2002 Crown Victoria/Grand Marquis Workshop Manual

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1 Page 1 of 24 SECTION : Engine 2002 Crown Victoria/Grand Marquis Workshop Manual INSTALLATION Procedure revision date: 01/02/2003 Cylinder Heads Special Tool(s) Installer, Crankshaft Vibration Damper (T74P-6316-B) Installer, Front Cover Oil Seal (T88T-6701-A) Holding Tool, Crankshaft (T93P-6303-A) Installer, Crankshaft Front Oil Seal Teflon Seal Replacer Set 211-D027 (D90P-3517-A) Engine Lift Bracket Set 303-DS086 (D93P-6001-A) Compressor, Valve Spring (T97P-6565-AH) Spacer, Valve Spring Compressor (T91P-6565-AH) Strap Wrench 303-D055 (D85L-6000-A) Remover/Installer, Cylinder Head (T97T-6000-A) Material Item SAE 5W-20 Premium Synthetic Blend Motor Oil XO-5W20-QSP or equivalent Metal Surface Cleaner F4AZ-19A536-RA or equivalent Silicone Gasket and Sealant F7AZ EA or equivalent Motorcraft Silicone Gasket Remover ZC-30 Motorcraft Metal Surface Prep ZC-31 Hydraulic Chain Tensioner Retaining Clip Specification WSS-M2C153-H WSE-M5B392-A WSE-M4G323-A4 1L3Z-6P250-AA

2 Page 2 of 24 Installation All vehicles 1. CAUTION: The gasket sealing surfaces on the cylinder head and cylinder block must be clean. For additional information, refer to Cylinder Heads in the Removal portion of this section. CAUTION: The use of sealing aids (aviation cement, copper spray, and glue) is not permitted. The gasket must be installed dry. CAUTION: The new gasket has a film coating which is crucial to the gasket's ability to seal correctly. Do not scratch the gasket. NOTE: RH head gasket shown; LH head gasket similar. Install the head gasket over the dowel pins. 2. CAUTION: Cylinder head machining or milling is not authorized by the Ford Motor Company. Cylinder head flatness must be within mm (0.001 in) across a 38.1 mm (1.5 in) square area. CAUTION: The gasket sealing surfaces on the cylinder head and cylinder block must be clean. For additional information, refer to Cylinder Heads in the Removal portion of this section. CAUTION: The use of sealing aids (aviation cement, copper spray, and glue) is not permitted. The gasket must be installed dry. CAUTION: Do not allow the dowels to scratch the sealing surface of the cylinder head during cylinder head installation. NOTE: The new cylinder head bolts must be lightly oiled with a rag and allowed to drain for a few minutes prior to installation. NOTE: RH cylinder head shown; LH cylinder head similar. Install the cylinder head on the dowels and the head gasket. Loosely install new bolts. 3. Tighten the cylinder head bolts in six stages, in the sequence shown. 1. Stage 1: Tighten bolts to 40 Nm (30 lb-ft). 2. Stage 2: Tighten bolt an additional 90 degrees (1/4 turn). 3. Stage 3: Loosen the bolts a minimum of one full turn (360 degrees). 4. Stage 4: Tighten bolts to 40 Nm (30 lb-ft). 5. Stage 5: Tighten bolts an additional 90 degrees (1/4 turn). 6. Stage 6: Tighten bolts an additional 90 degrees (1/4 turn). 4. Remove the special tools from both ends of the cylinder head.

3 Page 3 of NOTE: Lubricate the hydraulic lash adjusters with clean engine oil. Install the hydraulic lash adjusters in their original locations. LH cylinder head 6. NOTE: Lubricate the O-ring seal with clean engine oil. Install the oil level indicator tube. Install a new O-ring seal on the oil level indicator tube. 7. Install the LH exhaust manifold. Install a new exhaust manifold gasket. Install the LH exhaust manifold. Tighten the nuts in the sequence shown. RH cylinder head 8. Install the RH exhaust manifold. Install a new exhaust manifold gasket. Install the RH exhaust manifold. Tighten the nuts in the sequence shown.

4 Page 4 of 24 Engines with ratcheting timing chain tensioners 9. CAUTION: Timing chain procedures must be followed exactly or damage to valves and pistons will result. CAUTION: Do not compress the ratchet assembly. This will damage the ratchet assembly. NOTE: LH shown, RH similar. Compress each tensioner plunger, using an edge of a vise. 10. Using a small screwdriver or pick, push back and hold the ratchet mechanism. 11. While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing. 12. Install a paper clip into the hole of each tensioner housing to hold the ratchet assembly and plunger in during installation. Remove the tensioner from the vise. Engines with non-ratcheting timing chain tensioners

5 Page 5 of CAUTION: Timing chain procedures must be followed exactly or damage to valves and pistons will result. NOTE: LH shown, RH similar. Compress each tensioner plunger, using a vise. 14. Install a retaining clip on each tensioner to hold the plunger in during installation. All engines 15. If the copper links are not visible, mark one link on one end and one link on the other end, and use as timing marks. 16. Using the special tool, position the crankshaft. Remove the special tool after crankshaft positioning. 17. Install the crankshaft sprocket, making sure the flange faces forward. 18. Install the timing chain guides. 1. Position the LH timing chain guide. 2. Install and tighten the LH bolts.

