Engine

303-00-1 Engine System — General Information 303-00-1
SPECIFICATIONS
General Specifications
Item Specification
Lubricants and Sealants
SAE 5W-20 Premium WSS-M2C930-A
Synthetic Blend Motor Oil
XO-5W20-QSP
Threadlock 262 WSK-M2G351-A6
TA-26
Copyright  2004, Ford Motor Company

Last updated: 6/29/2004 2005 Lincoln Aviator, 09/2004
DESCRIPTION AND OPERATION

Engine The engine incorporates the following features:
WARNING: To avoid the possibility of • a closed positive crankcase ventilation (PCV)
personal injury or damage to the vehicle, do not system. For additional information, refer to
operate the engine with the hood open until the Section 303-08.
fan blade has been examined for possible cracks • an exhaust emission control system. For additional
and separation. information, refer to Section 303-08.
NOTE: Specifications show the expected minimum • an evaporative emission control system. For
or maximum condition. Refer to the appropriate additional information, refer to Section 303-13.
section in Group 303 for the procedure.
Some engines incorporate a fail-safe cooling system.
NOTE: If a component fails to meet the Refer to the appropriate section in Group 303 for
specifications, it is necessary to install a new the procedure.
component or refinish. If the component can be
The engine, fuel system, ignition system, emissions
refinished, wear limits are provided as an aid to
system and exhaust system all affect exhaust
making a decision. A new component must be
emission levels and must be maintained according
installed for any component that fails to meet
to the maintenance schedule. Refer to the scheduled
specifications and cannot be refinished.
Maintenance Guide.
NOTE: This section contains information, steps and
Correct engine identification is required to order
procedures that may not be specific to your engine.
parts. Refer to the appropriate section in Group 303
This section covers general procedures and for the procedure.
diagnosis and testing of the engine system, except
For complete vehicle and engine identification
for exhaust emission control devices, which are
codes, refer to Section 100-01.
covered in the Powertrain Control/Emissions
Diagnosis Manual.

DIAGNOSIS AND TESTING

Engine Special Tool(s)
UV Leak Detector Kit
Special Tool(s) 164-R0756 or equivalent
Commercially Available
Hydraulic Lash Adjuster
Leakdown Tester
—
Vacuum/Pressure Tester
164-R0253 or equivalent
Quick Disconnect Compression
Tester
Material
Dial Indicator Gauge Adapter Item Specification

303-007 (TOOL-6565-AB) or Gasoline Engine Oil Dye ESE-M99C103-B1
equivalent 164-R3705 or equivalent
Engine Oil Refer to owner literature
Inspection and Verification

WARNING: To avoid the possibility of
Dial Indicator Gauge with personal injury or damage to the vehicle, do not
Holding Fixture operate the engine with the hood open until the
100-002 (TOOL-4201-C) or
equivalent fan blade has been examined for possible cracks
and separation.
NOTE: Specifications show the expected minimum
or maximum condition. Refer to the appropriate
Engine Cylinder Leak
Detection/Air Pressurization Kit NOTE: If a component fails to meet the
014-00708 or equivalent specifications, it is necessary to install a new
component or refinish. If the component can be
refinished, wear limits are provided as an aid to
making a decision. A new component must be
installed for any component that fails to meet
Oil Pressure Gauge specifications and cannot be refinished.
303-088 (T73L-6600-A) 1. Verify the customer concern by operating the
engine to duplicate the condition.
2. Visually inspect for obvious signs of
mechanical damage. Refer to the following
chart.
(Continued)

DIAGNOSIS AND TESTING (Continued)

Visual Inspection Chart 4. If the concerns remain after the inspection,
Mechanical determine the symptoms. GO to Symptom
Chart.
• Engine coolant leaks
• Engine oil leaks
• Fuel leaks
• Damaged or severely worn parts
• Loose mounting bolts, studs and nuts
3. If the inspection reveals obvious concerns that

can be readily identified, repair as necessary.
Symptom Chart
Symptom Chart
Condition Possible Sources Action
• Difficult starting • Damaged ignition system. • Refer to the appropriate
section in Group 303 for the
procedure. REFER to the
Powertrain Control/Emissions
Diagnosis (PC/ED) manual.
• Damaged fuel system. • Refer to the appropriate
• Damaged starting system. • Refer to the appropriate
• Damaged charging • REFER to Section 414-00.
system/battery.
• Burnt valve. • INSTALL a new valve.
• Worn piston. • INSTALL a new piston.
• Worn piston rings. • INSTALL new piston rings.
• Worn cylinder. • REPAIR or INSTALL a new
cylinder block.
• Damaged head gasket. • INSTALL a new head gasket.
• Damaged cooling system. • Refer to the appropriate
2005 Lincoln Aviator, 09/2004


Symptom Chart (Continued)
• Poor idling • Vacuum leaks. • Refer to the appropriate
• Malfunctioning or damaged • Refer to the appropriate
ignition system. section in Group 303 for the
fuel system. section in Group 303 for the
• Damaged valve tappet or lash • INSTALL a new valve tappet
adjuster. or lash adjuster.
• Damaged valve tappet guide • INSTALL a new valve tappet
or lash adjuster. guide or valve tappet.
• Incorrect valve-to-valve seat • REPAIR or INSTALL a new
contact. valve or valve seat.
• Abnormal combustion • Malfunctioning or damaged • Refer to the appropriate
air intake system. section in Group 303 for the
• Damaged valve tappet or lash • INSTALL a new valve tappet
adjuster. or lash adjuster.
or valve tappet. guide or valve tappet.
• Burnt or sticking valve. • REPAIR or INSTALL a new
valve.
• Weak or broken valve spring. • INSTALL a new valve
spring.
• Carbon accumulation in • ELIMINATE carbon buildup.
combustion chamber.


• Excessive oil consumption • Leaking oil. • REPAIR oil leakage.
• Malfunctioning PCV system. • REPAIR or INSTALL new
necessary components.
• Worn valve stem seal. • INSTALL a new valve stem
seal.
• Worn valve stem or valve • INSTALL a new valve and
guide. valve guide.
• Sticking piston rings. • REPAIR or INSTALL new
piston rings.
• Worn piston ring groove. • INSTALL a new piston and
piston pin.
• Worn piston or cylinder. • REPAIR or INSTALL a new
piston or cylinder block.


• Engine noise • Leaking exhaust system. • REPAIR exhaust leakage.
• Incorrect drive belt tension. • REFER to Section 303-05.
• Malfunctioning generator • Refer to the appropriate
bearing. section in Group 414 for the
procedure.
• Malfunctioning water pump • REFER to Section 303-03.
bearing.
• Malfunctioning or damaged • REFER to Section 303-03.
cooling system.
• Loose timing chain/belt. • ADJUST or INSTALL a new
timing chain/belt.
• Damaged timing chain • INSTALL a new timing chain
tensioner. tensioner.
• Excessive main bearing • CAUTION: Remove the
clearance. cylinder heads before
removing the crankshaft.
Failure to do so can result
in engine damage.
ADJUST clearance or
INSTALL a new crankshaft
main bearing.
• Seized or heat-damaged • INSTALL a new crankshaft
crankshaft main bearing. main bearing.
• Excessive crankshaft end • INSTALL a new thrust
play. bearing or crankshaft.
• Excessive connecting rod • INSTALL a new connecting
bearing clearance. rod bearing or connecting
rod.
• Heat damaged connecting rod • INSTALL a new connecting
bearing. rod bearing.
• Damaged connecting rod • INSTALL a new connecting
bushing. rod bushing.
• Worn cylinder. • REPAIR or INSTALL a new
cylinder block.
• Worn piston or piston pin. • INSTALL a new piston or
piston pin.
• Damaged piston rings. • INSTALL new piston rings.
• Bent connecting rod. • INSTALL a new connecting
rod.
• Malfunctioning valve tappet • INSTALL a new valve tappet
or lash adjuster. or lash adjuster.
• Excessive valve tappet or lash • ADJUST clearance or
adjuster clearance. INSTALL a new valve tappet
guide or valve tappet.
• Broken valve spring. • INSTALL a new valve
spring.
• Excessive valve guide • ADJUST clearance or
clearance. INSTALL a new valve guide
or valve.


• Insufficient power • Malfunctioning or damaged • Refer to the appropriate
air intake system. section in Group 303 for the
• Damaged or plugged exhaust • INSPECT exhaust system.
system.
• Incorrect tire size. • REFER to Section 204-04.
• Dragging brakes. • REFER to Section 206-00.
• Slipping transmission. • Refer to the appropriate
procedure.
• Malfunctioning valve tappet • INSTALL a new valve tappet
or lash adjuster. or lash adjuster.
or valve tappet. guide or valve tappet.
• Compression leakage at valve • REPAIR or INSTALL a new
seat. valve, valve seat or cylinder
head.
• Seized valve stem. • INSTALL a new valve.
• Weak or broken valve spring. • INSTALL a new valve
spring.
• Worn or damaged camshaft. • INSTALL a new camshaft.
• Cracked or distorted cylinder • INSTALL a new cylinder
head. head.
• Damaged, worn or sticking • REPAIR or INSTALL a new
piston ring(s). piston ring(s).
• Worn or damaged piston. • INSTALL a new piston and
piston pin.
Component Tests 1. Add gasoline engine oil dye. Use a minimum

14.8 ml (0.5 ounce) to a maximum 29.6 ml (1
Engine Oil Leaks ounce) of fluorescent additive to all engines. If
NOTE: When diagnosing engine oil leaks, the the oil is not premixed, fluorescent additive
source and location of the leak must be positively must first be added to crankcase.
identified prior to repair. 2. Run the engine for 15 minutes. Stop the engine
Prior to carrying out this procedure, clean all and inspect all seal and gasket areas for leaks
sealing surface areas with a suitable solvent to using the UV Leak Detector Kit. A clear bright
remove all traces of oil. yellow or orange area will identify the leak. For
extremely small leaks, several hours may be
Engine Oil Leaks — Fluorescent Oil Additive required for the leak to appear.
Method
Use the UV Leak Detector Kit to carry out the
following procedure for oil leak diagnosis.


Leakage Points — Underhood Oil leaks at crimped seams in sheet metal parts and
Examine the following areas for oil leakage: cracks in cast or stamped parts can be detected
when using the dye method.
• Valve cover gaskets.
• Intake manifold gaskets. Compression Test — Compression Gauge
Check
• Cylinder head gaskets.
1. Make sure the oil in the crankcase is of the
• Oil bypass filter. correct viscosity and at the correct level and
• Oil filter adapter. that the battery is correctly charged. Operate the
• Engine front cover. vehicle until the engine is at normal operating
temperature. Turn the ignition switch to the
• Oil filter adapter and filter body. OFF position, then remove all the spark plugs.
• Oil level indicator tube connection. 2. Set the throttle plates in the wide-open position.
• Oil pressure sensor. 3. Install a compression gauge such as the
Leakage Points — Under Engine — With Compression Tester in the No. 1 cylinder.
Vehicle on Hoist 4. Install an auxiliary starter switch in the starting
circuit. With the ignition switch in the OFF
• Oil pan gaskets.
position, and using the auxiliary starter switch,
• Oil pan sealer. crank the engine a minimum of five
• Oil pan rear seal. compression strokes and record the highest
reading. Note the approximate number of
• Engine front cover gasket.
compression strokes required to obtain the
• Crankshaft front seal. highest reading.
• Crankshaft rear oil seal. 5. Repeat the test on each cylinder, cranking the
• Crankshaft main bearing cap side bolts. engine approximately the same number of
• Oil filter adapter and filter body. compression strokes.
• Oil cooler, if equipped. Compression Test — Test Results
Leakage Points — With Transmission and The indicated compression pressures are considered
Flywheel Removed within specification if the lowest reading cylinder is
at least 75 percent of the highest reading. Refer to
• Crankshaft rear oil seal. the Compression Pressure Limit Chart.
• Rear main bearing cap parting line.
• Rear main bearing cap and seals.
• Flywheel mounting bolt holes (with flywheel
installed).
• Camshaft rear bearing covers or pipe plugs at the
end of oil passages.
Compression Pressure Limit Chart
Maximum Minimum Maximum Minimum Maximum Minimum Maximum Minimum
Pressure Pressure Pressure Pressure Pressure Pressure Pressure Pressure
924 kPa 696 kPa 1131 kPa 848 kPa 1338 kPa 1000 kPa 1544 kPa 1158 kPa
(134 psi) (101 psi) (164 psi) (123 psi) (194 psi) (146 psi) (224 psi) (168 psi)


Compression Pressure Limit Chart (Continued)
Maximum Minimum Maximum Minimum Maximum Minimum Maximum Minimum
Pressure Pressure Pressure Pressure Pressure Pressure Pressure Pressure
1110 kPa 834 kPa 1324 kPa 993 kPa 1631 kPa 1145 kPa — —
(161 psi) (121 psi) (192 psi) (144 psi) (222 psi) (166 psi)
If one or more cylinders reads low, squirt Cylinder Leakage Detection

approximately one tablespoon of engine oil on top When a cylinder produces a low reading, use of the
of the pistons in the low-reading cylinders. Repeat Engine Cylinder Leak Detection/Air Pressurization
the compression pressure check on these cylinders. Kit will be helpful in pinpointing the exact cause.
Compression Test — Interpreting The leakage detector is inserted in the spark plug
Compression Readings hole, the piston is brought up to dead center on the
1. If compression improves considerably, piston compression stroke, and compressed air is admitted.
rings are faulty. Once the combustion chamber is pressurized, a
2. If compression does not improve, valves are special gauge included in the kit will read the
sticking or seating incorrectly. percentage of leakage. Leakage exceeding 20
percent is excessive.
3. If 2 adjacent cylinders indicate low compression
pressures and squirting oil on each piston does
not increase compression, the head gasket may
be leaking between cylinders. Engine oil or
coolant in cylinders could result from this
condition.
Use the Compression Pressure Limit Chart
when checking cylinder compression so that the
lowest reading is at least 75 percent of the
highest reading.


While the air pressure is retained in the cylinder, Basic Pre-Checks
listen for the hiss of escaping air. A leak at the 1. For persistent complaints of oil consumption,
intake valve will be heard in the throttle body. A interview the customer to determine the oil
leak at the exhaust valve can be heard at the tail consumption characteristics. If possible,
pipe. Leakage past the piston rings will be audible determine the brand and grade of oil currently
at the positive crankcase ventilation (PCV) in the oil pan. Look at the oil filter or
connection. If air is passing through a blown head oil-change station tags to determine if
gasket to an adjacent cylinder, the noise will be Ford-recommended maintenance schedules have
evident at the spark plug hole of the cylinder into been followed. Make sure that the oil has been
which the air is leaking. Cracks in the cylinder changed at the specified mileage intervals. If
block or gasket leakage into the cooling system may vehicle mileage is past the first recommended
be detected by a stream of bubbles in the radiator. drain interval, the OEM production filter should
have been changed.
Excessive Engine Oil Consumption
2. Ask how the most current mileage was
Nearly all engines consume oil, which is essential
accumulated. That is, determine whether the
for normal lubrication of the cylinder bore walls and
vehicle was driven under the following
pistons and rings. Determining the level of oil
conditions:
consumption may require testing by recording how
much oil is being added over a given set of miles. • Extended idling or curbside engine operation
Customer driving habits greatly influence oil • Stop-and-go traffic or taxi operation
consumption. Mileage accumulated during towing or • Towing a trailer or vehicle loaded heavily
heavy loading generates extra heat. Frequent short
• Frequent short trips (engine not up to
trips, stop-and-go type traffic or extensive idling,
normal operating temperature)
prevent the engine from reaching normal operating
temperature. This prevents component clearances • Excessive throttling or high engine-rpm
from reaching specified operating ranges. driving
The following diagnostic procedure may be utilized 3. Verify that there are no external leaks. If
to determine internal oil consumption. Make sure necessary, review the diagnostic procedure
that the concern is related to internal oil under Engine Oil Leaks in the Diagnosis and
consumption, and not external leakage, which also Testing portion of this section.
consumes oil. Verify there are no leaks before 4. Inspect the crankcase ventilation system for:
carrying out the test. Once verified, the rate of • disconnected hoses at the valve cover or
internal oil consumption can be tested. throttle body.
A new engine may require extra oil in the early • loose or missing valve cover fill cap.
stages of operation. Internal piston-to-bore
clearances and sealing characteristics improve as the • missing or incorrectly seated engine oil level
engine breaks in. Engines are designed for close indicator.
tolerances and do not require break-in oils or • incorrect or dirty PCV valve.
additives. Use the oil specified in the Owner Guide. • a PCV valve grommet unseated in the valve
Ambient temperatures may determine the oil cover (if so equipped)
viscosity specification. Verify that the correct oil is
being used for the vehicle in the geographic region 5. Inspect for signs of sludge. Sludge affects PCV
in which it is driven. performance and can plug or restrict cylinder
head drainback wells. It can also increase oil
pressure by restricting passages and reducing
the drainback capability of piston oil control
rings. Sludge can result from either excessive
water ingestion in the crankcase or operation at
extremely high crankcase temperatures.


6. Inspect the air filter for dirt, sludge or damage. 4. After a 5-minute drainback period, record the
A hole in the filter element will allow unfiltered location of the oil level again. Mark the oil
air to bypass into the air induction system. This level indicator with the new oil level location.
can cause premature internal wear (engine (Note: Both marks should be very close to the
dusting), allowing oil to escape past rings, MIN-MAX upper and lower limits or the upper
pistons, valves and guides. and lower holes on the oil level indicator.
7. If the engine is hot or was recently shut down, These marks will exactly measure the engine’s
wait at least 5 minutes to allow the oil to drain use of oil, with a one quart differential between
back. Ask the customer if this requirement has the new marks.) Demonstrate to the customer
been followed. Adding oil without this wait that the factory-calibrated marks on the dipstick
period can cause an overfill condition, leading are where the oil should fall after an oil
to excessive oil consumption and foaming change with the specified fill amount. Explain
which may cause engine damage. however, that this may vary slightly between
MIN-MAX or the upper and lower holes on the
8. Make sure the oil level indicator (dipstick) is oil level indicator.
correctly and fully seated in the indicator tube.
Remove the oil level indicator and record the 5. Record the vehicle mileage.
oil level. 6. Advise the customer that oil level indicator
readings must be taken every 320 km (200
Detailed Pre-Checks miles) or weekly, using the revised marks as
1. Check the thermostat opening temperature to drawn. Remind the customer that the engine
make sure that the cooling system is operating needs a minimum 5-minute drainback for an
at the specified temperature. If it is low, accurate reading and that the oil level indicator
internal engine parts are not running at must be firmly seated in the tube prior to taking
specified internal operating clearances. the reading.
2. Verify the spark plugs are not oil saturated. Oil 7. When the subsequent indicator readings
leaking into one or more cylinders will appear demonstrate a full quart (liter) has been used,
as an oil soaked condition on the plug. If a record the vehicle mileage. The mileage driven
plug is saturated, a compression check may be between the 2 readings should not be less than
necessary at the conclusion of the oil 1,500 miles. The drive cycle the vehicle has
consumption test. been operated under must be considered when
making this calculation. It may be necessary to
Oil Consumption Test have the customer bring the vehicle in for a
Once all of the previous conditions are met, carry periodic oil level indicator reading to closely
out an oil consumption test. monitor oil usage.
1. Drain the engine oil and remove the oil filter. Post Checks, Evaluation and Corrective
Install a new manufacturer-specified oil filter. Action
Make sure the vehicle is positioned on a level
surface. Refill the oil pan to a level one quart 1. If test results indicate excessive oil
(liter) less than the specified fill level, using consumption, carry out a cylinder compression
manufacturer-specified oil. test. The cylinder compression test should be
carried out with a fully charged battery and all
2. Run the engine for 3 minutes (if hot) or 10 spark plugs removed. See the Compression Test
minutes (if cold). Allow for a minimum Chart in this section for pressure range limits.
5-minute drainback period and then record the
oil level shown on the oil level indicator. Place 2. Compression should be consistent across all
a mark on the backside of the oil level indicator cylinders. For additional information, refer to
noting the oil level location. the Compression Testing portion of this section.
If compression tested within the specifications
3. Add the final 1 quart (liter) to complete the found in this section, the excessive oil
normal oil fill. Restart the engine and allow it consumption may be due to wear on the valve
to idle for 2 minutes. Shut the engine down. guides, valves or valve seals.


3. A cylinder leak detection test can be carried out
using an Engine Cylinder Leak Detection/Air
Pressurization Kit. This can help identify
valves, piston rings, or worn valve guides/valve
stems, inoperative valve stem seals or other
related areas as the source of oil consumption.
NOTE: An oil-soaked appearance on the porcelain
tips of the spark plugs also indicates excessive oil
use. A typical engine with normal oil consumption
will exhibit a light tan to brown appearance. See
Spark Plug Analysis in this section for details. A
single or adjoining, multiple cylinder leak can be
traced by viewing the tips.
4. If an internal engine part is isolated as the root
cause, determine if the repair will exceed cost
limits and proceed with a repair strategy as
required.
5. Once corrective action to engine is complete
and verifying that all pre-check items were
eliminated in the original diagnosis, repeat the
Oil Consumption Test as described above and
verify consumption results.
Intake Manifold Vacuum Test
Bring the engine to normal operating temperature.
Connect the Vacuum/Pressure Tester to the intake 1. NORMAL READING: Needle between 51-74
manifold. Run the engine at the specified idle speed. kPa (15-22 in-Hg) and holding steady.
The vacuum gauge should read between 51-74 kPa 2. NORMAL READING DURING RAPID
(15-22 in-Hg), depending upon the engine condition ACCELERATION AND DECELERATION:
and the altitude at which the test is carried out. When the engine is rapidly accelerated (dotted
Subtract 4.0193 kPa (1 in-Hg) from the specified needle), the needle will drop to a low reading
reading for every 304.8 m (1,000 feet) of elevation (not to zero). When the throttle is suddenly
above sea level. released, the needle will snap back up to a
higher than normal figure.
The reading should be steady. If necessary, adjust
3. NORMAL FOR HIGH-LIFT CAMSHAFT
the gauge damper control (where used) if the needle
WITH LARGE OVERLAP: The needle will
is fluttering rapidly. Adjust the damper until the
register as low as 51 kPa (15 in-Hg) but will be
needle moves easily without excessive flutter.
relatively steady. Some oscillation is normal.
Intake Manifold Vacuum Test — Interpreting 4. WORN RINGS OR DILUTED OIL: When the
Vacuum Gauge Readings engine is accelerated (dotted needle), the needle
A careful study of the vacuum gauge reading while drops to 0 kPa (0 in-Hg). Upon deceleration,
the engine is idling will help pinpoint trouble areas. the needle runs slightly above 74 kPa (22
Always conduct other appropriate tests before in-Hg).
arriving at a final diagnostic decision. Vacuum 5. STICKING VALVES: When the needle (dotted)
gauge readings, although helpful, must be remains steady at a normal vacuum but
interpreted carefully. occasionally flicks (sharp, fast movement) down
Most vacuum gauges have a normal band indicated and back about 13 kPa (4 in-Hg), one or more
on the gauge face. valves may be sticking.
The following are potential gauge readings. Some
are normal; others should be investigated further.

6. BURNED OR WARPED VALVES: A regular, 16. When vacuum leaks are indicated, search out
evenly-spaced, downscale flicking of the needle and correct the cause. Excess air leaking into
indicates one or more burned or warped valves. the system will upset the fuel mixture and cause
Insufficient hydraulic lash adjuster or hydraulic concerns such as rough idle, missing on
lash adjuster (HLA) clearance will also cause acceleration or burned valves. If the leak exists
this reaction. in an accessory unit such as the power brake
7. POOR VALVE SEATING: A small but regular booster, the unit will not function correctly.
downscale flicking can mean one or more Always fix vacuum leaks.
valves are not seating. Oil Pressure Test
8. WORN VALVE GUIDES: When the needle 1. Disconnect and remove the oil pressure sensor
oscillates over about a 13 kPa (4 in-Hg) range from the engine.
at idle speed, the valve guides could be worn.
As engine speed increases, the needle will 2. Connect the Oil Pressure Gauge to the oil
become steady if guides are responsible. pressure sender oil galley port.
9. WEAK VALVE SPRINGS: When the needle 3. Run the engine until normal operating
oscillation becomes more violent as engine rpm temperature is reached.
is increased, weak valve springs are indicated. 4. Run the engine at the specified rpm and record
The reading at idle could be relatively steady. the gauge reading.
10. LATE VALVE TIMING: A steady but low 5. The oil pressure should be within specifications;
reading could be caused by late valve timing. refer to the specification chart in the appropriate
11. IGNITION TIMING RETARDING: Retarded engine section.
ignition timing will produce a steady but 6. If the pressure is not within specification, check
somewhat low reading. the following possible sources:
12. INSUFFICIENT SPARK PLUG GAP: When • insufficient oil
spark plugs are gapped too close, a regular, • oil leakage
small pulsation of the needle can occur.
• worn or damaged oil pump
13. INTAKE LEAK: A low, steady reading can be
caused by an intake manifold or throttle body • oil pump screen cover and tube
gasket leak. • excessive main bearing clearance
14. BLOWN HEAD GASKET: A regular drop of • excessive connecting rod bearing clearance
fair magnitude can be caused by a blown head
gasket or warped cylinder head-to-cylinder Valve Train Analysis — Engine Off — Valve
Cover Removed
block surface.
Check for damaged or severely worn parts and
15. RESTRICTED EXHAUST SYSTEM: When the
correct assembly. Make sure correct parts are used
engine is first started and is idled, the reading
with the static engine analysis as follows.
may be normal, but as the engine rpm is
increased, the back pressure caused by a Valve Train Analysis — Engine Off,
clogged muffler, kinked tail pipe or other Camshaft Roller Followers and Hydraulic
concerns will cause the needle to slowly drop Lash Adjusters, Overhead Camshaft
to 0 kPa (0 in-Hg). The needle then may slowly
rise. Excessive exhaust clogging will cause the • Check for loose mounting bolts on camshaft
needle to drop to a low point even if the engine carriers.
is only idling. • Check for plugged oil feed in the camshaft roller
followers, lash adjusters or cylinder heads.


Valve Train Analysis — Engine Off, If insufficient oiling is suspected, check oil passages
Camshaft — Engines for blockage, then accelerate the engine to 1,200
• Check for broken or damaged parts. rpm with the transmission in NEUTRAL and the
engine at normal operating temperature. Oil should
Valve Train Analysis — Valve Springs spurt from the rocker arm oil holes such that valve
tips and camshaft roller followers are well oiled.
• Check for broken or damaged parts. With the valve covers off, some oil splash may
Valve Train Analysis — Engine Off, Valve overshoot camshaft roller followers.
Spring Retainer and Valve Spring Retainer
Valve Train Analysis — Engine Running,
Keys
Camshaft Lobe Lift — OHC Engines
• Check for correct seating of the valve spring Check the lift of each camshaft lobe in consecutive
retainer key on the valve stem and in valve spring order and make a note of the readings.
retainer.
1. Remove the valve covers.
• Check for correct seating on the valve stem.
2. Remove the spark plugs.
Valve Train Analysis — Engine Off, Valves 3. Install the Dial Indicator Gauge with Holding
and Cylinder Head Fixture so the rounded tip of indicator is on top
• Check for plugged oil drain back holes. of the camshaft lobe and on the same plane as
the valve tappet.
• Check for worn or damaged valve tips.
4. Rotate the crankshaft using a breaker bar and
• Check for missing or damaged guide-mounted socket attached to the crankshaft pulley retainer
valve stem seal. bolt. Rotate the crankshaft until the base circle
• Check collapsed valve tappet gap. of the camshaft lobe is reached.
• Check installed valve spring height.
• Check for missing or worn valve spring seats.
• Check for plugged oil metering orifice in cylinder
head oil reservoir (if equipped).
Static checks (engine off) are to be made on the
engine prior to the dynamic procedure.
Valve Train Analysis — Engine Running
• Start the engine and, while idling, check for
correct operation of all parts. Check the
following:
Valve Train Analysis — Engine Running, 5. Zero the dial indicator. Continue to rotate the
Valves and Cylinder Head crankshaft until the (1) high-lift point of the
• Check for plugged oil drain back holes. camshaft lobe is in the fully-raised position
(highest indicator reading).
• Check for missing or damaged valve stem seals or
guide-mounted valve stem seals. 6. To check the accuracy of the original indicator
reading, continue to rotate crankshaft until the
• Check for a plugged oil metering orifice in the (2) base circle is reached. The indicator reading
cylinder head oil reservoir (4.6L engine only). should be zero. If zero reading is not obtained,
repeat Steps 1 through 6.
7. NOTE: If the lift on any lobe is below
specified service limits, install a new camshaft,
and new camshaft roller followers.
Remove the Dial Indicator Gauge with Holding
Fixture.

8. Install the spark plugs. An incorrectly functioning valve tappet can be
9. Install the valve covers. sticking, caused by contaminants or varnish inside
the tappet. The tappet can have a check valve that is
Valve Train Analysis — Engine Running, not functioning correctly, which can be caused by
Valve Tappet an obstruction, such as dirt or chips that prevent
Valve tappet noise can be caused by any of the the check valve from closing, or a broken check
following: valve spring. A tappet with a leakdown time out of
specification can cause tappet noise. If no other
• excessive valve tappet gap (collapsed) cause for noisy valve tappets can be found, the
• incorrectly functioning valve tappet leakdown rate should be checked and new valve
• air in lubrication system tappets installed if found to be out of specification.
• excessive valve guide wear Assembled valve tappets can be tested with
Hydraulic Lash Adjuster Leakdown Tester to check
• low oil pressure the leakdown rate. The leakdown rate specification
Excessive collapsed valve tappet gap can be caused is the time in seconds for the plunger to move a
by loose rocker arm seat bolts/nuts, incorrect initial specified distance while under a 22.7 kg (50 lb)
adjustment or wear of valve tappet face, or worn load.
roller valve tappets, push rod, rocker arm, rocker Air bubbles in the lubrication system will prevent
arm seat or valve tip. With valve tappet collapsed, the valve tappet from supporting the valve spring
check gap between the valve tip and the rocker arm load. This can be caused by too high or too low an
to determine if any other valve train parts are oil level in the oil pan or by air being drawn into
damaged, worn or out of adjustment. the system through a hole, crack or leaking gasket
on the oil pump screen cover and tube.

GENERAL PROCEDURES
Sprockets
1. WARNING: To avoid the possibility of

personal injury or damage to the vehicle, do
not operate the engine with the hood open
until the fan blade has been examined for
possible cracks and separation. Failure to
follow these instructions may result in
personal injury.
NOTE: Specifications show the expected
minimum or maximum condition.
NOTE: If a component fails to meet the
specifications, it is necessary to install a new
component or refinish the component. If the
component can be refinished, wear limits are
provided as an aid to making a decision. If a
component fails to meet specifications and
cannot be refinished, a new component must be
installed.
Inspect the timing chain/belt and the sprocket.
• Install new components as necessary. Refer
to the appropriate section in Group 303 for
the procedure.

GENERAL PROCEDURES
Camshaft Journal — Diameter
1. Measure each camshaft journal diameter in two

directions.
• If out of specification, install new
components as necessary. Refer to the
appropriate section in Group 303 for the
procedure.

GENERAL PROCEDURES
Camshaft Journal — Clearance,
Plastigage Method
Special Tool(s)
Plastigage
303-D031 (D81L-6002-B) or
equivalent
NOTE: The camshaft journals must meet 3. Use Plastigage to verify the camshaft journal
specifications before checking camshaft journal clearance.
clearance.
1. Remove the camshaft bearing cap and lay components as necessary. Refer to the
Plastigage across the surface. Refer to the appropriate section in Group 303 for the
appropriate section in Group 303 for the procedure.
procedure.
2. NOTE: Do not turn the camshaft while

carrying out this procedure.
Position the camshaft bearing cap and install
the bolts. Refer to the appropriate section in
Group 303 for the procedure.

GENERAL PROCEDURES
Camshaft — End Play, OHC Engines 5. Move the camshaft to the front of the cylinder
head. Note and record the camshaft end play.
Special Tool(s) • If camshaft end play exceeds specifications,
install new camshaft and recheck end play.
Dial Indicator with Bracketry
100-002 (TOOL-4201-C) or Refer to the appropriate section in Group
equivalent 303 for the procedure.
• If camshaft end play exceeds specification
after camshaft installation, install a new
cylinder head. Refer to the appropriate
1. Remove the roller followers. Refer to the

procedure.
2. Use a Dial Indicator with Bracketry to measure

camshaft end play.
3. Position the camshaft to the rear of the cylinder

head.
4. Zero the indicator.

GENERAL PROCEDURES
Camshaft — Lobe Surface
1. Inspect camshaft lobes for pitting or damage in

the contact area. Minor pitting is acceptable
outside the contact area.
• If excessive pitting or damage is present,
install new components as necessary. Refer
to the appropriate section in Group 303 for
the procedure.

GENERAL PROCEDURES
Camshaft — Lobe Lift
Special Tool(s)
100-002 (TOOL-4201-C) or
equivalent
1. Use a Dial Indicator with Bracketry to measure

camshaft intake/exhaust lobe lift.
• Rotate the camshaft and subtract the lowest
indicator reading from the highest indicator
reading to figure the camshaft lobe lift.
• For additional information, refer to
Specifications in the appropriate section in
Group 303.

GENERAL PROCEDURES
Camshaft — Runout
Special Tool(s)
100-002 (TOOL-4201-C) or
equivalent
1. NOTE: Camshaft journals must be within

specifications before checking runout.
Use a Dial Indicator with Bracketry to measure
the camshaft runout.
• Rotate the camshaft and subtract the lowest
indicator reading from the highest indicator
reading.
• For additional information, refer to the
specification chart in the appropriate engine
section.
procedure.

GENERAL PROCEDURES
Crankshaft Main Bearing Journal —
Diameter
1. Measure each of the crankshaft main bearing

journal diameters in at least two directions.
• Refer to the appropriate section in Group
303 for the procedure.
procedure.

GENERAL PROCEDURES
Crankshaft Main Bearing Journal —
Taper
1. Measure each of the crankshaft main bearing

journal diameters in at least two directions at
each end of the main bearing journal.
procedure.

GENERAL PROCEDURES
Crankshaft Main Bearing Journal — 3. NOTE: Do not turn the crankshaft while
Clearance carrying out this procedure.
Install and remove the crankshaft main bearing
Special Tool(s) cap.
Plastigage 4. Verify the crankshaft journal clearance.
303-D031 (D81L-6002-B) or
equivalent • Refer to the appropriate section in Group
procedure.
NOTE: Crankshaft main bearing journals must be
within specifications before checking journal
clearance.
1. Remove the crankshaft main bearing caps and

crankshaft main bearing.
2. Lay a piece of Plastigage across the face of

each crankshaft main bearing surface.

GENERAL PROCEDURES
Crankshaft — End Play 4. Move the crankshaft to the front of the cylinder
block. Note and record the crankshaft end play.
Special Tool(s) • If crankshaft end play exceeds
specifications, install a new crankshaft thrust
100-002 (TOOL-4201-C) or washer (6334) or crankshaft thrust main
equivalent bearing (6337). Refer to the appropriate
1. Measure the crankshaft end play. Use a Dial

Indicator with Bracketry to measure crankshaft
end play.
2. Position the crankshaft to the rear of the

cylinder block.
3. Zero the indicator.

GENERAL PROCEDURES
Crankshaft — Runout
Special Tool(s)
100-002 (TOOL-4201-C) or
equivalent
1. NOTE: Crankshaft main bearing journals must

be within specifications before checking runout.
Use the Dial Indicator with Bracketry to
measure the crankshaft runout.
Group 303.
• Rotate the crankshaft and subtract the lowest
dial indicator reading from the highest dial
indicator reading to figure the crankshaft
runout. If it is out of specification, install
new components as necessary. Refer to the
procedure.

GENERAL PROCEDURES
Crankshaft — Connecting Rod
Journal Taper, Out of Round
1. Measure the crankshaft connecting rod journal

diameters in two directions perpendicular to one
another at each end of the connecting rod
journal. The difference in the measurements
from one end to the other is the taper. Verify
measurement is within the wear limit.
procedure.

GENERAL PROCEDURES
Cylinder Bore — Taper
1. Measure the cylinder bore at the top, middle,

and bottom of piston ring travel in two
directions as indicated. Verify the cylinder bore
is within the wear limit. The difference
indicates the cylinder bore taper. Bore the
cylinder to the next oversize.

GENERAL PROCEDURES
Cylinder Bore — Out-of-Round
1. Measure the cylinder bore in two directions.

The difference is the out-of-round. Verify the
out-of-round is within the wear limit and bore
the cylinder to the next oversize limit.

GENERAL PROCEDURES
Piston — Inspection
Special Tool(s)
Piston Ring Groove Cleaner
303-D033 (D81L-6002-D) or
equivalent
CAUTION: Do not use a caustic cleaning

solution or a wire brush to clean the pistons or 2. Use the Piston Ring Groove Cleaner to clean
damage can occur. the piston ring grooves.
1. Clean and inspect the (1) ring lands, (2) skirts, • Make sure the oil ring holes are clean.
(3) pin bosses, and the (4) tops of the pistons.
If wear marks, scores or glazing is found on the
piston skirt, check for a bent or twisted
connecting rod.

