3154_U01.qxd 8/1/03 7:28 AM Page 1 Continental 1 BRAKES...1-27 DRIVE TRAIN...1-21 ENGINE REPAIR...1-7 FUEL SYSTEM...1-20 PRECAUTIONS...1-7 SPECIFICATION CHARTS...1-2 STEERING AND SUSPENSION...1-22 A Air Bag...1-22 Disarming...1-22 Precautions...1-22 Air Spring...1-24 Removal & Installation...1-24 Alternator...1-7 Installation...1-7 Removal...1-7 B Brake Caliper...1-27 Removal & Installation...1-27 C Camshaft and Valve Lifters...1-15 Removal & Installation...1-15 Coil Spring...1-24 Removal & Installation...1-24 CV-Joint...1-22 Removal And Replacement...1-22 Cylinder Head...1-12 Removal & Installation...1-12 D Disc Brake Pads...1-27 Removal & Installation...1-27 E Engine Assembly...1-7 Removal & Installation...1-7 Exhaust Manifold...1-15 Removal & Installation...1-15 F Fuel Filter...1-20 Removal & Installation...1-20 Fuel Injector...1-21 Removal & Installation...1-21 Fuel Pump...1-20 Removal & Installation...1-20 Fuel System Pressure...1-20 Relieving...1-20 Fuel System Service Precautions...1-20 H Halfshaft...1-21 Removal & Installation...1-21 Heater Core...1-9 Removal & Installation...1-9 I Ignition Timing...1-7 Adjustment...1-7 Intake Manifold...1-14 Removal & Installation...1-14 L Lower Ball Joints...1-25 Removal & Installation...1-25 Lower Control Arm...1-25 Control Arm Bushing Replacement...1-26 Removal & Installation...1-25 O Oil Pan...1-16 Removal & Installation...1-16 Oil Pump...1-16 Removal & Installation...1-16 P Piston and Ring...1-19 Positioning...1-19 Power Rack and Pinion Steering Gear...1-22 Removal & Installation...1-22 R Rear Main Seal...1-16 Removal & Installation...1-16 Rocker Arms...1-13 Removal & Installation...1-13 S Shock Absorber...1-23 Removal & Installation...1-23 Starter Motor...1-16 Removal & Installation...1-16 Strut...1-23 Removal & Installation...1-23 T Timing Chain, Sprockets, Front Cover and Seal...1-17 Removal & Installation...1-17 Transaxle Assembly...1-21 Removal & Installation...1-21 U Upper Control Arm...1-25 Control Arm Bushing Replacement...1-25 Removal & Installation...1-25 V Valve Lash...1-16 Adjustment...1-16 W Water Pump...1-8 Removal & Installation...1-8 Wheel Bearings...1-26 Adjustment...1-26 Removal & Installation...1-26
3154_U01.qxd 8/1/03 7:28 AM Page 2 1-2 CONTINENTAL SPECIFICATION CHARTS 2380LC01 2380LC02 2380LC03
3154_U01.qxd 8/1/03 7:28 AM Page 3 CONTINENTAL 1-3 93003G03 79224G26 4.6L Engine Firing order: 1 3 7 2 6 5 4 8 Distributorless ignition system (One coil on each cylinder) Serpentine accessory drive belt routing 4.6L (VIN V) engine 2380LC04 2380LC05
3154_U01.qxd 8/1/03 7:28 AM Page 4 1-4 CONTINENTAL 2380LC06 2380LC07 2380LC08
3154_U01.qxd 8/1/03 7:28 AM Page 5 CONTINENTAL 1-5 2380LC09 2380LC10 2380LC11
3154_U01.qxd 8/1/03 7:28 AM Page 6 1-6 CONTINENTAL 2380LC12
3154_U01.qxd 8/1/03 7:28 AM Page 7 CONTINENTAL 1-7 Before servicing any vehicle, please be sure to read all of the following precautions, which deal with personal safety, prevention of component damage, and important points to take into consideration when servicing a motor vehicle: Never open, service or drain the radiator or cooling system when the engine is hot; serious burns can occur from the steam and hot coolant. Observe all applicable safety precautions when working around fuel. Whenever servicing the fuel system, always work in a well-ventilated area. Do not allow fuel spray or vapors to come in contact with a spark, open flame, or excessive heat (a hot drop light, for example). Keep a dry chemical fire extinguisher near the work area. Always keep fuel in a container specifically designed for fuel storage; also, always properly seal fuel containers to avoid the possibility of fire or explosion. Refer to the additional fuel system precautions later in this section. Fuel injection systems often remain pressurized, even after the engine has been turned OFF. The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in fire and/or personal injury. Brake fluid often contains polyglycol ethers and polyglycols. Avoid contact with the eyes and wash your hands thoroughly after handling brake fluid. If you do get brake fluid in your eyes, flush your eyes Disconnecting the negative battery cable on some vehicles may interfere with