6 Page 6 of Position the RH timing chain guide. 4. Install and tighten the RH bolts. 19. Rotate the RH camshaft sprocket until the timing mark is approximately at the 11 o'clock position. Rotate the LH camshaft sprocket until the timing mark is approximately at the 12 o'clock position. 20. Position the LH (inner) timing chain on the crankshaft sprocket, aligning the copper (marked) link with the timing mark on the sprocket. 21. Install the LH timing chain on the camshaft sprocket, aligning the copper (marked) link with the timing marks on the sprocket. 22. NOTE: The LH timing chain tensioner arm has a bump near the dowel hole for identification. Position the LH timing chain tensioner arm on the dowel pin and install the LH timing chain tensioner.

7 Page 7 of 24 Engines with ratcheting timing chain tensioners 23. Remove the retaining clip from the LH timing chain tensioner. Engines with non-ratcheting timing chain tensioners 24. Remove the retaining clip from the LH timing chain tensioner. All engines 25. Position the RH (outer) timing chain on the crankshaft sprocket, aligning the copper (marked) link with the timing mark on the sprocket. 26. Install the RH timing chain on the camshaft sprocket, aligning the copper (marked) link with the timing marks on the sprocket. 27. Position the RH timing chain tensioner arm on the dowel pin and install the RH timing chain tensioner.

8 Page 8 of 24 Engines with ratcheting timing chain tensioners 28. Remove the retaining clip from the RH timing chain tensioner. Engines with non-ratcheting timing chain tensioners 29. Remove the retaining clip from the RH timing chain tensioner. All engines 30. Make sure that the copper (marked) chain links are lined up with the dots on the crankshaft sprockets and the camshaft sprocket. 31. Rotate the camshaft until the lobe is in the up position. 32. Install the special tool between the valve spring coils to prevent valve stem seal damage.

9 Page 9 of NOTE: Lubricate the camshaft roller followers using clean engine oil. Install the camshaft roller followers. 1. Install the special tool. 2. Compress the valve spring. 3. Install the camshaft roller followers in their original locations. 34. Remove the special tool. 35. Install all eight spark plugs. 36. Install the crankshaft sensor ring. 37. NOTE: If the engine front cover is not secured within four minutes, the sealant must be removed and the sealing area cleaned with metal surface cleaner. Allow to dry until there is no sign of wetness, or four minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage. Apply a bead of sealant along the head-to-block surface and the oil pan-to-block surface as specified.

10 Page 10 of Install a new engine front cover gasket on the engine front cover. Position the engine front cover. Install the fasteners finger-tight. 39. Tighten the front cover fasteners in the sequence shown to 25 Nm (18 lb-ft). Item Part Number Description 1 N Bolt, hex flange head pilot, M8 x 1.25 x 53 2 N Bolt, hex flange head pilot, M8 x 1.25 x 53 3 N Bolt, hex flange head pilot, M8 x 1.25 x 53 4 N Bolt, hex flange head pilot, M8 x 1.25 x 53 5 N Bolt, hex flange head pilot, M8 x 1.25 x 53 6 W Stud hex shoulder pilot, M8 x 1.25 x 50 M6 x 1 x 10 7 N Stud, and washer, hex head pilot, M8 x 1.25 x 60 M6 x 1 x 26 8 N Bolt, hex flange head pilot, M8 x 1.25 x 53 9 N Bolt, hex flange head pilot, M8 x 1.25 x N Bolt, hex flange head pilot, M8 x 1.25 x N Stud, hex shoulder pilot, M8 x 1.25 x 65 M6 x 1.25 x N Stud, hex shoulder pilot, M8 x 1.25 x 65 M6 x 1.25 x N Stud, hex shoulder pilot, M8 x 1.25 x 65 M6 x 1.25 x N Stud, hex shoulder pilot, M8 x 1.25 x 65 M6 x 1.25 x N Stud, hex shoulder pilot, M8 x 1.25 x 65 M6 x 1.25 x Loosely install the bolts, then tighten the bolts in two stages, in the sequence shown. State 1: Tighten to 20 Nm (15 lb-ft). Stage 2: Tighten an additional 90 degrees.

11 Page 11 of Install the RH engine mount. 42. Lubricate the engine front cover and the front oil seal inner lip with clean engine oil. 43. Using the special tools, install the front oil seal. 44. NOTE: If not secured within four minutes, sealant must be removed and the sealing area cleaned with metal surface cleaner. Allow to dry until there is no sign of wetness, or four minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage. Apply sealant to the Woodruff key slot on the crankshaft pulley.