GENERAL PROCEDURES
Piston — Pin to Bore Diameter
1. WARNING: Cover the end of the pin

bore with a hand or shop rag when removing
the retainer ring, since it has a tendency to
spring out. Wear eye protection.
NOTE: Piston and piston pins are a matched
set and should not be interchanged.
Measure the piston pin bore diameter in two
directions on each side. Verify the diameter is
within specification.
procedure.

GENERAL PROCEDURES
Piston — Diameter
1. Measure the piston diameter 90 degrees from

the piston pin and 42 mm down from the top of
the piston at the point indicated. Refer to the
procedure.
procedure.

GENERAL PROCEDURES
Piston — to Cylinder Bore Clearance
1. Subtract the piston diameter from the cylinder

bore diameter to find the piston-to-cylinder bore
clearance.

GENERAL PROCEDURES
Piston — Selection 2. NOTE: For precision fit, new pistons are
divided into three categories within each size
NOTE: The cylinder bore must be within the range based on their relative position within the
specifications for taper and out-of-round before range. A paint spot on the new pistons indicates
fitting a piston. the position within the size range.
Choose the piston with the correct paint color.
1. Select a piston size based on the cylinder bore. • Refer to the appropriate section in Group

GENERAL PROCEDURES
Piston — Ring End Gap 2. Use a feeler gauge to measure the top piston
ring end gap and the second piston ring end
gap.
CAUTION: Use care when fitting piston
rings to avoid possible damage to the piston ring • Refer to the appropriate section in Group
or the cylinder bore. 303 for the procedure.
CAUTION: Piston rings should not be

transferred from one piston to another.
NOTE: Cylinder bore must be within specification

for taper and out-of-round.
1. Use a piston without rings to push a piston ring

in a cylinder to the bottom of ring travel.

GENERAL PROCEDURES
Piston — Ring-to-Groove Clearance
1. Inspect the piston for ring land damage or

accelerated wear.
2. Measure the piston ring-to-groove clearance.

procedure.

GENERAL PROCEDURES
Piston — Pin Diameter
1. Measure the piston pin diameter in two

directions at the points shown. Verify the
diameter is within specification.
procedure.

GENERAL PROCEDURES
Connecting Rod — Cleaning
CAUTION: Do not use a caustic cleaning

solution or damage to connecting rods can occur.
1. NOTE: The connecting rod large end is a

matched set. The connecting rod cap must be
installed on the original connecting rod in the
original position. Do not reverse the cap. Parts
are not interchangeable.
Mark and separate the parts and clean with
solvent. Clean the oil passages.

GENERAL PROCEDURES
Connecting Rod — Large End Bore
1. Tighten the bolts to specification, then measure

the bore in two directions. The difference is the
connecting rod bore out-of-round. Verify the
out-of-round is within specification.
procedure.

GENERAL PROCEDURES
Connecting Rod — Bushing Diameter
1. Measure the inner diameter of the connecting

rod bushing, if equipped. Verify the diameter is
procedure.

GENERAL PROCEDURES
Connecting Rod — Bend
1. Measure the connecting rod bend on a suitable

alignment fixture. Follow the instructions of the
fixture manufacturer. Verify the bend
measurement is within specification.
procedure.

GENERAL PROCEDURES
Connecting Rod — Twist
1. Measure the connecting rod twist on a suitable

alignment fixture. Follow the instructions of the
fixture manufacturer. Verify the measurement is
procedure.

GENERAL PROCEDURES
Connecting Rod — Piston Pin Side
Clearance
1. Measure the clearance between the connecting

rod and the piston. Verify the measurement is
procedure.

GENERAL PROCEDURES
Connecting Rod — Bearing Journal 4. Measure the Plastigage to get the connecting
Clearance rod bearing journal clearance. The Plastigage
should be smooth and flat. A changing width
indicates a tapered or damaged connecting rod
Special Tool(s)
or connecting rod bearing.
Plastigage • Refer to the appropriate section in Group
303-D031 (D81L-6002-B) or
equivalent 303 for the procedure.
procedure.
NOTE: The crankshaft connecting rod journals

must be within specifications to check the
connecting rod bearing journal clearance.
1. Remove the connecting rod bearing cap.
2. Position a piece of Plastigage across the bearing

surface.
3. NOTE: Do not turn the crankshaft during this

step.
Install and tighten to specifications, then
remove the connecting rod bearing cap.

GENERAL PROCEDURES
Roller Follower — Inspection OHC engines
Push rod engines
1. Inspect the roller for flat spots or scoring. If

any damage is found, inspect the camshaft
lobes and valve tappet for damage.

GENERAL PROCEDURES
Valve Tappet — Inspection OHC engines
Push rod engines
1. Inspect the hydraulic valve tappet and roller for

damage. If any damage is found, inspect the
camshaft lobes and valves for damage.

GENERAL PROCEDURES
Valve — Stem Diameter
1. Measure the diameter of each intake and

exhaust valve stem at the points shown. Verify
the diameter is within specification.
procedure.

GENERAL PROCEDURES
Valve — Stem to Valve Guide
Clearance
Special Tool(s)
100-002 (TOOL-4201-C) or
equivalent
Valve Stem Checking Tool

303-004 (TOOL-6505-E) or 2. Move the Valve Stem Clearance Tool toward
equivalent the indicator and zero the indicator. Move the
Valve Stem Clearance Tool away from the
indicator and note the reading. The reading will
be DOUBLE the valve stem-to-valve guide
clearance. Valves with oversize stems will
need to be installed if out of specification.
NOTE: Valve stem diameter must be within
specifications before checking valve stem to valve
guide clearance.
1. NOTE: If necessary, use a magnetic base.

Install a Valve Stem Clearance Tool on the
valve stem and install a Dial Indicator with
Bracketry. Lower the valve until the Valve
Stem Clearance Tool contacts the upper surface
of the valve guide.

GENERAL PROCEDURES
Valve — Inspection
1. Inspect the following valve areas:

1 the end of the stem for grooves or scoring
2 the valve face and the edge for pits, grooves
or scores
3 the valve head for signs of burning, erosion,
warpage and cracking
4 the valve margin for wear

GENERAL PROCEDURES
Valve — Guide Inner Diameter 2. If the valve guide is not within specifications,
ream the valve guide and install a valve with an
oversize stem or remove the valve guide and
1. Measure the inner diameter of the valve guides
install a new valve guide.
in two directions where indicated.

GENERAL PROCEDURES
Valve — Guide Reaming 3. Clean the sharp edges left by reaming.
1. Use a hand-reaming kit to ream the valve

guide.
2. Reface the valve seat.

GENERAL PROCEDURES
Valve — Spring Installed Length
1. Measure the installed length of each valve

spring.
components. Refer to the appropriate section
in Group 303 for the procedure.

GENERAL PROCEDURES
Valve — Spring Free Length
1. Measure the free length of each valve spring.

procedure.

GENERAL PROCEDURES
Valve — Spring Squareness
1. Measure the out-of-square on each valve spring.

• Turn the valve spring and observe the space
between the top of the valve spring and the
square. Install a new valve spring if out of
square. Refer to the appropriate section in
Group 303 for the procedure.

GENERAL PROCEDURES
Valve — Spring Strength
Special Tool(s)
Valve/Clutch Spring Tester
303-006 (TOOL-6513-DD) or
equivalent
1. Use a Valve/Clutch Spring Tester to check the

valve spring for correct strength at the specified
valve spring length.
Group 303.
procedure.

GENERAL PROCEDURES
Valve — Seat Inspection
Valve and Seat Refacing Measurements
CAUTION: After grinding valves or valve

seats, check valve clearance.
1. Check the valve head and seat.

• Check valve angles.
• Check margin width.
2. Inspect for abnormalities on the valve face and
• Be sure margin width is within specification. seat.

GENERAL PROCEDURES
Valve — Seat Width
1. Measure the valve seat width. If necessary,

grind the valve seat to specification.
• Measure the intake valve seat width.
• Measure the exhaust valve seat width.
• Recheck the valve spring installed length
after the seats have been ground, and shim
the valve springs as necessary to achieve the
correct installed spring length.

GENERAL PROCEDURES
Valve — Seat Runout
1. Use the Valve Seat Runout Gauge to check

valve seat runout.

GENERAL PROCEDURES
Cylinder Head — Distortion
Special Tool(s)
Straight Edge
303-D039 (D83L-4201-A) or
equivalent
1. Use a straight edge and a feeler gauge to

inspect the cylinder head for flatness. If the
cylinder head is distorted, install a new cylinder
head.

GENERAL PROCEDURES
Cylinder Bore — Cleaning 2. Thoroughly rinse with clean water and wipe dry
with a clean, lint-free cloth.
1. CAUTION: If these procedures are not 3. Use a clean, lint-free cloth and lubricate the
followed, rusting of the cylinder bores may cylinder bores.
occur.
• Use clean engine oil meeting Ford
Clean the cylinder bores with soap or detergent specification.
and water.

GENERAL PROCEDURES
Cylinder Block — Core Plug Cup-Type
Replacement
1. CAUTION: Use care during this
Special Tool(s) procedure so as not to disturb or distort the
cup sealing surface.
Impact Slide Hammer
100-001 (T50T-100-A) CAUTION: When installed, the flanged
edge must be below the chamfered edge of
the bore to effectively seal the bore.
Use a tool suitable to seat the cup-type cylinder
block core plug.
Material
Item Specification
High Strength WSK-M2G351-A6
Threadlocker
TA-26 or equivalent
1. Use a slide hammer or tools suitable to remove

the cylinder block core plug.
Expansion-Type
1. CAUTION: Do not contact the crown

when installing an expansion-type cylinder
block core plug. This could expand the plug
before seating and result in leakage.
Use tool suitable to seat the expansion-type
cylinder block core plug.
2. Inspect the cylinder block plug bore for any

damage that would interfere with the correct
sealing of the plug. If the cylinder block plug
bore is damaged, bore for the next oversize
plug.
3. NOTE: Oversize plugs are identified by the OS

stamped in the flat located on the cup side of
the plug.
Coat the cylinder block core plug and bore
lightly with Threadlock 262 and install the
cylinder block core plug.

GENERAL PROCEDURES
Spark Plug — Inspection 3. Inspect for carbon fouling. Look for black, dry,
fluffy carbon deposits on the insulator tips,
exposed shell surfaces and electrodes, caused by
1. Inspect the spark plug for a bridged gap.
a spark plug with an incorrect heat range, dirty
• Check for deposit build-up closing the gap air cleaner, too rich a fuel mixture or excessive
between the electrodes. Deposits are caused idling.
by oil or carbon fouling.
• Clean the spark plug.
4. Inspect for normal burning.

2. Check for oil fouling.
• Check for light tan or gray deposits on the
• Check for wet, black deposits on the firing tip.
insulator shell bore electrodes, caused by
excessive oil entering the combustion
chamber through worn rings and pistons,
excessive valve-to-guide clearance or worn
or loose bearings.
• Correct the oil leak concern.
• Install a new spark plug.

GENERAL PROCEDURES (Continued)

5. Inspect for pre-ignition, identified by melted
electrodes and a possibly damaged insulator.
Metallic deposits on the insulator indicate
engine damage. This may be caused by
incorrect ignition timing, wrong type of fuel or
the unauthorized installation of a heli-coil
insert in place of the spark plug threads.
7. Inspect for fused deposits, identified by melted

or spotty deposits resembling bubbles or
blisters. These are caused by sudden
acceleration.
6. Inspect for overheating, identified by a white or

light gray spots and with bluish-burnt
appearance of electrodes. This is caused by
engine overheating, wrong type of fuel, loose
spark plugs, spark plugs with an incorrect heat
range, low fuel pump pressure or incorrect
ignition timing.

GENERAL PROCEDURES
Exhaust Manifold — Inspection
Special Tool(s)
Straight Edge
303-D039 (D83L-4201-A) or
equivalent
1. Place a straight edge across the exhaust

manifold flanges and check for warping with a
feeler gauge.

GENERAL PROCEDURES
Bearing — Inspection
1. Inspect bearings for the following defects.

Possible causes are shown:
1 Cratering — fatigue failure.
2 Spot polishing — incorrect seating.
3 Imbedded dirt engine oil.
4 Scratching — dirty engine oil.
5 Base exposed — poor lubrication.
6 Both edges worn — journal damaged.
7 One edge worn — journal tapered or
bearing not seated.

303-01-1 Engine 303-01-1
SPECIFICATIONS
General Specifications (Continued)
Item Specification
Valve arrangement (front All primary
Item Specification to rear) — exhaust, RH
Lubricants and Sealants Valve clearance — intake 0.0445 mm (0.0018 in)
Metal Surface Cleaner WSE-M5B392-A Valve clearance — 0.0705 mm (0.0028 in)
ZC-21 exhaust
Silicone Gasket and WSE-M4G323-A4 Valve guide bore diameter 7.015-7.044 mm
Sealant F7AZ-19554-EA (0.2762-0.2773 in)
Motorcraft Premium Gold WSS-M97B51-A1 Valve stem diameter — 6.975-6.995 mm
Engine Coolant VC-7-A intake (standard) (0.2754-0.2746 in)
(in California and Oregon
VC-7-B, in Canada Valve stem diameter — 6.949-6.970 mm
VC-7-C) or equivalent exhaust (standard) (0.2744-0.2736 in)
(yellow color) Valve stem-to-guide 0.020-0.069 mm
Thread Sealant with WSK-M2G350-A2 clearance — intake (0.00078-0.00272 in)
PTFE TA-24 Valve stem-to-guide 0.046-0.095 mm
SAE 5W-20 Motorcraft WSS-M2C930-A clearance — exhaust (0.0018-0.0037 in)
Premium Synthetic Blend Valve head diameter — 37 mm (1.46 in)
Motor Oil XO-5W20-QSP intake
or equivalent Valve head diameter — 30 mm (1.18 in)
Motorcraft Silicone Brake ESE-M1C171-A exhaust
Caliper Grease and Valve head diameter — 35.0 and 28.0 mm
Dielectric Compound gauge diameters (1.378-1.102 in)
XG-3-A or equivalent
Valve face runout 0.05 mm (0.002 in)
Threadlock 262 TA-26 WSK-M2G351-A6
Valve face angle 45.5 degrees
Engine
Valve seat width 1.8-2.2 mm (0.071-0.086
Displacement 4.6L (4V) (281 CID) in)
Number of cylinders 8 Valve seat runout (TIR) 0.05 mm (0.002 in)
Bore 90.2 mm (3.55 in) max.
Stroke 90.0 mm (3.54 in) Valve seat angle 45 degrees
Firing order 1-3-7-2-6-5-4-8 Valve spring free length 45.5 mm (1.6598 in)
Oil pressure (hot 1,500 138-310 kPa (approx.)
rpm) Valve spring squareness 2 degrees
Oil capacity 6 ± 0.25 (quarts U.S.) a Valve spring compression 711.47 N @ 26.19 mm
Compression ratio 10.1:1 pressure (159.9 lb-ft @ 1.031 in)
Cylinder Head and Valve Train Valve spring installed 36.14 mm (1.4228 in)
height
Cylinder head gasket 0.10 mm (0.004 in) max.
surface flatness overall Valve spring installed 289.1 N @ 36.14 mm
pressure (64.99 lb-ft @ 1.4228 in)
Combustion chamber 53.0 ± 1.5 cm3 (cc5)
volume (cc) Valve spring installed 10% pressure loss @
pressure — service limit 28.02 mm (1.103 in)
Valve arrangement (front All primary
to rear) — intake, LH Roller follower ratio 1.8:1
Valve arrangement (front All primary Hydraulic Lash Adjuster

to rear) — exhaust, LH Diameter (standard) 16.000-15.988 mm
Valve arrangement (front All primary (0.6299-0.6294 in)
to rear) — intake, RH Clearance to bore 0.018-0.069 mm
(0.000709-0.002717 in)

Last updated: 3/19/2005 2005 Aviator, 09/2004
303-01-2 Engine 303-01-2
SPECIFICATIONS (Continued)
General Specifications (Continued) General Specifications (Continued)
Item Specification Item Specification
Service limit 0.016 mm (0.0006299 in) Main bearing journal 0.004 mm (0.0002 in)
Hydraulic leakdown rate b 5-25 seconds maximum taper
Collapsed lash adjuster 0.45-0.85 mm Main bearing journal 0.006 mm (0.0002 in)
gap — desired (0.0177-0.0334 in) maximum out-of-round
Camshaft Main bearing 0.025-0.045 mm

journal-to-cylinder block (0.00098-0.00177 in)
Theoretical valve lift @ 0 10.0 mm (0.3937 in) clearance — desired
lash
Main bearing 0.025-0.050 mm
Lobe lift 5.54 mm (0.218 in) journal-to-cylinder block (0.00098-0.00197 in)
Allowable lobe lift loss 0.130 mm (0.0051 in) clearance — allowable
Journal diameter (all) 26.962-26.936 mm Connecting rod journal 52.983-53.003 mm
(1.0615-1.0605 in) diameter (2.085941-2.086728 in)
Camshaft journal bore 27.012-26.987 mm Connecting rod journal 0.004 mm (0.0002 in)
inside diameter (all) (1.0635-1.0625 in) maximum taper
Camshaft 0.025-0.076 mm Connecting rod journal 0.004 mm (0.0002 in)
journal-to-bearing (0.00098-0.002992 in) maximum out-of-round
clearance Crankshaft maximum end 0.130-0.301 mm
Camshaft 0.100 mm (0.003937 in) play (0.005118-0.011850 in)
journal-to-bearing max. Piston and Connecting Rod
clearance — service limit
Piston diameter — 0.028 mm (0.0010 in)
Runout 0.025 mm (0.0010 in) standardd
End play 0.025-0.165 mm Piston diameter — coded 90.167-90.188 mm
(0.00098-0.00649 in) red 1d (3.299-3.5505 in)
End play — service limit 0.190 mm (0.007480 in) Piston diameter — coded 90.180-90.195 mm
Cylinder Block blue 2d (3.5504-3.5510 in)
Cylinder bore diameter — 0.2-0.6 microns Piston diameter — coded 90.198-90.208 mm
surface finish (RMS)c yellow 3d (3.5511-3.5515 in)
Cylinder bore diameter — 0.015 mm (0.0006 in) Piston-to-cylinder bore -0.010/+0.026 mm
out-of-round limitc clearance (-0.0003937/+0.0010236
in)
Cylinder bore diameter — 0.020 mm (0.0008 in)
out-of-round service limitc Piston ring end gap — 0.150-0.300 mm
compression (top)e (0.006-0.0018 in)
Cylinder bore diameter — 0.006 mm (0.0002 in)
taper service limitc Piston ring end gap — 0.300-0.550 mm
compression (bottom)e (0.0018-0.0022 in)
Cylinder bore maximum 0.006 mm (0.0002 in)
taper Piston ring end gap — oil 0.15-0.66 mm
ring (steel rail)e (0.00591-0.02598 in)
Cylinder bore maximum 0.015 mm (0.0006 in)
out-of-round Piston ring groove width 1.230-1.250 mm
— compression (top) (0.0484-0.0492 in)
Main bearing bore inside 72.400-72.424 mm
diameter (2.8504-2.8513 in) Piston ring groove width 1.520-1.540 mm
— compression (bottom) (0.05984-0.06062 in)
Camshaft bearing bore 26.987-27.012 mm
inside diameter (1.0625-1.0635 in) Piston ring groove width 3.030-3.055 mm
— oil ring (0.1193-0.1203 in)
Head gasket surface 0.15 mm (0.006 in) max.
flatness overall Piston ring width — 1.00 mm (0.03937 in)
compression (top and max.
Crankshaft bottom)
Main bearing journal 67.481-67.505 mm Piston ring width — oil 1.15 mm (0.04528 in)
diameter (2.6567269-2.6576718 in) ring max.
2005 Aviator, 09/2004

303-01-3 Engine 303-01-3
General Specifications (Continued) General Specifications (Continued)
Item Specification Item Specification
Piston ring-to-groove 0.0090-0.0235 mm Connecting rod side 0.15-0.45 mm
clearance — compression (0.000354-0.000925 in) clearance (assembled to (0.00591-0.01772 in)
(top) crank) — standard
Piston ring-to-groove 0.030-0.080 mm Connecting rod side 0.50 mm (0.01969 in)
clearance — compression (0.00118-0.00315 in) clearance (assembled to max.
(bottom) crank) — service limit
Piston ring-to-groove snug fit a With installation of a new filter.
clearance — oil ring b Time necessary for plunger to leak down 1.6 mm of
Piston pin bore diameter 21.9985-22.0035 mm travel with 222 N force and leak down fluid in
(0.8661-0.8663 in) tappet.
c Cylinder bore diameter
Piston pin diameter 22.0005-22.0030 mm Red — 90.200-90.213
(0.8661596-0.8662581 in) Blue — 90.213-90.226
Piston pin length 61.601-62.030 mm Yellow — 90.226-90.239
(2.42523-2.44212 in) d Measured at 42 mm from piston dome, at 90
Piston pin-to-piston fitf -0.0045/+0.002 mm degrees to the piston pin.
(-0.000177/+0.0000787 in) e Specification in 90.200 mm diameter gauge.
f Piston pin outer diameter is larger than piston pin
Connecting rod-to-pin 0.004-0.0175 mm bore, providing a possible interference fit.
clearance — standard (0.000157-0.00689 in)
Connecting rod-to-pin 0.35 mm (0.01378 in) Torque Specifications
clearance — service limit
Description Nm lb-ft lb-in
Connecting rod pin bore 21.9985-22.0025 mm
Camshaft sprocket bolt a — — —
diameter (0.866081-0.866238 in)
Connecting rod bolt a — — —
Connecting rod length 150.7 mm (5.933 in)
(center-to-center) Engine front cover — — —
Connecting rod maximum 0.038 per 25 mm bolta
allowed bend (0.00150 per 0.9843 in) Cylinder head bolta — — —
Connecting rod maximum 0.050 per 25 mm Pulley-to-crankshaft — — —
allowed twist (0.00197 per 0.9843 in) bolta
Connecting rod bearing 56.866-56.886 mm Exhaust manifold studs 12 9 —
bore diameter (2.23881-2.23960 in)
Lower intake — — —
Connecting rod 0.027-0.069 mm manifold-to-cylinder
bearing-to-crankshaft (0.0010629-0.0027165 in) head bolta
clearance — desired and
allowable Main bearing cap bolta — — —
Oil filter adapter bolt 25 18 —
Heater coolant 10 — 89
outlet-to-cylinder head
bolts
Oil pump screen cover 10 — 89
and tube-to-oil pump
bolt
Oil pan-to-cylinder — — —
block bolta
Oil pan-to-engine front — — —
cover boltsa
Oil pump-to-cylinder 10 — 89
block bolt
2005 Aviator, 09/2004

303-01-4 Engine 303-01-4
Torque Specifications (Continued) Torque Specifications (Continued)
Description Nm lb-ft lb-in Description Nm lb-ft lb-in
Oil pump screen and 25 18 — Ignition coil cover 10 — 89
pickup tube-to-main bolts
bearing cap stud spacer Generator mounting 10 — 89
bolt bracket retainers
Valve cover bolts and 10 — 89 Oil level indicator tube 10 — 89
studs retainer
Power steering pump to 25 18 — Primary timing chain 10 — 89
engine guide-to-engine bolts
Camshaft cap cluster to 19 14 — Oil pump screen and 25 18 —
cylinder head pickup tube
Timing chain tensioner 25 18 — spacer-to-main bearing
bolts — primary stud
Timing chain tensioner 10 — 89 Subframe brace nuts 41 30 —
bolts — secondary
a Refer to the procedure in this section.
A/C compressor studs 25 18 —
2005 Aviator, 09/2004

303-01-1 Engine 303-01-1

Engine Induction System
The sequential multiport fuel injection (SFI)
WARNING: Do not operate the engine
provides the fuel/air mixture needed for combustion
with the hood open until the fan blade has been
in the cylinders. The 8 solenoid-operated fuel
first examined for possible cracks and separation.
injectors:
The 4.6L (281 CID) is a V-8 engine with the
following features: • are mounted in the lower intake manifold.
• meter fuel into the air intake stream in accordance
• Dual overhead camshafts
with engine demand.
• 4 valves per cylinder
• are positioned so that their tips direct fuel just
• Sequential multiport fuel injection (SFI) ahead of the engine intake valves.
• Aluminum cylinder heads • are connected in series with the fuel pressure
• Cast aluminum, 90-degree V-cylinder block sensor.
• Individual chain-driven camshafts with a hydraulic • supply fuel from the fuel tank with a fuel pump
timing chain tensioner on each timing chain mounted in the fuel tank.
• Electronic ignition system with 8 ignition coils A constant fuel pressure is maintained across the
fuel injectors by the fuel pressure sensor. The fuel
Identification pressure sensor:
Always refer to these labels when installation of
• is positioned upstream from the fuel injectors on
new parts is necessary or when checking engine
the fuel injection supply manifold.
calibrations. The engine parts often differ within a
CID family. Verification of the identification codes Valve Train
will make sure that the correct parts are obtained.
The valve train operates as follows:
These codes contain all the pertinent information
relating to the dates, optional equipment and • Ball-tip hydraulic lash adjusters provide automatic
revisions. The Ford Master Parts Catalog contains a lash adjustment.
complete listing of the codes and their applications. • Roller followers ride on the camshaft lobe,
Code Information transferring the up-and-down motion of the
camshafts to the valves in the cylinder heads.
The engine code information label, located on the
side of the valve cover and the front side of the Positive Crankcase Ventilation System
valve cover, contains the following: All engines are equipped with a closed-type positive
• Engine build date crankcase ventilation (PCV) system recycling the
crankcase vapors to the upper intake manifold.
• Engine plant code
• Engine code Lubrication System
The engine lubrication system operates as follows:
Exhaust Emission Control System
Operation and necessary maintenance of the exhaust • Oil is drawn into the oil pump through the oil
emission control devices used on this engine are pump screen cover and tube in the sump of the
covered in the Powertrain Control/Emissions oil pan.
Diagnosis (PC/ED) manual. • Oil is pumped through the oil filter on the left
front side of the cylinder block.
• Oil enters the main gallery where it is distributed
to the crankshaft main journals and to both
cylinder heads.

303-01-2 Engine 303-01-2
DESCRIPTION AND OPERATION (Continued)
• From the main journals, the oil is routed through • Oil pump displacement has been selected to
cross-drilled passages in the crankshaft to provide adequate volume to make sure of correct
lubricate the connecting rod bearings. Controlled oil pressure, both at hot idle and maximum speed.
leakage through the crankshaft main bearings and • The relief valve calibration protects the system
connecting rod bearings is slung radially outward from excessive pressure during high viscosity
to cool and lubricate the cylinder walls as well as conditions.
the entire connecting rod, piston and piston ring
assembly. • The relief valve is designed to provide adequate
connecting rod bearing lubrication under
• The left cylinder head is fed from a drilling into high-temperature and high-speed conditions.
the supply passage feeding the main gallery at the
front of the cylinder block. The right cylinder Cooling System
head is fed from a drilling into the rear of the The engine cooling system includes the following:
main gallery. Main gallery pressure is reduced as
it enters the cylinder head galleries through fixed • Radiator
serviceable orifices, located at the upper part of • Coolant pump
the feed passages. The reduced pressure in the
• Electric cooling fan motor and fan blade
cylinder head galleries feeds the camshaft
journals, the hydraulic lash adjusters and the • Degas bottle, which aids in maintaining the
primary and secondary timing chain tensioners. correct volume of engine coolant
• The camshaft lobe and roller followers are • Thermostat
lubricated by splash created through valve train • Upper radiator hose
operation. • Lower radiator hose
Oil Pump • Heater hose
The lubrication system of the 4.6L (4V) engine is Drive Belt System
designed to provide optimum oil flow to critical
components of the engine through its entire The 4.6L (4V) DOHC engine is equipped with a
operating range. The heart of the system is a serpentine drive belt. To make sure of maximum
positive displacement internal gear oil pump using life, install a new drive belt of the same type as
top seal rotors. Generically this design is known as originally installed.
a gerotor pump, which operates as follows: • The accessories mounted on the front of the
• The oil pump is mounted on the front face of the engine are belt-driven by the crankshaft.
cylinder block. • The serpentine drive belt is routed over each
• The inner rotor is piloted on the crankshaft post accessory pulley, driven by the crankshaft pulley
and is driven through flats on the crankshaft. bolted to the crankshaft.
• System pressure is limited by an integral,
internally-vented relief valve which directs the
bypassed oil back to the inlet side of the oil
pump.
2005 Aviator, 09/2004

303-01-1 Engine 303-01-1
IN-VEHICLE REPAIR
Upper Intake Manifold
Item Part Number Description Item Part Number Description

1 6K817 Positive crankcase ventilation 6 W527351-S Coolant hose clamp
(PCV) valve hose 7 18465 Coolant hose
2 382984-S Brake booster hose clamp 8 382984 Coolant hose clamp
3 9C482-A Brake booster vacuum hose 9 18465 Coolant hose
4 — Evaporative emissions 10 9A758 Accelerator cable
(EVAP) hose (part of 9E498)
11 9A825 Speed control cable
5 9E498 Vacuum harness connector (Continued)
(Continued)

303-01-2 Engine 303-01-2
IN-VEHICLE REPAIR (Continued)
Item Part Number Description 2. WARNING: Never remove the
12 — Accelerator cable return pressure relief cap under any conditions
spring while the engine is operating. Failure to
13 — Accelerator cable pin-type follow these instructions could result in
retainer damage to the cooling system or engine or
14 N807309-S Accelerator cable bracket personal injury. To avoid having scalding hot
bolts (2 required) coolant or steam blow out of the cooling
15 9728-A Accelerator cable bracket system or reservoir, use extreme care when
(position aside) removing the pressure relief cap from a hot
16 14A464 Idle air control (IAC) valve cooling system or reservoir. Wait until the
electrical connector engine has cooled, then wrap a thick cloth
17 14A424 Throttle position (TP) sensor around the pressure relief cap and turn it
electrical connector slowly until the pressure begins to release.
18 N805320 Fuel rail shield nuts (2 Step back while the pressure is released from
required) the cooling system. When certain all pressure
19 9G609 Fuel rail shield has been released, remove the pressure cap
20 — Radio capacitor nut (still with a cloth).
21 — Radio capacitor (position CAUTION: The coolant must be
aside) recovered in a suitable, clean container for
22 N806154 Upper intake manifold bolts reuse. If the coolant is contaminated, it must
(10 required) be recycled or disposed of correctly.
23 W704683 Upper intake manifold studs
(3 required) CAUTION: Vehicle cooling systems are
24 9425 Upper intake manifold filled with Motorcraft Premium Gold Engine
Coolant VC-7-A (in California and Oregon,
Removal and Installation VC-7-B, in Canada VC-7-C) or equivalent
meeting Ford specification WSS-M97B51-A1
(yellow color). Always fill the cooling system
1. Disconnect the battery ground cable. For
with the same coolant that is present in the
additional information, refer to Section 414-01.
system. Do not mix coolant types.
Wrap a thick cloth around the coolant pressure
relief cap on the degas bottle. Slowly turn the
cap counterclockwise (left) until the pressure
begins to release.
• Step back while the pressure releases.
3. Drain the cooling system. For additional

information, refer to Section 303-03.
4. Remove the air cleaner outlet pipe. For

5. Remove the exhaust gas recirculation (EGR)

system module. For additional information, refer
to Section 303-08.
6. Disconnect the positive crankcase ventilation

(PCV) hose from the intake manifold.
7. Disconnect the brake booster vacuum hose from

the intake manifold.
2005 Aviator, 09/2004

303-01-3 Engine 303-01-3
8. Disconnect the evaporative emissions (EVAP)
hose from the upper intake and position aside.
9. Disconnect the vacuum harness connector from

10. Disconnect the coolant hoses from the intake

manifold.
• Plug the coolant hoses.
11. Disconnect the accelerator cable and the speed

control cable (if equipped) from the throttle
body linkage.
• Remove the accelerator cable return spring.
12. Remove the 2 bolts and position aside the

accelerator cable and bracket.
• Disconnect the accelerator cable pin-type
retainer.
13. Disconnect the idle air control (IAC) electrical

connector.
14. Disconnect the throttle position (TP) sensor

electrical connector.
15. Remove the 2 fuel rail shield nuts and the 18. Remove the upper intake manifold.
shield. • Clean and inspect the gasket. Install new if
• To install, tighten to 10 Nm (89 lb-in). necessary.
16. Remove the radio capacitor nut and the radio 19. To install, reverse the removal procedure.
capacitor.
20. Fill and bleed the cooling system. For
• To install, tighten to 10 Nm (89 lb-in).
17. NOTE: Locations 3, 5 and 9 use studs.
Remove the upper intake manifold bolts and
studs.
• To install, tighten to 10 Nm (89 lb-in) in the
sequence shown.
2005 Aviator, 09/2004

303-01-1 Engine 303-01-1
IN-VEHICLE REPAIR
Lower Intake Manifold
Material
Item Specification
Motorcraft Premium Gold WSS-M97B51-A1
Engine Coolant
VC-7-A (in California and
Oregon VC-7-B, in
Canada VC-7-C) or
equivalent (yellow color)

303-01-2 Engine 303-01-2
Item Part Number Description 7. Disconnect the coolant crossover tube and
1 N805320 Generator bracket nuts (2 position it aside.
required) • Discard the used O-rings.
2 N807309 Generator bracket bolts (2 • To install, lubricate the new O-rings with
required) Motorcraft Premium Gold Engine Coolant
3 10153 Generator bracket VC-7-A (in California and Oregon VC-7-B,
4 W706438 Studs (2 required) in Canada VC-7-C) or equivalent (yellow
5 8548 Coolant crossover tube color) WSS-M97B51-A1.
(position aside)
6 — Vacuum hose 8. Disconnect the 4 engine harness retainers from
7 — Engine harness retainers the lower intake manifold.
8 14A464-AG Fuel rail pressure (FRP)
sensor electrical connector 9. Disconnect the fuel rail pressure sensor vacuum
hose and electrical connector.
9 14A464-C Intake manifold runner
control (IMRC) motor
electrical connector 10. Disconnect the intake manifold runner control
(IMRC) motor electrical connector.
10 14A464-AA Fuel injector connectors (8
required)
11. Disconnect the 8 fuel injector electrical
11 W708607 Lower intake manifold bolts
(10 required) connectors.
12 9S455 Lower intake manifold 12. NOTE: Replace the intake manifold gaskets if
assembly
necessary.
13 9439 Intake manifold gaskets (2
required) Remove the lower intake manifold bolts and the
manifold.
Removal and Installation • To install, hand tighten, then tighten to 10
Nm (89 lb-in) in the sequence shown.
1. Remove the upper intake manifold. For
additional information, refer to Upper Intake
Manifold in this section.

3. Disconnect the fuel line spring lock couplings.

For additional information, refer to Section
310-01.
4. Remove the exhaust gas recirculation (EGR)

system module tube. For additional information,
refer to Section 303-08.
13. To install, reverse the removal procedure.
5. Remove the 2 generator bracket nuts, 2 bolts
and the bracket. 14. Fill and bleed the cooling system. For
• To install, tighten to 10 Nm (89 lb-in). additional information, refer to Section 303-03.
6. Remove the 2 generator bracket studs.

• To install, tighten to 25 Nm (18 lb-ft).
2005 Aviator, 09/2004

303-01-1 Engine 303-01-1
IN-VEHICLE REPAIR
Valve Cover — LH
Material
Item Specification
Silicone Gasket and WSE-M4G323-A4
Sealant
F7AZ-19554-EA
Metal Surface Cleaner WSE-M5B392-A
ZC-21
Item Part Number Description Removal

1 N806155-S Oil level indicator tube bolt
2 6758 Positive crankcase ventilation CAUTION: Do not use metal scrapers,
closure tube (fresh air) wire brushes, power abrasive discs or other
3 W708441 Valve cover bolts (6 required) abrasive means to clean sealing surfaces. These
tools cause scratches and gouges which make
4 W708442 Valve cover studs (4
required) leak paths.
5 6A513 Valve cover
1. Remove the LH ignition coils. For additional
6 6A559A Valve cover gasket information, refer to Section 303-07.
2. Remove the oil level indicator tube bolt and

position the oil level indicator tube aside.

303-01-2 Engine 303-01-2
3. Disconnect the positive crankcase ventilation Installation
closure tube from the valve cover.
1. NOTE: If the valve cover is not secured within
4. Disconnect the 2 wiring harness retainers from 4 minutes, the sealant must be removed and the
the studs. sealing area cleaned with metal surface cleaner.
Allow to dry until there is no sign of wetness,
or 4 minutes, whichever is longer. Failure to
follow this procedure can cause future oil
leakage.
Install the LH valve cover.
• To install, apply a minimum of 8-mm
(0.32-in) diameter drop of sealant to the
front cover gasket intersection.
5. Disconnect the electrical connector, unclip and

position the evaporative (EVAP) emissions
purge valve aside.
6. Remove the 6 valve cover bolts and 4 studs.
7. Remove the valve cover.

