Lincoln Mark VIII V8-281 4.6L DOHC
     
Replacement Procedure
1. Turn off air ride system (switch is located in trunk on LH side of compartment).

2. Place vehicle on hoist.

3. Windshield Wiper Motor Module Assembly Removal:

a. Turn ignition to "RUN" position.

b. Cycle wipers to mid-wipe position (blades straight up).

c. Turn ignition off.

d. Remove battery.

e. Remove LH and RH wiper arms.

f. Remove cowl top-to-hood seal.

g. Remove LH and RH cowl vent screens.

 

h. Remove seven (7) retaining screws and washers and cowl top extension (Figure 1).

 

i. Remove five (5) retaining bolt/washer assemblies and one (1) nut from the wiper module (Figure 2).

j. Disconnect the two (2) wiring connectors from the motor.

k. Lift module slightly to disengage the support bracket from the dash panel mounting stud.

l. Move the module sideways about 2" (50 mm) toward the passenger side and remove the module.

4. Preparation for Cylinder Front Cover Removal:

 

a. Remove engine appearance cover (Figure 3).

 

b. Remove engine air cleaner outlet tube and resonator assembly (Figure 4).

c. Disconnect throttle cables from bracket on engine.

d. Loosen water pump pulley bolts.

e. Remove accessory drive belt.

f. Drain cooling system and remove the coolant bypass hose and upper radiator hose from the coolant crossover tube.

NOTE :HOSE CLAMPS MUST BE PLACED IN SAME POSITION DURING REINSTALLATION.

g. Remove water pump pulley and lower water pump-to-cylinder block retaining bolt for front cover removal clearance.

h. Remove two (2) bolts and one (1) stud retaining power steering pump reservoir to LH coil bracket.

i. Remove radiator cooling fan shroud.

j. Remove coolant overflow hose from coolant reservoir.

k. Raise vehicle on hoist.

l. Using Steering Pump Pulley Remover (T69L-10300-B), remove power steering pump pulley to provide access to the front lower pump mounting bolt.

m. Remove bolts retaining power steering pump to engine block and cylinder front cover and move pump out of the way.

NOTE :THE FRONT LOWER BOLT ON THE POWER STEERING PUMP WILL NOT COME ALL THE WAY OUT.

n. Remove four (4) bolts retaining the oil pan to the front cover.

o. Remove crankshaft damper retaining bolt and washer from crankshaft.

p. Lower vehicle.

q. Using Front Damper Puller (T58P-6316-D), remove the damper pulley from the crankshaft.

r. Remove the strut appearance cover from LH fender apron next to the power distribution box.

s. Remove bolt retaining the main harness to the front engine cover.

t. Loosen the power distribution box and bracket.

u. Leaving the brake lines attached, remove three (3) nuts securing the brake master cylinder and wire harness bracket to the vacuum brake booster. Move master cylinder away from the booster and secure off to the side, away from the LH cam cover.

v. Remove two (2) bolts retaining the main harness to the lower portion of the cylinder front cover.

 

w. Disconnect the fuel injector wiring harness at the 42-pin connector (Figure 5).

x. Disconnect the vacuum hose from the brake vacuum booster.

 

5. Cam Cover Removal, LH Side (Figure 6):

a. Remove PCV valve from cam cover grommet.

b. Remove two (2) nuts retaining EGR control bracket and vacuum hose clip; position valve/bracket assembly out of the way.

c. Remove nut retaining the oil dipstick tube to the LH cam cover.

d. Move tube out of the way, but do not remove tube from engine.

e. Remove four (4) nuts retaining the ignition wire cover and remove cover.

f. Disconnect ignition wires from spark plugs.

g. Remove bolts retaining the LH and RH coil brackets to the front cover.

h. Move coil assemblies out of the way, leaving the plug wires attached to the coils.

i. Remove seven (7) bolts and three (3) stud bolts retaining cam cover to the cylinder head.

j. Remove cam cover.

NOTE :THE CAM COVER CAN BE VERY DIFFICULT TO REMOVE DUE TO LIMITED SPACE IN THE ENGINE COMPARTMENT. DO NOT TRY TO FORCE THE CAM COVER DURING REMOVAL.

6. Cam Cover Removal, RH Side (Figure 6)

a. Remove two (2) retaining nuts from engine air cleaner outlet support bracket to cam cover and remove bracket.

b. Remove four (4) nuts retaining the ignition wire cover and remove cover.

c. Remove eight (8) bolts and two (2) stud bolts retaining cam cover to the cylinder head.

d. Remove cam cover.

