meeting Ford specification shaft and position out of the way. Refer to Section
WSS-M2C 1 53-F. 1 1 -Q4.

03-01 8-50 Engine, 4.6L (2V) 03-01 8-50
9. Remove eight nuts retaining LH exhaust manifold 5. Position and connect steering shaft. Refer to
and remove LH exhaust manifold and two Section 1 1-Q4.
exhaust manifold gaskets (9448). 6. NOTE: Loosen line nut at EGR valve (EGR
valve)(9D475) prior to installing assembly into
vehicle. This will allow enough movement to align
EGR valve retaining bolts.
Position and connect EGR valve to exhaust
manifold tube to exhaust manifold. Tighten line nut
to 35-45 N-m (26-33 1b-ft).
7. NOTE: Two through bolts required on LH front
engine support insulator (6038) and one through
bolt required on RH front engine support insulator.
NOTE: Make sure exhaust system clears No. 3
crossmember. Adjust as necessary.
Remove wire and position three way catalytic
converter. Install four nuts and tighten to 27-41
N·m (2Q-30 lb-ft).
NOTE: LH EXHAUST MANIFOLD SHOWN 8. Connect fuel charging wiring to heated oxygen
RH EXHAUST MANIFOLD TYPICAL sensors.
9. Lower vehicle.
1 0. For RH exhaust manifold, remove eight nuts
retaining exhaust manifold to cylinder head 10. Connect battery ground cable.
(6049) and studs and remove RH exhaust 1 1 . Start engine and check for exhaust leaks.
manifold and exhaust manifold gasket.
Installation
1. If RH exhaust manifold is being replaced, transfer Oil Pan/Oil Pump Screen Cover and Tube
EGR valve tube to manifold connector (9F485)
and tighten to 45-65 N·m (34-47 1b-ft). Removal
2. Clean mating surfaces of exhaust manifolds and 1. Disconnect battery ground cable ( 1 430 1). Refer
cylinder heads. to Section 1 4-o 1 .
3. Position exhaust manifold gasket and LH exhaust 2. Remove air cleaner outlet tube (98659). Refer to
manifold to cylinder head and studs and install Section 03- 1 2.
eight retaining nuts. Tighten in sequence to 1 8-22 3. Drain engine cooling system and remove cooling
N·m ( 1 4- 1 6 1b-ft). fan motor I fan blade (8600) and fan shroud
(81 46) assembly. Refer to Section 03-03.
Installation Sequence
4. Relieve fuel system pressure and disconnect fuel
lines. Refer to Section 1 o-o 1 .
5. Remove upper radiator hose (8260).
6. Remove windshield wiper governor ( 1 7C476)
and support bracket. Refer to Section 0 1 - 1 6.
7. Recover air conditioning system. Refer to Section
1 2-oo.
8. Disconnect air conditioning compressor outlet
hose at A / C compressor ( 19703) and remove
bolt retaining hose to RH ignition coil bracket.
9. Remove fuel charging wiring, 42-pin connector
from retaining bracket on power brake booster
NOTE: ENGINE SHOWN REMOVED (2005).
FOR CLARITY 10. Disconnect 42-pin connector and 8-pin connector.
NOTE: LH EXHAUST MANIFOLD SHOWN
RH EXHAUST MANIFOLD SIMILAR
1 1 . Remove EGR backpressure transducer and
AA0637-A disconnect heater water hose ( 1 8472).
4. Position two exhaust manifold gaskets and LH

exhaust manifold to cylinder head and studs and
install eight retaining nuts. Tighten in sequence to
18-22 N·m ( 1 4- 1 6 1b-ft). Refer to above
illustration.

03-018-5 1 Engine, 4.6L (2V) 03-01 8-51
12. Remove stud bolts retaining heater water hose to 1 7 . Raise vehicle on a hoist.
RH cylinder head (6049) and position out of way. 18. Drain engine oil.
1 9. NOTE: Two through bolts required for LH front
engine support insulator and one through bolt
required for RH front engine support insulator.
Remove front engine support insulator through
� bolts.
FRONT OF ENGINE
/" 20. Remove EGR valve to manifold tube nut from RH
exhaust manifold (9430) and remove EGR valve
to exhaust manifold tube.
2 1 . Disconnect three way catalytic converter
(TWCX5E2 1 2) from RH and LH exhaust
manifolds. Refer to Section 09-00.
22. Lower exhaust and secure to crossmember in
positions shown with wire.
NO. 3 CROSSMEMBER
PERPENDICULAR
TO CENTER LINE OF
ENGINE
NOTE: POSITION HOSE

CLAMP AS SHOWN
45 DEGREES
VIEW A
A24302-A
NOTE: WIRE BOTH RH AND LH

Part PIPE TO NO. 3 CROSSMEMBER
Item Number Description A13631-B
1 N807381 Stud Bolt 23. Position a screw-type jackstand and a block of

2 18472 Heater Water Hose wood under oil pan (6675), rearward of oil drain
3 6010 Cylinder Blocks hole.
4 6049 Cylinder Head, RH 24. Raise engine approximately 1 00 mm (4 inches).
A -
Tighten to 20-30 N·m (15-22 25. Insert two wood blocks approximately 60-70 mm
Lb-Ft) (2.5-2. 75 inches) thick under each front engine
support insulator.
13. Remove heater blower motor switch resistor
26. Lower engine onto wood blocks and remove jack
( 18591 ). Refer to Section 1 2-Q3A.
from under oil pan.
14. Remove bolt retaining RH front engine support
27. NOTE: It may be necessary to loosen (DO NOT
insulator (6038) to front sub-frame (5C1 45).
REMOVE) the two nuts on transmission support
15. Disconnect vacuum hose from EGR valve (EGR insulator (6068).
valve)(9D475) and EGR backpressure
With a screw-type jackstand raise the extension
transducer hoses from EGR valve to exhaust
housing (7A039) of the transmission slightly to
manifold tube (9D477).
remove oil pan.
16. Remove two bolts retaining EGR valve to throttle
body adapter.

03-01 8-52 Engine, 4.6L (2V) 03-01 8-52
28. Remove bolts retaining oil pan to engine. Remove · Installation

oil pan. 1. Clean oil pan. Inspect for damage and replace as
required.
2. Clean sealing surfaces of engine front cover
(60 1 9), crankshaft rear oil seal and retainer
(6K30 1 ) and cylinder blocks (60 1 0).
3. Inspect oil pump screen cover and tube and
replace if necessary.
4. If removed, position oil pump screen cover and
tube on oil pump and hand start two bolts.
5. Install bolt retaining oil pump screen cover and
tube to main bearing stud spacer hand-tight.
6. Tighten oil pump screen cover and tube-to-oil
pump bolts to 8- 1 2 N·m (7 1 - 1 06 lb-in). Tighten oil
pump screen cover and tube-to-main bearing stud
spacer bolt to 2Q-30 N·m ( 1 5-22 1b-ft).
WOODEN
BLOCKS A13647-B
BOLT
2 REQ'D
29. If necessary, remove two bolts retaining oil pump TIGHTEN TO
screen cover and tube (6622) to oil pump (6600) 8-12 N·m
and remove bolt retaining oil pump screen cover (71-106 LB-IN)
and tube to main bearing stud spacer. Remove oil
pump screen cover and tube.
BOLT
2 REQ'D
TIGHTEN TO
8-12 N·m
(71-106 LB-IN)
0
BOLT
��
TIGHTEN TO MAIN BEARING OIL PUMP
2G-30 N·m STUD SPACER 6600
(1 5-22 LB-FT) N806180-S AA0759-A
7. Position new oil pan gasket (67 1 0) on oil pan.
0
BOLT
TIGHTEN TO MAIN BEARING OIL PUMP
2G-30 N·m STUD SPACER 6600
(15-22 LB-FT) N806180-S AA0759-A

03-018-53 Engine, 4.6L (2V) 03-o1 B-53

surfaces with Metal Surface Cleaner Part
F4AZ-1 9A536-RA or equivalent meeting Ford Item Number Description
specification WSE-M5B392-A, to remove all B -
Tighten to 1 1 - 1 6 N·m (9-1 1
residues that may interfere with the sealer's Lb-Ft)
ability to adhere.
9. Position screw-type jackstand and block of wood
under oil pan, rearward of oil pan drain hole.
F6AZ- 19562-AA or equivalent meeting Ford
specification WSE-M4G323-A6 where engine 10. Raise engine enough to remove wood blocks.
front cover meets cylinder blocks and crankshaft
rear oil seal retainer meets cylinder blocks.
Position oil pan on engine and install retaining
bolts. lighten bolts in sequence shown to 20 N·m
(14 1b-ft, then an additional 60 degrees) in no
more than four minutes after applying sealer.
e TIGHTEN BOLTS IN SEQUENCE
0 REFER TO LEGEND
0
WOODEN
BLOCKS A13647-B
1 1 . Lower engine onto fro• engine support insulator

and remove jack.
12. NOTE: Two through bolts required on LH front
engine support insulator and one through bolt
required on RH front engine support insulator.
Install front engine support insulator through bolts
and tighten to 2Q-30 N·m ( 1 5-22 1b-ft).
1 3. NOTE: Loosen nut at EGR valve prior to installing
assembly into vehicle. This will allow enough
movement to align EGR valve retaining bolts.
Position EGR valve to exhaust manifold tube in
vehicle and connect to exhaust manifold. lighten
line nut to 35-45 N·m (26-33 lb-ft).
14. NOTE: Make sure exhaust system clears No. 3
/ crossmember. Adjust as necessary.
FRONT OF
ENGINE Remove wire and position exhaust system to both
exhaust manifolds. Install tour nuts and tighten to
/ 27-4 1 N·m (2Q-30 lb-ft).
A14940-D 15. Replace oil bypass filter (67 1 4) as described.
1 6. Lower vehicle.
Part 1 7. Install bolt retaining RH front engine support
Item Number Description insulator to front sub-frame. lighten to 2Q-30 N·m
( 1 5-22 1b-ft).
1 6675 Oil Pan
1 8. Install a new EGR valve gasket (90476) on EGR
2 6010 Cylinder Blocks valve and position on throttle body adapter.
3 67 10 Oil Pan Gasket 19. Install two bolts retaining EGR valve to intake
4 W70 1240-5309 Bolt (16 Req'd) manifold (9424) and tighten to 2Q-30 N·m ( 1 5-22
5 6730 Oil Pan Drain Plug lb-ft).
-
A Tighten to 20 N·m (15 Lb-Ft
Then an Additional 60
Degrees)
(Continued)

03-01 8-54 Engine, 4.6L (2V) 03-o1 B-54
20. lighten EGR valve-to-exhaust manifold tube nut at 26. Connect A / C compressor to condenser
EGR valve to 35-45 N·m (26-33 lb-ft). discharge line ( 1 9972) to A I C compressor and
install bolt retaining hose to RH ignition coil
bracket.
27. Install upper radiator hose.
28. Connect fuel lines. Refer to Section 10-Q 1 .
29. Install windshield wiper governor and retaining
bracket. Refer to Section 0 1 - 1 6.
30. Fill crankcase to specified level on oil level
dipstick (6750) with engine oil meeting Ford
specification WS8-M2C 1 53-F.
3 1 . Evacuate and recharge air conditioning. Refer to
Section 1 2-oo.
32. Install cooling fan motor /fan blade and fan shroud
assembly and fill engine cooling system. Refer to
Section 03-Q3.
03- 1 2 .
Oil Pump
Removal
1. Remove valve covers (6582), engine front cover
(60 1 9), oil pan (6675) and oil pump screen cover
Part and tube (6622) as described.
Item Number Description 2. Remove timing chain as described.
1 90475 EGA Valve 3. Remove four bolts retaining oil pump (6600) to
2 9430 Exhaust Manifold, RH cylinder blocks (60 10). Remove oil pump.
3 9F485 EGA Valve Tube to Manifold
Connector
4 90477 EGA Valve to Exhaust
Manifold Tube
-
5 EGA Backpressure
Transducer Hoses (Part of
9J460)
6 9J460 EGA Backpressure BOLT
Transducer 4 REQ'O
-
A Tighten to 45-65 N-m (33-47 TIGHTEN TO
Lb-Ft) 8-12 N·m
(71-106 LB-IN) ,
� FRONT /
-
8 Tighten to 35-45 N-m (26-33 CYLINDER BLOCK
Lb-Ft) 6010
OF
2 1 . Install heater blower motor switch resistor with ENGINE
two retaining screws. Refer to Section 1 2-Q3A. /
22. Install EGR backpressure transducer bracket and A14816-D
heater water hose. Install upper bolt and lower
stud bolt. lighten to 2Q-30 N·m ( 1 5-22 lb-ft). Installation
23. Connect vacuum hoses to EGR valve and EGR 1. Rotate inner rotor of oil pump to align with flats on
backpressure transducer hoses to EGR valve to crankshaft (6303) and install oil pump flush with
exhaust manifold tube. cylinder blocks.
24. Connect heater water hose. 2. Install four retaining bolts and tighten to 8- 1 2 N-m
25. Connect 42-pin connector and 8-pin connector. (7 1 - 1 06 1b-in).
3. Replace oil filter (673 1 ) as described.
4. Install timing chain as described.

03-018-55 Engine, 4.6L (2V) 03-018-55
5. Install engine front cover, oil pump screen cover 5. Remove oil pump and oil pump screen cover and
and tube, oil pan and valve covers as described. tube (6622).
6. Fill engine to specified level on oil level dipstick
(6750) with engine oil meeting Ford specification
WS5-M2C 1 53-F.
Pistons and Connecting Rods

Removal
1. Remove RH and LH cylinder heads (6049) as
described.
2. Remove and discard head gaskets (605 1 ).
3. If cylinder heads are to be serviced, refer to
Subassemblies, Cylinder Head in Disassembly
and Assembly.
4. Remove oil pan (6675) and oil pan gasket (67 10)
as described.
FRONT OF
/
/
ENGINE
A24303-A
Part
1 N806 180-S Stud Spacer
2 N605904-S Bolt
3 6622 Oil Pump Screen Cover and
Tube
/ 4 6354 Crankshaft Main Bearing
FRONT OF Cap Stud
ENGINE
/ A13653-B 6 N806 1 83 Bolt (4 Req'd)
7 6600 Oil Pump
Part 8 3Z728 0-Ring
Item Number Description 9 N806 1 55-S2 Bolt (2 Req'd)
1 W701240-S309 Bolt (16 Req'd) A -
Tighten to 20-30 N·m ( 1 5-22
2 6730 Oil Pan Drain Plug Lb-Ft)
-
3 6675 Oil Pan B Tighten to 8- 12 N-m (7 1-106
Lb-ln)
4 6710 Oil Pan Gasket
-
A Tighten to 20 N·m ( 1 5 Lb-Ft)
-
B Tighten to 1 1 - 16 N·m (9- 1 1
Lb-Ft)

03-01 8-56 Engine, 4.6L (2V) 03-o1B-56
6. NOTE: Pistons (6 1 08), connecting rods (6200) Installation

and connecting rod bearings (62 1 1) should be 1. Coat piston bores, pistons and rings, crankshaft
numbered to make sure they are assembled in journal and bearing surfaces with clean engine oil.
their original positions.
2. CAUTION: Be sure not to scratch cylinder
NOTE: Before removing pistons, inspect the top wall or crankshaft journal with connecting
of the cylinder bores. If necessary, remove the rod. Push piston down until connecting rod
ridge and I or carbon deposits from each cylinder bearing seats on crankshaft journal.
using Rotunda Cylinder Ridge Reamer
0 1 4-Q0292 or equivalent as described in Section NOTE: Make sure piston ring gaps are rotated 30
03-QO. degrees apart.
Turn crankshaft (6303) until piston to be removed NOTE: Notch on piston to front of engine.
is at the high point of its travel. If more than one Turn crankshaft until the crankshaft throw is at
piston is being removed, identify the pistons, bottom of stroke. Install correctly numbered
connecting rods and connecting rod caps for piston and connecting rod assemblies with Piston
cylinder position. Ring Compressor 081 L-6002-C or equivalent and
7. CAUTION: Care should be taken not to a suitable connecting rod guide tool.
damage the fractured rod and cap joint face
surfaces. Possible damage to the engine
may occur.
NOTE: Connecting rod bolts (62 1 4) are retained
in the bolt hole with a light press fit. The
connecting rod bolts have been torqued to yield
at least twice and must be discarded. Use a
hammer and punch to drive connecting rod bolts
from connecting rod cap.
Remove the connecting rod cap and lower
connecting rod bearing. Keep cap and lower
connecting rod bearing together. Push the piston
connecting rod assembly and upper connecting
rod bearing through the top of the cylinder bore.
Use care to prevent damage to the bearing and
cylinder bore surfaces. Keep upper connecting
rod bearing and connecting rod together.
DRIVE BOLTS OUT

USING HAMMER AND PUNCH
/
FRONT OF
ENGINE NOTCH TOWARD
/ FRONT OF ENGINE
AA0633-A
Part
1 62 14 Connecting Rod Bolt (16
SUPPORT BEARING Req'd)
CAP WHILE -
REMOVING BOLTS 2 Cap (8 Req'd) (Part of 6200)
A15051·B
3 62 1 1 Connecting Rod Bearing,
8. Using a new connecting rod bolt, attach cap and Lower (8 Req'd)
lower connecting rod bearing to connecting rod 4 6303 Crankshaft
and upper bearing to prevent mixing parts and 5 62 1 1 Connecting Rod Bearing,
damaging the fractured joint face surfaces. Upper (8 Req'd)
9. Clean and inspect piston, connecting rod, 6 6 108 Piston (8 Req'd)
connecting rod bearings and cylinder block bores 7 6200 Connecting Rod (8 Req'd)
as described in Section 03-QO.
8 08 1L-6002-C Piston Ring Compressor Tool
10. If required, disassemble piston from connecting
rod as described.
9 T93P-6 136-A Connecting Rod Guide Tool
(Continued)
1 1 . If required, replace piston rings as described.

03-01 8-57 Engine, 4.6L (2V) 03-018-57
Part
-
Lb-Ft), Then rotate an
additional 9Q-1 20 degrees
3. NOTE: Due to the use of a cracked connecting
rod joint face surface, the connecting rod cap
must be properly aligned to the connecting rod.
The connecting rod and connecting rod eap
bearing tangs should be located on the same side
of the connecting rod.
Alternately tighten new connecting rod cap bolts
in several passes to obtain 4Q-45 N·m (3Q-33
lb-ft) and rotate connecting rod bolts an additional
9Q-120 degrees. After installation, rotate
crankshaft to ensure smooth operation.
4. Check connecting rod side clearance using Dial
Indicator with Bracketry TOOL-420 1-c or
equivalent. Clearance should be 0 . 1 5-Q.45 mm
(0.006-Q.O 1 77 inch). If side clearance is greater
than maximum service limit of 0.50 mm (0.020
inch), replace connecting rods and I or
crankshaft.
DIAL
FRONT?
INDICATOR
WITH BRACKETRY
TOOL-4201-C
/
ENGINE
A24303-A
Part
2 N605904-S Bolt
5. NOTE: Install new 0-ring on oil pump screen Tube
cover and tube and then start all bolts on oil pump
(6600) and oil pump screen cover and tube
4 6354 Crankshaft Main Bearing
Cap Stud
before tightening.
5 60 10 Cylinder Blocks
Install oil pump screen cover and tube.
6 N606021 -S Bolt (4 Req'd)
7 6600 Oil Pump
8 N80738-S96 0-Ring
9 N806 1 55-S2 Bolt (2 Req'd)
-
Lb-ln)
-
B Tighten to 8- 1 2 N·m (7 1-106
Lb-ln)

03-018-58 Engine, 4.6L (2V) 03-018-58
6. Install oil pan with new oil pan gasket as

described.
RH HEAD
GASKET
6051
A13854-8
9. NOTE: RH and LH head gaskets are not

interchangeable.
Position new head gaskets on cylinder head.
10. CAUTION: Failure to position crankshaft as
shown will cause damage to pistons and/ or
valve train components.
NOTE: With crankshaft in this position, no piston
will be at top dead center (TDC).
Rotate crankshaft to position as shown.
./
FRONT OF
ENGINE
/ A13653-B
Part
1 W70 1240-5309 Bolt (16 Req'd)
2 6730 Oil Pan Drain Plug
3 6675 Oil Pan
5 6010 Cylinder Blocks CRANKSHAFT
-
KEYWAY A13655-B
A Tighten to 20 N·m (15 Lb-Ft,
Then Rotate Bolts an
Additional 50 Degrees) 1 1 . CAUTION: Use care when positioning
-
cylinder heads. Damage to cylinder blocks
B Tighten to 1 1-16 N·m (9- 1 1 (601 0) or cylinder heads may result.
Lb-Ft)
Install cylinder heads as described.
Disassembly and Assembly, Subassemblies,
Cylinder Head.
8. CAUTION: Do not use sandpaper coarser Connecting Rod Bearings
than 600 grit as damage to the cylinder head
gasket surface may occur. Removal
Clean cylinder head gasket surface with a 1. Remove oil pan (6675) and oil pump screen cover
toluene-based paint thinner or gasket remover. If and tube (6622) as described.
gasket material remains on head after cleaning, 2. NOTE: Connecting rod caps, connecting rods
use a 600 grit sandpaper to remove remai�ing (6200) and connecting rod bearings (62 1 1)
material. should be numbered to make sure they are
assembled in their original positions.
Turn crankshaft (6303) until connecting rod
bearing to be removed is accessible. If more than
one connecting rod bearing is being removed,
identify the connecting rod caps, connecting rods
and connecting rod bearings for cylinder position.

03-018-59 Engine, 4.6L (2V) 03-01 8-59
3. Remove the connecting rod cap, lower 5. Install connecting rod caps and alternately tighten
connecting rod bearing and upper connecting rod new connecting rod cap bolts in several passes
bearing. Keep cap and connecting rod bearings to obtain 40-45 N·m {30-33 1b-ft) and rotate
together. Use care to prevent damage to the connecting rod bolts an additional 90- 1 20
bearing and cylinder bore surfaces. degrees. After installation, rotate crankshaft to
4. CAUTION: Care should be taken not to ensure smooth operation.
damage the cracked rod and cap joint face 6. Check connecting rod side clearance using Dial
surfaces. Damage to the engine may occur. Indicator with Bracketry TOOL-420 1-C or
Connecting rod bolts {62 1 4) are retained in the equivalent. Clearance should be 0. 1 5..0.45 mm
connecting rod cap hole with a light press fit. The {0.006..0.0 1 77 inch). If side clearance is greater
connecting rod bolts have been torqued to yield than maximum service limit of 0.50 mm {0.020
at least twice and must be discarded. Use a inch), replace connecting rods and I or
hammer and punch to drive connecting rod bolt crankshaft.
from connecting rods.
DIAL
INDICATOR
DRIVE BOLTS OUT WITH BRACKETRY
USING HAMMER AND PUNCH TOOL-4201 -C
SUPPORT BEARING 7. Install oil pump screen cover and tube and oil pan
CAP WHILE with new oil pan gasket {67 1 0) as described.
REMOVING BOLTS A15051-B
5. Inspect the connecting rods, connecting rod caps

and crankshaft as described in Section 03-00. Flywheel
Installation Removal
1. Clean crankshaft connecting rod journals with a 1. Remove transmission. Refer to Section 07..0 1 .
clean cloth. 2. Remove six bolts retaining flywheel {6375) to
2. Lubricate crankshaft and connecting rod bearing crankshaft {6303) and remove flywheel.
surfaces with clean engine oil meeting Ford
specification WS8-M2C 1 53-F.
3. CAUTION: Be sure not to scratch cylinder
wall or crankshaft journal with connecting
rod. Pull piston (6 1 08) down until connecting
rod bearing seats on crankshaft journal.
Install upper connecting rod bearings in the
connecting rod cap(s). Align retaining tang of
connecting rod bearing with notch in connecting
rod.
4. NOTE: Due to the use of a cracked connecting
rod joint face surface, the connecting rod cap
must be properly aligned to the connecting rod.
The connecting rod and connecting rod cap BOLT . /
bearing tangs should be located on the same side 6 REQ'D FRONT OF
of the connecting rod. TIGHTEN TO ENGINE
73-87 N·m FLYWHEEL /
Install lower connecting rod bearings in the (54-64 LB-FT) 6375 A24304-A
connecting rod cap(s). Align retaining tang of
connecting rod bearing with notch in connecting Installation
rod cap.
1. Position flywheel on crankshaft and install six
retaining bolts. lighten in alternating sequence to
73-87 N·m {54-64 lb-ft).

03-01 8-60 Engine, 4.6L (2V) 03-018-60
2. Check flywheel runout, if necessary. Refer to

Section 03-00. CYUNDER BLOCK
6010
3. Install transmission. Refer to Section 07-Q 1 .
ANAEROBIC GASKET
COMPOUND SEALER
MEETING FORD
Crankshaft Rear Oil Seal SPECIFICATION
WSK-M2G348-A9
NOTE: A one-piece crankshaft rear oil seal (670 1 ) is
used for replacement on all engines. If replacement is AA0629-A
necessary, this type of crankshaft rear oil seal MUST
BE used. The complete crankshaft rear oil seal can be 3. Install crankshaft rear oil seal retainer and tighten
replaced without removing the crankshaft (6303). bolts in sequence shown to 8- 1 2 N·m (7 1-106
I b-in).

Slide Hammer T50T- 1 00-A
Rear Crankshaft Slinger Remover T95P-670 1 -AH
Rear Crankshaft Seal Remover T95P-670 1 -EH
Rear Crankshaft Seal Adapter T95P-6701-DH
Rear Crankshaft Seal Replacer T95P-670 1 -BH
Rear Crankshaft Slinger Replacer T95P-6701-CH 4. Install new crankshaft rear oil seal using Rear
Main Seal Replacer T95P-670 1-BH and Rear
Removal Crank Seal Replacer Adapters T95P-6701 -DH.
1. Remove transmission from vehicle. Refer to
Section 07-0 1 . REAR CRANKSHAFT SEAL ADAPTER
2. Remove flywheel (6375). T95P-6701-DH
3. Remove crankshaft oil slinger (63 1 0) using Rear
Crankshaft Slinger Remover T95P-670 1-AH and
Slide Hammer T50T- 1QO-A.
CRANKSHAFT
4. Remove crankshaft rear oil seal using Rear REAR MAIN
Crankshaft Seal Remover T95P-6701 -EH and SEAL
Slide Hammer T50T- 1 0Q-A. 6701
5. If required, remove crankshaft rear oil seal
retainer (6335).
Installation
1. Clean and inspect crankshaft rear oil seal retainer
and retainer-to-cylinder block mating surfaces.
REAR CRANKSHAFT SEAL REPLACER
T95P-6701-BH
2. NOTE: Prior to applying sealer, clean sealing AA0243-A
ability to adhere.
NOTE: Crankshaft rear oil seal retainer must be
installed and bolts tightened to specification
within five minutes of sealer application.
Apply a 2.0 mm (0.08 inch) continuous bead of
Anaerobic Gasket Compound Sealer or
WSK-M2G348-A9 to cylinder blocks (60 1 0) as
shown.

03-01 8-61 Engine, 4.6L (2V) 03-01 8-6 1
5. Install crankshaft oil slinger using Rear 5. If removal of the oil filter adapter is required,
Crankshaft Slinger Replacer T95P-6701-cH. proceed with the following:
a. Disconnect the engine control sensor wiring
REAR CRANKSHAFT OIL SLINGER ( 1 2A58 1 ) from the oil pressure sensor
6310 (9278).
REAR CRANKSHAFT SEAL ADAPTER b. Drain the cooling system as described in
T95P-6701-DH Section 03-Q3.
c. Disconnect the lower radiator hose (8286)
from the oil filter adapter. Refer to Section
03-Q3.
d. Remove the oil filter adapter retaining bolts,
oil filter adapter and oil filter adapter gasket
(6840).
e. Clean and inspect the sealing surfaces of the
oil filter adapter gasket and cylinder blocks
(60 1 0).
Installation
REAR CRANKSHAFT SLINGER REPLACER 1. If only the oil bypass filter was removed, go to
T95P-6701 -CH Step 2. If removal of the oil filter adapter was
required, proceed with the following:
T95P-6701-BH AA0244-A a. Install new oil filter adapter gasket, oil filter
adapter and retaining bolts. Tighten bolts to
6. Install flywheel. 2Q-30 N-m (1 5-22 1b-ft).
7. Install transmission. Refer to Section 07-o 1 . b. Install the lower radiator hose onto the oil
filter adapter. Install the hose clamp
securely. Refer to Section 03-D3.
c. Connect the engine control sensor wiring to
Oil Bypass Filter I Adapter the oil pressure sensor.
Removal 2. NOTE: The oil bypass filter has a 22 mm metric
1. Raise vehicle on a hoist. thread and an anti-drain back valve. Make sure
the replacement oil bypass filter is equipped with
2. Position a drain pan under oil bypass filter (67 1 4). a 22 mm metric thread and the anti drain-back
3. Unscrew the oil bypass filter from oil filter adapter valve.
(688 1 ) using an oil filter wrench. Coat rubber seal of oil bypass filter with clean
4. Clean the sealing surface of oil filter adapter. engine oil meeting Ford specification
WS8-M2C 1 53-F.
3. Install oil bypass filter on oil filter adapter until
rubber seal contacts sealing surface of oil filter
adapter.
4. Tighten an additional three-quarter turn after seal
contact.
5. Lower vehicle.
6. Check oil level and fill to specified level with
engine oil meeting Ford specification
WS8-M2C 1 53-F.
7. If required, fill cooling system as described in
NOTE: LUBRICATE SEAL Section 03-D3 and bleed engine.
WITH CLEAN ENGINE OIL
MEmNG FORD 8. Start engine and check for leaks.
SPECIFICATION
wss-M2C91D-A1 AND
TIGHTEN 314 TURN
AFTER SEAL CONTACT AA0630-A
Oil Level Indicator Tube
Removal
1. Remove LH front engine support insulator (6038)
as described in Section 02-Q3.

03-0 18-62 Engine, 4.6L (2V) 03-018-62
2. Remove nut retaining oil level indicator tube Sens ors

(6754) to cylinder head (6049) and remove oil
level indicator tube. Oil Pressure Sensor
1. Disconnect fuel charging wiring (9D930) from oil
pressure sensor (9278).
2. Remove oil pressure sensor from oil filter adapter
(688 1 ).
3. To install, reverse Removal procedure. lighten oil
pressure sensor to 1 6-24 N·m ( 1 2- 1 7 lb-ft).
Engine

Spring Lock Coupling Disconnect Tool T8 1P·19623·G1
(3 / S inch)
Spring Lock Coupling Disconnect Tool T81P-19623·G2
( 1 1 2 1nch)
--
FRONT OF ENGINE Removal
---
2. Drain engine cooling system. Refer to Section
03-Q3.
3. Remove air cleaner outlet tube (98659) and
engine air cleaner (ACLX9600). Refer to Section
03- 1 2.
4. Recover air conditioning system. Refer to Section
1 2-0Q.
A24305-A
5. Remove cooling fan motor I fan blade (8600) and
fan shroud (8 1 46) assembly. Refer to Section
Part 03-Q3.
Item Number Description 6. Relieve fuel system pressure and disconnect fuel
1 6582 Valve Cover, LH lines. Refer to Section 1 o-o 1 .
2 N805320 Nut 7. Disconnect fuel charging wiring 42-pin connecter
3 6754 Oil Level Indicator Tube and 8-pin connector and position out of the way.
4 6010 Cylinder Blocks 8. Disconnect accelerator cable (9A758) and speed
A -
Tighten to 8-1 2 N·m (7 1-106 control actuator cable (9A825).
Lb-ln) 9. Disconnect fuel charging wiring (9D930) and
front evaporative emission hose from evaporative
Installation
emission canister purge valve (EVAP canister
1. Inspect Q-ring and replace as needed. purge valveX9C9 1 5).
2. Lubricate Q-ring with engine oil meeting Ford 10. Disconnect positive battery cable from power
specification WSS-M2C 1 53-F and route oil level distribution box.
indicator tube through exhaust manifold (9430)
1 1 . Disconnect body vacuum supply hose from main
and into cylinder blocks (60 1 0).
emission vacuum control connector (9E498).
3. Fully seat tube into cylinder blocks and install
1 2 . Disconnect transmission oil cooler tubes from
retaining nut. lighten to 8- 1 2 N·m (7 1 · 1 06 1b-in).
transmission oil cooler.
4. Install LH front engine support insulator as
1 3. Disconnect upper radiator hose (8260) from
described.
radiator (8005).
1 4. Disconnect heater supply and return hoses.

03-01 8-63 Engine, 4.6L (2V) 03-01 8-63
15. Disconnect air conditioning compressor inlet and 30. Loosen rear differential bracket to body bolts and
outlet hoses from A I C compressor ( 1 9703) using lower.
Spring Lock Coupling Disconnect Tool (3 I 8 inch) 3 1 . Slide driveshaft (4A376) rearward until it is free
T8 1 P- 19623-G 1 and ( 1 I 2 inch) T8 1 P-1 9623-G2. of extension housing (7A039).
32. Remove lower radiator hose (8286) from
radiator.
33. Loosen spring clamps and remove power
steering hoses from power steering fluid cooler
(3D746) . .
34. Disconnect wiring connector bulkhead (7G276).
35. Support front sub-frame (5C 1 45) using Rotunda
Powertrain Lift 0 1 4-Q0765 and Adapter
0 1 4-D034 1 or equivalent.
SPRING LOCK OUTLET

COUPLING DISCONNECT HOSE
TOOL
T81 P-19623-G1 AND
T81P-1 9623-G2 A14802·B
16. Disconnect engine to frame wire ( 14324) from

dash panel (0 1 6 1 0).
17. Partially raise vehicle on a hoist.
18. Remove front wheels and tires. Refer to Section
04-Q4.
19. Disconnect RH and LH front anti-lock sensor and
brackets wiring connectors.
20. Remove RH and LH front disc brake caliper bolts.
Remove disc brake calipers (28 1 20) and support
to vehicle using wire.
2 1 . Disconnect RH and LH front suspension upper
arms from .
22. Disconnect front spring and shocks (3C098) from A1�A
front suspension lower arms (3079).
36. Remove rear engine support insulator retaining
23. Raise vehicle. bolts.
24. Drain engine oil . 37. Disconnect steering coupling at pinch bolt joint.
25. Disconnect dual converter Y pipe (5F250) from 38. Remove eight front sub-frame retaining bolts.
RH and LH exhaust manifolds (9430). Refer to
Section 09-QO. 39. Lower engine and transmission from vehicle.
26. Disconnect shift cable and bracket (7E395). 40. Disconnect power steering pressure hose
(3A7 1 9) and power steering return hose (3A7 1 3)
27. Index driveshaft centering socket yoke (4782) to from the power steering pump (3A674).
rear axle universal joint flange (485 1 ).
4 1 . Remove engine wire harness retainers from front
28. Remove four bolts connecting driveshaft sub-frame.
centering socket yoke to rear axle universal joint
flange. Support rear axle assembly (4200) with 42. Remove LH and RH front engine support insulator
jackstand. through bolts.
29. Remove two nut and bolt assemblies retaining the

front of the rear axle assembly to the rear
sub-frame.

03-01 8-64 Engine, 4.6L (2V) 03-01 8-64
43. NOTE: Attach Rotunda Engine Lift Bracket Set

0 14-Q0334 or equivalent using two M- 1 2 x 1 . 75 x Part
20 mm bolts. Item Number Description
Install engine lifting eye from Rotunda Engine Lift 5 6049 Cylinder Head, LH
Bracket Set 0 1 4-Q0334 or equivalent on side of -
LH cylinder head (6049) at front as shown. Install Lb-Ft)
engine lifting eye from Rotunda Engine Lift
Bracket Set 0 14-Q0334 or equivalent on side of 44. Connect Rotunda Floor Crane 0 1 4-Q007 1 or
RH cylinder head at r&ar as shown. equivalent to the lift brackets.
45. Raise engine and transmission assembly and
carefully separate engine from front sub-frame.
,.....
FRONT OF 46. Remove starter motor ( 1 1 002). Refer to Section
ENGINE 03-Q6.
_......-
4 7. Remove transmission oil cooler tubes. Refer to
Section 07-Q2.
48. Remove retaining nut from transmission line stud
to cylinder blocks (60 1 0) ..
49. Remove transmission housing cover (7986) from
cylinder blocks to gain access to torque
converter retaining nuts. Rotate crankshaft
(6303) until each nut (four required) is accessible .
and remove nuts.
50. Lower engine and transmission assembly to a
level, stationary surface.
5 1 . Disconnect transmission wire harness
connectors at transmission.
52. Remove six bolts retaining transmission to
engine. Separate engine from transmission.
53. Position engine on a work stand.
54. Remove engine lifting equipment.
Installation
1. Install Rotunda Engine Lifting Bracket Set
0 1 4-00334 or equivalent in positions shown in
above illustration.
2. Connect floor crane to lifting brackets and
remove engine from work stand.
3. Carefully lower engine and transmission to a level
and stationary surface.
4. NOTE: Make sure studs on torque converter
(7902) align with holes in flywheel (6375).
-- Start torque converter pilot into flywheel and align
FRONT OF
--- ENGINE paint marks on flywheel and torque converter.
AA0631-A 5. Fully engage engine to transmission and install six
retaining bolts. Tighten bolts to 4Q-60 N·m (3Q-44
lb-ft).
Part
Item Number Description 6. NOTE: Rotate crankshaft until each nut (four
required) is accessible.
1 6049 Cylinder Head, RH
Install four torque converter retaining nuts.
2 1B198A RH Engine Lift Eye (Part of Tighten to 3Q-35 N·m (23-25 1b-ft).
Rotunda Engine Lift Bracket
Set) 7. Install transmission housing cover to cylinder
3 N81 1 187-M 12 X Bolt (2 Req'd Each Side) blocks.
1 .5 X 40 8. Install starter motor. Refer to Section 03-06.
4 18198A LH Engine Lift Eye (Part of 9. Position transmission case to cylinder block
Rotunda Engine Lift Bracket brackets and install three bolts and one stud.
Set)
Tighten bolts and stud to 25-43 N·m ( 1 9-3 1 1b-ft).
(Continued)

03-018-65 Engine, 4.6L (2V) 03-G1B-65
10. Position transmission oil cooler tube bracket to 27. lighten two rear axle differential insulator nuts to
transmission case to cylinder block bracket stud 1 02- 1 27 N·m (76-93 1b-ft).
and install retaining nut. lighten to 2Q-30 N·m 28. Align driveshaft centering socket yoke to rear
(1 5-22 1b-ft). axle universal joint flange and install four retaining
1 1 . Install transmission oil cooler tubes to bolts. lighten to 95- 1 30 N·m (7Q-95 lb-ft).
transmission. Refer to Section 07-Q2. 29. Connect transmission shift linkage. Refer to
12. Connect transmission wire harness connector to Section 07-Q 1 .
transmission. 30. Position front suspension lower arms to front
13. Raise engine and transmission assembly with spring and shock and install retaining bolt. lighten
Rotunda Floor Crane 077-Q0043 or equivalent. to 1 6Q-220 N-m ( 1 1 8- 1 62 1b-ft).
14. Carefully lower engine and transmission 3 1 . Install lower radiator hose.
assembly onto front sub-frame. 32. Connect power steering hoses to power steering
15. Install LH and RH front engine support insulator oil cooler. Refer to Section 1 1 -Q2.
through bolts. lighten through bolts to 2Q-30 N·m 33. Connect engine to frame wire to dash panel.
( 1 5-22 1b-ft).
34. Install dual converter Y pipe. Refer to Section
16. Install engine wire harness retainers to front 09-QO.
sub-frame.
35. Connect front suspension upper arms to front
17. Install power steering pressure hose and power wheel knuckles (3K 1 85). lighten to 68-92 N·m
steering return hose to power steering pump. (5 1-67 1b-ft).
18. Remove lift bracket from cylinder heads. 36. Connect front anti-lock sensor and brackets
19. Raise engine, transmission and front sub-frame wiring connectors.
using Rotunda Powertrain Lift 0 1 4-Q0765 and 37. Install disc brake calipers. Refer to Section
Adapter 0 1 4-0034 1 or equivalent into vehicle. 06-Q3.
38. Install front wheels and tires. Refer to Section
04-Q4.
39. Lower vehicle.
40. Connect A I C lines to A I C compressor. Refer to
Section 1 2-Q3B.
4 1 . Install transmission oil cooler tubes to
transmission fluid cooler (7A095). Refer to
Section 07-Q2.
42. Install upper radiator hose to radiator.
43. Connect heater supply and return hoses.
44. Connect body vacuum supply hose to main
emission vacuum control connector adapter
vacuum port.
45. Connect positive battery cable to power
distribution box.
46. Connect fuel charging wiring and front
ROTUNDA evaporative emission hose to evaporative
POWERTRAIN LIFT emission canister purge valve.
01�765
A18848-A 47. Connect accelerator cable and speed control
actuator cable to the throttle body (9E926).
20. Align front sub-frame to body and install 48. Connect 42-pin and 8-pin fuel charging wiring
sub-frame-to-body bolts. lighten to 95- 1 30 N·m connectors.
(7Q-96 1b-ft).
49. Connect fuel lines. Refer to Section 10-Q 1 .
2 1 . Connect steering coupling at pinch bolt joint.
50. Install cooling fan motor I fan blade and fan
22. Install rear engine support insulator retaining shroud. Refer to Section 03-Q3.
bolts. lighten to 2Q-30 N·m ( 1 5-22 1b-ft).
5 1 . Install air cleaner outlet tube and engine air
23. Remove powertrain lift and position out of way. cleaner. Refer to Section 03- 1 2.
24. Install driveshaft to transmission. 52. Fill and bleed engine cooling system. Refer to
25. Lift rear axle assembly into position. Section 03-Q3.
26. Install two nut and bolt assemblies retaining front 53. Evacuate and recharge air conditioning system.
of the rear axle assembly to the rear sub-frame. Refer to Section 1 2-QO.
lighten to 98- 1 20 N·m (73-88 lb-ft). 54. Connect battery ground cable.

03-018-66 Engine, 4.6L (2V) 03-o1 B-66

-,
55. Fill crankcase to specified level on oil level 7. Remove RH and LH valve covers (6582) from
dipstick (6750) with engine oil meeting Ford cylinder heads (6049).
specification WSS-M2C 1 53-F.
56. Start engine and check for coolant, oil and fuel
leaks.
Crankshaft

Slide Hammer T50T- 100-A
r Rear Crankshaft Slinger Remover T95P-670 1 -AH
� Rear Crankshaft Seal Remover T95P-670 1 -EH
f.
Rear Crankshaft Seal Adapter T95P-670 1 -DH
�
r
Rear Crankshaft Slinger Replacer T95P-670 1 -CH
r Removal
r
r
1. NOTE: This procedure will remove and install the
r crankshaft (6303) with the engine removed from
/
� the vehicle.
r
Remove ignition wires as described
. in Section
� � 03-Q78. FRONT OF
ENGINE
r
/
r 2. Remove six flywheel retaining bolts and remove
flywheel (6375) from crankshaft.
3. Remove accessory drive belt (8620). Refer to
Section 03-Q5. LH SIDE SHOWN
RH SIDE SIMILAR
4. Remove water pump pulley (8509). AA0636-A
5. Remove drive belt idler pulley (8679) and drive

belt tensioner (68209) with ignition coils ( 1 2029). Part
6. Remove oil bypass filter (67 1 4) as described. Item Number Description
1 6582 Valve Cover, RH
Req'd)
5 N8061 83-S Bolt (LH 7 Req'd, RH 9
Req'd)
6 6582 Valve Cover, LH
7 6049 Cylinder Head, LH
8 N807441 Stud Bolt
A - Tighten to 8� 12 Nom (71-106
NOTE: LUBRICATE SEAL
WITH CLEAN ENGINE OIL Lb-ln)
MEETING FORD
SPECIFICAnON 8. Remove crankshaft pulley bolt (6A340) and
wss-M 2C91D-A1 AND crankshaft pulley retaining washer (6378).
nGHTEN 314 TURN
AFTER SEAL CONTACT AA0630-A

03-018-67 Engine, 4.6L (2V) 03-018-67
9. Using Crankshaft Damper Remover

Part
-
T58P-63 16-D, pull crankshaft pulley (63 1 2) from
crankshaft. Item Number Description
B Tighten to 8- 12 N-m (7 1-1 06
Lb-ln)
1 2 . Remove oil pan (6675) and oil pan gasket (67 1 0).
A13&68-B

crankshaft position sensor (CKP sensor)(6C3 1 5)
and camshaft position sensor (CMP
sensor)(6B288).
1 1 . Remove crankshaft position sensor and camshaft
position sensor from engine front cover (601 9).
/
FRONT OF
ENGINE
/
/
FRONT OF
ENGINE
/ A13853-B
Part
I
'-00
1 W70 1240-S309 Bolt (16 Req'd)
3 6675 Oil Pan
A24307·A 4 67 10 Oil Pan Gasket
Part
5
A -
Tighten to 20 N·m ( 14 Lb-Ft)
-
Item Number Description Then Rotate and Additional
60 Degrees
1 6C315 Crankshaft Position Sensor B Tighten to 1 1 · 16 N-m (9-1 1
2 W701240-S309 Bolt (4 Req'd) Lb·Ft)
1 3. Remove engine front cover.
4 N806155-S2 Bolt
5
A -
N806 155-S2 Bolt
Tighten to 20 N·m (14 Lb-Ft,
Degrees)
(Continued)

03-018-68 Engine, 4.6L (2V) 03-o1 B-68
Engine Front Cover

.
Pa rt Part
(Continued)
14. NOTE: This will position all pistons (6 1 08) below 1 5. Remove timing chains as described.
top of cylinder block deck face. 1 6. Remove camshafts (6250) as described.
Position crankshaft on TDC No. 1 .
CRANKSHAFT
KEYWAY A13658-B

03-018-69 Engine, 4.6L (2V) 03-01 8-69
1 7. Remove oil pump screen cover and tube (6622) 1 8. Remove crankshaft rear oil seal retainer (6335).
and oil pump (6600).
AA0632·A
Part
2 6303 Crankshaft
FRONT OF
./ 3 6335 Crankshaft Rear Oil Seal
Retainer
/
ENGINE 4 6701 Crankshaft Rear Oil Seal
5 N806 155-2 Bolt (6 Req'd)
A24303-A 6 6310 Crankshaft Oil Slinger
-
A Tighten to 8- 12 N·m (7 1-1 06
Lb-ln)
Part
Item Number Description 1 9. NOTE: Connecting rods (6200), connecting rod
caps and connecting rod bearings (621 1 ) should
1 N806 180-S Stud Spacer be numbered to make sure they are assembled in
2 N605904-S Bolt their original positions.
3 6622 Oil Pump Screen Cover and Turn crankshaft until connecting rod cap to be
Tube removed is accessible. Identify the connecting
4 6345 Crankshaft Main Bearing rods connecting rod caps and connecting rod
Cap Stud bearings for cylinder position.
5 6010 Cylinder Blocks 20. Remove the connecting rod cap, lower and upper
6 N806 183-S2 Bolt (4 Req'd) connecting rod bearing. Keep cap and connecting
7 6600 Oil Pump rod bearings together. Use care to prevent
damage to the bearing and cylinder bore
8 3Z728 0-Ring surfaces.
9 N806 155-S2 Bolt (2 Req'd)
-
Lb-Ft)
-
B Tighten to 8- 12 N-m (7 1- 106
Lb-ln)

03-018-70 Engine, 4.6L (2V) 03-G1 B-70
2 1 . CAUTION: Care should be taken not to

damage the cracked rod and cap joint face
surfaces. Engine damage may occur.
Connecting rod bolts (62 14) are retained in the
bolt hole with a light press fit. The connecting rod
bolts have been torqued to yield at least twice
and must be discarded. Use a hammer and punch
to drive connecting rod bolts from connecting rod
cap.
DRIVE BOLTS OUT

SUPPORT BEARING
CAP WHILE
REMOVING BOLTS A15051-B
22. Remove horizontal main bearing cap side bolts
�. from cylinder blocks (60 10).
23. Loosen crankshaft main bearing cap adjusting
screws (6C360) on bearing main caps.
24. Remove bearing main cap retaining bolts. These A13637-D
are torque-to-yield bolts, and should not be
reused.
Part
25. NOTE: The location of the main bearing caps and Item Number Description
the crankshaft main bearings (6333) should be
identified. When the engine is assembled, 1 6C360 Crankshaft Main Bearing
crankshaft main bearings which are to be reused
Cap Adjusting Screw (10
should be installed in their original positions.
Req'd)
Remove each main bearing cap and lower Cap Bolt (9 Req'd)
crankshaft main bearing and crankshaft thrust
main bearing (6337). Keep each cap, lower 3 6345 Crankshaft Main Bearing
Cap Stud
crankshaft main bearings and crankshaft thrust
main bearing together. 4 6337 Crankshaft Thrust Main
Bearing, Lower
5 6333 Crankshaft Main Bearing,
Lower
6 6303 Crankshaft
7 6334 Crankshaft Thrust Washer
8 6C357 Crankshaft Main Bearing
Cap Side Bolt
Upper
11 N80620 1-S Woodruff Key
26. CAUTION: When removing the crankshaft,
use care not to damage any of the bearing
surfaces on the crankshaft.
Remove crankshaft.

03-018-7 1 Engine, 4.6L (2V) 03-01 8-7 1
27. If required, replace crankshaft main bearings,

crankshaft thrust main bearing and crankshaft
thrust washer (6334) as described.
Installation
1. NOTE: All sealing surfaces must be clean and
free of chips, dirt, paint and foreign material.
Also, make sure oil passages are clear.
Lubricate and install crankshaft main bearings
into cylinder blocks. Install crankshaft main
bearings and crankshaft thrust main bearing into
main bearing caps.
2. Install crankshaft into cylinder blocks.
3. Push crankshaft rearwards. Lubricate and install
upper crankshaft thrust washer, by rolling the
crankshaft thrust washer onto machined shelf
between rear side of No. 5 bulkhead and thrust
surface of crankshaft. Make sure coated side of
crankshaft thrust washer with three 5 mm wide
oil grooves faces the crankshaft thrust surface.
A13637-D
Part
Cap Adjusting Screw
Cap Bolt
Cap Stud
4 6337 Crankshaft Thrust Main
Bearing, Lower
Lower
6 6303 Crankshaft
7 6334 Crankshaft Thrust Washer
Cap Side Bolt
Upper
11 N80620 1 -S Woodruff Key

03-01 8-72 Engine, 4.6L (2V) 03-01 8-72
4. NOTE: Crankshaft main bearing cap adjusting 7. CAUTION: Main bearing bolts must be
screws must be bottomed on main bearing caps replaced with new bolts. They are
prior to installation of main bearing cap. torque-to-yield designed and cannot be
Install main bearing caps. Tap main bearing caps reused.
with a brass hammer to seat caps properly. Tighten new main bearing cap bolts one through
ten in two steps as follows:
a. Tighten bolts in sequence to 37-43 N·m
NOTE: ALL MAIN BEARING CAPS
MUST BE TAPPED INTO POSmON (28-3 1 lb-ft).
PRIOR TO TIGHTENING. FAILURE b. Rotate bolts in sequence an additional 85-95
TO DO SO MAY RESULT IN MAIN BEARING
IMPROPER TORQUE. CAP degrees.
5. Push crankshaft forward using a prybar or similar

tool to seat crankshaft thrust main bearing and
crankshaft thrust washer.
/
FRONT OF
ENGINE
/'
NOTE: ITEMS 1 THROUGH 10 ARE
MAIN BEARING CAP SOLTS, 1 1
THROUGH 18 ARE CRANKSHAFT MAIN
BEARING CAP ADJUSTING SCREWS, AND
19 THROUGH 26 ARE CRANKSHAFT
MAIN BEARING CAP BOLTS A13638-D
8. Tighten crankshaft main bearing cap adjusting

NOTE: PUSH CRANKSHAFT IN DIRECTION screws 1 1 through 20 in two steps as follows:
OF ARROW TO FULLY SEAT THRUST a. lighten crankshaft main bearing cap
BEARING. LEAVE PRYBAR IN POSmON
UNTIL ALL MAIN BEARING BOLTS ARE adjusting screws in sequence to 5 N·m (44
TIGHTENED A13642-c Ib-in).
b. lighten crankshaft main bearing cap
6. NOTE: No. 5 main bearing cap must be seated adjusting screws in sequence to 9-1 1 N·m
until the main bearing cap bolts are fully tightened (8Q-97 lb-in).
as described below. 9. Tighten main bearing cap side bolts 2 1 through
With crankshaft pushed forward, install pry bars 30 in two steps as follows:
or similar tools to push both RH and LH front a. lighten main bearing cap side bolts in
edges of No. 5 main bearing cap rearward and sequence to 1 0 N·m (7 1b-ft).
position the lower crankshaft thrust main bearing
rear face properly against the thrust face of the b. lighten main bearing cap side bolts in
crankshaft. sequence to 1 9-23 N·m ( 1 4- 1 7 lb-ft).