• Clean and inspect the valve cover gasket
and install new if necessary.
2005 Aviator, 09/2004

303-01-3 Engine 303-01-3
2. Install the 6 valve cover bolts and 4 studs. 4. Connect the 2 wiring harness retainers to the
• To install, tighten to 10 Nm (89 lb-in) in the studs.
sequence shown.
5. Connect the positive crankcase ventilation

3. Install the EVAP purge valve and connect the closure tube to the valve cover.
6. Position the oil level indicator tube and install
the bolt.
7. Install the LH ignition coils. For additional

2005 Aviator, 09/2004

303-01-1 Engine 303-01-1
IN-VEHICLE REPAIR
Valve Cover — RH
Material
Item Specification
Sealant
F7AZ-19554-EA
ZC-21
Item Part Number Description Removal

1 W527351 Heater hose clamp
2 18465 Positive crankcase ventilation CAUTION: Do not use metal scrapers,
coolant hose wire brushes, power abrasive discs or other
3 14A163-A Crankshaft position sensor abrasive means to clean sealing surfaces. These
harness clip tools cause scratches and gouges which make
4 W708441 Valve cover bolts (5 required) leak paths.
5 W708442 Valve cover studs (5
required) 1. Drain the cooling system. For additional
6 6583 Valve cover
7 6584 Valve cover gasket 2. Remove the air cleaner assembly. For additional

303-01-2 Engine 303-01-2
3. Disconnect and plug the heated positive
crankcase ventilation (PCV) hose.
4. Disconnect the electrical connector from the

PCV valve.
5. Remove the RH ignition coils. For additional

6. Release the crankshaft position (CKP) sensor

harness clips.
7. Remove the 6 valve cover bolts and 4 studs.

2. Install the 6 valve cover bolts and 4 studs.
• To install, tighten to 10 Nm (89 lb-in) in the
sequence shown.
8. Disconnect the 2 heater hose retainers from the

valve cover studs.
9. Remove the valve cover.

3. Connect the 2 heater hose retainers to the valve
• Clean and inspect the valve cover gasket cover studs.
and install a new gasket if necessary.
4. Connect the crankshaft position (CKP) sensor
Installation
harness clips.
1. NOTE: If the valve cover is not secured within 5. Connect the PCV coolant hose.
4 minutes, the sealant must be removed and the
sealing area cleaned with metal surface cleaner. 6. Connect the electrical connector to the PCV
Allow to dry until there is no sign of wetness, valve.
follow this procedure can cause future oil 7. Install the RH ignition coils. For additional
leakage. information, refer to Section 303-07.
Install the valve cover.
8. Install the air cleaner assembly. For additional
• To install, apply a minimum of 8 mm (0.32 information, refer to Section 303-04.
in) diameter drop of sealant to the front
cover gasket intersection. 9. Fill and bleed the cooling system. For
2005 Aviator, 09/2004

303-01-1 Engine 303-01-1
IN-VEHICLE REPAIR
Lower End Components — Exploded
View, Crankshaft Pulley and
Crankshaft Front Oil Seal
Item Part Number Description 1. For additional information, refer to the

1 W701512 Crankshaft pulley bolt procedures in this section.
2 N806165 Crankshaft pulley washer
3 6316 Crankshaft pulley
4 6700 Crankshaft front seal

303-01-1 Engine 303-01-1
IN-VEHICLE REPAIR
Crankshaft Pulley
Special Tool(s)
Replacer, Crankshaft Damper
303-102 (T74P-6316-B)
Remover, Crankshaft Vibration

Damper
303-009 (T58P-6316-D) 5. Using the special tool, remove the crankshaft
pulley.
Strap Wrench
303-D055 (D85L-6000-A)
Material
Item Specification
Silicone Gasket and WSE-M4G323-A4 Installation
Sealant
F7AZ-19554-EA
1. NOTE: The crankshaft pulley must be installed
Removal within 4 minutes of applying silicone gasket
and sealant to the Woodruff key slot.
1. With the vehicle in NEUTRAL, position it on a Apply sealant to the Woodruff key slot on the
hoist. For additional information, refer to crankshaft pulley.
Section 100-02.
2. Remove the accessory drive belt. For additional

3. Remove the upper fan shroud and electric fan.

303-03.
4. Using the special tool to prevent the crankshaft

pulley from turning, remove the crankshaft
pulley bolt and washer.

303-01-2 Engine 303-01-2
2. Using the special tool, install the crankshaft
pulley.
4. Install the upper fan shroud and electric fan.

303-03.
pulley bolt and washer and tighten in 4 stages: 5. Install the accessory drive belt. For additional
• Stage 1: Tighten to 90 Nm (66 lb-ft). information, refer to Section 303-05.
• Stage 2: Loosen one full turn.
• Stage 3: Tighten to 50 Nm (37 lb-ft).
• Stage 4: Tighten an additional 90 degrees,
not exceeding 200 Nm (148 lb-ft).
2005 Aviator, 09/2004

303-01-1 Engine 303-01-1
IN-VEHICLE REPAIR
Crankshaft Front Seal
Special Tool(s)
Remover, Crankshaft Front Seal
303-107 (T74P-6700-A)
Installer, Front Cover Seal

303-335 (T88T-6701-A)
Installation
1. Lubricate the engine front cover and the

crankshaft seal inner lip with clean engine oil.
Installer, Crankshaft Front Seal

303-635
Material
Item Specification
SAE 5W-20 Motorcraft WSS-M2C930-A
Premium Synthetic Blend
Motor Oil
XO-5W20-QSP or 2. Using the special tools, install the front cover
equivalent seal.
Removal
1. Remove the crankshaft pulley. For additional

information, refer to Crankshaft Pulley in this
section.
2. Using the special tool, remove the front cover

seal.

303-01-2 Engine 303-01-2
3. Install the crankshaft pulley. For additional
information, refer to Crankshaft Pulley in this
section.
2005 Aviator, 09/2004

303-01-1 Engine 303-01-1
IN-VEHICLE REPAIR
Lower End Components — Exploded
View, Flexplate, Flywheel and
Crankshaft Rear Seal

1 N806168 Bolts (6 required) 6 N806155 Crankshaft rear oil seal
2 6375 Flexplate retainer plate bolts (6
required)
3 6A373 Rear cover plate
7 6K318 Crankshaft rear oil seal
4 6310 Crankshaft rear oil slinger retainer plate
5 6701 Crankshaft rear oil seal
(Continued) 1. For additional information, refer to the
procedures in this section.

303-01-1 Engine 303-01-1
IN-VEHICLE REPAIR
Flexplate
Removal and Installation
1. Remove the transmission. For additional

2. Remove the flexplate bolts and the flexplate.


303-01-1 Engine 303-01-1
IN-VEHICLE REPAIR
Flywheel

2. Remove the flywheel bolts and the flywheel.


303-01-1 Engine 303-01-1
IN-VEHICLE REPAIR
Crankshaft Rear Seal Material
Item Specification
Special Tool(s) SAE 5W-20 Motorcraft WSS-M2C930-A
Installer, Crankshaft Rear Seal Motor Oil
303-518 (T95P-6701-DH) XO-5W20-QSP or
equivalent
Removal

Remover, Crankshaft Rear Seal information, refer to Section 307-01.
303-519 (T95P-6701-DH)
2. NOTE: This step is necessary only if the rear
oil seal retainer plate is to be removed.
Remove the oil pan. For additional information,
refer to Oil Pan in this section.
Installer, Crankshaft Rear Seal 3. Remove the 6 flexplate or flywheel bolts and
303-516 (T95P-6701-EH) the flexplate or flywheel.
4. Using the special tools, remove the crankshaft

rear oil slinger.
Installer, Crankshaft Rear Oil

Slinger
303-517 (T95P-6701-CH)
Remover, Crankshaft Rear Oil

Slinger
303-514 (T95P-6701-AH)
Impact Slide Hammer

100-001 (T50T-100-A)

303-01-2 Engine 303-01-2
5. Using the special tools, remove the crankshaft Installation
rear oil seal.
1. NOTE: The silicone must be applied on the
groove along the retainer plate.
NOTE: If the rear crankshaft seal retaining
plate is not installed within 4 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 4
minutes, whichever is longer. Failure to follow
this procedure can cause future oil leakage.
If removed, install the rear oil seal retainer
plate.
• Apply a 4-mm (0.16-in) bead of silicone
gasket and sealant around the rear oil seal
6. CAUTION: Do not use metal scrapers, retainer sealing surface.
wire brushes, power abrasive discs, or other • Tighten the bolts to 10 Nm (89 lb-in) in the
abrasive means to clean the sealing surfaces. sequence shown.
These tools cause scratches and gouges which
make leak paths. Use a plastic scraping tool
to remove all traces of old sealant.
If necessary, remove the bolts and the rear oil
seal retainer.
2. Using the special tools, install the crankshaft

rear oil seal.
• Lubricate the crankshaft rear oil seal with
motor oil before installation.
2005 Aviator, 09/2004

303-01-3 Engine 303-01-3
3. Using the special tool, install the crankshaft 4. Install the 6 flexplate or flywheel bolts and the
rear oil slinger. flexplate or flywheel and tighten to 80 Nm (59
lb-ft).
5. If the rear oil seal retainer plate was removed,

install the oil pan. For additional information,
refer to Oil Pan in this section.
6. Install the transmission. For additional

2005 Aviator, 09/2004

303-01-1 Engine 303-01-1
IN-VEHICLE REPAIR
Engine Front Cover Material
Item Specification
Special Tool(s) SAE 5W-20 Motorcraft WSS-M2C930-A
Installer, Crankshaft Damper Motor Oil
303-102 (T74P-6316-B) XO-5W20-QSP or
equivalent
Sealant
F7AZ-19554-EA
Remover, Crankshaft Vibration ZC-21
Damper
303-009 (T58P-6316-D)
Strap Wrench
303-D055 (D85L-6000-A)
Installer, Front Cover Seal

303-335 (T88T-6701-A)
Installer, Crankshaft Front Seal

303-635

303-107 (T74P-6700-A)

303-01-2 Engine 303-01-2

1 8620 Accessory drive belt 6 N808102 Accessory drive belt idler
2 N808102 Accessory drive belt idler pulley mounting bolt
pulley mounting bolt 7 19A216 Accessory drive belt idler
3 19A216 Accessory drive belt idler pulley
pulley 8 W707288 Accessory drive belt idler
4 N808920 Accessory drive belt tensioner pulley mounting bolt
mounting bolts 9 6C348 Accessory drive belt idler
5 6B209 Accessory drive belt tensioner pulley
(Continued)
2005 Aviator, 09/2004

303-01-3 Engine 303-01-3

10 6303 Power steering reservoir 16 W520101 Power steering hose bracket
bracket bolts mounting nut
11 6A341 Power steering reservoir 17 — Power steering hose bracket
bracket 18 W701532 Power steering pump
12 N806155 Camshaft position (CMP) mounting bolts (2 required)
sensor electrical connector 19 W500316 Power steering pump
13 6A339 CMP sensor mounting bolt mounting bolt
14 6B288 CMP sensor 20 W500316 Power steering pump
15 6714 Oil filter mounting bolt
(Continued) 21 3A696 Power steering pump
(position aside)
2005 Aviator, 09/2004

303-01-4 Engine 303-01-4

22 12B637 A/C compressor electrical 28 W520101 Transmission tube clip
connector mounting nut
23 14A280 Battery wiring harness 29 7N291 Transmission tube clip
24 W707821 A/C compressor mounting 30 N806155 Crankshaft position sensor
stud electrical connector
25 N621939 A/C compressor mounting 31 N806155 Crankshaft position sensor
nuts (2 required) mounting bolt
26 W704795 A/C compressor mounting 32 6C315 Crankshaft position (CKP)
studs (2 required) sensor
27 19703 A/C compressor (position
aside)
(Continued)
2005 Aviator, 09/2004

303-01-5 Engine 303-01-5
Item Part Number Description 5. Remove the cooling fan clutch. For additional
33 N806282 Coolant pump pulley bolts information, refer to Section 303-03.
34 8A528 Coolant pump pulley 6. Remove the crankshaft pulley. For additional
35 W701512 Crankshaft pulley bolt information, refer to Crankshaft Pulley in this
36 N806165 Crankshaft pulley washer section.
38 6700 Crankshaft seal 7. Remove the accessory drive belt idler pulley
mounting bolts and the idler pulleys.
39 6C086 Engine front cover
40 6C086 Engine front cover gaskets 8. Remove the accessory drive belt tensioner
mounting bolts and the tensioner.
Removal
9. Remove the power steering reservoir bracket
1. With the vehicle in NEUTRAL, position it on a bolts and the bracket.
hoist. For additional information, refer to
Section 100-02. 10. Disconnect the camshaft position (CMP) sensor
additional information, refer to Section 414-01. 11. Remove the CMP sensor mounting bolt and the
sensor.
3. Drain the engine oil.
12. Remove and discard the oil filter.
4. Remove the valve covers. For additional
information, refer to Valve Cover — LH and 13. Remove the power steering hose bracket
Valve Cover — RH in this section. mounting nut and the bracket.
2005 Aviator, 09/2004

303-01-6 Engine 303-01-6
14. Remove the power steering pump mounting
bolts and position the power steering pump
aside.
15. Disconnect the A/C compressor electrical

connector.
16. Disconnect the battery wiring harness retainer.
17. Remove the A/C compressor mounting nuts.
18. Remove the A/C compressor mounting studs

and position the A/C compressor aside.
24. Remove the 4 oil pan-to-engine front cover
19. Remove the transmission tube clip mounting bolts.
nut and the tube clip.
20. Disconnect the crankshaft position (CKP) sensor

21. Remove the CKP sensor mounting bolt and the

sensor.
22. Using the special tool to keep the pulley from

turning, remove the bolts and the coolant pump
pulley.
25. Remove the fasteners and the engine front

cover.
23. Using the special tool, remove the crankshaft

seal.
2005 Aviator, 09/2004

303-01-7 Engine 303-01-7
26. CAUTION: Do not use metal scrapers,
wire brushes, power abrasive discs or other
abrasive means to clean the sealing surfaces.
These tools can cause scratches and gouges
which can create leak paths. Use a plastic
scraping tool to remove all traces of old
sealant.
Remove and discard the gaskets, clean and
inspect the sealing surfaces.
Installation
1. NOTE: If the engine front cover is not secured

within 4 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 4 minutes, whichever is longer.
Failure to follow these instructions can result
in future oil leakage.
Apply sealant in the locations shown.
3. Install the 4 oil pan-to-engine front cover bolts

in the sequence shown in 3 stages:
• Stage 1: Tighten to 2 Nm (18 lb-in).
• Stage 3: Tighten an additional 60 degrees.
2. Install the engine front cover and tighten the

fasteners in the sequence shown.
• Tighten to 25 Nm (18 lb-ft).
2005 Aviator, 09/2004

303-01-8 Engine 303-01-8
4. Lubricate the engine front cover and the 8. Install the CKP sensor and the mounting bolt.
crankshaft seal inner lip with clean engine oil. • Tighten to 10 Nm (89 lb-in).
9. Connect the crankshaft position (CKP) sensor

10. Install the transmission tube clip and the

mounting nut.
11. Reposition and install the A/C compressor and

mounting studs.
12. Install the A/C compressor mounting nuts.

5. Using the special tools, install the crankshaft • Tighten to 25 Nm (18 lb-ft).
seal.
13. Connect the battery wiring harness retainer.
14. Connect the A/C compressor electrical

connector.
15. Reposition the power steering pump and install

the mounting bolts.
16. Install the power steering hose bracket and the

mounting nut.
17. Install a new oil filter.

6. Install the crankshaft pulley. For additional
information, refer to Crankshaft Pulley in this 18. Install the CMP sensor and the mounting bolt.
section.
• Tighten to 10 Nm (89 lb-in).
7. Using the special tool to keep the pulley from
rotating, install the coolant pump pulley and the 19. Connect the camshaft position (CMP) sensor
bolts. electrical connector.
• Tighten to 25 Nm (18 lb-ft). 20. Install the power steering reservoir bracket and
the bolts.
21. Install the accessory drive belt tensioner and the

mounting bolts.
22. Install the accessory drive belt idler pulley and

the mounting bolts.
2005 Aviator, 09/2004

303-01-9 Engine 303-01-9
23. Install the cooling fan and upper fan shroud. 25. Fill the engine with clean oil.
303-03. 26. Connect the battery ground cable. For additional
24. Install the valve covers. For additional
information, refer to Valve Cover — LH and
Valve Cover — RH in this section.
2005 Aviator, 09/2004

303-01-1 Engine 303-01-1
IN-VEHICLE REPAIR
Timing Drive Components
Special Tool(s)
Holding Tool, Camshaft
303-446 (T93P-6256-AHR)
Holding Tool, Crankshaft

303-448 (T93P-6303-A)
Material
Item Specification
Hydraulic Chain Tensioner IL32-6P250-AA
Retaing Clip

303-01-2 Engine 303-01-2

1 12A227 Crankshaft sensor ignition 7 6L253 LH timing chain tensioner
pulse ring arm
2 N606543 RH timing chain tensioner 8 N811085 RH camshaft sprocket
mounting bolts (2 required) 9 N806164 RH camshaft sprocket washer
3 6L266 RH timing chain tensioner 10 6268 RH timing chain
4 6L253 RH timing chain tensioner 11 6265 RH camshaft sprocket
arm
12 N811085 LH camshaft sprocket
5 N606543 LH timing chain tensioner
mounting bolts (2 required) 13 N806164 LH camshaft sprocket washer
6 6M269 LH timing chain tensioner 14 6268 LH timing chain
(Continued) 15 6265 LH camshaft sprocket
(Continued)
2005 Aviator, 09/2004

303-01-3 Engine 303-01-3
Item Part Number Description
16 6306 Crankshaft gear

17 W500215 LH timing chain guide upper 21 N804958 RH timing chain guide lower
mounting bolt mounting bolt
18 N606527 LH timing chain guide lower 22 6M256 RH timing chain guide
mounting bolt 23 N811085 RH intake camshaft gear
19 6B274 LH timing chain guide mounting bolt
20 W500215 RH timing chain guide upper 24 N806164 RH intake camshaft gear
mounting bolt washer
(Continued) (Continued)
2005 Aviator, 09/2004

303-01-4 Engine 303-01-4
Item Part Number Description 4. CAUTION: Since the engine is not free
25 6265 RH intake camshaft gear wheeling, timing procedures must be
spacer followed exactly or piston and valve damage
26 N811085 LH intake camshaft gear can occur.
mounting bolt
CAUTION: Unless otherwise
27 N806164 LH intake camshaft gear
washer instructed, at no time when the timing chains
are removed and the cylinder heads are
28 6265 LH intake camshaft gear
spacer installed is the crankshaft or the camshaft to
be rotated. Severe piston and valve damage
29 W500215 LH secondary timing chain
tensioner mounting bolts will occur.
30 6C271 LH secondary timing chain Using the special tool, position the crankshaft
tensioner with the keyway at the 12 o’clock position.
31 W500304 RH secondary timing chain
tensioner mounting bolts
32 6C270 RH secondary timing chain
tensioner
33 6256 RH exhaust secondary
camshaft sprocket
34 6268 RH secondary camshaft
sprocket
35 6256 RH secondary camshaft
timing chain
36 6256 LH intake secondary camshaft
sprocket
37 6256 LH exhaust secondary
camshaft sprocket
38 6268 LH secondary camshaft 5. Install the special tool.
timing chain
Removal
1. Remove the engine front cover. For additional

information, refer to Engine Front Cover in this
section.
2. Remove the camshaft roller followers. For

additional information, refer to Camshaft Roller
Follower in this section.
3. Remove the crankshaft sensor ignition pulse

ring.
2005 Aviator, 09/2004

303-01-5 Engine 303-01-5
6. NOTE: RH shown, LH similar. 16. Remove the LH timing chain guide.
Remove the timing chain tensioning system
from both timing chains. 17. Remove the RH timing chain guide upper
mounting bolt.
• Remove the bolts.
• Remove the timing chain tensioners. 18. Remove the RH timing chain guide lower
• Remove the timing chain tensioner arms. mounting bolt.
19. Remove the RH timing chain guide.
20. Remove the RH intake camshaft gear mounting

bolt, washer and spacer.
21. Remove the LH intake camshaft gear mounting

bolt, washer and spacer.
22. Remove the LH secondary timing chain

tensioner mounting bolts and tensioner.
23. Remove the RH secondary timing chain

tensioner mounting bolts and tensioner.
7. Remove the RH camshaft sprocket mounting 24. Remove the RH exhaust secondary camshaft
bolt and the washer. sprocket.
8. Remove the RH timing chain. 25. Remove the RH secondary camshaft timing
chain.
9. Remove the RH camshaft sprocket.
26. Remove the RH intake secondary camshaft
10. Remove the LH camshaft sprocket mounting sprocket.
bolt and the washer.
27. Remove the LH intake secondary camshaft
11. Remove the LH timing chain. sprocket.
12. Remove the LH camshaft sprocket. 28. Remove the LH exhaust secondary camshaft
sprocket
13. Remove the crankshaft gear.
29. Remove the LH secondary camshaft timing
14. Remove the LH timing chain guide upper
chain.
mounting bolt.
15. Remove the LH timing chain guide lower

mounting bolt.
2005 Aviator, 09/2004

303-01-6 Engine 303-01-6
Installation
All engines
1. NOTE: Compress the tensioner and install the

retaining pin.
NOTE: LH tensioner shown, RH tensioner
similar.
Install the tensioners.
4. NOTE: Do not tighten the bolt at this time.

Install the camshaft spacer, washer and bolt.
2. CAUTION: Timing marks must be at

the 12 o’clock position and indexed at the 6
o’clock position.
Install the camshaft sprockets and chain as an 5. NOTE: Do not tighten the bolt at this time.
assembly.
Install the camshaft gear, washer and bolt.
3. Install the special tool.
2005 Aviator, 09/2004

303-01-7 Engine 303-01-7
6. Tighten the bolts in 2 stages:
9. While holding the ratchet mechanism, push the

ratchet arm back into the tensioner housing.
Engines with ratcheting tensioners
7. 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 plunger, using an edge of a
vise. 10. 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.
8. Using a small screwdriver or pick, push back

and hold the ratchet mechanism.
2005 Aviator, 09/2004

303-01-8 Engine 303-01-8
Engines with non-ratcheting tensioners All engines
11. CAUTION: If one or both tensioner 14. If the copper links are not visible, mark one
mounting bolts are loosened or removed, the link on one end and one link on the other end,
tensioner-sealing bead must be inspected for and use as timing marks.
seal integrity. Any cracks, tears, cuts or
separation from the tensioner body or
permanent compression of the seal bead, will
require replacement of the tensioner.
Inspect the RH and LH timing chain tensioners.
• Install new tensioners as necessary.

Compress each tensioner plunger, using a vise.
15. Install the timing chain guides.
13. Install a retaining clip on each tensioner to hold

the plunger in during installation.
2005 Aviator, 09/2004

303-01-9 Engine 303-01-9
16. Rotate the LH camshaft sprocket until the
timing mark is approximately at the 12 o’clock
position. Rotate the RH camshaft timing
sprocket until the timing mark is approximately
at the 11 o’clock position.
17. CAUTION: Unless otherwise

instructed, at no time when the timing chains
installed is the crankshaft or the camshaft to
be rotated. Severe piston and valve damage
will occur.
CAUTION: Rotate the crankshaft
counterclockwise only. Do not rotate past
position shown or severe piston or valve
damage will occur.
NOTE: The number one cylinder is at top dead
center (TDC) when the stud on the engine
block fits into the slot in the handle of the
special tool.
Using the special tool, position the crankshaft
so the number one cylinder is at TDC.
2005 Aviator, 09/2004

303-01-10 Engine 303-01-10
18. Position the LH (inner) timing chain on the
crankshaft sprocket, aligning the copper
(marked) link with the timing mark on the
sprocket.
21. Remove the retaining clip from the LH timing

chain tensioner.
19. Install the LH timing chain onto the camshaft

sprocket, aligning the copper (marked) link with
the timing marks on the sprocket.
Engines with non-ratcheting tensioners
22. Remove the retaining clip from the LH timing

chain tensioner.
20. NOTE: The LH timing chain tensioner arm has
a bump near the dowel hole for identification.
Position the LH timing chain tensioner arms on
the dowel pin and install the LH timing chain
tensioner.
2005 Aviator, 09/2004

303-01-11 Engine 303-01-11
All engines
23. Position the RH (outer) timing chain on the

crankshaft sprocket, aligning the copper
(marked) link with the timing mark on the
sprocket.
26. Remove the retaining clip from the RH timing

chain tensioner.
24. Install the RH timing chain onto the camshaft

sprocket, aligning the copper (marked) link with
the timing marks on the sprocket.
Engines with non-ratcheting tensioners
27. Remove the retaining clips from the RH timing

chain tensioner.
25. Position the RH timing chain tensioner arms on

the dowel pin and install the RH timing chain
tensioner.
2005 Aviator, 09/2004

303-01-12 Engine 303-01-12
All engines 30. Install the camshaft roller followers. For
additional information, refer to Camshaft Roller
28. Make sure that the copper (marked) chain links Follower in this section.
are lined up with the dots on the crankshaft
sprockets and the camshaft sprocket. 31. Install the engine front cover. For additional
information, refer to Engine Front Cover in this
29. Install the crankshaft sensor ignition pulse ring. section.
2005 Aviator, 09/2004

303-01-1 Engine 303-01-1
IN-VEHICLE REPAIR
Valve Train Components — Exploded
View, Camshafts, Valve Springs and
Valve Seals

1 6518 Exhaust valve spring retainer 9 W705438 Camshaft bearing cap bolts
keys (32 required) (outboard row) (12 required/6
2 6514 Exhaust valve spring retainers per cylinder head)
(16 required) 9 N807352 Camshaft bearing cap bolts (3
3 6513 Exhaust valve springs (16 inboard rows) (38 required/19
required) per cylinder head)
4 6A517 Exhaust valve stem seals (16 10 6B278 Camshaft bearing caps
required) (exhaust)
5 6518 Intake valve spring retainer 11 6B277 Camshaft bearing caps
keys (32 required) (intake)
6 6514 Intake valve spring retainers 12 6A273 Camshaft (exhaust)
(16 required) 13 6A271 Camshaft (intake)
7 6513 Intake valve springs (16
required) 1. For additional information, refer to the
8 6A517 Intake valve stem seals (16 procedures in this section.
required)
(Continued)

303-01-1 Engine 303-01-1
IN-VEHICLE REPAIR
Camshafts 2. NOTE: Lubricate the cam lobes with clean
engine oil before installation.
Material Remove the camshaft bearing cap bolts and the
Item Specification bearing caps.
SAE 5W-20 Motorcraft WSS-M2C930-A • To install, tighten to 10 Nm (89 lb-in) in the
Premium Synthetic Blend sequence shown.
Motor Oil
XO-5W20-QSP or
equivalent
1. Remove the timing drive components. For

additional information, refer to Timing Drive
Components in this section.
3. Remove the camshafts. 4. To install, reverse the removal procedure.

303-01-1 Engine 303-01-1
IN-VEHICLE REPAIR
Valve Springs
Special Tool(s)
Compressor, Valve Spring
303-452 (T93P-6565-AR)

303-567 (T97P-6565-AH)
3. Install the special tool between the valve spring
coils to protect the exhaust valve stem seal
from damage.
Installer, Valve Stem Oil Seal

303-383 (T91P-6571-A)
Spacer, Valve Spring

Compressor
303-382 (T91P-6565-AH)
4. Using the special tool, compress the exhaust

valve spring. Remove the exhaust valve spring
retainer keys and the valve spring.
1. Remove the roller followers. For additional

information, refer to Camshaft Roller Follower
in this section.
2. NOTE: Position the piston of the cylinder to be

serviced at the bottom of the stroke.
Use compressed air in the cylinder to be
serviced to hold both valves in position.

303-01-2 Engine 303-01-2
5. Install the special tool between the valve spring 6. Using the special tool, compress the intake
coils to protect the intake valve stem seal from valve spring. Remove the intake valve spring
damage. retainer keys and the valve springs.
2005 Aviator, 09/2004

303-01-1 Engine 303-01-1
IN-VEHICLE REPAIR
Valve Seals
Special Tool(s)
303-452 (T93P-6565-AR)

303-567 (T97P-6565-AH)
coils to protect the exhaust valve stem seal
from damage.

303-383 (T91P-6571-A)

Compressor
303-382 (T91P-6565-AH)

retainer keys.
Removal
1. Remove the roller followers. For additional

information, refer to Camshaft Roller Follower
in this section.

serviced at the bottom of the stroke.
Use compressed air in the cylinder to be
serviced to hold both valves in position.

303-01-2 Engine 303-01-2
5. Install the special tool between the valve spring Installation
coils to protect the intake valve stem seal from
damage. 1. Using the special tools, install the new intake
valve stem seal.
6. Using the special tool, compress the intake

valve spring. Remove the intake valve spring 2. Using the special tools, install the new exhaust
retainer keys. valve stem seal.
7. NOTE: Valve stem seals should be visually 3. Install the special tool between the valve spring
inspected if new seals are not installed. coils to protect the exhaust valve stem seal
Remove the valve spring retainer, the valve from damage.
spring and the valve stem seal.
2005 Aviator, 09/2004

303-01-3 Engine 303-01-3
4. Position the valve spring and spring retainer 6. Using the special tool, compress the exhaust
over the valve stem and valve seal. valve spring. Install the exhaust valve spring
retainer keys.

valve spring. Install the intake valve spring 7. Install the roller followers. For additional
retainer keys. information, refer to Camshaft Roller Follower
in this section.
2005 Aviator, 09/2004

303-01-1 Engine 303-01-1
IN-VEHICLE REPAIR
Valve Train Components — Exploded
View, Camshaft Roller Follower and

1 6529 Camshaft roller followers
(intake) (16 required)
2 6C501 Hydraulic lash adjusters
(intake) (16 required)
3 6529 Camshaft roller followers
(exhaust) (16 required)
4 6C501 Hydraulic lash adjusters
(exhaust) (16 required)
1. For additional information, refer to the


303-01-1 Engine 303-01-1
IN-VEHICLE REPAIR
Camshaft Roller Follower 4. NOTE: Position the piston of the cylinder to be
serviced at the bottom of the stroke and the
Special Tool(s) camshaft at the base circle.
Using the special tool, partially compress the
303-452 (T93P-6565-AR) intake valve spring and remove the camshaft
roller follower.
• Lubricate the roller follower with clean
engine oil prior to installation.

303-567 (T97P-6565-AH)
Material
Item Specification
Motor Oil 5. Using the special tool, partially compress the
XO-5W20-QSP or exhaust valve spring and remove the camshaft
equivalent roller follower.
Removal and Installation • Lubricate the roller follower with clean
1. Remove the RH and LH valve covers, as
necessary. For additional information, refer to
Valve Cover — RH or Valve Cover — LH in
this section.
2. Remove the cooling fan. For additional

3. NOTE: Remove any foreign material from the

spark plug wells with compressed air before
removing the spark plugs.
Remove the spark plugs.

303-01-1 Engine 303-01-1
IN-VEHICLE REPAIR
Special Tool(s)
303-452 (T93P-6565-AR)

303-567 (T97P-6565-AH)
5. Using the special tool, partially compress the
exhaust valve spring and remove the camshaft
roller follower.
Material
Item Specification
Motor Oil
XO-5W20-QSP or
equivalent
1. Remove the RH and LH valve covers, as

necessary. For additional information, refer to
Valve Cover — RH or Valve Cover — LH in
this section.
2. Remove the cooling fan. For additional

3. NOTE: Remove any foreign material from the

spark plug wells with compressed air before
removing the spark plugs.
Remove the spark plugs.

serviced at the bottom of the stroke and the
camshaft at the base circle.
Using the special tool, partially compress the
intake valve spring and remove the camshaft
roller follower.
303-01-2 Engine 303-01-2
6. NOTE: Mark the location of the hydraulic lash
adjusters to make sure they are assembled in
their original positions.
Remove the hydraulic lash adjusters.
• Lubricate the hydraulic lash adjuster with
clean engine oil prior to installation.
2005 Aviator, 09/2004

303-01-1 Engine 303-01-1
IN-VEHICLE REPAIR
Exhaust Manifold — LH
Item Part Number Description 2. Remove the steering intermediate shaft. For
1 W705443 Exhaust Y-pipe flange nuts (2 additional information, refer to Section 211-04.
required )
3. Remove the LH front wheel and tire. For
2 5F250 Exhaust Y-pipe
3 W500211 Heat shield bolts (3 required)
4 9Y427 Heat shield 4. Remove the LH front inner fenderwell. For
5 N805320 Oil indicator tube bracket nut additional information, refer to Section 501-02.
6 N806155 Oil indicator bracket bolt
7 W701706 Exhaust manifold nuts (8 5. Remove the 2 exhaust Y-pipe nuts and
required) disconnect the Y-pipe.
8 9431 Exhaust manifold • To install, tighten to 20 Nm (15 lb-ft).
9 9Y431-A Exhaust manifold gasket
6. Remove the 3 heat shield bolts and the heat
Removal and Installation shield.
1. With the vehicle in NEUTRAL position it on a
Section 100-02.

303-01-2 Engine 303-01-2
7. Remove the 8 exhaust manifold nuts and 8. To install, reverse the removal procedure.
manifold and discard the exhaust manifold
gasket.
• Install a new exhaust manifold gasket.
2005 Aviator, 09/2004

303-01-1 Engine 303-01-1
IN-VEHICLE REPAIR
Exhaust Manifold — RH

1 W705443 Exhaust Y-pipe flange nuts (2 5 9Y427 Heat shield
required) 6 W701706 Exhaust manifold nuts (8
2 5F250 Exhaust Y-pipe required)
3 9D477 Exhaust gas recirculation 7 9430 Exhaust manifold
(EGR) tube 8 9448 Exhaust manifold gasket
4 W500211 Heat shield bolts (3 required)
(Continued)

303-01-2 Engine 303-01-2
Removal and Installation 5. Disconnect the exhaust gas recirculation (EGR)
system module tube from the exhaust manifold.
1. With the vehicle in NEUTRAL, position it on a
hoist. For additional information, refer to 6. Remove the 3 heat shield bolts and the heat
Section 100-02. shield.
2. Remove the RH front wheel and tire. For
additional information, refer to Section 204-04. 7. Remove the 8 exhaust manifold nuts and
manifold and discard the exhaust manifold
3. Remove the RH front inner fender well. For gasket.
• Install a new exhaust manifold gasket.
4. Remove the 2 exhaust Y-pipe nuts and • To install, tighten to 20 Nm (15 lb-ft).
disconnect the Y-pipe.
2005 Aviator, 09/2004

303-01-1 Engine 303-01-1
IN-VEHICLE REPAIR
Engine Lubrication Components —
Exploded View, Oil Pan, Oil Pump, Oil
Pump Screen and Pickup Tube

1 N808403 Front axle bolts (3 required) 9 6710 Oil pan gasket
(if equipped) 10 N605904 Oil pump screen and pickup
2 16473 Crossmember bolt (1 tube bolt (1 required)
required) 11 N806155 Oil pump screen and pickup
3 5005 Crossmember bolts (3 tube bolts (2 required)
required) 12 6622 Oil pump screen and pickup
4 20605 Crossmember tube
5 W50031-S Inspection cover bolts (2 13 N806183 Oil pump bolts (3 required)
required) 14 6621 Oil pump
6 7986 Inspection cover
7 W701605 Oil pan bolts (16 required) 1. For additional information, refer to the
8 6676 Oil pan procedures in this section.
(Continued)

303-01-1 Engine 303-01-1
IN-VEHICLE REPAIR
Oil Pan 7. CAUTION: Do not use metal scrapers,
wire brushes, power abrasive discs, or other
Material abrasive means to clean the sealing surfaces.
These can cause scratches and gouges
Item Specification
resulting in leak paths. Use a plastic scraper
SAE 5W-20 Motorcraft WSS-M2C930-A to clean the sealing surfaces.
Motor Oil NOTE: Clean the sealing surfaces with metal
XO-5W20-QSP or surface cleaner.
equivalent
Remove the 16 oil pan bolts and the oil pan.
Silicone Gasket and WSE-M4G323-A4 Clean and inspect the sealing surfaces.
Sealant
F7AZ-19554-EA or Installation
equivalent
ZC-21 or equivalent All vehicles
Removal 1. NOTE: If the oil pan and gasket are not

secured within 4 minutes of sealer application,
All vehicles the sealant must be removed and the sealing
surfaces cleaned with metal surface cleaner.
1. With the vehicle in NEUTRAL, position it on a Apply silicone gasket and sealant in 2 places.
Section 100-02.
2. Drain the engine oil.
3. Remove the front stabilizer bar. For additional

information, refer to Section 204-01A.
4WD vehicles
4. CAUTION: Do not allow the inner

halfshaft boots to contact the lower control
arms. Damage to the boots can occur.
NOTE: Support the front axle using an
appropriate jack. Lower the front axle
approximately 150 mm (6 in).
Remove the 3 front axle bolts and lower the
axle.
All vehicles
5. Remove the 4 crossmember bolts and the

crossmember.
6. Remove the 2 inspection cover bolts and the

inspection cover.

