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Home >> Lincoln >> 2004 >> LS V6-3.0L DOHC VIN S >> Repair and Diagnosis >> Engine, Cooling and Exhaust >> Engine >> Service and Repair >> Assembly >> Part 1 of 3

Part 1 of 3

Engine

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Special Tool(s)

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1. Install the components in the order indicated in the illustration and table. Illustration 1 of 21.

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2. Install the components in the order indicated in the illustration and table. Illustration 2 of 21.

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3. Install the components in the order indicated in the illustration and table. Illustration 3 of 21.





4. Install the components in the order indicated in the illustration and table. Illustration 4 of 21.





5. Install the components in the order indicated by the following illustration and table. Illustration 5 off 21.





6. Install the components in the order indicated in the illustration and table. Illustration 6 of 21.





7. Install the components in the order indicated in the illustration and table. Illustration 7 of 21.





8. Install the components in the order indicated in the illustration and table. Illustration 8 of 21.





9. Install the components in the order indicated in the illustration and table. Illustration 9 of 21.

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10. Install the components in the order indicated in the illustration and table. Illustration 10 of 21.





11. Install the components in the order indicated in the illustration and table. Illustration 11 of 21.

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12. Install the components in the order indicated in the illustration and table. Illustration 12 of 21.

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13. Install the components in the order indicated in the illustration and table. Illustration 13 of 21.

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14. Install the components in the order indicated in the illustration and table. Illustration 14 of 21.





15. Install the components in the order indicated in the illustration and table. Illustration 15 of 21.

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16. Install the components in the order indicated in the illustration and table. Illustration 16 of 21.





17. Install the components in the order indicated in the illustration and table. Illustration 17 of 21.





18. Install the components in the order indicated in the illustration and table. Illustration 18 of 21.

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19. Install the components in the order indicated in the illustration and table. Illustration 19 of 21.





20. Install the components in the order indicated in the illustration and table. Illustration 20 of 21.





21. Install the components in the order indicated in the illustration and table. Illustration 21 of 21.

Item 1: Engine Assembly Assembly Note





1. Rotate the crankshaft to position the keyway at the nine o'clock position.





2. Position the oil pump and install the bolts.





3. Position the oil pan baffle and install the nuts. Tighten in two stages:
- Stage 1: Tighten to 5 Nm (44 inch lbs.).
- Stage 2: Tighten an additional 45 degrees.





4. NOTE: Lubricate the O-ring seal with clean engine oil before :installing.

Position the oil pump screen cover and tube and install the bolts.
- Use a new O-ring seal. if necessary.





5. Position the top-mounted Knock Sensor (KS) and install the bolt.





6. Using a new O-ring seal, position the coolant inlet tube and install the bolts.

Items 2-4: LH Cylinder Head, Gaskets and Bolts Assembly Note





1. CAUTION: The cylinder head gasket surfaces are ground to a precision finish. Do not rest cylinder heads on gasket surfaces. Do not use any abrasive materials during cleaning of the surfaces. Hairline scratches, small burrs, or dirt can provide a leak path for a cylinder head gasket to leak. If gasket material remains on the sealing surface, use only a plastic-tipped scraper to remove the material. Do not attempt to reuse the head gaskets.

CAUTION: Cylinder head bolts are torque-to-yield and cannot be reused.

NOTE: The LH and RH cylinder head gaskets are not interchangeable.

Using a new cylinder head gasket, position the LH cylinder head, and install new bolts. Tighten the bolts in six stages:
- Stage 1: Tighten to 30 Nm (22 ft. lbs.).
- Stage 2: Tighten an additional 90 degrees.
- Stage 3: Back out a minimum of one full turn (360 degrees).
- Stage 4: Tighten to 30 Nm (22 ft. lbs.).
- Stage 5: Tighten an additional 90 degrees.
- Stage 6: Tighten an additional 90 degrees.

Items 5-7: RH Cylinder Head, Gaskets and Bolts Assembly Note





1. CAUTION: The cylinder head gasket surfaces are ground to a precision finish. Do not rest cylinder heads on gasket surfaces. Do not use any abrasive materials during cleaning of the surfaces. Hairline scratches, small burrs, or dirt can provide a leak path for a cylinder head gasket to leak. If gasket material remains on the sealing surface, use only a plastic-tipped scraper to remove the material. Do not attempt to reuse the head gaskets.

CAUTION: Cylinder head bolts are torque-to-yield and cannot be reused.

NOTE: The LH and RH cylinder head gaskets are not interchangeable.

Using a new cylinder head gasket, position the RH cylinder head, and install new bolts.
Tighten the bolts in six stages:
- Stage 1: Tighten to 30 Nm (22 ft. lbs.)
- Stage 2: Tighten an additional 90 degrees
- Stage 3: Back out a minimum of one full turn (360 degrees).
- Stage 4: Tighten to 30 Nm (22 ft. lbs.).
- Stage 5: Tighten an additional 90 degrees.
- Stage 6: Tighten an additional 90 degrees





2. NOTE: LH is shown; RH is similar.

Install the LH and RH spark plugs.





3. NOTE: Be sure camshaft bearing caps are installed in their original positions.

Lubricate camshafts with clean engine oil and carefully position the camshafts into the cylinder head.





4. CAUTION: Do not install the camshaft journal thrust caps until all of the camshaft bearing caps have been installed, or damage to the thrust caps can occur.

Lubricate the bearing surfaces of the camshaft bearing caps with clean engine oil, install the bearing caps, and loosely install the bolts.





5. Lubricate the bearing surfaces of the camshaft bearing thrust caps with clean engine oil, install the caps, and loosely install the bolts.





6. Tighten the bolts in the sequence shown.

7. NOTE: If new camshafts were installed, refer to Valve Clearance Adjustment.

Lubricate the tappet shims and camshaft lobes with clean engine oil.
8. Rotate the camshafts to make sure they are not binding. If binding occurs, check to make sure that all bearing caps are in their original positions. Loosen all bearing cap bolts in reverse order and retighten.

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





1. With the two keyways facing forward, install the crankshaft sprockets.





2. Install the LH exhaust camshaft sprocket and a new bolt hand tight. Using a wrench on the flats of the camshaft, hold the camshaft in position and tighten the bolt in two stages.
- Stage 1: Tighten the exhaust camshaft sprocket bolt to 20 Nm (15 ft. lbs.).
- Stage 2: Tighten an additional 90 degrees.





3. Install the LH Variable Camshaft Timing (VCT) actuator and a new bolt hand tight. Using a wrench on the flats of the camshaft, hold the camshaft in position and tighten the bolt in two stages.
- Stage 1: Tighten the VCT actuator bolt to 20 Nm (15 ft. lbs.).
- Stage 2: Tighten an additional 90 degrees.





4. Install the RH exhaust camshaft sprocket and a new bolt hand tight. Using a wrench on the flats of the camshaft, hold the camshaft in position and tighten the bolt in two stages.
- Stage 1: Tighten the exhaust camshaft sprocket bolt to 20 Nm (15 ft. lbs.).
- Stage 2: Tighten an additional 90 degrees.





5. Install the RH Variable Camshaft Timing (VCT) actuator and a new bolt hand tight. Using a wrench on the flats of the camshaft, hold the camshaft in position and tighten the bolt in two stages.
- Stage 1: Tighten the VCT actuator bolt to 20 Nm (15 ft. lbs.).
- Stage 2: Tighten an additional 90 degrees.
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