03-018-73 Engine, 4.6L (2V) 03-01 8-73
10. NOTE: Pry against number two main bearing cap. 13. Using Rear Crankshaft Seal Adapter
Check crankshaft end play in both directions as T95P-670 1-DH and Rear Crankshaft Seal
shown. Replacer T95P-670 1-BH, install crankshaft rear
oil seal (670 1 ), if removed.
PRYBAR
REAR CRANKSHAFT SEAL ADAPTER
T95P-6701 -DH
CRANKSHAFT
REAR MAIN
SEAL
6701
DIAL
INDICATOR
..u-..-W
- ITH BRACKETRY
CRANKSHAFT END PLAY
0.130-0.301 mm TOOL-420 1 -C
(0.005-0.010 INCH) REAR CRANKSHAFT SEAL REPLACER
T95P-6701 -BH
NOTE: PRY CRANKSHAFT IN AA0243-A
NOTE TOTAL END PLAY 14. Using Rear Crankshaft Slinger Replacer
A13643-E
T95P-6701-CH, replace crankshaft oil slinger
1 1 . NOTE: Prior to applying sealer, clean sealing (63 1 0), if removed.
surfaces with Metal Surface Cleaner 1 5. Tum crankshaft until the crankshaft throw is at
F4AZ-1 9A536-RA or equivalent meeting Ford bottom of stroke. Install upper connecting rod
specification WSE-M5B392-A, to remove all bearing onto connecting rod. Lubricate
residues that may interfere with the sealer's connecting rod bearing and crankshaft with clean
ability to adhere. engine oil.
NOTE: The crankshaft rear oil seal retainer must 1 6. CAUTION: Be sure not to scratch cylinder
be installed and the bolts tightened to wall or crankshaft journal with connecting
specification within five minutes of sealer rod. Pull piston down untO connecting rod
application. bearing seats on crankshaft journal.
Apply a 2.0 mm (0.08 inch) continuous bead of NOTE: Due to the use of a connecting rod joint
Anaerobic Gasket Compound Sealer or face surface, the connecting rod cap must be
equivalent meeting Ford specification properly aligned to the connecting rod. The
WSK-M2G348-A9 to cylinder blocks as shown. connecting rod and connecting rod cap bearing
tangs should be located on the same side of the
connecting rod.
CYLINDER BLOCK
6010 Install connecting rod cap and lower connecting
rod bearing. Alternately tighten new connecting
ANAEROBIC GASKET rod cap bolts in several passes to obtain 4Q-45
COMPOUND SEALER N·m (3Q-33 1b-ft) and rotate connecting rod bolts
MEETING FORD an additional 85-95 degrees. After installation,
SPECIFICATION rotate crankshaft to ensure smooth operation.
WSK-M2G348-A9
AA0629-A
12. Install crankshaft rear oil seal retainer to cylinder

blocks. Tighten six bolts in sequence to 8-1 2 N·m
(7 1-106 1b-in).

03-01 8-74 Engine, 4.6L (2V) 03-018-74
1 7 . Check connecting rod side clearance using

Rotunda Dial Indicator with Bracketry
TOOL-420 1-G or equivalent. Clearance should be
0. 1 5-0.45 mm (0.006-0.0 1 77 inch). If side
clearance is greater than maximum service limit
of 0.50 mm (0.020 inch), replace connecting rods
and I or crankshaft.
DIAL
INDICATOR
WITH BRACKETRY
TOOL-4201 -C
1 8. NOTE: Install new 0-ring on oil pump screen

cover and tube and start all bolts on oil pump and
oil pump screen cover and tube before tightening.
Install oil pump and oil pump screen cover and
tube.
FRONT OF
/
/
ENGINE
A24303-A
Part
2 N605904-S Bolt
Tube
4 6K258 Crankshaft Main Bearing
Cap Stud
6 N806183-S2 Bolt (4 Req'd)
7 6600 Oil Pump
8 3Z728 0-Ring
9 N806 155-S2 Bolt (2 Req'd)
-
lb-Ft)
-
B Tighten to 8- 12 N·m (7 1-106
lb-ln)

03-018-75 Engine, 4.6L (2V) 03-01 8-75
19. CAUTION: Failure to position crankshaft as

shown will cause damage to pistons and/ or
A13858-B
2 1 . Install camshafts as described.
22. Install timing chains as described.
23. Replace crankshaft front seal (6700) in engine
front cover if required.
CRANKSHAFT 24. Install engine front cover as described.
KEYWAY A13655-B
20. CAUTION: Crankshaft must only be rotated in
the clockwise direction and only as far as top
dead center (TDC) No. 1 .
Rotate crankshaft clockwise 45 degrees. This
will position crankshaft at top dead center (TDC)
No. 1 .

03-0 1 8-76 Engine, 4.6L (2V) 03-01 8-76
Sealer Locations
--
FRONT OF ENGINE
.....---
VIEW A VIEW B
A25166-A
Part Part
1 6019 Engine Front Cover 5 12A227 Crankshaft Position Sensor
4 6303 Crankshaft 7 60 10 Cylinder Blocks
(Continued)

03-018-77 Engine, 4.6L (2V) 03-018-77
Retainer Locations
0
DIIIIIIIIIQJIIIIIIIII
REFER TO LEGEND
�
IN
1
A TIGHTEN SEQUENCE 2
W SHOWN
Part Part
2 N806 177 Bolt (7 Req'd) 4 6019 Engine Front Cover
(Continued)
25. Install crankshaft position sensor and camshaft

position sensors into engine front cover and
tighten retaining bolts to 8- 1 2 N·m (7 1 - 1 06 lb-in).

03-01 8-78 Engine, 4.6L (2V) 03-01 8-78
26. Reconnect fuel charging wiring to crankshaft

position sensor and camshaft position sensor.
/
FRONT OF
ENGINE
/
� /
A24307·A FRONT OF
ENGINE
/ A13653-B
Part
Part
1 6C315 Crankshaft Position Sensor
2 W70 1240-S309 Bolt (4 Req'd)
3 6B288 Camshaft Position Sensor 1 W70 1240-S309 Bolt (16 Req'd)
4 N806 155-S2 Bolt 2 6730 Oil Pan Drain Plug
5 N806 155-S2 Bolt 3 6675 Oil Pan
A -
Tighten to 20 N-m (14 Lb-Ft, 4 67 10 Oil Pan Gasket
Then Rotate Bolt an 5 6010 Cylinder Blocks
Additional 60 Degrees) A -
Tighten to 20 N-m (14 1:.b-Ft),
- Then Rotate an Additional 60
B Tighten to 8- 12 N·m (71-1 06
Lb-ln) Degrees
-
B Tighten to 1 1-16 N·m (9- 1 1
27. Install oil pan with new oil pan gasket as Lb-Ft)
described. Tighten bolts to 25-35 N·m (1 9·25
lb-ft) in no more than four minutes after applying
sealer.

03-018-79 Engine, 4.6L (2V) 03-01 8-79

ability to adhere.
NOTE: Silicone Gasket F6AZ-1 9562-AA or
WSE-M4G323-A6 must be applied to crankshaft
keyway prior to installing crankshaft pulley.
Install crankshaft pulley using Crankshaft Damper
Replacer T74P-63 16-B.
CRANKSHAFT
DAMPER REPLACER
T74P-6316-B
/
retaining washer. Tighten in four steps:
a. Tighten to 90 N·m (67 1b-ft).
FRONT OF
b. Loosen one full turn. ENGINE
c.
d.
Tighten to 50 N·m (37 lb-ft).
Tighten an additional 90 degrees.
/
30. Install RH and LH valve cover gaskets (6584). LH SIDE SHOWN
Tighten studs and bolts to 8- 1 2 N·m (7 1 - 1 06 RH SIDE SIMILAR
AA0636-A
Ib-in).
Part
1 6582 Valve Cover, RH
Req'd)
5 N806 183-S2 Bolt (LH 7 Req'd, RH 9
Req'd)
6 6582 Valve Cover, LH
7 6049 Cylinder Head, LH
8 N807441 Stud Bolt
-
A Tighten to 8- 1 2 N-m (7 1 -106
Lb-ln)

03-01 8-80 Engine, 4.6L (2V) 03-018-80
3 1 . Install new oil bypass filter as described. Installation

1. Fit crankshaft main bearings as described in
Section 03-QO.
2. Install upper crankshaft main bearing and
crankshaft thrust washer into cylinder blocks.
Install lower crankshaft main bearings and
crankshaft thrust main bearing into main bearing
caps.
3. Install crankshaft as described.
4. Install engine into vehicle as described.
NOTE: LUBRICATE SEAL DISASSEMBLY AND ASSEMBLY

WITM CLEAN ENGINE OIL
MEETING FORD
SPECIFICATION Engine
Wss-M2C91Q-A1 AND
TIGHTEN 314 TURN
AFTER SEAL CONTACT AA0630-A SPECIAL SERVICE TOOL(S) REQUIRED
32. Install drive belt idler pulley and drive belt Description Tool Number
tensioner with ignition coils and tighten seven nuts Crankshaft Damper Remover T58P-6316·D
to 2Q-30 N·m ( 1 5-22 lb-ft). Crankshaft Damper Replacer T74P-63 16-B
33. Install water pump pulley and tighten bolts to Slide Hammer T50T- 100-A
2Q-30 N·m ( 1 5-22 lb-ft).
Rear Crankshaft Slinger Remover T95P-6701 -AH
34. Install accessory drive belt. Refer to Section Rear Crankshaft Seal Remover T95P-670 1·EH
03-05.
Rear Crankshaft Seal Adapter T95P-670 1 -DH
35. Install flywheel and tighten six bolts to 73-87 N·m
(54-64 1b-ft).
� Rear Crankshaft Slinger Replacer T95P-670 1-CH
36. Install ignition wires as described in Section
03-078. Cam Positioning Tool T91 P-6256-A
37. Install engine as described. Cam Positioning Tool Adapters T92P·6256-A
Disassembly
1. NOTE: This procedure will disassemble and
Crankshaft Main Bearings assemble a complete engine with the engine
removed from the vehicle.
Removal
Remove ignition wires and spark plugs ( 1 2405).
1. Remove engine from vehicle as described. Refer to Section 03-o7B.
2. Remove crankshaft (6303) as described. 2. Disconnect fuel charging wiring (90930) from
3. Clean and inspect cylinder blocks (60 1 0), electronic engine controls, fuel injectors and
crankshaft, crankshaft main bearings (6333), ignition coils ( 1 2029). Remove fuel charging
crankshaft thrust main bearing (6337) and wiring.
crankshaft thrust washer (6334) as described in
Section 03-QO.

03-01 8-81 Engine, 4.6L (2V) 03-G1 B-81
DISASSEMBLY AND ASSEMBLY {Continued)
Fuel Charging Wiring
Part Part
- -
1 To 12A581 Harness (Part of 9 To Oil Pressure Sensor (Part
90930) of 90930)
-
2 90930 Fuel Charging Wiring 10 To 14290 Harness (Part of
3 -
To RH H02S (Part of 90930) 90930)
-
4 -
To EGR Backpressure 11 To Camshaft Position (CMP)
Transducer (Part of 90930) Sensor (Part of 90930)
5 -
To LH H02S (Part of 90930) 12 -
To LH Ignition Coil (Part of
90930)
-
6 To Fuel Injectors (8 Places, 13 -
To LH Radio Ignition
Part of 90930) Interference Capacitor (Part
-
7 To 14290 Harness (Part of of 90930)
90930) 14 -
To Crankshaft Position
-
8 To Electronic Variable (CKP) Sensor (Part of
Orifice (Part of 90930) 90930)

03-018-82 Engine, 4.6L {2V} 03-01 8-82
Part Part
15 - To A I C Compressor (Part of 20 - To Generator (Part of
90930) 90930)
16 - To EGR Vacuum Regulator 21 - To Engine Coolant
(EVR) Sensor (Part of Temperature (ECT) Sensor
90930) (Part of 90930)
17 - To RH Ignition Coil (Part of 22 - To Fuel Injection Supply
90930) Manifold Ground (Part of
18 - To RH Radio Ignition 90930)
Interference Capacitor (Part 23 - To Idle Air Control (lAC)
of 90930) Valve (Part of 90930)
19 - To Water Temperature 24 - To Throttle Position (TP)
Indicator Sender Unit (Part of Sensor (Part of 90930)
90930)
(Continued)
3. Remove six flywheel retaining bolts and remove

flywheel (6375) from crankshaft (6303).
FRONT OF
./
4. Remove crankcase vent connector and front ENGINE
vapor hose. Remove positive crankcase
ventilation valve (PCV valveX6A666).
/
5. Remove generator mounting bracket ( 1 0 1 53)
and two bolts retaining generator (GENX 10300)
to cylinder blocks (601 0).
!""'· 6. Remove water pump pulley (8509).
7. Remove A / C compressor ( 1 9703).
BOLT
3 REQ'D
TIGHTEN TO NOTE: LUBRICATE SEAL WITH CLEAN ENGINE
20-30 N·m OIL MEETING FORD SPECIFICATION Wss-M2C153-F
(15-22 LB-FT) ANDnGHTEN 314 TURN AFTER SEAL CONTACT
AA0639-B
Y . .._
Item
Part
Number Description
8. Remove drive belt idler pulley (8679) and drive 1 67 14 Oil Bypass Filter
belt tensioner (68209) with ignition coils.
9. Remove RH and LH exhaust manifolds (9430). 6010 Cylinder Blocks
3
10. Remove oil bypass filter (67 1 4) and oil filter 4 90290 Oil Pressure Sensor
adapter (688 1 ).
6 N806156-S2 Bolt (4 Req'd)
7 6881 Oil Filter Adapter
A - Tighten to 20-30 N·m (15-22
Lb-Ft)
1 1 . Remove water hose connection (8592), water
thermostat (8575) and Q-ring.
1 2. Remove remaining nine bolts retaining intake
manifold (9424) to cylinder heads (6049) and
remove intake manifold.

03-018-83 Engine, 4.6L (2V) 03-01 8-83
13. If necessary, disassemble intake manifold as

follows: Part
a. Remove throttle body (9E926) and throttle
body adapter. 7 6049 Cylinder Head (LH)
b. Remove idle air control valve (lAC 8 N807441 Stud Bolt
-
valve)(9F7 1 5). A Tighten to 8- 12 N·m (7 1-1 06
c. Remove engine coolant temperature sensor
Lb-ln)
(ECT sensor)( 12A648) and water 1 5. Remove crankshaft pulley bolt (6A340) and
temperature indicator sender unit (1 0884). crankshaft pulley retaining washer (6378).
d. Remove four bolts retaining fuel injection 1 6. Using Crankshaft Damper Remover
supply manifold (9F792) and remove fuel T58P-63 1 6-D, pull crankshaft pulley (63 1 2) from
injection supply manifold and fuel injectors. crankshaft.
14. Remove RH and LH valve cover (6582)
A13668-B
1 7. Remove connecting rod bolt (62 1 4) and camshaft

position sensor (CMP sensor)(6B288) from
engine front cover (60 1 9).
/
FRONT OF
ENGINE
/
/
FRONT OF
ENGINE
/
LH SIDE SHOWN
RH SIDE SIMILAR
AA0636·A
A24307·A
Part
Item Number Description Part
1 6582 Valve Cover (RH) Item Number Description
2 6584 Valve Cover Gasket 1 6C315 Crankshaft Position Sensor
3 N806356-S2 Stud (LH 4 Req'd, RH 2 2 N605907-S2 Bolt (4 Req'd)
Req'd)
4 N806 155-S2 Bolt
5 N806183-S2 Bolt (LH 7 Req'd, RH 9
Req'd) 5 N806 155-S2 Bolt
6 6582 Valve Cover (LH) (Continued)
(Continued)

03-01 8-84 Engine, 4.6L (2V) 03-018-84
19. Remove EGR backpressure transducer bracket

Part and heater water hose ( 1 8472) from rear of RH
Item Number Description cylinder head.
-
A Tighten to 20 N·m ( 14 Lb-Ft, 20. Remove water pump (850 1 ).
Degrees)
B -
Tighten to 8-12 N·m (7 1·1 06 NOTE: LUBRICATE 0-RING WITH
CLEAN ANTIFREEZE
Lb-ln)
1 8. Remove oil pan (6675) and oil pan gasket (67 1 0).
/
FRONT OF
ENGINE
/
A24309-A
./ Part
FRONT OF
ENGINE Item Number Description
/ A13653-B 1 6049 Cylinder Head (RH)
Part
3 N807381 Stud Bolt
Item Number Description 4 6010 Cylinder Blocks
-
1 W70 1240-8309 Bolt (16 Req'd) 5 Heater Water Hose

Connector (Part of 60 10)
·2 6730 Oil Pan Drain Plug 6 N806 177-8309 Bolt (4 Req'd)
3 6675 Oil Pan 7 8501 Water Pump
4 6710 Oil Pan Gasket 8 3Z728 0-Ring
5 6010 Cylinder Blocks A -
-
A Tighten to 20 N·m (14 Lb-Ft), Lb-Ft)
Then Rotate an Additional 60
Degrees 2 1 . Remove engine front cover.
-
B Tighten to 1 1-16 N·m (9- 1 1
Lb-Ft)

03-018-85 Engine, 4.6L (2V) 03-018-85
Engine Front Cover
Part Part
2 N806 177 Bolt (7 Req'd) 4 601 9 Engine Front Cover
(Continued)
22. NOTE: This will position all pistons (6 1 08) below

top of cylinder block deck face.
Position crankshaft at top dead center (TDC) of
No. 1 cylinder.
CRANKSHAFT
KEYWAY A13855-B
25. Remove RH and LH cylinder heads. Discard all

head bolts.
26. Remove and discard head gaskets (605 1 ).
A13658-B
Subassemblies, Cylinder Head Disassembly and
23. Remove timing chains as described.
Assembly.
24. Rotate crankshaft counterclockwise 45 degrees.

03-01 8-86 Engine, 4.6L (2V) 03-01 8-86
28. Remove oil pump (6600) and oil pump screen

cover and tube (6622). ./
FRONT OF
ENGINE
./ -
•
AA0632-A
Part
2 6303 Crankshaft
3 6335 Crankshaft Rear Oil Seal
Retainer
FRONT OF
/ 4
5
6701
N806 155-S2
Crankshaft Rear Oil Seal
Screw and Washer Assy (6
/
ENGINE Req'd)
6 63 10 Crankshaft Oil Slinger
-
A24303-A A Tighten to 8- 1 2 N·m (7 1-106
Lb-ln)
Part 30. NOTE: Pistons, connecting rods (6200) and
Item Number Description connecting rod bearings (62 1 1 ) should be
numbered to make sure they are assembled in
1 NB06180-S Stud Spacer their original positions.
2 N605904-S Bolt NOTE: Before removing pistons, inspect the top
3 6622 Oil Pump Screen Cover and of the cylinder bores. If necessary, remove the
Tube ridge and I or carbon deposits from each cylinder
4 6345 Crankshaft Main Bearing using Cylinder Ridge Reamer T64L-60 1 1 -EA or
Cap Stud equivalent as described in Section 03-00.
5 6010 Cylinder Blocks Turn crankshaft until piston to be removed is at
6 N806 183-S2 Bolt (4 Req'd) the high point of its travel. If more than one piston
7 6600 Oil Pump is being removed, identify the pistons, connecting
rods and connecting rod caps for cylinder
8 3Z728 0-Ring position.
9 NB06 155-S2 Bolt (2 Req'd) 3 1 . Remove the connecting rod cap and lower
-
A Tighten to 20-30 N·m (15-22 connecting rod bearing. Keep cap and lower
Lb-Ft) connecting rod bearing together. Push the piston,
- connecting rod and upper connecting rod bearing
B Tighten to 8- 12 N·m (7 1 - 1 06
Lb-ln) through the top of the cylinder bore. Use care to
prevent damage to the bearing and cylinder bore
29. Remove crankshaft rear oil seal retainer (6335). surfaces. Keep upper connecting rod bearing and
connecting rod together.

03-018-87 Engine, 4.6L (2V) 03-018-87
32. CAUTION: Care should be taken not to

damage the fractured rod and cap joint face
surfaces or damage to the engine may occur.
NOTE: Connecting rod bolts are retained in the REMOVAL
connecting rod cap with a light press fit. The
connecting rod bolts have been torqued to yield
at least twice and must be discarded. Use a
hammer and punch to drive connecting rod bolts PISTON
PIN
from connecting rod caps. 6135
Using new connecting rod bolts, attach
connecting rod cap and lower connecting rod
RECEIVING
TUBE
bearing to connecting rod and upper connecting
rod bearing to prevent mixing parts and damaging
the fractured joint face surfaces.
PRESS
DRIVE BOLTS OUT PLATES A8121..C
36. Remove horizontal main bearing cap side bolts
from cylinder blocks.
37. loosen crankshaft main bearing cap adjusting
screws (6C360).
38. Remove bearing main cap retaining bolts. These
are torque-to-yield bolts and should not be
reused.
39. NOTE: The location of the main bearing caps and
the main bearing inserts should be identified.
When the engine is assembled, bearings which
are to be reused should be installed in their
SUPPORT BEARING original positions.
CAP WHILE
REMOVING BOLTS A15051-B Remove each main bearing cap and lower
crankshaft main bearing (6333). Keep each cap
33. NOTE: Any piston rings that are removed from and lower crankshaft main bearings together.
piston should be discarded and replaced with 40. CAUTION: When removing the crankshaft,
new piston rings. use care not to damage any of the bearing
If piston ring replacement is required, use a surfaces on the crankshaft.
suitable piston ring expander. Remove two Remove crankshaft.
compression rings. Remove two oil ring rails and
expander by hand. 4 1 . Clean and inspect crankshaft and cylinder blocks.
Replace worn or damaged components as
34. Mark connecting rod cap to ensure reassembly required.
with same piston and installation in same
cylinders from which they were removed. Assembly
35. NOTE: The piston and piston pin (6 1 35) are a 1. NOTE: Before assembling cylinder blocks, all
matched set. Keep pistons, piston pin, piston sealing surfaces must be clean and free of chips,
rings, connecting rods and connecting rod dirt, paint and foreign material. Also, make sure
bearings together in proper cylinder order. coolant and oil passages are clear.
Using Piston Pin Tool D8 1 L-6 135-A or equivalent, lubricate and install crankshaft main bearings
press piston pin from piston and connecting rod. into cylinder blocks. Install crankshaft main
bearings and crankshaft thrust main bearing
(6337) into main bearing caps.
2. Install crankshaft into cylinder blocks.

03-0 18-88 Engine, 4.6L {2V) 03-01 8-88
3. Push crankshaft rearward. Lubricate and install

upper crankshaft thrust washer (6334), by rolling Part
the crankshaft thrust washer onto machined shelf Item Number Description
between rear side of No. 5 bulkhead and thrust 10 6333 Crankshaft Main CBearing,
face surface of crankshaft. Make sure coated Upper
0
side of crankshaft thrust washer with three 5 mm 11 N806201-S Woodruff Key
wide oil grooves is facing the crankshaft thrust
surface. 4. NOTE: Crankshaft main bearing cap adjusting
screws must be bottomed on main bearing cap
NOTE: ASSEMBLE ./ prior to installation of main bearing cap.
CAPS WITH ARROW 3 Install main bearing caps. Tap main bearing caps
POINTING FORWARD, FRONT OF
CAPS ARE STAMPED ENGINE with a brass hammer to seat caps properly.
/'
1 THROUGH 5 FRONT I'
TO REAR
NOTE: ALL MAIN BEARING CAPS
· �
MUST BE TAPPED INTO POSITION
PRIOR TO TIGHTENING. FAILURE
TO DO SO MAY RESULT IN MAIN BEARING
IMPROPER TORQUE. CAP
5. Push crankshaft forward using a prybar or similar

tool to seat crankshaft thrust main bearing and
crankshaft thrust washer.
A13637-D
Part
Cap Adjusting Screw
NOTE: PUSH CRANKSHAFT IN DIRECTION
2 6345 Crankshaft Main Bearing OF ARROW TO FULLY SEAT THRUST
Cap Bolt BEARING. LEAVE PRYBAR IN POSmON
UNTIL ALL MAIN BEARING BOLTS ARE
3 6345 Crankshaft Main Bearing TIGHTENED A13642.C
Cap Stud
4 6337 Crankshaft Thrust Main 6. NOTE: No. 5 main bearing cap must be seated
Bearing, Lower until the main bearing cap bolts are fully tightened
5 6333 Crankshaft Main Bearing, as described below.
Lower
With crankshaft pushed forward, install pry bars
6 6303 Crankshaft or similar tools to push both RH and LH front
7 6334 Crankshaft Thrust Washer edges of No. 5 main bearing cap rearward and
8 6345 Crankshaft Main Bearing position the lower crankshaft thrust main bearing
Cap Side Bolt rear face properly against the thrust face of the
9 60 10 Cylinder Blocks crankshaft.
(Continued)

03-018-89 Engine, 4.6L {2V) 03-01 8-89
7. CAUTION: Main bearing bolts must be

reused.
Tighten new main bearing cap bolts one through
ten in two steps as follows:
a. Tighten bolts in sequence to 37-43 N·m
(28-3 1 lb-ft).
b. Rotate bolts in sequence 85-95 degrees. DIAL
INDICATOR
CRANKSHAFT END PLAY !3 WITH BRACKETRY
TOOL-4201-C
0.1 30-0.301 mm
(0.005-0.010 INCH)
NOTE: PRY CRANKSHAFT IN

NOTE TOTAL END PLAY
A13643-E
1 1 . NOTE: Prior to applying sealer, clean sealing

ability to adhere.
NOTE: The crankshaft rear oil seal retainer must
be installed and bolts tightened to specification
within five minutes of sealer application.
/ Apply a 2.0 mm (0.08 inch) continuous bead of
FRONT OF Anaerobic Gasket Compound Sealer or
ENGINE equivalent meeting Ford specification
/ WSK-M2G348-A9 to cylinder blocks as shown.
NOTE: ITEMS 1 THROUGH 10 ARE

MAIN BEARING CAP BOLTS, 1 1 CYLINDER BLOCK
THROUGH 1 8 ARE CRANKSHAFT MAIN 6010
BEARING CAP ADJUSTING SCREWS, AND
19 THROUGH 26 ARE CRANKSHAFT
MAIN BEARING CAP BOLTS A1 3638-D
ANAEROBIC GASKET
COMPOUND SEALER
MEETING FORD
8. Tighten crankshaft main bearing cap adjusting SPECIFICATION
screws 1 1 through 20 in two steps as follows: WSK-M2G348-A9
a. Tighten crankshaft main bearing cap AA0629-A
adjusting screws in sequence to 5 N·m (44
lb-in). 1 2. Install crankshaft rear oil seal retainer to cylinder
blocks and tighten six bolts in sequence to 8- 1 2
b. Tighten crankshaft main bearing cap
N·m (7 1 - 1 06 1b-in).
adjusting screws in sequence to 9- 1 1 N·m
(8Q-97 lb-in).
9. Tighten main bearing cap side bolts 2 1 through
30 in two steps as follows:
a. Tighten main bearing cap side bolts in
sequence to 1 0 N·m (7 1b-ft).
b. Tighten main bearing cap side bolts in
sequence to 19-23 N·m ( 1 4- 1 7 1b-ft).
10. NOTE: Pry against number two main bearing cap. A13645-8
Check crankshaft end play in both directions as
shown. 1 3. Using Rear Crankshaft Seal Replacer Adapters
T95P-6701-BH, Rear Main Seal Replacer
T95P-670 1 -DH and Rear Crankshaft Slinger
Replacer T95P-6701..CH, install crankshaft rear
oil seal (670 1) and crankshaft oil slinger (63 1 0).

03-018-90 Engine, 4.6L (2V) 03-018-90
/'""- . Rear Main Seal Installation
REAR CRANKSHAFT SEAL ADAPTER

T95P-6701-DH
CRANKSHAFT
REAR MAIN
SEAL
6701

T95P-6701-BH
AA0243-A
Rear Oil Slinger Installation
REAR CRANKSHAFT OIL SLINGER

6310 /
FRONT OF
REAR CRANKSHAFT SEAL ADAPTER ENGINE
T95P-6701-DH NOTCH TOWARD ---""IIZY
/ FRONT OF ENGINE
AA0633-A
Part
1 62 14 Connecting Rod Bolt (16
Req'd)
2 6200 Cap (8 Req' d) (Part of 6200)
3 62 1 1 Connecting Rod Bearing,
Lower (8 Req'd)
4 6303 Crankshaft
REAR CRANKSHAFT SLINGER REPLACER 5 62 1 1 Connecting Rod Bearing,
T95P-6701 -CH Upper (8 Req'd)
REAR CRANKSHAFT SEAL REPLACER 6 6 108 Piston (8 Req'd)
T95P-6701-BH AA0244-A
7 6200 Connecting Rod (8 Req'd)
8 08 1L-6002-C Piston Ring Compression
14. Coat piston bores, pistons, rings, crankshaft Tool
journal and bearing surfaces with clean engine oil
meeting Ford specification WSS-M2C 1 53-F. 9 T93P-6 136-A Connecting Rod Guide
-
15. NOTE: Make sure piston ring gaps are rotated 30

Lb-Ft), then rotate an
degrees apart. additional 90-120 degrees
NOTE: Notch on piston to front of engine.
1 7. NOTE: Due to the use of a cracked connecting
Turn crankshaft until the crankshaft throw is at rod joint face surface, the connecting rod cap
bottom of stroke. Install correctly numbered must be properly aligned to the connecting rod.
pistons, connecting rods and upper connecting The connecting rod and connecting rod cap
rod bearings with Piston Ring Compressor Tool bearing tangs should be located on the same side
081 L-6002-C or equivalent and a suitable of the connecting rod.
connecting rod guide tool or equivalent.
Install connecting rod cap and lower connecting
16. CAUTION: Be sure not to scratch cylinder rod bearing and alternately tighten new
wall or crankshaft journal with connecting connecting rod cap bolts in several passes to
rod. obtain 4Q-45 N·m (30-33 lb-ft) and rotate
Push piston down until connecting rod bearing connecting rod bolts an additional 9Q- 1 20
seats on crankshaft. degrees. After installation, rotate crankshaft to
verify smooth operation.

03-018-91 Engine, 4.6L (2V) 03-01 8-91
18. Check connecting rod side clearance using

Rotunda Dial Indicator with Bracketry
TOOL-420 1 -G or equivalent. Clearance should be
0. 1 5-Q.45 mm (0.006-Q.0 1 77 inch). If side
clearance is greater than maximum service limit
of 0.50 mm (0.020 inch), replace connecting rods
and I or crankshaft.
DIAL
INDICATOR
WITH BRACKETRY
TOOL-4201-C
19. NOTE: Install new 0-ring on oil pump screen

cover and tube and then start all bolts on oil pump
and oil pump screen cover and tube before
tightening.
�
Install oil pump and oil pump screen cover and
tube.
FRONT
/
ENGINE
A24303-A
Part
2 N605904-S Bolt
; 3 6622 Oil Pump Screen Cover and
Tube
Cap Stud
6 N806183-S2 Bolt (4 Req'd)
7 6600 Oil Pump
8 3Z728 0-Ring
9 N806155-S2 Bolt (2 Req'd)
-
Lb-Ft)
-
B Tighten to 8-12 N·m (7 1-106
Lb-ln)
20. NOTE: Make sure cylinder heads are installed in
their original positions.
If cylinder heads are to be serviced, refer to
Subassemblies, Cylinder Head in Disassembly
and Assembly in this section.

03-01 8-92 Engine, 4.6L (2V) 03-01 8-92
2 1 . CAUTION: Do not use sandpaper coarser

than 600 grit. Damage to sealing surfaces RH CYLINDER LH CYUNDER
may occur.
HEAD 6049 HEAD 6049
NOTE: Clean cylinder head gasket surface with a
toluene-based paint thinner or gasket remover. If
gasket material remains on head after cleaning,
use a 600 grit sandpaper to remove remaining
material.
NOTE: RH and LH head gaskets are not
interchangeable.
Position new head gaskets on cylinder heads.
CRANKSHAFT
LH HEAD KEYWAY A1365&-B
GASKET
6051 24. CAUTION: Cylinder head bolts must be
reused.
RH HEAD
GASKET NOTE: Apply clean engine oil meeting Ford
6051 specification WSS-M2C 1 53-F to all head bolt
spot-fa�es.
A13654-B Tighten new cylinder head bolts as follows:
a. Tighten head bolts in sequence to 37-43 N·m
22. CAUTION: Failure to position crankshaft as (28-3 1 1b-ft).
shown will cause damage to pistons and/or
b. Rotate head bolts in sequence 85-95
degrees.
c. Loosen head bolts a minimum of one full turn
(360 degrees).
d. Retighten head bolts in sequence to 37-43
N·m (28-3 1 lb-ft).
e. Rotate head bolts in sequence 85-95
degrees.
f. Rotate head bolts in sequence an additional
85-95 degrees.
CRANKSHAFT
KEYWAY A13655-B RH CYLINDER LH CYLINDER
HEAD 6049 HEAD 6049
23. CAUTION: Use care when positioning CYLINDER HEAD TIGHTENING SEQUENCE
cylinder heads. Damage to cylinder blocks I
and/ or cylinder heads may result. FRONT OF
Position cylinder heads on cylinder blocks. Use ENGINE
Cam Positioning Tool Adapters T92P-6256-A and ' A13657-c
Cam Positioning Tool T91 P-6256-A to prevent
crankshafts from rotating.

03-01 8-93 Engine, 4.6L (2V) 03-01 8-93
25. CAUTION: Crankshaft must only be rotated 26. Install timing chains as described.
in the clockwise direction and only as far as 27. Replace crankshaft front seal (6700) in engine
top dead center (TDC) No. 1 cylinder. front cover if required.
Rotate crankshaft clockwise 45 degrees. This 28. Install engine front cover as described.
will position crankshaft at top dead center (TDC)
No. 1 cylinder.
A13658-B
Retainer Locations
0
11111QI1111
lillij
REFER TO LEGEND
II II I�
1
A TIGHTEN IN SEQUENCE 2
W SHOWN

03-01 8-94 Engine, 4.6L (2V) 03-01 8-94
Part Part
(Continued)
29. Install oil pan with new oil pan gasket. lighten 30. lubricate water pump housing gasket (8507)
bolts to 20 N·m ( 1 4 1b-ft), then an additional SO with Ford Premium Cooling System Fluid
degrees in no more than four minutes after E2FZ- 1 9549-AA (in Canada, Motorcraft
applying sealer. exe-s-B) or equivalent meeting Ford
specification ESE-M97B44-A and install water
pump and tighten retaining bolts to 2Q-30 N·m
( 1 5-22 1b-ft).
3 1 . Install heater water hose.
NOTE: LUBRICATE Q-RING WITH

CLEAN ANTIFREEZE
/
FRONT OF
ENGINE
/
/
FRONT OF
ENGINE
/ A13653-B
Part
A2�A
1 W70 1240-S309 Bolt (16 Req'd)
Part
3 6675 Oil Pan Item Number Description
4 6710 Oil Pan Gasket 1 6049 Cylinder Head (RH)
5 6010 Cylinder Blocks 2 18472 Heater Water Hose
-
A Tighten to 20 N·m (15 Lb-Ft), 3 N807381 Stud Bolt (2 Req'd)
Then Rotate an Additional 60
Degrees 4 6010 Cylinder Blocks
-
B Tighten to 1 1-16 N·m (9- 1 1 5 8555 Heater Water Hose
Lb-Ft) Connector (Part of 60 1 0)
6 N806 177-S309 Bolt (4 Req'd)
7 8501 Water Pump
8 3Z728 0-Ring
-
Lb-Ft)

03-018-95 Engine, 4.6L (2V) 03-018-95
32. Install crankshaft position sensor (CKP

sensor)(6C3 1 5) and camshaft position sensors
into engine front cover and tighten retaining bolts
to 8- 12 N·m (7 1 - 1 06 1b-in).
/
FRONT OF
ENGINE CRANKSHAFT
/ DAMPER REPLACER
T74P-6316-B

retaining washer. lighten in four steps:
a. lighten to 90 N·m (67 lb-ft).
c. lighten bolt to 50 N·m (37 lb-ft).
d. lighten an additional 90 degrees.
35. Install RH and LH valve cover gaskets (6584).
lighten studs and bolts to 8- 1 2 N·m (7 1 - 1 06
Ib-in).
I
'-00
A24307-A
Part
1 6C315 Crankshaft Position Sensor
2 N605907-S2 Bolt (4 Req'd)
4 N806155-S2 Bolt
5
-
N806155-S2 Bolt
-
A Tighten to 25·35 N-m ( 19-25
Lb-Ft)
B Tighten to 8- 12 N-m (7 1-1 06
(Lb-ln)
F4AZ- 19A536-RA or equivalent meeting Ford
/
ability to adhere.
NOTE: Silicone Gasket and Sealant FRONT OF
F6AZ- 1 9562-AA or equivalent meeting Ford ENGINE
/
specification WSE-M4G323-A6 must be applied
to crankshaft keyway prior to installing
crankshaft pulley.
Install crankshaft pulley using Crankshaft Damper LH SIDE SHOWN
Replacer T74P-63 16-B. AA0636-A
Part
(Continued)

03-018-96 Engine, 4.6L (2V) 03-018-96
Part
FRONT OF
./
ENGINE
Req'd) /
5 N806183-S2 Bolt (LH 7 Req'd, RH 9
Req'd)
�-
8 N80744 1 Stud Bolt
-
A Tighten to 8-12 N·m (7 1- 106
Lb-ln)
�--1
36. If intake manifold was disassembled, assemble
�
as follows:
a. Install fuel injector o-rings (9C99 1) on fuel
injectors with clean engine oil meeting Ford
NOTE: LUBRICATE SEAL WITH CLEAN ENGINE
specification WS8-M2C 1 53-F prior to OIL MEETING FORD SPECIFICATION WSS-M2C153-F
assembly. AND TIGHTEN 314TURN AFTER SEAL CONTACT
AA0639-B
b. Install fuel injection supply manifold and fuel
injectors and tighten four bolts to 8- 1 2 N·m
(7 1 - 1 06 1b-in). Part
c. Install engine coolant temperature sensor and Item Number Description
water temperature indicator sender unit and 1 67 14 Oil Bypass Filter
tighten to 16-24 N-m ( 1 2- 1 7 lb-ft).
d. Install idle air control valve and tighten bolts 3 60 10 Cylinder Blocks
r, to 8- 1 2 N·m (7 1 - 1 06 1b-in).
e. Install throttle body and throttle body
adapter. lighten bolts to 8- 12 N-m (7 1 - 1 06 5 9278 Oil Pressure Sensor
Ib-in). 6 N806 156-S2 Bolt (4 Req'd)
37. NOTE: Align tabs on intake manifold gasket 7 6881 Oil Filter Adapter
-
(946 1) with holes in cylinder heads. A Tighten to 20-30 N·m (15-22
Position intake manifold gasket on cylinder Lb-Ft)
heads. 42. Install LH exhaust manifold and tighten bolts to
38. Install intake manifold as described. lighten 2Q-30 N·m ( 1 5-22 1b-ft).
retaining bolts in sequence to 2Q-30 N·m ( 1 5-22 43. Install RH exhaust manifold and tighten bolts to
lb-ft). 2Q-30 N·m ( 1 5-22 lb-ft).
39. NOTE: Water outlet connection bolts are also 44. Install drive belt idler pulley and drive belt
intake manifold retaining bolts. tensioner with ignition coils and tighten seven nuts
Install water outlet connection D-ring and water to 2Q-30 N·m ( 1 5-22 lb-ft).
hose connection. lighten bolts to 2Q-30 N-m 45. Install A / C compressor and tighten three bolts to
( 1 5-22 1b-ft). 2Q-30 N·m ( 1 5-22 1b-ft).
40. Install oil filter adapter and tighten bolts to 2Q-30
N·m (1 5-22 1b-ft).
4 1 . Install oil bypass filter.
BOLT
3 AEQ'D
TIGHTEN TO
20-30 N·m
(15-22 LB-FT)
Y.311H
03-018-97 Engine, 4.6L (2V) 03-01 8-97
46. Install water pump pulley and tighten bolts to 49. Install positive crankcase ventilation valve and
2Q-30 N-m ( 1 5-22 lb-ft). front vapor hose.
47. Install generator and tighten generator-to-cylinder 50. Install flywheel to crankshaft and tighten six bolts
block retaining bolts to 2Q-30 N·m ( 1 5-22 lb-ft). to 73-87 N-m (56-64 1b-ft).
48. Install generator mounting bracket and tighten to 5 1 . Install fuel charging wiring and connect all
8- 1 2 N·m (7 1-106 1b-in). applicable wiring connectors.
A24308-A
Part Part
- -
1 To 12A581 Harness (Part of 5 To LH H02S (Part of 90930)
90930) 6 -
To Fuel Injectors (8 Places,
2 90930 Fuel Charging Wiring Part of 90930)
- -
3 To RH H02S (Part of 90930) 7 To 14290 Harness (Part of
4 -
To EGR Backpressure 90930)
Transducer (Part of 90930) (Continued)
(Continued)

03-01 8-98 Engine, 4.6L (2V) 03-018-98
Part Part
- -
8 To Electronic Variable 17 To RH Ignition Coil (Part of
Orifice (Part of 90930) 90930)
- -
9 To Oil Pressure Sensor (Part 18 To RH Radio Ignition
of 90930) Interference Capacitor (Part
10 -
To 14290 Harness (Part of of 90930)
-
90930) 19 To Water Temperature
11 -
To Camshaft Position (CMP) Indicator Sender Unit (Part of
Sensor (Part of 90930) 90930)
-
12 -
To LH Ignition Coil (Part of 20 To Generator (Part of
90930) 90930)
-
13 -
To LH Radio Ignition 21 To Engine Coolant
Interference Capacitor (Part Temperature (ECT) Sensor
of 90930) (Part of 90930)
-
14 -
To Crankshaft Position 22 To Fuel Injection Supply
(CKP) Sensor (Part of Manifold Ground (Part of
90930) 90930)
-
15 -
To A I C Compressor (Part of 23 To Idle Air Control (lAC)
90930) Valve (Part of 90930)
-
16 -
To EGR Vacuum Regulator 24 To Throttle Position (TP)
(EVR) Sensor (Part of Sensor (Part of 90930)
90930)
(Continued)
� 52. Install spark plugs. Tighten to 9-20 N-m (BQ- 1 77

lb-in).
53. Install ignition wires as described in Section
03-078.
Subassemblies
Cylinder Head

Valve Spring Spacer T91 P-6565-AH
Valve Stem Seal Replacer T9 1P-6571-A
Driver Handle TSOT-4000- W
Disassembly
1. NOTE: Camshaft (6250) must be at base circle
�
T91P-6565-AH
before compressing valve spring (65 1 3). Rotate
camshaft as required unt� all rocker arms (6564)
are removed. VIEW A
Install Valve Spring Compressor T91 P-6565-A
under camshaft and on top of valve spring A15052-C
retainer (65 14).
3. Compress valve spring far enough to remove
2. Install Valve Spring Spacer T9 1 P-6565-AH rocker arm.
Repeat Steps 1 , 2 and 3 until all rocker arms are
removed.
4. Remove all valve tappets (6500).

03-01 8-99 Engine, 4.6L (2V) 03-01 8-99
5. Further compress valve spring and remove valve 8. Tap upward on camshaft bearing caps to
spring retainer keys (65 1 8), valve spring retainer gradually lift camshaft bearing caps from cylinder
and valve spring. head. Remove camshaft.
NOTE: VALVE TAPPET MUST

BE PUMPED UP BEFORE
INSTALLAOON
Part NOTE: LH SHOWN
Item Number Description RH SIMILAR
1 6507 Intake Valve A14818-C
2 6505 Exhaust Valve
3 657 1 Valve Stem Seal Part
4 65 13 Valve Spring Item Number Description
5 6514 Valve Spring Retainer 1 6B280 Front Camshaft Bearing Cap

6 6518 Valve Spring Retainer Key 2 N807352 Bolt (2 Req'd)
3 6B280 Rear Camshaft Bearing Cap
6. Remove valve stem seal (657 1 ) using locking
pliers and remove intake valve (6507) and 4 6250 Camshaft
exhaust valves (6505). 5 6564 Rocker Arm (8 Req' d)
6 6500 Valve Tappet (8 Req'd)
8 N806070 Bolt (12 Req'd)
-
A Tighten to 8·12 N·m (7 1-106
Lb-ln)
Assembly
1. Position camshaft on cylinder head. Apply oil to
journals and lobes of camshaft.
2. Install and seat camshaft bearing cap. Hand-start
1 4 bolts.
3. NOTE: Each camshaft bearing cap is tightened
individually.
lighten camshaft bearing cap retaining bolts in
sequence to 8- 1 2 N·m (7 1 - 1 06 1b-ln).
7. Remove 1 4 bolts retaining camshaft bearing caps

(68280) to cylinder head (6049).

03-0 1 8- 1 00 Engine, 4.6L (2V) 03-0 1 8- 1 00
Installation Sequence 1 1 . Compress valve spring far enough to install valve

spring retainer key.
1 2. Repeat Steps 6 through 1 1 until all intake valves
and exhaust valves are installed.
13. NOTE: Camshaft must be at base circle prior to
compressing valve spring. Rotate camshaft as
necessary until all rocker arms are installed.
Compress valve spring using Valve Spring
Compressor T91 P-6565-A far enough to install
rocker arm.
Pistons and Piston Pins
Disassembly
1. Using Piston Pin Tool 08 1 L-6 1 35-A or equivalent,
press piston pin (6 1 35) through piston (61 08)
and connecting rod (6200).
_ FRONT OF __ __ FRONT OF 2. Clean and inspect piston and connecting rods.
-
ENGINE ENGINE Check piston and piston pin fit. Refer to Section
03-QO.
LH CYLINDER RH CYLINDER
HEAD HEAD Assembly
A14817-D
1. Apply a light coat of clean engine oil to all parts.
2. Verify that all parts to be assembled are for same
4. Loosen 14 camshaft bearing cap retaining bolts cylinder. Assemble piston to connecting rod.
approximately two turns or until head of bolt is
free. 3. Start piston pin in piston and connecting rod. This
may require a very light tap with a mallet. Using
5. Retighten all bolts in sequence to 8-1 2 N-m Piston Pin Tool 08 1 L-61 35-A or equivalent press
(7 1-106 1b-in). piston pin through piston until piston pin is
6. NOTE: A knotted rag or similar item must be centered in piston. After assembly, make sure
positioned under intake valve and exhaust valve connecting rod swings smoothly.
to hold them in the UP position.
Install valves into cylinder head.
MAKE CERTAIN
7. Install new valve stem seals using Valve Stem 'PISTON FLOATS
Seal Replacer T91 P-657 1-A. DURING
INSTALLATION
OPERATION
AB122..C
Piston Rings
AA0635-A Disassembly and Assembly

1. Remove piston rings using a piston ring expander.
8. Position valve spring and valve spring retainer
onto valves. 2. Clean and inspect
. piston as described in Section
03-QO.
9. Install Valve Spring CompresSor T91 P-6565-A,
under camshaft and on top of valve spring 3. Verify piston ring end gap as described in Section
retainer. 03-00.

03·018·101 Engine, 4.6L (2V) 03·018-101
4. Install oil ring expander and two rails by hand. 3. Remove the plunger, the check valve and the
Position oil ring rail and expander gaps as shown. check valve retainer and plunger spring. Carefully
remove the plunger spring, the check valve
retainer and the check valve disc from the
UPPER SIDE---- plunger.
RAIL £lil,ll;a...lllol1liL
Assembly
1. Place the plunger upside down on a clean work
bench.
2. Place the check valve (disc or ball check) in
EXPANDER position over the oil hole on the bottom of the
plunger. Set the check valve spring on top of the
check valve (disc or ball check).
3. Position the check valve retainer over the check
valve and spring and push the retainer down into
LOWER SIDE place on the plunger.
RAIL------- A15063-A 4. Place the plunger spring, and then the plunger
(open end up) into the valve tappet body.
5. Using a piston ring expander, install two
compression rings as shown. Follow instructions 5. Position the metering valve (disc) in the plunger,
on the piston ring package. and then place the push rod cup in the plunger.
6. Depress the plunger, and position the closed end
of the lock ring in the groove of the valve tappet
body. With the plunger still depressed, position
the open ends of the lock ring in the groove.
Release the plunger and then depress it again to
fully seat the lock ring.
Cylinder Block Assembly
Disassembly
1. Mount the engine i n a work stand and remove all
parts not furnished with the new cylinder blocks
(60 1 0), following procedures in-Removal and
Installation.
��ii� o- roP
�
2. Remove the cylinder head to block dowel
COMPRESSION (6A008) and the cylinder block drain plugs .
.,., RING
�
3. Remove the used cylinder blocks from the work
COMPRESSION stand.
D r--ef!- OIL RING

Assembly
1. Clean the gasket and seal surfaces of all
Leb EXPANDER AND RAILS serviceable parts and assemblies.
A15064-A 2. Position the new cylinder blocks in a work stand
and install the cylinder head to block dowel and
Hydraulic Valve Tappet cylinder block drain plugs.
The internal parts of each hydraulic valve tappet are 3. Transfer all serviceable parts removed from the
matched sets. Do not intermix the parts. Keep the used cylinder blocks, following procedures in
valve tappets intact until they are to be cleaned. Valve Removal and Installation.
tappets should always be tested after assembly.
Refer to the Service procedures in Section 03-00 . 4. Check all assembly clearances and correct as
necessary.
Disassembly
Cylinder Block, Bare
Disassemble and assemble each valve tappet
separately. Identify the valve tappets so they can be Before replacing a cylinder blocks, determine if if is
installed in their original bores. serviceable. Service as necessary.
. Refer to Section
03.00.
1. Grasp the lock ring with needle nose pliers to
release it from the groove. It may be necessary to Disassembly
depress the plunger to fully release lock ring. 1. Completely disassemble the used engine,
2. Remove the push rod ball, metering valve (disc), following procedures in Disassembly and
plunger and spring. Assembly.
2. Remember to ridge ream the cylinder bores
before removing pistons.