the functions of the on board computer system. The computer may undergo a relearning process once the negative battery cable is reconnected. Alternator REMOVAL 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Coolant recovery reservoir Accessory drive belt Alternator bracket Alternator PRECAUTIONS with clean, running water for 15 minutes. If eye irritation persists, or if you have taken brake fluid internally, IMMEDIATELY seek medical assistance. The EPA warns that prolonged contact with used engine oil may cause a number of skin disorders, including cancer. You should make every effort to minimize your exposure to used engine oil. Protective gloves should be worn when changing oil. Wash your hands and any other exposed skin areas as soon as possible after exposure to used engine oil. Soap and water, or waterless hand cleaner should be used. All new vehicles are now equipped with an air bag system, often referred to as a Supplemental Restraint System (SRS) or Supplemental Inflatable Restraint (SIR) system. The system must be disabled before performing service on or around system components, steering column, instrument panel components, wiring and sensors. Failure to follow safety and disabling procedures could result in accidental air bag deployment, possible personal injury and unnecessary system repairs. Always wear safety goggles when working with, or around, the air bag system. When carrying a non-deployed air bag, be sure the bag and trim cover are pointed away from your body. When placing a nondeployed air bag on a work surface, always face the bag and trim cover upward, away from the surface. This will reduce the INSTALLATION ENGINE REPAIR 1. Install or connect the following: Alternator. Tighten the bolts to 15 22 ft. lbs. (20 30 Nm). Alternator bracket. Tighten the nuts to 71 106 inch lbs. (8 12 Nm). Accessory drive belt Coolant recovery reservoir Ignition Timing ADJUSTMENT The ignition timing is controlled by the Powertrain Control Module (PCM) and is not adjustable. motion of the module if it is accidentally deployed. Refer to the additional air bag system precautions later in this section. Clean, high quality brake fluid from a sealed container is essential to the safe and proper operation of the brake system. You should always buy the correct type of brake fluid for your vehicle. If the brake fluid becomes contaminated, completely flush the system with new fluid. Never reuse any brake fluid. Any brake fluid that is removed from the system should be discarded. Also, do not allow any brake fluid to come in contact with a painted surface; it will damage the paint. Never operate the engine without the proper amount and type of engine oil; doing so WILL result in severe engine damage. Timing belt maintenance is extremely important. Many models utilize an interference-type, non-freewheeling engine. If the timing belt breaks, the valves in the cylinder head may strike the pistons, causing potentially serious (also time-consuming and expensive) engine damage. Disconnecting the negative battery cable on some vehicles may interfere with the functions of the on-board computer system(s) and may require the computer to undergo a relearning process once the negative battery cable is reconnected. When servicing drum brakes, only disassemble and assemble one side at a time, leaving the remaining side intact for reference. Engine Assembly REMOVAL & INSTALLATION Disable the air suspension before raising the vehicle. The switch is located on the left side of the luggage compartment. 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Turn the air suspension switch to the OFF position. 3. Recover the A/C refrigerant. 4. Drain the cooling system. 5. Remove or disconnect the following: Hood Steering column intermediate shaft