NOTE :THE CAM COVER CAN BE VERY DIFFICULT TO REMOVE DUE TO LIMITED SPACE IN THE ENGINE COMPARTMENT. DO NOT TRY TO FORCE THE CAM COVER DURING REMOVAL.

NOTE :AFTER REMOVING BOTH CAM COVERS, CHECK BOTH CAM COVERS TO ENSURE THE SPARK PLUG TOWER SEALS ARE IN PLACE. THESE SEALS MAY COME OFF DURING DISASSEMBLY DUE TO CAM COVER HANDLING.

 

7. Engine Front Cover Removal (Figure 7):

a. Disconnect the camshaft position sensor.

b. Remove bolt retaining accessory drive belt idler pulley and remove the pulley.

c. Remove accessory drive belt tensioner from front cover. This step is to provide clearance to the A/C lines for front cover removal / installation.

d. Disconnect the crankshaft position sensor.

e. Remove seven (7) studs and eight (8) bolts retaining the front cover to the block (Figure 7).

f. Remove front cover.

g. Remove ignition pulse sensor ring from crankshaft.

8. Preparation Steps for Secondary Tensioner Replacement:

a. Install damper bolt and washer into the nose of the crankshaft and tighten.

b. Rotate the crankshaft to # 1 firing T.D.C. (timing marks on the primary cam sprockets must be on the top of the sprockets).

c. Turn the crankshaft another 45 degrees until the crank key is in the 12 o'clock position (straight up, pointing at the water pump).

d. Using a paint pen or other suitable marking device, paint the link of the primary timing chain that is next to the cam sprocket timing mark on both the RH and LH cam sprockets.

9. LH Secondary Tensioner Replacement:

NOTE :THE REPLACEMENT PROCEDURE FOR THE LEFT HAND SECONDARY TENSIONER HAS UNIQUE STEPS FROM THE RIGHT HAND SECONDARY TENSIONER PROCEDURE.

 

a. Insert the Tensioner Tool (T93P-6256-BH) between the upper and lower rubbing blocks of the LH secondary tensioner. Rotate the knob on the top of the tensioning tool until spring pressure is applied onto the tensioner and the knob on tool rotates freely (Figure 8).
b. Install Camshaft Holding Tool (T93P-6256-AH) onto the machined centers of both the intake and exhaust camshafts on the LH side.

c. Torque the four (4) clamping bolts on the Camshaft Holding Tool evenly to 15 lb-ft (20 N-m).

CAUTION :FAILURE TO TIGHTEN THE HOLDING TOOL PROPERLY MAY ALLOW THE CAMSHAFTS TO SLIP POSITION. IF THIS OCCURS, THE CAMS WILL NEED TO BE RE-TIMED.

NOTE :THE CAMSHAFT AND CAMSHAFT SPROCKETS ARE NOT KEYED TOGETHER. THE KEYWAYS IN THE CAMSHAFT AND CAMSHAFT SPROCKETS ARE FOR PRODUCTION PURPOSES ONLY, NO KEYS ARE INSTALLED IN THE KEYWAYS.

d. Remove the spring-loaded tensioning tool from the LH secondary tensioner.

 

e. Unlock the LH Primary Tensioner Ratcheting Device (using a small pick or similar tool, hold ratchet lock mechanism away from ratchet stem, Figure 9).

f. Slowly compress primary tensioner piston in small increments with minimal force (Figure 9).

CAUTION :TENSIONER MUST BE COMPRESSED SLOWLY OR RUPTURE OF TENSIONER BODY CASTING WILL RESULT FROM EXCESSIVE HYDRAULIC PRESSURE. FAILURE TO RELEASE RATCHET LOCK MECHANISM WHILE COMPRESSING PISTON WILL RESULT IN RATCHET DAMAGE.


h. Insert the pre-made wooden wedge (Figure 14) as shown in Figure 10 to hold the primary timing chain in position.

i. Using a breaker bar and socket (do not use power impact tools), smoothly loosen the intake cam timing sprocket bolt and remove the bolt, washer, and spacer.

CAUTION :DO NOT USE A POWER IMPACT WRENCH TO LOOSEN THE INTAKE CAM TIMING BOLT. USING A POWER IMPACT WRENCH WILL CAUSE THE CAMSHAFT TO SLIP IN ITS HOLDING FIXTURE.

j. Using a breaker bar and socket (do not use power impact tools), smoothly loosen the primary timing chain sprocket bolt and remove the bolt and washer.