03·01 8- 1 02 Engine, 4.6L (2V) 03·01 8- 1 02
3. Remove the cylinder head to block dowel and the ENGINE SPECIFICATIONS (Cont'd)
cylinder block drain plug.
Description Specification
Assembly Valve Face Runout Limit 0.05 mm (0.00197 in)
1. Clean the gasket and seal surfaces of all Valve Face Angle 45.5 degrees
serviceable parts and assemblies.
Valve Stem Diameter (Std)
2. Position the new cylinder blocks in a work stand • Intake 6.995-6.975 mm
and install the cylinder head to block dowel and (0.2754-0.2746 in)
the cylinder block drain plugs. • Exhaust 6.970-6.949 mm
3. Transfer all serviceable parts removed from the (0.2744 1-Q.27358 in)
used cylinder blocks, following the procedures in Valve Springs
Disassembly and Assembly. Compresalon Pressure N @
Spec Length
necessary. e lntake 667 N@ 28.02 mm ( 1 50 Lb
@ 1 . 1031 in)
• Exhaust 667 N @ 28.02 mm ( 150 Lb
@ 1 . 1 03 1 in)
SPECIFICATIONS • Free Length
(Approximate)
ENGINE SPECIFICATIONS e lntake 50.2 mm ( 1 . 9764 in)
• Exhaust 50.2 mm ( 1 . 9764 in)
Installed Pressure N @ Spec
GENERAL SPECIFICATIONS Length
Displacement 4.6L (281 CID) • Intake 289. 1 N @ 40.0 mm
(84.9897 Lb @ 1 .5748 in)
Number of Cylinders 8
• Exhaust 289. 1 N@ 40.0 mm
Bore and Stroke 90.2 x 90.0 mm (3.55 x (84.9897 Lb @ 1.5748 in)
3.54 in)
• Service Limit 10% Pressure Loss @
Firing Order 1 -3-7-2-6-5-4-8 28.02 mm ( 1 . 1031 in)
011 Pressure (Hot, 1500 RPM) 138-3 10 kPa (20.01 -44.95 • Out of Square Limit 2.5 Degrees
psi) Rocker Arm
•
Drive BeH Tension • Ratio 1 .82: 1
CYLINDER HEAD AND VALVE TRAINb Valve Tappet
Combustion Chamber Volume 50 ± 1 cm3 (3. 1 73 ±0.09 1 5 • Diameter (Std) 18.000- 1 5.966 mm
in3) (0.6299-0.6294 in)
• Clearance to Bore 0.018-Q.089 mm
Valve Sests
(0.0007 1-0.00272 in)
• Width-Intake 1.9-2 . 1 mm (0.0748-Q.0827
• Service Limit 0.018 mm (0.006299 In)
in)
• Hydraulic Leakdown 5·25 seconds
• Width-Exhaust 1 .9-2. 1 mm (0.0748-Q.0827
Rate•
in)
• Collapsed Valve Tappet 0.85-Q.45 mm
• Angle 45 degrees
Gap-Desired (0.03346-0.0 1772 in)
• Runout (T.I.R.) MAX 0.025 mm (0.00098 in)
CAMSHAFT
Valve Arrangement
(Front-to-Rear) Lobe Lift
(Left Hand)E-1-E-1-E-1-E·I • Intake 8.58077 mm (0.2594 in)
(Right Hand)I-E-1-E-1-E-1-E • Exhaust 8.58077 mm (0.2594 in)
• Allowable Lobe Lift Loss
Valve Stem to Guide Clearance
• Intake 0.020-0.069 mm Theoretical Valve Lift @ Zero
(0.00787-0.027 1 7 in) Lash
• Exhaust 0.045-0.095 mm • Intake 1 2.0 mm (5.6693 in)
(0.00 181-Q.00374 in) • Exhaust 1 2.0 mm (5.6693 in)
Valve Head Diameter End Play 0. 025-o. 166
• Intake 44.5 mm ( 1 . 752 in) (0.06098·0.00740 in)
• Exhaust 34.0 mm ( 1 .339 in) • Service Limit 0. 1 90 mm (0.00748 in)
• Gauge Diameters 42.5 mm and 32.0 mm Journal to Bearing Clearance 0.025-Q.076 mm
( 1 .6732 in and 1 . 2598 in) (0.00098·0.00299 in)
(Continued) • Service Limit 0. 1 2 1 mm (0.00476 in)
(Continued)

03-018-103 Engine, 4.6L (2V) 03-01 8- 1 03
ENGINE SPECIFICATIONS (Cont'd) ENGINE SPECIFICATIONS (Cont'd)
Description Specification Description Specification

Journal Diameter (All) 26.962-26.936 mm CYLINDER BORE AND PISTON
( 1 .06 15-0. 1 0605 in)
Cylinder Bore
• Bearing Inside Diameter 27.0 1 2-26.987 mm
( 1 .0635- 1 .0628 in) Diameter
(All)
• Surface Finish (RMS) 0.2-Q.6 MICRONS
CYLINDER BLOCK
Head Gasket Surface b • Out-of-Round Service 0.020 mm (0.000787 in)
Head Gasket Surface Flnlshd Limit
Main Bearing Journal Diameter 72.402-72.422 mm • Taper Service Limit 0.006 mm (0.0002 36 in)
(2.850 1 -2.85 1 3 in) Piston
CRANKSHAFT AND FLYWHEEL • Diameter"
Main Bearing Journal Diameter 67.483-67.503 mm • Coded Red 1 90. 167-9.0 1 80 mm
(2.6569-2.6576 in) (3.549875-3.550387 in)
• Coded Blue 2 90. 1 80-90. 193 mm
Connecting Rod Journal 52. 988-53.003 mm
(3.550387-3.550896 in)
Diameter (2.086 14-2.08673 in)
• Coded Yellow 3 90. 1 93-90.206 mm
Crankshaft Free End Play 0. 1 30-0.301 mm (3.550898 -3.55 1 4 1 in)
(0.005 1 9-0.0 1 185 1 in)
Piston-to-Bore Interference
Crankshaft Runout to Rear 0.050 mm (0.00196 in)
• Clearance 0.012-0.026 mm
Face of Block MAX
(0.0004724-0.0010236 in)
Connecting Rod Bearings
Pin Bore Diameter 2 1 .995-2 1 .997 mm
Clearance to Crankshaft (0.86594-0.86602 in)
• Desired 0.027-0.069 mm Ring Groove Width
(0.00 106-0.002 7 1 7 in)
• Compression (Top) 1 . 530- 1 . 550 mm
• Allowable 0.027-0.069 mm (0.06024-0.061024 in)
(0.001 06-0.0027 1 7 in)
• Compression (Bottom) 1 . 520- 1 .540 mm
Bearing Wall Thickness (Std)" 2.444-2.452 mm (0.05984-0.060630 in)
(0.0962-0.0965 in) e Oii Ring 3.030-3.055 mm
Main Bearings (0. 1 1 929-0. 1 2028 in)
Clearance to Crankshaft Piston Pin

• Desired 0.027-0.065 mm • Length 61.93-62.05 mm
(0.00 1 06-0.00256 in) (2.4381 8-2.44291 in)
• Allowable 0.027-0.065 mm • Diameter 2 1 .994-21 ,999 mm
(0.00106-0.00256 in) (0.8659-0.8661 in)
Bearing Wall Thickness (STD)d 1 .920- 1 .928 mm Pin to Piston Interference 0.005-0.01 1 5 mm
(0.07559-0.07590 in) (0.000 1 968-0.0004527 in)
Connecting Rod, Piston and Pin to Rod Clearance 0.01 5-0.040 mm

Rings (0.00059 1 -0.001575 in)
Connecting Rod Piston Ring Gap

• Piston Pin Bore Diameter 2 1 .959-2 1 .979 mm • Compression (Top) 1 .0 mm (0.03937 in) MAX
(0.8645-0.8653 in) • Compression (Bottom) 1 . 0 mm (0.03937 in) MAX
• Crankshaft Bearing Bore 56. 756-56.876 mm Oil Ring
Diameter (2.23446-2.23921 in)
• Side Clearance 1 .25 mm (0.0492 in) MAX
• Length 150.7 mm (5.933 in)
• Compression (Top) 0.40-Q.090 mm
(Center-to-Center)
(0.001575-Q.003543 in)
Alignment (Bore-To-Bore Max. • Compression (Bottom) 0.030-Q.080 mm
Diff.)1 (0.001 1 8-0.003 1 5 in)
• Twist 0.050 mm per 25 mm • Oil Ring Snug Fit
(0.00 197 in per 0.9843 in)
• Service Limit 0.015 mm (0.00059 1 in)
• Bend 0.038 mm per 25 mm MAX
(0.00 150 in per 0.9843 in)
Ring Gap
Side Clearance (Assembled to
• Compression (Top) 0.23-0.49 mm
Crank) (0.009 1-Q.01 929 in)
• Standard 0.01 5-0.45
• Compression (Bottom) 0.23-0.49 mm
(0.00059-0.0 1 772 in)
(0.009 1-0.0 1 929 in)
• Service Limit 0.50 (0.0 196 in) MAX
• Oil Ring (Steel Rail) 0. 1 5-0.66 mm
(Continued) (0.0059 1 -0.02598 in)
(Continued)

03-01 8- 1 04 Engine, 4.6L (2V) 03-01 8- 1 04
ENGINE SPECIFICATIONS (Cont'd) TORQUE SPECIFICATIONS
Description Specification Description N-m Lb-Ft Lb-ln

LUBRICATION SYSTEM • • -
Crankshaft Main Bearing Cap
Oil Capacity 5.0 Liters (5.3 Quarts) Adjusting Screw
b .. -
a Newly installed -Refers to the condition of the NEW drive Main Bearing Cap Side Bolts
belt before the engine has made no more than one rotation Camshaft Sprocket Bolt 1 10- 1 30 82-95 -
and before the engine has made no more than one rotation
c c -
and before the belt has had a chance to stretch or seat into Connecting Rod Bolt
the pulley grooves. Engine Front Cover Bolt -
20-30 15-22
b Head Gasket Surface -WT= 10.0 minus 2.5 microns.
d d -
Rzdin= 13.5 microns with a 2.5 mm (0.0984 inch) cut off. Cylinder Head Bolt
c Time required for plunger to leak down 1 .6 mm of travel with h h -
222 N force and leak down fluid in tappet. Pulley to Crankshaft Bolt
d Head Gasket Surface Finish Overall: 0. 1 50 mm, 150 x 1 50: EGR Valve to Intake Manifold 20-30 1 5-22 -
0.50 mm, 40 x 40: 0.030 mm.
Exhaust Manifold to Cylinder 1 8-22 14- 1 6 -
TPI=63% mm@ 3.5 microns with 2% reference
RA=3.0-3.5. Head Nut
e 0.050 Undersize -add 0.025 to standard thickness. Flywheel to Crankshaft Bolt 73-87 54-64 -
f Pin bore and crank bearing bore must be parallel and in
same vertical plane within the specified total difference Intake Manifold to Cylinder 20-30 1 5-22 -
when measured at the ends of a 203 mm bar, 1 0 1 .5 mm on Head Bolt

each side of rod centerline. • • -
Main Bearing Cap Bolt
g Measured at the piston pin bore centerline, at 90 degrees to
the pin. Oil Filter Adapter Bolt 20-30 15-22 -
I I -
Oil Bypass Filter to Adapter
DRIVE BELT TENSION
Oil Inlet Tube to Oil Pump Bolt 8- 1 2 - 7 1 -106
NOTE: Belts have differing tension specifications
depending on whether they are Newly installed• or Oil Pan Drain Plug 1 1-16 9- 1 1 -
Used (more than ten minutes of engine operation). g g -
Oil Pan to Cylinder Block Bolt
When belts are found to be below the allowable
minimum they must be "RESET" (adjusted). Oil Pressure Sensor 16-24 12- 1 7 -
Specifications for these situations are shown below: -
Oil Pump to Cylinder Block Bolt 8- 1 2 7 1- 1 06
Belt Type Belt Tension In Lbs. Oil Inlet Tube t o Main Bearing 20-30 15-22 -
Cap Nut
6 Rib (Fixed)., 1 10- 1 20
Water Pump to Pulley Bolt 20-30 15-22 -
a. Newly Installed-Refers to the condition of the -
"NEW" drive belt before the engine has made no Spark Plug to Cylinder Head 9-20 80-177
more than one rotation and before the belt has Generator to Cylinder Block 20-30 15-22 -
had a chance to stretch or seat into the pulley Valve Cover Bolt I Stud Bolt 8- 1 2 - 7 1 -106
grooves.
Water Outlet Connection Bolt 20-30 15-22 -
b. "FIXED" refers to systems with manually adjusted
centers which are bolted in place and considered Water Pump to Cylinder Block 20-30 15-22 -
fixed. Bolt
H02S 37-45 28-33 -
LUBRICANTI ADHESIVE/CLEANER SPECIFICATIONS -
EGR Tube Connector 45-65 34-47
Ford EGR Valve to Exhaust Mani.fold 35-45 26-33 -
Description Part Number Specification Tube-to-Connector
Silicone Gasket F6AZ- 1 9562-AA WSE-M4G323-A6 Exhaust Manifold to Dual 27-41 2Q-30 -
and Sealant Converter and Pipe Nuts

Gasket and Trim D7AZ- 1 9B508-B ESR-M 1 1 P 1 7-A Front Engine Support 20-30 1 5-22 -
Adhesive Insulators
Metal Surface F4AZ- 1 9A536-RA WSE-M5B392-A Front Engine Support Insulator 20-30 15-22 -
Cleaner Through Bolts
Engine Oil X0-5W30-QSP WSS-M2C 153-F Power Steering Pump to 20-30 1 5-22 -
Premium Cooling E2F2- 19549-AA ESE-M97B44-A Engine
System Fluid Ignition Wire Separator-to-Coil 8- 1 2 - 7 1 - 1 06
Premium Cooling CXC-8-B (Canada) ESE-M97B44-A Brackets
System Fluid Oil Level Indicator Tube Nut 8- 1 2 - 7 1- 1 06
Anaerobic Gasket - WSK-M2G348-A9 Fuel Injection Supply Manifold 8-12 - 7 1 - 106
Compound Sealer Retaining Bolts
Heater Water Hose Retaining 20-30 1 5-22 -
Bolt
EGR Backpressure Transducer 20-30 1 5-22 -
Bracket Bolt
(Continued)

03-018-105 Engine, 4.6L (2V) 03-01 8- 1 05
TORQUE SPECIFICATIONS (Cont'd) d. lighten in 6 steps:

Description N·m Lb-Ft Lb-ln ( 1 ) lighten bolts in sequence to 37-43 N·m
Camshaft Bearing Cap to 8- 12 -
7 1 - 1 06
(27-32 Lb-Ft)
Cylinder Head (2) Rotate bolts in sequence 85-95 degrees
-
Rear Engine Support Insulator 40·60 30-44 (3) Loosen bolts a minimum of one full turn.
to Transmission Retaining Bolt
-
(4) lighten bolts in sequence to 37-43 N-m
Torque Converter Retaining 30-35 23-25
(28-3 1 Lb-Ft)
Nuts
Engine·to·Transmission 25·43 19-31 -
(5) Rotate bolts in sequence 85-95 degrees
Brackets (6) Rotate bolts in sequence an additional 85-95
Engine Lifting Eye Bolts 40-50 30-36 - degrees
Transmission Line Bracket 20-30 15·22 - e. lighten in 2 steps:
-
Timing Chain Tensioner Bolts 20·30 15·22 ( 1) lighten bolts in sequence to 37-43 N·m
A I C Compressor Retaining 20·30 15-22 - (28-3 1 Lb-Ft)
Bolts (2) Rotate bolts in sequence 85-95 degrees
-
CKP and CID Sensor Retaining 8· 1 2 7 1 - 106 f. lighten 3 I 4 turn after gasket contacts sealing
Bolts
surface.
-
ECT Sensor 16·24 12· 1 7
g. lighten bolts in sequence to 20 N·m ( 1 5 1b-ft) then
-
lAC Valve Bolts 8- 12 7 1 - 106 rotate bolts an additional 60 degrees
-
Water Temperature Indicator 1 6-24 1 2- 1 7 h. lighten in four steps:
Sending Unit
-
( 1 ) Ttghten to 90 N·m (67 1b-ft).
Throttle Body and Adapter 8- 1 2 7 1 - 1 06
Bolts (2) Loosen one full turn.
-
Cable Bracket Retaining Bolt 8- 1 2 7 1 - 106 (3) lighten to 50 N·m (37 1b-ft).
-
Front Sub-Frame to Body Bolts 95- 1 30 70·96 (4) lighten an additional 90 degrees.
-
Rear Engine Support Insulator 20-30 1 5-22
to Support
-
Differential Housing to Rear 98·120 73·88 SPECIAL SERVICE TOOLS/ EQUIPMENT
Sub-Frame Nut and Bolts
-
Front Suspension Lower Arm 1 60-220 1 18-162 SPECIAL SERVICE TOOLS REQUIRED
to Front Spring and Shock
Rear Axle Differential Insulator 102- 127 76-93 -
Tool NumberI
Nuts
- T58P-6316-D
Driveshaft Center Socket Yoke 95-130 7Q-95
Crankshaft Damper Remover
�
to Rear Axle 4·Joint Flange
-
Front Suspension Upper Arm 68-92 5 1 ·67
to Front Wheel Spindle
�111-11
a. lighten in 2 steps:
T74P·63 16·B
�
( 1) lighten to 5 N·m (44 Lb-ln) Crankshaft Damper Replacer
(2) lighten to 9-1 1 N·m (80-97 Lb-ln)
b. lighten in 2 steps:
T7_.....
( 1) lighten bolts in sequence to 1 0 N·m (7 Lb-Ft)
T74P-6700·A
(2) lighten bolts in sequence 1 9-23 N·m ( 1 4- 1 6 Front Cover Seal Remover
�
Lb-Ft)
c. lighten in 2 steps:
( 1) lighten bolts to 4Q-45 N·m (3Q-33 Lb-Ft) T7-
(2) Rotate bolts 9Q- 1 20 degrees

�
TSOT-4000- W
Driver Handle
TIOT�W
(Continued)

, --
03-01 8- 1 06 Engine, 4.6L (2V) 03-01 8- 1 06

(Continued)
SPECIAL SERVICE TOOLS REQUIRED (Cont'd) SPECIAL SERVICE TOOLS REQUIRED (Cont'd)
Tool NumberI Tool NumberI

Description Illustration Description Illustration
T88T-670 1-A T92P-6256-A
~ QTmP�a.A
Crankshaft Seal Cam Positioning Tool Adapters
Replacer I Cover Aligner
TUT.-701-A T93P-6303-A
~
Crankshaft Holding Tool
T81P- 1 9623-G 1
Spring Lock Coupling
~
Disconnect Tool (3 / S inch)
.... ... .
T64L-60 1 1 -EA
Cylinder Ridge Reamer
T8 1 P- 1 9623-G2
Spring Lock Coupling
Ta1P-1182S-G1
• lMI..-111 1.0
~
Disconnect Tool ( 1 / 2 1nch)
SPECIAL SERVICE TOOLS DESIRED
Tool Number Description

TB1P-11123-G2 081 L-6002-D Piston Ring Compressor
T91 P-6256-A D8 1 L-6 1 35-A Piston Pin Tool
�
Cam Positioning Tool TOOL-420 1-C Dial Indicator With Bracketry
ROTUNDA EQUIPMENT
Ta1-56-A
Model Description
T91P-6565-A 0 14-00292 Cylinder Ridge Reamer
~
Valve Spring Compressor
0 14-00334 Engine Lift Bracket Set
0 14-0034 1 Transmission Support
0 14-00765 Powertrain Lift
Ta1 P-11515-A
0 14-0007 1 Floor Crane
T91 P-6565-AH
Valve Spring Spacer
� Tl1 P-1151H
15-A
T91 P-657 1-A

Valve Stem Seal Replacer
o:===J Tt1 P-e571-A
(Continued)

03-03- 1 Engine Cooling 03-03-1
SECTION 03-03 Engine Cooling

VEHICLE APPLICATION .. . . . . . ... .. ... .. . .. ... . 03-03-1
...... .... .. .. ....... REMOVAL AND INSTALLATION (Cont'd.)
DESCRIPTION AND OPERATION Radiator Draincock . . . . . . . ... .. ... .. . ........................ . ... 03-o3-1 7
Block Heater . . . .
............. .
.... . .................
03-Q3-6 ..... ............. Radiator Hoses . .. .. .
......... ......... . ... ............ ............ 03-o3-1 3
Constant Control Relay Module . . . . ... ......
03-o3-5 .. ... ............ Thermostat, Water . . . . . . ... . .. .... ... ... ......................... 03-o3-1 3
Coolant Recovery System . . ... .. . .. ...
o3-o3-3 ........... . . . . . . .. . . . . . . Water Pump . .. .
......................... .. ......... ................. o3-o3-1 3
Cooling Fan, Electric . . . .. . . . .. . . .. . .
.. .. .. .......
o3-o3-5 .... .. ... ....... Water Temperature Indicator Sender
Cooling System ... .
................ . . .....................
03-o3-1 .. ........ Unit ... . . .
...... ... . .. . . .
.. ............... ... ... .. .. ............... . o3-o3-1 8
..
Electrical System .. . . . . . ..
.. ........ . . . . 03-o3-3
... ... .. .. ......... ... .. ... . SERVICE PROCEDURES
Radiator .... .. .
..... .. . . .
... . ..... . .. ..
.... ... ...........
o3-o3-4 ... ... ......... Radiator Core . . . . .
............ ... ... ... ... ......................... 03-o3-1 9
Thermostat, Water . . .. . . . ...... .
.... ..
... ...
03-o3-5 ... ........ ....... ..... Transmission Fluid Cooler Connection
DIAGNOSIS AND TESTING Leaks . . . .
... .. . .. . . . . .
.... ................ .. .. ... .. ... .. ........ . o3-o3-19
...
Electrical Schematic .. .......... .. . . .................

o3-o3-6 .... ......... CLEANING AND INSPECTION
Engine Cooling . .. .......... .. ..
.. . .o3-o3-6
................ ... ........... ... Coolant Condition Check . ...................... ....... . . .. ... 03-o3-20
Component Tests . . . . ..... . . . .. .
... .... ...
03-o3-10 ....... . ... .. ....... Cooling System Draining, Filling and
Inspection and Verification . . .. .... . . . . . . . 03-Q3-6
. .. .. ....... .. .. .. Bleeding .. . . . .. . ..
........ . . . .. .
.. ........ . ..... ... .. ... .. ....... .o3-o3-2 1
Pinpoint Tests . .
.............. . . .................
03-Q3-7 ... . . . . . . .. . . . . . . Cooling System Hoses and Clamps ................... . 03-o3-21
..
Symptom Chart .. .. .
...... ... ..
.. ..... . o3-o3-6
.......... .... ........... . Cooling System, Cleaning ... . ................... ... ... . ...... 03-o3-22
REMOVAL AND INSTALLATION Cooling System Flush Procedure ...................... 03-o3-22
Block Heater . .. .. .. . ... .
.......... . .. . ....... ........
03-o3-1 8 .. ... .......... Heater Core Back-Flushing . . ................. ... ... . . . 03-o3-22
.. .
Block Heater Wiring . .... . .

................ 03-03-1 8 ............... .. ..... Fan Blade . .
................ . . . ......... .. ... ..................... . . o3-o3-23
..
Control Relay Module, Constant . . ..

03-o3-1 5 ........... ............ Pressure Relief Cap . . . . .. .
..... .. ...... ................. ... . .03-o3-22
...
Engine Coolant Temperature (ECT) Radiator . .

............................... .. ........................... o3-o3-23
Sensor .. . .
............. .
...... . . 03-o3-18
............... ................. ... Radiator Coolant Level Check . . . . .. .. ..... ................. 03-o3-1 9
Engine Cooling Fan Motor, Fan Blade and Fan SPECIFICATIONS
Shroud Assembly, Electricai . . . . . ..03-Q3-1 5
.... .. ... .. ........ ... Coolant Mixture . .. . .
..... ... . . ............. .. ...... . .. ...... .. .... o3-o3-23
Radiator ... .. .
................... . . .. 03-o3- 14
.............. ............... ... . SPECIAL SERVICE TOOLS/EQUIPMENT . .. ............... 03-o3-24
Radiator Coolant Recovery Reservoir /Degas
Bottle ...
..... ...
............... .. . . . ...... .03-o3-1 4
......... ... .... . . . . . . . ..
VEHICLE APPLICATION
Thunderbird, Cougar
Cooling System • The coolant expands as the temperature rises and

pressure rises in the cooling system. When the
"Walter C. Avrea, the owner of patents 3, 60 1 , 1 8 1
and RE 27, 965, has granted Ford Motor Company limiting system working pressure is reached, the
rights with respect to cooling systems covered by pressure relief valve in the pressure relief cap is
these patents. " lifted from its seat and allows coolant to flow
through the radiator overflow hose (8075) into the
WARNING: TO AVOID THE POSSIBILITY OF radiator coolant recovery reservoir (8A080) on
PERSONAL INJURY OR DAMAGE TO THE 3.8L engines or degas bottle on 4.6L (2V) engines.
VEHICLE, DO NOT OPERATE THE ENGINE WITH
• Most vehicles use an ethylene glycol-base
THE HOOD { 1 66 1 2) OPEN UNTIL THE FAN BLADE
antifreeze solution to which the manufacturer has
{8600) HAS BEEN FIRST EXAMINED FOR
POSSIBLE CRACKS AND SEPARATION. added a dye color. The dye color makes the
antifreeze solution an excellent leak detector.
The engine cooling system operates in the following
• NOTE: Use only a permanent-type coolant such as
manner:
Premium Cooling System Fluid E2FZ- 1 9549-AA (in
• Engine coolant flows through the radiator tubes and Oregon, F5FZ- 1 9549-CC; in Canada, CXG-8-B),
is cooled by air passing over the cooling fins recycled coolant or equivalent meeting Ford
assisted by the cooling fan or fans (depending upon specification ESE-M97B44-A.
application).
• The pressure relief cap has a rubber seal on the
• Coolant is then circulated from the radiator outlet underside to prevent leakage.
tank through the water pump (850 1 ) and into the
cylinder blocks (60 1 0) to complete the circuit.

03-03-2 Engine Cooling 03-03-2
• When cooling system temperature and pressure • The constant control relay module
drop, the coolant contracts in volume, reducing (CCRM)( 1 2858 1 ) activates the cooling fan motor
pressure in the radiator (8005). Coolant in the when coolant or engine reach a specified
radiator coolant recovery reservoir on 3.8L engines temperature.
or degas bottle on 4.6L (2V) engines will then flow
• On vehicles equipped with air conditioning, the
back into the radiator through the vacuum relief
cooling fan motor is activated whenever the A / C
valve in the pressure relief cap.
clutch (2884) is engaged.
Engine Cooling System- Typical
Part Part
1 18476 Heater Core 9 - Radiator Outlet to Engine
2 - Heater Outlet (Part of (Part of 8005)
18476) 10 8501 Water Pump
3 9424 Lower Intake Manifold 11 60 10 Cylinder Blocks (RH Bank)
(Water Crossover I Outlet) 12 - Radiator Inlet from Engine
4 8A574 Coolant System Air Bleed (Part of 8005)
5 8575 Water Thermostat 13 8A080 Radiator Coolant Recovery
6 8597 Water Bypass Hose Reservoir or Degas Bottle
7 8592 Water Hose Connection (To 14 6049 Cylinder Head (RH Bank)
Radiator Inlet) 15 605 1 Head Gasket
8 6010 Cylinder Blocks (LH Bank) 16 - Heater Inlet (Part of 18476)
!""'""' (Continued)

Electrical System WARNING: ON VEHICLES EQUIPPED WITH THE

NOTE: With A I C ON, the cooling fan motor will run 4.6L ENGINES NEVER REMOVE THE PRESSURE
continuously. Cooling fan motor will not cycle ON and RELIEF CAP UNDER ANY CONDITIONS WHILE
OFF with AIC clutch (2884). THE ENGINE IS OPERATING. FAILURE TO
FOLLOW THESE INSTRUCTIONS COULD RESULT
NOTE: An exception to this is when vehicle speed is IN DAMAGE TO THE COOLING SYSTEM OR
over 72 km I h (45 mph) and coolant temperature is ENGINE AND/OR PERSONAL INJURY. TO AVOID
below 104 oc (220 °F). The cooling fan motor will then HAVING SCALDING HOT COOLANT OR STEAM
automatically shut off. BLOW OUT OF THE COOLING SYSTEM, USE
The cooling fan motor is mounted within a shroud EXTREME CARE WHEN REMOVING THE
behind the radiator (8005). The constant control relay PRESSURE RELIEF CAP FROM A HOT COOLING
module actuates the cooling fan motor when: SYSTEM. WAIT UNTIL THE ENGINE HAS COOl-ED,
THEN WRAP A THICK CLOTH AROUND THE
• the coolant reaches a specified temperature. PRESSURE RELIEF CAP ANO TURN IT SLOWLY
• the engine reaches a specified speed. UNTIL PRESSURE BEGINS TO RELEASE. STEP
BACK WHILE THE PRESSURE IS RELEASED
• the A I C clutch is activated (if equipped), and the FROM THE COOLING SYSTEM. WHEN CERTAIN
vehicle speed is below 72 km l h (45 mph). ALL THE PRESSURE HAS BEEN RELEASED,
PRESS DOWN ON THE PRESSURE RELIEF CAP
(STILL WITH A CLOTH), TURN AND REMOVE
PRESSURE RELIEF CAP.
Coolant Recovery System The coolant recovery system operates as follows:
The 3.8L engine is equipped with a radiator cap
(81 00). • The system uses a 1 10 kPa ( 1 6 psi) pressure relief
cap, a plastic radiator coolant recovery reservoir
WARNING: ON VEHICLES EQUIPPED WITH 3.8L (8A080) on 3.8L engines or degas bottle on 4.6L
ENGINES NEVER REMOVE THE RADIATOR CAP (2V), and radiator overflow hose (8075).
UNDER ANY CONDITIONS WHILE THE ENGINE IS
OPERATING. FAILURE TO FOLLOW THESE • When coolant in radiator expands to the overflow
INSTRUCTIONS COULD RESULT IN DAMAGE TO point, it passes through the pressure relief cap and
THE COOLING SYSTEM OR ENGINE AND/OR into the radiator coolant recovery reservoir on 3.8L
PERSONAL INJURY. TO AVOID HAVING SCALDING engines or degas bottle on 4.6L (2V). When coolant
HOT COOLANT OR STEAM BLOW OUT OF THE in radiator cools down and contracts, it pulls coolant
RADIATOR (8005), USE EXTREME CARE WHEN from the radiator coolant recovery reservoir
REMOVING THE RADIATOR CAP FROM A HOT through a spring-loaded vacuum relief valve in the
RADIATOR. WAIT UNTIL THE ENGINE HAS pressure relief cap and back into the radiator.
COOLED, THEN WRAP A THICK CLOTH AROUND - Extra coolant is carried in the radiator coolant
THE RADIATOR CAP AND TURN RADIATOR CAP recovery reservoir on 3.8L engines or degas
SLOWLY TO THE FIRST PRESSURE STOP. STEP bottle on 4.6L (2V) engines.
BACK WHILE THE PRESSURE IS RELEASED
- Any air bubbles trapped in the cooling system
FROM THE COOLING SYSTEM. WHEN CERTAIN
are vented in the radiator coolant recovery
ALL THE PRESSURE HAS BEEN RELEASED,
reservoir on 3.8L engines or degas bottle on
PRESS DOWN ON THE RADIATOR CAP (STILL
4.6L (2V) engines.
WITH A CLOTH), TURN AND REMOVE RADIATOR
CAP.
The 4.6L engine is equipped with a pressure relief cap.

Coolant Recovery System - 3.8L Shown, 4.6L Radiator

Similar
NOTE: Whenever leaks or damage to radiator (8005)
are found, the entire radiator must be replaced as an
assembly.
Aluminum Core, Crossflow
The crossflow radiators used in base 3.8L and 4.6L
(2V) model Thunderbird, Cougar vehicles:
• are an aluminum tube and louvered fin-core design
with tubes arranged horizontally for crossflow of the
engine coolant.
• have two tanks, one on each side of the radiator,
that provide uniform coolant distribution to the
crossflow tubes.
• have an integral transmission oil cooler in the tank
on the left side of the radiator for cooling the
LEVEL transmission fluid.
SENSOR • are equipped with a coolant recovery system.
COOLANT
RECOVERY MOUNTING
RESERVOIR AND TAB
SENSOR ASSY
Q2061-C

Radiator-4.6L Engine Shown, 3.8L Engine Similar
INLET
TANK
03279-8
Cooling Fan, Electric Constant Control Relay Module

The cooling fan system consists of a fan blade (8600) WARNING: DISCONNECT THE COOLING FAN
and a two-speed cooling fan motor attached to a fan MOTOR PRIOR TO PERFORMING ANY
shroud (8 1 46) located behind the radiator (8005). UNDERHOOD SERVICE SINCE THE COOLING FAN
The cooling fan motor is wired to operate only when MOTOR COULD CYCLE IF THE IGNITION SWITCH
the ignition switch is in the ON position. This prevents IS LEFT IN THE ON POSITION EVEN THOUGH THE
the cooling fan motor from operating after the ignition ENGINE IS NOT RUNNING.
switch is turned to the OFF position. The cooling fan NOTE: Cooling fan motor will not cycle with A I C clutch
motor is serviced only as an assembly with the fan (2884). The cooling fan motor will come on when A I C
blade and the fan shroud. switch is turned ON.
The cooling fan motor is controlled during vehicle
operation by the constant control relay module
(CCRM)( 1 2B58 1 ) and powertrain control module
Thermostat, Water (PCM)( 1 2A650), which will energize the cooling fan
The water thermostat (8575) operates as follows: motor under the following conditions:
Cooling fan motor will run at low speed:
• When coolant is cold, the water thermostat is in the
closed position and engine coolant flow is restricted • if engine temperature is higher than normal. Cooling
to the cylinder blocks (60 1 0), cylinder head (6049), fan motor starts running at 1 06 ° C (222°F) and
intake manifold (9424) and heater core ( 1 8476). stops running at 1 0 1 oc (2 1 4 °F).
• As temperature increases, the water thermostat • if A I C is on and vehicle speed does not provide
opens and a portion of the coolant is allowed to enough natural airflow. Cooling fan motor starts
pass into the radiator (8005). running at speeds at or below 69 km I h (43 mph)
and stops running at 77 km l h (48 mph).
Cooling fan motor will run at high speed:
• if engine temperature is higher than desirable and
cooling fan motor has been operating at a low
speed.
• at 1 09 ° C (228°F) and stops running at 1 05°C
(220°F).

Block Heater • If coolant condition is satisfactory, check

The block heater (6A05 1) is designed to keep the coolant concentration for proper protection
engine coolant warm during cold weather to aid in cold level as described under Coolant Condition
starting and consists of: Check.
• If concentration level is low, partially drain the
• electrical heating element installed in one of the core cooling system by opening the radiator
plug openings in the cylinder blocks (60 1 0). draincock (8 1 1 5) or partially removing the
• electrical cable which plugs into a standard 1 1 0-volt lower radiator hose (8286). Secure the
ac electrical outlet. radiator draincock or hose clamp and add 1 00
percent concentration of Premium Cooling
System Fluid E2FZ- 1 9549-AA or -8 (in
DIAGNOSIS AND TESTING Oregon, F5FZ- 1 9549-CC; in Canada,
CXC-8-B), recycled coolant or equivalent
meeting Ford specification ESE-M97844-A to
Electrical Schematic obtain the recommended protection level. Wet
the rubber sealing surface of the pressure
Refer to Electrical and Vacuum Troubleshooting relief cap before installing the pressure relief
Manual, Cell 33, Cooling Fan for schematic and cap.
connector information.
3. If inspection reveals obvious concern(s) which
can be readily identified, service as required.
4. If the concerns remain after the inspection,
Engine Cooling determine the symptoms and go to the Symptom
Chart:
Inspection and Verification
Symptom Chart
engine cooling system to duplicate the concern. Refer to the Electrical and Vacuum Troubleshooting
Manual for connector numbers cited in the pinpoint
2. Inspect to determine if one of the following tests.
mechanical or electrical concerns apply:
Use Rotunda 73 Digital Multimeter 1 05-R005 1 or
VISUAL INSPECTION CHART equivalent to perform pinpoint tests.
Mechanical Electrical
• Damaged hoses. • Circuitry open I shorted.
• Loose / damaged hose • Damaged constant control
clamps. relay module.
• Damaged water thermostat. • Damaged cooling fan motor.
• Damaged head gasket. • Damaged pusher cooling
• Damaged intake manifold fan motor.
gasket. • Damaged powertrain
• Damaged water pump. control module (PCM).
• Damaged radiator.
• Damaged radiator coolant
recovery reservoir or degas
bottle.
• Damaged heater core.

COOLING SYSTEM
• Loss of Coolant • Damaged radiator. • GO to Pinpoint Test A.
• Damaged water pump .
• Loose I damaged radiator hoses .
• Loose I damaged heater water
hoses.
• Damaged heater core .
• Damaged engine gaskets .
• Damaged radiator coolant
recovery reservoir or degas
bottle.
• Engine Overheats • Low engine coolant. • GO to Pinpoint Test B.
• Damaged water thermostat.
• Damaged water pump .
• Internal coolant leak .
• Cooling tan motor and fan blade
inoperative.
• Plugged radiator .
• Plugged heater core .
• Engine Does Not Reach Normai • Damaged water thermostat. • GO to Pinpoint Test C.
Operating Temperature • Cooling fan motor and fan blade.
• Block Heater Does Not Operate • Block heater power cable. • GO to Pinpoint Test D.
Properly • Block heater.
• Cooling Fan Operates • Circuit. • REFER to the Powertrain
Continuously • Constant control relay module Control1/ Emission Diagnosis
(CCRM). Manual •
• Powertrain control module .
• Engine coolant temperature
sensor.
• Cooling Fan Runs, No Low Speed • Circuit. • REFER to the Powertrain
• Constant control relay module . Control/1 Emission Diagnosis
• Powertrain control module . Manual •
• Cooling tan motor.
• Cooling Fan Runs, No High Speed • Circuit. • REFER to the Powertrain
• Constant control relay module . Control 1/ Emission Diagnosis
• Powertrain control module . Manual •
• Cooling tan motor.
Pinpoint Tests
PINPOINT TEST A: LOSS OF COOLANT

Test Step Result .... Action to Take
A1 I CHECK ENGINE COOLANT LEVEL
NOTE: If engine is hot, allow engine to cool down before Yes .... GO to A2.
proceeding. No .... REFILL as described. GO to A2.
• Check engine coolant level at radiator coolant
recovery reservoir or degas bottle.
• Is engine coolant level OK?
A2 I CHECK FOR VISIBLE LEAKAGE
• Engine coolant has an added dye color that makes Yes .... SERVICE as described. RESTORE
the coolant an excellent leak detector. vehicle. RETEST system.
• Check entire cooling system for visible leakage . No .... GO to A3.
• Is there visible leakage?
A3 I CHECK RADIATOR CAP
• Using a radiator cap pressure tester, test radiator Yes .... GO to A4.
cap as described in Component Testing. No .... REPLACE damaged radiator cap.
• Did pressure relief cap test OK?
RESTORE vehicle. RETEST
system.

PINPOINT TEST A: LOSS OF COOLANT (Continued)

A4 I CHECK COOLANT FOR INTERNAL LEAKAGE
• Inspect coolant in radiator and radiator coolant Yes .... If engine oil is evident, GO to
recovery reservoir or degas bottle (depending upon Section 03-oO. If transmission fluid
application) for signs of transmission fluid or engine is evident, GO to Section 07-0 1 .
oil. No .... GO to AS.
• Is oil evident in coolant?
AS I CHECK ENGINE AND TRANSMISSION FOR COOLANT
• Remove oil level dipstick from engine and Yes .... It coolant is in engine, GO to
transmission. Section 03-00. If coolant is in
• Carefully inspect oil level dipstick for evidence of transmission, GO to Section 07·01.
coolant. No .... GO to A6.
• Is coolant evident?
A6 I PRESSURE TEST COOLING SYSTEM
• Using a cooling system pressure tester, pressurize Yes .... SERVICE as described. RETEST
cooling system as described in Component Tests, system.
Pressure Test. No .... Cooling system is operational at
• Check for any signs of visible leakage .
this time. RETEST system.
NOTE: Check inside vehicle for possible heater
core leakage.
• Is there leakage?
PINPOINT TEST 8: ENGINE OVERHEATS

81 I CHECK ENGINE COOLANT LEVEL
NOTE: If engine is hot, allow engine to cool down before Yes .... G0 to 82.
proceeding. No .... REFILL as described. GO to
• Remove pressure relief cap or radiator cap and Pinpoint Test A.
check engine coolant level at radiator and radiator
coolant recovery reservoir or degas bottle
(depending upon application).
• Is engine coolant level OK?
82 I CHECK COOLANT CONDITION
• Check coolant tor contaminants such as rust or Yes .... G0 to 83.
corrosion. Also check tor discoloration and No .... FLUSH system as described.
concentration. RETEST system.
• Is coolant condition OK?
83 J CHECK FOR AIR FLOW OBSTRUCTION
• Visually inspect A/C condenser core and radiator Yes .... REMOVE obstruction and clean
for obstructions such as leaves or bugs. A I C condenser core and radiator
• Is there any obstruction? as described. RETEST system.
No .... G0 to 84.
84 I CHECK HEATER CORE OPERATION
• Install pressure relief cap or radiator cap . Yes .... GO to 85.
• Start engine and allow to run . No .... TURN engine OFF before it
• As engine starts to warm up, feel the heater inlet
and outlet hoses. They should feel the same after overheats. SERVICE heater core
three or tour minutes. as described in Section 1 2-Q3A.
• Is heater outlet hose the same temperature as
RETEST system.
the inlet hose?
85 I CHECK WATER THERMOSTAT OPERATION
• Allow engine to run tor 10 minutes . Yes .... REPLACE water thermostat as
• Feel the underside of the upper radiator hose . described. RETEST system.
• Is the upper radiator hose cold?
No .... LEAVE engine running. GO to 86.

PINPOINT TEST 8: ENGINE OVERHEATS (Continued)

Test Step Result � Action to Take
86 I CHECK ELECTRIC COOLING FAN
• Check temperature gauge at instrument cluster; Yes � GO to Section 03-00 for engine
allow engine to run until high side of normal range is service procedure.
attained. No � GO to Section 12-00 for proper
• Check for cooling fan motor and fan blade
operation. service procedure of cooling fan
• Did cooling fan motor and fan blade operate OK?
motor and fan blade.
PINPOINT TEST C: ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURE

C1 I CHECK ENGINE TEMPERATURE
• Start engine and allow to run for 10 minutes . Yes � REPLACE water thermostat as
• Feel heater inlet and outlet hoses and underside of described. RETEST system.
upper radiator hose. No � GO to Section 13-0 1 for proper
• Are hoses cold?
Temperature Gauge Diagnosis.
PINPOINT TEST D: ENGINE BLOCK HEATER DOES NOT OPERATE PROPERLY
Test Step Result Action to Take
D1 CHECK POWER CABLE OPEN
• Check resistance of Circuits 1 , 2 and 3 in power Yes � GO to D2.
cable using Rotunda 73 Digital Multimeter No � REPLACE power cable. RETEST
105-R0051 or equivalent. system.
• Is resistance less than 5.0 ohms?
0
+ ��
I
: I
I I
1.2 I I
\
� -�""L ��"'"\\
I I_ ""'" II
- - - - - - �
� - - - - - - _, L
-
AQ0045-A
D2 CHECK POWER CABLE SHORT

• Check resistance of Circuits 1 , 2 and 3 in power Yes � REPLACE block heater. RETEST
cable using Rotunda 73 Digital Multimeter system.
105-R005 1 or equivalent. No � REPLACE power cable. RETEST
• Is resistance more than 10 K ohms? system.
fJj
£-1
�
+
0 -
,_ _ _ -
..r '
I
'
_j
AQ0046-A

03-03- 10 Engine Cooling 03-03-1 0
Component Tests 7. If the pressure relief cap does not hold pressure,
remove and wash the radiator cap in clean water
Pressure Test-3.8L Engine
to dislodge all foreign particles from the gaskets.
1. Turn the engine OFF. Check the sealing surface in the filler neck.
2. WARNING: NEVER REMOVE THE RADIATOR Then inspect the cam lock flanges on both sides
CAP OR VENT PLUG UNDER ANY of the filler neck for maximum radiator cap
CONDITIONS WHILE THE ENGINE IS engagement.
OPERATING. FAILURE TO FOLLOW THESE CAUTION: If the pressure drops, check for
8.
INSTRUCTIONS COULD RESULT IN DAMAGE leaks at the engine-to-heater core hoses,
TO THE COOLING SYSTEM OR ENGINE engine-to-radiator hoses, bypass hose,
AND/OR PERSONAL INJURY. TO AVOID water valve hose {If applicable), water hose
HAVING SCALDING HOT COOLANT OR connection gasket {8255}, radiator and
STEAM BLOW OUT OF THE RADIATOR, heater core, etc. Also refer to engine system
RADIATOR COOLANT RECOVERY checks if a leak cannot be located in cooling
RESERVOIR OR VENT, USE EXTREME CARE system. Any leaks which are found must be
WHEN REMOVING THE RADIATOR CAP OR corrected and system rechecked or possible
VENT PLUG FROM THE VEHICLE. WAIT damage to the vehicle may occur.
UNTIL THE ENGINE HAS COOLED. THEN
WRAP A THICK CLOTH AROUND THE Pressurize the cooling system as described in
RADIATOR CAP AND TURN IT SLOWLY TO Step 6 (using a radiator cap that operates within
THE FIRST STOP. STEP BACK WHILE THE the specified upper and lower pressure limits) and
PRESSURE IS RELEASED FROM THE observe the gauge reading for approximately two
COOLING SYSTEM. WHEN CERTAIN ALL THE minutes. Refer to Specifications. Pressure should
PRESSURE HAS BEEN RELEASED, PRESS not drop during this time.
DOWN ON THE RADIATOR CAP {STILL WITH If the system holds pressure, proceed to Step 9.
A CLOTH), TURN AND REMOVE IT.
9. Release system pressure by loosening the
Check engine coolant level as described and radiator cap and remove the adapter. Re-install
reinstall radiator cap. the water temperature indicator sender unit.
3. NOTE: With the radiator cap installed and the Check engine coolant level and replenish if
cooling system pressure relieved, only a small necessary with a 50 I 50 mixture of Premium
amount of coolant will be lost when the water Cooling System Fluid E2FZ- 1 9549-AA or -B (in
temperature indicator sender unit ( 1 0884) is Oregon, F5FZ- 1 9549-CC; in Canada, CXC-8-B),
removed. recycled coolant or equivalent meeting Ford
specification ESE-M97B44-A and water.
Disconnect the electrical connector from the
water temperature indicator sender unit, Remove Pressure Test-4.6L {2V) Engine
the water temperature indicator sender unit from 1. Turn the engine OFF.
the engine.
2. WARNING: NEVER REMOVE THE RADIATOR
4. Install the adapter fitting from Rotunda CAP OR VENT PLUG UNDER ANY
Radiator I Heater Core Pressure Tester CONDITIONS WHILE THE ENGINE IS
0 1 4-R 1 072 or equivalent (male thread on one end OPERATING. FAILURE TO FOLLOW THESE
and hose connector on the other end to INSTRUCTIONS COULD RESULT IN DAMAGE
accommodate the tester hose) tightly into the TO THE COOLING SYSTEM OR ENGINE
intake manifold (9424) or cylinder head (6049) in AND/OR PERSONAL INJURY. TO AVOID
place of the water temperature indicator sender HAVING SCALDING HOT COOLANT OR
unit. STEAM BLOW OUT OF THE COOLING
5. Disconnect radiator overflow hose (8075) from SYSTEM, NEVER REMOVE THE PRESSURE
the radiator. Install a separate hose, making sure RELIEF CAP FROM A HOT DEGAS BOTTLE.
hose is firmly installed on the radiator overflow WAIT UNTIL THE ENGINE HAS COOLED.
nipple and is in good condition. Insert the free end THEN WRAP A THICK CLOTH AROUND THE
of the hose into a container of water. PRESSURE RELIEF CAP AND TURN IT
Attach the pressure pump and gauge to the SLOWLY ONE TURN
6.
adapter fitting and pressurize to the lower limit. {COUNTERCLOCKWISE). STEP BACK WHILE
THE PRESSURE IS RELEASED FROM THE
No bubbles should appear in water container. If COOLING SYSTEM. WHEN CERTAIN ALL THE
the system is satisfactory at the lower limit, PRESSURE HAS BEEN RELEASED, REMOVE
gradually increase the system pressure until a PRESSURE RELIEF CAP {STILL WITH A
slight stream of bubbles appears in the water CLOTH).
container. This is the upper limit of the radiator
cap . Check engine coolant level as described.
Replace any radiator cap that exceeds the

specified upper limit pressure without discharging
bubbles.

03-03- 1 1 Engine Cooling 03-o3-1 1
3. Connect Rotunda Radiator I Heater Core 7. CAUTION: If the pressure drops, check for
Pressure Tester 0 1 4-R 1 072 or equivalent to leaks at the engine-to-heater core hoses,
degas bottle nipple and de-aeration hose. Install engine-to-radiator hoses, water valve hose
pressure test pump to the quick-connect fitting of (if applicable), water hose connection
the test adapter. gasket, radiator and heater core or other
system components and connections. Also
refer to Service Procedures, Section 03-00,
ROTUNDA RADIATOR/HEATER CORE if a leak cannot be located in cooling system.
PRESSURE TESTER Any leaks which are found must be corrected
014-R1072 and system rechecked.
Pressurize the cooling system as described in
Step 4 (using a pressure relief cap that operates
within the specified upper and lower pressure
limits). Observe the gauge reading for
approximately two minutes. Refer to
Specifications. Pressure should not drop during
this time.
If the system holds pressure, proceed to Step 8.
8. Release system pressure by loosening the
pressure relief cap. Check engine coolant level
and replenish if necessary, with the correct
engine coolant mixture as described.
Radiator Cap Pressure Test
1. Remove radiator cap from neck following
described precautions.
2. NOTE: The adapter is designed to accept both
LOWER RADIATOR HOSE ----t deep and shallow neck radiator caps .
88273 Use water to clean the radiator cap in the area of
the rubber seal and the vacuum relief valve. Refer
to Cleaning and Inspection for procedure.
AQ0043-B Immerse the radiator cap in water. Install on the
shallow filler neck of the Rotunda
4. NOTE: If the plunger of the pump is depressed Radiator I Heater Core Pressure Tester
too fast, an erroneous pressure reading will 0 1 4-R 1 072 or equivalent.
result.
3. NOTE: The filler neck seal is reversible so it may
Slowly depress the plunger of the pressure test be used on either a deep or shallow filler neck. It
pump until the pressure gauge reading stops will also fit either end of the radiator cap pressure
increasing and note the highest pressure reading test adapter.
obtained.
Immerse the filler neck seal in water and install in
5. If the pressure relief cap does not hold pressure, the filler neck adapter.
remove and wash the pressure relief cap in clean
water to dislodge all foreign particles from the 4. Install the filler neck adapter with filler neck seal
gaskets. Check the sealing surface in the filler on the deep filler neck end to the radiator cap
neck. pressure test adapter.
6. If 89 kPa ( 13 psi) cannot be reached, replace 5. Connect the female quick connect fitting of the
pressure relief cap. If more than 1 24 kPa ( 1 8 psi) pressure test pump to the male quick connect
shows on gauge, replace pressure relief cap. fitting of the filler neck adapter.
6. NOTE: If the plunger of the pump is depressed
too fast, an erroneous pressure reading will
result.
Slowly depress the plunger of the pressure test
pump until the pressure gauge reading stops
increasing. Note the highest preSsure reading
obtained.

03-03- 1 2 Engine Cooling 03-03-1 2
7. NOTE: The lever of the pump turns clockwise 1. Check for any leaks in the following:
only, alternately holding and releasing pressure.
• radiator cap
Release the pressure by turning the pressure
relief lever one-half turn clockwise. Then turn the • pressure relief cap
pressure relief lever clockwise one-half turn and • heater hoses
repeat Step 6 (at least twice) to make sure the
• radiator hoses
pressure test reading is repeatable within the
acceptable gauge reading limits of the radiator • vent plug on bypass elbow located on the
cap. Make sure the reading is not erratic. Refer to intake manifold behind the water hose
Specifications. connection (8592)
8. If the pressure test gauge readings are not within • water hose connection gasket
the acceptable gauge reading limits, replace the • head gasket
radiator cap. If the pressure test gauge readings
are within the acceptable gauge reading limits, • water pump housing gasket (8507)
perform the Pressure Test as described. Replace leaking components as necessary
before continuing.
Rotunda Radiator / Heater Core Pressure Tester 2. Check the cold engine coolant level in the
014-R1072
radiator.
a. NOTE: On 3.8L engine, remove vent plug
before filling cooling system and securely
install after filling.
If the level is below the filler neck, fill to the
filler neck with a 50 I 50 mixture of Premium
Cooling System Fluid E2FZ- 1 9549-AA or -8
(in Oregon, F5FZ- 1 9549-CC; in Canada,
CXC-8-B), recycled coolant or equivalent
meeting Ford specification ESE-M97844-A
and water. Fill the radiator coolant recovery
reservoir on 3.8L engine or degas bottle on
4.6L (2V) engine to the FULL COLD mark.
b. If the cold engine coolant level in the radiator
coolant recovery reservoir on 3.8L engine or
degas bottle on 4.6L (2V) engine is sufficient,
run the vehicle for 1 0 minutes with the
pressure relief cap or radiator cap on. Check
for coolant circulation through the heater and
radiator hoses. If the coolant drops below the
FULL HOT mark, add coolant to the filler
AQ0054-A neck. Repeat the above procedure until all
the air is purged from the cooling system.
When this procedure has been completed,
Part feel the heater inlet and outlet hoses, and the
Item Number Desc ription underside of the upper radiator hose. The
1 8100 Radiator Cap water thermostat should be replaced only if
2 -
Quick Disconnect Fittings these hoses are cold after 1 0 minutes of
operation.
-
3 Pressure Cap Test Adapter
(Part of 0 14-R 1072)
4 -
Filler Neck Adapter (Part of
014-R 1072)
-
5 Pressure Relief Lever (Part FULL HOT
of 014-R 1072)
-
6 Temperature Sender
Pressure Hose Adapter (Part FULL COLD
of 014-R 1072)
-
7 Pump and Gauge Assy (Part
of 014-R 1072)
Thermostat, Water
When investigating a concern of overheating or an
insufficient heater I defroster performance, perform
the following:

03-03- 13 Engine Cooling 03-03- 1 3
Radiator Leak Test, Removed from Vehicle 5. Start engine and check all hoses and connections
CAUTION: Do not leak-test an aluminum radiator for leaks.
in the same water that copper /brass radiators
are tested in. Flux and caustic cleaners may be Thermostat lnstallation - 3.8L Engine Shown, 4.6L
present in the tank and will damage aluminum. A Engine Similar
separate clean test tank is necessary for
aluminum radiators. If conditions do not allow a WATER OUTLET
b==:::::�-- CONNECTION
separate tank for aluminum radiator leak testing, 8594
thoroughly clean the test tank each time before
testing an aluminum radiator in the tank. .--a--=::�-- ALIGNMENT TAB
Clean the radiator before leak-testing to prevent AND SLOT
contaminating the test tank. Leak-test the radiator in
clean water with 1 38 kPa (20 psi) air pressure.
Always install plugs in the transmission oil cooler
fittings before leak-testing or cleaning any radiator for
a vehicle with an automatic transmission. THERMOSTAT AND
0-RING ASSY
8A570
85202-A
Thermostat, Water
Removal Water Pump
1. Partially drain the cooling system so that the Refer to Section 03-0 1 A (3.8L) or Section 03-Q 1 8
coolant level is below the water thermostat (4.6L).
(8575).
2. Disconnect upper radiator hose (8260) at the
water hose connection (8592).
3. Remove two water outlet connection retaining Radiator Hoses
bolts and remove water hose connection and Removal
water hose connection gasket (8255).
Drain the radiator (8005) as described. Loosen the
Installation clamps at each end of the hose to be removed. Slide
1. Clean sealing surface on water hose connection the hose off the radiator connection and the water
and on intake manifold (9424). hose connection (8592)(upper radiator hose (8260))
or the water pump connection (lower radiator hose
2. NOTE: To prevent incorrect installation of the (8286)).
water thermostat, the water hose connection on
all engines contains an alignment slot which the Installation
water thermostat assembly fits it. Install the CAUTION: Make sure the clamps are beyond the
water thermostat with the bridge section in the bead and place in the center of the clamping
water hose connection. Turn the water surface of the connections. New screw-type hose
thermostat clockwise to lock it in position on the clamps must be Installed Inside the hose
flats cast into the water hose connection. alignment marks.
Position water thermostat, and water hose Position the clamps at least 50 mm (2 inches) from
connection on the intake manifold. Install the two each end of hose and slide hose on the connections.
retaining bolts and tighten to 8- 1 2 N·m (7 1 - 1 06
lb-in). lighten clamp to 2.2-3.4 N·m (2Q-30 lb-in) (when using
screw-type clamps). Fill the cooling system with a
3. Connect upper radiator hose to water hose 50 I 50 mixture of Premium Cooling System Fluid
connection. Move new hose clamp to water hose E2FZ- 1 9549-AA or -8 (in Oregon, F5FZ- 1 9549-GC; in
connection. Make sure clamp is between Canada, CXC-8-8), recycled coolant or equivalent
alignment marks on hose. meeting Ford specification ESE-M97844-A and water.
4. Fill cooling system with a 50 I 50 mixture of Operate the engine for several minutes then check the
Premium Cooling System Fluid E2FZ- 1 9549-AA hoses and connections for leaks.
or -8 (in Oregon, F5FZ- 1 9549-CC; in Canada,
CXC-8-8), recycled coolant or equivalent meeting
Ford specification ESE-M97844-A.