303-01-2 Engine 303-01-2
2. NOTE: If the oil pan and gasket are not 4. Install the inspection cover and the 2 bolts.
secured within 4 minutes of sealer application, • Tighten to 34 Nm (26 lb-ft).
the sealant must be removed and the sealing
surfaces cleaned with metal surface cleaner. 5. Install the crossmember and the 4 crossmember
Apply silicone gasket and sealant in 2 places. bolts.
4WD vehicles

NOTE: Support the front axle using an
appropriate jack. Lower the front axle
approximately 150 mm (6 in).
Raise and install the front axle and the 3 bolts.
3. Position the oil pan and tighten the bolts in the
sequence shown in 3 stages:
2005 Aviator, 09/2004

303-01-3 Engine 303-01-3
All vehicles 8. Fill the engine with clean oil.
7. Install the front stabilizer bar. For additional

2005 Aviator, 09/2004

303-01-1 Engine 303-01-1
IN-VEHICLE REPAIR
Oil Pump 6. Remove the oil pump bolts and the oil pump.
Installation
Material
Item Specification 1. NOTE: Oil pump must be held against block
SAE 5W-20 Motorcraft WSS-M2C930-A until bolts are tightened.
Motor Oil Align the inner rotor of the oil pump assembly
XO-5W20-QSP or to align with the flats on the crankshaft, and
equivalent slide the oil pump toward the block until it is
seated against the block.
Removal
2. Rotate the oil pump assembly to align with the
1. With the vehicle in NEUTRAL, position it on a bolt holes.
hoist. For additional information, refer to • Tighten to 10 Nm (89 lb-in).
Section 100-02.
3. Install the Timing Drive Components. For
2. Drain the engine oil. additional information, refer to Timing Drive
Components in this section.
3. Remove the front stabilizer bar. For additional
information, refer to Section 204-01A. 4. Install the oil pump screen and pickup tube. For
additional information, refer to Oil Pump
4. Remove the Timing Drive Components. For Screen and Pickup Tube in this section.
additional information, refer to Timing Drive
Components in this section. 5. Install the front stabilizer bar. For additional
5. Remove the oil pump screen and pickup tube.
For additional information, refer to Oil Pump 6. Fill the engine with clean oil.
Screen and Pickup Tube in this section.

303-01-1 Engine 303-01-1
IN-VEHICLE REPAIR
Oil Pump Screen and Pickup Tube 2. Remove the oil pump screen and pickup tube
bolt from the main bearing cap stud spacer.
Material • To install, tighten to 25 Nm (18 lb-ft).
Item Specification
3. NOTE: Install a new O-ring seal.
Premium Synthetic Blend NOTE: Lubricate the new O-ring seal with
Motor Oil clean engine oil before installation.
XO-5W20-QSP or Remove the 2 oil pump screen and pickup tube
equivalent
bolts and the oil pump screen and pickup tube
Removal and Installation from the oil pump.
1. Remove the oil pan. For additional information,
refer to Oil Pan in this section. 4. To install, reverse the removal procedure.

303-01-1 Engine 303-01-1
IN-VEHICLE REPAIR
Oil Filter Adapter
Material
Item Specification
Engine Coolant
Oregon VC-7-B, in
Canada VC-7-C) or

1 8287A Crossover tube hose clamp 9 W705128 Oil filter adapter bolts (4
2 8A593 Crossover tube hose required)
3 6714 Oil filter 10 6884 Oil filter adapter
4 W70709 Oil filter splash shield bolts 11 6A636 Oil filter adapter gasket
(3 required)
5 6N634 Oil filter splash shield Removal and Installation
6 15161 Lower radiator hose clamp
7 8286 Lower radiator hose
8 14A464 Oil pressure switch electrical Section 100-02.
connector
(Continued)

303-01-2 Engine 303-01-2
2. Drain the coolant. For additional information, 7. Disconnect the oil pressure switch electrical
refer to Section 303-03. connector.
3. Disconnect the crossover tube hose from the 8. NOTE: Clean and inspect the oil filter adapter
thermostat housing. gasket and replace if necessary.
Remove the 4 oil filter adapter bolts and the
4. Remove the oil filter. adapter.
5. Remove the 3 oil filter splash shield bolts and • To install, tighten to 25 Nm (18 lb-ft).
the splash shield.
6. Disconnect the lower radiator hose from the additional information, refer to Section 303-03.
thermostat housing.
2005 Aviator, 09/2004

303-01-1 Engine 303-01-1
IN-VEHICLE REPAIR
Oil Level Indicator and Tube

1 W705443 Exhaust Y-pipe flange nuts (2 6 N806155 Oil indicator bracket bolt
required) 7 W701706 Exhaust manifold nuts (8
2 5F250 Exhaust Y-pipe required)
3 W500211 Heat shield bolts (3 required) 8 9431 Exhaust manifold
4 9Y427 Heat shield 9 6A005 Oil level indicator
5 N805320 Oil indicator tube bracket nut 10 6754 Oil level indicator tube
(Continued) 11 6754-B Oil level indicator tube
O-ring

303-01-2 Engine 303-01-2
Removal and Installation 5. Remove the 3 LH exhaust manifold heat shield
bolts and the heat shield.
1. With the vehicle in NEUTRAL, position it on a • To install, tighten to 11 Nm (8 lb-ft).
Section 100-02. 6. Remove the 8 LH exhaust manifold nuts and
the exhaust manifold.
2. Remove the steering intermediate shaft. For
additional information, refer to Section 211-00. 7. Remove the oil level indicator from the tube.
3. Remove the LH front inner fenderwell. For 8. Remove the oil indicator tube bracket nut.
additional information, refer to Section 501-00. • To install, tighten to 9 Nm (80 lb-in).
4. Remove the 2 exhaust Y-pipe nuts and 9. Remove the oil indicator tube bracket bolt and
disconnect the Y-pipe. the oil indicator tube.
• To install, tighten to 20 Nm (15 lb-ft). • To install, tighten to 10 Nm (89 lb-in).
2005 Aviator, 09/2004

303-01-1 Engine 303-01-1
IN-VEHICLE REPAIR
Engine Support Insulators
Special Tool(s)
3-Bar Engine Support Kit
303-F072
Engine Support Bracket

303-639
Holding Wrench, Fan Pulley

303-239 (T84T-6312-C)
Wrench, Fan Clutch Nut

303-240 (T84T-6312-D)

303-01-2 Engine 303-01-2

1 5482C Stabilizer bar bracket bolts (4 6 6B032 LH engine support insulator
required) 7 6038 RH engine support insulator
2 N808403 Front axle bolts (3 required)
(if equipped) Removal and Installation
3 W706348-S426 Flag nuts (3 required) (if
equipped) All vehicles
4 N802330 LH engine support insulator
nut
5 N802330 RH engine support insulator
nut hoist. For additional information, refer to
(Continued)
Section 100-02.
2005 Aviator, 09/2004

303-01-3 Engine 303-01-3
3. Remove the air cleaner outlet tube. For

4. Using the special tools, loosen the fan blade

and the clutch assembly.
7. Remove the 2 stud bolts, the 2 bolts and the

generator bracket.
5. Rotate the tensioner clockwise and remove the

accessory drive belt from the generator pulley.
8. Loosen the bolts and position the power

steering cooler aside.
6. Remove the generator B+ nut and disconnect

the electrical connectors.
• Position the B+ cable cover aside.
2005 Aviator, 09/2004

303-01-4 Engine 303-01-4
9. Remove the cooling fan.
• Remove the 2 bolts and the lower fan
shroud.
• Remove the cooling fan and clutch as an
assembly from underneath the vehicle.
12. Remove the 2 transmission-to-crossmember

nuts.
10. NOTE: The generator must be removed from

underneath the vehicle.
Remove the 2 bolts and the generator.
13. Remove the bolt from the LH motor mount.

11. Remove the 2 bolts and position the shift cable

bracket aside.
2005 Aviator, 09/2004

303-01-5 Engine 303-01-5
14. Remove the 2 nuts from the RH motor mount 17. Raise the engine until the insulators can be
(through the wheel well). removed.
18. NOTE: Reposition the stabilizer bar to gain
clearance.
Remove the 4 stabilizer bar bracket bolts.
4WD vehicles

NOTE: Support the axle using an appropriate
jack. Disconnect the vent hose and lower the
axle approximately 25 mm (1 in).
15. Remove the exhaust gas recirculation (EGR) Remove the 3 front axle bolts and the flag nuts.
system module and the tube assembly. For
additional information, refer to Section 303-08. • To install, tighten to 100 Nm (74 lb-ft).
All vehicles
16. Install the special tools.
20. Remove the LH engine support insulator nut

and insulator.
21. Remove the RH engine support insulator nut

and insulator.

• Verify that the shifter cable is correctly
adjusted. For additional information, refer to
Section 307-01.
2005 Aviator, 09/2004

303-01-1 Engine 303-01-1
REMOVAL
Cylinder Heads
Special Tool(s)
Lifting Bracket, Engine (2
required)
303-D087 (D93P-6001-A1)

Damper
303-009 (T58P-6316-D) 3. Mount the engine on a suitable engine stand.

303-107 (T74P-6700-A)
Compressor, Intake Valve

Spring
303-452 (T93P-6565-AR)
4. NOTE: LH shown, RH similar.
Remove the LH and RH engine mounts.
Compressor, Exhaust Valve

Spring
303-567 (T97P-6565-AH)
Strap Wrench
303-D055 (D85L-6000-A)
1. Remove the engine. For additional information,

refer to Engine in this section.
2. Remove the flexplate and the spacer plate.

303-01-2 Engine 303-01-2
REMOVAL (Continued)
5. NOTE: RH shown, LH similar.
Remove the drain plugs from the engine block.
Allow the coolant to completely drain.
• Install the drain plugs when finished.
8. Disconnect the battery cable harness ground.
6. Remove the 2 bolts and the pin-type retainer

from the power steering reservoir bracket.
9. Disconnect the electrical connector and the

battery cable from the alternator.
7. Remove the power steering reservoir and

bracket.
• Disconnect the hose from the power steering
pump.
• Remove the bolt and the reservoir and
bracket.
2005 Aviator, 09/2004

303-01-3 Engine 303-01-3
REMOVAL (Continued)
10. Disconnect the 2 retainers from the engine front
cover studs.
14. Disconnect the vacuum harness from the intake

manifold and remove the harness.
11. Disconnect the 2 retainers from the A/C

compressor.
15. NOTE: LH shown; RH similar.

Remove the LH and RH coil covers.
12. Remove the bolt and the battery cable harness
from the RH engine mount.

vacuum hose from the fuel pressure sensor.
2005 Aviator, 09/2004

303-01-4 Engine 303-01-4
REMOVAL (Continued)
Disconnect the RH and LH ignition coil
electrical connectors.
20. Disconnect the camshaft position (CMP) sensor

electrical connector and the 2 retainers from the
valve cover.
17. Disconnect the radio interference capacitor

21. Disconnect the oil pressure sensor electrical

connector.
18. Disconnect the eight fuel injector electrical

connectors.
19. Separate the fuel charging wiring harness

retainers from the fuel injection supply
manifold.
2005 Aviator, 09/2004

303-01-5 Engine 303-01-5
REMOVAL (Continued)
22. Disconnect the pin-type retainers from the back
of the engine in the locations shown.
26. Disconnect the exhaust gas recirculation (EGR)

system module tube nut from the exhaust
manifold.
23. Disconnect the knock sensor (KS) electrical
connector and the pin-type retainer.
27. Disconnect the cylinder head temperature

(CHT) sensor electrical connector and the 2
24. Disconnect the wiring harness retainer from the pin-type retainers.
stud on the cylinder head.
25. Disconnect the intake manifold runner control

(IMRC) electrical connector.
2005 Aviator, 09/2004

303-01-6 Engine 303-01-6
REMOVAL (Continued)
28. Disconnect the positive crankcase ventilation
(PCV) electrical connector.
32. Disconnect the 2 retainers from the RH valve

cover studs.
29. Remove the PCV tube.
33. Disconnect the engine coolant temperature

(ECT) sensor electrical connector.
30. Disconnect the RH radio interference capacitor
electrical connector and the pin-type retainer.
31. Disconnect the throttle position (TP) sensor and

the idle air control (IAC) sensor electrical
connectors.
2005 Aviator, 09/2004

303-01-7 Engine 303-01-7
REMOVAL (Continued)
34. Disconnect the A/C compressor and the 37. Rotate the belt tensioner clockwise and remove
crankshaft position (CKP) sensor electrical the accessory drive belt.
connectors.
38. Remove the bolts and the generator support

35. Remove the upper radiator hose. bracket.
36. Remove the coolant bypass-to-thermostat 39. Remove the bolts and the generator.
housing hose.
2005 Aviator, 09/2004

303-01-8 Engine 303-01-8
REMOVAL (Continued)
40. Remove the crossover tube. 43. NOTE: RH shown, LH similar.
1 Disconnect the coolant hose. Remove the engine lifting eyes.
2 Remove the retainers and the crossover
tube.
44. Remove the bolts and the LH valve cover.
41. Remove the 8 ignition coils.
45. Remove the coolant hose retainers from the RH

valve cover.
42. Remove the nut and the bolt from the oil level
indicator tube and position the tube aside.
2005 Aviator, 09/2004

303-01-9 Engine 303-01-9
REMOVAL (Continued)
46. Remove the bolts and the RH valve cover.
49. Remove the bolt and the coolant bypass tube.

47. Remove the retainers and the upper-to-lower
intake bracket. Remove the exhaust manifolds.
1 Remove the 16 nuts.
2 Remove the exhaust manifolds.
3 Remove the exhaust manifold gaskets.
48. NOTE: Upper intake shown removed for

clarity.
Remove the bolts in the sequence shown and
remove the upper and lower intake.
51. Clean and inspect the exhaust manifolds. For
52. Remove the oil level indicator tube.
2005 Aviator, 09/2004

303-01-10 Engine 303-01-10
REMOVAL (Continued)
53. Remove the three remaining bolts and the
power steering pump.

1 Loosen the bolts.
56. Using the special tool to prevent the crankshaft

pulley from turning, remove the pulley bolt.
55. Remove the coolant pump pulley.

1 Remove the bolts.
2 Remove the coolant pump pulley.
2005 Aviator, 09/2004

303-01-11 Engine 303-01-11
REMOVAL (Continued)
57. Remove the bolt. 60. Remove the bolt and the belt idler pulley.
58. Using the special tool, remove the crankshaft 61. Remove the 4 front oil pan-to-timing cover
vibration damper. bolts.

front seal.
2005 Aviator, 09/2004

303-01-12 Engine 303-01-12
REMOVAL (Continued)
62. Remove the engine front cover fasteners in the Item Part Number Description
sequence shown. 11 N806300 Stud, Hex Shldr Pilot, M8 x
1.25 x 65 — M8 x 1.25 x 26
12 W706560 Stud, Hex Head Pilot, M8 x
1.25 x 65 — M8 x 1.25 x 16
13 N806300 Stud, Hex Shldr Pilot, M8 x
1.25 x 65 — M8 x 1.25 x 26
1.25 x 65 — M8 x 1.25 x 26
1.25 x 65 — M8 x 1.25 x 26
63. Remove the crankshaft position sensor pulse

wheel.
64. CAUTION: Mark the roller follower

Item Part Number Description locations. Reused roller followers must be
1 N806177 Bolt, Hex Flange Head Pilot, installed in their original locations.
M8 x 1.25 x 53
Position the piston of the cylinder in which the
2 N806177 Bolt, Hex Flange Head Pilot, roller followers are being removed at the
M8 x 1.25 x 53
bottom of the stroke and camshaft lobe at the
3 N806177 Bolt, Hex Flange Head Pilot, base circle.
M8 x 1.25 x 53
4 N806177 Bolt, Hex Flange Head Pilot, 65. Using the special tool, compress the intake
M8 x 1.25 x 53 valve spring and remove the roller follower.
5 N806177 Bolt, Hex Flange Head Pilot,
M8 x 1.25 x 53
6 W706508 Stud, Hex Shldr Pilot, M8 x
1.25 x 50 — M6 x 1 x 10
7 N808586 Stud and Washer, Hex Head
Pilot, M8 x 1.25 x 60 — M6
x 1 x 26
M8 x 1.25 x 53
M8 x 1.25 x 53
M8 x 1.25 x 53
(Continued)
2005 Aviator, 09/2004

303-01-13 Engine 303-01-13
REMOVAL (Continued)
66. Using the special tool, compress the exhaust 70. Remove the RH and the LH timing chains and
valve spring and remove the roller follower. the crankshaft sprocket.
67. Repeat the above steps to remove all the roller 71. Remove the RH and LH timing chain guides.
followers.
68. Remove the bolts and the RH and LH timing

chain tensioners.
72. NOTE: The hydraulic lash adjusters must be

reinstalled in their original locations. Record the
hydraulic lash adjuster locations.
Remove the hydraulic lash adjusters.
69. Remove the RH and LH timing chain tensioner
arms.
2005 Aviator, 09/2004

303-01-14 Engine 303-01-14
REMOVAL (Continued)
73. Remove the RH and LH cylinder heads. 74. Clean and inspect the cylinder heads. For
• Discard the cylinder head bolts. additional information, refer to Section 303-00.
• Discard the cylinder head gaskets.
2005 Aviator, 09/2004

303-01-1 Engine 303-01-1
REMOVAL
Engine 9. Drain the engine oil.
• Install the drain plug when finished.
Special Tool(s) • Tighten to 13 Nm (10 lb-ft).
required)
303-D087 (D93P-6001-A1)
Spreader Bar
303-D089 (D93P-6001-A3) or
equivalent
10. Disconnect the accelerator cable, the speed

Disconnect Tool, Spring Lock
Coupling (1/2 inch) control cable and the throttle return spring.
310-D005 (D87L-9280-A) or
equivalent
Removal

Section 100-02.

11. Release the speed control cable from the
3. Remove the hood. For additional information, pin-type retainer.
4. Discharge and recover the A/C system. For

5. Remove the air cleaner assembly. For additional

6. Remove the engine cooling fan. For additional

7. Remove the cooling module. For additional

8. Release the fuel system pressure. For additional


303-01-2 Engine 303-01-2
REMOVAL (Continued)
12. Remove the 2 bolts and position the bracket
and cables aside.
16. Disconnect the coolant hose from the intake

manifold.
13. Disconnect the 2 coolant hoses and position

aside.
17. Disconnect the engine wiring harness and the

electrical connector from the powertrain control
module (PCM).
14. Disconnect the 2 vacuum hoses and position
aside.
15. Release the coolant hose from the retaining

clips on the RH valve cover and position aside.
2005 Aviator, 09/2004

303-01-3 Engine 303-01-3
REMOVAL (Continued)
18. Release the engine wiring harness from the
three retaining clips and position aside.
22. Disconnect the EGR system module nut from

the EGR system module.
19. Disconnect the wiring harness and remove the

wiring harness retaining clip.
23. Remove the two bolts and the EGR system

module.
20. Remove the ground strap bolt.

vacuum hose from the exhaust gas recirculation
(EGR) system module.
2005 Aviator, 09/2004

303-01-4 Engine 303-01-4
REMOVAL (Continued)
24. Disconnect the vacuum harness from the 28. Open the power distribution supply box cover.
retainer.
29. Disconnect the power distribution supply

25. Disconnect the brake booster hose from the electrical connector.
intake manifold.
30. Disconnect the positive and negative battery

26. Disconnect the fuel tube. For additional cables from the battery. For additional
information, refer to Section 310-00. information, refer to Section 414-01.
27. Disconnect the 2 vacuum hoses from the vapor 31. Release the battery cable harness pin-type
management (VMV) valve-to-intake manifold. retainers and position the harness aside.
2005 Aviator, 09/2004

303-01-5 Engine 303-01-5
REMOVAL (Continued)
32. Disconnect the power steering reservoir hose 35. Disconnect the power steering pressure hose
from the power steering cooler. bracket from the front cover.
33. Disconnect the power steering pressure (PSP) 36. Disconnect the support bracket and position
switch electrical connector. aside.
34. Disconnect the power steering pressure tube 37. Remove the bolt and position the A/C
from the power steering pump. compressor manifold assembly aside.
2005 Aviator, 09/2004

303-01-6 Engine 303-01-6
REMOVAL (Continued)
38. Remove the LH engine mount through-bolt.
41. Install the special tools and remove the engine.
39. Remove the 2 nuts from the RH engine mount

(through the wheel well).
40. NOTE: Engine removal requires the use of 2

lifting eyes 303-D087.
NOTE: RH shown; LH similar.
Install the engine lifting eyes.
2005 Aviator, 09/2004

303-01-1 Engine 303-01-1
DISASSEMBLY
Special Tool(s) 303-107 (T74P-6700-A)

required)
303-D087 (D93P-6001-A1)

Spring
303-452 (T93P-6565-AR)
Spreader Bar
303-D089 (D93P-6001-A3) or
equivalent
Compressor, Exhaust Valve

Spring
303-567 (T97P-6565-AH)
Remover, Crankshaft Rear Seal
303-519 (T95P-6701-EH)
Installer, Connecting Rod

303-442 (T93P-6136-A)
Remover, Crankshaft Rear Oil

Slinger
303-514 (T95P-6701-AH)
Strap Wrench
303-D055 (D85L-6000-A)
Slide Hammer
100-001 (T50T-100-A)

Damper
303-009 (T58P-6316-D)
(Continued)

303-01-2 Engine 303-01-2
DISASSEMBLY (Continued)
CAUTION: Remove the cylinder heads 4. Remove the rear seal retainer plate.
before removing the crankshaft. Failure to do so
can result in engine damage.
1. Remove the flexplate and the spacer plate.
5. Mount the engine on a suitable engine stand.

oil slinger.
6. Remove the 2 bolts and the pin-type retainer

from the power steering reservoir bracket.

rear seal.
2005 Aviator, 09/2004

303-01-3 Engine 303-01-3
7. Remove the power steering reservoir and 10. Disconnect the 2 retainers from the engine front
bracket. cover studs.
• Disconnect the hose from the power steering
pump.
• Remove the bolt and the reservoir and
bracket.
11. Disconnect the 2 retainers from the A/C

compressor.
8. Disconnect the battery cable harness ground.
12. Remove the bolt and the battery cable harness

from the RH engine mount.

battery cable from the alternator.
2005 Aviator, 09/2004

303-01-4 Engine 303-01-4
vacuum hose from the fuel pressure sensor.
17. Disconnect the radio interference capacitor

14. Disconnect the vacuum harness from the intake

manifold and remove the harness.
18. Disconnect the 8 fuel injector electrical

connectors.

Remove the LH and RH coil covers.

Disconnect the RH and LH ignition coil
electrical connectors.
2005 Aviator, 09/2004

303-01-5 Engine 303-01-5
19. Separate the fuel charging wiring harness 22. Disconnect the pin-type retainers from the back
retainers from the fuel injection supply of the engine in the locations shown.
manifold.

20. Disconnect the camshaft position (CMP) sensor connector and the pin-type retainer.
electrical connector and the 2 retainers from the
valve cover.
24. Disconnect the wiring harness retainer from the

stud on the cylinder head.
21. Disconnect the oil pressure sensor electrical
connector.
2005 Aviator, 09/2004

303-01-6 Engine 303-01-6
25. Disconnect the intake manifold runner control 28. Disconnect the positive crankcase ventilation
(IMRC) electrical connector. (PCV) electrical connector.
26. Disconnect the exhaust gas recirculation (EGR) 29. Remove the PCV tube.
system module tube nut from the exhaust
manifold.
30. Disconnect the RH radio interference capacitor

(CHT) sensor electrical connector and the 2
pin-type retainers.
2005 Aviator, 09/2004

303-01-7 Engine 303-01-7
31. Disconnect the throttle position (TP) sensor and
connectors.
35. Remove the upper radiator hose.
32. Disconnect the 2 retainers from the RH valve

cover studs.
36. Remove the coolant bypass-to-thermostat

housing hose.


34. Disconnect the A/C compressor and the

crankshaft position (CKP) sensor electrical
connectors.
2005 Aviator, 09/2004

303-01-8 Engine 303-01-8
38. Remove the bolts and the generator support 41. Remove the 8 ignition coils.
bracket.
42. Remove the nut and the bolt from the oil level
39. Remove the bolts and the generator. indicator tube and position the tube aside.
40. Remove the crossover tube. 43. NOTE: RH shown; LH similar.

1 Disconnect the coolant hose. Remove the engine lifting eyes.
2 Remove the retainers and the crossover
tube.
2005 Aviator, 09/2004

303-01-9 Engine 303-01-9
44. Remove the bolts and the LH valve cover.
45. Remove the coolant hose retainers from the RH

valve cover.
47. Remove the retainers and the upper-to-lower

intake bracket.
46. Remove the bolts and the RH valve cover.
2005 Aviator, 09/2004

303-01-10 Engine 303-01-10
48. NOTE: Upper intake shown removed for 51. NOTE: LH shown; RH similar.
clarity. Remove the exhaust manifolds.
Remove the bolts in the sequence shown and 1 Remove the 16 nuts.
remove the upper and lower intake.
2 Remove the exhaust manifolds.
3 Remove the exhaust manifold gaskets.
49. Remove the bolt and the coolant bypass tube.
52. Remove the oil level indicator tube.

Remove the LH and RH engine mounts.
50. Remove the bolts and the KS.
2005 Aviator, 09/2004

303-01-11 Engine 303-01-11
Remove the drain plugs from the engine block.
Allow the coolant to completely drain.
58. Remove the bolts and the A/C compressor.
55. Remove the 4 bolts and the oil filter adapter.

• Discard the oil filter.
• Discard the gasket.

1 Loosen the bolts.
56. Clean and inspect the oil filter adapter.

• Flush the adapter with parts cleaner. If metal
particles are present, install a new oil filter
adapter.
57. Remove the 3 remaining bolts and the power

steering pump.
2005 Aviator, 09/2004

303-01-12 Engine 303-01-12
60. Remove the coolant pump pulley. 63. Using the special tool to prevent the crankshaft
1 Remove the bolts. pulley from turning, remove the pulley bolt.
2 Remove the coolant pump pulley.
64. Remove the bolt.
61. Remove the coolant pump from the cylinder 65. Using the special tool, remove the crankshaft
block. vibration damper.
• Clean and inspect the sealing surfaces.
62. To remove the crankshaft pulley bolt, remove

the upper fan shroud and electric fan. For
2005 Aviator, 09/2004

303-01-13 Engine 303-01-13
front seal.
67. Remove the bolt and the belt idler pulley.

M8 x 1.25 x 53
M8 x 1.25 x 53
68. Remove the 4 front oil pan-to-timing cover
bolts. M8 x 1.25 x 53
M8 x 1.25 x 53
M8 x 1.25 x 53
1.25 x 50 — M6 x 1 x 10
7 N808586 Stud and Washer, Hex Head
Pilot, M8 x 1.25 x 60 — M6
x 1 x 26
M8 x 1.25 x 53
M8 x 1.25 x 53
69. Remove the engine front cover fasteners in the M8 x 1.25 x 53
sequence shown.
1.25 x 65 — M8 x 1.25 x 26
(Continued)
2005 Aviator, 09/2004

303-01-14 Engine 303-01-14
12 W706560 Stud, Hex Head Pilot, M8 x
1.25 x 65 — M8 x 1.25 x 16
1.25 x 65 — M8 x 1.25 x 26
1.25 x 65 — M8 x 1.25 x 26
1.25 x 65 — M8 x 1.25 x 26
70. NOTE: Be careful when removing the gasket.

It is reusable if not damaged.
Remove the oil pan and the gasket.
valve spring and remove the roller follower.
71. Remove the crankshaft position sensor pulse

wheel.
75. Repeat the above steps to remove all the roller
followers.
76. Remove the bolts and the RH and LH timing

chain tensioners.
72. Position the piston of the cylinder in which the

roller followers are being removed at the
bottom of the stroke and camshaft lobe at the
base circle.

valve spring and remove the roller follower.
2005 Aviator, 09/2004

303-01-15 Engine 303-01-15
77. Remove the RH and LH timing chain tensioner
arms.
81. Remove the bolts and the oil pump screen and
pickup tube.
78. Remove the RH and the LH timing chains and

the crankshaft sprocket.
82. Remove the oil pump screen and pickup tube

spacer.
79. Remove the RH and LH timing chain guides.
80. Remove the RH and LH cylinder heads.

• Discard the cylinder head bolts.
2005 Aviator, 09/2004

303-01-16 Engine 303-01-16
83. Remove the spacers and the windage tray. 86. CAUTION: Do not scratch the cylinder
walls or crankshaft journals with the
connecting rod.
NOTE: Before removing pistons, inspect the
top of the cylinder bores. If necessary, remove
the ridge or carbon deposits from each cylinder
using a cylinder ridge reamer following
manufacturer’s instructions.
Using the special tool, push piston numbers 1
and 6 through the top of the cylinder block.
84. Remove the bolts and the oil pump.
87. To remove pistons 3 and 5, 4 and 7, 2 and 8,

turn the crankshaft 90 degrees and repeat the
previous 2 steps.
85. CAUTION: Do not stamp the top of

pistons, as ring land damage can occur.
NOTE: Connecting rods and rod caps should
be numbered to keep the correct orientation in
the following sequence.
Remove the connecting rod caps for piston
numbers 1 and 6.
• Discard the bolts.
2005 Aviator, 09/2004

303-01-17 Engine 303-01-17
CAUTION: Remove the cylinder heads 90. Remove the main bearing cap and the
before removing the crankshaft. Failure to do so crankshaft lower main bearings from the
can result in engine damage. cylinder block.
88. Remove the side bolts.
91. Remove the crankshaft, the crankshaft thrust

washer, and the crankshaft upper main bearings
from the cylinder block.
89. Remove and discard the bolts.
2005 Aviator, 09/2004

303-01-1 Engine 303-01-1
DISASSEMBLY AND ASSEMBLY

OF SUBASSEMBLIES
Cylinder Head
Special Tool(s)
303-452 (T93P-6565-AR)

303-567 (T97P-6565-AH)

Compressor
303-382 (T91P-6565-AH)

303-383 (T91T-6571-A)
Holding Tool, Camshaft

303-446 (T93P-6256-AHR)
Material
Item Specification
Motor Oil
XO-5W20-QSP or
equivalent

303-01-2 Engine 303-01-2
DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued)

1 6518 Valve spring retainer keys (32 7 N811085 Camshaft sprocket bolt
required) 8 N806164 Camshaft sprocket bolt
2 6514 Valve spring retainers (16 washer
required) 9 6256 Camshaft sprocket
2 6514 Valve spring retainers (16 10 N811085 Camshaft gear bolt
required)
11 N806164 Camshaft gear bolt washer
3 6513 Valve springs (16 required)
12 6268 Camshaft gear spacer
4 6A517 Valve seals (16 required)
13 6256 Timing chain
5 6505 Exhaust valves (8 required)
14 W500215 Timing chain tensioner bolts
6 6507 Intake valves (8 required) (2 required)
(Continued) (Continued)
2005 Aviator, 09/2004

303-01-3 Engine 303-01-3
Item Part Number Description 3. NOTE: Valve stem seals should be visually
15 6C271 Timing chain tensioner inspected if new seals are not installed.
16 W705438 Camshaft bearing cap bolts Remove the valve spring retainer, the valve
(outboard row) (12 required/6 spring and the valve stem seal.
per cylinder head)
16 N807352 Camshaft bearing cap bolts (3
inboard rows) (38 required/19
per cylinder head)
17 6B278 Camshaft bearing caps
(exhaust)
18 6B277 Camshaft bearing caps
(intake)
19 6A273 Camshaft (exhaust)
20 6A271 Camshaft (intake)
Disassembly

coils to protect the exhaust valve stem seal 4. Remove the valve from the cylinder head.
from damage.
5. Repeat the above 4 steps and remove all of the
exhaust valve and spring assemblies.

damage.

retainer keys.
2005 Aviator, 09/2004

303-01-4 Engine 303-01-4
valve spring. Remove the intake valve spring
retainer keys.
12. Remove the 2 bolts and the tensioner.
13. Remove the secondary camshaft spacer, washer

and bolt.
8. NOTE: Valve stem seals should be visually
inspected if new seals are not installed. 14. Remove the secondary camshaft sprockets and
Remove the valve spring retainer, the valve chain assembly.
spring and the valve stem seal.
15. Remove the 12 outboard camshaft bearing cap

9. Remove the valve from the cylinder head. bolts and bearing caps.
10. Repeat the preceeding 4 steps to remove all of 16. Remove the 19 inboard camshaft bearing cap
the intake valve and spring assemblies. bolts and bearing caps.
11. Remove the camshaft sprocket bolt and washer. 17. Remove the camshafts.
Assembly
1. NOTE: Lubricate the camshaft lobes with clean

engine oil.
Install the camshafts.
2005 Aviator, 09/2004

303-01-5 Engine 303-01-5
2. Install the camshaft bearing caps and bolts and
tighten to 10 Nm (89 lb-in) in the sequence
shown.
3. NOTE: Compress the tensioner and install the 4. CAUTION: Timing marks must be at
retaining pin. the 12 o’clock position and indexed at the 6
NOTE: LH tensioner is shown, RH tensioner is o’clock position.
similar. Install the secondary camshaft sprockets and
Install the tensioner. chain as an assembly.
2005 Aviator, 09/2004

303-01-6 Engine 303-01-6
9. Using the special tools, install the new intake

valve stem seals. Repeat this step to install all
6. NOTE: Do not tighten the bolt at this time. the intake valve stem seals.
Install the secondary camshaft spacer, washer
and bolt.
10. Using the special tools, install the new exhaust

valve stem seals. Repeat this step to install all
7. NOTE: Do not tighten the bolt at this time. the exhaust valve stem seals.
Install the camshaft gear, washer and bolt.
8. Tighten the bolts in 2 stages:

2005 Aviator, 09/2004

303-01-7 Engine 303-01-7
11. Install the special tool between the valve spring 15. Repeat the above 3 steps to install all of the
coils to protect the exhaust valve stem seal exhaust valve spring assemblies.
from damage.
damage.
12. Install the exhaust valve in the cylinder head.
13. Position the exhaust valve spring and the spring

retainer over the exhaust valve stem and valve 17. Install the intake valve into the cylinder head.
seal.
18. Position the intake valve spring and the spring
retainer over the intake valve stem and valve
seal.

valve spring. Install the exhaust valve spring
retainer keys.
2005 Aviator, 09/2004

303-01-8 Engine 303-01-8
19. Using the special tool, compress the intake 20. Repeat the preceeding 3 steps to install all of
valve spring. Install the intake valve spring the intake valve spring assemblies.
retainer keys.
2005 Aviator, 09/2004

303-01-1 Engine 303-01-1
DISASSEMBLY AND ASSEMBLY

OF SUBASSEMBLIES
Piston
Material
Item Specification
Motor Oil
XO-5W20-QSP or
equivalent

1 6150 Piston compression upper ring 8 6135 Piston pin
2 6152 Piston compression lower ring 9 6200 Connecting rod
3 6159 Piston oil control upper 10 6110 Piston
segment ring
4 6161 Piston oil control spacer Disassembly and Assembly
5 6159 Piston oil control lower
segment ring 1. Remove the piston compression upper ring.
6 6140 Piston pin retainer
7 6140 Piston pin retainer 2. Remove the piston compression lower ring.
(Continued)

303-01-2 Engine 303-01-2
3. Remove the piston oil control upper segment
ring.
4. Remove the piston oil control spacer.
5. Remove the piston oil control lower segment

ring.
6. Remove the piston pin retainers and the piston

pin.
7. NOTE: The connecting rod must be installed

into the piston with identification markings
toward the front.
Separate the piston from the connecting rod.
8. To assemble, reverse the disassembly procedure.
2005 Aviator, 09/2004

303-01-1 Engine 303-01-1
ASSEMBLY
Special Tool(s) 303-452 (T93P-6565-AR)
Guides, Connecting Rod

303-442 (T93P-6136-A)

Seal
303-516 (T95P-6701-BH)
Installer, Crankshaft Vibration
Damper
303-102 (T74P-6316-B)
Compressor, Piston Ring

303-D032 (D81L-6002-C) or
equivalent
Installer, Crankshaft Front Oil
Seal
303-635

303-448 (T93P-6303-A)
Installer, Front Cover Oil Seal

303-335 (T88T-6701-A)

required)
303-D087 (D93P-6001-A1)
Seal
303-518 (T95P-6701-DH)
Strap Wrench
303-D055 (D85L-6000-A)

Slinger
303-517 (T95P-6701-CH)
(Continued)

303-01-2 Engine 303-01-2
ASSEMBLY (Continued)
Material
Item Specification
SAE 5W-20 Super WSS-M2C153-H
Engine Oil
XO-5W20-QSP or
equivalent
ZC-21
Sealant
F7AZ-19554-EA or
equivalent
Silicone Brake Caliper ESE-M1C171-A
Grease and Dielectric 4. CAUTION: Make sure the coated side
Compound of the thrust washer, with the 5-mm wide oil
XG-3 or equivalent grooves, faces the crankshaft thrust surface.
Push the crankshaft rearward and install the
NOTE: Before assembling engine components, use
crankshaft thrust washer at the back of the No.
metal surface cleaner and a suitable plastic or
5 main boss.
wooden scraper to clean the sealing surfaces. All
sealing surfaces must be clean. Make sure coolant
and oil passages are clear.
All vehicles

Install the drain plugs into the engine block.
5. Loosely install the main caps and the bolts.
2. Install the upper main bearings into the cylinder

block and the lower main bearing into the
crankshaft main bearing caps. Lubricate the
main bearings with clean engine oil.
3. Install the crankshaft into the cylinder block.
2005 Aviator, 09/2004

303-01-3 Engine 303-01-3
6. Push the crankshaft forward to seat the
crankshaft thrust washer and hold the crankshaft
in the forward position.
7. Tighten bolts 1-20 in the sequence shown in 4

stages.
2005 Aviator, 09/2004

303-01-4 Engine 303-01-4
8. Install and tighten the cross-mounted bolts in 2
stages.
11. CAUTION: Do not scratch the cylinder

walls or the crankshaft journals with the
connecting rod.
NOTE: Make sure the crankshaft is at top dead
center (TDC).
Using the special tool, install the connecting
rod assemblies.
9. Check the crankshaft end play. For additional

10. CAUTION: Do not scratch the cylinder

walls or crankshaft journals with the
connecting rod.
NOTE: Make sure that the piston arrow is
facing forward.
NOTE: Lubricate the piston rings, cylinder
walls and connecting rod bearings with clean
engine oil.
Using the special tool, push the pistons through
the top of the cylinder block.
2005 Aviator, 09/2004

303-01-5 Engine 303-01-5
12. NOTE: The rod bearing cap bolts are
torque-to-yield. Install new bolts each time they
are serviced.
Install the connecting rod bearing caps and
bolts and tighten in 3 stages.
16. Position the oil pump, and tighten the bolts in

the sequence shown.
13. Check the connecting rod bearing clearance. For

14. Install the spacers and the windage tray.

17. NOTE: Install a new O-ring if necessary.

Install the oil pump screen cover and tube.
• Tighten the oil pump orifice bolts to 10 Nm
(89 lb-in).
• Tighten the pickup base bolt to 25 Nm (18
lb-ft).
15. Install and tighten the oil pump screen spacer.