CAUTION :DO NOT USE A POWER IMPACT WRENCH TO LOOSEN THE PRIMARY TIMING CHAIN SPROCKET BOLT. USING A POWER IMPACT WRENCH WILL CAUSE THE CAMSHAFT TO SLIP IN ITS HOLDING FIXTURE.

k. Keep the timing chain on the sprocket and let the chain and sprocket hang to the side.

l. Compress the secondary tensioner and remove the secondary sprockets and timing chain.

m. Remove two (2) secondary tensioner attaching bolts and remove the tensioner assembly.

n. Install new Secondary Cam Chain Tensioner (F5LY-6K254-B), torquing the two (2) attaching bolts to 6-9 lb.ft. (8-12 N-m).

o. Reinstall secondary timing sprockets and chain with the hubs on the sprockets facing the cylinder head.

p. Pull the locking pin from the new secondary tensioner.

q. Reinstall the primary sprocket and chain, ensuring the paint mark on the timing chain is still next to the timing mark in the primary sprocket.

r. Install the exhaust cam sprocket bolt and washer until snug and then loosen the bolt two (2) complete revolutions.

s. Insert the Tensioner Tool (T93P-6256-BH) between the upper and lower rubbing blocks of the secondary tensioner.

t. Rotate the knob on top of the tensioning tool until spring pressure is applied onto the tensioner and the knob on the tool rotates freely.

u. Remove the wooden wedge from the primary timing chain.

v. Pull the locking pin from the primary tensioner.

w. Tighten and torque the exhaust cam sprocket bolt to 89-96 lb-ft (120-130 N-m).

x. Tighten and torque the intake cam sprocket bolt to 89-96 lb-ft (120-130 N.m).

y. Remove the tensioning tool from the LH secondary tensioner.

z. Remove the Camshaft Holding Tool.

10. RH Secondary Tensioner Replacement:

NOTE :THE REPLACEMENT PROCEDURE FOR THE RIGHT HAND SECONDARY TENSIONER HAS UNIQUE STEPS FROM THE LEFT HAND SECONDARY TENSIONER PROCEDURE.

a. Insert the Tensioner Tool (T93P-6256-BH) between the upper and lower rubbing blocks of the RH secondary tensioner. Rotate the knob on the top of the tensioning tool until spring pressure is applied onto the tensioner and the knob on tool rotates freely (Figure 8).

b. Install Camshaft Holding Tool (T93P-6256-AH) onto the machined centers of both the intake and exhaust camshafts on the RH side.

c. Torque the four (4) clamping bolts on the Camshaft Holding Tool (T93P-6256-AH) evenly to 15 lb.ft. (20 N-m).

CAUTION :FAILURE TO TIGHTEN THE HOLDING TOOL PROPERLY MAY ALLOW THE CAMSHAFTS TO SLIP POSITION. IF THIS OCCURS, THE CAMS WILL NEED TO BE RE-TIMED.

NOTE :THE CAMSHAFT AND CAMSHAFT SPROCKETS ARE NOT KEYED TOGETHER. THE KEYWAYS IN THE CAMSHAFT AND CAMSHAFT SPROCKETS ARE FOR PRODUCTION PURPOSES ONLY, NO KEYS ARE INSTALLED IN THE KEYWAYS.

d. Remove the spring-loaded tensioning tool from the RH secondary tensioner.

e. Unlock the RH primary tensioner ratcheting device (using a small pick or similar tool, hold ratchet lock mechanism away from ratchet stem, Figure 9)

f. Slowly compress primary tensioner piston in small increments with minimal force.

g. Lock the primary tensioner ratcheting device with a small pin (e.g., paper clip) once the tensioner is fully compressed.

h. Insert the pre-made wooden wedge (Figure 14) as shown in Figure 10 to hold the primary timing chain in position.

i. Using a breaker bar and socket (do not use power impact tools), smoothly loosen the primary timing chain sprocket bolt and remove the bolt, washer, and spacer.

CAUTION :DO NOT USE A POWER IMPACT WRENCH TO LOOSEN THE PRIMARY TIMING CHAIN SPROCKET BOLT. USING A POWER IMPACT WRENCH WILL CAUSE THE CAMSHAFT TO SLIP IN ITS HOLDING FIXTURE.

j. Keep the timing chain on the sprocket and let the chain and sprocket hang to the side.

k. Compress the secondary tensioner.

l. Remove two (2) secondary tensioner attaching bolts and remove the tensioner assembly.

NOTE :DO NOT REMOVE THE SECONDARY TIMING CHAIN.

m. Install new Secondary Cam Chain Tensioner (F5LY-6K254-A), torquing the two (2) attaching bolts to 6-9 lb-ft (8-12 N-m).

n. Pull the locking pin from the new secondary tensioner.