3154_U01.qxd 8/1/03 7:28 AM Page 8 1-8 CONTINENTAL Engine appearance cover Intake Air Temperature (IAT) sensor connector Air cleaner outlet tube Upper motor mount Fuel line Dash panel ground straps Powertrain Control Module (PCM) connector Mass Air Flow (MAF) sensor connector Traction control motor connector Throttle Position (TP) sensor connector Cruise control cable Accelerator cable and bracket Shift selector cable Engine control wiring harness (3 connectors) and bracket Intake manifold vacuum lines Transaxle cooler lines Power steering return hose at the fluid reservoir Alternator wiring harness Radiator splash shield Heater hoses Radiator hoses Front wheels Suspension height sensor links Lower ball joints Stabilizer bar links Outer tie rod ends Halfshafts Heated Oxygen (HO 2 S) sensor connectors Dual converter Y-pipe Block heater connector Power steering cooler lines A/C compressor lines Starter motor Subframe brackets Torque converter shield and torque converter 6. Support the powertrain from below and remove the subframe bolts. 7. Raise the vehicle away from the powertrain. 8. Attach an engine hoist to the powertrain. 9. Remove or disconnect the following: Power steering sensor connector Power steering return line from the steering gear Turbine shaft speed sensor connector Transaxle range sensor connector Transaxle control harness connector Left and right engine support insulators Right engine support insulator bracket 10. Remove the transaxle flange bolts and separate the engine from the transaxle. To install: When installing suspension components and halfshafts, use new nuts, bolts, circlips and split pins. 11. Install or connect the following: Transaxle. Tighten the flange bolts to 25 34 ft. lbs. (34 46 Nm). Right engine support insulator bracket. Tighten the bolts to 16 21 ft. lbs. (22 29 Nm). Left and right engine support insulators. Tighten the through-bolts to 64 88 ft. lbs. (87 119 Nm). Transaxle control harness connector Transaxle range sensor connector Turbine shaft speed sensor connector Power steering return line from the steering gear Power steering sensor connector 12. Lower the vehicle on to the powertrain assembly. Use 2 pieces of ³ ₄ inch outside diameter pipe in the alignment holes behind the front subframe mounts to align the subframe to the body. Tighten the subframe mounting bolts to 57 76 ft. lbs. (77 103 Nm). 13. Install or connect the following: Torque converter shield and torque converter. Tighten the torque converter nuts to 20 34 ft. lbs. (27 46 Nm). Subframe brackets Starter motor A/C compressor lines Power steering cooler lines Block heater connector Dual converter Y-pipe HO 2S sensor connectors Halfshafts. Tighten the hub retainer nuts to 170 202 ft. lbs. (230 275 Nm). Outer tie rod ends. Tighten the nuts to 35 46 ft. lbs. (47 63 Nm). Stabilizer bar links. Tighten the nuts to 30 40 ft. lbs. (40 55 Nm). Lower ball joints. Tighten the nuts to 50 68 ft. lbs. (68 92 Nm). Suspension height sensor links Front wheels Radiator hoses Heater hoses Radiator splash shield Alternator wiring harness Power steering return hose at the fluid reservoir Transaxle cooler lines Intake manifold vacuum lines Engine control wiring harness (3 connectors) and bracket Shift selector cable Accelerator cable and bracket Cruise control cable TP sensor connector Traction control motor connector MAF sensor connector PCM connector Dash panel ground straps Fuel line Upper motor mount Air cleaner outlet tube IAT sensor connector Engine appearance cover Steering column intermediate shaft Hood 14. Fill the cooling system. 15. Check and adjust fluid levels as necessary. 16. Recharge the A/C system. 17. Turn the air suspension switch to the ON position. 18. Run the engine and check for leaks. Whenever the subframe is removed or lowered, the wheel alignment should be checked. Water Pump REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. 3. Remove or disconnect the following: Coolant reservoir 7922LG01 Exploded view of the water pump mounting
3154_U01.qxd 8/1/03 7:28 AM Page 9 Accessory drive belt Alternator Water pump pulley Water pump To install: 4. Install or connect the following: Water pump. Use a new O-ring seal and tighten the bolts to 15 22 ft. lbs. (20 30 Nm). Water pump pulley. Tighten the bolts to 15 22 ft. lbs. (20 30 Nm). Alternator Accessory drive belt Coolant reservoir 5. Fill the cooling system. 6. Start the engine and check for leaks. Heater Core CONTINENTAL 1-9 REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Disconnect the negative battery cable. Exploded view of the instrument panel and related components Continental 93111G99