2005 Aviator, 09/2004

303-01-6 Engine 303-01-6
18. Install the cylinder head gaskets. Engines with ratcheting timing chain tensioner

ratchet assembly.
Compress each tensioner plunger, using an edge
of a vise.

NOTE: Lubricate the bolt heads and threads.
Use clean engine oil.
Install the LH and RH cylinder heads and
tighten the bolts in 6 stages in the sequence
shown.
• Stage 3: Loosen the bolts a minimum of one
full turn.
• Stage 4: Tighten to 40 Nm (30 lb-ft). 21. Using a small screwdriver or pick, push back
2005 Aviator, 09/2004

303-01-7 Engine 303-01-7
26. Install a retaining clip on the tensioner to hold

the plunger in during installation.
23. Install a paper clip into the hole of each

27. Remove the tensioner from the vise.
All engines
28. If the copper links are not visible, mark one

Engines with non-ratcheting timing chain link on one end and one link on the other end,
tensioners and use as timing marks.
24. CAUTION: If one or both tensioner

mounting bolts are loosened or removed, the
tensioner-sealing bead must be inspected for
separation from the tensioner body or
permanent compression of the seal bead, will
require replacement of the tensioner.
Inspect the RH and LH timing chain tensioners.
25. Compress the tensioner plunger, using a vise.
2005 Aviator, 09/2004

303-01-8 Engine 303-01-8
29. Install the timing chain guides. 30. Rotate the LH camshaft timing sprocket until
the timing mark is approximately at the 12
o’clock position. Rotate the RH camshaft timing
sprocket until the timing mark is at
approximately the 11 o’clock position.
31. CAUTION: Unless otherwise

instructed, at no time when the timing chains
installed is the crankshaft or camshaft to be
rotated. Severe piston and valve damage will
occur.
Using the special tool, position the crankshaft.
• Remove the special tool.
2005 Aviator, 09/2004

303-01-9 Engine 303-01-9
32. Install the crankshaft sprocket with the flange
facing forward.
Engines with ratcheting timing chain tensioners
36. Remove the retaining clip from the timing chain

33. Install the LH and RH timing chains onto the tensioners.
crankshaft sprocket, aligning the one copper
link on the timing chain with the slot on the
crankshaft sprocket.
37. Remove the retaining clips from the timing

chain tensioners.
34. NOTE: If necessary, adjust the camshaft

sprocket slightly to obtain timing mark
alignment.
Position the LH and RH timing chains on the
camshaft sprockets. Make sure the
copper-colored links align with the camshaft
sprocket timing marks.
35. Position the LH and RH timing chain tensioner

arms on the dowel pins. Position the timing
chain tensioner assemblies, and install the bolts.
2005 Aviator, 09/2004

303-01-10 Engine 303-01-10
All vehicles 41. Tighten the bolts in 2 stages in the sequence
shown.
38. As a post-check, verify correct alignment of all • Stage 1: Tighten to 20 Nm (15 lb-ft).
timing marks. • Stage 2: Rotate an additional 60 degrees.
39. Position the crankshaft sensor ring on the

crankshaft.
42. Install the drain plug.

40. Install the oil pan and gasket and loosely install
the bolts.
2005 Aviator, 09/2004

303-01-11 Engine 303-01-11
43. NOTE: If the engine front cover is not secured Item Part Number Description
within 4 minutes, the sealant must be removed 1 N806177 Bolt, Hex Flange Head Pilot,
and the sealing area cleaned with metal surface M8 x 1.25 x 53
cleaner. Allow to dry until there is no sign of 2 N806177 Bolt, Hex Flange Head Pilot,
wetness, or 4 minutes, whichever is longer. M8 x 1.25 x 53
Failure to follow this procedure can result in 3 N806177 Bolt, Hex Flange Head Pilot,
future oil leakage. M8 x 1.25 x 53
Apply silicone gasket and sealant in the 4 N806177 Bolt, Hex Flange Head Pilot,
locations shown. M8 x 1.25 x 53
M8 x 1.25 x 53
1.25 x 50 — M6 x 1 x 10
7 N808586 Stud and Washer, Hex-Head
Pilot, M8 x 1.25 x 60 — M6
x 1 x 26
M8 x 1.25 x 53
M8 x 1.25 x 53
M8 x 1.25 x 53
44. Install the engine front cover. Tighten in the 1.25 x 65 — M8 x 1.25 x 26
sequence shown to 25 Nm (18 lb-ft). 12 W706560 Stud, Hex-Head Pilot, M8 x
1.25 x 65 — M8 x 1.25 x 16
1.25 x 65 — M8 x 1.25 x 26
1.25 x 65 — M8 x 1.25 x 26
1.25 x 65 — M8 x 1.25 x 26
45. Install the 4 oil pan bolts and tighten in 3

stages in the sequence shown.
2005 Aviator, 09/2004

303-01-12 Engine 303-01-12
46. Using the special tool, install the 32 roller
followers.

sealing area cleaned with metal surface cleaner.
follow this procedure can result in future oil
leakage.
Apply silicone gasket and sealant in the
locations shown.
49. Install the belt idler pulley.


Install the valve covers and tighten the bolts in
the sequence shown.
2005 Aviator, 09/2004

303-01-13 Engine 303-01-13
50. Lubricate the front oil seal and the engine front
cover with clean engine oil.
51. Using the special tools, install the front oil seal.
55. Install the bolt and washer. Tighten the bolt in

4 stages.
52. Apply silicone gasket and sealant to the
Woodruff key on the crankshaft pulley. • Stage 2: Loosen the bolt one full turn.

pulley.
2005 Aviator, 09/2004

303-01-14 Engine 303-01-14
56. NOTE: Lubricate the O-ring seal with clean 59. Install the power steering pump and the 3 bolts.
engine coolant. Use the same type of coolant • Tighten to 25 Nm (19 lb-ft).
that was drained from the system.
Install the coolant pump and the 3 bolts.
60. Install the oil filter adapter.

• Position the gasket and the oil filter adapter.
57. Install the coolant pump pulley.

Install the LH and RH engine mounts.
58. Install the A/C compressor and the 4 bolts.
2005 Aviator, 09/2004

303-01-15 Engine 303-01-15
62. NOTE: Install a new O-ring and lubricate with
clean engine oil.
Install the oil level indicator tube.
• Install the oil level indicator tube in the
engine block.
65. Install the coolant bypass tube.


Install the exhaust manifolds.
1 Install new exhaust manifold gaskets.
2 Install the exhaust manifolds.
3 Install the 16 nuts.
X Tighten to 20 Nm (15 lb-ft).

clarity.
Install the upper and lower intake.
• Tighten all fasteners in the sequence shown
to 10 Nm (89 lb-in).
64. Install the knock sensors (KS).

2005 Aviator, 09/2004

303-01-16 Engine 303-01-16
67. Install the upper-to-lower intake bracket and the
nuts.
71. Install the crossover tube.

1 Install the crossover tube and the nuts.
2 Connect the coolant hose.
68. Install the coolant hose retainers on the RH X Tighten to 25 Nm (18 lb-ft).
valve cover.
72. Install the generator and the bolts.

69. NOTE: RH shown; LH similar. • Tighten to 25 Nm (18 lb-ft).
70. Install the 8 ignition coils.
2005 Aviator, 09/2004

303-01-17 Engine 303-01-17
73. Install the generator support bracket and the 77. Position the engine wiring harness on the
bolts. engine.
78. Connect the A/C compressor and the crankshaft
position (CKP) sensor electrical connectors.
74. Install the accessory drive belt. For additional

79. Connect the engine coolant temperature (ECT)
75. Install the coolant bypass-to-thermostat housing sensor electrical connector.
hose.
80. Connect the 2 harness retainers to the RH valve

76. Install the upper radiator hose. cover studs.
2005 Aviator, 09/2004

303-01-18 Engine 303-01-18
81. Connect the throttle position (TP) sensor and
connectors.
85. Connect the cylinder head temperature (CHT)

sensor electrical connector and the 2 pin-type
retainers.
82. Connect the RH radio interference capacitor

86. Connect the exhaust gas recirculation (EGR)

system module tube to the exhaust manifold.
83. Install the positive crankcase ventilation (PCV)
tube.
84. Connect the PCV electrical connector.
2005 Aviator, 09/2004

303-01-19 Engine 303-01-19
87. Connect the intake manifold runner control
91. Connect the oil pressure sensor electrical

connector.
88. Connect the wiring harness retainer to the stud

on the cylinder head.
92. Connect the camshaft position (CMP) sensor

electrical connector and the 2 retainers to the
valve cover.
89. Connect the KS electrical connector and the
pin-type retainer.
90. Connect the pin-type retainers to the back of

the engine in the locations shown.
2005 Aviator, 09/2004

303-01-20 Engine 303-01-20
93. Install the fuel charging wiring harness retainers
to the fuel injection supply manifold.
97. NOTE: RH shown; LH similar.

Install the RH and LH coil covers.
94. Connect the 8 fuel injector electrical connectors. • Tighten to 10 Nm (89 lb-in).
95. Connect the radio interference capacitor 98. Position the vacuum harness and connect it to
electrical connector. the intake manifold.
96. Connect the 8 ignition coils electrical

connectors.
2005 Aviator, 09/2004

303-01-21 Engine 303-01-21
99. Connect the electrical connector and the
vacuum hose to the fuel pressure sensor.
103. Connect the electrical connector and the

battery cable to the alternator.
100. Install the battery cable harness and the bolt to
the RH engine mount.
104. Connect the battery cable harness ground.

101. Connect the 2 retainers to the A/C compressor.
102. Connect the 2 retainers to the engine front

cover studs.
2005 Aviator, 09/2004

303-01-22 Engine 303-01-22
105. Position the power steering reservoir and 108. NOTE: If not secured within 4 minutes, the
install the 2 bolts and the pin-type retainer. sealant must be removed and the sealing area
• Tighten to 25 Nm (18 lb-ft). cleaned with metal surface cleaner. Allow to
dry until there is no sign of wetness, or 4
minutes, whichever is longer. Failure to follow
this procedure can result in future oil leakage.
Apply a 4-mm (0.16-in) bead of silicone
gasket and sealant around the rear oil seal
retainer plate sealing surface. Also apply a
bead of silicone gasket and sealant at the
junction where the cylinder block, oil pan and
rear oil seal retainer plate meet.
106. Install the remaining bolt and the hose to the

power steering reservoir.
109. Install the rear oil seal retainer plate. Tighten

the 8 bolts in 4 stages in the sequence shown.
• Stage 1: Tighten 1-6 to 10 Nm (89 lb-in).
• Stage 2: Hand-tighten 7 and 8.
• Stage 3: Tighten 7 and 8 to 20 Nm (15
lb-ft).
• Stage 4: Tighten 7 and 8 an additional 60
107. Remove the engine from the stand. degrees.
2005 Aviator, 09/2004

303-01-23 Engine 303-01-23
110. Using the special tools, install the crankshaft 112. Install the spacer plate and the flexplate.
rear main seal. • Tighten to 80 Nm (59 lb-ft).

oil slinger.
2005 Aviator, 09/2004

303-01-1 Engine 303-01-1
INSTALLATION
Cylinder Heads Special Tool(s)
Special Tool(s) required)
303-D087 (D93P-6001-A1)
Installer, Crankshaft Vibration
Damper
303-102 (T74P-6316-B)
Spreader Bar
303-D089 (D93P-6001-A3) or
equivalent
Installer, Crankshaft Front Oil
Seal
303-635
Strap Wrench
303-D055 (D85L-6000-A)
Installer, Front Cover Oil Seal

303-335 (T88T-6701-A)
Material
Item Specification
Spring SAE 5W-20 Super WSS-M2C153-H
303-452 (T93P-6565-AR) Premium Synthetic Blend
Engine Oil
XO-5W20-QSP or
equivalent
ZC-21
Compressor, Exhaust Valve Silicone Gasket and WSE-M4G323-A4
Spring Sealant
303-567 (T97P-6565-AH) F7AZ-19554-EA or
equivalent
Silicone Brake Caliper ESE-M1C171-A
Grease and Dielectric
Compound
XG-3 or equivalent
303-448 (T93P-6303-A)
(Continued)

303-01-2 Engine 303-01-2
INSTALLATION (Continued)
NOTE: Before cylinder head installation, use metal 3. NOTE: Lubricate the hydraulic lash adjusters
surface cleaner and a suitable plastic or wooden with clean engine oil.
scraper to clean the sealing surfaces. All sealing Install the hydraulic lash adjusters in their
surfaces must be clean. Make sure coolant and oil original locations for both cylinder heads.
passages are clear.
All vehicles
1. Install new cylinder head gaskets.
4. CAUTION: If one or both tensioner

mounting bolts are loosened or removed, the
2. NOTE: LH shown, RH similar. tensioner-sealing bead must be inspected for
NOTE: Lubricate the new bolt heads and separation from the tensioner body or
threads. Use clean engine oil. permanent compression of the seal bead, will
Install the LH and RH cylinder heads and require replacement of the tensioner.
tighten the 10 bolts in 6 stages in the sequence Inspect the RH and LH timing chain tensioners.
shown.
• Stage 3: Loosen the bolts a minimum of one
full turn.
2005 Aviator, 09/2004

303-01-3 Engine 303-01-3
ratchet assembly.
Compress each tensioner plunger, using an edge
of a vise.
8. Install a paper clip into the hole of each

6. Using a small screwdriver or pick, push back

Engines with non-ratcheting timing chain

tensioners
9. Compress the tensioner plunger, using a vise.

2005 Aviator, 09/2004

303-01-4 Engine 303-01-4
10. Install a retaining clip on the tensioner to hold 13. Install the timing chain guides.
the plunger in during installation. • Tighten to 10 Nm (89 lb-in).
11. Remove the tensioner from the vise.
All engines
12. 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.
2005 Aviator, 09/2004

303-01-5 Engine 303-01-5
14. Rotate the LH camshaft timing sprocket until
the timing mark is approximately at the 12
o’clock position. Rotate the RH camshaft timing
sprocket until the timing mark is at
approximately the 11 o’clock position.
15. CAUTION: Unless otherwise 16. Install the crankshaft sprocket with the flange
instructed, at no time when the timing chains facing forward.
installed is the crankshaft or camshaft to be
rotated. Severe piston and valve damage will
occur.
Using the special tool, position the crankshaft.
2005 Aviator, 09/2004

303-01-6 Engine 303-01-6
17. Install the LH and RH timing chains onto the
crankshaft sprocket, aligning the one copper
link on the timing chain with the slot on the
crankshaft sprocket.
Engines with non-ratcheting timing chain

tensioners
21. Remove the retaining clips from the timing

chain tensioners.
18. NOTE: If necessary, adjust the camshaft
sprocket slightly to obtain timing mark
alignment.
Position the LH and RH timing chains on the
camshaft sprockets. Make sure the
copper-colored links align with the camshaft
sprocket timing marks.
19. Position the LH and RH timing chain tensioner

arms on the dowel pins. Position the timing
chain tensioner assemblies, and install the bolts.
All engines
22. As a post-check, verify correct alignment of all

timing marks.
20. Remove the retaining clip from the timing chain

tensioners.
2005 Aviator, 09/2004

303-01-7 Engine 303-01-7
23. Position the crankshaft sensor ring on the
crankshaft.
24. NOTE: If the engine front cover is not secured

within 4 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 4 minutes, whichever is longer.
Failure to follow this procedure can result in
future oil leakage.
locations shown.

M8 x 1.25 x 53
M8 x 1.25 x 53
M8 x 1.25 x 53
M8 x 1.25 x 53
M8 x 1.25 x 53
1.25 x 50 — M6 x 1 x 10
25. Install the engine front cover. Tighten in the 7 N808586 Stud and Washer, Hex-Head
sequence shown to 25 Nm (18 lb-ft). Pilot, M8 x 1.25 x 60 — M6
x 1 x 26
M8 x 1.25 x 53
M8 x 1.25 x 53
M8 x 1.25 x 53
1.25 x 65 — M8 x 1.25 x 26
(Continued)
2005 Aviator, 09/2004

303-01-8 Engine 303-01-8
Item Part Number Description 28. Using the special tool, compress the intake
12 W706560 Stud, Hex-Head Pilot, M8 x valve spring and install the roller follower.
1.25 x 65 — M8 x 1.25 x 16
1.25 x 65 — M8 x 1.25 x 26
1.25 x 65 — M8 x 1.25 x 26
1.25 x 65 — M8 x 1.25 x 26
26. Install the 4 oil pan bolts and tighten in 3

stages in the sequence shown.
valve spring and install the roller follower.
27. CAUTION: If reusing the roller

followers, install them in their original
locations. 30. Repeat the above steps to install all of the roller
followers.
Position the piston of the cylinder in which the
roller followers are being installed at the bottom
of the stroke and the camshaft lobe at the base
circle.
2005 Aviator, 09/2004

303-01-9 Engine 303-01-9
sealing area cleaned with metal surface cleaner.
follow this procedure can result in future oil
leakage.
locations shown.

Install the valve covers and tighten the 10 bolts
in the sequence shown.
33. Install the belt idler pulley.
2005 Aviator, 09/2004

303-01-10 Engine 303-01-10
34. Lubricate the front oil seal and the engine front
cover with clean engine oil.
38. Install the bolt and washer. Using the special

tool to hold the crankshaft pulley, tighten the
bolt in 4 stages.
35. Using the special tools, install the front oil seal. • Stage 1: Tighten to 90 Nm (66 lb-ft).
• Stage 2: Loosen the bolt.
36. Apply silicone gasket and sealant to the

Woodruff key on the crankshaft pulley.
39. Install the coolant pump pulley.


pulley.
2005 Aviator, 09/2004

303-01-11 Engine 303-01-11
40. Install the power steering pump and the 3 bolts.
43. Install the bolt and the coolant bypass tube.

41. NOTE: Install a new O-ring and lubricate with

clean engine oil.
Install the oil level indicator tube.
• Install the oil level indicator tube in the
engine block.

clarity.
Install the upper and lower intake.
• Tighten in the sequence shown to 10 Nm
(89 lb-in).

Install the exhaust manifolds.
1 Install new exhaust manifold gaskets.
2 Install the exhaust manifolds.
3 Install the 16 nuts.
X Tighten to 20 Nm (15 lb-ft).
2005 Aviator, 09/2004

303-01-12 Engine 303-01-12
45. Install the upper-to-lower intake bracket and the
2 nuts.
49. Install the crossover tube.

1 Install the crossover tube and the 2 nuts.
2 Connect the coolant hose.
46. Install the coolant hose retainers on the RH X Tighten to 25 Nm (18 lb-ft).
valve cover.
50. Install the generator and the 2 bolts.

47. NOTE: RH shown; LH similar. • Tighten to 25 Nm (18 lb-ft).
48. Install the 8 ignition coils.
2005 Aviator, 09/2004

303-01-13 Engine 303-01-13
51. Install the generator support bracket and the 4
bolts.
55. Position the engine wiring harness on the

engine.
56. Connect the A/C compressor and the crankshaft

52. Rotate the belt tensioner clockwise and install position (CKP) sensor electrical connectors.
the accessory drive belt.
57. Connect the engine coolant temperature (ECT)

53. Install the coolant bypass-to-thermostat housing sensor electrical connector.
hose.
54. Install the upper radiator hose.
2005 Aviator, 09/2004

303-01-14 Engine 303-01-14
58. Connect the 2 harness retainers to the RH valve 61. Install the positive crankcase ventilation (PCV)
cover studs. tube.
59. Connect the throttle position (TP) sensor and 62. Connect the PCV electrical connector.
connectors.
63. Connect the cylinder head temperature (CHT)

sensor electrical connector and the two pin-type
60. Connect the RH radio interference capacitor retainers.
2005 Aviator, 09/2004

303-01-15 Engine 303-01-15
64. Connect the exhaust gas recirculation (EGR) 67. Connect the KS electrical connector and the
system module tube to the exhaust manifold. pin-type retainer.
68. Connect the pin-type retainers to the back of

65. Connect the intake manifold runner control the engine in the locations shown.
69. Connect the oil pressure sensor electrical

66. Connect the wiring harness retainer to the stud connector.
on the cylinder head.
2005 Aviator, 09/2004

303-01-16 Engine 303-01-16
70. Connect the camshaft position (CMP) sensor
electrical connector and the 2 retainers to the
valve cover.
74. Connect the 8 ignition coil electrical connectors.
71. Install the fuel charging wiring harness retainers

to the fuel injection supply manifold.

Install the RH and LH coil covers.
72. Connect the 8 fuel injector electrical connectors.
73. Connect the radio interference capacitor

2005 Aviator, 09/2004

303-01-17 Engine 303-01-17
76. Position the vacuum harness and connect it to 79. Connect the 2 retainers to the A/C compressor.
80. Connect the 2 retainers to the engine front

77. Connect the electrical connector and the cover studs.
vacuum hose to the fuel pressure sensor.
81. Connect the electrical connector and the battery

78. Install the battery cable harness and the bolt to cable to the alternator.
the RH engine mount. • Tighten to 10 Nm (89 lb-in).
2005 Aviator, 09/2004

303-01-18 Engine 303-01-18
82. Connect the battery cable harness ground. 85. NOTE: LH shown, RH similar.
• Tighten to 20 Nm (15 lb-ft). Install the LH and RH engine mounts.
83. Position the power steering reservoir and install

the 2 bolts and the pin-type retainer. 86. Remove the engine from the stand.
84. Install the remaining bolt and the hose to the

power steering reservoir.
2005 Aviator, 09/2004

303-01-19 Engine 303-01-19
87. Install the spacer plate and the flexplate. 88. Install the engine. For additional information,
• Tighten to 80 Nm (59 lb-ft). refer to Engine in this section.
2005 Aviator, 09/2004

303-01-1 Engine 303-01-1
INSTALLATION
Engine 2. Install the 2 nuts to the RH engine mount
(through the wheel well).
Special Tool(s) • Tighten to 90 Nm (66 lb-ft).
required)
303-D087 (D93P-6001-A1)
Spreader Bar
303-D089 (D93P-6001-A3) or
equivalent
3. Install the LH engine mount through-bolt.

Installer Set, Teflon Seal
211-D027 (D90P-3517-A) • Tighten to 80 Nm (59 lb-ft).
Material
Item Specification
SAE 5W-20 Premium WSS-M2C153-H
XO-5W20-QSP or
equivalent
1. Using a suitable lifting crane, install the engine

in the vehicle. 4. NOTE: RH shown; LH similar.
Remove the engine lifting eyes.

303-01-2 Engine 303-01-2
5. NOTE: Install new O-ring seals lubricated in 8. Install the support bracket.
clean PAG oil. • Tighten to 10 Nm (89 lb-in).
Position the A/C compressor manifold assembly
and install the bolt.
9. Connect the PSP hose bracket to the front

cover.
6. Using the special tool, install a new O-ring seal

on the power steering pressure (PSP) tube
fitting.
10. Connect the PSP switch electrical connector.
7. Connect the PSP tube to the power steering

pump.
2005 Aviator, 09/2004

303-01-3 Engine 303-01-3
11. Connect the power steering reservoir hose to
the power steering cooler.
15. Close the power distribution box cover.
12. Position the battery cable harness and install the

pin-type retainers.
16. Connect the 2 vacuum hoses.
13. CAUTION: Do not connect the

negative battery cable at this time.
Connect the positive battery cable to the
battery. For additional information, refer to
Section 414-01.
14. Install the power distribution power supply

17. Connect the fuel tube. For additional

2005 Aviator, 09/2004

303-01-4 Engine 303-01-4
18. Connect the brake booster hose to the intake 21. Connect the EGR system module tube nut to
manifold. the EGR system module.
19. Position the vacuum harness and install it in the 22. Connect the electrical connector and the
retainer. vacuum hose to the EGR system module.
20. Install the 2 bolts and the exhaust gas 23. Position the ground strap and install the bolt.
recirculation (EGR) system module. • Tighten to 10 Nm (89 lb-in).
2005 Aviator, 09/2004

303-01-5 Engine 303-01-5
24. Install the wiring harness retaining clip and the 27. Install the coolant hose to the intake manifold.
wiring harness.
28. Install the coolant hose into the retaining clips

25. Install the engine wiring harness into the 3 on the RH valve cover.
retaining clips.
29. Position the vacuum harness and install the 2

26. Connect the engine wiring harness and the vacuum hoses.
electrical connector to the powertrain control
module (PCM).
2005 Aviator, 09/2004

303-01-6 Engine 303-01-6
30. Install the 2 coolant hoses. 33. Connect the accelerator cable, the speed control
cable and the throttle return spring.
31. Position the accelerator bracket and cables and

install the 2 bolts. 34. Install the transmission. For additional
• Tighten to 10 Nm (89 lb-in). information, refer to Section 307-01.
35. Install the cooling module. For additional

36. Install the engine cooling fan. For additional

37. Install the air cleaner assembly. For additional

38. Fill the engine with clean engine oil.
39. Connect the battery ground cable. For additional

32. Install the speed control cable into the pin-type 40. Fill and bleed the engine cooling system. For
retainer. additional information, refer to Section 303-03.
41. Charge the A/C system. For additional

42. Install the hood. For additional information,

2005 Aviator, 09/2004

303-03-1 Engine Cooling 303-03-1
SPECIFICATIONS
Torque Specifications
Block heater screw 3 — 27
Item Specification
Fan clutch nut 55 41 —
Cooling system capacity 18.6L (4.9 gallons)
Fan shroud bolts 10 — 89
Coolant
Idler pulley bolt 45 33 —
Engine Coolant VC-7-A Degas bottle bolts 10 — 89
(in California and Oregon, Radiator-to-cooling 12 9 —
VC-7-B in Canada, module bolts
VC-7-C) or equivalent Cooling 12 9 —
(yellow color) module-to-radiator
Other Chemicals support bolts
PAG Refrigerant WSH-M1C231-B Condenser-to-radiator 11 8 —
Compressor Oil mount bolts
F7AZ-19589-DA Transmission cooler 11 8 —
(YN-12-C) mounting bolts
Motorcraft Premium ESR-M14P7-A Thermostat housing 10 — 89
Cooling System Flush bolts
VC-1
Fan blade-to-fan clutch 7 — 62
Motorcraft Cooling WSS-M99B37-B6 bolts
System Stop Leak Pellets
VC-6 Electric fan bolts 12 9 —
Metal Surface Cleaner WSE-M5B392-A Coolant pump bolts 25 18 —
ZC-21 Coolant pump pulley 25 18 —
Cooling system pressure 138 kpa (20 psi) bolts
test specifications
Pressure relief cap 89-124 kPa (13-18 psi)
pressure test specifications
Thermostat Opening Temperature
Starts to open 79.5-83.3°C (175-182°F)
Fully open 94.5°C (202°F)


Engine Cooling When adding engine coolant, use a 50/50 mixture of
engine coolant and distilled water.
CAUTION: Vehicle cooling systems are
filled with Motorcraft Premium Gold Engine To maintain the integrity of the coolant and the
Coolant VC-7-A (in California and Oregon, cooling system:
VC-7-B, in Canada, VC-7-C) or equivalent • Add Motorcraft Premium Gold Engine Coolant
meeting Ford specification WSS-M97B51-A1 VC-7-A (in California and Oregon VC-7-B, in
(yellow color). Do not mix coolant types. Canada VC-7-C) or equivalent meeting Ford
NOTE: The addition of Cooling System Stop Leak specification WSS-M97B51-A1 (yellow color).
Pellets, VC-6, darkens Motorcraft Premium Gold Use the same coolant that is present in the
Engine Coolant from yellow to golden tan. system. Do not mix coolant types.
The engine cooling system consists of the • Do not add orange-colored extended life coolant
following: VC-2 (in Oregon VC-3, in Canada CXC-209) or
equivalent meeting Ford specification
• block heater WSS-M97B44-D. Mixing coolants may degrade
• fan blade and clutch the coolant’s corrosion protection.
• fan shroud • Do not add alcohol, methanol, brine, or any
• radiator degas bottle and pressure relief cap engine coolants mixed with alcohol or methanol
antifreeze. These can cause engine damage from
• thermostat overheating or freezing.
• coolant pump • Do not mix with recycled coolant unless it meets
• radiator the requirements of specification ESE-M97B44-A
• radiator hose or WSS-M97B51-A1. Not all coolant recycling
processes meet these specifications; use of such
• optional engine oil cooler
coolants may harm the engine and cooling system
• engine coolant temperature (ECT) sensor components.
• cylinder head temperature (CHT) sensor
• electric radiator fan
Engine coolant provides freeze protection, boil
protection, cooling efficiency and corrosion
protection to the engine and cooling components. In
order to obtain these protections, the engine coolant
must be maintained at the correct concentration and
fluid level in the degas bottle.


Engine Cooling Inspection and Verification
Special Tool(s) WARNING: To avoid personal injury, do

not unscrew the coolant pressure relief cap while
Pressure Tester the engine is operating or hot. The coolant
014-R1072 or equivalent system is under pressure; steam and hot liquid
can come out forcefully when the cap is loosened
slightly. Failure to follow these instructions can
result in personal injury.
CAUTION: Check the coolant level and
73III Automotive Meter engine oil, top off the coolant if needed. If there
105-R0057 or equivalent is engine coolant in the engine oil, the cause must
be corrected and the oil changed, or major
component damage can occur.
CAUTION: Vehicle cooling systems are
filled with Motorcraft Premium Gold Engine
Coolant VC-7-A (in California and Oregon
Worldwide Diagnostic System VC-7-B, in Canada VC-7-C) or equivalent
(WDS) meeting Ford specification WSS-M97B51-A1
Vehicle Communication Module (yellow color). Do not mix coolant types.
(VCM) with appropriate
adapters, or equivalent NOTE: The addition of Cooling System Stop Leak
diagnostic tool Pellets VC-6, darkens Motorcraft Premium Gold
Engine Coolant from yellow to golden tan.
1. Verify the customer’s concern by operating the
Battery/Anti-Freeze Tester engine to duplicate the condition.
2. Inspect to determine if any of the following
mechanical or electrical concerns apply.
Material
Item Specification
Engine Coolant
Oregon, VC-7-B in
Canada, VC-7-C) or
Cooling System Stop Leak WSS-M99B37-B6
Pellets
VC-6 or equivalent


Visual Inspection Chart X An iridescent sheen on top of the coolant
Mechanical Electrical could indicate a trace of oil is entering
the system. For additional information on
• Leaks • Damaged cylinder head
• Restricted airflow temperature sensor engine diagnosis, refer to Section 303-00.
through the • Damaged engine coolant X A milky brown color may indicate that
condenser/radiator temperature (ECT) engine oil is entering the cooling system.
• Damaged hoses sensor
• Loose/damaged hose • Damaged wiring If engine oil is suspected, the cause of
clamps • Damaged or faulty the leak may be internal to the engine.
• Damaged water gasket electric cooling fan For additional information on engine
• Damaged head gaskets • Fuse diagnosis, refer to Section 303-00.
• Damaged intake • Relay
manifold gasket • Damaged circuitry 2 If the engine coolant appearance is
• Damaged water pump acceptable, test the engine coolant freezing
• Damaged degas bottle point with a Battery/Anti-Freeze Tester. The
• Damaged heater core freezing point should be in the range of
• Damaged fan/fan clutch -50° F to -10° F. If the vehicle is driven in
• Coolant
condition/concentration cold climates less than -34° F, it may be
• Electric cooling fan necessary to increase the coolant
rotating in the wrong concentration to get adequate freeze
direction. Correct protection.
electric cooling fan
rotation is opposite the X Maximum coolant concentration is 60/40
mechanical cooling fan percent.
X Minimum coolant concentration is 40/60
3. If the inspection reveals an obvious concern percent.
that can be readily identified, repair it as 3 Adjust coolant range and level if necessary.
necessary. X If coolant is low, add specified coolant
4. Inspect the coolant condition. mixture only.
1 Inspect the coolant color. X If the engine coolant tests too weak, add
X If Motorcraft Premium Gold Engine straight engine coolant until the readings
Coolant VC-7-A (in California and are within acceptable levels.
Oregon VC-7-B, in Canada VC-7-C) or X If the engine coolant tests strong, remove
equivalent meeting Ford specification some of the engine coolant and add water
WSS-M97B51-A1 has a clear or pale until the readings are within acceptable
yellow color, this indicates a higher water levels.
content than required. 5. Verify the cooling system is correctly filled and
X Dark brown could indicate unauthorized bled. Refer to Cooling System Draining, Filling
stop leak may have been used. Use and Bleeding in this section.
Motorcraft Cooling System Stop Leak 6. If DTC P1474 or P0480 are present, refer to the
Pellets VC-6 or equivalent meeting Ford Powertrain Control/Emissions Diagnosis
specification WSS-M99B37-B6 only. (PC/ED) manual for diagnosis.
X A light or reddish brown color indicates 7. If the concern remains after the inspection,
that rust may be present in the cooling determine the symptom(s). GO to Symptom
system. Flush the system and refill with Chart.
the correct mixture Premium Gold Engine
Coolant.
X The addition of Cooling System Stop
Leak Pellets VC-6, darkens Motorcraft
Premium Gold Engine Coolant from
yellow to golden tan.


Symptom Chart
Symptom Chart
• Loss of engine coolant • Radiator. • GO to Pinpoint Test A.
• Coolant pump seal.
• Radiator hoses.
• Heater hoses.
• Heater core.
• Engine gaskets.
• Degas bottle.
• Heater control valve.
• Thermostat housing.
• The engine overheats • Coolant thermostat. • GO to Pinpoint Test C.
• Coolant pump.
• Airlock in system.
• Inoperative electric cooling
fan.
• Internal engine coolant leak.
• Radiator.
• Radiator airflow obstruction.
• Fan/fan clutch.
• Heater core.
• Pressure relief cap.
• Airlock in the system.
• Coolant
condition/concentration.
• The engine does not reach • Thermostat. • GO to Thermostat Electrical
normal operating temperature Test in this section.
• The block heater does not • Block heater power cable. • CHECK continuity in all
operate correctly three power cable circuits. If
any circuit tests over 5 ohms,
INSTALL a new power
cable.
• Block heater. • INSTALL a new block
heater. REFER to Block
Heater in this section.
• The electric cooling fan is • Circuitry. • GO to Pinpoint Test C.
inoperative • Relay.
• Cooling fan motor.
• The electric cooling fan stays • Circuitry. • GO to Pinpoint Test D.
on all the time • Fan relay.
• A/C system fault.


Connector Circuit Reference
Cooling Fan Relay
Pin Number(s) Circuit Designation/Description Normal Condition/Measurement

86 CKT 1153 (RD/BK) voltage supplied at all Greater than 10 volts at all times.
times
30 CKT 1153 (RD/BK) voltage supplied at all Greater than 10 volts at all times.
times
85 CKT 1154 (WH/BK) cooling fan relay to 10,000 ohms or greater to chassis ground and
PCM 0 volts.
87 CKT 1155 (YE/BK) cooling fan relay to Approximately 75 ohms to chassis ground.
cooling fan motor
PCM C175A

19 CKT 1154 (WH/BK) cooling fan relay to Greater than 10 volts at all times.
PCM
Cooling Fan Motor


1 CKT 1155 (YE/BK) cooling fan relay to fan Greater than 10 volts when cooling fan relay
motor engaged.
2 CKT 1205 (BK) cooling fan motor ground 0 ohms to chassis ground.
Pinpoint Tests
PINPOINT TEST A: LOSS OF ENGINE COOLANT

Test Step Result / Action to Take
A1 CHECK THE ENGINE COOLANT LEVEL
WARNING: To avoid personal injury, do not unscrew the

coolant pressure relief cap while the engine is operating or
hot. The cooling system is under pressure; steam and hot
liquid can come out forcefully when the cap is loosened
slightly. Failure to follow these instructions can result in
personal injury.
NOTE: Allow the engine to cool before checking the engine coolant Yes
level. GO to A2.
• Key in OFF position. No
• Visually inspect the engine coolant level at the degas bottle. FILL the engine coolant as necessary. GO
• Is the engine coolant level within specification? to A2.
A2 CHECK THE PRESSURE RELIEF CAP
WARNING: Never remove the pressure relief cap while

the engine is operating or hot. Failure to follow these
instructions can result in damage to the cooling system or
engine or personal injury. To avoid having scalding hot coolant
or steam blow out of the degas bottle when removing the
pressure relief cap, wait until the engine has cooled, then wrap
a thick cloth around the pressure relief cap and turn it slowly.
Step back while the pressure is released from the cooling
system. When you are sure that all the pressure has been
released, (still with a cloth) turn and remove the pressure relief Yes
cap. GO to A3.
• Carry out the pressure relief cap test. Refer to the Component No
Tests in this section. INSTALL a new pressure relief cap. TEST
• Is the pressure relief cap OK? the system for normal operation.
A3 CHECK THE ENGINE COOLANT FOR INTERNAL LEAK

liquid can come out forcefully when the cap is loosened
slightly. Failure to follow these instructions can result in
personal injury.
• Key in OFF position. Yes
• Inspect the engine coolant in the degas bottle for signs of REFER to Section 303-00.
engine oil. No
• Is oil evident in the coolant? GO to A4.
A4 CHECK THE ENGINE FOR COOLANT
• Remove the oil level indicator from the engine. Yes
• Is coolant evident in the oil? REFER to Section 303-00.
No
GO to A5.
A5 PRESSURE TEST THE ENGINE COOLING SYSTEM
• Pressure test the engine cooling system. Refer to the Yes
Component Tests in this section. REPAIR or INSTALL new components.
• Does the engine cooling system leak? TEST the system for normal operation.
No
The cooling system is operational. GO to
Symptom Chart.