03-03- 14 Engine Cooling 03-03- 14
Radiator Radiator Coolant Recovery Reservoir/Degas

Aluminum Core, Crossflow-3.8L (Base) and Bottle
4.6L Engines Removal
Removal 1. WARNING: ON VEHICLES EQUIPPED WITH
1. Drain engine cooling system as described. 3.8L ENGINES NEVER REMOVE THE
Disconnect upper radiator hose (8260) and lower RADIATOR CAP {8 1 00} UNDER ANY
radiator hose (8286) and radiator overflow hose CONDITIONS WHILE THE ENGINE IS
(8075) from the radiator (8005). Disconnect the OPERATING. FAILURE TO FOLLOW THESE
transmission oil cooler inlet and outlet lines from INSTRUCTIONS COULD RESULT IN DAMAGE
the radiator. TO THE COOLING SYSTEM OR ENGINE
AND/OR PERSONAL INJURY. TO AVOID
2. Remove cooling fan motor, fan blade (8600) and HAVING SCALDING HOT COOLANT OR
fan shroud (8 1 46) assembly as described. STEAM BLOW OUT OF THE RADIATOR
3. Remove radiator upper bracket retaining bolts (8005}, USE EXTREME CARE WHEN
and remove bracket. Lift radiator from vehicle. REMOVING THE RADIATOR CAP FROM A HOT
RADIATOR. WAIT UNTIL THE ENGINE HAS
Installation COOLED, THEN WRAP A THICK CLOTH
1. Position the radiator into the vehicle. Install upper AROUND THE RADIATOR CAP AND TURN
brackets and tighten bolts securely. RADIATOR CAP SLOWLY TO THE FIRST
PRESSURE STOP. STEP BACK WHILE THE
2. Connect the transmission oil cooler lines to the
PRESSURE IS RELEASED FROM THE
transmission oil cooler fittings.
COOLING SYSTEM. WHEN CERTAIN ALL THE
3. Install cooling fan motor, fan blade and fan shroud PRESSURE HAS BEEN RELEASED, PRESS
assembly as described. DOWN ON THE RADIATOR CAP {STILL WITH
4. CAUTION: Make sure the clamps are beyond A CLOTH}, TURN AND REMOVE RADIATOR
the bead and place in the center of the CAP.
clamping surface of the connections. New WARNING: ON VEHICLES EQUIPPED WITH
screw-type hose clamps must be installed THE 4.6L ENGINES NEVER REMOVE THE
inside the hose alignment marks or potential PRESSURE RELIEF CAP UNDER ANY
damage to the vehicle may occur. CONDITIONS WHILE THE ENGINE IS
Connect the upper radiator hose, lower radiator OPERATING. FAILURE TO FOLLOW THESE
hose and radiator overflow hose. Position the INSTRUCTIONS COULD RESULT IN DAMAGE
clamps at least 50 mm (2 inches) from each end TO THE COOLING SYSTEM OR ENGINE
of hose and slide hose on the connections. AND/OR PERSONAL INJURY. TO AVOID
HAVING SCALDING HOT COOLANT OR
lighten clamp to 2.2-3.4 N·m (20.30 lb-in). Fill the STEAM BLOW OUT OF THE COOLING
cooling system with a 50 / 50 mixture of Premium SYSTEM, USE EXTREME CARE WHEN
Cooling System Fluid E2FZ- 1 9549-AA or -B (in REMOVING THE PRESSURE RELIEF CAP
Oregon, F5FZ· 1 9549·CC; in Canada, CXC·8-B), FROM A HOT COOLING SYSTEM. WAIT UNTIL
recycled coolant or equivalent meeting Ford THE ENGINE HAS COOLED, THEN WRAP A
specification ESE-M97B44-A and water. THICK CLOTH AROUND THE PRESSURE
5. WARNING: TO AVOID THE POSSIBILITY OF RELIEF CAP AND TURN IT SLOWLY UNTIL
PERSONAL INJURY OR DAMAGE TO THE PRESSURE BEGINS TO RELEASE. STEP
VEHICLE, DO NOT OPERATE THE ENGINE BACK WHILE THE PRESSURE IS RELEASED
WITH THE HOOD OPEN UNTIL THE FAN FROM THE COOLING SYSTEM. WHEN
BLADE HAS BEEN FIRST EXAMINED FOR CERTAIN ALL THE PRESSURE HAS BEEN
CRACKS AND SEPARATION. RELEASED, PRESS DOWN ON THE
PRESSURE RELIEF CAP {STILL WITH A
Operate the engine for several minutes and check
CLOTH), TURN AND REMOVE PRESSURE
for leaks at the hose connections and the
RELIEF CAP.
transmission oil cooler lines. Check the automatic
transmission fluid level. It required, partially drain engine cooling system.
6. Turn engine off and check radiator and radiator 2. Disconnect radiator overflow hose (8075) from
coolant recovery reservoir on 3.8L engines or radiator coolant recovery reservoir (8A080) on
degas bottle on 4.6L (2V) engine coolant levels. 3.8L engines or degas bottle on 4.6L (2V).
3. Remove battery ( 1 0653). Refer to Section 1 4-Q 1 .
4. On 4.6L engines, disconnect lower radiator hose
(8286) from degas bottle.
5. Disconnect electrical connector to low coolant
level warning sensor ( 1 OD968) located in the
radiator coolant recovery reservoir on 3.8L
engines or degas bottle on 4.6L (2V) engines.

03-03- 1 5 Engine Cooling 03-o3-1 5
6. Remove radiator coolant recovery reservoir 3. Tighten electrical connector bolt securely.
retainers and radiator coolant recovery reservoir
on 3.8L engines or degas bottle on 4.6L (2V)
engines.
Installation Engine Cooling Fan Motor, Fan Blade and Fan
1. Follow removal procedure in reverse order. Shroud Assembly, Electrical
2. Tighten degas bottle retainers securely. Removal
1. Disconnect (pull apart) the male-female cooling
fan motor wiring connector at the side of the fan
shroud (8 1 46). Remove the male terminal
Control Relay Module, Constant connector retaining clip from the fan shroud
mounting tab.
Removal
2. Remove two fan shroud upper retaining bolts at
1. Remove radiator upper sight shield (8C29 1). the radiator tanks.
2. Disconnect electrical connector to constant 3. Lift cooling fan motor I fan blade (8600) I fan
control relay module. shroud assembly past radiator (8005),
3. Remove CCRM retainer bracket bolt located on disengaging fan shroud from two lower retaining
radiator support ( 1 6 1 38) and remove constant clips.
control relay module.
Installation
Installation 1. Follow removal procedure in reverse order.
1. Follow removal procedure in reverse order. 2. Tighten fan shroud retaining bolts to 5.2-7.2 N·m
2. Tighten constant control relay module bracket (46-63 1b-in).
retainer bolt to 2-3 N-m ( 1 2- 1 8 1b-in).

Cooling System-3.8L (Base) Engine
"
�
FRONT OF VEHICLE
03678-8
Part Part
1 8A080 Radiator Coolant Recovery 7 8K62 1 , 8600, Cooling Fan Motor and
Reservoir 8146 Shroud Assembly
2 N800369-S2 Screw (2 Req'd) 8 8075 Radiator Overflow Hose
3 16138 Radiator Support 9 1430 1 Battery Ground Cable
4 8260 Upper Radiator Hose 10 16055 Front Fender Apron
-
5 N3831352-S2 Bolt (2 Req'd) 11 8005 Radiator
6 8286 Lower Radiator Hose A Tighten to 5.2-7.2 N·m (46-63
(Continued)
Lb-ln)

03-03- 1 7 Engine Cooling 03-o3- 1 7
Cooling System- 4.6L Engine
/
FRONT OF VEHICLE
Part Part
-
1 N800369-S2 Bolt (2 Req'd) 8 Power Distribution Box (Part
2 8101 Pressure Cap of 145 16)
3 8075 Radiator Overflow Hose 9 8A080 Degas Bottle
4 8005 Radiator 10 N605891-S2 Bolt (2 Req'd)
5 8260 Upper Radiator Hose 11 8K62 1 , 8600, Cooling Fan Motor and
8146 Shroud Assembly
6 8286 Lower Radiator Hose 12 6881 Oil Filter Adapter
7 8592 Water Hose Connection A -
Tighten to 5.2-7.2 N·m (46-63
(Continued) Lb-ln)
Radiator Draincock 2. Turn the radiator draincock counterclockwise to

loosen. When the radiator draincock is
Aluminum Core Radiator unscrewed to the end of the threads, pull the
The radiator draincock {8 1 1 5) is located near the radiator draincock partially out from the radiator.
bottom of the radiator {8005). 3. Remove the radiator draincock from the radiator
Removal by squeezing the sides together with a pair of
needlenose pliers. Then pull the radiator
1. Drain engine cooling system as described.
draincock from the radiator.

03-03- 18 Engine Cooling 03-03- 1 8
Installation Block Heater Wiring

1. Make sure 0-ring is in groove on stem of radiator Removal
draincock.
1. Raise vehicle on hoist. Refer to Section QQ-02.
2. Water-saturate radiator draincock in order to wet
0-ring. 2. Disconnect block heater power cable from block
heater (6A05 1 ).
3. Push the radiator draincock into the radiator inlet
tank opening until it snaps into place. 3. Lower vehicle.
4. lighten the radiator draincock by turning 4. Disconnect block heater power cable retainer (if
clockwise to 1 .0 N·m (8 lb-in). equipped) and remove block heater power cable
from vehicle.
Installation
2. NOTE: Make sure power cable is routed and
secured away from rotating or hot components.
Block Heater
Removal
1. Open hood ( 1 66 1 2) and install protective fender
covers.
Water Temperature Indicator Sender Unit 2. Disconnect battery ground cable ( 1 4301 ). Refer
3.8L Engine to Section 1 4-Q 1 .
3. WARNING: NEVER REMOVE THE PRESSURE
Removal RELIEF CAP UNDER ANY CONDITIONS WHILE
1. Partially drain engine cooling system as THE ENGINE IS OPERATING. FAILURE TO
� described. FOLLOW THESE INSTRUCTIONS COULD
2. Disconnect engine control sensor wiring RESULT IN DAMAGE TO THE COOLING
( 1 2A58 1 ) from water temperature indicator SYSTEM OR ENGINE AND/OR PERSONAL
sender unit ( 1 0884). INJURY. TO AVOID HAVING SCALDING HOT
COOLANT OR STEAM BLOW OUT OF THE
3. Remove water temperature indicator sender unit. COOLING SYSTEM, USE EXTREME CARE
Installation WHEN REMOVING THE PRESSURE RELIEF
CAP FROM A HOT COOLING SYSTEM. WAIT
1. Follow removal procedure in reverse order. UNTIL THE ENGINE HAS COOLED, THEN
2. lighten water temperature indicator sender unit WRAP A THICK CLOTH AROUND THE
to 1 2- 1 6 N·m (106- 1 4 1 1b-in). PRESSURE RELIEF CAP AND TURN IT
SLOWLY TO THE FIRST STOP. STEP BACK
4.6L Engine WHILE THE PRESSURE IS RELEASED FROM
Removal THE COOLING SYSTEM. WHEN IT IS
CERTAIN ALL THE PRESSURE HAS BEEN
1. Drain engine cooling system as described. RELEASED, PRESS DOWN ON THE
2. Disconnect fuel charging wiring (9D930) from PRESSURE RELIEF CAP (STILL WITH A
water temperature indicator sender unit. CLOTH), TURN AND REMOVE.
3. Remove water temperature indicator sender unit Drain radiator (8005) as described.
from upper intake manifold (9424). 4. Disconnect block heater power cable from block
Installation heater (6A05 1 ).
1. Follow removal procedure in reverse order. 5. Loosen retaining screw and pry block heater from
cylinder blocks (60 1 0) while moving retaining
2. lighten water temperature indicator sender unit screw from side to side to disengage clamp
to 1 6-23 N·m ( 1 2- 1 7 1b-ft). strap.
6. Remove block heater while noting the position of
heating element.
Engine Coolant Temperature (ECT) Sensor 7. Remove block heater power cable.
Refer to Section 03- 1 4. Installation
1. Clean the inside diameter of the cylinder block
hole machined surface. Remove any burrs at the
hole entrance to avoid damage to the 0-ring.

03-03-19 Engine Cooling 03-o3-19
REMOVAL AND INSTALLATION (Continued) SERVICE PROCEDURES
2. Apply a liberal coating of Premium Long Life Radiator Core

Grease XC- 1 -K or equivalent meeting Ford
NOTE: With the introduction of a new radiator braze
specification ESA-M 1C75-8 to block heater process, there is no longer an approved service
Q-ring and cylinder block opening. method for repairing radiator core leaks. Due to the
3. Insert block heater in cylinder block hole in the type of flux used during brazing, the two component
same position as it was removed. epoxy materials previously used will not adhere to
4. lighten screw to 1 .6- 1 .8 N·m ( 1 5- 1 6 1b-in). aluminum radiator core. If the radiator core leaks, the
radiator (8005) should be replaced.
5. Connect block heater power cable to block
heater.
6. Install block heater power cable. Make sure
power cable is routed and secured away from Transmission Fluid Cooler Connection Leaks
rotating or hot components.
Check to see that the fitting nut is fully tightened. lf the
7. Refill engine cooling system with a 50 I 50 mixture leak persists, apply a thin, even coat of Dow Corning
of Premium Cooling System Fluid 1 200 primer or equivalent using a brush. Allow to dry
E2FZ- 1 9549-AA or -8 (in Oregon, for 1 0 minutes at room temperature. Apply Dow
F5FZ- 1 9549-GC; in Canada, CXC-8-8), recycled Corning Silastic 734RTV or equivalent in undiluted
coolant or equivalent meeting Ford specification form around the leaking connection and allow it to dry
ESE-M97844-A and water as described. for one hour.
8. Connect battery ground cable. Refer to Section
1 4-0 1 .
9. Start engine and check for leaks. CLEANING AND INSPECTION
10. Check engine coolant level as required.
Radiator Coolant Level Check
1 1 . Remove fender covers and close hood.
NOTE: If radiator coolant recovery reservoir (8A080)
on 3.8L engines or degas bottle on 4.6L (2V) are
empty, allow engine to cool and add a 50 I 50 mixture
of Premium Cooling System Fluid E2FZ- 1 9549-AA or
-8 (in Oregon, F5FZ- 1 9549-CC; in Canada, CXG-8-8),
recycled coolant or equivalent meeting Ford
specification ESE-M97844-A and water to the base of
the filler neck in the radiator coolant recovery
reservoir on 3.8L engines or degas bottle on 4.6L (2V)
engines as specified below.
Check engine coolant level in the radiator coolant
recovery reservoir on 3.8L engines or degas bottle on
4.6L (2V) engines at least once a month.
With a cold engine, the level must be maintained at or
above the FULL COLD mark.
At normal engine operating temperature, the coolant
level should be at the FULL HOT mark. If coolant level
in the radiator coolant recovery reservoir on 3.8L
engines or degas bottle on 4.6L (2V) engines are less
than the above indicated levels, a 50 I 50 mixture of
Premium Cooling System Fluid E2FZ- 1 9549-AA or -8
(in Oregon, F5FZ- 1 9549-GC; in Canada, CXC-8-8),
recycled coolant or equivalent meeting Ford
specification ESE-M97844-A and water should be
added to the radiator coolant recovery reservoir on
3.8L engines or degas bottle on 4.6L (2V) engines to
the specified levels.
If no engine coolant is observed in the radiator coolant
recovery reservoir on 3.8L engines or degas bottle on
Part 4.6L (2V) engines, or when a coolant level change
Item Number Description does not occur, check the system as follows:
1 6A05 1 Block Heater
-
2 0-Ring
3 6010 Cylinder Block
-
4 Power Cable

03·03·20 Engine Cooling 03.03·20
CLEANING AND INSPECTION (Continued)
1. With the engine cold, remove the pressure relief e. Observe the level of coolant in the radiator
cap or radiator cap (81 00) and inspect the filler coolant recovery reservoir on 3.8L engines
neck sealing gasket for foreign material between or degas bottle on 4.6L (2V) engines. The
the gasket and diaphragm. Refer to Pressure minimum level should be as specified in Step
Relief Cap Cleaning and Inspection. Rinse b. If not, adjust engine coolant level by
pressure relief cap or radiator cap in clean water. adding coolant mixture.
The pressure relief cap or radiator cap used on f. Check engine coolant level in radiator
this system is unique; replace only with the coolant recovery reservoir on 3.8L engines
proper cap. or degas bottle on 4.6L (2V) engines when
2. On 4.6L (2V) engine disconnect lower radiator engine has cooled. Engine coolant level
hose (8286) from degas bottle. should be to the FULL COLD mark. Add a
3. Remove the radiator overflow hose (8075) at the 50 / 50 mixture of Premium Cooling System
radiator connection. Disconnect electrical Fluid E2FZ- 1 9549-AA or -B (in Oregon,
connector to low coolant level warning sensor F5FZ-1 9549-CC; in canada, CXc-8-B),
( 1 0D968) (if equipped). Remove low coolant level recycled coolant or equivalent meeting Ford
warning sensor from radiator coolant recovery specification ESE-M97844-A and water if
reservoir on 3.8L engines or degas bottle on 4.6L necessary. Repeat Steps c, d and e.
(2V) engines. Remove radiator coolant recovery g. Check for leakage at the following:
reservoir on 3.8L engines or degas bottle on • all hoses and hose connections
4.6L (2V) engines from front fender apron
(1 6055) and flush with clean water. • radiator seams, radiator core and
radiator draincock (8 1 1 5)
4. Inspect the radiator overflow hose for
obstructions, cracks or cuts. Replace if • all cylinder block core plugs and drain
necessary. plugs
5. Install radiator coolant recovery reservoir on • edges of all engine cooling system
3.8L engines or degas bottle on 4.6L (2V) gaskets
engines, and connect radiator overflow hose at • transmission oil cooler fittings
the radiator connection. Replace low coolant
• vehicle heating system components
level warning sensor and connect electrical
connector (if equipped). • water pump (850 1)
6. Replenish the engine coolant in the radiator h. Examine oil level dipstick (6750) for
(8005) and radiator coolant recovery reservoir evidence of engine coolant in engine oil.
on 3.8L engines or degas bottle on 4.6L (2V) i. Check radiator coolant recovery reservoir
engines (depending upon application) as required. on 3.8L engines or degas bottle on 4.6L (2V)
7. Install the pressure relief cap or radiator cap. engines for evidence of oil in engine coolant
A low engine coolant level in the cooling system (leakage at transmission fluid cooler
can cause poor heater and defroster (7A095)).
performance. (Any level below the filler neck is Install cooling system analyzer to assist in testing
considered low.) If this condition exists, perform the cooling system. Follow the manufacturer's
the following: recommended connections and testing
procedures.
a. With cold engine, remove pressure relief cap
or radiator cap.
b. With a 50 / 50 mixture of Premium Cooling
System Fluid E2FZ- 1 9549-AA or -B (in Coolant Condition Check
Oregon, F5FZ- 1 9549-CC; in Canada,
exe-s-B), recycled coolant or equivalent Remove pressure relief cap or radiator cap (8 1 00)
meeting Ford specification ESE-M97B44-A following described precautions. Check coolant for
and water, fill cooling system and replace dirty or rusty appearance.
pressure relief cap or radiator cap. Observe If coolant does not appear dirty or rusty, check coolant
the level of fluid in the radiator coolant level and concentration as described in the following
recovery reservoir on 3.8L engines or degas procedures.
bottle on 4.6L (2V) engine. Adjust coolant If coolant appears dirty or rusty, drain the cooling
mixture to the FULL COLD mark on the system, recycle coolant using Rotunda Coolant
radiator coolant recovery reservoir on 3.8L Recycler 1 8 1 -Q0003, flush and refill as described.
engines or degas bottle on 4.6L (2V) engine.
c. Start the engine and run until the water
thermostat (8575) opens.
d. Shut off the engine and allow it to cool down.
This permits engine coolant to be drawn into
the radiator.

03-03-21 Engine Cooling 03-03-2 1
Check coolant concentration for recommended 4. Place heater temperature selector in maximum
protection level using Rotunda Battery and Antifreeze heat position.
Tester 0 1 4-R 1 060 or equivalent. If concentration is 5. CAUTION: The vent plug must be removed
low, partially drain the cooling system and add 1 00 before radiator fill or the engine may not fill
percent antifreeze solution such as Premium Cooling completely. Do not turn plastic cap under
System Fluid E2FZ- 1 9549-AA or -8 (in Oregon, vent plug or the gasket may be damaged. Do
F5FZ- 1 9549-CC; in Canada, CXC-8-8), recycled not try to add coolant through vent plug hole.
coolant or equivalent meeting Ford specification Install vent plug after filling radiator (8005)
ESE-M97B44-A, to obtain the recommended and before starting engine.
protection level.
Remove vent plug on water bypass elbow
(located on intake manifold (9424) behind water
hose connection (8592)) on 3.8L engines.
Cooling System Hoses and Clamps 6. NOTE: It important to maintain engine coolant
concentrate between 40 percent, -24° C (-1 1 ° F)
1. Inspect cooling system hoses and clamped hose
and 60 percent -52 °C (-62 ° F), depending on
connections for leaks or excessive deterioration.
climate conditions. Below 40 percent, there is a
Service or replace as required.
los� of freeze protection. Above 60 percent, the
2. lnspeet radiator core and tanks for leaks. Service engme may overheat on a warm day. Outside this
or replace as required. range, protection against rust and corrosion may
3. Inspect cooling system hose routing to ensure be greatly reduced. Refer to Specifications for
sufficient clearance to engine compartment specified coolant.
components. Reposition hoses if required. Fill engine cooling system with 50 / 50 mixture of
4. Check radiator supports ( 1 6 1 38) and brackets water and Premium Cooling System Fluid
for firm radiator retention. Correct as required. E2FZ- 1 9549-AA or -8 (in Oregon,
The radiator (8005) is installed with rubber F5FZ- 1 9549-<?C; in Canada, CXC-8-B), recycled
isolation mounts. coolant or equivalent meeting Ford specification
ESE-M97844-A.
7. WARNING: TO AVOID THE POSSIBILITY OF
PERSONAL INJURY OR DAMAGE TO THE
Cooling System Draining, Filling and VEHICLE, DO NOT OPERATE ENGINE WITH
Bleeding VEHICLE HOOD (166 1 2) OPEN UNTIL FAN
BLADE (8600) HAS BEEN FIRST EXAMINED
1. WARNING: NEVER REMOVE RADIATOR OR FOR POSSIBLE CRACKS AND SEPARATION.
COOLING SYSTEM CAP UNDER ANY
CONDITIONS WHILE ENGINE IS OPERATING. Leave pressure relief cap or radiator cap off and
FAILURE TO FOLLOW THESE INSTRUCTIONS run engine until water thermostat (8575) opens
COULD RESULT IN PERSONAL INJURY (coolant flowing through upper radiator hose
AND/OR DAMAGE TO THE COOLING (8260) becomes hot).
SYSTEM OR ENGINE. 8. Stop engine and add a 50 / 50 mixture of Premium
WARNING: TO AVOID BURNS FROM Cooling System Fluid E2FZ- 1 9549-AA or -8 (in
SCALDING COOLANT OR STEAM, USE Oregon, F5FZ- 1 9549-CC; in Canada, CXG-8-B),
EXTREME CARE WHEN REMOVING THE recycled coolant or equivalent meeting Ford
RADIATOR PRESSURE CAP. specification ESE-M97844-A and water to the
FULL HOT mark on the radiator coolant recovery
With the engine off and sufficiently cool, remove reservoir (8A080) on 3.8L engines or degas
pressure relief cap or radiator cap (8 1 00), open bottle on 4.6L (2V) engines.
radiator draincock (8 1 1 5) and remove the
cylinder block drain plugs (if equipped). Allow 9. Install pressure relief cap or radiator cap.
coolant to drain.
2. Close radiator draincock. Hand-tighten.
3. Check all hose clamps for proper tightness and
location. Make sure radiator draincock is closed
and cylinder block drain plugs are installed (if
equipped).

·-
10. On 3.8L engines, install cooling system vent plug. Heater Core Back-Flushing
lighten to 10- 1 5 N·m (89- 1 32 1b-in). CAUTION: The heater core must be back-flushed
separately from the engine cooling system for
proper back-flush water flow direction through
the heater core ( 1 8476).
All engine cooling system flushing and back-flushing
procedures must include a separate back-flushing of
the heater core after the flushing or back-flushing of
the engine cooling system. This will prevent engine
cooling system particles from clogging the heater core
tubes and reducing (or eliminating) coolant flow
through the heater core.
The correct heater core back-flushing procedure is as
follows:
1. Disconnect the heater core outlet heater hose
and install a female garden hose-end fitting
/ LOWER INTAKE adapter in the end of the outlet heater hose.
/ MANIFOLD 9424 Secure with a hose clamp.
AQ004G-A
2. Connect the female garden hose end of the outlet
heater hose to the male end of a water supply
garden hose.
3. Disconnect the heater core inlet heater hose and
Cooling System, Cleaning allow to drain into a suitable container.
Cooling System Flush Procedure 4. Turn the water supply valve on and off several
times so that the surge action will help to dislodge
Radiator Installed large stubborn particles from the heater core
To remove rust, sludge and other foreign material from tubes. Allow full water pressure to flow for
the cooling system, use Premium Cooling System approximately five minutes.
Flush F 1 AZ- 1 9A503-A or equivalent meeting Ford 5. Remove the hose clamp and female garden
specification ESR-M 1 4P7-A that is safe for use with hose-end adapter from the end of the outlet
aluminum radiators (8005). Remove the water heater hose. Reconnect the outlet heater hose.
thermostat (8575) prior to pressure-flushing. This
6. Connect the inlet heater hose.
cleaning restores cooling efficiency and helps prevent
overheating. A pulsating or reversed direction of 7. Fill the cooling system as described, using a
flushing water will loosen sediment more quickly than a 50 I 50 mixture of Premium Cooling System Fluid
steady flow in the normal coolant flow direction. In E2FZ- 1 9549-AA or -B (in Oregon,
severe cases where cleaning solvents will not properly F5FZ- 1 9549-CC; in Canada, CXG-8-B), recycled
clean the cooling system for efficient operation, use coolant or equivalent meeting Ford specification
the pressure flushing method using Rotunda Cooling ESE-M97B44-A and water.
System Flusher 1 8 1 -QOOO 1 or equivalent. Dispose of 8. Test the system for proper heater performance
old coolant and flushing water contaminated with with the specified engine cooling system
antifreeze and cleaning chemicals in accordance with conditions.
local, state and federal laws.
Radiator Removed
1. CAUTION: Radiator internal pressure must
not exceed 1 38 kPa (20 psi). Damage may Pressure Relief Cap
result. 1. Inspect the areas under the vacuum valve and
Back-flush radiator. With radiator upside down, rubber seal tor rust or dirt particles.
position a high-pressure water hose in bottom 2. Using warm tap water, raise the vacuum valve
hose location and back-flush. and rubber seal and thoroughly flush away loose
2. Remove water hose connection (8592) and water rust or trapped dirt particles.
thermostat. Refer to Thermostat, Washer 3. Inspect and remove any loose or imbedded rust
Removal. or dirt particles on the sealing surfaces of the
3. Back-flush engine. Position high-pressure hose rubber seal.
into engine through water thermostat location and
back-flush engine.

03-03-23 Engine Cooling 03-G3-23
4. NOTE: On 3.8L engines if paint is observed on Fan Blade

the filler neck sealing surface, remove it using WARNING: DO NOT ATTEMPT TO STRAIGHTEN
paint thinner. OR SERVICE A FAN BLADE (8600). REPLACE FAN
Inspect the filler neck opening for rust or dirt BLADE IF HUB OR BLADES ARE DAMAGED.
particles on the sealing surface at the bottom of Check fan blade for cracks or damage. Replace as
the filler neck opening. Use a clean cloth and wipe described.
the sealing surface to remove any rust or dirt
particles.
Typical Pressure Relief Cap Shown

SPECIFICATIONS
COOLING SYSTEM REFILL CAPACITIES

INSPECT/CLEAN
UNDER RUBBER Capacity
SEAL
Engine Uters• Quarts•
3.8L 1 1 .9 12.6
4.6L 13.3 14. 1
a Capacities shown mclude radiator coolant recovery
PRESSURE RELIEF CAP 8101 reservoir on 3.8L engine or degas bottle on 4.6L (2V)
engine filled to FULL COLD mark.
b To convert to imperial measure, multiply U.S. quarts shown
SEALING by 0.83.
SURFACE
COOLING SYSTEM PRESSURE SPECIFICATIONS
Description Pressure
Radiator Pressure Test 1 38 kPa (20 psi)
Pressure Relief Cap Pressure 1 1 0 kPa ( 1 6 psi) +
14 kPa (2 psi)
- 2 1 kPa (3 psi)
DEGAS BOTTLE
BAOBO
(FILLER NECK OPENING) AQ0048-A
Coolant Mixture
Service refill recommendations are 50 I 50 mix of
water and coolant meeting Ford specification
Radiator ESE-M97844-A such as Premium Cooling System
NOTE: With the introduction of a new radiator braze Fluid E2FZ- 1 9549-AA or -B (in Oregon,
process, there is no longer an approved service F5FZ- 1 9549-CC; in Canada, CXC-8-B), recycled
method for repairing radiator core leaks. Due to the coolant or equivalent.
type of flux used during brazing, the two component All figures shown are actual but may vary ± 1 5
epoxy materials previously used will not adhere to the percent due to system variations.
aluminum radiator core. If the radiator core leaks, the
radiator (8005) should be replaced. Most service refills will only take 80 percent of
capacity listed because some engine coolant does not
External drain unless cylinder block drain plugs are removed (if
Install steel or brass plugs in the transmission oil equipped).
cooler fittings before cleaning (if equipped). Keep
them installed during the entire service operation. WATER THERMOSTAT OPENING TEMPERATURE
NOTE: Do not use a metal brush to clean an aluminum Engine Description Specification
core. Use only horsehair, bristle or nylon brushes. 3.8L (232 CID) Starts to Open 90·93°C
Clean the outside of aluminum core with a soft bristle Fully Open ( 193·200°F}
brush, warm water and a mild household liquid 1os•c (221 "F>
detergent. Rinse with clear water. 4.6L (281 CID) Starts to Open 90·93" C
Fully Open ( 1 92·199"F)
Internal 1 04 " C (219"F)
NOTE: Do not use caustic cleaning solutions or
copper I brass radiator cleaning agents on aluminum
radiators.
To clean internal aluminum tubes use sonic cleaning
equipment. Rinse the core with clean water when
completed.

03-03-24 Engine Cooling 03-o3-24
TORQUE SPECIFICATIONS LUBRICANTI ADHESIVE/CLEANER SPECIFICATIONS

(Cont'd)
Fan Shroud to Radiator (3.8L 5.2-7.2 -
46-63
Ford
Base Engine, 4.6L)
-
Premium Cooling E2FZ-1 9549-B, ESE-M97B44-A
Water Temperature Indicator 1 2- 16 106- 1 4 1
System Fluid CXC-8-B (Canada)
Sender Unit 3.8L
-
-
Recycled Cooling ESE-M97B44-A
Water Temperature Indicator 16-23 12-16
System Fluid
Sender Unit 4.6L
-
Premium Long Life XC- 1-K ESA-M 1 C75-B
Hose Clamps 2.2-3.4 20-30
Grease
-
Vent Plug (3.8L) 10- 1 5 89- 132
Premium Cooling F 1 AZ-19A503-A ESR-M 1 4P7-A
-
Water Outlet 8- 1 2 7 1 - 1 06 System Flush
Connection-Bolts
-
Radiator Draincock (3.8L 1 8
SFI/ 4.6L) SPECIAL SERVICE TOOLS/ EQUIPMENT
-
Constant Control Relay Module 2-3 12-18
(CCRM) Bracket Bolt
ROTUNDA EQUIPMENT
-
Block Heater Retaining Screw 1 .6- 1 .8 1 5- 1 6
-
Model Description
Constant Control Relay Module 1 .4-2. 1 12-18
Connector Bolt 0 1 4-R1060 Battery and Antifreeze Tester
0 1 4-R 1072 Radiator / Heater Core Pressure Tester
LUBRICANTI ADHESIVE I CLEANER SPECIFICATIONS
1 05-R005 1 73 Digital Multimeter
Ford 1 8 1 -0000 1 Cooling System Flusher
Description Part Number Specification 1 8 1 -00003 Coolant Recycler
Premium Cooling E2FZ- 1 9549-AA ESE-M97B44-A
System Fluid
Premium Cooling F5FZ-1 9549-CC ESE-M97B44-A
System (Oregon)
(Continued)

03-04A- 1 Fuel Charging and Controls-3.8L 03-04A- 1
SECTION 03-04A Fuel Charging and Controls-3.8L

VEHICLE APPLICATION ••••••••••••••••.•••••.............•••••••• 03-o4A-1 REMOVAL AND INSTALLATION (Cont'd.)
DESCRIPTION AND OPERATION Post-Service Procedures ••••••......•••••••••••••••......• 03-04A-7
A/C Clutch Control Relay ..••..•.•.........•........••••.•••••03-o4A-6 Pre-Service Procedures ••••••..••....•••••••••••••.•....•• 03-04A-7
Air Induction System .................••.•••••••••.•••..••••••••03-o4A-2 Fuel Charging Wiring •••••••••••..•.•••••••••••••••••••.•••••• 03-o4A-1 3
Fuel Charging Wiring •••...•.......••.....•..••.••••••••••••••••
03-o4A-6 Fuel Injection Supply Manifold ....•••••••••••••••••.....• 03-04A-1 2
Fuel Injection Supply Manifold ••••••••.••••••••••...•••••••03-o4A-5 Fuel Injector •••••••••••••.••••...••.••••••••••••••••.•...••••••••• 03-o4A-10
Fuel Injection Timing ........•••..••••.••••.••••••••.••..•••••.•
o3-o4A-2 Fuel Pressure Regulator ....•.•••••••••••••••.......•••••••• 03-04A-1 3
Fuel Injectors •.••••••..•••••••••••••••........................•••••
03-o4A-4 Fuel Pressure Relief Valve •••••••......•••••.•••••••••.•... 03.04A-1 1
Fuel Pressure Regulator ••...•••••.•••...•••..........••.•••••03-o4A-5 Fuel Pump Relay .•.•.•..••.•••••••••••.••.•..•..•••••••••••••••• 03-o4A-1 3
Fuel Pressure Relief Valve ••••••••...••.••••••••••••.••••••••03-o4A-6 Spring Lock Coupling ••••••••••.•••••••••••••••••••••••.••••••• 03-04A-7
Fuel Pump Relay •..••••••...••••••••••...............••••.••••••••03-o4A-6 Throttle Body ......•.••••.•••••••••.........•••••••••••••••.•••...• 03-04A-9
Fuel System ••••••••.........•.•.•.•••••••••••••••.•••••••••••••...•
o3-o4A-1 CLEANING AND INSPECTION
Inertia Fuel Shutoff (IFS) Swltch •••••••••••••••••••••••••••
o3-o4A-6 Fuel Injector .••••••••••.••.•......••.•••••••••••••••••••...•••••••
03-o4A-13
Intake Manifold ......•••.••••••••••••••••••.••••••••.•••.....•••••
03-o4A-3 Throttle Body ••••••••...••••••••••••••••••••••.••••••••••••••••••
03-o4A-13
Sequential Multiport Fuel Injection (SFI) ••••.....••••••
03.04A-2 ADJUSTMENTS
Throttle Body •••••.••••••••••...••••.•.•.•••..••••••••••••.••••••••
o3-o4A-2 Idle Speed .••...••.•••••••••.••••......•••••••••••.•••••••••..••.••
03-o4A-14
DIAGNOSIS AND TESTING SPECIFICATIONS ••••••••••••••••••..••..••••••••••••••••...•....••
03-o4A-14
Fuel Charging and Controls ••.••••••••••••••••••..•••.•••••• 03-o4A-7 SPECIAL SERVICE TOOLS/EQUIPMENT •••••••••••••••
03-o4A-14
Fuel Charging System •••••.•••.•••.•.......•••..•••.•••.••••••• 03-o4A-7
VEHICLE APPLICATION
Thunderbird, Cougar-3.8L
Fuel System To maintain the required exhaust emission levels, the

WARNING: DO NOT SMOKE, CARRY LIGHTED fuel delivery system must be:
TOBACCO OR OPEN FLAME OF ANY TYPE WHEN • kept in good operating condition.
WORKING ON OR NEAR ANY FUEL-RELATED
COMPONENT. HIGHLY FLAMMABLE MIXTURES • adjusted to specifications listed in applicable
ARE ALWAYS PRESENT AND MAY BE IGNITED, section of the Powertrain Control I Emissions
RESULTING IN POSSIBLE PERSONAL INJURY. Diagnosis Manual 1 , or on the vehicle emission
control information decal.
An on-board vehicle powertrain control module
(PCM)( 1 2A650): Additional engine performance checks are required to
keep the exhaust emissions at the specified minimum
• accepts inputs from various electronic engine pollutant level.
sensors to compute the required fuel flow rate The unleaded fuel only nomenclature appear on the
necessary to maintain a prescribed air I fuel ratio instrument cluster.
throughout the operational range.
The fuel delivery subsystem consists of the following:
• outputs a command to the fuel injectors to meter the
appropriate quantity of fuel. • high-pressure, in-tank mounted electric fuel pump
• determines and compensates for the age of the (9350)
vehicle and its uniqueness. • fuel filter I reservoir delivering fuel from the fuel tank
• automatically senses and compensates for changes (9002)
in altitude (for example, from sea level to • 2Q-micron fuel filter (9 1 55)
mountains).
• fuel supply and return tubes
• permits push-starting the vehicle if it becomes • fuel injection supply manifold (9F792) incorporates
necessary (manual transmission only).
electrically-activated fuel injectors directly above
All engines use a closed-type positive crankcase each of the engine intake ports
ventilation (PCV) system and an exhaust emission
• fuel injectors which, when energized, spray a
system to control engine emissions within government
metered quantity of fuel into the intake air stream
specifications.

03·04A·2 Fuel Charging and Controls-3.8L 03·04A·2
A constant fuel pressure drop is maintained across the • air cleaner outlet tube (98659)
fuel injectors by a fuel pressure regulator (9C968). • mass air flow sensor (MAF sensorX 1 2B579)
The fuel pressure regulator is:
• throttle body (9E926)
• connected in series with the fuel injector.
• upper intake manifold (9424)
• positioned downstream from fuel injectors.
• lower intake manifold.
Excess fuel supplied by the fuel pump, but not required
by the engine, passes through the fuel pressure
regulator and returns to the fuel tank through a fuel
return line. Throttle Body
The throttle body (9E926) functions as follows:
• The throttle body controls airflow to the engine.
Fuel Injection Timing
• A single lever and accelerator cable (9A758)
For fuel injection timing: rotates the throttle shaft from idle to wide open
throttle cwon position.
• each fuel injector is energized once every other
crankshaft revolution in sequence with firing order. • The plate position at idle is set by the lever
contacting a throttle return control screw. The
• the period of time that the fuel injectors are
throttle return control screw setting is permanent.
energized (fuel injector on time or pulse width) is
Do not attempt to adjust idle I minimum plate setting
controlled by the vehicle's powertrain control
with the throttle return control screw. Refer to the
module (PCM)( 1 2A650).
Powertrain Control I Emissions Diagnosis Manual2 •
• air entering the engine is monitored by flow and
• The throttle body is a single-piece die casting made
temperature sensors.
of aluminum.
• the outgoing signals of the electronic engine control
• The throttle body has a single bore with an air
sensors are processed by the powertrain control
bypass channel around the throttle plate. This
module.
bypass channel controls both cold and warm engine
• the powertrain control module determines the idle airflow control as regulated by an idle air control
needed fuel injector pulse width and sends a valve (lAC valveX9F7 1 5) mounted directly to the
command to the fuel injectors to meter the exact throttle body.
quantity of fuel.
• The idle air control valve is an electro-mechanical
device controlled by the powertrain control module
(PCMX 1 2A650).
Sequential Multipart Fuel Injection (SFI) • The idle air control valve uses a linear actuator
which positions a variable area metering valve.
The sequential multiport fuel injection (SFI) system is
classified as: Other features of the throttle body include:
• multi-point, • a preset stop to locate the wide open throttle

cwon position.
• pulse time and
• a throttle body-mounted throttle position sensor (TP
• mass air flow controlled. sensorX9B989). .
Fuel is metered into each intake port in a sequential • This produces an electrical signal which is used as
firing order. Fuel injectors pulse to follow ignition firing an input to the powertrain control module.
order according to engine demand. Fuel injectors are
mounted on the cylinder heads (6049).
Air Induction System

The air induction system supplies filtered air to the
engine to mix with the fuel for combustion purposes
and consists of the following:
• engine intake air resonator (9F763)
• engine air cleaner with air cleaner element (ACL
elementX960 1)
2 Can b e purchased a s a separate item.

• a sealant applied to the downstream side of the

throttle plate and bore to reduce plate-to-bore
leakage.
NOTE: Cleaning may remove sealant. Do not clean.
IDLE AIR CONTROL

VALVE 9F715
V101 19-A
Intake Manifold • vacuum taps are provided to support various engine

The intake manifolds (9424): accessories.
• pockets for the fuel injectors are machined into the
• consist of the upper intake manifold and the lower cylinder heads (6049) to prevent both air and fuel
intake manifold. leakage.
• runner lengths are tuned to optimize engine torque
and power output.
• provide mounting flanges for the throttle body
(9E926), fuel injection supply manifold (9F792) and
accelerator cable bracket (9723) and the EGR
valve (EGR valve)(9D475).
Fuel Charging System

03·04A-4 Fuel Charging and Controls-3.8L 03·04A·4
Part Part
1 9C968 Fuel Pressure Regulator 13 9424 Intake Manifold, Lower
2 9H323 Fuel Pressure Relief Valve 14 9E936 Throttle Body Gasket
Cap 15 N804758-S2 Nut (4 Req'd)
2 9H32 1 Fuel Pressure Relief Valve 16 9E926 Throttle Body
4 9F792 Fuel Injection Supply 17 90475 EGR Valve
Manifold -
A Tighten to 0.6 N·m (5 Lb-ln)
5 N804836-S53 Retaining Clip -
B Tighten to 7.75 N·m (68
6 9F593 Fuel Injector Lb-ln)
7 N805 1 17-S8M Bolt (4 Req'd) c - Tighten to 8- 1 1 N·m (7 1-97
8 N60669 1-S2 Bolt Lb-ln)
-
9 N804835-S2 Stud Bolt (2 Req'd) D Tighten to 20-30 N·m ( 15-22
10 9424 Intake Manifold, Upper Lb-Ft)
E - Tighten in three steps:
11 N804839-S2 Bolt (4 Req'd) - 10 N-m (88 Lb-ln)
12 9H486 Intake Manifold Upper -20 N·m (15 Lb-Ft)
Gasket -32 N·m (23 Lb-Ft)
(Continued)
Fuel Injectors
The six fuel injectors are:
• electro-mechanical devices which both meter and
r-. atomize fuel delivered to the engine.
• mounted in the cylinder head pockets.
· • positioned so that their tips are directing fuel just
before the engine intake valves (6507).
The fuel injector valve body consists of the following:
• solenoid
• needle and valve assembly
• director / metering plate
An electrical control signal from the powertrain control
module (PCMX 1 2A650) activates the fuel injector
solenoid, causing the needle to move inward, off the V10186-A
seat, allowing the fuel to flow. Since the fuel injector
flow orifice is fixed and the fuel pressure drop across Part
the injector tip is constant: Item Number Description
• fuel flow to the engine is regulated by the length of 1 - Outer 0-Ring Seal
time the solenoid is energized. (Upper)(Part of 9F593)
• atomization of the fuel is obtained by a 2 - Outer 0-Ring Seal
director I metering plate where the fuel separates. (Lower)(Part of 9F593)
-
3 End Cap (Part of 9F593)
-
4 Washer (Part of 9F593)
-
5 Coil Terminal (Part of 9F593)

03·04A·5 Fuel Charging and Controls-3.8L 03-o4A-5

Part
The fuel injection supply manifold (9F792) delivers
high-pressure fuel from the vehicle fuel supply line to
-
the fuel injectors. The fuel injection supply manifold A Tighten to 20-30 N-m ( 15-22
consists of the following: Lb-Ft)
-
B Tighten to 8- 1 1 N·m (7 1-97
• a tubular fuel rail Lb-ln)
• fuel injector connectors
• a mounting flange to the fuel pressure regulator
(9C968)
Fuel Pressure Regulator
• mounting attachments which locate the fuel injection
supply manifold and provide fuel injector retention The fuel pressure regulator (9C968):
• fuel inlet and outlet connections with push connect • is mounted on the fuel injection supply manifold
fittings (9F792) downstream of the fuel injectors.
• regulates the fuel pressure supplied to the fuel
injectors .
• is a diaphragm-operated relief valve in which one
side of the diaphragm senses fuel pressure and the
other side is subjected to intake manifold vacuum.
• nominal fuel pressure is established by a spring
preload applied to the diaphragm.
• balances one side of the diaphragm with manifold
pressure to maintain a constant fuel pressure drop
across the fuel injectors.
• bypasses and returns excess fuel to the fuel tank
(9002). .
V9238-B
Part
Part
1 90930 Fuel Charging Wiring
2 9C968 Fuel Pressure Regulator -
1 Engine Vacuum Reference
3 N60669 1-S2 Bolt Tube (Part of 9C968)
4 N8051 17-S8M Bolt (4 Req'd) 2 -
Ball Seat (Part of 9C968)
5 9F593 Fuel Injector 3 -
Spring (Part of 9C968)
6 9F792 Fuel Injection Supply 4 -
Upper Housing (Part of
Manifold 9C968)

03-04A-6 Fuel Charging and Controls-3.8L 03-04A·6
When a sharp impact occurs:

Pa rt
Item Number Description • the ball breaks loose from the magnet, rolls up a
-
ramp and strikes a target plate which opens the
5 Diaphragm (Part of 9C968) electrical contacts of the inertia fuel shutoff switch
-
6 Lower Housing (Part of and shuts off the fuel pump.
9C968)
-
• and the inertia fuel shutoff switch is open, the inertia
7 Fuel Outlet (Return) Tube fuel shutoff switch must be manually reset before
(Part of 9C968) restarting the vehicle.
-
8 Fuel Inlet (Supply) Tube (Part
of 9C968)
-
9 0-Ring Grooves (Part of
9C968)
-
10 Mounting Plate (Part of
9C968)
-
11 Fuel Filler Screen (Part of
9C968)
-
12 Spring Seat (Part of 9C968)
-
13 Valve Assembly (Part of
9C968)
A20827-A
Fuel Pressure Relief Valve
The fuel pressure relief valve (9H32 1 ):
• is used to relieve fuel pressure from the fuel delivery
system. Fuel Pump Relay
• is located on the fuel injection supply manifold The fuel pump relay ( 14N089) supplies power to the
(9F792). fuel pump (9350) when the powertrain control module
For fuel system pressure relief procedures, refer to (PCMX 1 2A650) grounds the relay during START and
Section 1 o-o 1 . engine running conditions.
Fuel Charging Wiring A/C Clutch Control Relay

The fuel charging wiring (90930): The A / C compressor clutch control relay ( 14N089)
improves idle smoothness after engine start-up and
• connects the engine control sensor wiring ( 1 2A58 1) also improves acceleration performance. The A I C is
to each fuel injector or other electronic engine cut off for approximately five seconds:
controls such as throttle position sensor (TP
sensor)(9B989) and idle air control valve (lAC • just after the engine is started.
valve)(9F7 1 5). • when the throttle position sensor (TP
• receives fuel injector signals from the powertrain sensorX9B989) indicates a full throttle condition.
control module (PCMX 1 2A650) and transfers the
signals to the fuel injectors (9F593).
The signals from the powertrain control module
determine the fuel injection sequence and duration
each fuel injector will stay open to allow fuel into the
combustion chambers.
Inertia Fuel Shutoff (IFS) Switch

The inertia fuel shutoff switch (IFS switch)(934 1 ):
• is used in conjunction with an electric fuel pump
� (9350).
• shuts off the fuel pump in the event of a collision.
• consists of a steel ball held in place by a magnet.

Fuel Charging and Controls 4. WARNING: THE FUEL SYSTEM IS NORMALLY

Refer to the Powertrain Control I Emissions Diagnosis PRESSURIZED TO 276 KPA (40 PSI). USE
Manual3 for Diagnosis and Testing Procedures. CARE WHEN SERVICING THE FUEL SYSTEM
OR POSSIBLE PERSONAL INJURY MAY
OCCUR.
REMOVAL AND INSTALLATION NOTE: Check all connections at fuel injection
supply manifold, fuel injectors, push connect
fittings and other appropriate areas.
Turn ignition switch from ON I OFF position
Pre-Service Procedures several times without starting engine to check for
fuel leaks.
SPECIAL SERVICE TOOL(S) REQUIRED 5. Start engine and warm to operating temperature.
Description Tool Number Check for coolant leak if coolant was removed.
Multiport Fuel Injection (MFI) Fuel TBOL-9974-B
6. Perform Powertrain Control Module Self Test to
Pressure Gauge check systems function. Refer to the Powertrain
Control I Emissions Diagnosis Manual3•
WARNING: THE FUEL SYSTEM IS NORMALLY
PRESSURIZED TO 276 KPA (40 PSI). USE CARE
WHEN SERVICING THE FUEL SYSTEM OR
POSSIBLE INJURY MAY OCCUR. Spring Lock Coupling
NOTE: The fuel charging system consists of the WARNING: DO NOT SMOKE, CARRY LIGHTED
throttle body (9E926) and the upper and lower intake TOBACCO OR AN OPEN FLAME OF ANY TYPE
manifolds (9424). WHEN FUELING VEHICLE OR WHEN WORKING ON
Prior to service or removal of the fuel charging system, OR NEAR ANY FUEL-RELATED COMPONENT.
the following steps must be taken: HIGHLY FLAMMABLE MIXTURES ARE ALWAYS
PRESENT AND MAY BE IGNITED, RESULTING IN
. 1. Disconnect battery ground cable ( 1 430 1 ). Refer POSSIBLE PERSONAL INJURY.
WARNING: FUEL SUPPLY LINES ON VEHICLES
2. Remove fuel tank filler cap (9030) at fuel tank EQUIPPED WITH FUEL-INJECTED ENGINES WILL
(9002) and release pressure. REMAIN PRESSURIZED FOR LONG PERIODS OF
Fuel Pressure Relief TIME AFTER ENGINE SHUTDOWN. FUEL SYSTEM
PRESSURE MUST BE RELIEVED PRIOR TO FUEL
1. NOTE: A fuel pressure relief valve (9H32 1 ) on the SYSTEM SERVICE TO PREVENT POSSIBLE
fuel injection supply manifold (9F792) is provided INJURY. REFER TO FUEL PRESSURE RELIEF.
for this procedure.
Install Multipart Fuel Injection (MFI) Fuel Pressure Removal
Gauge T80L-9974-B to the fuel pressure relief 1. Remove clip from spring lock coupling.
valve on the fuel injection supply manifold.
2. Release pressure from fuel system. Refer to
Section 1 o-o 1 .
Post-Service Procedures
After the service is complete and the fuel charging
system is installed into the engine, the following steps
must be taken: CLIP
1. Install fuel tank filler cap at fuel tank.
V101 47-A
3. Add engine coolant (if required). Refer to Section
03-Q3.