12 Page 12 of Using the special tool, install the crankshaft pulley. 46. NOTE: Use special tool or suitable strap wrench to hold the pulley. Tighten the crankshaft pulley bolt in four stages. Stage 1: Tighten to 90 Nm (66 lb-ft). Stage 2: Loosen 360 degrees. Stage 3: Tighten to 50 Nm (37 lb-ft). Stage 4: Rotate an additional 90 degrees (1/4 turn). 47. Position the coolant pump pulley on the water pump and install the bolts. 48. Install the accessory drive belt idler pulley. 49. NOTE: If not secured within four minutes, sealant must be removed and the sealing area cleaned with metal surface cleaner. Allow to dry until there is no sign of wetness, or four minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage. Apply sealant in two places where the engine front cover meets the cylinder head.

13 Page 13 of Install the gasket into the valve cover and position on the cylinder head. Tighten the bolts in the sequence shown. 51. NOTE: If not secured within four minutes, sealant must be removed and the sealing area cleaned with metal surface cleaner. Allow to dry until there is no sign of wetness, or four minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage. Apply sealant in two places where the engine front cover meets the cylinder head. 52. Install the gasket into the valve cover and position on the cylinder head. Tighten the bolts in the sequence shown. 53. Inspect the O-ring seals. Install new seals if necessary. 54. Install the coolant bypass tube.

14 Page 14 of Install the ground strap on the rear of the RH cylinder head. 1. Install the stud bolt. 2. Install the ground strap. 3. Install the retaining nut. 56. NOTE: Align the gasket locator tabs to slots in cylinder head. Install new intake manifold gaskets. 57. Install the intake manifold and hand-tighten the bolts at the locations shown. 58. Install the eight ignition coils and tighten the eight bolts.

15 Page 15 of Install the crash bracket and loosely install the bolt and the stud. 60. Install the thermostat. 61. Install the coolant outlet adapter and loosely install the bolts. 62. Tighten the bolts in the sequence shown.

16 Page 16 of Tighten the stud. 64. Tighten the bolts. Natural gas engines 65. Install the bolts in the isolation valve. 66. Reposition the fuel charging wiring harness and install the bolts.

17 Page 17 of Connect the isolation valve jumper to the fuel charging wiring electrical connector and reposition the connector on the upper generator support bracket. 68. Connect the fuel charging wiring electrical connector to the fuel temperature sensor. 69. Connect the fuel charging wiring electrical connector to the fuel pressure sensor. All engines 70. Install the throttle body and tighten the bolts. 71. Install the throttle return spring.

18 Page 18 of Install the transmission harness support bracket. 73. Connect the exhaust gas recirculation (EGR) tube to the EGR valve. 74. Connect the EGR tube to the exhaust manifold connector. 75. Position the fuel charging wiring at two locations at the back of the intake manifold. 76. Install the generator. 77. Connect the electrical connector to the idle air control (IAC) valve and the throttle position (TP) sensor.

19 Page 19 of Install the generator mounting bracket. 79. Connect the generator electrical connector. 80. Connect the electrical connector to the EGR vacuum regulator solenoid. 81. Install the generator wiring harness anchor to the LH front stud. 82. Connect the engine coolant temperature (ECT) sensor electrical connector.

20 Page 20 of Connect the crankcase ventilation tube. 84. Install the EGR tube heat shield. 85. Connect the eight fuel injector electrical connectors. 86. Connect the eight ignition coil electrical connectors. 87. Connect the differential pressure feedback EGR system electrical connector.

21 Page 21 of NOTE: Only three bolts are required for installation. Install the power steering pump. 89. Connect the camshaft position (CMP) sensor electrical connector. 90. Connect the A/C compressor electrical connector. 91. Connect the crankshaft position (CKP) sensor electrical connector. 92. Connect the radio interference capacitor electrical connector.

22 Page 22 of Connect the oil pressure sensor and the power steering pressure (PSP) switch electrical connectors and attach the wiring harness anchor. 94. Using the special tool, install a new seal on the power steering pressure hose fitting. 95. Position the power steering reservoir and install the two studs and one bolt. 96. Connect the cylinder head temperature (CHT) sensor electrical connector and attach it to the power steering reservoir bracket. 97. Connect the high pressure power steering tube to the power steering pump.

23 Page 23 of Install the high pressure power steering tube bracket. 99. Connect the ground wire to the right rear fuel rail stud Install the battery cables and the bolt Install the accessory drive belt Install the lifting brackets Remove the engine from the engine stand.

24 Page 24 of Install the engine/transmission spacer plate Position the flexplate and install the bolts in the sequence shown Install the engine. For additional information, refer to Engine in this section.

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