PINPOINT TEST B: THE ENGINE OVERHEATS
B1 CHECK THE ENGINE COOLANT LEVEL

liquid can come out forcefully when the cap is loosened Yes
slightly. Failure to follow these instructions can result in GO to B2.
personal injury. No
• Check the engine coolant level at the degas bottle. FILL the degas bottle. GO to Pinpoint Test
• Is the engine coolant level OK? A.
B2 CHECK THE COOLANT CONDITION
• Check the coolant for dirt, rust or contamination. Yes
• Is the coolant condition OK? GO to B3.
No
FLUSH the engine cooling system.
REFER to Cooling System Flushing in this
section. TEST the system for normal
operation.
B3 CHECK FOR AN AIRFLOW OBSTRUCTION
• Inspect the A/C condenser core and radiator for obstructions Yes
such as leaves or dirt. REMOVE the obstruction. CLEAN the A/C
• Is there an obstruction? condenser core and radiator. TEST the
system for normal operation.
No
GO to B4.
B4 CHECK THE THERMOSTAT OPERATION
• Key in START position. Yes
Start the engine and allow the engine to run for 10 minutes. INSTALL a new thermostat. TEST the
• Feel the underside of the lower radiator hose. system for normal operation.
• Is the lower radiator hose cold? No
GO to B5.
B5 CHECK THE ELECTRIC COOLING FAN OPERATION
• NOTE: The electric cooling fan should rotate in the opposite
direction of the mechanical engine cooling fan. Yes
Using the diagnostic tool, cycle the cooling fan to the ON GO to B6.
position. No
• Does the cooling fan operate? GO to Pinpoint Test C.
B6 CHECK THE MECHANICAL COOLING FAN OPERATION
• Key in OFF position. Yes
Carry out the cooling fan component tests. Refer to the Fan REFER to Section 303-00 for diagnosis
Clutch Test in this section. and testing of the engine.
• Is the cooling fan operation OK? No
INSTALL new fan components as
necessary. TEST the system for normal
operation.
Pinpoint Test C: The Electric Cooling Fan Is Normal Operation

Inoperative Under normal operation, the power distribution box
Refer to Wiring Diagrams Cell 149 for component (PDB) supplies power to the cooling fan relay on
testing. circuit 1153 (RD/BK) through the No. 8 fuse. The
PCM supplies ground on circuit 1154 (WH/BK) to
engage the cooling fan relay when any of the
following conditions are met:
• The engine temperature is above 99°C (210°F).
• The transmission oil temperature is above 110°C
(230°F).
• The A/C compressor is commanded ON.


Power is then supplied on circuit 1155 (YE/BK) to • An open or short to power in circuit 1154
turn the fan on. Ground for the cooling fan motor is (WH/BK).
supplied through circuit 1205 (BK) to chassis • Defective cooling fan relay.
ground.
• An open or short to ground in circuit 1155
Possible Causes (YE/BK).
• Defective fuse. • Defective cooling fan motor.
• An open or short to ground in circuit 1153 • An open or short to power in circuit 1205 (BK).
(RD/BK).
PINPOINT TEST C: THE ELECTRIC COOLING FAN IS INOPERATIVE
C1 CHECK FAN CONTROL FAULT PIDs TO VERIFY FAN
CONTROL PRIMARY CIRCUITS
• Key in ON position. Yes
Verify A/C is OFF and the engine temperature is below the Refer to Powertrain Control/Emissions
temperature where the cooling fan would come on. Diagnosis (PC/ED) manual to diagnose
• Access the LFCF PIDs. the cooling fan system.
• Does the LFCF PID indicate a fault (or YES)? No
GO to C2.
C2 CHECK THE OPERATION OF THE ELECTRIC COOLING FAN
• Using the diagnostic tool, command the cooling fan ON. Yes
• Does the cooling fan operate? Cooling fan system is OK. GO to
Symptom Chart for additional diagnosis.
No
GO to C3.
C3 CHECK THE COOLING FAN RELAY
• Disconnect the electric cooling fan relay. Yes
• Carry out the cooling fan relay component test. Refer to Wiring GO to C4.
Diagrams Cell 149 for component testing. No
• Did the cooling fan relay pass the component test? INSTALL a new cooling fan relay. TEST
the system for normal operation.
C4 CHECK THE VOLTAGE TO THE COOLING FAN RELAY
• Measure the voltage between cooling fan relay pin 1, circuit
1153B (RD/BK) harness side and ground.
•
Yes
GO to C5.
No
REPAIR circuit 1153B (RD/BK). TEST the
• Is the voltage greater than 10 volts? system for normal operation.
C5 CHECK THE VOLTAGE TO THE ELECTRIC COOLING FAN
• Disconnect the harness connector from cooling fan motor C1-1.
• Using the diagnostic tool, cycle the cooling fan ON.
(Continued)


PINPOINT TEST C: THE ELECTRIC COOLING FAN IS INOPERATIVE (Continued)
C5 CHECK THE VOLTAGE TO THE ELECTRIC COOLING FAN
(Continued)
• Measure the voltage between cooling fan motor C1-1, circuit
1155 (YE/BK) harness side and ground.
Yes
GO to C6.
No
REPAIR circuit 1155 (YE/BK). TEST the
• Is the voltage greater than 10 volts? system for normal operation.
C6 CHECK THE COOLING FAN
• Connect a fused (20A) jumper wire between the positive battery
post and cooling fan motor C1-1, circuit 1155 (YE/BK) and
connect a fused (20A) jumper wire between the negative battery
post and cooling fan motor C1-1, circuit 1205 (BK) component
side.
Yes
GO to C7.
No
INSTALL a new cooling fan motor. TEST
• Does the cooling fan operate? the system for normal operation.
C7 CHECK CIRCUIT 1205 (BK)
• Measure the resistance between cooling fan motor C1-1, circuit
1205 (BK) harness side and ground.
Yes
TEST the system for normal operation.
No
REPAIR circuit 1205 (BK). TEST the
• Is the resistance less than 5 ohms? system for normal operation.


Pinpoint Test D: The Electric Cooling Fan Power is then supplied on circuit 1155 (YE/BK) to
Stays On All The Time turn the fan on. Ground for the cooling fan motor is
Refer to Wiring Diagrams Cell 149 for component supplied through circuit 1205 (BK) to chassis
testing. ground.
Normal Operation Possible Causes
Under normal operation, the power distribution box • A short to ground in circuit 1154 (WH/BK).
(PDB) supplies power to the cooling fan relay on
• A short to ground in circuit 1155 (YE/BK).
circuit 1153 (RD/BK) through the No. 8 fuse. The
PCM supplies ground on circuit 1154 (WH/BK) to • A short to power in circuit 1205 (BK).
engage the cooling fan relay when any of the • A defective cooling fan relay.
following conditions are met: • A defective A/C high pressure switch.
• The engine temperature is above 99°C (210°F).
• The transmission oil temperature is above 110°C
(230°F).
• The A/C is commanded ON.
PINPOINT TEST D: THE ELECTRIC COOLING FAN STAYS ON ALL THE TIME
D1 CHECK THE A/C HIGH PRESSURE SWITCH INPUT TO THE
PCM
• Key in START position.
• Verify the A/C is OFF. Yes
• Connect the diagnostic tool. GO to D4.
• Monitor the A/C high pressure switch ACP PID. No
• Does the A/C high pressure switch ACP PID read CLOSED? GO to D2.
D2 CHECK THE A/C HIGH PRESSURE SWITCH
• Disconnect the A/C high pressure switch. Yes
• Using the diagnostic tool, monitor the A/C high pressure switch GO to D3.
ACP PID. No
• Does the A/C high pressure switch ACP PID read closed? If the A/C system is working correctly,
INSTALL a new A/C high pressure switch.
If the A/C is not working correctly, REFER
to Section 412-00 to diagnose the A/C
system.
D3 CHECK CIRCUIT 1154 (WH/BK) FOR A SHORT TO GROUND
• Key in OFF position.
• Disconnect: PCM.
• Measure the resistance between the PCM pin A47, circuit 1154
(WH/BK), harness side and ground.
Yes
INSTALL a new PCM. REFER to Section
303-04.
No
REPAIR circuit 1154 (WH/BK). TEST the
• Is the resistance greater than 10,000 ohms? system for normal operation.
(Continued)

303-03-10 Engine Cooling 303-03-10

PINPOINT TEST D: THE ELECTRIC COOLING FAN STAYS ON ALL THE TIME (Continued)
D4 CHECK THE FAN RELAY
• Disconnect the fan relay. Yes
• Did the cooling fan stop? INSTALL a new fan relay. TEST the
No
REPAIR circuit 1155 (YE/BK) for a short
to power. TEST the system for normal
operation.
Component Tests 7. Release the pressure by turning the relief screw

counterclockwise. Then tighten the pressure
Cap relief screw and repeat Step 6 (at least twice) to
WARNING: Never remove the pressure make sure the reading is repeatable within the
relief cap while the engine is operating or hot. specification of the pressure relief cap.
Failure to follow these instructions can result in 8. If the pressure test gauge readings are not
damage to the cooling system or engine or within specifications, install a new pressure
personal injury. To avoid having scalding hot relief cap. If the pressure test gauge readings
coolant or steam blow out of the degas bottle are within specifications, carry out the cooling
when removing the pressure relief cap, wait until system Pressure Test.
the engine has cooled, then wrap a thick cloth
around the pressure relief cap and turn it slowly. Pressure Test
Step back while the pressure is released from the 1. Turn the engine OFF.
cooling system. When you are sure that all the
pressure has been released, (still with a cloth) 2. WARNING: Never remove the
remove the pressure relief cap. pressure relief cap while the engine is
operating or hot. Failure to follow these
1. Remove the pressure relief cap from the degas instructions can result in damage to the
bottle. cooling system or engine or personal injury.
2. Immerse the pressure relief cap in water and To avoid having scalding hot coolant or
install it on the shallow filler neck of the steam blow out of the degas bottle when
Radiator/Heater Core Pressure Tester and removing the pressure relief cap, wait until
Radiator Cap Adapter, part of the the engine has cooled, then wrap a thick
Radiator/Heater Core Pressure Tester. cloth around the pressure relief cap and turn
3. Immerse the filler neck seal in water and install it slowly. Step back while the pressure is
it in the filler neck adapter. released from the cooling system. When you
are sure that all the pressure has been
4. Install the filler neck adapter with the filler
released, (still with a cloth) remove the
neck seal to the Radiator Cap Adapter.
pressure relief cap.
5. Connect the female quick connect fitting of the
Check the engine coolant level. For additional
pressure test pump to the male quick connect
information, refer to Cooling System Draining,
fitting of the filler neck adapter.
Filling and Bleeding in this section.
6. NOTE: If the plunger of the pump is depressed
3. Connect the Radiator Heater Core Pressure
too fast, an erroneous pressure reading will
Tester to the degas bottle nipple and overflow
result.
hose. Install a pressure test pump to the quick
Slowly depress the plunger of the pressure test connect fitting of the test adapter.
pump until the pressure gauge reading stops
increasing and note the highest pressure reading
obtained.

303-03-11 Engine Cooling 303-03-11

4. NOTE: If the plunger of the pump is pressed NOTE: Running this test with the vehicle in gear or
too fast, an erroneous pressure reading will with the A/C compressor clutch engaged (running)
result. will cause incorrect diagnoses.
Slowly press the plunger of the pressure test 3. Place the transmission in PARK (P) or
pump until the pressure gauge reading stops NEUTRAL (N).
increasing, and note the highest pressure 4. Start the engine and allow the engine to idle
reading obtained. throughout this test. Allow the engine to run for
5. CAUTION: If the pressure drops, 2 minutes, then record the ECT
check for leaks at the engine-to-heater core voltage/temperature. Record the ECT
hoses, engine-to-radiator hoses, water valve voltage/temperature every 60 seconds. When the
hose (if applicable), oil cooler return tube ECT voltage/temperature trend changes
gasket, radiator and heater core, or other direction or only changes slightly (0.03 volt or
system components and connections. Any less) from the previous reading, record this as
leaks that are found must be corrected and the thermostat opening voltage/temperature. Use
the system rechecked. the voltage and corresponding coolant
temperature chart listed below.
Pressurize the engine cooling system as
described in Step 4 (using a pressure relief cap Coolant Temperature
that operates within the specified upper and °C (°F) ECT (Volts)
lower pressure limits). Observe the gauge 22 (71) 3.00
reading for approximately two minutes. For
43 (109) 2.01
additional information, refer to General
Specifications in this section. Pressure should 71 (159) 1.01
not drop during this time. 82 (180) 0.75
6. Release the system pressure by loosening the 91 (195) 0.59
pressure relief cap. Check the engine coolant 97 (206) 0.50
level and replenish, if necessary, with the 105 (221) 0.40
correct engine coolant mixture. For additional
Filling and Bleeding in this section. 5. If the thermostat opening voltages are not
between 0.75 volt or 82°C (180°F) and 0.50
Thermostat volt or 97°C (206°F), install a new water
Install a new coolant thermostat only after the thermostat.
following electrical and mechanical tests are carried 6. If the thermostat opening voltages are within
out. the specified range, the water thermostat is
good and a new thermostat is not required.GO
Thermostat — Electrical Test
to Symptom Chart for additional instructions.
NOTE: The electrical thermostat test is most
accurate if carried out indoors at less than 37.8°C Thermostat — Mechanical Test
(100°F) ambient air. This test may be carried out 1. Remove the coolant thermostat.
with or without the hood open and with the engine
2. Check the coolant thermostat for seating. Hold
warm or cold.
the coolant thermostat up to a lighted
1. Check the engine coolant level. Fill as needed. background. Leakage of light around the
2. Use the scan tool to monitor the ECT thermostat valve at room temperature indicates
voltage/temperature on vehicles equipped with that a new coolant thermostat is required. Some
data link connector (DLC). coolant thermostats have a small leakage notch
at one location on the perimeter of the
thermostat valve, which is considered normal.
3. Immerse the coolant thermostat in a boiling
antifreeze and water mixture.

303-03-12 Engine Cooling 303-03-12

4. See the General Specifications chart for coolant 8. Aim the digital photoelectric tachometer at the
thermostat opening temperatures. fan blade bolts. Adjust the strobe light until the
light flash is synchronized with the marked fan
Radiator Leak Test, Removed From Vehicle blade bolt (the fan blade appears to stand still).
CAUTION: Never leak test an aluminum 9. The fan blade speed must not be greater than
radiator in the same water that copper/brass 1,500 rpm at 3,000 coolant pump rpm.
radiators are tested in. Flux and caustic cleaners 10. Turn the engine OFF.
may be present in the cleaning tank and they will
damage aluminum radiators. 11. If the fan blade speed was greater than 1,500
rpm, install a new fan clutch (8A616).
NOTE: Always install plugs in the transmission
fluid cooler fittings before leak testing or cleaning Fan Clutch Test — Maximum Speed
any radiator. Requirement
1. Leak test the radiator in clean water with 138 1. Carry out Steps 1 through 5 of the Fan Clutch
kPa (20 psi) of air pressure. Test—Minimum Speed Requirement.
Fan Clutch Test 2. NOTE: Make sure the engine coolant
temperature is above 99°C (210°F ) for
1. Spin the fan blade by hand. A light resistance maximum fan speed.
should be felt. If there is no resistance or very
high resistance, check the minimum and Block off areas on each side of the radiator in
maximum fan speeds as follows: the engine compartment and the front of the
radiator grille. This will raise the temperature of
Fan Clutch Test — Minimum Speed the air striking the fan clutch and will cause the
Requirement fan blade to operate at maximum speed.
1. Use a suitable marker to mark the coolant pump 3. Select the DEFROST and HIGH BLOWER
pulley, one of the fan blade retaining bolts and mode on the DATC module.
the crankshaft pulley. 4. Adjust the strobe to 3,000 rpm.
2. Connect a tachometer to the engine.
5. WARNING: To avoid the possibility of
3. Install a throttle adjusting tool. personal injury or damage to the vehicle, do
4. Connect a digital photoelectric tachometer. not operate the engine until the fan blade has
been first examined for possible cracks and
5. WARNING: To avoid the possibility of separation.
personal injury or damage to the vehicle, do
not operate the engine until the fan blade has Start the engine and adjust the engine speed
been first examined for possible cracks and until the digital photoelectric tachometer light
separation. and the coolant pump pulley mark are
synchronized.
NOTE: Make sure the engine coolant
temperature is below 84°C (183°F) for 6. Aim the digital photoelectric tachometer light at
minimum fan speed. the fan blade retaining bolts. Adjust the digital
photoelectric tachometer light until the light
Start the engine and run it at approximately flash is synchronized with the marked fan blade
1,500 rpm until the normal operating bolt (the fan blade appears to stand still).
temperature has been achieved. The A/C must
be OFF.
6. Adjust the engine speed to 2,300 rpm.
7. Operate the digital photoelectric tachometer at
3,000 rpm and aim it at the coolant pump
pulley. Adjust the engine speed until the light
flash and the coolant pump pulley mark are
synchronized.

303-03-13 Engine Cooling 303-03-13

7. If the fan blade speed is less than 2,300 rpm,
install a new fan clutch.

GENERAL PROCEDURES
Cooling System Draining, Filling and 1. Wrap a thick cloth around the coolant pressure
Bleeding relief cap on the degas bottle. Slowly turn the
cap counterclockwise (left) until the pressure
begins to release.
Special Tool(s)
RADKITPLUS 2. Step back while the pressure releases.
078-00497
3. When certain all the pressure has been released,
use the cloth to turn and remove the cap.
4. Place a suitable container below the radiator

draincock. Drain the coolant.
• Tighten the radiator draincock when
Draining
finished.
WARNING: Never remove the pressure 5. If necessary, remove the engine block drain
relief cap under any conditions while the engine plugs and drain the engine block.
is operating. Failure to follow these instructions
could result in damage to the cooling system or Filling and Bleeding with RADKITPLUS
engine or personal injury. To avoid having
scalding hot coolant or steam blow out of the 1. Using the special tool, INSTALL the
cooling system or reservoir, use extreme care RADKITPLUS and follow the RADKITPLUS
when removing the pressure relief cap from a manufacturer’s instructions to fill and bleed the
hot cooling system or reservoir. Wait until the cooling system.
engine has cooled, then wrap a thick cloth
around the pressure relief cap and turn it slowly Filling and Bleeding without RADKITPLUS
until the pressure begins to release. Step back
while the pressure is released from the cooling WARNING: Do not open the cooling
system. When certain all pressure has been system while it is hot or the engine is running.
released, remove the pressure cap (still with a Failure to follow these instructions can result in
cloth). personal injury.
CAUTION: The coolant must be recovered CAUTION: This engine is equipped with a
in a suitable, clean container for reuse. If the cold side thermostat. Whenever the engine block
coolant is contaminated, it must be recycled or or the front or rear (auxiliary) heater cores have
disposed of correctly. been drained, fill and bleed procedures must be
carried out in the sequence presented or damage
CAUTION: Vehicle cooling systems are to the engine can occur.
filled with Motorcraft Premium Gold Engine
Coolant VC-7-A (in California and Oregon CAUTION: Engine coolant provides freeze
VC-7-B, in Canada VC-7-C) or equivalent protection, boil protection, cooling efficiency and
meeting Ford specification WSS-M97B51-A1 corrosion protection to the engine and cooling
(yellow color). Always fill the cooling system with components. In order to obtain these protections,
the same coolant that is present in the system. the engine coolant must be maintained at the
Do not mix coolant types. correct concentration and fluid level. When
adding engine coolant, use a 50/50 mixture of
NOTE: Less than 80 percent of the coolant capacity clean drinkable water and engine coolant.
can be recovered with the engine in the vehicle. If
coolant is contaminated, fill with new coolant.


• Add Motorcraft Premium Gold Engine Coolant Rear (Auxiliary) Heater Core Filling
VC-7-A (in California and Oregon VC-7-B, in
Canada VC-7-C) or equivalent meeting Ford WARNING: Do not open the cooling
specification WSS-M97B51-A1 (yellow color) system while it is hot or the engine is running.
meeting Ford specification WSS-M9B51-A1. Failure to follow these instructions can result in
Use the same coolant that was drained from personal injury.
the cooling system. Do not mix coolant types.
• Do not add orange-colored extended life CAUTION: This engine is equipped with a
coolant such as VC-2, meeting Ford cold side thermostat. Whenever the engine block
specification WSS-M97B44-D. Mixing coolants or the front or rear (auxiliary) heater cores have
can degrade the coolant’s corrosion protection. been drained, fill and bleed procedures must be
• Do not add alcohol, methanol, or brine, or any
to the engine can occur.
engine coolants mixed with alcohol or methanol
antifreeze. These can cause engine damage
1. Remove the pressure relief cap.
from overheating or freezing.
• Do not mix recycled coolant unless it meets the 2. Prepare to fill the rear heater core.
requirements of specification ESE-M97B44-A 1 Remove the engine crossover fill plug.
or WSS-M97B51-A1. Not all coolant recycling
processes meet these specifications; use of such 2 Disconnect the heater supply hose from the
coolants can harm the engine and cooling engine crossover tube.
system components. 3 Clamp the front heater supply hose between
the heater core and the coolant shut-off
1. Remove the engine appearance cover. valve.


3. Raise the heater supply hose to the maximum Front Heater Core Filling
possible elevation and, using a funnel, slowly
pour approximately 2 liters of coolant into the 1. Remove the pressure relief cap.
heater supply hose.
2. Prepare to fill the front heater core.
4. Remove the clamp from the front heater core
1 Remove the engine crossover fill plug.
supply hose.
2 Disconnect the heater supply hose from the
5. Connect the heater supply hose to the engine crossover tube.
crossover tube. 3 Clamp the rear (auxiliary) heater core
supply hose below the system supply line
6. Top off the coolant in the engine crossover tube tee.
and install the fill plug.
7. Top off the coolant to the MAX cold fill line

and install the pressure relief cap and tighten
until 2 audible clicks are heard.
3. Raise the heater supply hose to the maximum 5. Connect the heater supply hose to the engine
possible elevation and, using a funnel, pour crossover tube.
approximately 1 liter of coolant into the hose.
6. Top off the coolant in the engine crossover tube
4. Remove the clamp from the rear heater core and install the fill plug.
supply hose.


7. Top off the coolant to the MAX cold fill line Deaeration
and install the pressure relief cap and tighten
until 2 audible clicks are heard. WARNING: Do not open the cooling
system while it is hot or the engine is running.
Engine and Radiator Filling
Failure to follow these instructions can result in
personal injury.
WARNING: Do not open the cooling
system while it is hot or the engine is running. CAUTION: This engine is equipped with a
Failure to follow these instructions can result in cold side thermostat. Whenever the engine block
personal injury. or the front or rear (auxiliary) heater cores have
been drained, fill and bleed procedures must be
CAUTION: This engine is equipped with a carried out in the sequence presented or damage
cold side thermostat. Whenever the engine block to the engine can occur.
or the front or rear (auxiliary) heater cores have
been drained, fill and bleed procedures must be 1. Start the engine.
to the engine can occur. 2. Select the defrost mode on the DATC module.
1. Remove the pressure relief cap. 3. WARNING: If during this time the
temperature gauge indicates a hot engine,
2. Remove the engine crossover fill plug. stop the engine and carry out the front and
rear heater core fill procedures to remove
3. Add coolant at the engine crossover fill until
trapped air in the system.
the level of the coolant in the degas bottle is at
the MAX cold fill line. Run the engine at 2,000 rpm until the
thermostat opens (approximately 10-15 minutes)
4. Install the engine crossover fill plug. indicated by a drop in the degas bottle coolant
level.
5. Install the pressure relief cap and tighten until 2
audible clicks are heard. 4. Set the climate control system to maximum heat
and run the engine for an additional 2 minutes
6. Install the engine appearance cover. at 2,000 rpm.
5. After the system has cooled, carefully remove

the pressure relief cap.
6. Top off the coolant level to the MAX fill line.
7. Install the pressure relief cap and tighten until 2

audible clicks are heard.

GENERAL PROCEDURES
Cooling System Flushing 1. WARNING: To avoid personal injury,
do not unscrew the coolant pressure relief
Special Tool(s) cap while the engine is operating or hot. The
cooling system is under pressure; steam and
Flush Kit
164-R3658 or equivalent hot liquid can come out forcefully when the
cap is loosened slightly. Failure to follow
these instructions can result in personal
injury.
Drain the cooling system. For additional
Drain Kit Filling and Bleeding in this section.
164-R3662
2. Remove the thermostat. For additional
information, refer to Thermostat in this section.
3. Install the coolant hose connection without the

thermostat.
Pro Flush and Fill Coolant 4. NOTE: Refer to the Cooling System Pro Flush
Flush and Fill
023-00154 or equivalent and Fill operating instructions for specific
vehicle hook-up.
Use Cooling System Pro Flush and Fill, Flush
Kit and Drain Kit to flush the engine and
radiator.
Material 5. Install the thermostat. For additional

Item Specification information, refer to Thermostat in this section.
Motorcraft Premium ESR-M14P7-A 6. Fill the cooling system. For additional
Cooling System Flush
VC-1 information, refer to Cooling System Draining,

REMOVAL AND INSTALLATION

Block Heater
Material
Item Specification
Engine Coolant
Oregon VC-7-B, in
Canada VC-7-C) or
Item Part Number Description 2. Drain the cooling system. For additional
1 6B019 Block heater power cable information, refer to Cooling System Draining,
2 6A051 Block heater retaining screw
3 6A051 Block heater 3. Disconnect the block heater power cable.
• To install, make sure the power cable is
routed and secured away from rotating or
hot components or damage to the cable can
1. With the vehicle in NEUTRAL, position it on a occur.
hoist. For additional information refer to
Section 100-02.

REMOVAL AND INSTALLATION (Continued)

4. NOTE: Do not loosen the block heater 6. To install, reverse the removal procedure.
retaining screw more than necessary for
removal. 7. Fill and bleed the cooling system. For
Loosen the block heater retaining screw. additional information, refer to Cooling System
Draining, Filling and Bleeding in this section.
5. Remove the block heater.

• Clean and inspect the engine block mating
surface before installing the block heater.
Lubricate the block heater seal and the
cylinder block hole with clean engine
coolant to ease installation.


Thermostat and Thermostat Housing
— Exploded View

1 500014 Coolant inlet connector bolts 5 — Thermostat housing bolts
2 8594 Coolant inlet connector 6 — Thermostat housing
3 8582 O-ring seal
4 8575 Thermostat 1. For additional information, refer to the
(Continued) procedures in this section.


Thermostat Housing 4. Remove the coolant inlet connector bolts.
Material
5. NOTE: Clean and inspect the O-ring seal and
Item Specification
install a new seal if necessary.
Engine Coolant Remove the coolant inlet connector.
Oregon VC-7-B, in 6. Remove the thermostat.
Canada VC-7-C) or
equivalent (yellow color) 7. Disconnect the coolant hose.
8. Remove the thermostat housing bolts and the
housing.
Section 100-02.
additional information, refer to Cooling System
3. Remove the bolts and the oil filter drip shield.


Thermostat 3. Remove the bolts and the oil filter drip shield.
Material
4. Remove the coolant inlet connector bolts.
Item Specification
Motorcraft Premium Gold WSS-M97B51-A1 • To install, tighten to 10 Nm (89 lb-in).
Engine Coolant
VC-7-A (in California and 5. NOTE: Clean and inspect the O-ring seal and
Oregon VC-7-B, in install a new seal if necessary.
Canada, VC-7-C) or
equivalent (yellow color) Remove the coolant inlet connector.
Removal and Installation 6. Remove the thermostat.

Section 100-02.


Coolant Pump
Material
Item Specification
Engine Coolant
Oregon VC-7-B, in
Canada VC-7-C) or
Item Part Number Description Removal and Installation

1 806282 Coolant pump pulley bolts
2 8509 Coolant pump pulley 1. Drain the cooling system. For additional
3 806177 Coolant pump bolts (4
required) Filling and Bleeding in this section.
4 8501 Coolant pump 2. Remove the cooling fan. For additional
5 — Coolant pump O-ring information, refer to Cooling Fan Clutch in this
section.
3. Remove the upper fan shroud. For additional

information, refer to Cooling Fan Shroud in this
section.


4. Loosen the 4 coolant pump pulley bolts. 8. CAUTION: Do not rotate the coolant
pump housing once installed in the engine.
5. Remove the accessory drive belt. For additional Damage to the O-ring seal can occur, causing
information, refer to Section 303-05. the coolant pump to leak
6. Remove the 4 bolts and the coolant pump Remove the coolant pump.
pulley. • Install a new O-ring seal and lubricate with
• To install, tighten to 25 Nm (18 lb-ft). clean engine coolant before installing the
pump.
7. Remove the 4 coolant pump bolts.


Cooling Fan Clutch
Special Tool(s)
Holding Wrench, Fan Pulley
303-239 (T84T-6312-C)
Wrench, Fan Clutch Nut

303-240 (T84T-6312-D)


1 811864 Lower fan shroud bolts
2 8146 Lower fan shroud 1. Remove the lower fan shroud bolts and the
shroud.
3 8A616 Clutch
4 602527 Fan-to-clutch bolts • To install, tighten to 10 Nm (89 lb-in).
5 8K620 Fan


2. NOTE: The large clutch assembly nut has a
right-hand thread and must be rotated
counterclockwise to remove it.
Remove the fan clutch.
• Using the special tools, remove the fan and
clutch as an assembly.
• To install, use the special tools to install the
fan and clutch as an assembly.
3. Remove the fan-to-clutch bolts and the fan.



Cooling System Components —
Exploded View

1 8075 Degas bottle hose 10 8K820 Electric cooling fan
2 811864 Degas bottle bolt 11 19E746 A/C tube clip
3 8075 Lower degas bottle hose 12 N606691 Upper radiator track bolts
4 8A080 Degas bottle and hose 13 8286 Lower radiator hose
5 811864 Fan shroud bolts 14 N606676 Transmission fluid cooler
6 8260 Upper radiator hose retainers
7 8146 Fan shroud 15 N606691 Lower radiator track bolts
8 503934 Electric cooling fan bolts 16 8005 Radiator
9 8C607 Cooling fan electrical
connector 1. For additional information, refer to the
(Continued) procedures in this section.


Degas Bottle 3. Disconnect the upper degas bottle-to-radiator
hose.
Material
4. Remove the degas bottle bolt.
Item Specification
Engine Coolant 5. Disconnect the lower degas bottle hose at the
Oregon VC-7-B, in radiator.
Canada VC-7-C) or
equivalent (yellow color) 6. Remove the degas bottle and hose.
Removal and Installation 7. To install, reverse the removal procedure.
1. With the vehicle in NEUTRAL, position it on a 8. Fill and bleed the cooling system. For
hoist. For additional information, refer to additional information, refer to Cooling System
Section 100-02. Draining, Filling and Bleeding in this section.



Cooling Fan Shroud 4. Remove the degas bottle bolt.
Material
5. Disconnect the lower degas bottle hose at the
Item Specification
radiator.
Engine Coolant 6. Remove the degas bottle and hose.
Oregon VC-7-B, in
Canada VC-7-C) or 7. Remove the cooling fan shroud bolts.
equivalent (yellow color) • To install, tighten to 7 Nm (62 lb-in).
8. Disconnect the upper radiator hose from the
radiator.
hoist. For additional information, refer to 9. Remove the cooling fan shroud.
Section 100-02.
information, refer to Cooling System Draining, 11. Fill and bleed the cooling system. For
Filling and Bleeding in this section. additional information, refer to Cooling System
3. Disconnect the upper degas bottle-to-radiator
hose.


Radiator 8. Remove the 2 upper radiator track bolts.
Material
9. Disconnect the lower radiator hose from the
Item Specification
radiator.
Engine Coolant 10. NOTE: Remove the push pin from the splash
Oregon VC-7-B, in shield covering the condenser and transmission
Canada VC-7-C) or cooler and remove the shield.
equivalent (yellow color) Disconnect the transmission cooler retainers.

Section 100-02.

3. Remove the cooling fan shroud. For additional

information, refer to Cooling Fan Shroud in this
section.
11. Remove the lower radiator track bolts.
4. Remove the electric cooling fan bolts.
12. Remove the radiator.
5. Disconnect the electric cooling fan electrical
connector. 13. To install, reverse the removal procedure.
6. Remove the electric cooling fan. 14. Fill and bleed the cooling system. For
7. Disconnect the A/C tube clip.


Cooling Module Material
Item Specification
Special Tool(s) Motorcraft Premium Gold WSS-M97B51-A1
Engine Coolant
Disconnect Tool, Transmission VC-7-A (in California and
307-441 Oregon VC-7-B, in
Canada VC-7-C) or
PAG Refrigerant WSH-M1C231-B
Compressor Oil (R-134a
Systems)
F7AZ-19589-DA
(YN-12-C)

1 8334 A/C high pressure switch 6 8264 Condenser outlet tube
electrical connector 7 7H189 Transmission oil cooler tubes
2 813266 Condenser inlet tube nut 8 8286 Lower radiator hose
3 8268 Condenser inlet tube 9 — Splash shield
4 8C607 Cooling fan electrical 10 706509 Cooling module retainers
connector
11 030300 Cooling module
5 8266 Condenser outlet tube nut
(Continued)



Section 100-02.

3. Recover the refrigerant. For additional

4. Remove the fan shroud. For additional 12. Disconnect the lower radiator hose from the
information refer to Cooling Fan Shroud in this radiator.
section.
13. NOTE: LH shown, RH similar.
5. Disconnect the A/C high pressure switch Remove the 4 push pins from the lower radiator
electrical connector. splash shield and remove the shield.
6. Remove the condenser inlet tube nut.
7. Disconnect the condenser inlet tube.

• Release the condenser inlet tube from the
retaining clips and position aside.
• To install, use new O-rings lubricated in
clean PAG oil.
8. Disconnect the electric cooling fan electrical

connector.
9. Remove the condenser outlet tube nut.

14. Remove the 2 cooling module retainers.
15. NOTE: Lift the cooling module up and toward
10. Disconnect the condenser outlet tube. the engine to remove it from the vehicle.
• Disconnect the condenser outlet tube and Remove the cooling module.
position aside.
• To install, use new O-rings lubricated in 16. To install, reverse the removal procedure.
clean PAG oil.
11. NOTE: If equipped, remove the safety retainer

from the connectors and set aside for
installation.
Using the special tool, disconnect the quick
couplers on the oil cooler tubes.
• To install, connect the fittings and pull on
them to make sure they are fully engaged.



303-04-1 Fuel Charging and Controls 303-04-1
SPECIFICATIONS
Torque Specifications — Torque
specifications (Continued)
Torque Specifications — Torque specifications Description Nm lb-ft lb-in
Description Nm lb-ft lb-in Fuel pressure relief 8 — 71
Air cleaner outlet 10 — 89 valve
retaining nut Fuel injection supply 10 — 89
Throttle body boltsa — — — manifold bolts
Fuel pulse damper 6 — 53 a Refer to procedure.

bolts


Fuel Charging and Controls • are deposit-resistant.
The fuel injection supply manifold: • each have an internal solenoid that opens a needle
valve to inject fuel into the lower intake manifold.
• delivers fuel to the individual fuel injector.
The fuel pressure relief valve is used to inspect and
• receives fuel from the fuel supply line. relieve fuel pressure.
The throttle body: The fuel pulse damper:
• controls air supply to the upper intake manifold • maintains constant fuel pressure throughout the
by positioning the throttle plate. fuel system and to the fuel injectors.
• connects the accelerator cable and, if equipped, • is spring-loaded and operated by intake manifold
the speed control actuator cable to the throttle vacuum.
lever.
The A/C compressor clutch control relay (if A/C
• is not adjustable. equipped):
• cannot be cleaned.
• is controlled by the PCM.
The fuel injectors:
• interrupts A/C clutch operation during engine start
• are electrically operated by the powertrain control or manual transmission clutch engagement to
module (PCM). reduce engine load.
• atomize the fuel as the fuel is delivered. The fuel pump relay engages the fuel pump when
energized by the PCM.