2. Position Spring Lock Coupling Disconnect Tool 6. NOTE: Inspect coupling for missing or damaged
D87L-928D-A 1 or equivalent for 3 I 8 inch tube or 0-rings. If either 0-ring is damaged, both 0-rings
D87L-928D-B or equivalent for 1 I 2 inch tube onto must be replaced. Replace 0-rings or garter
coupling. Make sure that tool can enter cage springs with the appropriate replacement parts
opening to release the garter spring. only.
Clean fittings with solvent.
SPRING LOCK COUPLING
DISCONNECT TOOL:
D87L-9280-A - 318 INCH
D87L-9280-B - 1/2 JNCH
0-RINGS SPRING V10156-A
CAGE Installation
OPENING 1. Lubricate the 0-rings with clean engine oil.
V10148-A
3. Push the Spring Lock Coupling Disconnect Tool

into the cage opening to release the female fitting USE ONLY SPECIFIED FUEL
from the garter spring.
RESISTANT 0-RINGS
(COLOR: BLACK)
PUSH TOOL INTO CHECK

CAGE OPENING FOR
CORROSION
LUBRICATE 0-RINGS
V101 49-A
AV0219-A
4. Pull the coupling male and female fittings apart.
2. Insert male fitting into female fitting and push
together until garter spring is engaged.
V10150-A
GARTER SPRING
5. Remove the disconnect tool from the V10153-A
disconnected spring lock coupling.
3. Pull on fittings to ensure coupling engagement.
V10151-A

03-04A-9 Fuel Charging and Controls-3.8L 03-04A·9
4. Install clip to spring lock coupling. Throttle Body

Removal
CORRECT FUEL LINE 1. Loosen engine air cleaner tube clamps (9C632)
and remove air cleaner outlet tube (98659).
Refer to Section 03- 1 2.
2. Disconnect accelerator cable (9A758) from
throttle body lever.
TETHER 3. Disconnect fuel charging wiring (9D930) from
CLAMPED throttle position sensor (TP sensor)(9B989) and
idle air control valve (lAC valve)(9F7 1 5).
/
4. Remove four throttle body retaining nuts.
5. Carefully separate throttle body (9E926) from
upper intake manifold (9424).
6. Remove and discard throttle body gasket (TB
gasket)(9E936).
Installation
1. NOTE: If scraping is necessary, do not damage
gasket surfaces or allow material to drop into
WRONG - WHEN FLARE OR upper fuel charging wiring.
O·RINGS ARE SHOWING
FEMALE Clean gasket mating surfaces.
V10154-B
2. Install throttle body with new throttle body gasket
5. Make sure clip is correctly installed. on the four studs of the upper intake manifold.
lighten retaining nuts to 2Q-30 N·m ( 1 5-22 1b-ft).
3. Connect fuel charging wiring to the throttle
position sensor and idle air control valve.
4. Connect accelerator cable to throttle body lever.
5. Install air cleaner outlet tube and securely tighten
engine air cleaner tube clamp. Refer to Section
03· 1 2 .
V10155-A

03·04A- 1 0 Fuel Charging and Controls-3.8L 03·04A· 10
V9236-B
r- Part Part
1 9C968 Fuel Pressure Regulator 13 9424 Intake Manifold, Lower
2 9H323 Fuel Pressure Relief Valve 14 9E936 Throttle Body Gasket
Cap 15 N804758-S2 Nut (4 Req'd)
3 9H32 1 Fuel Pressure Relief Valve 16 9E926 Throttle Body
4 9F792 Fuel Injection Supply 17 90475 EGR Valve
Manifold -
A Tighten to 0.6 N·m (5 Lb-ln)
5 N804836-S53 Retaining Clip -
B Tighten to 7. 75 N·m (68
6 9F593 Fuel Injector Lb-ln)
7 N8051 17 -saM Bolt (4 Req'd) c - Tighten to 8- 1 1 N·m (7 1-97
8 N60669 1-S2 Bolt Lb-ln)
9 N804835-S2 Stud Bolt (2 Req'd) D - Tighten to 20-30 N·m (15-22
10 9424 Intake Manifold, Upper Lb-Ft)
E - Tighten in three steps:
11 N804839-S2 Bolt (4 Req'd) - 10 N·m (88 Lb-ln)
12 9H486 Intake Manifold Upper -20 N·m (15 Lb-Ft)
Gasket -32 N·m (23 Lb-Ft)
(Continued)
Fuel Injector 3. Remove fuel injection supply manifold (9F792) as

described.
Removal
4. Remove fuel injector retaining clips as required.
1. Perform Pre-Service and Fuel Pressure Relief
Procedures. Refer to Fuel Charging System.
2. Remove upper intake manifold (9424) as
described in Section 03-0 1 A.

03·04A·1 1 Fuel Charging and Controls-3.8L 03·04A· 1 1
5. Carefully remove connectors from fuel charging 2. Install fuel injectors. Use a light twisting, pushing
wiring (90930) to individual fuel injectors as motion.
required. 3. Reinstall fuel injector retaining clips as required.
4. Install fuel injection supply manifold as described.
FUEL CHARGING 5. Install connectors from fuel charging wiring to fuel
WIRING 90930
ELECTRICAL injectors.
CONNECTOR 6. Install upper intake manifold as described in
Section 03-o1 A. Perform Fuel Charging System,
Post-Service Procedures as described.

FUEL
INJECTOR 9F593 Description Tool Number
Multiport Fuel Injection (MFI) Fuel TSOL-9974-B
6. Grasping fuel injector body, pull up while gently Pressure Gauge
rocking fuel injectors from side to side.
7. Inspect fuel injector 0-rings (two per fuel injector) Removal
for signs of deterioration. Replace as required. 1. NOTE: Fuel pressure relief valve cap (9H323) on
8. Inspect fuel injector body, end cap and washer for fuel pressure relief valve (9H32 1 ) must be
signs of dirt and deterioration. removed.
If fuel injection supply manifold (9F792) is
mounted to engine, remove fuel tank filler cap
(9030); then release pressure from system at fuel
pressure relief valve on fuel injection supply
manifold using Multiport Fuel Injection (MFI) Fuel
Pressure Gauge TBOL-9974-B. Refer to Section
1 Q-o 1 .
V10186-A
Part
V9230-A
-
1 Outer 0-Ring Seal
(Upper)(Part of 9F593)
2 -
Outer 0-Ring Seal Part
(Lower)(Part of 9F593) Item Number Description
- 1 9H323 Fuel Pressure Relief Valve
3 End Cap (Part of 9F593)
4 -
Washer (Part of 9F593) Cap
5 -
Coil Terminal (Part of 9F593) 2 9H32 1 Fuel Pressure Relief Valve
3 9F792 Fuel Injection Supply
Installation Manifold
1. CAUTION: Never use silicone grease. 4 9C968 Fuel Pressure Regulator
Silicone grease will clog the fuel injectors. 5 -
Fuel Supply and Return
Lubricate 0-rings with clean engine oil meeting Connectors (Part of 9F792)
Ford specification WS5-M2C 1 53-F and install on A -
Tighten to 0.6 N-m (5 Lb-ln)
each fuel injectors. 8 -
Tighten to 7. 75 N-m (68
Lb-ln)

03-04A- 1 2 Fuel Charging and Controls-3.8L 03-04A- 1 2
2. Using an open-end wrench or suitable deep well

socket, remove fuel pressure relief valve.
Installation
1. Install fuel pressure relief valve. Tighten fuel
pressure relief valve to 7. 75 N·m (68 1b-in).
2. Perform Post-service Procedures. Refer to Fuel
Charging System.
3. Install fuel pressure relief valve cap. Tighten fuel
pressure relief valve cap to 0.6 N·m (5 lb-in).

Removal
1. Perform Fuel Charging System, Pre-Service and
Fuel Pressure Relief Procedures as described.
2. Remove upper intake manifold (9424) as
described in Section 03-Q 1A.
3. Remove spring lock coupling retainer clips from
fuel inlet and return fittings.
4. Using Spring Lock Coupling Disconnect Tool
D87L -928Q-A (3 / 8 inch) or D87L-928Q-B ( 1 / 2
inch) or equivalent, disconnect the inlet and outlet
fuel lines from the fuel injection supply manifold
(9F792).
5. Remove fuel pressure regulator bracket retaining
bolt.
6. NOTE: It may be easier to remove fuel injectors
with the fuel injection supply manifold as an
assembly. V9238-B
Carefully disengage fuel injection supply manifold
from fuel injectors and remove fuel injection Part
supply manifold. Item Number Description
7. Use a rocking, side-to-side motion while lifting to 1 90930 Fuel Charging Wiring
remove fuel injectors from cylinder head pockets. 2 9C968 Fuel Pressure Regulator
3 N606691-S2 Bolt
4 N805 1 17-S8M Bolt (4 Req'd)
5 9F593 Fuel Injector
Manifold
A - Tighten to 20-30 N·m ( 15-22
Lb-Ft)
B - Tighten to 8- 1 1 N·m (7 1-97
Lb-ln)
Installation
1. CAUTION: When Installing fuel injection
supply manifold, particular attention should
be paid to proper o-rlng seating to make
sure that no fuel leaks exist.
Push fuel injection supply manifold down to make
sure all fuel injector Q-rings are fully seated in the
fuel injection supply manifold cups and cylinder
!"""" head pockets.
2. Install retaining bolts while holding fuel injection
supply manifold. Tighten bolts to 8-1 1 N·m (7 1 -97
lb-in).

03-04A- 13 Fuel Charging and Controls-3.8L 03-04A- 1 3
3. Install fuel pressure regulator bracket retaining 2. Disconnect fuel charging wiring {9D930) from fuel
bolt. Tighten to 2Q-30 N·m { 1 5-22 lb-ft). injectors {9F593) and electronic engine controls.
4. Install inlet and outlet fuel line spring lock 3. Disconnect fuel charging wiring from engine
couplings as described. control sensor wiring { 1 2A58 1 ).
5. Connect fuel charging wiring {9D930). Installation
6. Install upper intake manifold as described in 1. Follow removal procedure in reverse order.
Section 03-0 1 A.
2. Verify all connections.
7. Perform Fuel Charging System, Post-Service
Procedures as described.
Fuel Pump Relay

Fuel Pressure Regulator Removal
Removal 1. Disconnect battery ground cable { 1 430 1 ). Refer

to Section 14-Q 1 .
1. Perform Pre-Service and Fuel Pressure Relief
Procedures as described if removing fuel 2. Locate fuel pump relay { 1 4N089) in the engine
pressure regulator {9C968) while fuel injection compartment power distribution center and
supply manifold {9F792) is installed on engine. remove fuel pump relay.
Refer to Fuel Charging System. Installation
2. Remove vacuum line from fuel pressure regulator. 1. Follow removal procedure in reverse order.
3. Remove two Allen-head retaining screws from
fuel pressure regulator housing.
4. Remove fuel pressure regulator, return seal and CLEANING AND INSPECTION
Q-rings. Discard fuel pressure regulator return
seal and 0-rings. Throttle Body
5. If scraping is necessary, do not damage fuel WARNING: DO NOT SMOKE OR CARRY LIGHTED
pressure regulator or fuel injection supply TOBACCO OR OPEN FLAME OF ANY TYPE WHEN
manifold sealing surfaces. WORKING ON OR NEAR ANY FUEL-RELATED
Installation COMPONENT. HIGHLY FLAMMABLE .MIXTURES
ARE ALWAYS PRESENT AND MAY BE IGNITED,
1. CAUTION: Never use silicone grease. RESULTING IN POSSIBLE PERSONAL INJURY.
Silicone grease will clog the fuel injectors.
The throttle body {9E926) for this vehicle is a
Lubricate fuel pressure regulator Q-rings with sludge-resistant design with a coating on the bore and
clean engine oil meeting Ford Specification plate. Sludge accumulation will not affect the throttle
WS8-M2C 1 53-F. body air flow. Any attempt to clean the bore and plate
2. Make sure sealing surfaces of fuel pressure area will impair the effectiveness of the coating. Do
regulator and fuel injection supply manifold are not clean the bore and plate area of the throttle body.
clean.
3. Install new fuel pressure regulator Q-rings and
new return seal on fuel pressure regulator and in
fuel injection supply manifold return port. Fuel Injector
4. Install fuel pressure regulator on fuel injection Testing/Cleaning
supply manifold. Tighten retaining screws to CAUTION: The fuel injectors for this vehicle are a
3.Q-4.5 N·m {27-39 1b-in). deposit-resistant design and should NOT be
5. Install vacuum line to fuel pressure regulator. cleaned.
6. Perform Fuel Charging System, Post-Service Test fuel injectors using Rotunda Fuel Injector
Procedures as described. Tester I Cleaner 1 64-R3759 or equivalent. Follow tool
manufacturer's operating instructions.

Removal
1. Remove upper intake manifold {9424) as
described in Section 03-Q 1 A.

03-04A- 14 Fuel Charging and Controls-3.8L 03-04A- 14
ADJUSTMENTS SPECIAL SERVICE TOOLS/EQUIPMENT
Idle Speed SPECIAL SERVICE TOOLS REQUIRED

Refer to the Powertrain Control I Emissions Diagnosis Tool NumberI
Manual4 • Description Illustration
TSOL-9974-B
Multiport Fuel Injection (MFI)
~
SPECIFICATIONS Fuel Pressure Gauge
Ford TIOL...7....
Engine Oil - WSS-M2C 1 53-F
TORQUE SPECIFICATIONS Tool Number Description

Description N·m Lb·Ft Lb·ln D87L-9280-A Spring Lock Coupling Disconnect Tool
•
(3 / 8 inch)
• -
Upper Intake
Manifold-to-Lower Intake D87L-9280-B Spring Lock Coupling Disconnect Tool
Manifold Bolts (1 /2 inch)
Throttle Body-to-Upper Intake 8- 1 1 - 7 1 -97

ROTUNDA EQUIPMENT
Manifold
Fuel Pressure Regulator to 3.0-4.5 - 27-39 Model Description
Fuel Injection Supply Manifold 164-R3759 Fuel Injector Tester I Cleaner
Fuel Injection Supply Manifold 8- 1 1 - 7 1 -97
to Lower Intake Manifold
Fuel Pressure Relief 7.75 - 68
Valve-To-Fuel Injection Supply
Manifold
Fuel Pressure Relief Valve Cap 0.6 - 5
to Pressure Relief Valve
Fuel Pressure Regulator 20-30 15-22 -
Bracket-To-Cylinder Head
a Tighten in three steps:
• 10 N·m (88 Lb-ln)
e 20 N·m ( 15 Lb-Ft)
e 32 N·m (23 Lb-Ft)

03-04B- 1 Fuel Charging and Controls-4.6L (2V) 03-04B- 1
SECTION 03-048 Fuel Charging and Controls-4.6L

(2V)
VEHICLE APPLICATION . .. . • • • . . . . . . . . . . . .. . . . • • • . • . . . . . . . . . . . . . . . 03-o4B-1 REMOVAL AND INSTALLATION (Cont'd.)
DESCRIPTION AND OPERATION Fuel Injector • • • . . . . . . . . . . . . . . . .....•••.••••..•••.•••••... . . . . ....... 03-o4B-8
A/C Clutch Control Relay . . • • • . . . . . . . . . . . . .. • . . ••••.••...•.... o3-o4B-5 Installation •. . . . . ..•............ . . . . . . .•••••... . . . . . . . . . . . . . . . . . . . 03-o4B-9
Air Induction System • . • • • . . . . . . . . . . • • • . . . • . . • • . . . . . . . •• . • • . •••• o3-o4B-2 Removai ...••••••••••••••••.•• • . .......... . ......•..••.•••••••••..• 03-o4B-8
Fuel Charging Wiring ••••.. . . . . . . . . . . . . . . • • . . . • . . .. . . . . . . . . . ..•. 03-o4B-5 Fuel Pressure Regulator ••••••.••.•.•....••..•.....•.••••••• 03-o4B-1 1
Fuel Injection Supply Manifold ......••.••••••••••••..•..... 03-o4B-3 Installation ..•...••..•....•..•••••••• .•••.•..•....... ........••• o3-o4B-1 1
Fuel Injection Timing ...• . . . . . . . . . . . . . . .. . . . • • • . • . . . . . . . . . . . . . . . 03-o4B-2 Removai . . . . . . .. . . . . . . . . . . . . . . . . . . • • • . . • . . . . . . ...... . . . . . . . . . . ... 03-o4B-1 1
Fuel Injectors •.••.•••... .•......•••••••• . . . . .. . . . . • • • . . . •• . •••••••• 03-o4B-3 Fuel Pressure Relief Valve ••••••.•••••••••••••.•...........•• 03-o4B-9
Fuel Pressure Regulator ........•••...••...........•..•...•••• 03-o4B-4 Installation • • . • • . • • • . • • . . • . . . . . . . . . . . . . . . . • . . • • . •• . ••••••••••••.•• 03-o4B-9
Fuel Pressure Relief Valve . . . ....•••••• • . . • . . ..........•••••• 03-o4B-5 Removai . .•..••••.•••••.•••.••.......... . . . . . . . .•••••••••••••••••.. 03-o4B-9
Fuel Pump Relay . . . . . . . . . • . • . . . . . . .. . . . . ..••• . • • . . . . . . .. . . . . . . . . . . 03-o4B-5 Fuel Pump Relay . . . . . . . • • . • • • . . ..•. . . . . . . . . . . . .. . . . . .• . ••••••••• 03-o4B-1 1
Fuel System ••••••••.••... . . .•••.•.••••.. •••••• . • • . . • • • . . • • . ••••••.. 03-o4B-1 Installation . . . . . . . . • . . . . . . . .•••.••••••.......... . .. . . . . . ..•.•••• 03-o4B- 1 1
Inertia Fuel Shutoff (IFS) Switch •••.•.•..........•..••.•••• 03-04B-5 Removai . . • . . • • . . • • . • • . . • . . . . . . .. . . . . • . . • . • • . •••••••••.••••.••... 03-o4B-1 1
Intake Manifold • • • . • . . . . • . • . . . . . . . . • . . .•••••..••.•.......•.••••••• 03-o4B-3 Spring Lock Coupling • . • . . . . . . . . . . . .. . . . . . • . . . •••••••..•....... 03-o4B-6
Sequential Multiport Fuel Injection (SFI) •.............• 03-o4B-2 Installation . . .. . ...•••••• . . • • • . . . • . . . . . . .• • • . •••••••••••.••••.•••. 03-o4B-7
Throttle Body •.•....... ....•••••..••••••... . . . . . . . . ••••••••••••.... 03-o4B-2 Removai • . . . . . . . . . . . . . . . . . . . . • .••••••.•............ ..........•••••• 03-o4B-6
DIAGNOSIS AND TESTING Throttle Body •••••.•••.••.........•••.••.••••••••••.•••••.....•••.. 03-o4B-8
Fuel Charging and Controls . . . . . . . . • . •• • • • • • • • • • . . . . . . • • • • • • 03-o4B-6 Installation . . . . . . . . • • • • • • . . . . . . . . . . . . . . . . .....•.••••••••••.•...... 03-o4B-8
REMOVAL AND INSTALLATION Removai ••••..•........••••••.•••••....•...•••••••••••••••••••••••• 03-o4B-8
Fuel Charging System . . . . . . . . . . . •• • • • . . • . . . . . . . . .....•••..••••• 03-o4B-6 CLEANING AND INSPECTION
Post-Service Procedures . . ....•.•••..•••••••• . . . . . . ..•.••• 03-o4B-6 Fuel Injector . • . . ••••••••• . . • .. .. . . . • . . . . . . ••••••••••••••••••••••.. 03-o4B-1 1
Pre-Service Procedures . • . . . . . . . . . .. . ....••••••.•••....... 03-o4B-6 Testing /Cieaning . • . • • • • • • . • • • . . . . . . . . . . . . . . . . . . • . • • •• • • • . • • o3-o4B-1 1
Fuel Charging Wiring ......••................••..•••..••...... 03-o4B-1 1 Throttle Body .......•.•••.•..•••••••...............••••.••••••••• 03-o4B-1 1
.
lnstallation .••••••• . . . . . . . . . . . . . . . . . • • • • . . • . . . . . . . . . . . . . ..•..••• 03-o4B- 1 1 ADJUSTMENTS
Removai ...... . . . . . . • • • • • . . . . . . . . . ......••• . . • . . • • . • . . . . . . . . . . . . • 03-o4B-1 1 Idle Speed • • • • . • • • • • • • • • • • • • . . . . . . • . • . . . . . . • • • • • • • • • • • •• . . • . • • . • • . . 03-o4B-1 2
Fuel Injection Supply Manifold ..............••...••...... 03-o4B-10 SPECIFICATIONS ...........•••••••••..••.•...•...•..••••.••••••••. 03-()48-1 2
Installation •................••...•....................••.••..... o3-o4B-1 0 SPECIAL SERVICE TOOLS/EQUIPMENT .••••••••••••••• 03-o4B-1 2
Removai . . . . . . . . . •..•••• • . . . . . . . . . . . .. . . . . • • • • • . . • . . . . . . . . . . . . . . . 03-o4B-10
VEHICLE APPLICATION
Thunderbird, Cougar-4.6L (2V)
Fuel System All engines use a closed-type positive crankcase

WARNING: DO NOT SMOKE, CARRY LIGHTED ventilation (PCV) system and an exhaust emission
TOBACCO OR OPEN FLAME OF ANY TYPE WHEN system to control engine emissions within government
WORKING ON OR NEAR ANY FUEL-RELATED specifications.
COMPONENT. HIGHLY FLAMMABLE MIXTURES To maintain the required exhaust emission levels, the
ARE ALWAYS PRESENT AND MAY BE IGNITED, fuel delivery system must be:
RESULTING IN POSSIBLE PERSONAL INJURY.
• kept in good operating condition.
(PCM)( 1 2A650): • adjusted to specifications listed in the applicable
section of the Powertrain Control I Emissions
• accepts inputs from various engine electronic Diagnosis Manual 1 , the applicable section of this
sensors to compute the required fuel flow rate group or on the vehicle emission control information
necessary to maintain a prescribed air I fuel ratio decal.
throughout the entire engine operational range. Additional engine performance checks are required to
• sends a command to the fuel injectors to meter the keep the exhaust emissions at the specified minimum
appropriate quantity of fuel. pollutant level.
• determines and compensates for the age of the The UNLEADED FUEL ONLY nomenclature appears
vehicle and its uniqueness. Automatically senses on the instrument cluster.
and compensates for changes in altitude (for
example, from sea level to mountains).

03-048-2 Fuel Charging and Controls-4.6L (2V) 03-048-2
The fuel delivery sub-system delivers fuel to the fuel Sequential Multiport Fuel Injection (SFI)
charging system and consists of the following: The sequential multiport fuel injection (SFI) system is
• a high-pressure, in-tank mounted, electric fuel pump classified as:
(9350) • multi-point,
• a fuel filter I reservoir delivering fuel from the fuel • pulse time and
tank (9002)
• mass air flow controlled.
• a 20-micron fuel filter (9 1 55)
Fuel is metered into each intake port in sequence with
• fuel supply and return tubes the ignition firing order according to engine demand
• the fuel injection supply manifold (9F792) which through the fuel injectors mounted on a tuned intake
incorporates electrically-actuated fuel injectors manifold (9424).
(9F593) directly above each of the engine's intake
ports
• the fuel injectors which, when energized, spray a
metered quantity of fuel into the intake air stream. Air Induction System
A constant fuel pressure drop is maintained across the The intake air system supplies filtered air to the engine
fuel injectors by a fuel pressure regulator (9C968). to mix with the fuel for combustion purposes and
The fuel pressure regulator is: consists of the following:
• connected in series with the fuel injectors. • engine air cleaner (ACL)(9600) with an air cleaner
element (ACL element)(960 1)
• positioned downstream from the fuel injectors.
• mass air flow sensor (MAF sensor)( 1 28579)
Excess fuel supplied by the fuel pump, but not required
by the engine, passes through the fuel pressure • air cleaner outlet tube (98659)
regulator and returns to the fuel tank through a fuel • throttle body (9E926)
return line.
• intake manifold (9424)
Fuel Injection Timing

Throttle Body
For fuel injection timing:
The throttle body (9E926) functions as follows:
• Each fuel injector is energized once every other
crankshaft revolution in sequence with ignition firing • The throttle body controls airflow to the engine.
order. • A cam lever and accelerator cable (9A758) rotates
• The period of time that the fuel injectors are the throttle shaft from idle to wide open throttle
energized (fuel injector "on time" or pulse width) is (WOT) position.
controlled by the vehicle's powertrain control • The plate position at idle is factory set by the lever
module (PCM)( 1 2A650). contacting a throttle return control screw. The head
• Air entering the engine is monitored by flow and of the throttle return control screw is removed to
temperature sensors. make the idle plate set permanent. Do not attempt
to adjust idle I minimum plate setting with the throttle
• The outgoing signals of the electronic engine control return control screw. Refer to the Powertrain
sensors are processed by the powertrain control Control I Emissions Diagnosis Manual.2
module.
• The powertrain control module determines the
needed fuel injector pulse width and outputs a
command to the fuel injectors to meter the exact
quantity of fuel.

• The throttle body airflow is factory set by the idle air

adjust needle (trim screw) within the throttle body
casting. Do not attempt to adjust. Refer to the
Powertrain Control I Emissions Diagnosis Manual. 3 FUEL INJECTOR
9F593
• Throttle body idle airflow provides minimum engine 8 REO'D
airflow, while the idle air control valve (lAC
valve)(9F7 1 5) provides supplemental engine airflow
to maintain the desired engine idle speed.
Other features of the throttle body include:
• the WOT plate position, which is obtained when the
lever contacts the throttle body casting.
• throttle position sensor (TP sensor)(98989), which
provides an electrical signal used as an input to the
powertrain control module (PCM)( 1 2A650).
• a sealant is applied to the downstream side of the INTAKE
throttle body plate and bore, to reduce plate-to-bore MANIFOLD
leakage. � 9424
Cleaning may remove sealant. DO not clean. FRONT OF ENGINE
,.,..-
�
V10121-A
THROTILE POSITION
"'c:'�"''-'n 98989
FRONT OF ENGINE
�
Fuel Injectors
The eight fuel injectors are:
• electro-mechanical devices which both meter and
atomize fuel delivered to the engine.
• mounted in the intake manifold (9424).
• positioned so that their tips direct fuel just ahead of
the engine intake valve (6507).
The injector bodies consist of the following:
• solenoid
V1012Q-A • needle and valve assembly
• director I metering plate
An electrical control signal from the powertrain control
Intake Manifold module (PCM)( 1 2A650) activates the fuel injector
solenoid causing the needle to move inward, off the
The intake manifold (9424) has the following seat allowing fuel to flow. Since the fuel injector flow
characteristics: orifice is fixed and the fuel pressure drop across the
injector tip is constant:
• one-piece aluminum casting
• runner lengths tuned to optimize engine torque and • fuel flow to the engine is regulated by the length of
power output time the solenoid is energized.
• pockets in which the fuel injectors are mounted • atomization is obtained at the point where the fuel
placed to direct the injector fuel spray immediately separates at the end cap.
in front of each engine intake valve (6507).
• machined pockets for the fuel injectors (9F593) to
prevent both air and fuel leaks
The fuel injection supply manifold (9F792) is the
component that delivers high-pressure fuel from the
vehicle fuel supply line to the eight fuel injectors. The
fuel injection supply manifold consists of the following:
• a tubular fuel rail
• eight fuel injector connectors

• mounting flange to the fuel pressure regulator • nominal fuel pressure is established by a spring
(9C968) preload applied to the diaphragm.
• mounting attachments that locate the fuel injection • balances one side of the diaphragm with manifold
supply manifold and provide fuel injector retention pressure to maintain a constant fuel pressure drop
• fuel inlet and outlet connections with push connect across the fuel injectors.
fittings • bypasses and returns excess fuel to the fuel tank
(9002).
Fuel Pressure Regulator
�
FRONT OF ENGINE
..-----
V10122-A Part
Item Number De scri pti on
-
Part 1 Engine Vacuum Reference
Item Number Description Tube (Part of 9C968)
-
1 -
Bolt (4 Req'd) 2 Ball Seat (Part of 9C968)
-
2 9C968 Fuel Pressure Regulator 3 Spring (Part of 9C968)

-
3 9F792 Fuel Injection Supply 4 Upper Housing (Part of

Manifold 9C968)
-
4 9F593 Fuel Injector (8 Req'd) 5 Diaphragm (Part of 9C968)

-
5 9424 Intake Manifold 6 Lower Housing (Part of

9C968)
-
A Tighten to 8- 12 N·m (7 1- 106 7 -
Fuel Outlet (Return) Tube
Lb-ln) (Part of 9C968)
-
8 Fuel Inlet (Supply)Tube (Part
of 9C968)
-
Fuel Pressure Regulator 9 0-Ring Grooves (Part of
9C968)
The fuel pressure regulator (9C968): -
10 Mounting Plate (Part of
• is mounted on the fuel injection supply manifold 9C968)
-
(9F792) upstream of the fuel injectors. 11 Fuel Filter Screen (Part of
• regulates the fuel pressure supplied to the fuel
9C968)
-
injectors. 12 Spring Seat (Part of 9C968)
-
• is a diaphragm-operated relief valve in which one 13 Valve Assembly (Part of
side of the diaphragm senses fuel pressure and the 9C968)
other side is subjected to intake manifold vacuum.

03·048·5 Fuel Charging and Controls-4.6L (2V) 03·048·5

The fuel pressure relief valve (9H32 1):
• is used to relieve fuel pressure from the fuel delivery
system.
• is located on the fuel injection supply manifold
(9F792).
For fuel system pressure relief procedures, refer to
Section 1 0-0 1 .

A20827·A
The fuel charging wiring (90930):
• connects the engine control sensor wiring ( 1 2A58 1 )
to each fuel injector and other electronic engine
controls such as throttle position sensor (TP Fuel Pump Relay
sensorX9B989) and idle air control valve (lAC
valve)(9F7 15). The fuel pump relay ( 1 4N089) supplies power to the
fuel pump (9350) when the powertrain control module
• receives fuel injector signals from the powertrain (PCMX 1 2A650) grounds the relay during START and
control module (PCMX 1 2A650) and transfers the engine RUN conditions.
signals to the fuel injectors.
The signals from the powertrain control module
determine the fuel injection sequence and duration
each fuel injector will stay open to allow fuel into the A/ C Clutch Control Relay
combustion chambers.
The A / C clutch control relay ( 1 90572) is used to
improve idle smoothness after engine start-up and to
improve acceleration performance. The A I C is cut off
for approximately five seconds:
Inertia Fuel Shutoff (IFS) Switch
The inertia fuel shutoff switch (IFS switch)(934 1 ): • just after the engine is started.
• when the throttle position sensor (TP
• is used in conjunction with an electric fuel pump sensorX9B989) indicates a wide-open-throttle
(9350). (WOT) condition.
• shuts off the fuel pump in the event of a collision.
• consists of a steel ball held in place by a magnet.
When a sharp impact occurs:
• the ball breaks loose from the magnet, rolls up a
ramp and strikes a target plate that opens the
electrical contacts of the inertia fuel shutoff switch
and shuts the fuel pump off.
• once opened, the inertia fuel shutoff switch must be
manually reset before restarting the vehicle.

03-04B-6 Fuel Charging and Controls-4.6L (2V) 03-048-6
Fuel Charging and Controls 5. Start engine and warm to operating temperature.
Refer to the Powertrain Control I Emissions Diagnosis Check for engine coolant leak if coolant was
Manual. 4 removed.
6. Perform powertrain control module seH-test to
check systems function. Refer to the Powertrain
REMOVAL AND INSTALLATION Control I Emissions Diagnosis Manual4 _

Pre-Service Procedures Spring Lock Coupling
WARNING: DO NOT SMOKE, CARRY LIGHTED
SPECIAL SERVICE TOOL(S) REQUIRED TOBACCO OR AN OPEN FLAME OF ANY TYPE
WHEN WORKING ON OR NEAR ANY
FUEL-RELATED COMPONENT. HIGHLY
Fuel Pressure Gauge TSOL-9974-B FLAMMABLE MIXTURES ARE ALWAYS PRESENT
AND MAY BE IGNITED, RESULTING IN POSSIBLE
1. WARNING: THE FUEL SYSTEM IS NORMALLY PERSONAL INJURY.
PRESSURIZED TO 276 KPA (40 PSI). USE
CARE WHEN SERVICING THE FUEL SYSTEM WARNING: FUEL SUPPLY LINES ON VEHICLES
OR PERSONAL INJURY COULD OCCUR. EQUIPPED WITH FUEL INJECTED ENGINES WILL
REMAIN PRESSURIZED FOR LONG PERIODS OF
NOTE: The fuel charging system consists of the TIME AFTER ENGINE SHUTDOWN. FUEL SYSTEM
fuel injection supply manifold (9F792), fuel PRESSURE MUST BE RELIEVED PRIOR TO FUEL
injectors, fuel pressure regulator (9C968) and the SYSTEM SERVICE TO PREVENT POSSIBLE
intake manifold (9424). Prior to service or INJURY. REFER TO SECTION 1 Q-0 1 , FUEL
removal of the fuel charging system, the following SYSTEM PRESSURE RELIEF.
steps must be taken.
Removal
Disconnect battery ground cable ( 1430 1 ). Refer
to Section 14-0 1 . 1. Remove clip from spring lock coupling.
2. Remove fuel tank filler cap (9030) and release
fuel tank pressure.
Fuel Pressure Relief
1. NOTE: A fuel pressure relief valve (9H32 1 ) on the
fuel injection supply manifold is provided for this
procedure.
CLIP
Install Fuel Pressure Gauge TSOL-9974-8 to the
fuel pressure relief valve on the fuel injection
supply manifold. V101 47-A
2. Release pressure from fuel system. Refer to 2. Position Spring Lock Coupling Disconnect Tool
Section 1 0-0 1 . D87L-928Q-A for 3 I 8 inch tube or D87L-928Q-B
Post-Service Procedures for 1 I 2 inch tube or equivalent onto coupling.
Make sure that tool can enter cage opening to
After the service is complete and the fuel charging release the garter spring.
system is installed to engine, the following steps must
be taken:
1. Install fuel tank filler cap at fuel tank (9002). SPRING LOCK COUPLING
DISCONNECT TOOL:
2. Connect battery ground cable. D87l-9280-A - 318 INCH
3. Add engine coolant if required. Refer to Section
D87L-9280-B - 1/2 INCH
03-Q3.
4. WARNING: THE FUEL SYSTEM IS NORMALLY
PRESSURIZED TO 276 KPA (40 PSI). USE
CARE WHEN SERVICING THE FUEL SYSTEM
OR PERSONAL INJURY COULD OCCUR.
NOTE: Check all connections at fuel injection
supply manifold, fuel injector or fuel line push
connect fittings. CAGE
OPENING V10148-A
Turn ignition switch ON I OFF several times
without starting engine to check for fuel leaks.

3. Push the spring lock coupling disconnect tool into

the cage opening to release the female fitting USE ONLY SPECIFIED FUEL
RESISTANT 0-RINGS
from the garter spring. (COLOR: BLACK)
PUSH TOOL INTO CHECK

CAGE OPENING FOR
CORROSION
LUBRICATE 0-RINGS
V10149-A
AV0219-A
4. Pull the coupling male and female fittings apart.
2. Insert male fitting into female fitting and push
together until garter spring is engaged.
V10150-A
GARTER SPRING
5. Remove the spring lock coupling disconnect tool V10153-A
from the disconnected spring lock coupling.
3. Pull on fittings to verify coupling engagement.
4. Install clip to spring lock coupling.
CORRECT FUEL LINE
V10151-A
6. NOTE: Inspect coupling for missing or damaged

Q-rings. H either Q-ring is damaged both Q-rings
must be replaced. Replace 0-rings or garter
springs with the appropriate replacement parts
only.
Clean fittings with solvent.
WRONG - WHEN FLARE OR

0-RINGS ARE SHOWING
FEMALE V10154-B
0-RINGS SPRING V1 0156-A
Installation
1. Lubricate the Q-rings with clean engine oil.

5. Make sure clip is correctly installed.
BOLT
�
FRONT OF ENGINE
4 REQ'D
TIGHTEN TO �
8-12 N·m THROTTLE
(71 -106 LB-IN) BODY 9E926
V10155-A
THROTTLE
Throttle Body BODY ADAPTER
9A589
Removal V10123-A
Section 03- 1 2.
2. Disconnect fuel charging wiring (90930) from the
throttle position sensor (TP sensor)(9B989) as Fuel Injector
well as accelerator cable (9A758) at the throttle Removal
lever.
1. Perform Fuel Charging System, Pre-Service
3. Remove four throttle body retaining bolts. Procedures and Fuel Pressure Relief as
4. Carefully separate throttle body (9E926) from described.
intake manifold adapter. 2. Remove fuel injection supply manifold (9F792) as
5. Remove and discard throttle body gasket (TB described.
gasket)(9E936) between throttle body and 3. Carefully remove fuel charging wiring (90930)
adapter. from individual fuel injectors at the connectors as
Installation required.
1. NOTE: If scraping is necessary, do not damage
gasket surfaces or allow material to drop into FUEL CHARGING
intake manifold (9424). WIRING 9D930
ELECTRICAL
Clean gasket mating surfaces. CONNECTOR
2. Install throttle body, new throttle body gasket and
four bolts to the intake manifold adapter. lighten
retaining bolts to 8- 1 2 N·m (7 1 - 1 06 I b-in).
3. Connect the fuel charging wiring to the throttle
position sensor as well as accelerator cable to
the throttle lever.
4. Install air cleaner outlet tube as described in
Section 03- 1 2 .

4. Remove fuel injectors from the fuel injection Removal

supply manifold. Grasp fuel injector body and pull 1. NOTE: Fuel pressure relief valve cap (9H323) on
up while gently rocking fuel injectors from side to fuel pressure relief valve (9H32 1 ) must be
side. removed.
If fuel injection supply manifold (9F792) is
mounted to engine, remove fuel tank filler cap
(9030). Then release pressure from system at
FUEL INJECTOR fuel pressure relief valve on fuel injection supply
9F593 manifold using Fuel Pressure Gauge
8 REO'D T80L-9974-8. Refer to Section 1 o-o 1 .
2. Using an open-end wrench or suitable deep well
socket, remove fuel pressure relief valve.
Installation
1. Install fuel pressure relief valve. lighten fuel
pressure relief valve to 7. 75 N·m (68 1b-in).
2. Perform Fuel Charging System Post-Service
Procedures as described_
3. Install fuel pressure relief valve cap_ lighten fuel
pressure relief valve cap to 0.6 N·m (5 lb-in).
INTAKE
MANIFOLD
� 9424
FRONT OF ENGINE
�
V10121-A
5. Inspect fuel injector Q-rings (two per fuel injector)
for signs of deterioration. Replace as required.
6. Inspect fuel injector end cap, body and washer for
signs of dirt and deterioration.
Installation
1. CAUTION: Never use silicone grease.
Lubricate new fuel injector Q-rings with clean
engine oil Motorcraft meeting Ford specification
FRONT OF
--- ENGINE
--
0
WSS-M2C 1 53-F. V1012�A
2. Install fuel injectors into fuel injection supply
manifold using a light, twisting-pushing motion.
Part
3. Install fuel injection supply manifold as described. Item Number Description
4. Connect fuel charging wiring to fuel injectors. 1 9F792 Fuel Injection Supply
5. Perform Fuel Charging System, Post-Service Manifold
Procedures as described. 2 9C968 Fuel Pressure Regulator
3 9H32 1 Fuel Pressure Relief Valve
4 9H323 Fuel Pressure Relief Valve
Cap
Fuel Pressure Relief Valve 5 -
Fuel Line Fittings (Part of
9F792)
SPECIAL SERVICE TOOL(S) REQUIRED -
A Tighten to 7. 75 N·m (68
Description Tool Number Lb-ln)
-
Fuel Pressure Gauge TSOL-9974-8 B Tighten to 0.6 N·m (5 Lb-ln)

03-048-10 Fuel Charging and Controls-4.6L(2V) 03-048-10

Removal
1. Perform Fuel Charging System, Pre-Service
Procedures and Fuel Pressure Relief as
described.
Section 03- 1 2 .
3. Disconnect vacuum line from fuel pressure
regulator (9C968).
4. Remove spring lock coupling retainer clip from
fuel inlet and return fittings.
5. Using Spring Lock Coupling Disconnect Tool
D87L-928Q-A (3 / 8 inch) or D87L-928Q-B ( 1 I 2
inch) or equivalent, disconnect the fuel supply and
return lines from the fuel injection supply manifold
(9F792) as described.
6. Disconnect fuel charging wiring (9D930) from fuel
injectors.
7. Remove four fuel injection supply manifold
retaining bolts (two on each side).
8. NOTE: It may be easier to remove fuel injectors __,..-
with the fuel injection supply manifold as an FRONT OF ENGINE
assembly. .......---
Carefully disengage fuel injection supply manifold V10122-A
from fuel injectors and remove fuel injection
supply manifold. Part
9. Use a rocking, side-to-side motion while lifting fuel Item Number Description
injectors to remove fuel injectors from intake 1 -
Bolt (4 Req'd)
manifold (9424).
2 9C968 Fuel Pressure Regulator
Manifold
4 9F593 Fuel Injector (8 Req'd)
5 9424 Intake Manifold
-
A Tighten to 8· 12 N•m (7 1- 106
Lb-ln)
Installation
1. CAUTION: When instaHing fuel injection
supply manifold, particular attention should
be paid to proper 0-ring seating to make
sure that no fuel leaks exist.
Push fuel injection supply manifold down to make
sure all fuel injector Q-rings are fully seated in the
fuel injection supply manifold cups and intake
manifold pockets.
2. Install retaining bolts while holding fuel injection
supply manifold down. Tighten retaining bolts to
8- 1 2 N·m (7 1 - 1 06 1b-in).
3. Install inlet and outlet fuel lines spring lock
couplings as described.
4. Connect vacuum line to fuel pressure regulator.
5. Connect fuel charging wiring to fuel injectors.
6. Install air cleaner outlet tube as described in
Section 03- 1 2 .
7. Perform Fuel Charging System Post-Service
Procedures.

03-04B- 1 1 Fuel Charging and Controls-4.6L (2V) 03-04B- 1 1
Fuel Pressure Regulator 4. Disconnect fuel charging wiring from engine

control sensor wiring ( 1 2A58 1).
Removal
5. Remove fuel charging wiring retaining bolts and
1. Perform Pre-Service Procedures and Fuel fuel charging wiring from intake manifold (9424).
Pressure Relief if removing fuel pressure
regulator (9C968) while fuel injection supply Installation
manifold (9F792) is installed on engine. Refer to 1. Follow removal procedure in reverse order.
Fuel Charging System.
2. Tighten fuel charging wiring retaining bolts to 8- 1 2
2. Remove air cleaner outlet tube (98659). Refer to N·m (7 1 - 1 06 1b-in). Verify all electrical
Section 03- 1 2 . connections.
3. Remove vacuum line from fuel pressure regulator.
4. Remove two Allen-head retaining screws from
fuel pressure regulator housing and discard.
5.
Fuel Pump Relay
Remove fuel pressure regulator, return seal and
0-rings. Discard fuel pressure regulator return Removal
seal and 0-rings.
6. H scraping is necessary, do not damage fuel to Section 1 4-0 1 .
pressure regulator or fuel injection supply
2. Locate fuel pump relay ( 1 4N089) in the engine
manifold sealing surfaces.
compartment power distribution center and
Installation remove fuel pump relay.
1. CAUTION: Never use silicone grease. Installation
Lubricate new fuel pressure regulator 0-rings
with clean engine oil meeting Ford specification
WSS-M2C 1 53-F. CLEANING AND INSPECTION
2. Make sure sealing surfaces of fuel pressure
regulator and fuel injection supply manifold are
clean. Throttle Body
3. Install new fuel pressure regulator 0-rings and WARNING: DO NOT SMOKE OR CARRY LIGHTED
TOBACCO OR OPEN FLAME OF ANY TYPE WHEN
new return seal on fuel pressure regulator.
WORKING ON OR NEAR ANY FUEL-RELATED
4. Install fuel pressure regulator return seal on fuel COMPONENT. HIGHLY FLAMMABLE MIXTURES
injection supply manifold. ARE ALWAYS PRESENT AND MAY BE IGNITED,
5. Using new Allen-head retaining screws, install fuel RESULTING IN POSSIBLE PERSONAL INJURY.
pressure regulator on fuel injection supply The throttle body (9E926) for this vehicle is a
manifold. Tighten retaining screws to 3-4.5 N·m sludge-resistant design with a coating on the bore and
(27-39 1b-in). plate. Sludge accumulation will not affect the throttle
6. Install vacuum line to fuel pressure regulator. body air flow. Any attempt to clean the bore and plate
area will impair the effectiveness of the coating. Do
7. Install air cleaner outlet tube as described in not clean the bore and plate area of the throttle body.
Section 03- 12.
8. Perform Fuel Charging System, Post-Service
Procedures as described.
Fuel Injector
Testing/ Cleaning
Fuel Charging Wiring CAUTION: The fuel injectors for this vehicle have
a deposit-resistant design and should NOT be
Removal cleaned.
1. Remove air cleaner outlet tube (98659). Refer to Test fuel injectors using Rotunda Fuel Injector
Section 03-12. Tester / Cleaner 1 64-R3759 or equivalent. Follow tool
2. Disconnect battery ground cable ( 1 430 1 ). Refer manufacturer's operating instructions.
3. Disconnect fuel charging wiring (9D930) from fuel
injectors and electronic engine controls.

03-048- 1 2 Fuel Charging and Controls-4.6L (2V) 03-048- 1 2
ADJUSTMENTS SPECIAL SERVICE TOOLS/EQUIPMENT
Idle Speed SPECIAL SERVICE TOOLS REQUIRED
Refer to the Powertrain Control I Emissions Diagnosis Tool NumberI

Manual.5 Description Illustration
T80L-9974-B
Fuel Pressure Gauge
~
SPECIFICATIONS
Description N·m Lb-ln TIOL-91174-11
Throttle Body-to-Intake Manifold 8- 1 2 7 1 - 106

Adapter SPECIAL SERVICE TOOLS DESIRED
Fuel Pressure Relief Valve to Fuel 7.75 68
Injection Supply Manifold Tool Number Description
Fuel Pressure Regulator-to-Fuel 3-4.5 27-39 D87L-9280-A Spring Lock Coupling Disconnect Tool
Injection Supply Manifold (3 / 8 1nch)
Fuel Injection Supply Manifold -to- 8- 1 2 7 1 - 106 D87L-9280-B Spring Lock Coupling Disconnect Tool
Intake Manifold ( 1 / 2 1nch)
Fuel Pressure Relief Valve Cap 0.6 5

ROTUNDA EQUIPMENT
Fuel Charging Wiring to Intake 8- 1 2 7 1 - 106
Manifold Bolts Model Description
1 64-R3759 Fuel Injector TesterI Cleaner
Ford
-
Engine Oil WSS-M2C 1 53-F

03-05- 1 Drive Belts, Accessory 03-05- 1
SECTION 03-05 Drive Belts, Accessory

VEHICLE APPLICATION •••••••••••••••• •••••••••••••.•••.••••.•••••• 03.05-1 REMOVAL AND INSTALLATION
DESCRIPTION AND OPERATION Drive Belt Replacement •••••••.•..•••••••••••.••••••••.•.••••••• 03.05-5
Drive Belts, Accessory •••••••.•••••••••..•••.••••••••..•••••••••• 03.05-1 Drive Belt Tensioner, Automatic . • • . •••••••••••.•••••• . . • • • . • 03.05-5
DIAGNOSIS AND TESTING ADJUSTMENTS
Component Tests ••••••••••••••••• .••••••••.•••••••••••••••••.••••• 03.05-4 Drive Belt Tension Adjustment •••••••••••••.••••••••••••••••• 03.05-7
Drive Belt Tensioner, Automatic •••••••.•••••••••••••••.•• 03.05-4 Drive Belt Tensioner, Automatic • • • • . • • • • • • • • • • • •• • • • • • • • • • • • 03.05-8
Inspection and Verification •••••••••••••••••••••••••••••••••••• 03.05-3 SPECIFICATIONS •••••••••.••.•••••.•••.•• .•••••••••••.•••..••••••••••• 03.05-8
Symptom Chart ••••••.•••••••••••.•••••••• •••.••••••••••••.•••••••••• o3-o5-3
VEHICLE APPLICATION
Thunderbird, Cougar
Drive Belts, Accessory Droning or periodic vibrations at particular engine

speeds can be caused by the following:
NOTE: New drive belts {8620) are made of a special
cord construction and are subjected to special testing • Loose or stripped bolts: Replace or tighten bolts as
before they are approved for use. If a replacement required. lighten all bolts to specification including
drive belt rides beyond the edge of the drive belt fan blade-to-fan clutch {if equipped), fan
tensioner pulley, it should be replaced with an original clutch-to-water pump {if equipped), all bracket and
equipment drive belt to avoid premature drive belt accessory bolts and drive belt tensioner retaining
failure or loss of the drive belt during cold operation. bolts.
These vehicles are equipped with: • Drive belt flutter: Observe drive belt with engine
running and transmission in PARK {NEUTRAL for
• a V-ribbed serpentine accessory drive belt and
manual transmission) with parking brake set. Slowly
• automatic drive belt tensioners {6B209). increase engine speed until
The drive belt selected for each engine is based on noise I vibration I harshness condition occurs. If
engine performance requirements. Replacement drive drive belt is vibrating more than 1 2 . 7 mm {0.5 inch),
belts should be of the same type as originally installed. then drive belt flutter is occurring. Drive belt flutter is
normally caused by external forces such as bent
pulleys, worn accessories, excessive A I C head
V-Ribbed Drive Belt pressures or similar factors. To verify accessory
drive is functioning properly, check automatic drive
belt tensioner wear indicator marks to make sure
drive belt is not worn and that the correct length
drive belt is installed. Replace drive belt as required.
If drive belt is correct and is in good condition,
check automatic drive belt tensioner as described.
Service components as required.
• Binding or frozen automatic drive belt tensioner:
02258-C Rotate automatic drive belt tensioner and check for
a binding or frozen condition. Service as required.
Check automatic drive belt tensioner as described.
• NOTE: Look at the pulley grooves {not at the pulley
flanges) for wobbling condition.
Bent pulley: Inspect all pulleys for a wobbling
condition. Service components as required.
• Worn accessories: Check accessories for smooth
rotation and proper operation. Service components
as required.

03-05-2 Drive BeHs, Accessory 03-05-2
Rattling noise with A I C on can be caused by the CAUTION: If drive belt chirp is present, determine
following: the cause and correct it. Do not use any type of
lubricant on the drive belt.
• Automatic drive belt tensioner hitting the stops:
Check wear indicator marks on drive belt tensioner NOTE: V-ribbed serpentine drive belts are sensitive to
and make sure drive belt is not worn and correct pulley alignment. If a pulley is not in the same plane as
length drive belt is installed. Replace drive belt as the others, the drive belt may exhibit a periodic chirp.
required. Sometimes a chirp will occur in a system that is
perfectly aligned.
• Excessive drive belt rideout: Although rare, the
drive belt groove depth may vary enough to cause Removing and installing the same drive belt will often
excessive drive belt tensioner actions. Try replacing correct drive belt chirp permanently. Regardless of
the drive belt with a new drive belt. how the chirp is corrected, the vehicle should be
allowed to idle for approximately 20 minutes with the
Sharp metallic click with a chirp when A I C accessories loaded down {headlamps, A I C system
compressor clutch is engaged: and other accessories, turned on). Recheck to make
• The click is caused by the A I C compressor clutch sure the chirp is corrected.
engagement and should be considered normal. NOTE: Water also acts as a lubricant but quickly
• This click is sometimes accompanied by a clutch evaporates. A vehicle just out of a car wash may
chirp. This should also be considered normal and exhibit drive belt squeal for a short period of time while
not confused with drive belt chirp. the drive belt dries out. This is normal but the
accessory load should be reduced {turn OFF A I C
Loud drone or moan while turning the wheels: system and minimize power steering effort) until drive
belt dries. This will prevent the drive belt from
• This is usually an indication of low power steering
becoming glazed or damaged.
fluid.
NOTE: Squirting water {in small amounts) on the
• Check and refill the power steering fluid as required.
grooves of a noisy drive belt should temporarily
Muted ticking noise on cold weather start: change, reduce or eliminate the noise.
• This can sometimes be heard with the hood Using a squirt bottle or equivalent, squirt the grooves
{ 1 66 1 2) open during a cold start. of the noisy drive belt.
• It is caused by the drive belt label making contact If the water has no effect on the noise, the condition is
with the backside of the pulleys and should be being caused by something other than that drive belt.
considered normal. NOTE: Incorrect drive belt installation may cause chirp
NOTE: The V-ribbed drive belt is dependent on friction or squeal.
to deliver power to a pulley. If the horsepower load of Other possible causes of drive belt chirp include the
the accessories exceeds the drive belt frictional following:
capability, a loud, continuous drive belt squeal will
result. • idler I tensioner pulley bearings
The frictional capability of the drive belt will be • A I C compressor clutch {during engagement)
compromised if: • accessory bearings
• the drive belt tension is below specification. Other possible causes of drive belt squeal include the
• there is any type of lubrication or belt dressing on following:
the drive belt. • idler I tensioner pulley bearings
Do not use any type of belt dressing, silicone spray or • accessory bearings
rubber conditioner on a V-ribbed drive belt.
Check the drive belts for proper routing, seating and
The use of a lubricant may temporarily silence a for wear. Refer to the illustrations in Removal and
squealing drive belt, but it does so by allowing the Installation.
drive belt to slip in the pulleys. The squeal will
eventually return and the drive belt will often be: CAUTION: Incorrect drive belt installation will
cause excessive drive belt wear and may cause
• glazed. the drive belt to come off the drive pulleys.
• damaged or destroyed. Check the drive belts and pulleys for contamination,
NOTE: If the accessory drive system has been antifreeze, belt dressing, undercoating or other
contaminated, all pulleys should be cleaned with a possible causes.
suitable solvent before installing a new drive belt. • Antifreeze contamination: A thorough rinsing of
Pulleys will also become contaminated by the lubricant belts and pulleys with clean water should restore
and then will contaminate the replacement drive belt, the frictional capability of the drive belts.
reducing its frictional capability. • Other contaminants: Remove and discard drive belt.
Clean all pulleys with a suitable solvent and install a
new drive belt.