Throttle Body
Item Part Number Description WARNING: Do not smoke or carry lighted

1 031900 Speed control cable tobacco or open flame of any type when working
2 9581 Throttle return spring on or near any fuel-related components. Highly
flammable mixtures are always present and can
3 031800 Accelerator cable
be ignited. Failure to follow these instructions
4 14A464 Throttle position (TP) sensor may result in personal injury.
electrical connector
5 N806154 Throttle body bolts (4 CAUTION: Throttle body bore and plate
required)
area have a special coating and cannot be
6 9E927 Throttle body cleaned, or possible damage to the throttle body
7 9E936 Throttle body gasket can occur.
1. Remove the air cleaner outlet tube. For

additional information, refer to Section 303-12
in this section.
2. Disconnect the speed control cable from the

throttle body.
3. Disconnect the accelerator cable from the

throttle body.

4. Disconnect the throttle return spring from the 7. Remove the throttle body.
throttle body. • Inspect and clean the sealing surfaces before
installation.
electrical connector. 8. To install, reverse the removal procedure.
6. Remove the 4 throttle body bolts.
• To install, tighten to 10 Nm (89 lb-in), then
rotate an additional 90 degrees.
2005 Aviator, 09/2004


Fuel Rail and Fuel Injector —
Exploded View

1 14A464 Throttle position (TP) sensor 15 9J471 EGR system module tube
electrical connector nut-to-exhaust manifold
2 14A464 Idle air control (IAC) sensor 16 9D477 EGR system module tube
electrical connector 17 9737 Throttle return spring
3 Fuel pulse damper electrical 18 031900 Accelerator cable
connector
19 031800 Speed control cable
4 — Fuel pulse damper vacuum
hose (part of 9E498) 20 N807304 Accelerator control assembly
bracket bolts
5 14A464 Fuel injector electrical
connectors (8 required) 21 9728 Accelerator control assembly
bracket (position aside)
6 14A464 Exhaust gas recirculation
(EGR) system module 22 706214 Fuel injection supply
electrical connector manifold bolts
7 382984 Brake booster hose clamp 23 9F972 Fuel injection supply
manifold and fuel injectors
8 9C482 Brake booster hose
24 9F593 Fuel injectors (8 required)
9 9E498 Engine emissions vacuum
hose 25 — Fuel injector O-rings
10 — Evaporative emission (EVAP) 26 — EGR vacuum lines
canister purge valve vacuum 27 14A464 Intake manifold runner
hose (part of 9E498) control (IMRC) electrical
11 N800167 Upper intake connector
manifold-to-lower intake 28 14489 Radio capacitor electrical
manifold bracket nuts connector
12 9G609 Upper intake 29 6A614 Positive crankcase ventilation
manifold-to-lower intake (PCV) tube
manifold bracket
13 9J274 Fuel tube spring lock 1. For additional information, refer to the
coupling procedures in this section.
14 9J471 EGR system module tube
nut-to-EGR system module
(Continued)
2005 Aviator, 09/2004


Fuel Rail 7. Disconnect the 8 fuel injector electrical
connectors.
Special Tool(s)
8. Remove the positive crankcase ventilation
Disconnect Tool, Spring Lock (PCV) tube.
Coupling (1/2 inch)
310-D004 (D87L-9280-B) or 9. Disconnect the intake manifold runner control
equivalent
(IMRC) and radio capacitor electrical
connectors.
10. Disconnect the exhaust gas recirculation (EGR)

system module electrical connector and vacuum
1. WARNING: Do not smoke or carry lines.
lighted tobacco or open flame of any type
when working on or near any fuel-related 11. Disconnect the brake booster hose from the
components. Highly flammable mixtures are intake manifold.
always present and can be ignited. Failure to
follow these instructions may result in 12. Disconnect the engine emissions vacuum hose
personal injury. from the intake manifold.
WARNING: Fuel in the system 13. Disconnect the evaporative emission (EVAP)
remains under high pressure even when the canister purge valve vacuum hose from the
engine is not running. Before working on or intake manifold.
disconnecting any of the fuel lines or fuel
system components, the fuel system must be 14. Remove the upper intake manifold-to-lower
relieved. Failure to follow these instructions intake manifold bracket nuts.
can result in personal injury. • To install, tighten to 10 Nm (89 lb-in).
NOTE: During the repair or replacement of
fuel-related components, all liquid and vapor 15. Remove the upper intake manifold-to-lower
fuel openings shall be capped, taped or intake manifold bracket.
otherwise appropriately protected to prevent the
ingress of dirt or other contamination. All caps, 16. Remove the fuel tube safety clip.
tape and other protective materials shall be
removed prior to installation.
Disconnect the battery ground cable. For
2. Remove the air cleaner assembly. For additional

3. Release the fuel system pressure. For additional


5. Disconnect the idle air control (IAC) sensor

6. Disconnect the fuel pulse damper electrical

connector and vacuum hose.

20. Disconnect the EGR system tube nuts and

remove the tube.
18. Close and push the special tool into the open • To install, tighten to 40 Nm (30 lb-ft).
side of the cage.
21. Disconnect the throttle return spring from the
throttle body.
22. Disconnect the accelerator cable and the speed

control cable (if equipped) from the throttle
body.
23. Remove the accelerator cable assembly bracket

bolts and position the bracket and cables aside.
24. Remove the fuel rail bolts and the fuel rail.
19. Disconnect the fuel tube.
• To install, align the fuel tube fittings and
press together until an audible click is heard.
• Pull on the fittings to make sure they are
fully engaged, and then install the safety
clip.
2005 Aviator, 09/2004


Fuel Injectors
Material
Item Specification
SAE 5W-20 Motor Oil WSS-M2C153-H
XO-5W20-QSP
1. WARNING: Do not smoke or carry

when working on or near any fuel-related
components. Highly flammable mixtures are
always present and can be ignited. Failure to
follow these instructions may result in 3. To install, reverse the removal procedure.
personal injury. • Install new O-rings and lubricate with clean
WARNING: Fuel in the system engine oil.
remains under high pressure even when the
engine is not running. Before working on or
disconnecting any of the fuel lines or fuel
system components, the fuel system must be
relieved. Failure to follow these instructions
can result in personal injury.
fuel-related components, all liquid and vapor
fuel openings shall be capped, taped or
ingress of dirt or other contamination. All caps,
removed prior to installation.
Remove the fuel rail. For additional
information, refer to Fuel Rail in this section.
2. NOTE: Use O-ring seals that are made of

special fuel-resistant material. Use of ordinary
O-rings can cause the fuel system to leak. Do
not reuse the O-ring seals.
Remove the 8 fuel injectors.
• Remove and discard the O-ring seals.


Fuel Pulse Damper
Material
Item Specification
SAE 5W-20 Motor Oil WSS-M2C153-H
XO-5W20-QSP

1 14A464 Fuel pulse damper electrical 3 N800145 Fuel pulse damper bolts
connector 4 9C968 Fuel pulse damper
2 9E498 Vacuum hose 5 — Fuel pulse damper O-ring
(Continued)

WARNING: Do not smoke or carry lighted 2. Release the fuel system pressure. For additional
tobacco or open flame of any type when working information, refer to Section 310-00.
on or near any fuel-related components. Highly
flammable mixtures are always present and can 3. Disconnect the fuel pulse damper electrical
be ignited. Failure to follow these instructions connector.
may result in personal injury.
4. Disconnect the fuel pulse damper vacuum hose.
WARNING: Fuel in the system remains
5. Remove the fuel pulse damper bolts.
under high pressure even when the engine is not
running. Before working on or disconnecting any • To install, tighten to 6 Nm (53 lb-in).
of the fuel lines or fuel system components, the
fuel system must be relieved. Failure to follow 6. CAUTION: Use O-ring seals that are
these instructions can result in personal injury. made of special fuel resistant material. Use
of ordinary O-ring seals can cause the fuel
NOTE: During the repair or replacement of system to leak. Do not reuse O-ring seals.
fuel-related components, all liquid and vapor fuel
Remove the fuel pulse damper.
openings shall be capped, taped or otherwise
appropriately protected to prevent the ingress of dirt • Install new O-ring seals and lubricate with
or other contamination. All caps, tape and other clean engine oil to aid in installation.
protective materials shall be removed prior to
installation. 7. To install, reverse the removal procedure.
1. Remove the air cleaner outlet tube assembly.

303-12.
2005 Aviator, 09/2004


Fuel Pressure Relief Valve
Item Part Number Description NOTE: During the repair or replacement of

1 — Fuel pressure relief valve cap fuel-related components, all liquid and vapor fuel
(part of 9H231) openings shall be capped, taped or otherwise
2 9H231 Fuel pressure relief valve appropriately protected to prevent the ingress of dirt
or other contamination. All caps, tape and other
WARNING: Do not smoke or carry lighted installation.
tobacco or open flame of any type when working
on or near any fuel-related components. Highly 1. Release the fuel system pressure. For additional
flammable mixtures are always present and can information, refer to Section 310-00.
may result in personal injury. 2. Remove the fuel pressure relief valve cap.
WARNING: Fuel in the system remains 3. Remove the fuel pressure relief valve.
under high pressure even when the engine is not • To install, tighten to 8 Nm (71 lb-in).
running. Before working on or disconnecting any
of the fuel lines or fuel system components, the 4. To install, reverse the removal procedure.
fuel system must be relieved. Failure to follow
these instructions can result in personal injury.

303-05-1 Accessory Drive 303-05-1
SPECIFICATIONS
Torque Specifications (Continued)
Belt idler pulley bolt 25 18 —
Drive belt tensioner 25 18 —
bolts


Accessory Drive
Component Locations 4.6L (4V)

1 19A216 Belt idler pulley
2 10300 Generator
3 8620 Drive belt
4 3D673 Power steering pump pulley
6 8A528 Coolant pump pulley
7 19D629 A/C compressor
8 6B209 Drive belt tensioner pulley
9 19A216 Belt idler pulley
10 6C348 Belt idler pulley
The accessory drive:

• has a single serpentine drive belt (6 ribs).
• has an automatic tensioner.
• is not adjustable.


Accessory Drive 5. NOTE: Up to 15 cracks in a rib over a
distance of 100 mm (4.0 in) can be considered
Inspection and Verification acceptable. If damage exceeds the acceptable
CAUTION: Under no circumstances should limit or any chunks are found to be missing
the accessory drive belt, tensioner or pulleys be from the ribs, a new belt must be installed.
lubricated as potential damage to the belt Check the belt for cracks. Up to 15 cracks in a
material and tensioner damping mechanism will rib over a distance of 100 mm (4.0 in) can be
occur. Do not apply any fluids or belt dressing to considered acceptable. If cracks exceed this
the accessory drive belt or pulleys. standard, install a new belt.
1. Verify the customer concern by operating the V- Ribbed Serpentine Belt With Piling
system.
NOTE: Piling is an excessive buildup in the
2. Visually inspect for obvious signs of V-grooves of the belt.
mechanical damage.
Visual Inspection Chart
Mechanical
• Drive belt cracking/chunking/wear
• Belt/pulley contamination
• Incorrectly routed belt
• Pulley misalignment or excessive pulley runout
• Loose or mislocated hardware
• Incorrectly routed power steering tubes (rubbing)
3. Eliminate all other non-belt related noises that

could cause belt misdiagnosis, such as A/C
compressor engagement chirp, power steering
cavitations at low temperatures, variable
camshaft timing (VCT) tick or generator whine.
4. If a concern is found, correct the condition
before proceeding to the next step.
V-Ribbed Serpentine Drive Belt With Cracks Across
Ribs
6. The condition of the V-ribbed drive belt should

be compared against the illustration and
appropriate action taken.
1 Small scattered deposits of rubber material.
This is not a concern, therefore, installation
of a new belt is not required.
2 Longer deposit areas building up to 50
percent of the rib height. This is not
considered a concern but it can result in
excessive noise. If noise is apparent, install
a new belt.

3 Heavy deposits building up along the 7. There should be no chunks missing from the
grooves resulting in a possible noise and belt ribs. If the belt shows any evidence of this,
belt stability concern. If heavy deposits are install a new accessory drive belt.
apparent, install a new belt. 8. If the concern is not visually evident, verify the
V-Ribbed Serpentine Belt With Chunks of Rib symptom and GO to Symptom Chart.
Missing
Symptom Chart
Symptom Chart
• Accessory drive belt cracking • Accessory drive belt. • INSPECT the accessory drive
(over 15 cracks in a rib over belt. REFER to Inspection
a distance of 100 mm [4.0 and Verification in this
in]) section. INSTALL a new
accessory drive belt as
necessary.
• Accessory drive belt chunking • Accessory drive belt. • INSPECT the accessory drive
belt. REFER to Inspection
and Verification in this
section. INSTALL a new
accessory drive belt as
necessary.
• Accessory drive belt noise, • Defective/worn or incorrect • REFER to Component Tests,
squeal, chirping or flutter accessory drive belt. Drive Belt, Noise/Flutter in
• Misaligned pulley(s). this section. REPAIR or
• Pulley runout. INSTALL new parts as
• Damaged or worn accessories. necessary.
• Fluid contamination of
accessory drive belt or
pulleys.
• Damaged or worn accessory • REFER to Component Tests,
drive belt tensioner. Belt Tensioner — Mechanical
and Belt Tensioner —
Dynamics in this section.
INSTALL a new accessory
drive belt tensioner as
necessary.
2005 Aviator, 09/2004

• Premature accessory drive • Defective accessory drive • REFER to Component Tests,
belt wear belt. Drive Belt Noise/Flutter and
• Misaligned pulley(s). Incorrect Drive Belt
• Pulley runout. Installation in this section.
• Damaged accessories. REPAIR or INSTALL new
• Incorrectly installed drive parts as necessary.
belt.
• Fluid contamination.
• Accessory drive belt does not • Accessory drive belt has • INSPECT the drive belt.
hold proper tension excessive cracking or damage. REFER to Inspection and
Verification in this section.
INSTALL a new drive belt as
necessary.
• Drive belt tensioner worn or • CHECK the drive belt
damaged. tensioner for damage and
correct operation. REFER to
the Component Tests, Belt
Tensioner — Mechanical and
Belt Tensioner — Dynamics
in this section. INSTALL a
new drive belt tensioner as
necessary.
• Accessory drive component • CHECK the accessory drive
failure. components. INSTALL new
components as necessary.
• Accessory drive belt idler • INSPECT the accessory drive
pulley bearing failure. belt idler pulley for freedom
of rotation and damage.
INSTALL a new accessory
drive belt idler pulley as
necessary.
Component Tests A short intermittent squeal may occur during engine

start-up and shut down or during very rapid engine
Drive Belt Noise/Flutter acceleration and decelerations, such as:
Drive belt chirp occurs due to pulley misalignment
or excessive pulley runout. It can be the result of a • wide open throttle 1-2 and 2-3 shifts or 2-3 and
damaged or an incorrectly aligned grooved pulley. 3-4 back out shifts on automatic transmissions.
To correct, determine the area where the noise • wide open throttle 1-2 and 2-3 shifts and any
comes from. Check each of the pulleys in that area combination of rapid downshifting on manual
with a straightedge to the crankshaft pulley. Look transmissions.
for accessory pulleys out of position in the fore/aft These special short-term transient events are
direction or at an angle to the straightedge. expected, and are due to the higher system inertias
required to meet the electrical and cooling demands
CAUTION: Do not apply any fluids or belt
on today’s vehicle systems. Constant or re-occurring
dressing to the accessory drive belt or pulleys.
drive belt squeal can occur under these conditions:
Drive belt squeal may be an intermittent or constant
noise that occurs when the drive belt slips on an • if the A/C discharge pressure goes above
accessory pulley under certain conditions. specifications:
— the A/C system is overcharged.
— the A/C condenser core airflow is blocked.
• if the A/C OFF equalized pressure (the common
discharged and suction pressure that occurs after
several minutes) exceeds specifications.
2005 Aviator, 09/2004
• if any of the accessories are damaged or have a Incorrect Installation
worn or damaged bearing. All accessories should
be rotatable by hand in the unloaded condition, if
not, inspect the accessory.
• if there is evidence of fluid contamination on the
accessory drive belt. When the drive belt has been
exposed to fluid contamination during vehicle
operation, such as leaks from the power steering
system, A/C system or cooling system, clean all
pulleys with soap and water, rinse with clean
water and install a new accessory drive belt. If the
drive belt has been exposed to fluids in a
localized area during routine vehicle service, such
as replacement of hoses or fluids, the drive belt
Correct Installation
and pulleys should be washed with soap and
water immediately (prior to starting the engine),
and rinsed with clean water.
• if the accessory drive belt is too long. A drive
belt that is too long will allow the accessory drive
belt tensioner arm to go all the way to the arm
travel stop under certain load conditions, which
will release tension to the drive belt. If the
accessory drive belt tensioner indicator is outside
the normal installation wear range window, install
a new accessory drive belt.
• NOTE: The accessory drive belt tensioner arm
should rotate freely without binding.
With the engine running, check accessory drive belt
Install a new accessory drive belt tensioner if the
tracking on all pulleys. If the edge of the accessory
drive belt tensioner is worn or damaged.
drive belt rides beyond the edge of the pulleys,
Incorrect Drive Belt Installation noise and premature wear will occur. Make sure the
accessory drive belt rides correctly on the pulley. If
CAUTION: Incorrect accessory drive belt an accessory drive belt tracking condition exists,
installation will cause excessive drive belt wear proceed with the following:
and can cause the drive belt to come off the
pulleys. • Visually check the accessory drive belt tensioner
for damage, especially the mounting pad surface.
Non-standard accessory drive belts can track
If the accessory drive belt tensioner is not
differently or incorrectly. If an accessory drive belt
installed correctly, the mounting surface pad will
tracks incorrectly, install a new accessory drive belt
be out of position. This will result in chirp and
to avoid performance failure or loss of the drive
squeal noises.
belt.
• With the engine running, visually observe the
grooves in the pulleys (not the pulley flanges or
the pulley forward faces) for excessive wobble.
Install new components as necessary.
• Check all accessories, mounting brackets and the
accessory drive belt tensioner for any interference
that would prevent the component from mounting
correctly. Correct any interference condition and
recheck the accessory drive belt tracking.
2005 Aviator, 09/2004

• Tighten all accessories, mounting brackets and 5. Inspect the area surrounding the accessory drive
accessory drive belt tensioner retaining hardware belt tensioner for oil leaks or contamination and
to specification. Recheck the accessory drive belt repair any leaks. Install a new accessory drive
tracking. belt tensioner as necessary.
Belt Tensioner — Mechanical 6. If the accessory drive belt tensioner meets the
above criteria, proceed to testing the tensioner
The only mechanical check that needs to be made is dynamically. If the accessory drive belt
a check for tensioner stick, grab or bind. tensioner does not meet the above criteria,
1. With the engine OFF, check routing of the install a new tensioner.
accessory drive belt. For additional information,
refer to the illustrations under Description and Belt Tensioner — Dynamics
Operation in this section. The accessory drive belt tensioner can be checked
2. NOTE: The accessory drive belt tensioner dynamically as follows:
spring is very strong and requires substantial 1. With the engine running, observe the accessory
force to release. drive belt tensioner movement. The accessory
Using a suitable, commercially available drive tensioner should move (respond) when the
serpentine belt tensioner release tool, release the air conditioning clutch cycles (if equipped), or
tension on the belt and detach the accessory when the engine is accelerated rapidly. If the
drive belt in the area of the tensioner. accessory drive belt tensioner movement is
excessive without air conditioning clutch
3. Using the suitable, commercially available cycling or engine acceleration, check belt
serpentine belt tensioner release tool, move the rideout. Excessive belt rideout (uneven depth of
tensioner from its relaxed position, through its grooves in the belt) can cause excessive
full stroke and back to the relaxed position to accessory drive belt tensioner movement.
make sure there is no stick, grab or bind, and to Check rideout condition by installing a new
make sure that there is tension on the tensioner belt. If excessive accessory drive belt tensioner
spring. movement still exists, install a new accessory
4. Rotate the tensioner pulley by hand and check drive belt tensioner.
for a binding, contaminated or seized condition.
Install a new accessory drive belt tensioner if
necessary.
2005 Aviator, 09/2004


Front End Accessory Drive (FEAD) —
Exploded View

1 12B579 Mass air flow (MAF)
2 9R504 Air cleaner outlet tube to
cover clamp
3 9A612 Air cleaner assembly


4 8620 Accessory drive belt 10 19A216 Accessory drive belt idler
5 N808102 Accessory drive belt idler pulley
pulley mounting bolt 11 W707288 Accessory drive belt idler
6 19A216 Accessory drive belt idler pulley mounting bolt
pulley 12 6C348 Accessory drive belt idler
7 N808920 Accessory drive belt tensioner pulley
mounting bolts
8 6B209 Accessory drive belt tensioner 1. For additional information, refer to the
9 N808102 Accessory drive belt idler procedures in this section.
pulley mounting bolt
(Continued)
2005 Aviator, 09/2004


Accessory Drive Belt
1. Disconnect the mass air flow (MAF) sensor

2. Loosen the clamp and disconnect the air cleaner

outlet tube from the air cleaner cover.
3. Remove the air cleaner assembly.

• Pull up and then away on the air cleaner
assembly to release it from the body.
4. Rotate the belt tensioner clockwise and remove

the accessory drive belt.


Accessory Drive Belt Idler Pulley



4. Rotate the belt tensioner clockwise and remove 5. Remove the accessory drive belt idler pulley
the accessory drive belt. mounting bolt.
6. Remove the accessory drive belt idler pulley.


Accessory Drive Belt Tensioner



4. Rotate the belt tensioner clockwise and remove 5. Remove the accessory drive belt tensioner
the accessory drive belt. mounting bolts.
6. Remove the accessory drive belt tensioner.

303-06-1 Starting System 303-06-1
SPECIFICATIONS
Starter motor bolts 25 18 —
Item Specification
Starter solenoid to 13 10 —
Starting System battery cable nut
Normal engine cranking 140-220 rpm Starter solenoid S 6 — 44
speed terminal nut
Starter motor no load 60-80 amps
current draw
Starter motor normal load 130-220 amps
current draw
Starter motor maximum 800 amps
load current draw
Starter motor minimum 14.7 Nm (10.8 lb-ft)
stall torque (at 5 volts)
Starting circuit maximum 0.5 volt
voltage drop (engine at
normal operating
temperature)


Starting System • ignition switch.
The starting system consists of the: • digital transmission range (TR) sensor.
• starter motor. • battery.
• starter solenoid. The function of the starting system is to crank the
engine at a speed fast enough to permit the engine
• starter drive. to start.


Starting System Inspection and Verification
Refer to Wiring Diagrams Cell 20 for schematic and WARNING: When servicing starter motor
connector information. or carrying out other underhood work in the
Special Tool(s) vicinity of the starter motor, be aware that the
heavy gauge battery input lead at the starter
73 Digital Multimeter solenoid is ‘‘electrically hot’’ at all times. A
105-R0051 or equivalent protective cap or boot is provided over the
terminal of this lead and must be installed after
servicing.
WARNING: When working in area of the
starter motor, be careful to avoid touching hot
SABRE Premium Battery and exhaust components.
Electrical System Tester NOTE: When working on the starter system, make
010-00736 or equivalent sure the anti-theft system is deactivated, if equipped.
1. Verify the customer concern by operating the
starting system.
2. Visually inspect for obvious signs of
mechanical and electrical damage. Refer to the
following chart:
Visual Inspection Chart
Mechanical Electrical
• Starter motor • Battery
• Brackets • Damaged wiring harness
• Anti-theft relay • Loose or corroded
connections
3. If the concern is not visually evident, verify the

symptom. GO to Symptom Chart.
Symptom Chart
Symptom Chart
• The engine does not crank or • Battery. • GO to Pinpoint Test A.
relay clicks • Starter motor.
• Starter motor relay.
• Ignition switch.
• Anti-theft system.
• Circuitry.
• The engine cranks slowly • Battery. • CARRY OUT the Starter
• Starter motor. Motor — Voltage Drop Test
• Circuitry. Component Test.
• Unusual starter noise • Starter mounting. • GO to Pinpoint Test B.
• Flywheel/ring gear.
• Starter motor.


• The starter spins but the • Starter motor. • INSPECT the starter motor
engine does not crank mounting and engagement.
INSTALL a new starter
motor.
• Damaged flywheel/ring gear • INSPECT the flywheel/ring
teeth. gear for damaged, missing or
worn teeth. REPAIR as
required.
Connector Circuit Reference
Starter Motor Relay

85 CKT 33 (WT/PK) starter motor relay to Greater than 10 volts with ignition in
transmission range (TR) sensor START position.
86 CKT 461 (OR) starter motor relay to 10,000 ohms or greater to chassis ground and
powertrain control module (PCM) 0 volts.
30 CKT 1050 (LG/VT) starter relay to power Greater than 10 volts at all times.
distribution box (PDB)
87 CKT 113 (YE/LB) starter motor relay to Greater than 10 volts with ignition in
starter motor S terminal START position.
Ignition Switch

4 CKT 37 (YE) PDB to ignition switch Greater than 10 volts at all times.


7 CKT 1522 (DG) ignition switch to power Greater than 10 volts in START position.
junction box (PJB)
(TR) Sensor

12 CKT 32 (RD/LB) TR sensor to PJB fuse 10 volts or greater in START position.
No.29
10 CKT 33 (WT/PK) TR sensor to starter relay 10 volts or greater in START position.
PCM C175

39 CKT 461 (OR) starter relay to PCM 10,000 ohms or greater to chassis ground and
0 volts.
Normal Operation
Under normal operation the PDB supplies constant
power to the starter relay on circuit 1050 (LG/VT)
through fuse 12 (50A). When the key is placed in
the START position, with the vehicle in PARK or
NEUTRAL, the TR sensor provides power on
circuit 33 (WT/PK) and the PCM provides ground
on circuit 461 (OR). The coil of the relay is
energized and sends power to the starter motor on
circuit 113 (YE/LB).


Pinpoint Tests
PINPOINT TEST A: THE ENGINE DOES NOT CRANK OR RELAY CLICKS

A1 CHECK FOR VOLTAGE DROP
• Check starter motor feed and ground circuits for voltage drop. Yes
Refer to Component Tests in this section. GO to A2.
• Is the voltage drop within specification? No
REPAIR as necessary.
A2 CHECK THE STARTER MOTOR
• Connect one end of a fused jumper wire to the B-terminal of the
starter motor and momentarily connect the other end to the
starter solenoid S-terminal.
Yes
GO to A3.
No
INSTALL a new starter motor. TEST the
• Does the starter motor engage and the engine crank? system for normal operation.
A3 CHECK THE START INPUT TO THE STARTER MOTOR
• Disconnect: Starter S Connector.
• Hold the ignition switch in the START position.
• Measure the voltage at the starter motor solenoid S connector.
Yes
CLEAN the starter solenoid S-terminal and
connector. CHECK the wiring and the
starter motor for a loose or intermittent
connection. TEST the system for normal
operation.
No
• Is the voltage reading greater than 10 volts? GO to A4.
A4 CHECK THE START INPUT TO THE STARTER RELAY
• Disconnect: Starter Relay.
• Hold the ignition switch in the START position.
(Continued)


PINPOINT TEST A: THE ENGINE DOES NOT CRANK OR RELAY CLICKS (Continued)
A4 CHECK THE START INPUT TO THE STARTER RELAY
(Continued)
• Measure the voltage between starter relay connector pin 85,
circuit 33 (WT/PK) and ground.
Yes
GO to A5.
No
• Is the voltage reading greater than 10 volts? GO to A10.
A5 CHECK THE BATTERY SUPPLY POWER TO THE STARTER
RELAY
• Measure the voltage between starter relay connector pin 30,
circuit 1050 (LG/VT) and ground.
Yes
GO to A6.
No
REPAIR the open in circuit 1050 (LG/VT).
• Is the voltage reading greater than 10 volts? TEST the system for normal operation.
A6 CHECK CIRCUIT 113 (YE/LB) FOR A SHORT TO GROUND
• Measure the resistance between starter relay connector pin 87,
circuit 113 (YE/LB) and ground.
Yes
REPAIR circuit 113 (YE/LB) for a short to
ground. TEST the system for normal
operation.
No
• Is the resistance reading less than 10,000 ohms? GO to A7.
(Continued)


A7 CHECK CIRCUIT 113 (YE/LB) FOR AN OPEN
• Measure the resistance of circuit 113 (YE/LB) between starter
relay connector pin 87 and the starter S connector.
Yes
GO to A8.
No
REPAIR circuit 113 (YE/LB) for an open.
• Is the resistance reading less than 5 ohms? TEST the system for normal operation.
A8 CHECK CIRCUIT 461 (OR) FOR A SHORT TO GROUND
• Measure the resistance of circuit 461 (OR) between starter relay
connector pin 86 and ground.
Yes
REPAIR circuit 461 (OR) for a short to
ground. TEST the system for normal
operation.
No
• Is the resistance reading less than 10,000 ohms? GO to A9.
A9 CHECK CIRCUIT 461 (OR) FOR AN OPEN
• Measure the resistance of circuit 461 (OR) between starter relay
connector pin 86 and the PCM module connector pin 39.
Yes
INSTALL a new starter relay. TEST the
No
REPAIR circuit 461 (OR) for an open.
• Is the resistance less than 5 ohms? TEST the system for normal operation.
(Continued)


A10 CHECK CIRCUIT 33 (WT/PK) FOR VOLTAGE
• Measure the voltage between TR sensor circuit 33 (WT/PK)
harness side and ground, while holding the ignition switch in the
START position.
Yes
GO to A11.
No
REPAIR circuit 33 (WT/PK). TEST the
• Is the voltage reading greater than 10 volts? system for normal operation.
A11 CHECK FOR VOLTAGE AT THE TR SENSOR
• Measure the voltage between circuit 32 (RD/LB), TR sensor
harness side, and ground in the START position.
Yes
INSTALL a new TR sensor switch.
No
• Is the voltage greater than 10 volts? GO to A12.
A12 CHECK CIRCUIT 1522 (DG) FOR AN OPEN
(Continued)


A12 CHECK CIRCUIT 1522 (DG) FOR AN OPEN (Continued)
• Measure the resistance of circuit 1522 (DG) between ignition
connector pin 7, circuit 1522 (DG), and the input cavity of fuse
29 (10A).
Yes
GO to A13.
No
REPAIR circuit 1522 (DG). TEST the
• Is the resistance less than 5 ohms? system for normal operation.
A13 CHECK THE POWER SUPPLY TO THE IGNITION SWITCH
• Disconnect: Ignition Switch C233.
• Measure the voltage at ignition switch connector pin 4, circuit 37
(YE).
Yes
INSTALL a new ignition switch.
No
REPAIR circuit 37 (YE) for an open. TEST
• Is the voltage reading greater than 10 volts? the system for normal operation.


PINPOINT TEST B: UNUSUAL STARTER NOISE
B1 CHECK THE STARTER MOUNTING
• Inspect the starter mounting bolts and brackets for looseness, Yes
and the starter housing to confirm a flush, tight fit to the rear GO to B2.
cover plate. No
• Is the starter motor mounted correctly? INSTALL the starter motor correctly.
REFER to Starter Motor in this section.
TEST the system for normal operation.
B2 CHECK FOR ENGINE NOISE
• Connect a remote starter switch between the starter solenoid
B-terminal and the starter solenoid S-terminal.
Yes
GO to B3.
• Engage the starter motor and verify the noise is due to the No
starter operation. REFER to Section 303-00 to continue the
• Is the noise due to the starter motor engagement? diagnosis.
B3 CHECK FOR UNUSUAL WEAR
• Remove the starter motor. Refer to Starter Motor in this section. Yes
• Inspect the ring gear for damaged or worn teeth. INSTALL a new ring gear. EXAMINE the
• Is the noise due to ring gear tooth damage? starter pinion teeth. If damaged, INSTALL
a new starter motor. TEST the system for
normal operation.
No
INSTALL a new starter motor. TEST the


Component Tests Motor Feed Circuit
Starter Motor — Voltage Drop Test

WARNING: When servicing the starter
motor or carrying out other underhood work in
the vicinity of the starter motor, be aware that
the heavy gauge battery input lead at the starter
solenoid is ‘‘electrically hot’’ at all times.
CAUTION: A protective cap or boot is
provided over the battery input terminal on all
vehicle lines and must be installed after servicing.
Be sure to disconnect the battery ground cable
before servicing the starter motor.
Always make the Rotunda 73 Digital Multimeter Item Part Number Description
connections at the component terminal rather than at 1 11002 S-terminal
the wiring end connector. Making a connection at 2 — Remote starter switch
the wiring end connector could result in false 3 10653 Battery
readings because the meter will not pick up a high 4 105-R0051 Rotunda 73 Digital
resistance between the wiring connector and the Multimeter
component. 5 11002 B-terminal
Starter Motor — Motor Feed Circuit 6 11002 M-terminal
1. Make sure the battery is fully charged. Refer to 5. Engage the remote starter switch. Read and
Section 414-01. record the voltage. The voltage reading should
2. Disconnect the inertia fuel shutoff switch (IFS be 0.5 volts or less.
switch). 6. If the voltage reading is 0.5 volts or less, go to
3. Connect a remote starter switch between the the Starter Motor — Motor Ground Circuit
starter solenoid S-terminal and the battery Component Test.
positive (+) terminal. 7. If the voltage reading is greater than 0.5 volts,
4. Connect the Rotunda 73 Digital Multimeter indicating excessive resistance, move the
positive lead to the battery positive (+) post. Rotunda 73 Digital Multimeter negative lead to
Connect the negative lead to the starter solenoid the starter solenoid B-terminal and repeat the
M-terminal. test. If the voltage reading at the B-terminal is
lower than 0.5 volts, the concern is either in
the connections at the starter solenoid or in the
solenoid contacts.


Motor Feed Circuit 1. Disconnect the inertia fuel shutoff switch.
2. Connect a remote starter switch between the
starter solenoid S-terminal and the battery
positive (+) terminal.
3. Connect the Rotunda 73 Digital Multimeter
positive lead to the starter motor housing (the
connection must be clean and free of rust or
grease). Connect the negative lead to the
negative (-) battery terminal.
Motor Ground Circuit

1 — S-terminal (part of 11002)
2 — Remote starter switch
3 10653 Battery
4 105-R0051 Rotunda 73 Digital
Multimeter
5 — B-terminal (part of 11002)
6 — M-terminal (part of 11002)
8. Remove the cables from solenoid B-, S- and

M-terminals. Clean the cables and connections Item Part Number Description
and reinstall the cables to the correct terminals. 1 105-R0051 Rotunda 73 Digital
Repeat Steps 3 through 6. If the voltage drop Multimeter
reading is still greater than 0.5 volts when 2 10653 Battery
checked at the M-terminal and less than 0.5
3 — S-terminal (part of 11002)
volts when checked at the B-terminal, the
concern is in the solenoid contacts. Install a 4 — M-terminal (part of 11002)
new starter motor. 5 — B-terminal (part of 11002)
9. If the voltage reading taken at the solenoid 6 — Remote starter switch
B-terminal is still greater than 0.5 volts after 4. Engage the remote starter switch and crank the
cleaning the cables and connections at the engine. Read and record the voltage reading.
solenoid, the concern is either in the positive The reading should be 0.2 volts or less.
(+) battery cable connection or in the positive
5. If the voltage drop is more than 0.2 volts, clean
battery cable itself.
the negative cable connections at the battery
10. By moving the Rotunda 73 Digital Multimeter and body connections, and retest.
negative lead toward the battery and checking
6. If the voltage drop is greater than 0.2 volts,
each mechanical connection point, the excessive
connect the Rotunda 73 Digital Multimeter
voltage drop can be located. When the high
positive lead to the end of the cable nearest
reading disappears, the last mechanical point
battery positive.
that was checked is the concern. Repair or
install a new connection as required. 7. Connect the multimeter negative lead to the
terminal at the other end of the cable.
Starter Motor — Motor Ground Circuit
A slow cranking condition can be caused by
resistance in the ground or return portion of the
cranking circuit. Check the voltage drop in the
ground circuit as follows:


8. Crank the engine and observe the voltage
reading. The voltage reading should be 0.2 volts
or lower. If the voltage drop is too high, clean
the terminal ends. Retest, and if still high,
install a new cable. If the voltage reading is
less than 0.2 volts and the engine still cranks
slowly, install a new starter motor.


Starter Motor

1 11N087 Starter motor solenoid
terminal cover WARNING: When performing
2 N800136 Starter solenoid battery cable maintenance on the starting system be aware
nut that the heavy gauge leads are connected directly
3 N800156 Starter solenoid wire nut to the battery. Make sure the protective caps are
4 14463 Starter solenoid battery cable in place when maintenance is completed.
5 14463 Starter solenoid wire
6 N808980 Starter motor bolts (3 hoist. For additional information, refer to
required)
Section 100-02.
7 11000 Starter motor and solenoid
3. Remove the starter solenoid terminal cover.
4. Remove the nut and disconnect the starter

solenoid battery cable.


5. Remove the nut and disconnect the starter 6. Remove the 3 starter motor bolts and the starter
solenoid wire. motor.
• To install, tighten to 6 Nm (44 lb-in). • To install, tighten to 25 Nm (18 lb-ft).