03-05-3 Drive Belts, Accessory 03-05-3
Check the power steering pump pulley (3A733). 1t Check all pulleys (except crankshaft pulley (63 1 2))
should be flush with the end of the power steering and accessories for smooth, free operation. Service
pump shaft within ± 0.25 mm (0.010 inch). If any components as required.
corrections are necessary, refer to Section 1 1 -Q2.
Inspection and Verification V-Ribbed Serpentine Drive Belt With Chunks of Rib
Missing
engine to duplicate the condition.
2. Inspect to determine if any of the following
mechanical concerns apply:
VISUAL INSPECTION CHART
Mechanical
• Drive belt noise or squeal.
• Pulley misaligned or excessive pulley runout.
CHUNKS OF RIBS MISSING ARE
NOT ACCEPTABLE 03243-C
3. Inspect for drive belt cracking I chunking I wear as
described. Cracks on the rib side of a drive belt are considered
4. If the concerns remain after the inspections, acceptable. The drive belt should be replaced if two or
determine the symptoms and go to the Symptom more adjacent ribs have lost sections 13 mm ( 1 I 2
Chart. inch) or longer, or if the missing sections are creating a
noise I vibration I harshness condition.
Drive Belt Cracking/Chunking/Wear
Under severe operating conditions (high V-Ribbed Serpentine Drive Belt With Cracks Across
temperatures, low humidity), drive belt rib cracking Backing
can occur at less than 1 60,000 km ( 1 00,000 miles).
Drive belt rib cracking (cracks across backing):
• is not a reason for concern.
• has no detrimental effect on drive belt performance.
However, cracks running with backing are not
acceptable.
The drive belt (8620) is still perfectly functional until rib
CRACKS ACROSS RIBS ARE ACCEPTABLE.
CRACKS PARALLEL TO BACKING ARE NOT.
chunking occurs. Drive belt chunking is where the
rubber material actually chunks out between the
cracks. The drive belt should be replaced if the chunks
are 5 mm (0.0 19 inch) or longer.
Symptom Chart
DRIVE BELTS, ACCESSORY

Co nditio n Possible Source Action
• Drive Belt Cracking • Drive belt . • System OK.
• Drive Belt Chunking • Drive belt. • REPLACE drive belt as described .
• Drive Belt Noise or Squeal • Drive belt . • DETERMINE what area of the
• Pulley(s) . pulley(s) the noise is coming from,
then CHECK that area with a
straightedge and LOOK for the
accessory pulley(s) to be out of
position in the fore I aft direction or
at an angle to the straightedge.

DRIVE BELTS, ACCESSORY (Continued)

• Drive Belt Does Not Hold Tension • Drive belt cracking or damaged. • INSPECT drive belt for cracking
parallel with and through to
backing. REPLACE drive belt if
required.
• Drive belt tensioners worn or • CHECK drive belt tensioner for
damaged. damage and correct operation.
REPLACE drive belt tensioner if
required.
• Drive Belt Squeal or Chirp • Incorrect drive belt installed. • CHECK drive belt for correct part
application.
• Lubricant or other contamination • CHECK drive belt for oil, coolant,
on drive belt. power steering fluid, brake fluid or
other contamination. REMOVE
drive belt and WASH with
detergent and water. If drive belt
cannot be cleaned or is damaged
(softened) by contamination,
REPLACE drive belt.
• Drive belt pulleys and devices not • CHECK pulleys for proper
aligned properly, damaged or not alignment, devices and pulleys for
rotating freely. proper freedom of rotation and
damage. SERVICE pulleys and
devices as required.
Component Tests 5. With the engine running, check drive belt tracking
(the position of the belt on the drive belt tensioner
Drive Belt Tensioner, Automatic pulley). If the edge of the drive belt rides beyond
The automatic drive belt tensioner (68209) can be the edge of the drive belt tensioner pulley, this
checked as follows: can cause noise and premature wear. If a drive
1. With the engine running, observe drive belt belt tracking condition exists, proceed with the
tensioner movement. The drive belt tensioner following:
should move (respond) when the A I C • Check the drive belt tensioner for damage,
compressor ( 1 9703) cycles or when the engine is especially the mounting pad surface. If the
accelerated rapidly. If the drive belt tensioner drive belt tensioner is not installed correctly
movement is constant and excessive, a pulley or with the locating pins in the locating holes, the
shaft is probably bent or a pulley is out of round. mounting surface pad will be out of position.
In rare cases, excessive drive belt rideout This will result in drive belt mistracking,
(uneven depth of grooves in drive belt (8620)) improper drive belt tension and chirp and
can cause excessive drive belt tensioner squeal noises.
movement. This condition can be checked by
replacing the suspect drive belt with a new drive • lighten the drive belt tensioner-to-bracket
belt and repeating the observation. retaining bolt to specification. Recheck drive
belt tracking.
2. With engine off, check for proper drive belt
routing. Refer to the illustrations under Removal • Use a straightedge or similar tool to check the
and Installation. Service as required. drive belt tensioner pulley for crown.
3. Inspect the drive belt tensioner wear indicator as • Pulley crown acts to center the drive belt. If there is
described under Drive Belt Tensioner, Automatic no crown, replace drive belt tensioner. Recheck
in Adjustments, to make sure the drive belt is drive belt tracking.
within operating range. Replace the drive belt as • Check all accessories, mounting brackets and drive
required. belt tensioner for any interference that would
4. Rotate the drive belt tensioner and check for a prevent the component from mounting properly.
binding or frozen condition. Replace components Correct any interference condition and recheck
as required. drive belt tracking.
• lighten all accessory mounting brackets and drive
belt tensioner retaining hardware to specification.
Recheck drive belt tracking.

03-05-5 Drive Belts, Accessory 03-G5·5
DIAGNOSIS AND TESTING {Continued)
• With engine running, watch the grooves in the

pulleys (not the pulley flanges) for excessive DRIVE BELT
wobble. Replace components as required. 8620
If the above procedures do not correct the drive
belt noise, try replacing the drive belt with a new
drive belt. However, the drive belt noise may
return again (with mileage) if one of the above
conditions has not been corrected.
Drive Belt Replacement

Drive Belt, Serpentine
WARNING: DO NOT ALLOW DRIVE BELT PULLEY
TENSIONER {6B209) TO SNAP BACK AS DAMAGE 01834-C
TO DRIVE BELT TENSIONER OR PERSONAL
4. Check drive belt tension as described. If drive
INJURY COULD RESULT. . belt tension is not within specification, install new
NOTE: Minor cracks in the V-ground portion of the drive belt tensioner as described.
drive belt (8620) are considered normal and
acceptable. If the drive belt has chunks missing from
the ribs, the drive belt should be replaced.
Conditions requiring drive belt replacement are as Drive Belt Tensioner, Automatic
follows:
3.8L SFI
• rib chunk-out Removal and Installation
• excessive wear 1. Remove serpentine drive belt (8620) as
• severe glazing described.
• frayed cords or similar conditions 2. Remove drive belt tensioner retaining bolt and
Replace any drive belt exhibiting one of these drive belt tensioner (68209).
conditions. 3. To install, reverse Removal procedures. Install
new drive belt tensioner locating pin in bracket
Removal and Installation hole prior to and during tightening of drive belt
1. Rotate automatic drive belt tensioner away from tensioner retaining bolt. lighten
. bolt to 7Q-95 N·m
drive belt. (52-70 lb-ft).
On 3.8L SFI engines, lift drive belt tensioner
pulley by applying counterclockwise torque to
pulley bolt with wrench and socket.
On 4.6L engines, depress drive belt tensioner
pulley by applying clockwise torque to square
slot with 1 I 2 inch drive breaker bar.
2. Remove drive belts.
3. CAUTION: Incorrect drive belt installation will
cause excessive drive belt wear and may
cause the drive belt to come off the drive
pulleys.
Install drive belt over pulleys through appropriate
drive belt routing as shown in following
illustrations. Make sure that all V-grooves make
proper contact with the pulley as shown.

.---
Serpentine Drive Belt System - 3.8L SFI Engine
VIEW A
NOTE: LOCATING PIN MUST BE IN

BRACKET HOLE PRIOR TO AND
DURING BOLT TORQUING
ASSEMBLY OF TENSIONER
TO MOUNTING BRACKET
VIEW A VIEW B 03271-A
Part Part
1 6B209 Drive Belt Tensioner 6 3A733 Power Steering Pump Pulley
2 2882 A/C Compressor Mounting 7 63 12 Crankshaft Pulley
Bracket 8 8509 Water Pump Pulley
3 19703 A I C Compressor 9 N805901·S2 Bolt
4 6B217 Drive Belt Tensioner Pulley A -
Tighten to 70·95 N·m (52·70
5 10300 Generator Lb-Ft)
(Continued)
4.6L SFI Engine 3. Remove drive belt tensioner retaining nut and bolt
and drive belt tensioner from engine front cover
Removal and Installation (60 1 9).
1. Remove serpentine drive belt as described. 4. To install, reverse Removal procedure. lighten
2. Remove RH ignition coil bracket from drive belt drive belt tensioner retaining nut and bolts to
tensioner as described in Section 03-078. 20-30 N-m ( 1 5-22 1b-ft).

Drive Belt Tensloner-4.6L SFI Engine

Drive Belt Routing
NUT
TIGHTEN
TO
2Q-30 N·m
(15-22 LB-FT)
J_
,-
BOLT
2 AEQ'D
TIGHTEN TO
20-30 N·m
(15-22 LB-FT)
VIEW A FRONT OF ENGINE
I
AQ0041·A
03003-C
Part
1 10300 Generator
2 8509 Water Pump Pulley
3 3A733 Power Steering Pump Pulley
4 6312 Crankshaft Pulley
5 19703 A I C Compressor
6 8620 Drive Belt
7 6B209 Drive Belt Tensioner
8 8678 Belt Idler Pulley
ADJUSTMENTS
Drive Belt Tension Adjustment

Serpentine Drive Belt
Drive belts {8620) have an automatic drive belt
tensioner (68209) and DO NOT require adjustment.
�·.
ADJUSTMENTS (Continued)
Drive Belt Tensioner, Automatic The only mechanical check that need be made, if there
NOTE: The drive belt tensioner indicator mark is any doubt as to the tensioner function, would be to
inspection is done with the engine OFF at 1 60,000 km remove the belt, in the area of the tensioner, to avoid
(100,000 mile) intervals. belt contact, then using the proper tool, rotate the
tensioner from its relaxed position thru its full stroke
Automatic tensioners are calibrated at the factory to and back to the relaxed position to assure that there is
provide the correct amount of tension to the belt, for a no "stick, grab, bind", and to assure that there is
given FEAD system. Unless a spring within the tension on the tensioner spring. It is a normal condition
tensioner assembly breaks, or some other mechanical for the tensioner to be moving under certain conditions
part of the tensioner fails, there is no need to check while the engine is running. If the tensioner meets
tensioners for proper tension. these criteria, it should be assumed to be a good .
tensioner.
Locate the tab on the drive belt tensioner mounting
plate. The tab should be approximately between the
stops on the drive belt tensioner arm.
Drive Belt Tensioner
TAB IN THIS AREA,

BELT WORN
OR INCORRECT LENGTH
(REPLACE BELn
TAB IN THIS AREA,

BELT LENGTH
INCORRECT STOP
(REPLACE BELn
AQ0042-A
SPECIFICATIONS
DRIVE BELT SPECIFICATIONS TORQUE SPECIFICATIONS

Wldth x Description N·m Lb-Ft
Application Usage Length Minimum Drive Belt Tensioner Retaining Bolt 70-95 52-70
3.8L SFI Accessory 6K x 2500 329 N (74 (3.8L)
mm Lbs) 20-30 15-22
Drive Belt Tensioner Retaining Nut
:1:: 6 mm
and Bolts (4.6L)
4.6L SFI Accessory 6K x 2485.0 329 N (74
mm Lbs)
:1:: 6 mm
DRIVE BELT TENSIONER SPECIFICATIONS

Part Application/ Minimum
Number Usage Torque
E9SE·6B209·GA 3.8L SFI 28.5 N·m
Accessory (2 1 Lb-Ft)
Drive
F4AE-6B209-AA 4.6L Accessory 44.8 N·m
Drive (33 Lb-Ft)

03-()6- 1 Starting System 03-06-1
SECTION 03-06 Starting System

VEHICLE APPLICATION •••.••••••••••••••.••••••••••••••••.••••••••• 03-06-1 DIAGNOSIS AND TESTING (Cont'd.)
DESCRIPTION AND OPERATION Inspection and Verification ••••••••••••••••••••.•••••••••••• 03-06-3
Sequence of Operation ••••..•••••••••••••.•••••••••••••.••••.••• 03.06-2 Pinpoint Tests •••••••••••••••••••••••••••••••••••••••••••••••.•••• 03-06-4
Starter Motor •••••••••.••••••••••.•...••••••.••..•••••••••••••.••.•..• 03.06-2 Symptom Chart •....•.•••••••..•••....•..•••••••••••••••••..••.•• 03-06-3
Starter Relay •••••••••••••.••..•••••...•••••.••••••••.•••••••••••••••• 03.06-2 REMOVAL AND INSTALLATION
Starter System •••••••••.•....••••••••..•.•.••••••••••..••••••••••••• 03.06-1 Starter Motor ••.•..............••••••••••••.•..••..••••••••••••••••• 03.06-10
DIAGNOSIS AND TESTING DISASSEMBLY AND ASSEMBLY
Electrical Schematlc ••••.•.......•.••••...•....•.•••••........•••• 03.06-2 Armature Replacement, Starter Motor ••.....••.•..••••• 03-06-14
Starting System •••.•••••••••••••••••••••••••••••••••••••••..•••••••• 03.06-3 Bushings ........•••••••••••............•••..•••••.........••••••••••• 03-06-1 4
Component Tests ••••••.•.•.•••••••••••••••..••••••••••..•..•••• 03.06-6 Starter Drive Replacement ...........••••••.•••....••.••.•••• 03.06-14
Armature-Grounded Circuit Test •••••••••••••.••••• 03.06-9 Starter Motor ...•.••••••.•••.••......•.••••••••••••••••...•••••••••• 03.06-1 1
Armature-Open Circuit Test ••••••........••••........ 03.06-9 SERVICE PROCEDURES
Individual Cable •••••..••.....••••••••••...•••••••.••.•...•••• 03.06-8 Road Service ..........•.••.••.••............••••••.•••••.......•••• 03.06-1 5
Motor Feed Circuit .••••..••.......•••..........•.••.••.••... 03.06-7 CLEANING AND INSPECTION
Motor Ground Clrcult ••.••••..••••••.••••...•••••••••••••.•• 03.06-8 Armature Coli, Starter Motor .••....•••••••.•••••••.•...•••••
03.06- 1 5
Solenoid M-Terminal ...••••••.........•••.............••••• 03.06-9 Bushings ..........••••••••.••......•••••.••••.•••....••••••••••••••••
03.06-1 5
Solenoid s-Terminal Circuit Starter Drive/Flywheel Ring Gear
Resistance •••••..•........•••••.......••••••..........••••••03.06-9 Inspection ....•.••••.•••.........••••••••••••.•.••.••••••••••••••• 03-06-1 5
Starter •••••...••••.••.•....•••.••••••...••..••••••••..•.••••••••••
03-o6-6 Starter Frame and Magnet ••.•••.•.••.....••••••••••••••••... 03.06-1 5
Starter Drive Pinion Test .••••.••.......•.•••••••......•••03.06-9 SPECIFICATIONS .....•••.••••••.•..•.•.••••••••••••••••••••••••••••• 03.06-16
Starter Solenoid •••••.•.....•••••••....•.•••••••••...•....••.•03.06-9 SPECIAL SERVICE TOOLS/EQUIPMENT ••..•••••••••••••• 03.06-16
Voltage Drop Tests ••.•••......••••••.••..•.••••••.••••.•••.•03.06-7
VEHICLE APPLICATION
Thunderbird, Cougar
Starter System The starting system includes the following:

The starting system cranks the engine at a speed fast • the permanent magnet gear-reduction starter motor
enough to permit the engine to start. with a solenoid-actuated drive
• Heavy cables, connectors, and switches are used in • the battery
the starting system because of the large current • a remote control starter switch (part of the ignition
required by the starter motor ( 1 1 002) while it is switch ( 1 1 572))
cranking the engine.
• the transmission range (TR) sensor (automatic
• The amount of resistance in the starting circuit must transmission)
be kept to an absolute minimum to provide maximum
current for starter motor operation. • the starter solenoid ( 1 1 390)
• A discharged or damaged battery ( 1 0653), loose or • heavy circuit wiring
corroded connections or partially broken cables • Vehicles equipped with an automatic transmission
result in slower than normal cranking speeds . These have a transmission range (TR) sensor in the starter
concerns may even prevent the starter motor from control circuit, which prevents operation of the
cranking the engine. starter motor unless the transmission range
• In case of starting system difficulty, the operator selector lever is in NEUTRAL or PARK.
may have discharged the battery before calling for
assistance.

03-06-2 Starting System 03-06-2
Starter Motor Starter Relay

The starter motor ( 1 1 002) is a 1 2-volt unit that has the The starter interrupt relay ( 14N089) consists of the
starter solenoid ( 1 1 390)mounted on the drive end following:
housing.
• pull-in coil
• The motor is energized when the starter solenoid • contacts
contacts are closed.
When the ignition switch is in the START position and
• This engages the starter drive ( 1 1 350) with the the selector lever is in NEUTRAL or PARK:
flywheel ring gear and starts the engine.
• An overrunning clutch in the starter drive protects • current passes from the (TR) sensor to the pull-in
the starter motor from excessive speed when the coil.
engine starts. • pull-in coil is activated and pulls the contacts
• The current flows through the solenoid energizing together.
coil until the solenoid plunger is at the end of its • current passes through the starter relay from the
travel. engine compartment power distribution box to the
• The plunger then closes a set of contacts that starter solenoid ( 1 1 390).
bypass the energizing coil, letting the holding coil The starter interrupt relay is energized by the anti-theft
keep the starter drive engaged and passing starting controller and opens the starter circuit.
current to the starter motor.
Starter Motor, 3.8L Engine

Sequence of Operation
When the ignition switch is turned to the START
position:
• Voltage is provided to the starter solenoid ( 1 1 390).
The starter solenoid is energized directly from the
ignition circuit. A magnetic field is created in the
solenoid coil.
• The iron plunger core is drawn into the solenoid coil.
• A lever connected to the starter drive ( 1 1 350)
engages the drive pinion gear to the flywheel ring
gear.
STARTER MOTOR
11000 • When the iron plunger core is all the way into the
AJ0141·A
coil, its contact disc closes the circuit between the
battery ( 1 0653) and the starter motor terminals.
Starter Motor, 4.6L Engine • The current flows to the motor and the drive pinion
gear cranks the flywheel (6375) and the engine
crankshaft (6303).
• As current flows to the motor, the solenoid pull-in
coil is bypassed.
• The hold-in coil keeps the starter drive engaged
with the flywheel.
• The starter drive remains engaged until the ignition
switch is released from the START position.
An overrunning clutch in the starter drive protects the
starter motor ( 1 1 002) from excessive speeds during
the brief period before the driver releases the ignition
switch from the START position (as the engine starts).
STARTER
MOTOR
11000
J5539-A
Electrical Schematic
Refer to Electrical and Vacuum Troubleshooting
Manual, Cell 20, Starting System for schematic and
connector information.

Starting System VISUAL INSPECTION CHART
Inspection and Verification Mechanical Electrical

1. WARNING: WHEN SERVICING STARTER • Starter motor mounting • Connections loose,
MOTOR (1 1 002) OR PERFORMING OTHER misaligned. damaged or shorting.
UNDERHOOD WORK IN THE VICINITY OF THE • Flywheel! ring gear tooth • Damaged baHery.
damage.
STARTER MOTOR, BE AWARE THAT THE
HEAVY GAUGE BATTERY INPUT LEAD AT 3. If inspection reveals obvious concern(s) that can
THE STARTER SOLENOID ( 1 1 390) IS be readily identified, service as required.
ELECTRICALLY HOT AT ALL TIMES. A
PROTECTIVE CAP OR BOOT IS PROVIDED 4. If the concerns remain after the inspection,
OVER THIS TERMINAL THAT MUST BE determine the symptoms and go to the Symptom
REPLACED AFTER SERVICING. BE SURE TO Chart.
DISCONNECT BATTERY NEGATIVE CABLE Symptom Chart
BEFORE SERVICING STARTER.
Refer to Electrical and Vacuum Troubleshooting
WARNING: WHEN WORKING IN AREA OF THE Manual for the connector numbers cited in the pinpoint
STARTER, BE CAREFUL TO AVOID tests.
TOUCHING HOT EXHAUST COMPONENTS.
Use Rotunda 73 Digitai iVIultimeter 1 05-R005 1 or
Verify the customer's concern by operating the equivalent to perform pinpoint tests.
starter system to duplicate the concern.
2. Inspect to determine if any of the following
mechanical or electrical concerns apply:
STARTER SYSTEM DIAGNOSIS

• Engine Cranks Slowly • Discharged battery (base circuit • GO to Pinpoint Test A.
voltage under 12.2 volts).
• Low battery capacity (charged
battery with less than 9.6 cranking
volts).
• High resistance in cranking circuit
(starter draw may be higher than
normal).
• Starter motor (worn
bushings I bearings, shorted
windings).
• Engine mechanical concerns .
• Engine Does Not Crank • Low battery. • GO to Pinpoint Test B .
• Open fuse .
• Open ignition switch .
• Shorts to ground .
• Engine system .
• Inoperative starter motor.
• High resistance in battery cables.
• Open or short to ground in S
terminal or circuit.
• Unusual Starter Noise • Clutch pressure plate . • GO to Pinpoint Test C.
• Ring gear tooth damage or
excessive ring gear runout.
• Inoperative starter motor.
• Inoperative components .

Pinpoint Tests
PINPOINT TEST A: ENGINE CRANKS SLOWLY

A1 I CHECK BATTERY STATE OF CHARGE
NOTE: To perform an accurate base circuit voltage Yes .... GO to A2.
reading, remove the surface charge by cranking engine No .... SERVICE battery and charging
(5 seconds maximum) or turning on the head lamps ( 10 system as required. REFER to
seconds maximum). Read base circuit voltage after Section 14·00.
battery voltage stabilizes.
• Connect voltmeter to battery positive and negative
terminals.
• Measure open circuit voltage .
• Is voltage 12.4 volts or higher?
A2 I CHECK BATTERY CAPACITY
• Perform Starter Test as described in this section. Yes .... GO to A3.
• Does battery pass starter test?
No .... REPLACE battery. REFER to
Section 14-01.
A3 I CHECK STARTER B+ CURRENT RESISTANCE
•
Connect voltmeter positive lead to battery positive Yes .... GO to A4.
terminal and voltmeter negative lead to the battery No .... SERVICE connections between
negative terminal. battery negative terminal and
• Disconnect inertial fuel shutoff switch electrical
connector to prevent engine from starting. engine block and starter
• Crank engine and record voltmeter reading during
motor-to-transmission housing
engine cranking. connection.
• Is voltage more than 6.0 volts?
A4 I CHECK STARTER GROUND CIRCUIT RESISTANCE
• Connect voltmeter positive lead to the starter motor Yes .... SERVICE connections between
housing. battery negative terminal and
• Connect voltmeter negative lead to battery negative engine block starter
terminal. motor-to-transmission housing
• Disconnect inertia fuel shutoff switch electrical connection.
connector to prevent engine from starting. No .... GO to A5.
• Crank engine and record voltmeter reading during
engine cranking.
• Is voltage more than 0.3 volts?
AS I CHECK STARTER CURRENT DRAW
• Perform Starter Test as described in this section. Yes .... REFER to Section 03-00 for engine
• Is starter motor OK? mechanical concerns.
No .... SERVICE starter motor as
required.
PINPOINT TEST 8: ENGINE DOES NOT CRANK
81 I CHECK FOR VOLTAGE TO STARTER
NOTE: Hoist vehicle (if necessary) to access starter Yes .... G0 to 82.
solenoid terminals. No .... CHECK wire connections between
NOTE: Remove plastic safety cap at starter solenoid battery and starter solenoid.
and disconnect hardshell connector at solenoid CHECK ground connections at
S-terminal as described under Removal and Installation battery to ground and starter
in this section. solenoid to ground for an open,
• Ignition switch OFF. Transmission in PARK or
short or security. If secure, REFER
NEUTRAL. to Section 14-00 and check
• Check for voltage from starter B+ terminal to starter
battery charge system.
drive housing (ground).
• Does voltmeter Indicate 12 to 1 2.45 volts DC?

--
PINPOINT TEST 8: ENGINE DOES NOT CRANK (Continued)

82 I MANUALLY CRANK STARTER
• Ignition switch OFF. Transmission in PARK or Yes � GO to 83.
NEUTRAL No � REPLACE starter motor. REFER to
• Connect one end of a jumper wire to the starter B+
terminal and momentarily touch the other end to Removal and Installation. RETEST
solenoid S-terminal. new starter motor.
• Does starter motor crank and crank quickly?
83 I VERIFY VOLTAGE TO S-TERMINAL
•
Disconnect Circuit 32 (R I LB) from S-Terminal Yes � SERVICE Circuit 32 (R I LB) and 33
C1064. (WI PK) for intermittent open or
• Connect voltmeter between S-Terminal Circuit 32 short. CHECK starter operation.
(RILB) and ground. REFER to Pinpoint Test A.
• Transmission range sensor (TR) in PARK or
No � GO to 84.
NEUTRAL
• Turn ignition switch to start .
• Is 8+ present?
84 I CHECK VOLTAGE TO TRANSMISSION RANGE SENSOR
• Disconnect transmission range sensor Connector Yes � For base vehicles GO to 86. For
C1057. vehicles with anti-theft GO to 87.
• Turn ignition switch to START.
No � GO to 85.
• Connect voltmeter positive lead to Connector
C1057-4, Circuit 32 (R ILB) and negative lead to
ground.
• Does voltmeter Indicate 8+?
85 I CHECK CIRCUIT 32 FOR OPEN
• Disconnect ignition switch . Yes � SERVICE ignition switch. REFER to
• Measure resistance of Circuit 32 (R I LB) between Section 1 1-05. RESTORE vehicle.
C21 1-STA to C1057-4. RETEST system.
• Is resistance 5 ohms or less? No � SERVICE open in Circuit 32
(R ILB). RESTORE vehicle.
RETEST system.
86 I CHECK CIRCUIT 33 FOR OPEN
• Disconnect TR sensor. Yes � REPLACE transmission range
• Measure resistance of Circuit 33 (WI PK) between sensor.
C1057- 1 and C1064. No � SERVICE open in Circuit 33
• Is resistance 5 ohms or less? (W I PK). RESTORE vehicle.
RETEST system.
87
I RELAY
CHECK CIRCUIT 33 (W I PK) TO START INTERRUPT
•
FOR OPEN
Disconnect Connector C 1057 at interrupt relay. Yes � GO to 88.
• Measure resistance at Circuit 33 (WI PK) from the No � SERVICE open circuit. RESTORE
transmission range sensor to the start interrupt vehicle. RETEST system.
relay socket pin 30 and 86.
• Is resistance 5 ohms or less?
I
88 CHECK ANTI-THEFT CONTROLLER MODULE CIRCUIT
342 (LG I P) FOR SHORT TO GROUND
• Disconnect module Connector C409. Yes � GO to 89.
• Measure resistance of Circuit 342 (LG I P) from relay
No � SERVICE short to ground. REFER
socket pin 85 to ground. to Section 13- 1 1 . RESTORE
• Is resistance more than 10 k ohms? vehicle. RETEST system.
89 I CHECK FOR OPEN CIRCUIT 32 (R I LB) TO STARTER
• Measure resistance between relay socket Pin 87A Yes � REPLACE starter interrupt relay.
and starter S-connector C1064, Circuit 32 (R ILB). RESTORE vehicle. RETEST
• Is resistance 5 ohms or less? system .
No � SERVICE open in Circuit 32
(R ILB). RESTORE vehicle.
RETEST system.

PINPOINT TEST C: UNUSUAL STARTER NOISE

C1 I CHECK STARTER MOUNTING
• Check starter mounting to be flush (not cocked). Yes .... GO to C2.
Check that all connections are secure. REFER to No .... SERVICE or REPLACE wiring or
Removal and Installation for mounting information. component mountings as required.
• Check other necessary components related to the
starting system to be securely mounted (ignition RETEST starting system for
switch, regulatorI distributer, battery and noises.
transmission switches).
• Check wiring connection for damage or shorting due
to corrosion or stray wires.
• Are the starting system components and wiring
secure and undamaged?
C2 I CRANK ENGINE
• Put ignition switch in START then RUN. As engine is Yes .... REPLACE starter solenoid and
starting, listen to individual components for noise INSPECT starter drive or ring gear
due to gear tooth damage, shorting, sparking or for damage. REPLACE as
knocking. necessary.
• Is noise due to ring gear tooth damage? No .... If noise sounds like shorting or
sparking, CHECK for grounded
feeds to battery or starter motor.
REFER to Section 14-00. If noise
sounds like knocking, REFER to
Section 03-00.
Component Tests 4. Clamp the red load lead of the ARBST to the
battery positive terminal. Make sure both load
Starter leads are connected securely.
Conduct this test if the starter motor cranks slowly 5. Zero the ammeter of the ARBST by removing the
and also to compare starter motor electrical current to gray amp probe from all wires and pressing the
specifications. Use Rotunda Alternator, Regulator, ZERO AMPS key.
Battery and Starter Tester (ARBSD 0 1 Q-00725 or
equivalent when performing starter tests. 6. NOTE: Make sure the gray amp probe is around
all wires connected to the negative battery
1. Disconnect the low voltage wires at the coil pack terminal during this test.
connector. This prevents the coil from activating
the secondary ignition and the engine from Clamp the gray amp probe of the ARBST around
starting. the battery ground cable so that the arrow on the
probe points toward the battery.
2. Disconnect inertia fuel switch power to the fuel
pump to disable fuel flow on vehicles equipped
with electronic fuel injection (EFI).
3. NOTE: Make sure battery terminals and cable
connections are clean.
Clamp the black load lead of the Rotunda
Alternator, Regulator, Battery and Starter Tester
(ARBSD 0 1 Q-00725 or equivalent to the battery
negative terminal.

Starter Test
57 BK
016444-A
Part Part
- -
1 Red Load Lead (Connect to 4 Gray Amps Probe (Connect
Positive Battery Terminal) Around Negative Battery
2 -
Black Load Lead (Connect Cable with Arrow on Probe
to Negative Battery Pointing Toward Battery)
Terminal) 5 1 100 1 Starter Motor
- 6 10653 Battery
3 Rotunda Alternator,
Regulator, Battery and
Starter Tester (ARBST)
0 10-00725 or Equivalent
(Continued)
7. Press STARTING TEST. The display will read 1 1 . To view cranking volts again press the
INPUT # CYLS = <<ENTER> >. Type in the CONTINUE key. To display cranking amps again
vehicles number of cylinders on the numeric press the CONTINUE key a second time. To exit
keypad and press the ENTER key. The tester will the loop, select another test.
accept numbers from 2 to 1 2 .
Voltage Drop Tests
8. The display will then read DISABLE IGNITION
If the starter motor cranks slowly and the battery is
AND CRANK ENGINE. Make sure that you have
disabled the ignition system so that the engine will satisfactory, there may be a malfunction of the starter
not start when cranked. motor or in the cranking circuit wiring. To determine if
the problem is in the wiring, a voltage drop test must
9. Once the vehicle has been disabled, crank the be performed.
engine. The display will read MAINTAIN
CRANKING. Continue to crank the engine until the These tests are performed to determine if there is
display reads either TEST COMPLETE or TEST excessive resistance in the starter motor circuit.
INCOMPLETE. Then discontinue engine cranking. Always make the volt-ohmmeter connections at the
component terminal rather than at the cable wiring end
10. Press the CONTINUE key to display the cranking connector. Making a connection at the wiring end
volts. Press the CONTINUE key once again to connector could result in false readings because the
display the cranking amps. Press the CONTINUE meter will not pick up a high resistance between the
key once again to display the starter motor wiring connector and the component.
diagnosis. The display will read either GOOD
STARTER or BAD STARTER. Motor Feed Circuit
1. Prevent the engine from starting by disconnecting
the low voltage wires at the coil pack connectors.

2. Connect a remote starter switch between the Motor Ground Circuit

starter solenoid S-terminal and the battery A slow cranking condition can be caused by
positive (B+) terminal. resistance in the ground or return portion of the
3. Connect multimeter positive lead to the battery cranking circuit. Check the voltage drop in the ground
positive (B+) post. Connect negative lead to the circuit as follows:
starter solenoid M-terminal. 1. Prevent the engine from starting by disconnecting
4. Engage the remote starter switch. Read and the low voltage wires at the coil pack connectors.
record the voltage. The voltage reading should be 2. Connect a remote starter switch between the
0.5 volt or less. starter solenoid S-terminal and the battery
5. H the voltage reading is higher than this, positive (B+) terminal.
indicating excessive resistance, move the 3. Connect multimeter positive lead to the starter
volt-ohmmeter negative lead to the starter motor housing (connection must be clean and free
solenoid B-terminal and repeat the test. H the of rust or grease). Connect negative lead to the
voltage reading at the B-terminal is lower than 0.5 negative (B-) battery terminal.
volt, the concern is either in the connections at
the starter solenoid or in the solenoid contacts. 4. Engage the remote starter switch and crank the
engine. Read and record the volt-ohmmeter
6. Remove the cables from solenoid 8-, S-, and reading. The reading should be 0.2 volt or less.
M-terminals. Clean the cables and connections
and reinstall the cables to the proper terminals. 5. H the voltage drop is more than 0.2 volt, clean the
Repeat Steps 1 through 5 above. H the voltage negative cable connections at the battery and
drop reading is still higher than 0.5 volt when body connections, and retest. H the voltage drop
checked at the M-terminal or lower when is still too high, perform the following test:
checked at the 8-terminal, the concern is in the
solenoid contacts. Remove and replace the Motor Ground Circuit
starter motor or starter solenoid if available.
7. H the voltage reading taken at the solenoid ROTUNDA 73 DIGITAL
8-terminal is still higher than 0.5 volt after MULTIMETER
cleaning the cables and connections at the
1 05-R0051
starter solenoid, the concern is either in the
positive (B+) battery cable connection or in the REMOTE
STARTER
positive battery cable itself. SWITCH
8. By moving the volt-ohmmeter negative lead
toward the battery and checking each
mechanical connection point, the excessive 8-TERMINAL
voltage drop can be located. When the high
reading disappears, the last mechanical point
that was checked is the concern.
B
Motor Feed Circuit
REMOTE STARTER
S-TERMINAL SWITCH
BATTERY
S-TERMINAL 10653
AJ0131-A
Individual Cable
r The resistance of any cable can be checked in the
�
same manner by using Rotunda 73 Digital Multimeter
1 05-R005 1 or equivalent.
1. Determine which way the current is flowing in the
� BATTERY 2.
cable. Connect multimeter positive lead to the
end of the cable nearest battery positive.
Connect negative lead to the terminal at the other
10653
end of the cable.
3. Crank the engine and observe multimeter. The
voltage reading should be 0.2 volt or lower. H the
ROTUNDA 73 DIGITAL voltage drop is too high, clean the terminal ends.
MULTIMETER Retest, and if still high, replace the cable.
105-R0051 AJ0130-A

Starter Drive Pinion Test Starter Solenoid

1. Remove starter motor as described. Make sure that the starter solenoid is isolated
electrically from the starter motor. Check for
2. Disassemble starter drive { 1 1 350) from starter
continuity between solenoid S-terminal and solenoid
motor as described.
M-terminal, and between 8-terminal and ground
3. Turn the starter drive pinion by hand and hold the {starter frame and magnet). If there is no continuity,
overrunning clutch. Replace the starter drive if the following conditions may exist:
the pinion turns in both directions or does not turn.
• Open wire; replace starter solenoid.
• Ice, dirt or other foreign material preventing contact;
service as necessary.
PINION
J4581 -A J3390-A
Armature-Open Circuit Test Solenoid S-Terminal Circuit Resistance

An open circuit starter motor armature { 1 1 005) may Check the resistance of the entire 8-terminal circuit,
sometimes be detected by examining the commutator including all the switches, wires and connections.
for evidence of burning. A burn spot on the Resistance should be less than 0.08 ohm.
commutator is caused by an arc formed every time the
commutator segment, connected to the open circuit Solenoid M-Terminal
winding, passes under a brush. 1. Check for continuity between the starter solenoid
Armature-Grounded Circuit Test M-terminal and the starter solenoid housing.
This test will determine if the winding insulation has 2. If there is no continuity, replace the starter
been damaged, permitting a conductor to touch the solenoid.
starter frame and magnet { 1 1 075) or armature core.
To determine if the armature windings are grounded,
check with a multimeter. Infinite resistance indicates a ROTUNDA 73 DIGITAL
normal condition.
MULTIMETER
105.-R0051
ROTUNDA 73 DIGITAL STARTER
MULTIMETER
1 05-R0051
SOLENOID
1 1390
AJ0138-A

03-06- 1 0 Starting System 03-06- 10
Starter Motor Installation

Removal 1. Position starter motor to engine and install upper
and lower bolts finger-tight.
1. WARNING: WHEN SERVICING STARTER
MOTOR ( 1 1 002) OR PERFORMING ANY 2. lighten the upper bolt to 2Q-27 N·m ( 1 5-20 lb-ft).
MAINTENANCE IN THE AREA OF THE 3. On 3.8L engine, tighten the lower bolt to 2Q-27
STARTER MOTOR, NOTE THAT THE HEAVY N·m ( 1 5-20 lb-ft). On 4.6L engine, tighten lower
GAUGE INPUT LEAD CONNECTED TO THE two bolts to 2Q-27 N·m ( 1 5-20 lb-ft).
STARTER SOLENOID ( 1 1 390) IS HOT AT ALL
4. Connect starter solenoid connector to S-terminal.
TIMES. MAKE SURE THE PROTECTIVE CAP
lighten nut to 5 N·m (44 1b-in).
IS INSTALLED OVER THE TERMINAL AND IS
REPLACED AFTER SERVICE. 5. Install starter cable nut to starter solenoid
8-terminal. lighten to 9- 1 4 N·m (8Q- 1 23 1b-in).
Disconnect the battery ground cable ( 1 430 1 ).
Refer to Section 1 4-0 1 . 6. Replace red starter solenoid safety cap.
2. Raise the vehicle on a hoist. 7. Lower vehicle to floor.
3. Disconnect starter cable and connector 8. Connect battery ground cable.
S-terminal from starter solenoid.
4. Remove upper bolt.
5. Remove one lower bolt on 3.8L engine and two
lower bolts on 4.6L engine and starter motor.

03·06· 1 1 Starting System 03·06- 1 1
DISASSEMBLY AND ASSEMBLY
Starter Motor
NOTE: Although disassembly and service procedures
are shown for the starter motor ( 1 1 002) in this
section, it is recommended that the starter motor be
returned to Ford Return Parts Center for analysis and
review.
Starter Motor-Disassembled VIew 3.8L Engine
AJ0126-A
Part Part
1 N805403 Terminal Nut 10 1 1223 Stop Ring Retainer
2 1 1390 Starter Solenoid 11 1 1222 Starter Drive Stop Ring
3 1 1A171 Housing Seal 12 - Magnet Retainer (6 Req'd)
4 1 1 135 Bushing (Part of 1 1075)
5 1 1 130 Drive End Housing 13 1 1075 Starter Frame and Magnet
6 N805405 Solenoid Screw (2 Req'd) 14 1 106 1 Brush Holder
7 1 1002 Starter Motor 15 1 1059 Brush Spring (4 Req'd)
16 - Bushing (Part of 1 1049)
8 1 1067 Drive Lever and Pin
9 1 1350 Starter Drive 17 1 1049 Brush End Plate and Bushing
(Continued)
18 N805406 Brush Plate Bolt (2 Req'd)
(Continued)

03-06- 1 2 Starting System 03-06- 12
Part Part
19 N805428 Through-Bolt (2 Req'd) 27 1 1036 Pinion Thrust Washer
20 1 1005 Starter Motor Armature 28 1 1355 Output Shaft
21 1 1A172 Armature Thrust Ball 29 1 1A 167 Planet Gear Retainer
-
22 1 1K190 Planet Gear A . Tighten to 9- 14 N·m (80- 123
23 1 1A165 Stationary Gear Lb-ln)
-
24 N805404 Truarc® E-Ring B Tighten to 5- 10 N·m (45-88

Lb-ln)
-
25 Magnet Pole Piece (6 Req'd) c -
Tighten to 2-3 N-m ( 1 8-26
(Part of 1 1075) Lb-ln)
-
26 Pole Shunt (6 Req'd) (Part of
1 1075)
(Continued)
Starter Motor-Disassembled VIew 4.6L Engine
17
AJ0127-A

03-06- 13 Starting System 03-06-1 3
Part Part
1 N805403 Terminal Nut 19 N805428 Through-Bolt (2 Req'd)
2 1 1390 Starter Solenoid 20 1 1005 Starter Motor Armature
3 1 1A171 Housing Seal 21 1 1A 1 72 Armature Thrust Ball
4 1 1 135 Bushing 22 1 1K 1 90 Planet Gear
5 1 1 130 Drive End Housing 23 1 1A 165 Stationary Gear
6 N805405 Solenoid Screw (2 Req'd) 24 N805404 Truarce E-Ring
-
7 1 1002 Starter Motor 25 Magnet Pole Piece (6 Req'd)
8 1 1067 Drive Lever and Pin (Part of 1 1075)
-
9 1 1350 Starter Drive 26 Pole Shunt (6 Req'd) (Part of

1 1075)
10 1 1223 Stop Ring Retainer 27 1 1036 Pinion Thrust Washer
11 1 1222 Starter Drive Stop Ring 28 1 1355 Output Shaft
-
12 Magnet Retainer (6 Req'd) 29 1 1A167 Planet Gear Retainer
(Part of 1 1075)
13 1 1075 Starter Frame and Magnet 30 1 1355 Output Shaft
14 1 106 1 Brush Holder 31 1 1A 167 Planet Gear Retainer
-
15 1 1059 Brush Spring (4 Req'd) A Tighten to 9- 14 N·m (80- 123

Lb-ln)
-
16 Bushing (Part of 1 1049) B -
Tighten to 5- 10 N·m (45-88
17 1 1049 Brush End Plate and Bushing Lb-ln)
-
18 N805406 Brush Plate Bolt (2 Req'd) c Tighten to 2-3 N·m ( 18-26
(Continued)
Lb-ln)
Disassembly Assembly
1. Remove positive brush connector from starter 1. NOTE: Sealer material meeting Dow Formulation
solenoid M-terminal. Silastic 737 or GE Silicone RTV 1 23 or equivalent
2. Remove starter solenoid retaining screws and meeting Ford specification ESA-M4G294-A
starter solenoid { 1 1 390). should be replaced on starter motor during
reassembly.
3. Remove through-bolts and separate drive end
housing from starter frame and magnet { 1 1 075). Install starter motor armature in starter frame and
Remove seal { 1 1 A 1 7 1 ) from drive end housing. magnet. Apply a thin coating of Syncolube {PTFE)
Remove starter drive and gear assembly from Low Temperature Grease or equivalent meeting
drive end housing. Ford specification WSG-M 1 C2 1 8-B2 on both
ends of armature shaft and spline. Install brush
4. Remove drive lever and pin { 1 1 067) from starter holder while making sure brushes fit over
drive { 1 1 350). commutator. Apply grease to bushing bore in
5. Remove starter drive stop ring { 1 1 222) and stop brush end plate and bushing. Push back grommet
ring retainer { 1 1 223) from output shaft { 1 1 355); onto starter frame and magnet and attach brush
then remove starter drive from output shaft. end with brush plate bolts. Tighten to 2-3 N·m
{ 1 8-26 1b-in).
6. Push E-ring off output shaft and separate gear
assembly from output shaft. 2. Apply grease to output shaft spline and place
stationary gear { 1 1 A 1 65) over output shaft.
7. Remove brush plate screws and brush end plate Install armature thrust washer and push E-ring
and bushing { 1 1 049) from starter frame and onto output shaft. Place starter drive onto output
magnet. snaft and install starter dl'ive stop ring and stop
8. Remove brush holder { 1 1 06 1 ) and push starter ring retainer. Attach drive lever to starter drive.
motor armature { 1 1 005) out of starter frame and 3. Grease and install planet gears { 1 1 K 1 90).
magnet.
4. Apply grease into drive end housing bushing bore
{approximately one-quarter full). Install starter
drive gear assembly into housing, making sure to
line up bolt holes in gear assembly and housing.
Place planet gear retainer { 1 1 A 1 67) over gear
assembly. Install housing seal into drive end
housing.

03-06- 14 Starting System 03-06- 1 4
5. Position starter frame and magnet to housing and 3. Remove brush end plate screws, brush end plate
install through-bolts. lighten to 5- 1 0 N·m (45-88 and bushing { 1 1 049) and brush holder { 1 1 06 1 )
lb-in). from starter frame and magnet { 1 1 075). Remove
6. Position starter solenoid to housing making sure starter motor armature { 1 1 005) from starter
that solenoid plunger is attached through drive frame and magnet.
lever (bottom starter solenoid M-terminal should 4. Install new starter motor armature in starter
have a metal strip attached to it). lighten starter frame and magnet. Apply a thin coating of
solenoid screws to 5- 1 0 N·m (45-BS ib-in). Syncolube {PTFE) Low Temperature Grease or
7. Attach positive brush connector to starter equivalent meeting Ford specification
solenoid (bottom terminal). lighten nut to 9- 1 4 WSG-M 1 C2 1 8-B2 on both ends of armature shaft
N·m (8Q- 1 23 lb-in). and pinion.
8. Check that starter motor no-load current draw is 5. Install brush holder. Make sure that brushes fit
within specification. Refer to Component Tests over commutator. Push black grommet onto
under Diagnosis and Testing. frame. Apply grease to bushing bore in brush end
plate and bushing and attach to starter frame and
magnet.
6. Position starter frame and magnet to starter drive
Starter Drive Replacement { 1 1 350) and drive end housing and install
through-bolts. lighten to 5- 1 0 N·m {45-88 1b-in).
1. Remove positive brush connector from starter
solenoid M-terminal. Remove starter solenoid 7. Attach positive brush connector to starter
retaining screws and remove starter solenoid solenoid M-terminal. lighten nut to 9- 1 4 N·m
( 1 1 390). {8Q- 1 23 1b-in).
2. Remove through-bolts and separate motor 8. Check that starter motor no-load current draw is
assembly from drive end housing. Remove within specification. Refer to Component Testings
housing seal from drive end housing. Remove under Diagnosis and Testing.
starter drive gear assembly from housing and
detach drive lever and pin ( 1 1 067).
3. Remove starter drive stop ring ( 1 1 222) and stop
ring retainer { 1 1 223) from output shaft { 1 1 355) Bushings
and then remove starter drive assembly. Disassembly and Assembly
4. Apply a thin coating of Syncolube {PTFE) Low 1. The bushings can be pressed or tapped out of
Temperature Grease or equivalent meeting Ford their housing using a driver of the appropriate
specification WSG-M 1 C2 1 8-82 on output shaft size. Be sure the housing is well supported.
spline. Install new starter drive gear assembly on
output shaft. Install new starter drive stop ring 2. Immerse new bushings in engine oil {SAE 30 or
and stop ring retainer. Attach drive lever and pin. 40) for at least 20 minutes before installation.
5. Partially fill drive end housing bushing bore with 3. NOTE: Do not ream the bushings after installation
grease {approximately one-quarter full). Install since the self-lubricating qualities of the bushing
drive gear assembly in housing, making sure to may be damaged.
line up bolt holes in starter drive gear assembly Press or tap the new bushing into position using a
and housing. driver.
6. Install lever support and housing seal in drive end
housing. 4.6L Engine Starter Shown, 3.8L Engine Starter
Similar
7. Position starter frame and magnet { 1 1 075) to
housing and install through-bolts. lighten to 5- 1 0 BUSHING DRIVE END
N·m {45-88 1b-in). (PART OF HOUSING
1 1 049) 1 1 1 30
8. Install starter solenoid. Refer to Starter Motor,
Assembly.
Armature Replacement, Starter Motor

1. Remove positive brush connector from starter
solenoid M-terminal.
2. Remove through-bolts and separate motor from
starter drive gear assembly and drive end
housing. BRUSH END BUSHING
PLATE AND 1 1 135
BUSHING
1 1 049 J3732-C

03-06- 15 Starting System 03-06- 1 5
SERVICE PROCEDURES
Road Service 2. Replace bushings if worn or scored. Check the

For cases of a starter motor ( 1 1 002) that cranks the output shaft ( 1 1 355) for wear if the bushings are
excessively scored or worn. Service or replace
engine very slowly, connect a 1 2-volt booster battery
output shaft as necessary.
(10653) to the system.
CLEANING AND INSPECTION

Starter Frame and Magnet
1. Check the starter frame and magnet ( 1 1 075) for
Armature Coil, Starter Motor damage and replace as necessary.
1. Inspect starter motor armature windings for
broken or burned insulation and unwelded or open
connections. STARTER
2.
FRAM E
Check starter motor armature ( 1 1 005) for open AND MAGNET
circuits, shorts and grounds. Check for pole rub 1 1 075
or rub on magnetic shunts.
3. Check commutator for runout. Inspect armature
shaft and two bushings for scoring and excessive
wear with Dial Indicator / Magnetic Base
D78P-420 1 -B or equivalent. H commutator is
rough, or more than 0. 1 2 mm (0.005 inch) out of
round, it must be replaced.
DIAL INDICATOR/ J4577-B

MAGNETIC BASE
D78P-4201 -B
ROTATE ARMATURE
SHAFTS ON Starter Drive/Flywheel Ring Gear Inspection
BEARING SURFACES
1. CAUTION: Do not wash the starter drive
( 1 1 350) because the solvent will wash out
the lubricant, causing starter drive to slip.
Use a brush or compressed air to clean the
starter drive, starter motor armature
( 1 1 005), brush, gear assemblies, drive end
housing, pole pieces and planet gears
( 1 1 K 1 90). Wash all other parts In solvent and
dry.
Examine gears and spline on output shaft
( 1 1 355) and drive pinion for chipped, broken or
worn conditions. Replace if required.
Bushings
1. Inspect the self-lubricating bronze I iron armature
bushings in the drive housing and brush end plate
and bushing ( 1 1 049). Replace bushings
whenever excessive starter motor armature
shaft side-play is evident (maximum allowable 0.2
mm (0.008 inch.)