303-07-1 Engine Ignition 303-07-1
SPECIFICATIONS
General Specifications (Continued)
Item Specification
Base ignition timing 10 degrees BTDC ± 2
Item Specification degrees non-adjustable
Lubricants and Chemicals Firing order 1-3-7-2-6-5-4-8
Motorcraft Silicone Brake ESE-M1C171-A Spark plug gap 1.32-1.42 mm
Caliper Grease and
Dielectric Compound Spark plug type AGSE-32WM
XG-3-A, or equivalent
High Temperature Nickel ESE-M12A4-A Torque Specifications — Torque specifications
Anti-Seize Lubricant XL-2
(in Canada CXG-2) or Description Nm lb-ft lb-in
equivalent Ignition coil cover 10 — 89
Engine Ignition Spark plug 20 15 —


Engine Ignition The CKP sensor:
The electronic ignition (EI) system is a coil-on-plug • is a variable reluctance sensor.
(COP) ignition system. The COP ignition system • is triggered by a 36-minus-1 tooth trigger wheel
consists of the: mounted on the crankshaft.
• camshaft position (CMP) sensor. • provides base timing and crankshaft speed (rpm)
• crankshaft position (CKP) sensor. to the PCM.
• ignition coils. The 8 separate ignition coils:
• spark plugs. • change low voltage to high voltage pulses, based
The CMP sensor: on signals from the PCM.
• produce the high voltage pulses to the spark
• sends the powertrain control module (PCM) a
plugs.
signal indicating camshaft position used for fuel
and spark synchronization. • are connected directly to each spark plug.
The spark plugs:
• change high voltage pulses into a spark which
ignites the fuel and air mixture.
• originally equipped on the vehicle have a
platinum-enhanced active electrode for long life.


Engine Ignition Components —
Exploded View

1 N807309 Ignition coil cover bolts
2 6P067 Ignition coil cover
3 14A464 Ignition coil electrical
connectors (8 required)
4 12A366 Ignition coils (8 required)
5 12405 Spark plugs (8 required)
1. For additional information, refer to the



Ignition Coil-On-Plug 3. Remove the ignition coil covers.
Material 4. Disconnect the 8 ignition coil electrical

connectors.
Item Specification
Motorcraft Silicone Brake ESE-M1C171-A 5. Remove the 8 ignition coils from the spark
Caliper Grease and plugs.
Dielectric Compound
XG-3-A • Apply silicone dielectric compound to the
inside of the ignition coil boots when
1. Disconnect the negative battery cable. For installing.
2. Remove the ignition coil cover bolts.


Spark Plugs 3. Remove the ignition coil covers.
Material 4. Disconnect the 8 ignition coil electrical

connectors.
Item Specification
Silicone Brake Caliper ESE-M1C171-A 5. Remove the 8 ignition coils from the spark
Grease and Dielectric plugs.
Compound
XG-3-A, or equivalent • Apply silicone dielectric compound to the
inside of the ignition coil boot when
High Temperature Nickel ESE-M12A4-A
Anti-Seize Lubricant installing.
XL-2
6. Remove the 8 spark plugs.
1. Disconnect the negative battery cable. For • To install, tighten to 20 Nm (15 lb-ft).
2. Remove the ignition coil cover bolts.

303-08-1 Engine Emission Control 303-08-1
SPECIFICATIONS
Exhaust gas 25 18 —
recirculation (EGR)
system module to
intake manifold
EGR system 40 30 —
module-to-exhaust
manifold tube nuts
EGR system module 10 — 89
heat shield bolts


Engine Emission Control
CAUTION: Do not remove any part of the
engine emission control system. Operating the
engine without the engine emission control
system will reduce fuel economy and engine
ventilation. This will weaken engine performance
and shorten engine life.
The engine emission control system consists of the:
• positive crankcase ventilation (PCV) system.
• exhaust gas recirculation (EGR) system.
Typical Vehicle Emission Control Information (VECI) Decal
Item Part Number Description The vehicle emission control information (VECI)
1 — Adjustment procedure notes decal shows:
2 — Ignition timing specifications • components of the emission control system.
3 — Engine vacuum hose routing • the correct vacuum hose routing.
(typical)
• the color stripe of the vacuum hoses.
4 — Spark plug gap specifications
5 — Engine type For additional information, refer to Section 100-01.
The PCV system uses intake manifold vacuum to
ventilate the crankcase and return the fumes to the
intake manifold for combustion.

DESCRIPTION AND OPERATION (Continued)
EGR System Components The EGR system returns a portion of the exhaust
gas to the intake manifold to reduce the combustion
temperature. This results in lower nitrous oxide
formation.
The powertrain control module (PCM) controls the
EGR vacuum regulator solenoid. The EGR vacuum
regulator solenoid controls the vacuum to the EGR
valve. When the EGR valve opens, exhaust gas
flows to the intake manifold. The EGR transducer
measures the flow through the EGR valve to the
exhaust manifold tube and sends a signal to the
PCM.
The EGR system module-to-exhaust manifold tube:
• connects the exhaust manifold to the EGR valve.
The EGR system module transducer:
• monitors the EGR system module flow rate
through the EGR to exhaust manifold tube.
• sends an EGR system module flow rate signal to
the PCM.
The EGR vacuum regulator solenoid uses input
from the powertrain control module to change the
EGR system module operation.
The PCV valve:
• controls the amount of ventilating air and blow-by
Item Part Number Description gases going to the intake manifold.
1 12A650 Powertrain control module
• prevents a backfire from reaching the crankcase.
2 9D475 EGR system module
3 9D477 EGR valve-to-exhaust
manifold tube
2005 Aviator, 09/2004


Exhaust Gas Recirculation (EGR)
System Components — Exploded
View

1 — Exhaust manifold-to-EGR 5 W701232 EGR system module bolts (2
system module tube lower required)
fitting (part of 9D477) 6 9D475 EGR system module
2 — Exhaust manifold-to-EGR 7 9D476 EGR system module gasket
system module tube upper
fitting (part of 9D477)
3 9D477 Exhaust manifold-to-EGR 1. For additional information, refer to the
system module tube procedures in this section.
4 14A464 EGR system module electrical
connector
(Continued)


Exhaust Gas Recirculation (EGR) 5. To install, reverse the removal procedure.
System Module • Install a new EGR system module gasket
with the side with the raised circle facing
1. NOTE: Access to the exhaust gas recirculation the intake manifold.
(EGR) tube is through the right front wheel
well.
Disconnect the exhaust manifold-to-exhaust gas
recirculation (EGR) valve system module tube
upper fitting.
2. Disconnect the EGR system module electrical

connector.
3. Remove the 2 EGR system module bolts.

• When installing, tighten the bolts to 10 Nm
(89 lb-in).
4. NOTE: The EGR system module sealing

surfaces are soft metals.
Remove the EGR system module.
• Carefully clean and inspect the EGR sealing
surfaces.
• Discard the EGR system module gasket.


Exhaust Manifold to Exhaust Gas 2. Disconnect the exhaust manifold-to-exhaust gas
Recirculation (EGR) Valve Tube recirculation (EGR) valve system module tube
upper fitting.
1. NOTE: Access to the exhaust gas recirculation • To install, tighten to 40 Nm (30 lb-ft).
(EGR) tube is through the right front wheel
3. Disconnect the exhaust manifold-to-exhaust gas
well.
recirculation (EGR) valve system module tube
With the vehicle in NEUTRAL, position it on a lower fitting.
Section 100-02.
4. Remove the EGR system module tube.


Positive Crankcase Ventilation (PCV)
Valve
Item Part Number Description 3. CAUTION: A new PCV valve must be

1 6K817 Positive crankcase ventilation installed if removed from the cam cover.
(PCV) hose Damage will occur to the locking mechanism
2 14A464 PCV valve electrical or the PCV valve.
connector Remove the PCV valve.
3 6A666 PCV valve
• Twist the PCV valve counterclockwise to
remove the PCV valve from the valve cover.
1. Disconnect the PCV hose.
2. Disconnect the PCV valve electrical connector.

303-12-1 Intake Air Distribution and Filtering 303-12-1
SPECIFICATIONS
Torque Specifications — Torque specifications

Air cleaner outlet 10 — 89
retaining nut


Intake Air System Components —
Exploded View

1 12B579 Mass air flow (MAF) 7 9R504 Air cleaner outlet tube
electrical connector assembly
2 9H308 Air bypass valve inlet tube 8 9628 Air cleaner cover retaining
3 6758 Crankcase vent tube clips
4 805320 Air cleaner outlet retaining 9 9A610 Air cleaner cover
nut 10 9601 Air cleaner element
5 — Air cleaner outlet tube clamp 11 9A612 Air cleaner tray
(part of 9R504)
6 — Air cleaner outlet 1. For additional information, refer to the
tube-to-cover clamp (part of procedures in this section.
9R504)
(Continued)


Air Cleaner 5. Loosen the air cleaner outlet tube clamp and
disconnect the outlet tube from the throttle
body.
1. Disconnect the mass air flow (MAF) electrical
connector. 6. Remove the air cleaner assembly.
2. Disconnect the air bypass valve inlet tube. • Pull up and then forward on the air cleaner
3. Disconnect the crankcase vent tube from the air
cleaner outlet tube. 7. To install, reverse the removal procedure.
4. Remove the air cleaner outlet tube retaining

nut.


Air Cleaner Outlet Pipe 4. Loosen the air cleaner outlet tube clamp and
disconnect the outlet tube from the throttle
body.
1. Disconnect the air bypass valve inlet tube.
5. Loosen the air cleaner outlet tube-to-air cleaner
2. Disconnect the crankcase vent tube from the air
assembly cover clamp and remove the outlet
cleaner outlet tube.
tube.
3. Remove the air cleaner outlet tube retaining
nut.

303-13-1 Evaporative Emissions 303-13-1
SPECIFICATIONS
Description Nm lb-in
Evaporative emission (EVAP) 10 89
Item Specification canister mounting nuts
Lubricant Dust separator mounting bolt 10 89
SAE 5W-20 Premium WSS-M2C930-A EVAP canister purge valve 10 89
Synthetic Blend Motor Oil nut
X0-5W20-QSP or
equivalent


Evaporative Emissions The fuel tank filler cap:
The evaporative emission (EVAP) system: • relieves system pressure above 14 kPa (56.21
inches H2O).
• prevents hydrocarbon emissions from reaching the
atmosphere. • relieves system vacuum below 3.8 kPa (15.26
inches H2O).
• stores fuel vapors in the EVAP canister that are
generated during vehicle operation or hot soak, The canister vent solenoid:
until they can be consumed by the engine during • is normally open.
normal engine operation.
• seals the evaporative emissions system for the
• routes the stored fuel vapors to the engine during inspection and maintenance (I/M 240) test and
engine operation. OBD II leak and pressure tests.
• is controlled by the powertrain control module The EVAP canister purge valve:
(PCM) which, using various sensor inputs,
calculates the desired amount of purge flow. The • is normally closed.
PCM regulates the purge flow, induced by the • regulates the purging of the EVAP canister.
application of intake manifold vacuum, by varying
the duty cycle applied to the EVAP canister
purge valve. The EVAP system test port:
• has an EVAP test port for test purposes. • is located on the EVAP canister purge valve.
The fuel vapors are routed: • is used to connect the Evaporative Emissions
System Tester to the EVAP system.
• from the fuel tank through the fill limit valve and
fuel vapor vent valve. The fuel vapor vent valves The evaporative emission dust separator:
are part of the fuel tank assembly and cannot be • prevents suspended dust and dirt particles from
serviced separately. entering the evaporative emission system.
• to the EVAP canisters through a vapor line. • is serviced as a separate item.
• to the engine when the EVAP canister purge The evaporative emission system monitor:
valve is opened by the PCM.
The fuel tank pressure (FTP) sensor: • is a self-test strategy within the PCM which tests
the integrity of the EVAP system.
• monitors the pressure levels in the fuel tank. • monitors the EVAP system for leaks.
• communicates the pressure reading to the PCM • monitors electronic EVAP components for
during the OBD II leak test. irrationally high or low voltages.
The EVAP canisters: • monitors for correct EVAP system operation.
• are located on top of the fuel tank. • uses negative leak test methods to test and
• contain activated carbon. activate the EVAP system.
• store fuel vapors. • a ‘‘CHECK FUEL CAP’’ message will be
displayed by the message center if the EVAP
system fails the test.
The EVAP running loss system leak test:
• utilizes intake manifold vacuum to test the system
and involves several stages.

GENERAL PROCEDURES
Evaporative Emission System Leak 2. Close the canister vent solenoid. For additional
Test information, refer to Canister Vent Solenoid
Closing Procedure in this section.
Special Tool(s)
3. Using the Rotunda Smoke Machine, pressurize
VACUTEC Smoke Machine the EVAP system.
Fuel Evaporative Emission
System Tester 4. Monitor the indicator flag on the Smoke
218-0002 or equivalent Machine Tester. If the measurement is below
the indicator flag, the system has passed the
leak test and the test procedure is complete. If
the measurement is above the indicator flag, the
Worldwide Diagnostic System system has failed the leak test. Proceed to
(WDS) Phase 2.
Vehicle Communication Module
(VCM) with appropriate Phase 2 — System Leak Check
adapters, or equivalent
diagnostic tool 1. Introduce smoke from the Rotunda Smoke
Machine into the EVAP system. For additional
information, refer to the manufacturer’s
Phase 1 — Leak Verification instructions.
1. Connect the Rotunda Smoke Machine Leak 2. Use the halogen light provided with the Smoke
Tester to the evaporative emission (EVAP) test Machine to look for smoke coming from the
port. For additional information, refer to the EVAP system. This would indicate a leak point.
manufacturer’s instructions.
3. Repair any leaks as necessary.
4. Repeat the leak test until the system passes.

GENERAL PROCEDURES
Evaporative Emission Repair Drive Cycle Preparation
Verification Drive Cycle
NOTE: For best results, follow each of the
Special Tool(s)
following steps as accurately as possible.
Worldwide Diagnostic System 4. NOTE: This step bypasses the engine soak
(WDS) timer and resets OBD II monitor status.
Vehicle Communication Module
Install the diagnostic tool. Turn the key ON
adapters, or equivalent with the engine OFF. Cycle the key off, then
diagnostic tool on. Select the appropriate vehicle and engine
qualifier. Clear all diagnostic trouble codes
(DTCs) and carry out a PCM reset.
Drive Cycle Recommendations 5. Begin to monitor the following PIDs: ECT,
EVAPDC, FLI (if available) and TP MODE.
NOTE: The following procedure is designed to Press Diagnostic Data Link, PCM, PID/Data
execute and complete the evaporative emission monitor and record, press trigger to select each
repair verification drive cycle and to clear the Ford PID, then start.
P1000, inspection and maintenance (I/M) readiness
code. When the ambient air temperature is below 6. Start the engine without returning the key to the
4.4°C (40°F) or above 37.8°C (100°F), or the OFF position.
altitude is above 2,438 meters (8,000 feet), the
EVAP monitor will not run. If the P1000 must be Preparation for Monitor Entry
cleared in these conditions, the powertrain control
module (PCM) must detect them once (twice on WARNING: Strict observance of posted
some applications) before the EVAP monitor can be speed limits and attention to driving conditions
bypassed and the P1000 cleared. The EVAP are mandatory when proceeding through the
bypassing procedure is described in the following following drive cycle.
drive cycle.
7. NOTE: This step allows engine warm-up and
1. Most OBD II monitors will complete more provides intake air temperature (IAT) input to
readily using a steady foot driving style during the PCM.
cruise or acceleration modes. Operating the
throttle in a smooth fashion will minimize the Idle the vehicle for 15 seconds. Drive at 64
time necessary for monitor completion. km/h (40 mph) until the ECT is at least 76.7°C
(170°F).
2. Fuel tank level should be between one-half and
three-quarters full with three-quarters full being 8. Is IAT above 4.4°C (40°F) and below 37.8°C
the most desirable. (100°F)? If not, continue with the following
steps but note that the EVAP Monitor Bypass
3. The evaporative monitor can only operate portion of the drive cycle (step 13) will be
during the first 30 minutes of engine operation. required to bypass the EVAP monitor and clear
When executing the procedure for this monitor, the P1000.
stay in part throttle mode and drive in a smooth
fashion to minimize fuel slosh. 9. NOTE: This step executes the heated oxygen
sensor (HO2S) monitor.
Cruise at 64 km/h (40 mph) for 60 seconds.

10. NOTE: This executes the EVAP monitor if Pending Code and EVAP Monitor Bypass Check
IAT is above 4.4°C (40°F) and below 37.8°C
(100°F). 12. NOTE: This determines if a pending code is
NOTE: To initiate the monitor, TP MODE preventing the clearing of P1000.
should equal PT, EVAPDC must be greater NOTE: If the EVAP monitor is not complete
than 75%, and FLI must be between 15 and and IAT was below 4.4°C (40°F) or above
85%. 37.8°C (100°F) temperature range in Step 8, or
NOTE: Avoid sharp turns and hills. the altitude is above 2,438 meters (8,000 feet),
Cruise at 72 to 104 km/h (45 to 65 mph) for 10 the EVAP Monitor Bypass (Step 13) must be
minutes. carried out.
Using the diagnostic tool, check for pending
11. NOTE: This step executes the ISC portion of codes. Conduct normal repair procedures for
the Secondary Air/CCM. any pending code concerns. Rerun any
Bring the vehicle to a stop. Idle with the incomplete monitor.
transmission in DRIVE (for automatic EVAP Monitor Bypass
transmission) or NEUTRAL (for manual
transmission) for 2 minutes.
13. NOTE: This allows the bypass counter to
increment to 2.
NOTE: Do not repeat Step 4.
Park the vehicle for a minimum of 8 hours.
Repeat Steps 5 through 12.
2005 Aviator, 09/2004

GENERAL PROCEDURES
Canister Vent Solenoid Closing CAUTION: The canister vent solenoid
Procedure must not be energized for more than 9 minutes
at one time. Once the canister vent solenoid is
Special Tool(s) energized and de-energized, adequate time must
be allowed for the component to cool adequately.
Worldwide Diagnostic System Failure to allow the component to cool may
(WDS)
create a false failure in the diagnostics, causing
Vehicle Communication Module unnecessary repairs.
adapters, or equivalent
diagnostic tool 1. Connect the diagnostic tool and select the
output test mode.
2. Select the fuel tank pressure (FTP) and the

volts (V) parameter identification (PID) for
monitoring.
3. Select the ALL OFF mode.
4. Close the canister vent solenoid by pushing the

START button on the diagnostic tool.


Dust Separator
Material
Item Specification
X0-5W20-QSP or
equivalent

1 9S321 Fuel vapor hose 3 W707079-S Bolt
2 — Fuel filler pipe (part of 9034) 4 9B328 Dust separator
(Continued)

Removal and Installation NOTE: During the repair or replacement of
WARNING: The evaporative emissions openings shall be capped, taped or otherwise
system contains fuel vapor and condensed fuel appropriately protected to prevent the ingress of dirt
vapor. Although not present in large quantities, or other contamination. All caps, tape and other
it still presents the danger of explosion or fire. protective materials shall be removed prior to
Disconnect the battery ground cable from the installation.
battery to minimize the possibility of an
electrical spark occurring, possibly causing a fire 1. With the vehicle in NEUTRAL, position on a
or explosion if fuel vapor or liquid fuel are hoist. For additional information, refer to
present in the area. Failure to follow these Section 100-02.
instructions can result in personal injury.
WARNING: Do not smoke or carry lighted additional information, refer to Section 414-01.
3. Disconnect the fuel vapor hose from the dust
on or near any fuel related component. Highly
separator.
flammable mixtures are always present and may
be ignited. Failure to follow these instructions • To install, lubricate with clean engine oil.
4. Disconnect the fuel filler-to-dust separator hose.
• To install, lubricate with clean engine oil.
5. Remove the bolt and the dust separator.

2005 Aviator, 09/2004


Fuel Tank Pressure Sensor
Material
Item Specification
X0-5W20-QSP or
equivalent

1 14A464 Fuel pressure sensor electrical
connector 1. With the vehicle in NEUTRAL, position on a
2 9S321 Fuel vent vapor hose hoist. For additional information, refer to
3 9S321 Fuel vent vapor hose Section 100-02.
4 9S321 Fuel vent vapor hose 2. Disconnect the battery ground cable. For
5 9E616 Fuel pressure sensor and tube additional information, refer to Section 414-01.
assembly
6 — Fuel pressure sensor tube
(part of 9E616)

3. WARNING: The evaporative emissions 6. NOTE: Cut and discard the fuel tank shield
system contains fuel vapor and condensed strap to remove the fuel pressure sensor tube
fuel vapor. Although not present in large assembly.
quantities, it still presents the danger of Disconnect the fuel pressure sensor tube
explosion or fire. Disconnect the battery assembly from the evaporative emissions
ground cable from the battery to minimize (EVAP) canister.
the possibility of an electrical spark
occurring, possibly causing a fire or
explosion if fuel vapor or liquid fuel are
present in the area. Failure to follow these
WARNING: Do not smoke or carry
when working on or near any fuel related
component. Highly flammable mixtures are
always present and may be ignited. Failure
to follow these instructions may result in
personal injury.
fuel-related components, all liquid and vapor 7. Remove the fuel pressure sensor and tube
fuel openings shall be capped, taped or assembly.
ingress of dirt or other contamination. All caps, 8. To install, reverse the removal procedure.
removed prior to installation. 9. Leak test the evaporative emission system. For
Remove the fuel tank. For additional additional information, refer to Evaporative
information, refer to Section 310-01. Emission System Leak Test in this section.
4. Disconnect the fuel pressure sensor electrical 10. Carry out the evaporative emission repair drive
connector. cycle. For additional information, refer to
Evaporative Emission Repair Verification Drive
5. Disconnect the 3 fuel vent vapor hoses from the Cycle in this section.
fuel pressure sensor tube assembly.
2005 Aviator, 09/2004


Fuel Vapor Vent Valve
Material
Item Specification
X0-5W20-QSP or
equivalent

1 — Evaporative emission (EVAP) 3 9S321 Fuel vapor hose
canister vent solenoid 4 9F945 Fuel vapor vent valve
2 9S321 Fuel vapor hose
(Continued)

Removal and Installation NOTE: During the repair or replacement of
WARNING: The evaporative emissions openings shall be capped, taped or otherwise
system contains fuel vapor and condensed fuel appropriately protected to prevent the ingress of dirt
vapor. Although not present in large quantities, or other contamination. All caps, tape and other
it still presents the danger of explosion or fire. protective materials shall be removed prior to
Disconnect the battery ground cable from the installation.
battery to minimize the possibility of an
electrical spark occurring, possibly causing a fire 1. With the vehicle in NEUTRAL, position on a
or explosion if fuel vapor or liquid fuel are hoist. For additional information, refer to
present in the area. Failure to follow these Section 100-02.
WARNING: Do not smoke or carry lighted additional information, refer to Section 414-01.
3. Disconnect the EVAP canister vent solenoid
4. Disconnect the fuel vapor hoses from the fuel
vapor vent valve.
5. Remove the fuel vapor vent valve.
2005 Aviator, 09/2004


Evaporative Emission Canister
Material
Item Specification
X0-5W20-QSP or
equivalent

Item Part Number Description NOTE: During the repair or replacement of
1 9002 Fuel tank fuel-related components, all liquid and vapor fuel
2 — Fuel vapor hose connector
(part of 2S284) appropriately protected to prevent the ingress of dirt
3 Fuel vapor hose connector
4 — Fuel vapor Y (part of 9E616) installation.
5 9K318 Fuel vapor hose
6 9S321 Fuel vapor hose 1. With the vehicle in NEUTRAL, position on a
7 W520101-S Canister mounting nut hoist. For additional information, refer to
8 W520101 Canister mounting nut Section 100-02.
9 9D653 Fuel vapor canister 2. Disconnect the battery ground cable. For
10 9D653 Fuel vapor canister additional information, refer to Section 414-01.
Removal and Installation 3. Remove the fuel tank. For additional

WARNING: The evaporative emissions
system contains fuel vapor and condensed fuel 4. Disconnect the fuel vapor hose from the fuel
vapor. Although not present in large quantities, vapor Y.
it still presents the danger of explosion or fire. • To install, lubricate with clean engine oil.
Disconnect the battery ground cable from the
battery to minimize the possibility of an 5. Disconnect the 2 fuel vapor hose connectors
electrical spark occurring, possibly causing a fire from the fuel vapor Y and remove the fuel
or explosion if fuel vapor or liquid fuel are vapor tee.
instructions can result in personal injury. 6. Disconnect the 2 fuel vapor hoses from the
EVAP canisters.
WARNING: Do not smoke or carry lighted
tobacco or open flame of any type when working 7. Remove the 2 EVAP canister mounting nuts.
on or near any fuel related component. Highly • To install, tighten to 10 Nm (89 lb-in).
be ignited. Failure to follow these instructions 8. Remove the 2 EVAP fuel vapor canisters.
2005 Aviator, 09/2004


Evaporative Emission Canister Purge Removal and Installation
Valve
WARNING: The evaporative emissions
Material system contains fuel vapor and condensed fuel
vapor. Although not present in large quantities,
Item Specification it still presents the danger of explosion or fire.
SAE 5W-20 Premium WSS-M2C930-A Disconnect the battery ground cable from the
Synthetic Blend Motor Oil battery to minimize the possibility of an
X0-5W20-QSP or
equivalent electrical spark occurring, possibly causing a fire
or explosion if fuel vapor or liquid fuel are
WARNING: Do not smoke or carry lighted


appropriately protected to prevent the ingress of dirt
installation.
1. With the vehicle in NEUTRAL, position on a

Section 100-02.

3. Disconnect the vacuum hose from the EVAP

canister purge valve.
Item Part Number Description 4. Disconnect the 2 fuel vapor hoses from the
1 — Vacuum hose (part of 2S284) EVAP canister purge valve.
2 — Fuel vapor hoses (part of • To install, lubricate with clean engine oil.
2S284)
3 14A464 Electrical connector 5. Disconnect the EVAP canister purge valve
4 — Evaporative emission (EVAP) electrical connector.
canister purge valve nut
5 9F933 EVAP canister purge valve

6. Remove the nut and the EVAP canister purge 7. To install, reverse the removal procedure.
valve.
2005 Aviator, 09/2004

303-14-1 Electronic Engine Controls 303-14-1
SPECIFICATIONS
Torque Specifications — Torque
specifications (Continued)
General Specifications Description Nm lb-ft lb-in
Item Specification PCM retaining nuts 8 — 71
Lubricants PCM bracket bolt 10 — 89
High Temperature Nickel ESE-M12A4-A Idle air control (IAC) 10 — 89
Anti-Seize Lubricant XL-2 valve bolts
(in Canada CXG-2) or Engine coolant 20 15 —
equivalent temperature (ECT)
sensor
Torque Specifications — Torque specifications Mass air flow (MAF) 10 — 89
sensor bolts
Knock sensor (KS) 20 15 —
A/C compressor bolts 25 18 —
Cylinder head 26 19 —
Camshaft position 10 — 89 temperature (CHT)
(CMP) sensor bolt sensor
Crankshaft position 10 — 89 Heated oxygen sensor 41 30 —
(CKP) sensor bolt (HO2S)
Powertrain control 7 — 62 Catalyst monitor sensor 41 30 —
module (PCM)
electrical connectors


Electronic Engine Controls The CMP sensor:
The electronic engine controls consist of the: • sends the PCM a signal indicating camshaft
position used for fuel and spark synchronization.
• powertrain control module (PCM).
The CKP sensor:
• throttle position (TP) sensor.
• idle air control (IAC) valve. • sends the PCM a signal indicating crankshaft
position.
• engine coolant temperature (ECT) sensor.
• is essential for calculating spark timing.
• camshaft position (CMP) sensor.
The MAF sensor:
• crankshaft position (CKP) sensor.
• mass air flow (MAF) sensor. • uses a hot wire sensing element to measure the
amount of air entering the engine. Air passing
• heated oxygen sensor (HO2S). over the hot wire causes it to cool.
• catalyst monitor sensor. The front HO2S:
• knock sensor (KS).
• creates a voltage signal dependent on exhaust
The PCM carries out the following functions: oxygen content.
• accepts input from various engine sensors to • provides feedback information to the PCM used to
compute the fuel flow rate necessary to maintain a calculate fuel delivery.
prescribed air/fuel ratio and spark synchronization The catalyst monitor sensor:
throughout the entire engine operating range.
• outputs a command to the fuel injectors to meter • monitors oxygen content after it flows through the
the appropriate quantity of fuel. catalytic converter.
The TP sensor: • provides a voltage to the PCM used to calculate
catalytic converter integrity.
• sends the PCM a signal indicating the throttle The KS:
plate angle.
• is the main input to the PCM from the driver. • is used to detect engine detonation.
The IAC valve: • sends a voltage signal to the PCM.
• is able to provide a signal which retards the
• controls bypass air around the throttle plate at low ignition timing, as necessary.
speeds.
The ECT sensor:
• sends the PCM a signal indicating engine
temperature.
• voltage decreases as coolant temperature
increases.


Camshaft Position (CMP) Sensor
Item Part Number Description 3. Disconnect the camshaft position (CMP) sensor
1 14A464 Camshaft position (CMP) electrical connector.
sensor electrical connector
4. Remove the CMP sensor bolt.
2 N806155 CMP sensor bolt
3 6B288 CMP sensor • To install, tighten to 10 Nm (89 lb-in).
5. Remove the CMP sensor.

additional information, refer to Section 414-01. 6. To install, reverse the removal procedure.
2. Remove the power steering reservoir and
bracket. For additional information, refer to
Section 211-02.


Crankshaft Position (CKP) Sensor
Item Part Number Description 3. Disconnect the crankshaft position (CKP) sensor
1 14A464 Crankshaft position (CKP) electrical connector.
sensor electrical connector
4. Disconnect the A/C compressor electrical
2 14A464 A/C compressor electrical
connector connector.
3 N812677 A/C compressor bolt (3
required) 5. Loosen the 3 A/C compressor bolts enough to
allow the compressor to move approximately 1
4 19D629 A/C compressor (position
aside) inch.
5 N806155 CKP sensor bolt • To install, tighten to 25 Nm (18 lb-ft).
6 6C315 CKP sensor
6. Remove the CKP sensor bolt.
1. Disconnect the battery ground cable. For • To install, tighten to 10 Nm (89 lb-in).
7. Remove the CKP sensor.


Powertrain Control Module (PCM)
Item Part Number Description 6. Lower the glove box past the stops and
1 14A464 Powertrain control module disconnect the cable from the side of the glove
(PCM) electrical connectors box.
2 N621927 PCM nuts
3 N606675 PCM bracket bolt
4 03140 PCM and bracket assembly

2. Remove the RF door scuff plate.
3. Remove the RH cowl side trim panel.
4. Disconnect the powertrain control module

(PCM) electrical connectors.
7. Remove the PCM bracket bolt.
5. Remove the PCM mounting nuts.


8. Remove the pin-type retainer and position the
sound deadening insulation upward.
10. Remove the PCM and bracket as an assembly.

9. Remove the lower screw for the fuel pump
driver module and position back and disconnect
the electrical connector.


Throttle Position (TP) Sensor
Item Part Number Description 2. Disconnect the throttle position (TP) sensor
1 14A464 Throttle position (TP) sensor electrical connector.
3. Remove the TP sensor retaining screws.
2 N80014 TP sensor retaining screws
3 9B989 TP sensor • To install, tighten to 10 Nm (89 lb-in).
4. Remove the TP sensor.

additional information, refer to Section 414-01. 5. To install, reverse the removal procedure.


Heated Oxygen Sensor (HO2S) and
Catalyst Monitor Sensor — Exploded
View
Item Part Number Description 1. For additional information, refer to the

1 14A464 Heated oxygen sensor procedures in this section.
(HO2S) and catalyst monitor
electrical connectors
2 031403 Heated oxygen sensor
(HO2S) and catalyst monitors


Catalyst Monitor Sensor 3. Disconnect the catalyst monitor sensor electrical
connector.
Special Tool(s)
4. Using the special tool, remove the catalyst
Socket, Exhaust Gas Oxygen monitor sensor.
Sensor
303-476 (T94P-9472-A) • To install, tighten to 41 Nm (30 lb-ft).
Material
Item Specification
Anti-Seize Lubricant
XL-2 (in Canada CXG-2)
or equivalent

Section 100-02. 5. To install, reverse the removal procedure.
• Apply a light coat of anti-seize lubricant to
2. Disconnect the battery ground cable. For the threads of the catalyst monitor sensor.


Heated Oxygen Sensor (HO2S) 3. Disconnect the Heated oxygen sensor (HO2S)
Special Tool(s)
4. Using the special tool, remove the HO2S.
Socket, Exhaust Gas Oxygen
Sensor • To install, tighten to 41 Nm (30 lb-ft).
303-476 (T94P-9472-A)
Material
Item Specification
Anti-Seize Lubricant
XL-2 (in Canada CXG-2)
or equivalent
1. With the vehicle in NEUTRAL, psition it on a

hoist. For additional information, refer to 5. To install, reverse the removal procedure.
Section 100-02. • Apply a light coat of anti-sieze lubricant to
the threads of the HO2S.


Idle Air Control (IAC) Valve
Item Part Number Description 2. Disconnect the idle air control (IAC) valve
1 14A464 Idle air control (IAC) valve electrical connector.
3. Remove the IAC bolts.
2 N806155 IAC bolts (2 required)
3 9F715 IAC valve • To install, tighten to 10 Nm (89 lb-in).



Engine Coolant Temperature (ECT)
Sensor

1 14A464 Engine coolant temperature
(ECT) sensor electrical
connector
2 12A648 ECT sensor



4. Remove the ECT sensor.




Mass Air Flow (MAF) Sensor
Item Part Number Description 2. Disconnect the MAF sensor electrical

1 14A464 Mass air flow (MAF) sensor connector.
3. Disconnect the air cleaner outlet tube.
2 — Air outlet tube clamp (part of
9R504)
4. Remove the 4 MAF sensor bolts.
3 9R504 Air cleaner outlet tube
(position aside) • To install, tighten to 10 Nm (89 lb-in).
4 705761 MAF sensor bolts (4
required)
5 12B579 MAF sensor
6 9E931 MAF sensor gasket
CAUTION: The mass air flow (MAF)

sensor electronics module and body are
calibrated as a unit and must be serviced as a
unit. Do not tamper with the sensing elements
located in the air flow bypass of the MAF body.



5. Remove the MAF sensor and gasket. 6. To install, reverse the removal procedure.


Knock Sensor (KS)

1 14A464 Knock sensor (KS) electrical
connector
2 W500110 Knock sensor bolts
3 12A699 Knock sensor

2. Remove the lower intake manifold. For


connector.
4. Remove the knock sensor bolts.

5. Remove the knock sensor.


Cylinder Head Temperature (CHT)
Sensor

1 14A464 Cylinder head temperature
(CHT) sensor electrical
connector
2 980429 CHT sensor

Section 100-02.
2. Remove the RF fender splash shield.
3. Remove the front Y-pipe. For additional


(CHT) sensor electrical connector.


5. Remove the CHT sensor. 6. To install, reverse the removal procedure.

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303-00-1 Engine System — General Information 303-00-1

Copyright  2004, Ford Motor Company

DESCRIPTION AND OPERATION

Copyright  2004, Ford Motor Company

DIAGNOSIS AND TESTING

Dial Indicator Gauge Adapter Item Specification

Inspection and Verification

Copyright  2004, Ford Motor Company

DIAGNOSIS AND TESTING (Continued)

3. If the inspection reveals obvious concerns that

2005 Lincoln Aviator, 09/2004

DIAGNOSIS AND TESTING (Continued)

2005 Lincoln Aviator, 09/2004

DIAGNOSIS AND TESTING (Continued)

2005 Lincoln Aviator, 09/2004

DIAGNOSIS AND TESTING (Continued)

2005 Lincoln Aviator, 09/2004

DIAGNOSIS AND TESTING (Continued)

Component Tests 1. Add gasoline engine oil dye. Use a minimum

2005 Lincoln Aviator, 09/2004

DIAGNOSIS AND TESTING (Continued)

2005 Lincoln Aviator, 09/2004

DIAGNOSIS AND TESTING (Continued)

If one or more cylinders reads low, squirt Cylinder Leakage Detection

2005 Lincoln Aviator, 09/2004

DIAGNOSIS AND TESTING (Continued)

2005 Lincoln Aviator, 09/2004

DIAGNOSIS AND TESTING (Continued)

2005 Lincoln Aviator, 09/2004

DIAGNOSIS AND TESTING (Continued)

DIAGNOSIS AND TESTING (Continued)

2005 Lincoln Aviator, 09/2004

DIAGNOSIS AND TESTING (Continued)

DIAGNOSIS AND TESTING (Continued)

2005 Lincoln Aviator, 09/2004

1. WARNING: To avoid the possibility of

Copyright  2004, Ford Motor Company

1. Measure each camshaft journal diameter in two

Copyright  2004, Ford Motor Company

2. NOTE: Do not turn the camshaft while

Copyright  2004, Ford Motor Company

1. Remove the roller followers. Refer to the

2. Use a Dial Indicator with Bracketry to measure

3. Position the camshaft to the rear of the cylinder

4. Zero the indicator.

Copyright  2004, Ford Motor Company

1. Inspect camshaft lobes for pitting or damage in

Copyright  2004, Ford Motor Company

1. Use a Dial Indicator with Bracketry to measure

Copyright  2004, Ford Motor Company

1. NOTE: Camshaft journals must be within

Copyright  2004, Ford Motor Company

1. Measure each of the crankshaft main bearing

Copyright  2004, Ford Motor Company

1. Measure each of the crankshaft main bearing

Copyright  2004, Ford Motor Company

1. Remove the crankshaft main bearing caps and

2. Lay a piece of Plastigage across the face of

Copyright  2004, Ford Motor Company

1. Measure the crankshaft end play. Use a Dial

2. Position the crankshaft to the rear of the

3. Zero the indicator.

Copyright  2004, Ford Motor Company

1. NOTE: Crankshaft main bearing journals must