03-06- 1 6 Starting System 03-06-16
Starter Drive and F lywheel Ring Gear Wear STARTER SPECIFICATIONS (Cont'd)
PINION AND RING GEAR WEAR PATTERNS Description Specification
\'f
Starter Motor Normal Engine 1 40-220 RPM
Cranking Speed
Starter Motor Minimum Stall 14.7 N·m ( 1 1 .0 Lb-Ft)
Torque @ 5 Volt
~
Maximum Load 800 Amps
No Load 60-80 Amps
Starter Brushes Manufactured 14 mm (0.55 1nch)
Length
Starter Brushes Spring 18 N (64 oz)
NORMAL WEAR PATTERN
Tension
Maximum Commutator Runout 0. 1 2 mm (0.005 1nch)
Maximum Starting Circuit 0.5 Volt
Voltage Drop (Battery Positive
Terminal to Starter Terminal)
at Normal Engine Temperature
LUBRICANTIADHESIVE /CLEANER SPECIFICATIONS

Ford
-
Dow Formulation ESA-M4G294·A
SMALL WEAR PATTERN 737 or GE Silicone
RTV 1 23
MILLED CONDITION -
EXCESSIVE WEAR Syncolube (PTFE) WSG-M 1C218-B2
M(j�
ON 2 OR 3 TEETH Low Temperature
Grease
MILLED TOOTH-METAL
BUILD-UP WILL NOT Description N·m Lb-ln
��IT EN
Solenoid Screws 5-10 45-88
Solenoid M-Terminal Nut 9- 1 4 80- 1 23
Solenoid B-Terminal Nut 9- 1 4 80-123
Solenoid S-Terminal Nut 5-6 44-53
Through-Bolts 5- 10 45-88
MILLED GEARS J546�A Mounting Bolts 20-27 1 5-20
(Lb-Ft)
2. Inspect the entire circumference of the flywheel
ring gear for damage when the starter drive gear Brush Plate Bolts 2-3 18-26
teeth are damaged. The flywheel ring gear
pattern will usually be found in two places around
flywheel ring gear. If the starter drive gear or SPECIAL SERVICE TOOLS/EQUIPMENT
flywheel ring gear show signs of excessive wear
or milling, they must be replaced.
Tool Number Description
SPECIFICATIONS D78P-420 1-B Dial Indicator/ Magnetic Base
STARTER SPECIFICATIONS ROTUNDA EQUIPMENT
Description Specification Model Description

Starter Motor Diameter 78 mm (3 1nches) 0 1 0-00725 Alternator, Regulator, Battery and
Starter Tester (ARBsn
Starter Motor Current Draw 130-220 Amps
Under Normal Load 105-R005 1 73 Digital Multimeter
(Continued)

03-07A- 1 Ignition, Electronic-3.8L 03-07A-1
SECTION 03-07 A Ignition, Electronic-3.8L

VEHICLE APPLICATION ••••..• •••.•••••••••••••••••••••••••••••••• 03.07A-1 REMOVAL AND INSTALLATION (Cont'd.)
DESCRIPTION AND OPERATION Radio Ignition Interference Capacitor • • • . . ••••••••••••.03-o7A-6
Crankshaft Position (CKP) Sensor •••••••••••••••••••••••• 03-o7A-1 Spark Plugs •••••..•••.•••••..• •••.••••••••••••• ••••••••••••...••••.• 03.07 A-6
Ignition Coii ••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 03-o7A-2 CLEANING AND INSPECTION
Ignition Components, Electronic .•••••••••••••••••••••••• 03-o7A-1 Ignition Coii • • . ••••••••••••••••••.•••••••• . • • • • • . • • . • • • . . •••••••••••• 03.07A-8
DIAGNOSIS AND TESTING Ignition Wires ••••••••••••••••••• ••••• • • • . • • . • • . • • . • •••••••••••••••• 03-o7 A-8
lgnition ••••••••••••••••••••••••••••••••••• ••••••••.•••••••••••• .•••.••• 03-o7A-2 Spark Plugs ••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 03-o7 A-6
REMOVAL AND INSTALLATION ADJUSTMENTS
Bracket, Ignition Coii ••••••••••••••••••••••••••••••••••••••••••• 03-o7A-3 Ignition Timing ••••••••••••••••••••••••••.•••••••••••••.••••••...••• 03-o7A-8
Crankshaft Position (CKP) Sensor •••..••••••••.••.••••••• 03-o7A-2 Spark Plugs ••.• •••• • • • . • • . . . .•••.•••.••. •••••.•••••••••••••••••••••• 03-o7A-8
Ignition Coii •••••••• . . . •••..•••••..••••••••••••••••.••••••••••••••••• 03.07A-3 SPECIFICATIONS ••••••••••••••••. ••••••••••••••••••••••••••••••••••• 03-o7A-8
Ignition Wires •••••••••••••••••••••••••••••••••••••••••••••••••••••• 03-o7A-4 SPECIAL SERVICE TOOLS/EQUIPMENT . • • . •••.•••.•••••• 03-o7A-8
VEHICLE APPLICATION
Thunderbird, Cougar
Ignition Components, Electronic

The electronic ignition (EI) system for the 3.8L engine
consists of the following components:
• crankshaft position sensor (CKP sensor)(6C3 1 5)
• ignition coil (1 2029) ·
• misfire detection sensor

• related wiring
Crankshaft Position (CKP) Sensor

NOTE: Initial engine ignition timing is set at 1 0 degrees
± 2 degrees before top dead center (BTDC) and is not
adjustable.
The crankshaft position sensor (CKP sensor)(6C3 1 5)
is a variable reluctance sensor which is mounted on
the engine front cover (60 19) and is triggered by a
36-minus- 1 tooth trigger wheel located on the
crankshaft puHey and damper.
The crankshaft position (CKP) signal from the
crankshaft position sensor provides:
• base timing.
V10103-A
• crankshaft speed (rpm).
The powertrain control module (PCM)( 1 2A650) will
use this information to determine ignition coil ( 1 2029) Part
turn on and turn off time. Item Number Description
-
1 Stud Bolt (2 Req'd)
-
2 Nut (2 Req'd)
3 6K342 Crankshaft Position Sensor
Shield
4 6C3 15 Crankshaft Position Sensor
(Continued)

.- -
03·07A-2 Ignition, Electronic-3.8L 03-07A·2
DESCRIPTION AND OPERATION (Continued) REMOVAL AND INSTALLATION

Part
Item Number Description Removal
5 6019 Engine Front Cover 1. Disconnect battery ground cable ( 1 430 1). Refer
-
A Tighten to 8- 12 N·m (7 1-1 06
Lb-ln) 2. Raise vehicle on hoist.
-
B Tighten to 2-4 N-m (18-35 3. Disconnect engine control sensor wiring
Lb-ln) ( 1 2A58 1) from the crankshaft position sensor
(CKP sensor)(6C3 1 5).
4. Remove crankshaft position sensor shield, stud
bolts and remove crankshaft position sensor from
Ignition Coil the engine front cover (60 1 9).
The ignition coil ( 1 2029) is mounted on the front of the
RH cylinder head (6049). The ignition coil contains two
separate ignition coils. Each ignition coil is controlled
by the powertrain control module (PCM)( 1 2A650)
through two coil leads. Each ignition coil activates two
spark plugs ( 1 2405) simultaneously:
• one spark plug on the compression stroke; this
spark plug uses the majority of the ignition coil's
stored energy.
• one spark plug on the exhaust stroke; this spark
plug will use very little of the ignition coil's stored
energy.
- These two spark plugs are connected in series,
so the firing voltage of one spark plug will be V10103-A
negative with respect to ground and the other
spark plug will be positive with respect to
ground. Part
Refer to the Powertrain Control I Emissions Diagnosis
Manual 1 1 -
Stud Bolt (2 Req'd)
-
2 Nut (2 Req'd)
HIGH VOLTAGE 3 6K342 Crankshaft Position Sensor
COIL 1 TOWERS Shield
4 6C3 15 Crankshaft Position Sensor
5 6019 Engine Front Cover
-
A Tighten to 8- 12 N·m (7 1-1 06
Lb-ln)
-
B Tighten to 2-4 N-m (18-35
Lb-ln)
Installation
1. CAUTION: Do not overtighten crankshaft
PIN 4 - BATTERY position sensor retaining stud bolts or
VOLTAGE damage to crankshaft position sensor may
PIN 3 - COIL 1 occur.
PIN 2 - COIL 3
PIN 1 - COIL 2 Position crankshaft position sensor and install
8491G-B retaining stud bolts. Tighten stud bolts to 8- 1 2
N·m (7 1 - 1 06 1b-in).
2. Install crankshaft position sensor shield and
DIAGNOSIS AND TESTING retaining nuts. Tighten nuts to 2-4 N·m ( 1 8-35
lb-in).
3. Properly route engine control sensor wiring and
Ignition connect to crankshaft position sensor.
4. Lower vehicle.
Manual 1 •

03-07A-3 Ignition, Electronic-3.8L 03-07A-3
Ignition Coil
Removal
1. Disconnect engine control sensor wiring
{ 1 2A58 1 } from ignition coil { 1 2029} and radio
ignition interference capacitor { 1 880 1}.
2. Disconnect ignition wires by squeezing locking
tabs and twisting while pulling upward.
-Q-SQUEEZE LOCKING TABS

TO REMOVE
84400-8
3. Remove four ignition coil retaining screws and
remove ignition coil and radio ignition interference
capacitor. Save radio ignition interference
capacitor for installation with ignition coil.
Installation
1. Position ignition coil and radio ignition interference
capacitor to ignition coil bracket.
2. Install retaining screws and tighten to 4.5-7.0 N·m
{40-6 1 1b-in}.
3. Apply Silicone Brake Caliper Grease and
Dielectric Compound D7AZ- 1 9A33 1 -A
{Motorcraft WA- 10} or equivalent meeting Ford
specification ESE-M 1 C 1 7 1 -A to all ignition wire
boots.
4. Install each ignition wire connector to the proper FRONT OF
terminal on the ignition coil. Make sure boots are -ENGINE
fully seated.
5. Connect engine control sensor wiring to the
85196-A
ignition coil and radio ignition interference
capacitor. Part
1 1880 1 Radio Ignition Interference
Capacitor
Bracket, Ignition Coil 2 12029 Ignition Coil
3 - Bolt
Removal
1. Remove the ignition coil { 1 2029} as described. 4 12043 Ignition Coil Mounting Strap
2. Remove the two ignition coil bracket nuts, one 5 9424 Intake Manifold, Lower
ignition coil bracket bolt and ignition coil bracket. 6 8501 Water Pump
7 - Nut (2 Req'd)
Installation
1. Position the ignition coil bracket and nuts and 8 N606502-S36M Screw (4 Req'd)
-
install the mounting bolt and nuts. lighten the bolt A Tighten to 20-30 N·m ( 15-22
and nuts to 2Q-30 N·m { 1 5-22 1b-ft}. Lb-Ft)
B - Tighten to 4.5-7.0 N·m (40-6 1
2. Install the ignition coil as described.
Lb-ln)

03-07A-4 Ignition, Electronic-3.8L 03-07A-4
Ignition Wires 3. Open ignition wire separators ( 1 2297) and

remove ignition wire.
Installation
Description Tool Number 1. Whenever an ignition wire is removed from a
Spark Plug Wire Remover T74P-6666-A spark plug or ignition coil or a new ignition wire is
installed, coat the entire interior surface of the
Removal boot with Silicone Brake Caliper Grease and
Dielectric Compound D7AZ- 1 9A33 1 -A
1. CAUTION: Do not pull on the ignition wire
(Motorcraft WA- 1 0) or equivalent meeting Ford
directly as the wire may separate from the
specification ESE-M 1 C 1 7 1 -A with a small, clean
connector inside the boot. tool prior to installation.
When removing ignition wires from spark plugs 2. CAUTION: Proper installation of Ignition
( 1 2405) use Spark Plug Wire Remover wires is critical to vehicle operation. If any
T74P-6S66-A. Grasp and twist the ignition wire
ignition wire is not properly installed on
spark plug boot back and forth on the spark plug spark plug or ignition coil, both spark plugs
insulator to free the boot. connected to that ignition coil may not
operate under load.
Install each ignition wire to the proper terminal on
the ignition coil. The terminals on the ignition coil
and the ignition wire are numbered. Make sure
the boots are fully seated and that both ignition
coil boot locking tabs are engaged.
3. Route ignition wire and ignition wire separators.
4. Connect ignition wire to spark plug.
A6626-D

connector Inside the boot.
Disconnect the ignition wire from the ignition coil
( 1 2029) by squeezing the locking tabs and
twisting while pulling upward.
-Q-SQUEEZE
TOLOCKIREMOVE
NG TABS
84400-B

03-07A 5
- Ignition, Electronic-3.8L 03-07A-5
Ignition Wire Routing Diagram
_..,.-
FRONT OF ENGINE t
�
I
FRONT OF ENGINE
NOTE: INSTALLAnON
ORDER FOR LH IGNmON
WIRES ARE SPARK PLUG BOOTS SPARK PLUG
oeo NUMBERS 1 ,2,3,4 AND 5 BOOT NUMBER 6
NOTE: SPARK PLUG NOTE: WIRE SEPARATORS TO BE NOTE: MAKE SURE

BOOTS MUST BE FULLY SEATED IN VALVE COVER RETAINER CUP IS
SECURELY PRESSED STUDS FULLY ENGAGED
ONTO SPARK PLUGS ON COIL TOWER
NOTE: INSTALLAnoN
ORDER FOR RH IGNmON
WIRES ARE
·e e e
�
FRONT OF ENGINE
�
A .IGNmON WIRE
W ROUTING
0 REFER TO LEGEND
FIRING ORDER: NUMBER 1-4-2-5-3-6

851 97 A
-

03·07A·6 Ignition, Electronic-3.8L 03·07A·6
Part Part
1 12286 Ignition Wire (6 Req'd) 4 6049 Cylinder Head (RH)
2 12297 Ignition Wire Separator (7 5 12029 Ignition Coil
Req'd) 6 6049 Cylinder Head (LH)
3 12405 Spark Plug (6 Req'd) A -
Tighten to 9-20 N·m (80- 1 77
(Continued) Lb-ln)
Radio Ignition Interference Capacitor 5. To install, reverse Removal procedure. Install

spark plugs by hand and tighten spark plugs to
Removal and Installation 9-20 N·m {8Q- 1 77 lb-in).
1. Disconnect fuel charging wiring {9D930) from
radio ignition interference capacitor { 1 880 1). LH Side Shown, RH Side Similar
2. Remove retaining screw and radio ignition
interference capacitor from ignition coil { 1 2029)
·
and mounting bracket. --- FRONT OF ENGINE

3. To install, reverse Removal procedure. Tighten
retaining screw to 4.5-7.0 N·m {4Q-6 1 lb-in).
Spark Plugs
1. Disconnect ignition wires from spark plugs
{1 2405) as described.
2. Loosen spark plugs 1 I 4 turn and remove any dirt
or foreign material from spark plug areas of
cylinder heads {6049) with compressed air.
3. NOTE: Three different styles of
platinum-enhanced spark plugs are produced for
the 3.8L engine. Each plug has a different part
number and use. AWSF-44E spark plugs have a
platinum-enhanced center electrode and are used AV01 1 5-A
in cylinders 4, 5 and 6. AWSF-44EG spark plugs
have a platinum-enhanced ground {side)
electrode and are used in cylinders � , 2 and 3. If
any spark plug is removed and re-installed, it CLEANING AND INSPECTION
must be installed in the same cylinder from which
it was removed. If any spark plug is replaced, use
only spark plugs with part number AWSF-44EE Spark Plugs
as listed on the vehicle emission control Inspect the electrode and outer surfaces. Refer to
information label. This replacement spark plug Spark Plug Inspection Chart. Replace spark plugs
has double platinum enhancement on both the { 1 2405) if they are worn or damaged.
center and ground electrode and may be used in Use the following inspection chart when inspecting
all six cylinders. spark plugs.
Remove spark plugs.
4. NOTE: Refer to the Spark Plug Inspection Chart
to determine the condition of spark plugs.
Check and adjust spark plug gap as described.

03-07A-7 Ignition� Electronic-3.8L 03-07A-7
Spark Plug Inspection Chart
GAP BRIDGED OIL FOULED
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SPARK
03·07A·8 Ignition, Electronic-3.8L 03-07A·8
Ignition Coil LUBRICANTI ADHESIVE/CLEANER SPECIFICATIONS

Wipe the ignition coil towers with a clean cloth Ford
dampened with soap and water. Remove any soap film Description Part Number SpeclflcaUon
and dry with compressed air. Inspect ignition coil Silicone Brake D7AZ- 19A33 1 -A ESE-M 1 C 1 7 1 -A
(1 2029} for cracks, carbon tracking, dirt or damage. Caliper Grease and
Dielectric
Compound
Ignition Wires TORQUE SPECIFICATIONS

Wipe the ignition wires with a clean, damp cloth prior Description N-m Lb-Ft Lb-ln
to inspection. Without removing the ignition wires from -
Crankshaft Position Sensor 8- 1 2 7 1 - 106
the spark plugs ( 1 2405} or ignition coil ( 1 2029}, Stud Bolts
inspect the ignition wires for visible damage such as
-
burns, cuts, pinches, cracks or torn boots. Replace Crankshaft Position Sensor 2-4 1 8-35
Shield Nuts
only the damaged ignition wires.
-
Ignition Coil Screws 4.5-7.0 40-6 1
-
Ignition Coil Bracket Retainers 20-30 15-22
ADJUSTMENTS Spark Plugs 9-20 -
80- 1 77
-
Capacitor Retaining Screw 4.5-7.0 44-61
Spark Plugs
Using a suitable spark plug gap tool, adjust spark plug
gap to 1 .3- 1 .4 mm (0.052-0.056 inch} following tool SPECIAL SERVICE TOOLS/EQUIPMENT
manufacturer's instructions.
Tool Number I
Description lllustraUon
Ignition liming
�
T74P-6666-A
Base ignition timing is referenced to the position of the Spark Plug Wire Remover
crankshaft position sensor (CKP sensor}(6C3 1 5} and
is set at 10±2 degrees before top dead center
(BTDC} and is not adjustable.
T7....-A
SPECIFICATIONS
IGNITION SYSTEM SPECIFICATIONS

Spark Plug Type AWSF-44EE8
Spark Plug Gap 1 .3- 1 .4 mm (0.052-0.056 inch)
Firing Order 1 -4-2-5-3-6
Ignition Timing Refer to Powertrain
Control/ Emissions Diagnosis
Manual 2
a Three different styles of platinum-enhanced spark plugs are
produced for the 3.8L engine. Each plug has a different part
number and use. AWSF-44E spark plugs have a
platinum-enhanced center electrode and are used in
cylinders 4, 5 and 6. AWSF-44EG spark plugs have a
platinum-enhanced ground (side) electrode and are used in
cylinders 1, 2 and 3. If any spark plug is removed and
re-installed, it MUST be installed in the same cylinder from
which it was removed. If any spark is replaced, use only
spark plugs with part number AWSF-44EE as listed on the
vehicle emission control information label. This
replacement spark plug has double platinum enhancement
on both the center and ground electrode and may be used in
all six cylinders.

03-078- 1 Ignition, Electronic-4.6L (2V) 03-078-1
SECTION 03-078 Ignition, Electronic-4.6L (2V)

VEHICLE APPLICATION ........................••..•••.••.•••.••..
03-07B·1 REMOVAL AND INSTALLATION (Cont'd.)
DESCRIPTION AND OPERATION Installation ••••••••...•.....•.•.••••••••••••••••.•..•..•.••••.•••• 03-o7B-8
Crankshaft Position (CKP) Sensor ......•••.••••••..••...•
03-G7B- 1 Spark Plugs .•......••..•.••••••••••••••••.......•••••••••••••••••.•• 03-o7B-8
Ignition Coii �
............................. .•.....•.••••..••..••......
03-G7B-2 lnstallation ..........••••••••••••••••••....•..•..••••••••••••••••. 03-o7B-8
Ignition Components, Electronic ••••••••••••••...........
03-07B-1 CLEANING AND INSPECTION
DIAGNOSIS AND TESTING Ignition Coii.... .......•••.••••••••••••••.•......•••••••••••••••.•• 03-o7B-1 1
lgnition .....................•••.•••..•••.•••...•.........••.......•....
03-G7B-2 Ignition Wires .•.••••••••••••..••.•.•....•..••.••••••••••••.••.... 03-G7B-1 1
REMOVAL AND INSTALLATION Spark Plugs •••••••••••••••.•..•.•..•.•••••••••••••••••...•.•.••••••• 03-o7B-9
Bracket, Ignition Coii ••.........................................
03-07B-4 ADJUSTMENTS
lnstallation •••...••.•..•........•.•...•.••..•...•••••.•.••••••••••
03-G7B-4 Ignition Timing ••••••••.•••••••••••••••••••••••••••••••••••••••••• 03-o7B-1 1
Crankshaft Position (CKP) Sensor ........................ 03-G7B-2 Spark Plugs ••••••••••••••••....•.•..••.••••••••••••••..•••..••.••• 03-G7B-1 1
Ignition Coii .........................................•.••••..•.•••••.
03-G7B-3 SPECIFICATIONS ............•.••••••••••••••••••....•.•••••••••••• 03-o7B-1 1
Ignition Wires .•.......................................•...•••.•••.•
03-G7B-5 SPECIAL SERVICE TOOLS/EQUIPMENT ......•...•••••• 03-G7B-1 1
Radio Ignition Interference Capacitor ••••••••••••••••••
03-G7B-8
VEHICLE APPLICATION
Thunderbird, Cougar
Ignition Components, Electronic • the powertrain control module (PCMX 1 2A650)

provides desired spark plug signal
The electronic ignition (EI) system for the 4.6L (2V)
engine consists of the following components: • related wiring
• crankshaft position sensor (CKP sensor)(6C3 1 5)
• ignition coil ( 1 2029)
Crankshaft Position (CKP) Sensor The powertrain control module will use the crankshaft
NOTE: Initial engine ignition timing is set at 1 0 degrees position sensor for misfire detection.
± 2 degrees before top dead center (BTDC) and is not
adjustable.
The crankshaft position sensor (CKP sensor)(6C3 1 5)
is a variable reluctance sensor triggered by a
36-minus- 1 tooth trigger pulse wheel located on the
crankshaft (6303) inside the engine front cover
(60 19).
The signal generated from the crankshaft position
sensor provides two types of information:
• One is the position of the crankshaft in 10 degree
increments.
• The other is the crankshaft speed (rpm).
- The powertrain control module (PCM)( 1 2A650)
uses this information to determine ignition coil
turn on arid turn off times.

03-078-2 Ignition, Electronic-4.6L (2V) 03-078-2
Ignition Coil NOTE: The numbers on the ignition coil tower

The ignition coils ( 1 2029) contain two separate terminals shown in the illustration are engine cylinder
ignition coils. Each coil is controlled by the ignition numbers. These numbers are shown for information
control module (ICMX 1 2K072) through two coil leads. only and are not shown on ignition coil towers. Actual
Each ignition coil activates two spark plugs ( 1 2405) identification labels are shown in View A. The ignition
simultaneously: wire connected to a particular ignition coil tower
should be connected at the other end to the spark plug
• one spark plug on the compression stroke; this for the same numbered cylinder.
spark plug use the majority of the ignition coil stored
energy. HICOIGHL 2VOLTAGE
• one spark plug on the exhaust stroke; this spark TOWERS
plug uses very little of the ignition coil stored energy.
• These two spark plugs are connected in series.
- The firing voltage of one spark plug will be
negative with respect to ground.
- The voltage of the other spark plug will be
positive with respect to ground.
Manual 1 for additional information on spark plug
polarity.
The ignition coils are mounted on ignition coil brackets
retained to the engine front cover (60 1 9). There are
two cylinder numbers on each ignition coil terminal to PICOI1-COI
NS-LL 120L2H49IGNITION
allow the ignition coil to be interchangeable.
2-BATTERY
POSIIN START/TAGEIVE R(BUN+)
VOL
3-COIL 3 )
(·)
)(+ 74//61 213 (+
8/5 (·)
VIEW A
Ignition
Manual 1 •

Removal
to Section 1 4·0 1 .
2. Remove serpentine drive belt (8620). Refer to
Section 03-Q5.

REMOVAL AND INSTALLATION {Continued)

4. Disconnect the engine control sensor wiring
( 1 2A581) from the crankshaft position sensor
(CKP sensor)(6C3 1 5) and A / C compressor
( 1 9703).
5. Discharge A / C system and remove A / C
compressor. Refer to Section 1 2-00.
6. Remove crankshaft position sensor retaining
screw and remove crankshaft position sensor.
VIEW A
SCREW
TIGHTEN TO --
8-12 N·m FRONT OF ENGINE
(71-1 06 LB-IN) _.-
CRANKSHAFT POSITION
SENSOR (CKP)
6C31 5 84487-C
Installation
1. Make sure the crankshaft position sensor
mounting surface is clean and that the crankshaft
position sensor 0-ring is in proper location on
crankshaft position sensor.
2. CAUTION: Do not overtighten crankshaft
position sensor retaining screw or damage
to the crankshaft position sensor may occur.
851 91-A
Position crankshaft position sensor and install
retaining screw. lighten to 8- 1 2 N·m (7 1 - 1 06
lb-in). Part
3. Install A/C compressor. Evacuate and recharge Item Number Description
AIC system. Refer to Section 1 2-00. 1 N806 155-S309 Screw
4. Properly route engine control sensor wiring and 2 6C3 15 Crankshaft Position Sensor
connect electrical connectors to A I C
compressor and crankshaft position sensor.
3 60 19 Engine Front Cover
4 12A227 CKP Pulse Wheel
5. Lower vehicle.
-
A Tighten to 8- 12 N·m (7 1 - 1 06
6. Install serpentine drive belt. Refer to Section Lb-ln)
03-05.
Ignition Coil
Removal
( 1 2A58 1) from ignition coils ( 1 2029) and radio
ignition interference capacitors ( 1 880 1 ).

2. Disconnect ignition wires by squeezing locking

tabs and twisting while pulling upward.
-Q-SQUEEZE
TOLOCKIREMOVE
NG TABS
84400-8
3. Remove four ignition coil retaining screws and

remove ignition coils and radio ignition
interference capacitors from mounting bracket.
Save radio ignition interference capacitors for
reinstallation with ignition coils.
Installation
1. Position ignition coils and radio ignition
interference capacitors to mounting bracket.
2. Install ignition coil retaining screws and tighten to
5-7 N·m (45-6 1 1b-in). -
FRONT OF
3. Apply Silicone Brake Caliper Grease and _.- ENGINE
Dielectric Compound D7AZ- 1 9A33 1 -A 851 92-A
(Motorcraft WA- 1 0) or equivalent meeting Ford
specification ESE-M 1 C 1 7 1 -A to all ignition wire
spark plug boots. Part
!"""' 4. Install each ignition wire connector to the proper Item Number Description
terminal on the ignition coil. Make sure boots are ScRadiCapacireowI(gt8onriReq't(io2nReq'dIn)terdf)erence
5.
fully seated.
Connect the engine control sensor wiring to the
ignition coils and radio ignition interference
231 N606502-
1182801029 S309
capacitors.
45 1122043043 IILIgggHnnniiitttiiiooonnn CoiCoiCoilll (MouMou2 Req'nnttiinndgg)StStrraap,p,
A - TiRHLb-ghlnt)en to 5-7 N·m (45-61
Bracket, Ignition Coil
Removal
1. Remove ignition coils ( 1 2029) as described.
2. Remove power steering oil reservoir (3A697)
from LH ignition coil mounting bracket. Refer to
Section 1 1-Q2.
3. Remove ignition coil mounting bracket retainers
and ignition coil mounting brackets from the
engine front cover (60 1 9).
Installation

2. lighten ignition coil mounting bracket retainers to Removal

20-30 N·m ( 1 5-22 1b-ft). 1. CAUTION: The generator (GEN)( 1 0300) must
be removed to allow for accessibility of the
ignition wires that are routed below the
generator.
1 -
FRONT OF CAUTION: Do not pull on the ignition wire
--- ENGINE directly as the wire may separate from the
connector inside the boot.
When removing ignition wires from spark plug
( 1 2405), use Spark Plug Wire Remover
T74P-6666-A. Grasp and twist the ignition wire
spark plug boot back and forth on the spark plug
insulator to free the boot.
A6626-D

connector inside the boot.
Disconnect the ignition wire from the ignition coil
( 1 2029) by squeezing the locking tabs and
twisting while pulling upward.
- -
Q
85193-A
SQUEEZE
TOLOCKIREMOVENG TABS
Part
84400-8
231 N80880
N80712043959-1-SS309309 StBolutd Bolt
RHIEngngitiinoenFrMouontnCovtingeBrr acket, 3. Open ignition wire separators ( 1 2297) and
remove ignition wire.
Installation
564 6N80411020194378-S309 NuILgHntit(i4onReq'CoildMou) nting Strap, 1. Whenever an ignition wire is removed from a
spark plug or ignition coil or a new ignition wire is
installed, coat the entire interior surface of the
boot with Silicone Brake Caliper Grease and
A - Dielectric Compound D7AZ- 1 9A33 1 -A
Lb-TighFte)n to 20-30 N·m (15-22 (Motorcraft WA- 1 0) or equivalent meeting Ford
specification ESE-M 1 C 1 7 1 -A with a small, clean
tool prior to installation.
Ignition Wires

Spark Plug Wire Remover T74P-6666-A

03-078-6 Ignition, Electronic-4.6L (2V) 03·078-6
2. CAUTION: Proper installation of ignition 3. Route ignition wire through ignition wire
wires is critical to vehicle operation. If any separators and close ignition wire separators.
ignition wire is not properly installed on 4. NOTE: Ignition wire spark plug boot must be
spark plug or ignition coli, both spark plugs positioned 90 degrees from crankshaft centerline
connected to that Ignition coil may not (outboard and forward) to make sure the boot
operate under load. seal is fully seated.
Install each ignition wire to the proper terminal on Connect ignition wire to spark plug.
the ignition coils. The terminals on the ignition
coils are numbered. Make sure the boots are fully
seated and that both locking tabs are engaged.

Ignition Wire Installation
NOTE: MAKE SURE WIRE NOTE: REVERSE LETTERS

SEPARATOR IS FULLY AND NU-ERS ON IGNITION
ENGAGED ON STUD WIRES INDICATE INSTALLATION
LOCATIONS ON CORRESPONDING
REVERSE LETTERS AND NUMBERS
ON ENGINE.
VIEW D
CRANKSHAFT { CRANKSHAFT ct
VIEW C VIEW D
TYPICAL RH TYPICAL LH
SECTION E
FRONT OF -
-- ENGINE
NOTE: MAKE SURE IGNITION

COIL RETAINER CLIP IS
FULLY ENGAGED ON
COIL TOWER
AB0061-A

Part Part
231 6049112228976 IIggnniittiioonn WiWirree Separ(8 Req'adto)r 67 1182801029 RadiICapac

ognitionIigtCoionrit(iol2, nRHReq'Interdf)erence
45 1122040295 CylSparinkderPluHeadg (8 Req'd) A -
TiLb-ghlnt)ento 9-20 N·m (80-177
(Continued)
Ignition Coil, LH
Radio Ignition Interference Capacitor
Part
Removal Item Number Description
1. Disconnect engine control sensor wiring 34 1122004329 IBrIggnnaiittcketiioonn CoiCoi, LHll Mou(2 Req'ntindg)
( 1 2A58 1) from radio ignition interference
capacitors ( 1 880 1) at connectors.
2. Remove retaining screws and radio ignition 5 12043 IBrTigngaihtcktioeenntCoit,oRH5-l Mou7 N·mnti(n45-g 61
interference capacitors from ignition coils
( 1 2029) and mounting bracket. -
A
Installation
Lb-ln)
2. lighten retaining screws to 5-7 N·m (45-6 1 1b-in).
�0
Spark Plugs
Removal
1. Disconnect ignition wires from spark plugs
( 1 2405) as described.
I
2. Loosen spark plugs a 1 I 4 turn and remove dirt or
foreign material from spark plug areas of cylinder
heads (6049) with compressed air.
3. NOTE: Three different styles of
platinum-enhanced spark plugs are produced for
the 4.6L-(2V) engine. Each plug has a different
part number and use. AWSF-32P spark plugs
have a platinum-enhanced center electrode and
are used in cylinders 5, 6, 7 and 8. AWSF-32PG
spark plugs have a platinum-enhanced ground
(side) electrode and are used in cylinders 1 , 2, 3
and 4. If any spark plug is removed and
re-installed, it must be installed in the same
cylinder from which it was removed. If any spark
plug is replaced, use only spark plugs with part
number AWSF-32PP as listed on the vehicle
emission calibration identification label. This
replacement spark plug has double platinum
enhancement on both the center and ground
- electrode and may be used in all eight cylinders.
FRONT OF
_.- ENGINE Remove spark plugs.
851 92-A 4. NOTE: Refer to the Spark Plug Inspection Chart
to determine the condition of the spark plugs.
Part Check and adjust spark plug gap as described.
Item Number Description Installation
21 N80802 ScRadireowI(gt8onriReq'tion dIn)terference

18801 7-S309 Capaci 1. Follow removal procedure in reverse order.
(Continued)

03-078-9 Ignition, Electronic-4.6L (2V} 03-o7B-9
REMOVAL AND INSTALLATION (Continued) CLEANING AND INSPECTION
2. Tighten spark plugs to 9-20 N·m (80- 1 77 1b-in). ·Spark Plugs

Inspect the electrode and outer surface. Refer to
Spark Plug Inspection Chart. Replace spark plugs
_,....- ( 1 2405) if they are worn or damaged.
FRONT OF Use the following inspection chart when inspecting
ENGINE
_......- spark plugs.
NOTE: USE
SPARK PLUG, LH 12405 CYLINDER HEAD, RH

4 REQ'D 6049
HAND START AND
TIGHTEN TO 9-20 N·m
(80-177 LB-IN)
FRONT OF.---
__....- ENGINE A80054-A

03-078- 1 0 Ignition, Electronic-4.6L (2V) 03-078- 10
Spark Plug Inspection Chart
GAP BRIDGED OIL FOULED
IDENTIFIED BY DEPOSIT BUILD IDENTIFIED BY WET BLACK

UP CLOSING GAP BETWEEN DEPOSITS ON THE INSULATOR
ELECTRODES. SHELL BORE ELECTRODES.
CAUSED BY OIL OR CARBON CAUSED BY EXCESSIVE OIL
FOULING. CLEAN SPARK PLUG. ENTERING COMBUSTION CHAMBER
THROUGH WORN RINGS AND
PISTONS, EXCESSIVE CLEARANCE
BETWEEN VALVE GUIDES AND
STEMS, OR WORN OR LOOSE
BEARINGS. CORRECT OIL
PROBLEM. REPLACE SPARK PLUG.
CARBON FOULED NORMAL PRE-IGNITION
IDENTIFIED BY BLACK, DRY FLUFFY

CARBON DEPOSITS ON INSULATOR
TIPS, EXPOSED SHELL SURFACES
AND ELECTRODES. IDENTIFIED BY MELTED ELECTRODES
CAUSED BY TOO COLD A PLUG, IDENTIFIED BY LIGHT TAN OR GRAY AND POSSIBLY BLISTERED INSULATOR.
DIRTY AIR CLEANER, DAMAGED DEPOSITS ON THE FIRING TIP. METALLIC DEPOSITS ON INSULATOR
FUEL PUMP, TOO RICH A FUEL INDICATE ENGINE DAMAGE.
MIXTURE OR EXCESSIVE IDLING.
CLEAN SPARK PLUG.
OYERHEAnNG FUSED SPOT DEPOSIT
IDENTIFIED BY MELTED OR SPOTTY

DEPOSITS RESEMBLING BUBBLES OR
BLISTERS.
CAUSED BY SUDDEN ACCELERATION.
CLEAN SPARK PLUG.
�..
03-078- 1 1 Ignition, Electronic-4.6L (2V) 03-078-1 1
Ignition Coil LUBRICANTI ADHESIVE/CLEANER SPECIFICATIONS

Wipe the ignition coil towers with a clean cloth Ford
dampened with soap and water. Remove any soap film Description Part Number Specification
and dry with compressed air. Inspect ignition coil Silicone Brake D7AZ· 19A33 1-A ESE-M 1 C 1 7-A
( 1 2029) for cracks, carbon tracking or dirt. Caliper Grease and
Dielectric
Compound
Ignition Wires TORQUE SPECIFICATIONS

Wipe the ignition wires with a clean , damp cloth prior Description N·m Lb-Ft Lb-ln
to inspection. Without removing the ignition wires from -
Crankshaft Position Sensor 8- 1 2 7 1 - 1 06
the spark plugs ( 1 2405) or ignition coils ( 1 2029), Screw
inspect the ignition wires for visible damage such as
-
cuts, pinches, cracks or torn boots. Replace only the Ignition Coil Retaining Screws 5· 7 45-6 1
-
damaged ignition wires. Ignition Coil Mounting Bracket 20·30 15-22
Retainers
-
Spark Plugs 9-20 80- 1 77
ADJUSTMENTS Capacitor Retaining Screws 5-7 -
45-61
Spark Plugs
Using a suitable spark plug gap tool, adjust spark plug
gap to 1 .3- 1 .4 mm (0.052-0.056 inch) following tool
manufacturer's instructions. SPECIAL SERVICE TOOLS REQUIRED
Tool NumberI
T74P-6666-A
Ignition Timing
�
Spark Plug Wire Remover
Base ignition timing is referenced to the position of the
crankshaft position sensor (CKP sensor)(6C3 1 5) and
is set at 10 ± 2 degrees before top dead center T7-A
(BTDC) and is not adjustable.
SPECIFICATIONS
IGNITION SYSTEM SPECIFICATIONS

Spark Plug Type AWSF-32PP"
Spark Plug Gap 1 .3· 1 .4 mm (0.052-0.056 inch)
Firing Order 1 ·3· 7· 2·6·5·4-8
Ignition Timing 10±2 Degrees BTDC (NOT
ADJUSTABLE)
a Three different styles of platinum-enhanced spark plugs are
produced for the 4.6L-(2V) engine. Each plug has a
different part number, and use. AWSF-32P spark plugs have
a platinum-enhanced center electrode and are used in
cylinders 5, 6, 7 and 8. AWSF-32PG spark plugs have a
platinum-enhanced ground (side) electrode, and are used in
cylinders 1, 2, 3 and 4. If any spark plug is removed and
re-installed, it MUST be installed in the same cylinder from
which it was removed. If any spark plug is replaced, use
only spark plugs with part number AWSF-32PP as listed on
the vehicle emission calibration identification label. This
replacement spark plug has double platinum enhancement
on both the center and ground electrode and may be used in
all eight cylinders.

03-08- 1 Engine Emission Control 03-08- 1
r' SECTION 03-08 Engine Emission Control

VEHICLE APPLICATION ••.••• •••• . . . • • . . . . . . • • • . • • . . • • . . .•••.•.••... 03-oS- 1 IN-VEHICLE SERVICE {Cont'd.)
DESCRIPTION AND OPERATION EGR Valve . . • . . . . . • • • . . . . . . . . . . •. . . . . . • . . . • . . . . . . . • • • . . . • • • . . . • • . . . . • . • • 03-o8-6
Exhaust Emission Control System •••••.•••. •••••••••••••••• 03-08-3 EGR Valve to Exhaust Manifold Tube . . . . • • • . . . ••••..•••••• 03-oB-7
Exhaust Gas Recirculation {EGR) System ... ..••...•..•• 03-oS-2 PCV Hoses ••......•••.••.....•••..•.......••......•••••.•••••••.••••..• 03-o8-4
Positive Crankcase Ventilation {PCV) PCV Valve • • . • • • . • • • . . • • • . • • . . ••••••.••..•••.••••• • . . . . . •• . . . . . • • . . . • • • . 03-oB-3
System • • . . •••••• . . • • . . ••••••••••• . . . •• • . . • • . . • • . • • • • . • . . • . . • • . . • • . . • • 03-o8-1 CLEANING AND INSPECTION
DIAGNOSIS AND TESTING EGR Vacuum Regulator Solenoid •••.••••..••.•••••.•...••• 03-o8-1 1
Engine Emission Controi • . . • • . . •• • . . • • • • . • . . • • • . • .•••••••.•••••• 03-o8-3 EGR Valve . . • . . . . . • • • . . . . . . • • • . . • . . . • . • • • . • • . . • . . . • • • . . . . . . •• • • . • . . . • • 03-o8- 1 1
IN-VEHICLE SERVICE PCV Valve ••..•..••...••...•...••..•...•..••.•••.••...•••••.•.••.••••• 03-oS-1 1
EGR Backpressure Transducer • . . • . . • . . •• . • • • . . • . . •• . . •••.••
03-oS-9 SPECIFICATIONS . . . • . . . . . . . . • • • . . • . .•••..•• •••••.•.•••...•••••• . . . . • 03-oB-1 1
EGR Vacuum Regulator Solenoid • . . ••••••••• . . • . . . • • . . • • . . 03-o8- 10
VEHICLE APPLICATION
Thunderbird, Cougar
Positive Crankcase Ventilation (PCV) System Typical PCV Air Flo w Diagram
CAUTION: Do not remove the PCV system from
the engine. Operating engine without PCV
system will reduce both fuel economy and engine
ventilation. This will weaken engine performance
and shorten engine life.
The positive crankcase ventilation (PCV) system
cycles crankcase gases back through the engine
where they are burned. The positive crankcase
ventilation valve (PCV valve)(6A666):
• regulates the amount of ventilating air and blow-by
fuel vapor to the intake manifold (9424).
• prevents backfire from traveling into the crankcase.
A1 8842-B
• is mounted in a vertical position.
Part
1
3
2 65826758
-
ToValCr{ParaAivntekrofcCovClas6758)eaneerVener Outilatlteiot nTuTubebe
564 9E926
94246A666 ThIntarokteleManBodyifold
VenPositliavteioCrn Valankvcease

03-08-2 Engine Emission Control 03·08·2
Exhaust Gas Recirculation (EGR) System Differential Pressure Feedback EGR Flow Diagram
The exhaust gas recirculation {EGA) system is
designed to:
• reintroduce exhaust gas into the combustion cycle.
• lower combustion temperatures.
• reduce the formation of nitrous oxide {N20).
The amount of exhaust gas reintroduced and the
timing of the cycle varies by calibration.
liming and volume are controlled by the following:
• engine rpm
• engine vacuum
• exhaust system backpressure
• engine coolant temperature
• throttle position
The EGA valve {EGA valve){9D475) is vacuum
actuated. The vacuum hose routing diagram is shown
on the vehicle emission control information decal.
The EGA system is a differential pressure feedback
EGA system. Differential pressure feedback EGA is a
subsonic closed loop EGA system. The differential
pressure feedback EGA system:
• monitors EGA flow rate by the pressure drop across
the metering orifice.
• uses an EGA backpressure transducer as the
/
feedback device.
•
_
controlled pressure is varied by the valve movement
using vacuum output of the EGA vacuum regulator
solenoid.
e
V9925-A
• uses the EGA valve only as a pressure regulator
rather than as a flow metering device.
Part
• allows for a more accurate assessment of EGA flow Item Number D escription
requirements.
-
231 12A650
-
AnPoweralogtrVolaintConagetIrnopluModut le
DuEGASolteynCyclVacuoid eumOuRegutput lator
45 9J459
-
VacuIntakeumVacuSouurmce
-
67-
-
EGRFi o w
89-
MetExhaeurisntgFlOrowifice (Part of
90475)
-
1110-
-
ExhExhaauusstt PrPreess uurree Input
1123 9J460 ConTrEGAantsrBackdoul ceerdpPrreessuurere Input
-
1145 90475 VacuEGA ValumvOue tput

03-08-3 Engine Emission Control 03-08-3
Exhaust Emission Control System

Vehicle Emission Control Information Decal
Vacuum hoses on the engine use a color stripe to aid in
hose routing checks. The stripe will usually be the
same color as on the vehicle emission control
information decal, but the correct vacuum hose routing
must be verified by using the correct component
connections shown on the vehicle emission control
information decal.
Typical Vehicle Emission Control Information Decal
( f.:/
'-'/- J -)
ORf:: F or d rn1 1 0 to r C o rn p a n y V E H I C L E E l .l i S S I O t J
c o r n R D L l t J f O H I . l !IT I O ; J
Thll V8hlde Is equipped wllh electronic engine control ---
systlms. Engine Ide speed, Idle mlxlure, and Ignition

lln*'CI .,. not adJU8Iable. See Powertraln Conlroll
Emlulona Diagnosis Manual for addlllonal lnfonnallori.
To check engine liming 181 parking brake and block

wheels. Engine must be at normal operallng
temperature, transmla8lon In neulral, and
accesries
so Olf.
=-, t
(1) Tum Olf engine.
.I
(2) Dleconnect the In-line Spout Connector (oOII ).
(3) Re-start previously warmed-up �·
(4) V.,tty 1hat the Ignition timing Is 10 BTDC. If
.-bm .
I! I �I
not ... shop manual.
(5) Tum engine Olf and restore eleclrlcal connecl.lon ��....--....
... ....
... ...;.;
-� ; "'.;;
- ��---=�
Glp: .052·.058
•
I c
'i Use SAE 5W-30 01 API Se1v1ce SG Ene1gy eor.vq U.
•
��----�
J D U
A18847-A
Engine Emission Control 2. Remove positive crankcase ventilation valve from

PCV valve crankcase ventilation grommet
(6A892).
Manual 1 •
3. Inspect PCV valve and crankcase ventilation
grommet for deterioration. Replace if necessary.
IN-VEHICLE SERVICE
PCV Valve
3.8L Engine
Removal
1. Disconnect crankcase ventilation tube (6758)
from positive crankcase ventilation valve (PCV
valve)(6A666).

Installation
VIEW A
1. Follow removal procedure in reverse order. �
FRONT OF ENGINE
_.,..-
----
FRONT OF ENGINE
---
A24293-A
Part
231 94246A666
6A892 PosVenCrIntaaknitkeliavcManetasioCrneiaValVenfonkldvct,easiUpperlaetion
45 6582381188 ValHosGrovmmetee(Cov2 Req'er,dRH)
6 6758 Crankcase Ventilation Tube
�
4.6L (2V) Engine
Removal FRONT OF NE
/
1. Remove air cleaner outlet tube (98659) as
described in Section 03- 1 2 . A24288-A
2. Disconnect crankcase vent connector and hose
(6C324) from positive crankcase ventilation Part
valve. Item Number Description
3. Remove positive crankcase ventilation valve from 12 6A666
crankcase ventilation grommet in RH valve cover
(6582). 6C324 VenCranPosadniHostkliavcasetieoCrneaValVennkvcasteCone nector
4. Inspect positive crankcase ventilation valve and
crankcase ventilation grommet for deterioration. CarCrabnkucreastoerGasVentkileattion Tube
Replace if necessary.
Installation
453 944767586582 ValValvvee CovCoveerr,, RHLH
1. Follow removal procedure in reverse order. 67 65826A892 GrCraonmmetkcase Ventilation
PCV Hoses
Crankcase Ventilation Tube-3.8L Engine
Removal
from upper intake manifold (9424).

2. Disconnect crankcase ventilation tube from

positive crankcase ventilation valve (PCV VIEW A
valve)(6A666) and remove from vehicle. ___,..
FRONT OF ENGINE
3. Inspect crankcase ventilation tube and hoses for �
deterioration. Replace if necessary.
Installation
----
FRONT OF ENGINE
---
A24293-A
Part
9424
231 6A892
6A666 PosVenCrIntaaknitkeilavcManetasioCrneiaValVenfonkldvct,easiUpperlaetion
45 6582381188 ValGrHosovmmetee(Cov2 Req'er, dRH) FRONT OF
/
� NE
6 6758 Crankcase Ventilation Tube A24288-A
Crankcase Ventilation Tube- 4.6L Engine Part

Removal Item Number Description
2.
described in Section 03- 1 2 .
Remove crankcase ventilation tube from L H valve
12 6A666
6C324 VenanPosCrdaniHostkilavcetasieoCrneaValVennkvcteasCone nector
cover (6582).
3. Inspect crankcase ventilation tube for
deterioration. Replace as necessary.
34 94476758 CarCrabnkurceastoer GasVentkileattion Tube
Installation
65826582
657 6A892 ValValvvee CovCoveerr,, LRHH
GrCraonmmetkcase Ventilation
Crankcase Ventilation Hose- 3.8L Engine
Removal
1. Disconnect crankcase vent connector and hose
(6C324) from LH valve cover and air cleaner
outlet tube.
2. Remove crankcase vent connector and hose.
3. Inspect crankcase vent connector and hose for
deterioration. Service as necessary.

Installation
VIEW A
FRONT OF ENGINE
___..-
_.,.-
CRANKCASE VENT .......
CONNECTOR FRONT OF
6C342 AND HOSE _..-
ENGINE
6L5H8VAL2 VE COVER
Crankcase Ventilation Hose-4.6L Engine
A24294-A
Removal
1. Removeair cleaner outlet tube as described in
Section 03- 1 2.
2. Disconnectcrankcase vent connector and hose
from positive crankcase ventilation valve and
throttle body adapter.
3. Inspect crankcase vent connector and hose for
deterioration. Replace if necessary. FRONT OF
/
� NE
Installation
A24288-A
Part
12 6C324
6A666 VenCranPosadniHostklivacetasieoCrneaValVennkvcteasCone nector
34 67589A589 ThCrraontkcleasBodye VenAdapttilatioenrTube
657 65826A892
6582 ValValvvee CovCoveerr,, RHLH
GrCroanmmetkcase Ventilation
EGR Valve
Removal
(90477) from EGR valve (EGR valveX9D475}.
2. Disconnect vacuum hose from EGR valve.

3. Remove two retaining bolts for the EGR valve. Installation

4. Remove EGR valve and EGR valve gasket 1. Clean EGR valve sealing surfaces with a
(9D476) from vehicle. plastic-tipped scraper to remove any residual
EGR valve gasket material.
EGR Valve- 3.8L Engine 2. NOTE: Do not tighten EGR valve to exhaust
BOLTIGHTENT D TO 20-30 N·m manifold tube nut on EGR valve at this time.
2REQ' ___...- Position EGR valve to exhaust manifold tube into
FRONT OF ENGINE
EGR valve and loosely connect EGR valve to
(15-2 LB-FT) ....---
exhaust manifold tube nut to EGR valve.
EGR VALVE 90475 3. Position EGR valve gasket and EGR valve.
4. Install two bolts retaining EGR valve. lighten
bolts to 2Q-30 N·m ( 1 5-22 1b-ft).
5. lighten exhaust manifold tube nut to 35-45 N·m
(26-33 lb-ft).
6. Connect vacuum hose to EGR valve.
EGR Valve to Exhaust Manifold Tube

3.8L Engine
Removal
described in Section 03- 1 2 .
9UPPER424 INTAKE MANIFOLD A24295-A 2. Disconnect EGR backpressure transducer hoses
from EGR valve to exhaust manifold tube
EGR Valve- 4.6L Engine (9D477).
THROTIL E at EGR valve (EGR valve)(9D475) and EGR valve
� BODY9A589ADAPTER tube to manifold connector (9F485).
FRONT OF ENGINE
........- Installation
9EGRD47VAL6 VE GASKETBOLT
TI(215REQ'G-HTEN2 LDB-TOFT)20-30 N·m
A24289-A

2. lighten EGR valve to exhaust manifold tube to 7. Disconnect EGR valve to exhaust manifold tube
EGR valve and EGR valve tube to manifold from the EGR valve and remove the EGR valve to
connector to 35-45 N·m (26-33 lb-ft). exhaust manifold tube from the vehicle.
___,-
9EGR0475VALVE FRONT OF ENGINE
_.,......
Part
1 EGRVal
NOTE: EXHAUST MANIFOLD
REMOVED FOR CLARITY A24296-A
23 90475
94309F485 ExhEGRConanValeuscttvvoManeer Tuifboeldto, RHManifold
4.6L Engine
Removal
1. Raise vehicle on hoist. Refer to Section 00-02.
45 90477
-
ManiTrEGAEGAansfValBackodludcvTuereptrbHosoeeExhs eursaeu(Psart t of
2. CAUTION: Use care not to damage EGR valve 9JTrEGRa4n60)sBackducerpres ure
tube to manifold connector.
NOTE: Hold EGR valve tube to manifold
connector with a wrench while disconnecting
6 9J490
A -
EGR valve to exhaust manifold tube.

Disconnect EGR valve to exhaust manifold tube
from EGR valve tube to manifold connector.
B -
Lb-TiLb-TigghhFFttee))nn ttoo 46-35-4655 N·N·mm ((326-4-3437
3. Lower vehicle. Installation
4. Disconnect EGR backpressure transducer hoses 1. NOTE: Do not tighten EGR valve to exhaust
from EGR valve to exhaust manifold tube. manifold tube nut on EGA valve at this time.
5. Disconnect accelerator cable (9A758) and speed Position EGR valve to exhaust manifold tube into
control actuator cable (9A825) from the throttle EGR valve and loosely connect EGR valve to
body (9E926). exhaust manifold tube nut to EGR valve.
6. Remove accelerator cable bracket retainers and 2. Raise vehicle.
position accelerator cable bracket (9723) with
the accelerator cable and the speed control
actuator cable out of the way.

3. NOTE: Hold EGR valve tube to manifold

connector with a wrench while tightening EGR
valve to exhaust manifold tube nut.
FRONT OF ENGINE
/
Connect EGR valve to exhaust manifold tube to
EGR valve tube to manifold connector. lighten nut �
to 35-45 N·m (26-33 1b-ft}.
4. Lower vehicle.
5. lighten EGR valve to exhaust manifold tube nut to
the EGR valve to 35-45 N·m (26-33 lb-ft}.
6. Position the accelerator cable bracket. Install and
tighten retainers to 8- 1 2 N·m (7 1 - 1 06 I b-in}.
7. Connect the accelerator cable and speed control
actuator cable to the throttle body.
8. Connect EGR backpressure transducer hose to
the EGR valve to exhaust manifold tube.
EGR Backpressure Transducer

3.8L Engine
Removal
1. Disconnect fuel charging wiring (9D930} from
EGR backpressure transducer.
A24297-A
2. Disconnect EGR backpressure transducer hoses
from EGR backpressure transducer.
Part
3. Remove EGR backpressure transducer retaining Item Number Description
nuts and EGR backpressure transducer from
-
transducer mounting bracket (9J432}.
4. If necessary, remove the EGR vacuum regulator
solenoid as described and the transducer
mounting bracket from the upper intake manifold
231 9J9J446032 TrBrEGRNuatncksBackdeutcerprMoues unrteing
(9424}. TrNuatn(s2dReq'ucerd)
-
Installation
45 9J459 EGRSolNutenVacuoid um Regulator
2. If removed, tighten retaining nuts for the -
67 9E498
transducer mounting bracket as illustrated.
lighten EGR backpressure transducer retaining
nuts to 5-7 N·m (45-6 1 1b-in}.
89 9E926 ConThMaironttrEmiolel ConBodys inoenctVacuor um
A
9424
-
ITiLb-ntgahFktee)nManto 1if5o-l2d0, UpperN·m (1 1-14
-
B
c -
TiTiLb-gghhlntt)eenn ttoo 8-5-712N·N·mm(4(5-716-1106
4 6L Engine
.
Lb-ln)
Removal
1. Disconnect fuel charging wiring connector from
EGR backpressure transducer.
2. Disconnect EGR backpressure transducer hoses
from EGR backpressure transducer.
3. Remove EGR backpressure transducer retaining
nuts and EGR backpressure transducer from
transducer mounting bracket.

03-08- 10 Engine Emission Control 03-08- 10
4. If necessary, remove the transducer mounting 2. Disconnect main emission vacuum control
bracket from the RH cylinder head (6049). connector (9E498) from EGA vacuum regulator
solenoid.
Installation
3. Remove retaining nuts and EGA vacuum regulator
1. Follow removal procedure in reverse order. solenoid from mounting bracket.
2. If removed, tighten retainers for the transducer
mounting bracket to 8- 1 2 N·m (7 1 - 1 06 lb-in). Installation
lighten EGR backpressure transducer retaining 1. Follow removal procedure in reverse order.
nuts to 5-7 N·m (45-6 1 1b-in). 2. lighten retaining nuts to 5-7 N·m (45-6 1 1b-in).
4.6L Engine
---
FRONT OF ENGINE Removal
---
1. Disconnect fuel charging wiring from EGR
vacuum regulator solenoid.
2. Disconnect main emission vacuum control
connector from EGA vacuum regulator solenoid.
3. Remove retaining nuts and EGR vacuum regulator
solenoid from mounting bracket located at RH
side of engine front cover (60 1 9).
4. If necessary, remove mounting bracket.
Installation
2. If removed, tighten mounting bracket nut to 8- 1 2
N·m (7 1 - 1 06 lb-in).
3. lighten retaining nuts for EGR vacuum regulator
solenoid to 5-7 N·m (45-6 1 1b-in).
A24291 -A �
FRONT OF ENGINE
Part �
12 9J9J446032 TrBrEGRancksBackdeutcerprMoues unrteing
-
34 6049 TrNuatn(s2dReq'ucerd)
-
CylBoltinderHead, RH
6A5 -
-
TiTiNuLb-ggthhlntt)eennttoo 8-5-712N·N·mm(4(5-716-1106
-
B Lb-ln)
A24292-A
EGR Vacuum Regulator Solenoid
3.8L Engine Part
Removal
1. NOTE: On 3.8L engines, the EGR vacuum
regulator solenoid is located on a bracket
12 9J95492459 EGRSolMouennVacutoinidg BrumackReguet lator
attached to the upper intake manifold (9424).
-
Disconnect fuel charging wiring (9D930) from

EGR vacuum regulator solenoid.
34 6019
(Continued)
EnNutgi(n4eReq'Frondt)Cover
03-08- 1 1 Engine Emission Control 03-08- 1 1
Item
Part
N umber Description
EGRVACUUM
9REGUL
J459 ATOR SOLENOID
-
5A -
NuLb-Tigthlnte) n to 5-7 N-m (45-61
-
B
Lb-Tighlnte) n to 8-12 N·m (71-106
ELECTRICAL
CONNECTOR
PCV Valve
Cleaning of the positive crankcase ventilation valve
(PCV valveX6A666) is not recommended. The TOCONTROLCONNECTOR
MAIN EMISSION VACUUM
positive crankcase ventilation valve should be A2�A
replaced at the specified mileage intervals. Shake
positive crankcase ventilation valve and carefully
inspect for splits or cracks. If positive crankcase
ventilation valve does not rattle or is damaged, replace SPECIFICATIONS
positive crankcase ventilation valve.
Description N•m Lb-Ft Lb-ln
-
EGR Valve EGR Valve Bolts 20-30 1 5-22
-
Inspect the EGR valve (EGR valve)(9D475) for EGR Valve to Exhaust Manifold 35-45 26-33
Tube Nuts
blockage or contamination. Clean EGR valve using a
-
commercially available EGR valve cleaner following Transducer Mounting Bracket 8- 1 2 7 1 - 106
manufacturer's instructions. Inspect EGR valve for Retainers
vacuum leakage and replace if necessary. Transducer Mounting Bracket 15-20 1 1-14 -
Retaining Nut-to-Intake
Manifold Stud Bolt
-
Transducer Mounting 8- 1 2 7 1 - 1 06
EGR Vacuum Regulator Solenoid Bracket-to-Throttle Body Stud
Bolt (3.8L)
1. Disconnect the vacuum hoses from the EGR -
EGR Valve Tube Connector to 46-65 34-47
vacuum regulator solenoid.
Exhaust Manifold
2. Lightly blow air into the EGR vacuum regulator EGR Backpressure Transducer 5-7 -
45-6 1
solenoid and verify that air does not flow. to Bracket Nuts
3. Disconnect the fuel charging wiring (9D930) from EGR Vacuum Regulator 5-7 -
45-6 1
the EGR vacuum regulator solenoid. Solenoid to Bracket Nuts
4. Apply battery voltage and a ground to the EGR Accelerator Cable Retainers 8- 1 2 -
7 1 - 106
vacuum regulator solenoid at the connector. 4.6L (2V)
-
5. Lightly blow air into the EGR vacuum regulator EGR Vacuum Regulator 8- 1 2 7 1 - 106
solenoid and verify that air does flow through the Solenoid Mounting Bracket Nut
4.6L (2V)
EGR vacuum regulator solenoid.
6. If air does not blow through the EGR vacuum
regulator solenoid, replace the EGR vacuum
regulator solenoid as described.

03- 12- 1 Intake Air System 03- 1 2-1
SECTION 03- 1 2 Intake Air System

VEHICLE APPLICATION . . • • • . • . . • • . . • • . . . •• • • • • • • • • • • • . • • . • • • . . • • . . . 03- 1 2- 1 REMOVAL AND INSTALLATION (Cont'd.)
DESCRIPTION AND OPERATION Engine Air Cleaner • . • • . ••••••••••••••• •••••••••••.••••.•••••••••••• 03-1 2-3
Air Cleaner Element ...••••..•••...•...•••.•••••.•.•..•..•.•.••..•• 03- 1 2- 1 Engine Intake Air Resonator •••••••• .••..•• .••••••.•••••..••..• 03-1 2-4
Intake Air System . . . • . . ••••••• • • • • •• • . • •• • • . . ••••••• . . • . . •• • • • • • • • • 03- 1 2- 1 CLEANING AND INSPECTION
DIAGNOSIS AND TESTING Air Cleaner Element • • • • • •• • ••••••••• ••••••••• . . • • . • • • . •••••••••••• 03- 1 2-4
Intake Air System • • . . . .•••• . • . • • • • • •• . •• • • . . . ••••••• . • • . . • • • • • • • • • • 03- 1 2- 1 Engine Air Cleaner • • . • • . • • • . • • . . • • • . . • • . ••••••.•••.••..•••.••.••.•• 03- 1 2-4
REMOVAL AND INSTALLATION Engine Air Cleaner Intake Air Tube ••••••••••••••••••••••••• 03-1 2-4
Air Cleaner Element ••••.• . . • • • . . • • . • . •• • • . • . . . . •• • • . . • . . ••.•••.••• 03-1 2-2 Engine Intake Air Resonator •••.••••••••••••..•••.•••.•••.••.•• 03-1 2-4
Air Cleaner Outlet Tube •...•••••••••••••..•••..•••.••.•..••••..•• 03-1 2-3 SPECIFICATIONS • • • • • • • • • •• • • • • • • • • • . • • . • • . • • . ••••.•••.••.•••..•••.•••
03-1 2-4
VEHICLE APPLICATION
Thunderbird, Cougar
Intake Air System • From the engine air cleaner, the filtered air travels
through the mass air flow sensor (MAF
NOTE: All engines are equipped with a replaceable
sensor)( 1 28579) and air cleaner outlet tube
dry-type air cleaner element (ACL element)(960 1 ).
(98659) to the throttle body.
The air induction system performs the following
• Supplies clean air to the positive crankcase
functions:
ventilation (PCV) system through a fitting on the air
• Supplies clean air to the throttle body (9E926). cleaner outlet tube.
• Allows outside air to enter from an engine intake air • On 3.8L engines, eliminates air induction noise by
resonator (9F763)-3.8L engine, or engine intake means of the sealed and tuned engine intake air
air tube-4.6L (2V) engine, through an opening in resonator.
the front fender apron ( 1 6054) to the engine air
cleaner (ACL)(9600).
• Filters air in the engine air cleaner by means of the
air cleaner element.
Air Cleaner Element

The air cleaner element (ACL elementX960 1 ) is:
• a dry-type filtering element.
• chemically-treated, pleated paper air filtering
element which permits air flow through the air
induction system, filtering out unwanted dust, dirt
and debris.
Intake Air System

Manual1 •

03-12-2 Intake Air System 03-1 2-2

'-
1 r-
Air Cleaner Element Installation
Removal 1. Clean all inside surfaces of the engine air cleaner
(ACL)(9600) as described.
1. NOTE: Do not remove the mass air flow sensor
(MAF sensor)( 1 28579) from the air cleaner 2. Install the air cleaner element.
cover except for replacement. 3. Position air cleaner cover and install tabs into
Loosen engine air cleaner tube clamp (9C632) at three slots on inboard side of air cleaner body
air cleaner outlet tube (98659) to mass air flow and center the air cleaner cover. Snap the two
sensor and remove air cleaner outlet tube from retaining clips into locked position.
the mass air flow sensor. 4. Install air cleaner outlet tube to mass air flow
2. Release the retaining clips to remove the air sensor. lighten engine air cleaner tube clamp to
cleaner cover. Position air cleaner cover aside. 2.3-3.4 N·m (2 1-30 lb-in), on 3.8L engines. On
4.6L engines, tighten engine air cleaner tube
3. Remove air cleaner element (ACL clamp to 2.8-4.6 N·m (25-40 lb-in).
element)(960 1 ).
Intake Air Components-3.8L SFI Engine
/
FRONT OF
ENGINE
/'
V7542-D
Part Part
Item Number Description Item Nu m ber Description
231 9C632
98659 AiClEnragClmpineean(Ai2erReq'rClOueandtl)eetrTuTubbee 67 9F763 EnEnggiinnee AiIntraClkeeAianreResr onator
45 9601N621128579907-S2 MasAirClseAianr eFlroElweSenmenstor A8 9600
-
-
TiTiLb-gghhlntt)eennttoo 2.2.03--32..44 N·Nomm ((2181--3201
(Continued)
Nut (3 Req'd) Lb-ln)

03- 1 2-3 Intake Air System 03- 1 2-3
Engine Air Cleaner

Intake Air Components-4.6L SFI Engine Removal
...... 1. Loosen engine air cleaner tube clamp (9C632) at
FRONT OF mass air flow sensor (MAF sensor)( 1 2B579).
VEHICLE
2. Remove air cleaner outlet tube (98659) from
' mass air flow sensor.
( 1 2A58 1 ) from mass air flow sensor. On 4.6L
engines, disconnect engine control sensor wiring
from intake air temperature sensor (IAT
sensor)( 1 2A697).
4. Remove air cleaner element (ACL
element)(960 1 ) as described.
5. Remove engine air cleaner retaining nuts and
engine air cleaner (ACL)(9600).
Installation
2. Tighten engine air cleaner retaining nuts to
2.0-2.4 N·m ( 1 8-2 1 1b-in). On 3.8L engines,
tighten engine air cleaner tube clamp to 2.3-3.4
N·m (2 1 -30 lb-in). On 4.6L engines, tighten engine
air cleaner tube clamp to 2.8-4.6 N·m (25-40
Ib-in).
Air Cleaner Outlet Tube

3.8L Engine
Removal
1. Disconnect crankcase ventilation hose (6853)
from air cleaner outlet tube (98659).
AV0053-A
2. Loosen engine air cleaner tube clamps (9C632)
and remove air cleaner outlet tube from throttle
Part body (9E926) and mass air flow sensor (MAF
Item Number Description sensor)( 1 28579).
12 9C632
9C632 EnClAiragClmp-ineeantAioe-rTrClhOureoanttleletrBodyTube lnstaHation
TuAiSenrbCle-soetroanCl-MeaasrmpOus AitlertFlTuobwe 2. Tighten engine air cleaner tube clamp to 2.3-3.4
N·m (2 1 -30 lb-in).
453 9B659
1122AB579697 IMasSenntaksseoAirAirrFlTemper a t u r e 4.6L Engine
Removal
67 9601N621907-S2 AiNurtCl(3eReq'anerodElw)eSenmenstor 2.
and idle air control valve inlet tube from air
cleaner outlet tube.
Loosen engine air cleaner tube clamps and
89 96009A675 EnEnggiinnee IAintraClkeeAianreTur be remove air cleaner outlet tube.
Installation
1A0 9H308
- TiTiAiLb-ggrhhBypas
tlnt)eennttoos2.2.Val08--42ve..64InN-N·lemmt Hos((2185--e4201 1.
2.
Follow removal procedure in reverse order.
Tighten air cleaner outlet tube clamps to 2.8-4.6
B - N·m (25-40 lb-in).
Lb-ln)
03- 1 2-4 Intake Air System 03- 1 2-4
Engine Intake Air Resonator Engine Intake Air Resonator

Removal Visually check the engine intake air resonator (9F763)
for signs of leakage, damage, foreign material
1. Remove engine air cleaner (ACL)(9600) as blockage,or dust entry into the engine intake air
described. resonator. Replace if necessary.
2. Remove engine intake air resonator (9F763) from
RH front fender apron ( 1 6054).
Installation
Engine Air Cleaner Intake Air Tube
Visually check the engine intake air tube for signs of
leakage, damage, foreign material blockage or dust
entry into the engine intake air tube. Replace if
CLEANING AND INSPECTION necessary.
Air Cleaner Element

CAUTION: Cleaning the air cleaner element (ACL SPECIFICATIONS
element)(960 1) is not recommended.
Visually inspect the air cleaner element and the air TORQUE SPECIFICATIONS
cleaner cover and body for signs of dust or dirt leaking Description N·m Lb-ln
through holes in the filter media or past the end seals.
Place a light on the inside (clean side) of the air Engine Air Cleaner Tube Clamp 2.3·3.4 2 1 ·30
cleaner element and look through the filter media at (3.8L)
the light. Even the smallest hole is cause for Engine Air Cleaner Tube Clamp 2.8·4.6 25·40
replacement. (4.6L)
Also check the air cleaner element for deformed seals Engine Air Cleaner Retaining Nuts 2.0·2.4 18·21
or brittle spots that could fail under engine operation
and cause a hole. Discoloration only is not a cause for
replacement.
Engine Air Cleaner

Clean the air cleaner body and the cover with a solvent
or compressed air. Wipe the air cleaner body and
cover dry if a solvent is used. Inspect the air cleaner
body and cover for distortion or damage at the gasket
mating surfaces. Replace cover or body if they are
damaged beyond service.

03- 1 3-1 Evaporative Emissions 03- 1 3-1
SECTION 03- 1 3 Evaporative Emissions

VEHICLE APPLICATION •...... ....•......•....•...•..••...•.......•• 03- 1 3- 1 DIAGNOSIS AND TESTING
DESCRIPTION AND OPERATION Evaporative Emissions •••••••.••••••.••••••••••••••••••••••••••• 03-1 3-3
Evaporative Emission Canister ...•....•••..••..•..••...••..• 03- 1 3-2 REMOVAL AND INSTALLATION
Evaporative Emission Canister Purge Evaporative Emission Canister ••.••••.•••.• .•••. •••••••••••• 03-1 3-4
Valve . . . . . . . . . . •••••.•.• .•••••• . . . ••.••••••.•••.••••.••• . • • . . • • • • • • • • • • 03-1 3-2 Evaporative Emission Canister Purge
Evaporative Emission Control System ••••..•...•••••••••• 03- 1 3- 1 Valve . • • . . . • . . • • . . • • . . • • . . • • . . •• . . •• . ••••••••••••• • • • • . • • . . . •• . •••.•••• 03-1 3-6
Evaporative Emission Hose . . . . • . . . . • • • • . •• . . . • . . . . . . • • • . • . • • • • 03- 1 3-2 Evaporative Emission Hose . • • . . • .• • . .••••••••••••••••••••••••• 03- 1 3-6
Evaporative Emission Valve •...••...•••..••..•••..•...•..••... 03-1 3-3 Evaporative Emission Valve . • . . • • . • • • . • • • . . • • . • • . • • . ••••.•••.. 03-1 3-6
Fill Control Vent System •........••..••••••.•••.•...•..•••.•••••• 03- 1 3- 1 SPECIFICATIONS . . . • • • . • • . • • • • •••••• . . . . . • • . ••••••.•.••••••••••••••••• 03-1 3-6
Pressure and Vacuum Relief System • . .• . . • • . • • . . • • . . • • • • • 03- 1 3-3
System Components . . . • • . • • . • • . . . . • • . . . . • • . . • • • . • •• . • . . . • . . . • . . • 03- 1 3-2
VEHICLE APPLICATION
Thunderbird, Cougar
Evaporative Emission Control System • Parking after driving long distances in high
temperature conditions.
As a part of the fuel system, all vehicles are equipped
with fuel vapor evaporative emission control systems • Climbing long grades, especially while towing a
to meet federal requirements in effect at the time of trailer or while vehicle is fully loaded.
production. A normally functioning fuel tank evaporative emission
The fuel tank evaporative emission system allows for system will relieve the pressure build-up.
controlled release of fuel tank pressure through the No service is required if these conditions caused the
evaporative emissions canister (EVAP customer concern.
canister)(9D653). Under normal operating conditions,
this system will allow sufficient venting to prevent a A blocked fuel tank evaporative emission system can
build-up of internal fuel tank pressure. cause abnormal fuel tank pressure and must be
serviced.
Some operating conditions may cause temporary
build-up of internal fuel tank pressure. Some conditions Most component parts of the evaporative emission
are: control system are retained by a simple nut, bolt or
screw. If push pins are removed they must be replaced
• If the vehicle is parked after filling the fuel tank with new push pins. Refer to system illustrations for
(9002) on warm or hot days, the fuel is cool from specific part references.
underground storage and vaporizes rapidly when
warmed.
• Parking after driving over rough roads, washboard
or other harsh surfaces, after filling the fuel tank.
Agitation of fuel increases vaporization.
Fill Control Vent System • As the fuel level rises to cover the fill vent, pressure
Fill control and fuel vapor venting is accomplished by rising in the fuel tank causes fuel to back up and
the following method: shut off the fuel dispensing nozzle.
• The vent system is designed to provide an air
• A vent line attached to the fuel tank filler pipe (9034) space, approximately 10 percent of the fuel tank
extends inside the fuel tank (9002). volume, above the fuel level in a full fuel tank.
• The evaporative emission valve (98593) mounted in • The air space allows for thermal expansion of fuel
the top panel of the fuel tank and the evaporative and provides clearance between the fuel level and
emissions tube attached to the evaporative the evaporative emission valve, which is mounted in
emissions canister (EVAP canisterX9D653) also the top panel of the fuel tank.
contribute to fill control by controlling pressure in the
fuel tank.

• The clearance is sufficient to allow fuel vapor Typical Evaporative Emission Canister
venting through the evaporative emission valve
under all static and most dynamic vehicle
conditions.
System Components
Fuel Tank Evaporative Emission System
This system consists of:
• sealed fuel tank {9002) and fuel tank filler pipe
{9034).
• pressure I vacuum relief fuel tank filler cap {9030).
• evaporative emission valve {98593) with open flow
to vacuum and pressure.
• vapor tube and fuel vapor hoses.
• evaporative emissions canister {EVAP
canister){90653).
Engine Evaporative Emission System
This system consists of the following:
ACTICARBONVATED V3508-E
• evaporative emission canister purge valve {EVAP

canister purge valve){9C9 1 5)
• evaporative emissions canister Evaporative Emission Hose
System control and operation are accomplished The fuel vapor hoses transmit stored fuel vapor from
through five separate basic functions in the system: the evaporative emissions canister {EVAP
canister){90653) and evaporative emission canister
• fill control vent system purge valve {EVAP canister purge valve){9C9 1 5) to
• fuel tank evaporative emissions venting and storage the engine.
system
• evaporative emissions purge system
• pressure and vacuum relief {fuel tank filler cap and Evaporative Emission Canister Purge Valve
evaporative emission valve)
The evaporative emission canister purge valve {EVAP
canister purge valve){9C9 1 5):
• is in-line with the evaporative emissions canister
Evaporative Emission Canister {EVAP canisterX9D653) and controls the flow of
Fuel vapor emitted through the evaporative emission fuel vapors out of the evaporative emissions
valve {98593) is stored in a evaporative emissions canister.
canister {EVAP canister){90653). • is normally closed.

-
03- 13-3 Evaporative Emissions 03- 1 3-3
When the engine is shut OFF, vapors from the fuel tank Evaporative Emission Valve
(9002) flow into the evaporative emissions canister. Fuel vapor in the fuel tank (9002) is vented to the
After the engine is started, the evaporative emission evaporative emissions canister (EVAP
c�nister purge valve is engaged and opens, drawing canisterX9D653) through the evaporative emission
a1r through the evaporative emissions canister which valve (98593). The evaporative emission valve is
purges the fuel vapors from the evaporative emissions mounted in a rubber grommet at a central location in
canister into the engine. With the evaporative emission the upper surface of the fuel tank.
canister purge valve open, vapors from the fuel tank
are routed directly into the engine. A vapor space between the fuel level and the fuel tank
upper surface is combined with a small orifice and float
shut-off valve in the evaporative emission valve. These
prevent liquid fuel from passing to the evaporative
emissions canister. The vapor space also allows for
FROM thermal expansion of the fuel.
CANISTER -'-'�f---;�Lj,d;� TO ENGINE
Evaporative Emission Valve
TO
EVAPORAnYE
EMISSION
CANISTER
V7531-D
Pressure and Vacuum Relief System

Fuel Tank Filler Cap V5187-D
The fuel tank filler cap (9030) is a sealed cap with a
built-in pressure-vacuum relief valve and:
• fuel system vacuum relief is provided after negative DIAGNOSIS AND TESTING
1 . 7 kPa (0.25 psi).
• provides pressure relief above 14 kPa (2 psi). Evaporative Emissions
Under extreme conditions, the fuel tank filler cap Refer to the Powertrain Control I Emissions Diagnosis
operates as a check valve, allowing air to enter the Manual 1 for diagnosis of engine evaporative emission
fuel tank (9002) as fuel is used, while preventing fuel system individual components.
vapors from escaping the fuel tank through the fuel
tank filler cap.

03-13-4 Evaporative Emissions 03-13-4
Evaporative Emission Canister 3. Partially lower evaporative emissions canister

{EVAP canister){9D653) and disconnect
Removal evaporative emission hose, evaporative emission
1. Raise vehicle on hoist. canister purge valve {EVAP canister purge
2. Remove evaporative emission canister retaining valve){9C9 1 5) and front fuel supply return and
bolt. vapor tube {98286) from evaporative emissions
canister.
Installation
2. lighten evaporative emission canister retaining
bolt to 5.2-7.2 N·m {46-63 1b-in).
Evaporative Emission System-3.8L Engine
FRONT OF ENGINE
/
/
Part Part
231 9C919C987
10218 EvEvCanFroaanporporisttSieaardttPueiivveeOurgEmiEmieteValrssMember
ivooenn Hose 90665
89 96297 EvEvCanaaporporisteaarttBriivveeackEmiEmietss iioonn Hose
5 i 111102 96321
N388577- 5 PuEvFroasnhport PiSiandte(iv2IenReq'Emier Member
sd)ion Hose
564 90653
17757 S2
N800369- FrBolotntBumper 1
1A3 6758 0009
7 N610959-S2
(Continued)
CanBolEvatpori(s2teReq'artivedEmi) s ions -
TiLb-Crgahlnntk)ecnastoe5.Ven2-7t.i2laN-tiomn(Tu46-be63
Evaporative Emission System - 4.6L SFI Engine
/
FRONT OF ENGINE
/
/
FRONT OF VEHICLE
V�A
Part Part
1 6A666 Positive Crankcase 8 90665 Evaporative Emission
Ventilation Valve Canister Bracket
2 9C987 Evaporative Emission Hose 9 10218 Front Side Outer Member
3 17757 Front Bumper 10 96321 Evaporative Emission Hose
4 9C9 15 Evaporative Emission 11 9627 1 Evaporative Emission Hose
Canister Purge Valve 12 10009 Front Side Inner Member
5 N800369·S2 Bolt 13 N388577-S Push Pin (2 Req'd)
6 90653 Evaporative Emissions A -
Tighten to 5.2·7.2 N-m (46·63
Canister Lb-ln)
7 N6 10959·S2 Bolt (2 Req'd)
(Continued)

Evaporative Emission Hose 3. Remove evaporative emission tube push pin from
front bumper ( 1 7757).
Removal
4. Carefully disconnect evaporative emission
1. Remove evaporative emission canister purge canister purge valve from evaporative emission
valve (EVAP canister purge valve)(9C9 1 5) as hose and remove evaporative emission canister
described. purge valve.
2. Disconnect evaporative emission hose push pin
from front bumper ( 1 7757). Installation
3. Lower vehicle. 1. Follow removal procedure in reverse order.
4. On 3.8L engines, disconnect evaporative

emission hose from crankcase ventilation tube
(6758). On 4.6L engines, disconnect evaporative
emission hose from positive crankcase ventilation
valve (PCV valveX6A666). Refer to Section 1 0-0 1 for Evaporative Emission Valve
Removal and Installation procedure.
5. Remove two push pins from front side inner
member ( 1 0009) and carefully remove
evaporative emission hose from vehicle.
SPECIFICATIONS
Installation
1. Follow removal procedure in reverse order. TORQUE SPECIFICATIONS
1 Description N·m Lb-ln

Evaporative Emission Canister 5.2-7.2 46·63
Evaporative Emission Canister Purge Valve Retaining Bolt
Removal
2. Disconnect evaporative emission canister purge
r-- valve (EVAP canister purge valveX9C9 1 5) at
wire harness connector.

03- 13-5 Evaporative Emissions 03· 1 3-5
Evaporative Emission System-4.6L SFI Engine
/
FRONT OF ENGINE
/
/
FRONT OF VEHICLE
V�A
Part Part
1 6A666 Positive Crankcase 8 90665 Evaporative Emission
Ventilation Valve Canister Bracket
2 9C987 Evaporative Emission Hose 9 10218 Front Side Outer Member
3 1 7757 Front Bumper 10 9632 1 Evaporative Emission Hose
4 9C9 15 Evaporative Emission 11 9627 1 Evaporative Emission Hose
Canister Purge Valve 12 10009 Front Side Inner Member
5 N800369-S2 Bolt 13 N388577-S Push Pin (2 Req'd)
6 90653 Evaporative Emissions A -
Tighten to 5.2-7.2 N·m (46-63
Canister Lb-ln)
7 N6 10959-S2 Bolt (2 Req'd)
(Continued)

Evaporative Emission Hose 3. Remove evaporative emission tube push pin from
front bumper ( 1 7757).
Removal
4. Carefully disconnect evaporative emission
1. Remove evaporative emission canister purge canister purge valve from evaporative emission
valve (EVAP canister purge valve)(9C9 1 5) as hose and remove evaporative emission canister
described. purge valve.
2. Disconnect evaporative emission hose push pin
from front bumper ( 1 7757). Installation
3. Lower vehicle. 1. Follow removal procedure in reverse order.
4. On 3.8L engines, disconnect evaporative

emission hose from crankcase ventilation tube
(6758). On 4.6L engines, disconnect evaporative
emission hose from positive crankcase ventilation
valve (PCV valveX6A666). Refer to Section 1 0-0 1 for Evaporative Emission Valve
Removal and Installation procedure.
5. Remove two push pins from front side inner
member ( 1 0009) and carefully remove
evaporative emission hose from vehicle.
SPECIFICATIONS
Installation
1. Follow removal procedure in reverse order. TORQUE SPECIFICATIONS
1 Description N·m Lb-ln

Evaporati�e Emission Canister 5.2-7.2 46-63
Evaporative Emission Canister Purge Valve Retaining Bolt
Removal
2. Disconnect evaporative emission canister purge
� valve (EVAP canister purge valveX9C9 1 5) at
wire harness connector.

03- 14-1 Engine Controls, Electronic 03- 1 4- 1
SECTION 03- 1 4 Engine Controls, Electronic

VEHICLE APPLICATION •••••••••••••.••••.••.. ••••••••••••••.••••••• 03·14-1 REMOVAL AND INSTALLATION (Cont'd.)
DESCRIPTION AND OPERATION Engine Coolant Temperature (ECT)
Camshaft Position (CMP) Sensor ••••••. ••••••••••••••••••••• 03-14-3 Sensor • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •• • • • • • • • • • • • • • • • • • • • •
03-1 4-6
Engine Control Systems, Electronic ••••••••••.•••••••••••• 03- 1 4-1 Heated Oxygen Sensor (H02S) •••••••••••••••••••••••••••••• 03-14-7
Engine Coolant Temperature (ECT) Idle Air Control (lAC) Valve ••••••••••••••••••••••••••••••••••••• 03-14-5
Sensor ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 03-1 4-3 Intake Air Temperature (IAT) Sensor ••••••••••••••••••••••• 03-14-5
Heated Oxygen Sensor (H02S) •••••••••.•••••••••••••••••••• 03-1 4-3 Mass Air Flow (MAF) Sensor ••••••••••••••••••••••••••••••••••• 03-1 4-5
Idle Air Control (lAC) Valve .••••••••••••••••••••••••.••••••••••• 03-14-3 Powertraln Control Module (PCM) •••••••••••••••••••••••••• 03-14-4
Intake Air Temperature (IAT) Sensor ••••••••••••••••••••••• 03-14-3 Safeguards • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •• • • • • • • • •03-1 4-4
Mass Air Flow (MAF) Sensor ••••••••••••••••••••••••••••••••••• 03-14-2 Throttle Position (TP) Sensor ••••••••••••••••••• •••••••••••••• 03-14-4
Powertraln Control Module (PCM) •••••••••••••••••••••••••• 03-1 4-2 Vehicle Speed Sensor (VSS) ••••••••••••••••••••••••••••••••••• 03-14-9
Throttle Position (TP) Sensor ••••••••••••••••••••• •••••••••••• 03-1 4-2 CLEANING AND INSPECTION
Vehicle Speed Sensor (VSS) •••••••••••••••••••••••.••••••••••• 03-14-3 Idle Air Control (lAC) Valve ••••••••••••••••••••••••••••••••••••• 03-14·9
DIAGNOSIS AND TESTING ADJUSTMENTS
Engine Controls, Electronic • • . . ••••••••••••••••••••••••••••••• 03-14-4 Throttle Position (TP) Sensor ; ••••••• ••••••••••••••••••••••••• 03-14-9
REMOVAL AND INSTALLATION SPECIFICATIONS • • • • • • • • • • • • • • • • • • • • • •• • • • • • • • • • • • • • • • • • • • •• • • • • • • • • • • 03-14-9
Camshaft Position (CMP) Sensor •••.•••••••••••••••••••••••• 03-14-7 SPECIAL SERVICE TOOLS/EQUIPMENT •••••••••••••••••••• 03-14-9
VEHICLE APPLICATION
Thunderbird, Cougar
Engine Control Systems, Electronic • the Engine I Emissions Facts Book Summary
WARNING: DO NOT SMOKE, CARRY LIGHTED • the vehicle emission control information (VECI)
TOBACCO OR OPEN FLAME OF ANY TYPE WHEN decal
WORKING ON OR NEAR ANY FUEL-RELATED Additional engine performance checks are required to
COMPONENT. HIGHLY FLAMMABLE MIXTURES keep the exhaust emissions at the specified minimum
ARE ALWAYS PRESENT AND MAY BE IGNITED, pollutant levels.
RESULTING IN POSSIBLE PERSONAL INJURY.
Always refer to the Master Parts Catalog for parts
The sequential multi-port fuel injection (SFI) system is usage and interchangeability before replacing:
classified as follows:
• throttle body (9E926).
• multi-point
• component part of a throttle body.
• pulse time
• mass air flow controlled
To maintain the required exhaust emission levels, the
fuel metering system must be kept in good operating
condition and adjusted to the specifications listed
in I on the following sources:
• the applicable section of the Powertrain
Control I Emissions Diagnosis Manual1
• the applicable section of this group

03- 14-2 Engine Controls, Electronic 03- 1 4-2
Powertrain Control Module (PCM) Throttle Position Sensor - 3.8L Engine

THROTTLE BODY
(PCM)( 1 2A650) performs the following functions: 9E926
• accepts information from various engine sensors to
compute the required fuel flow rate necessary to
maintain a prescribed air / fuel ratio throughout the
entire engine operational range.
• sends out a command to the fuel injectors to meter
the appropriate quantity of fuel.
• determines and compensates for the age of the
vehicle and its uniqueness.
• automatically senses and compensates for changes
in altitude (for example, from sea level to
mountains).
Powertraln Control Module (PCM)

THROTTLE POSITION SENSOR
98989 V10125-A
Throttle Position Sensor - 4.6L Engine
�
FRONT OF ENGINE
THROTTLE POSITION
SENSOR 98989
V9929-A
Throttle Position (TP) Sensor

The throttle position sensor (TP sensor)(98989) is: V10120-A
• a potentiometer that provides a signal to the

powertrain control module (PCM)( 1 2A650) that is
directly proportional to the throttle plate position.
Mass Air Flow (MAF) Sensor
• mounted to the throttle body (9E926) and is
connected to the throttle plate shaft. The mass air flow sensor (MAF sensor)( 1 28579):
• is located between the air cleaner element (ACL
element)(960 1) and the air cleaner outlet tube
(98659).
• uses a hot wire sensing element to measure the
amount of air entering the engine. Air passing over
the hot wire causes it to cool.
• sends out an analog voltage signal to the PCM
( 1 2A650) to determine the intake air mass. The
PCM wiU then calculate the required fuel injector
pulse width in order to provide the desired air /fuel
ratio.
• hot wire sensing element and housing are calibrated
as a unit and must be serviced as a complete
assembly.

Intake Air Temperature (IAT) Sensor The heated oxygen sensors are located in the dual
The intake air temperature sensor (IAT converter Y pipe (5F250) below the exhaust manifolds
sensor)( 1 2A697): (9430).
• changes resistance in response to intake air

temperature.
• decreases resistance as the surrounding air
temperature increases, providing a signal to the
PCM ( 1 2A650) indicating temperature of the
incoming intake air.
INTAKE AIR
TEMPERATURE
(IAT) SENSOR
12A697
V10190-A
V9951-B
Camshaft Position (CMP) Sensor

3.8L Engine
Idle Air Control (lAC) Valve The camshaft position sensor (CMP sensor)( 1 2 1 26)
The idle air control valve (lAC valve)(9F7 1 5): is:
• is used to control engine idle speed (rpm). • is a single Hall-effect magnetic switch activated by
• is mounted on the throttle body (9E926) or the a single vane which is driven by the camshaft
throttle body adapter (depending upon application). (6250).
• allows air to bypass the throttle plate. The amount • provides camshaft position information which is
of air allowed to bypass is determined by the used by the powertrain control module
powertrain control module (PCM)( 1 2A650) and (PCM)( 1 2A650) for fuel synchronization.
controlled by a duty-cycle signal. 4.6L Engine
The camshaft position sensor (CMP sensor)(6B288)
is a variable reluctance sensor which is triggered by
the high-point mark on the camshaft sprocket (6256).
Engine Coolant Temperature (ECT) Sensor
The engine coolant temperature sensor (ECT
sensor)( 1 2A648):
• changes resistance in response to the engine Vehicle Speed Sensor (VSS)
coolant temperature. The vehicle speed sensor (VSS)(9E73 1 ) is a magnetic
• decreases resistance as the surrounding pickup that sends a signal to the powertrain control
temperature increases, providing a signal to the module (PCM)( 1 2A650). This VSS signal transmits
powertrain control module (PCM)( 1 2A650) that vehicle speed to the powertrain control module.
indicates the engine coolant temperature.
Heated Oxygen Sensor (H02S)

The heated oxygen sensors (H02S)(9F472) react
with the oxygen in the exhaust gases and generate a
voltage based on this reaction as follows:
• A low voltage indicates too much oxygen or a lean AD007D-A
condition.
• A high voltage indicates not enough oxygen or a rich
condition.

r DIAGNOSIS AND TESTING
Engine Controls, Electronic

Refer to the Powertrain Control / Emissions Diagnosis
Manual2• 2
Safeguards
1. NOTE: When the battery ( 1 0653) has been
disconnected or reconnected, some abnormal
drive symptoms may occur while the powertrain
control module (PCM)( 1 2A650) relearns its
adaptive strategy. The vehicle may need to be
driven 1 6 km ( 10 miles) or more to relearn· the
strategy. Refer to Section 1 4-Q 1 .
Always disconnect battery ground cable ( 1430 1 )
before servicing or replacing electronic engine
controls.
2. Follow diagnostic procedures as described in the
'
FRONT OF VEHICLE
Powertrain Control / Emissions Diagnosis
Manual2•
....... V9827·8
3. Disconnect electronic engine controls from wire

Part
harness before measuring for
continuity-resistance or energizing by using a Item Number Description
1 2-volt source. 1 N80 1846-S36MG Bolt (2 Req'd)
4. Never measure voltage or resistance directly at 2 12A659 Powertrain Control Module
the powertrain control module. Bracket
3 12A650 Powertrain Control Module
4 02038 Cowl Side Panel
A - Tighten to 2.7-3.7 N·m (24-32
Powertrain Control Module (PCM) Lb-ln)
Removal
to Section 14-Q 1 .
Throttle Position (TP) Sensor
2. Remove RH cowl side trim panel (02344) to
expose powertrain control module Removal
(PCM)( 1 2A650). 1. Disconnect battery ground cable ( 1 430 1). Refer
3. Loosen engine control sensor wiring to PCM to Section 1 4-Q 1 .
connector retainer bolt. 2. Disconnect fuel charging wiring (9D930) from
4. Remove engine control sensor wiring connector throttle position sensor (TP sensor)(98989).
from PCM. 3. Remove two throttle position sensor retaining
5. Remove PCM from powertrain control module screws.
bracket (PCM bracket)( 1 2A659) by pulling 4. Remove throttle position sensor.
powertrain control module downward.
Installation
Installation
2. lighten retaining screws to 2.8-3.8 N·m (25-33
2. lighten engine control sensor wiring connector lb-in).
retainer bolt to 2.7-3.7 N-m (24-32 1b-in).

03-14-5 Engine Controls, Electronic 03- 1 4-5
Throttle Position Sensor - 3.8L Engine 3. Loosen engine air cleaner tube clamps (9C632)
on air cleaner outlet tube (98659) and air cleaner
cover.
4. Disconnect air cleaner outlet tube from mass air
flow sensor.
5. Remove air cleaner cover and remove retaining
bolts from mass air flow sensor. Remove mass
air flow sensor from air cleaner cover.
Installation
2. Tighten retaining bolts for mass air flow sensor to
the air cleaner cover to 5-7 N-m (45-6 1 1b-in).
SCREW 2 REO'D 3. Tighten engine air cleaner tube clamps to 2.3-3.2
TIGHTEN TO 2.8-3.8 N·m N·m (2 1 -28 lb-in).
THROTTLE POSITION SENSOR (25-33 LB-IN)
98989 AV0039·A
Intake Air Temperature (IAT) Sensor

Throttle Position Sensor - 4.6L Engine
Removal
SCREW
2 REQ'D 1. Disconnect battery ground cable ( 1 430 1). Refer
TIGHTEN TO 2.8-3.8 N·m to Section 14-Q 1 .
(25-33 LB-IN) THROTTLE BODY 9E926
( 1 2A58 1 ) from intake air temperature sensor (JAT
sensor)( 1 2A697).
3. Turn intake air temperature sensor 90 degrees
counterclockwise and remove intake air
temperature sensor from air cleaner cover.
4. Inspect intake air temperature sensor (JAT
sensor) O-ring for damage or deterioration and
replace as necessary.
Installation
FRONT -- Idle Air Control (lAC) Valve

OF Removal
.......--vEHICLE
AV0052-A
to Section 1 4-0 1 .
2. Disconnect the fuel charging wiring (9D930) from
the idle air control valve (lAC valveX9F7 1 5).
Mass Air Flow (MAF) Sensor
3. Remove the two idle air control valve retaining
CAUTION: The mass air flow sensor hot wire
bolts.
sensing element and housing are calibrated as a
unH and must be serviced as a complete 4. Remove the idle air control valve and idle air
assembly. Do not damage the sensing element control valve gasket.
(Internal to housing) or possible failure of the
mass air flow sensor (MAF sensor)( 1 28579) may
Installation
occur. 1. NOTE: If scraping is necessary, do not damage
the idle air control valve gasket surfaces or drop
Removal gasket material into throttle body (9E926) or
1. Disconnect battery ground cable ( 1 430 1). Refer throttle body adapter (depending upon
to Section 14-Q 1 . application).
2. Disconnect engine control sensor wiring Clean idle air control valve gasket mating
( 1 2A58 1 ) from mass air flow sensor and intake surfaces.
air temperature sensor (JAT sensor)( 1 2A697).

03- 14-6 Engine Controls, Electronic 03-14-6
2. To install idle air control valve, reverse Removal 4. On 3.8L engine, remove engine coolant
procedure. Tighten retaining bolts to 8- 1 2 N·m temperature sensor from hot water heater elbow
(7 1 - 1 06 1b-in). connection ( 18599). On 4.6L engine, remove
engine coolant temperature sensor from heater
Idle Air Control Valve - 3.8L Engine tube located on lower intake manifold (9424).
Installation
2. On 3.8L engine, tighten engine coolant
temperature sensor to 1 4- 1 9 N·m ( 1 Q- 1 4 1b-ft).
On 4.6L engine, tighten engine coolant
temperature sensor to 1 6-24 N·m ( 1 2- 1 7 lb-ft).
3. Refill engine cooling system. Refer to Section
03-Q3.
Engine Coolant Temperature Sensor - 3.8L Engine
SCREW 2 REQ'D
TIGHTEN TO 2.8-3.8 N·m
THROTTLE POSITION SENSOR (25-33 LB-IN)
98989 AV0039-A
Idle Air Control Valve -4.6L E ngine
--
FRONT OF ENGINE
THROTTLE BODY
ADAPTER 9A589 ---- /
FRONT OF
ENGINE
/
V9258-C
Engine Coolant Temperature Sensor - 4.6L Engine
ENGINE COOLANT
TEMPERATURE
SENSOR 12A648
TIGHTEN TO
16-24 N·m
BOLT (12-1 7 LB-FT)
2 REO'D
TIGHTEN TO
8-12 N·m
(71-106 LB-IN)
V10127-A
Engine Coolant Temperature (ECT) Sensor

Removal
1. Partially drain engine cooling system. Refer to INTAKE MANIFOLD
Section 03-03. � 9424
FRONT OF ENGINE
2. Disconnect battery ground cable ( 1 430 1). Refer
to Section 14-Q 1 . �
V101 28-A
engine coolant temperature sensor (ECT
sensorX 1 2A648).

03-14-7 Engine Controls, Electronic 03· 1 4-7
Heated Oxygen Sensor (H02S) 5. CAUTION: Before proceeding with this

NOTE: Four heated oxygen sensors (H02S)(9F472) , procedure, set cylinder No. 1 0 degrees Top
located in the dual converter Y pipe (5F250), are used Dead Center (TDC) of the compression
for the engine control system. stroke. Then note the position of the
camshaft position sensor electrical
connector. The installation procedure
requires that the connector be located in the
Description Tool Number same position.
Oxygen Sensor Wrench T94P-9472-A Remove retaining bolt and hold-down clamp
( 1 2270).
Removal 6. NOTE: The oil pump intermediate shaft (6A6 1 8)
1. Disconnect battery ground cable ( 1 4301 ). Refer should be removed with the camshaft position
to Section 14-0 1 . sensor housing.
2. Raise vehicle on hoist. Refer to Section OO-Q2. Remove camshaft position sensor housing from
engine front cover.
3. Disconnect heated oxygen sensors at wiring
·.
connector. Installation
4. NOTE: If excessive force is needed to remove 1. CAUTION: Special service tool Syncro
heated oxygen sensor, lubricate with penetrating Positioning Tool T96T- 1 220G-A must be
oil prior to removal. obtained prior to installation of the camshaft
Remove heated oxygen sensors from dual position sensor. Failure to follow this
converter Y pipe using Oxygen Sensor Wrench procedure will result In improper camshaft
T94P-9472-A. position sensor alignment. This will result In
the fuel system being out of time with the
Installation engine, possibly causing engine damage.
1. Follow removal procedure in reverse order. Attach Syncro Positioning Tool T96T- 1 2200-A on
2. lighten heated oxygen sensors to 37-45 N·m camshaft position sensor housing and turn it
(28-33 lb-ft). clockwise until tool boss engages notch in
camshaft position sensor housing.
2. Transfer oil pump intermediate shaft from old
camshaft position sensor housing to replacement
Camshaft Position (CMP) Sensor camshaft position sensor housing.
3. Install camshaft position sensor housing so drive
3.8L Engine
gear engagement occurs when arrow on locator
tool is pointed as shown in the illustration. This
step will locate the camshaft position sensor
Description Tool Number electrical connector in the pre-removal position.
Syncro Positioning Tool T96T- 1 2200-A 4. Rotate Syncro Positioning Tool T96T- 1 220Q-A
clockwise slightly. This will engage the oil pump
Removal intermediate shaft. Push downward adjusting the
syncro Positioning Tool T96T- 1 220Q-A until the
1. Disconnect battery ground cable ( 1 430 1). Refer
Syncro gear engages the camshaft gear.
to Section 14-0 1 .
5. Install hold-down clamp and retaining bolt and
tighten bolt to 20-30 N·m ( 1 5-22 lb-ft).
camshaft position sensor (CMP sensor)( 1 2 1 26).
6. Remove Syncro Positioning Tool T96T- 1 220Q-A.
3. Remove camshaft position sensor retaining
screws and camshaft position sensor from 7. CAUTION: If camshaft position sensor
camshaft position sensor housing. electrical connector is not positioned
properly, DO NOT reposition the connector
4. If removing camshaft position sensor housing
by rotating the camshaft position sensor
from the engine front cover (60 1 9), proceed with
housing. This will result in the fuel system
Removal Step 5. If camshaft position sensor
being out of time with the engine, possibly
housing is not being removed, proceed to
causing engine damage. Remove the
Installation Step 7 .
camshaft position sensor housing and repeat
installation procedure, beginning with Step
1.
Install camshaft position sensor and retaining
screws. lighten screws to 2.5-3.5 N·m (22-30
Ib-in).
8. Connect fuel charging wiring connector to
camshaft position sensor.


14-Q 1 .
Camshaft Position Sensor and Housing
4 r----- CENTER LINE

OF CMP SENSOR
PARALLEL TO
CENTER LINE
POSITION AFTER DRIVE OF ENGINE
GEAR IS ENGAGED AND
CLAMP FLANGE IS I
SEATED AGAINST THE FRONT OF
CYUNDER BLOCK
'
ENGINE
--- VIEW A
FRONT OF ENGINE
---
AV0248-A
Part Part
Item N umber Description I te m Number Description
1 T96T- 12200-A Syncro Positioning Tool 6 12 126 Camshaft Position (CMP)
2 6019 Engine Front Cover Sensor
-
3 12270 Hold-Down Clamp 7 N602704-S Screw (2 Req'd)
A Tighten to 20-30 N·m ( 1 5-22
-
4 6A6 18 Oil Pump Intermediate Shaft Lb-Ft)
5 T2A362 Camshaft Position Sensor 8 Tighten to 2.5-3.5 N·m (22-30
Housing (Part of 1 2 1 26) Lb-ln)
(Contmued)
4.6L (2V) Engine 3. Remove camshaft position sensor retaining

screw and remove camshaft position sensor from
Removal engine front cover.
1. Disconnect battery ground cable. Refer to
Section 14-0 1 . Installation
2. Disconnect engine control sensor wiring 1. Make sure camshaft position sensor mounting
( 1 2A58 1 ) from camshaft position sensor (CMP surface is clean and that camshaft position
sensor Q-ring is in proper location on camshaft
sensorX6B288).
position sensor.

REMOVAL AND INSTALLATION (Continued) ADJUSTMENTS
2. CAUTION: Do not overtighten camshaft Throttle Position (TP) Sensor

position sensor retaining screw or damage
The throttle position sensor (TP sensor)(9B989)
to the camshaft position sensor or engine
cannot be adjusted and must be replaced.
mounting surface may occur.
Position camshaft position sensor and install
retaining screw. lighten to 8- 1 2 N-m (7 1 - 1 06 SPECIFICATIONS
lb-in).
3. Connect engine control sensor wiring to camshaft TORQUE SPECIFICATIONS
position sensor.
-
1 4-Q 1 . Engine Control Sensor Wiring 2.7-3.7 24-32
Connector-to-PCM
-
Throttle Position Sensor 2.8-3.8 25-33
/
CAMSHAFT Retaining Screws
POSITION (CMP) -
FRONT OF ENGINE
SENSOR 6B288 Mass Air Flow Sensor Bolts 5-7 45-6 1
/
-
Engine Air Cleaner Tube 2.3-3.2 2 1 -28
Clamps
-
Idle Air Control Valve Bolts 8- 1 2 7 1 - 106
-
ECT Sensor (3.8L) 1 4- 1 9 10- 1 4
-
ECT Sensor (4.6L (2V)) 16-24 12-17
-
H02S-to-Dual Converter and 37-45 28-33
Pipe
-
Camshaft Position Sensor 2.5-3.5 22-30
Retaining Screws (3.8L)
-
Hold-Down Clamp Bolt (3.8L)- 20-30 1 5-22
-
Camshaft Position Sensor Bolt 8- 1 2 7 1 - 1 06
(4.6L)
Tool NumberI
V9273-C T94P-9472-A
Oxygen Sensor Wrench
Vehicle Speed Sensor (VSS)

Refer to Section 07-o 1 .
Idle Air Control (lAC) Valve T96T- 1 2 200 ·A

Syncro Positioning Tool
CAUTION: Do not use Carburetor Tune-Up
Cleaner D9AZ· 1 9579-BA meeting Ford
specification ESR·M 14P9-A or any other type of
solvent or damage to the valve internal
components may occur.
The idle air control valve (lAC valve)(9F7 1 5) cannot
be cleaned and must be replaced (if required).
ST1 446-A

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03-oo-1

SECTION 03-00 Engine-Service

Hydraulic Valve Tappets or Hydraulic Roller

1997 Thunderbird, Cougar July 1996

SECTION 03-00 Engine-Service -

SUBJECT PAGE SUBJECT PAGE

Valves, Inspection •••••••••••••••••••••••••.•••••••••••••••••••••03.00·33 SPECIFICATIONS 03-Go-37

VEHICLE APPLICATION • ignition system

1 Can be purchased as a separate item.

DESCRIPTION AND OPERATION (Continued)

Vehicle Certification Label Always refer to this label when:

I 1FABP43F9U3100001 I • replacement parts are required.

MFD. BY FORD MOTOR CO. IN U.S.A.

• engine calibration number 3. If inspection reveals obvious concerns that can

Emission Calibration Label

7·25F-ROO ESAE -6E061- AAA

2 Can be purchased as a separate 1tem.

DIAGNOSIS AND TESTING (Continued)

3 Can be purchased as a separate item.

DIAGNOSIS AND TESTING (Continued)

ENGINE DIAGNOSIS (Continued)

4 Can be purchased as a separate item.

5 Can be purchased as a separate item.

03-oo-7 Engine-Service 03-oo-7

SERVICE PROCEDURES (Continued)

• distributor 0-ring With Transmission and Flywheel Removed

Compression Test 3. Install an auxiliary starter switch in starting

COMP RESSION P RESSURE LIMIT CHART

1997 Thunderbird, Cougar July 1 996

SERVICE PROCEDURES (Continued)

COMP RESSION P RESSURE LIMIT CHART (Cont'd)

If one or more cylinders reads low, squirt Example Readings

1997 Thunderbird, Cougar July 1996

SERVICE PROCEDURES (Continued)

Intake Manifold Vacuum Test

Oil Leak and Valve Guide Seal Test

1997 Thunderbird, Cougar July 1 996

SERVICE PROCEDURES (Continued)

1997 Thunderbird, Cougar July 1996

SERVICE PROCEDURES (Continued)

1997 Thunderbird, Cougar July 1 996

SERVICE PROCEDURES (Continued)

1997 Thunderbird, Cougar July 1996

SERVICE PROCEDURES (Continued}

• Check the head gasket (6051) for proper

Typical Engine With Push Rods

1997 Thunderbird, Cougar July 1 996

SERVICE PROCEDURES (Continued)

9. Remove dial indicator, adapter and auxiliary Leakdown Testing

1 997 Thunderbird, Cougar July 1 996

SERVICE PROCEDURES {Continued)

Camshaft End Play

2. Zero the dial indicator. Pull camshaft forward and

Crankshaft End Play

1997 Thunderbird, Cougar July 1 996

SERVICE PROCEDURES (Continued)

1997 Thunderbird, Cougar July 1 996

SERVICE PROCEDURES (Continued)

The following procedure should be used to service Cylinder Walls, Refinishing

1997 Thunderbird, Cougar July 1 996