0. Reinstall the primary sprocket and chain, ensuring the paint mark on the timing chain is still next to the timing mark in the primary sprocket.

p. Install the exhaust cam sprocket bolt until snug and then loosen the bolt two (2) complete revolutions.

q. Insert the Tensioner Tool (T93P-6256-BH) between the upper and lower rubbing blocks of the secondary tensioner.

r. Rotate the knob on top of the tensioning tool until spring pressure is applied onto the tensioner and the knob on the tool rotates freely.

s. Remove the wooden wedge from the primary timing chain.

t. Pull the locking pin from the primary tensioner.

u. Tighten and torque the exhaust cam sprocket bolt to 89-96 lb-ft (120-130 N-m).

v. Remove the tensioning tool from the RH secondary tensioner.

w. Remove the Camshaft Holding Tool.

x. Remove crankshaft damper bolt and washer from crankshaft.

y. Install ignition pulse sensor ring on crankshaft.

 

Reassembly Procedure

1. Engine Front Cover Installation:

a. Carefully clean sealing surfaces of the block, heads and front cover (use a suitable solvent (e.g., D-Limonene) and, if needed, a plastic tipped scraper). Refer to TSB 93-23-14 for additional procedures / information.

CAUTION :WHEN REMOVING RTV SILICONE SEALANT FROM THE OIL PAN TO CYLINDER BLOCK JOINTS, BE EXTREMELY CAREFUL NOT TO CUT OR TEAR THE SILICONE BEAD ON THE OIL PAN CARRIER GASKET. IF A LEAK SHOULD DEVELOP IN THIS AREA AFTER REASSEMBLY, THE OIL PAN MUST BE REMOVED AND THE OIL PAN GASKET REPLACED.

b. Replace front cover gaskets.

 

c. Apply RTV Silicone Gasket and Sealant (F1AZ-19562-A, or equivalent) in the six (6) locations shown in Figure 11.

d. Install seven (7) studs and eight (8) bolts retaining the front cover to the engine.

e. Torque, in sequence (Figure 12), the engine front cover bolts to 15-22 lb-ft (20-30 N-m).

f. Install lower water pump bolt.

g. Torque water pump bolt to 15-22 lb-ft (20-30 N-m).

h. Connect crank position sensor.

i. Apply RTV Silicone Gasket and Sealant (F1AZ-19562-A, or equivalent) in the keyway of the crankshaft damper pulley.

j. Position damper pulley on crankshaft. Ensure key and keyway are lined up.

k. Using Crankshaft Damper Replacer (T74P-6316-B), install the damper pulley.

CAUTION :DO NOT USE THE CRANKSHAFT BOLT TO INSTALL THE DAMPER PULLEY. USING THE CRANKSHAFT BOLT COULD DAMAGE THE BOLT AND/OR THE DAMPER PULLEY.

l. Install crankshaft damper pulley bolt and washer.

m. Torque the crankshaft damper pulley bolt to 114-121 lb.ft. (155-165 N-m).

n. Raise vehicle on hoist.

0. Install four (4) bolts retaining the oil pan to the front cover.

p. Tighten the oil pan-to-front cover bolts to 15-22 lb.ft. (20-30 N-m).

q. Position power steering pump on the engine.

r. Tighten the power steering pump bolts to 15-22 lb.ft. (20-30 N-m).

5. Using Steering Pump Pulley Replacer (T91P-3A733-A), install power steering pump pulley.

t. Lower vehicle.

2. Left Side Cam Cover Installation:

a. Carefully clean sealing surfaces of the cylinder head and cam cover (use a suitable solvent (e.g., D-Limonene) and, if needed, a plastic tipped scraper). Refer to TSB 93-23-14 for additional procedures / information.

b. Using Loctite Super Bonder # 414 adhesive (obtain locally), glue the new gasket onto the cam cover. Apply glue in drops spaced about 1" apart.

c. Apply RTV Silicone Gasket and Sealer (F1AZ-19562-A, or equapart.

d. Apply RTV Silicone Gasket and Sealer (F1AZ-19562-A, or equivalent) where the front cover meets the cylinder head.

e. Install left side cam cover onto engine, being careful not to dislodge the spark plug tower seals when installing the cam cover.

NOTE :AFTER THE CAM COVER IS IN PLACE, VERIFY THAT THE SPARK PLUG TOWER SEALS ARE STILL IN PLACE BY LOOKING DOWN THE SPARK PLUG HOLES. IF THE SEALS HAVE FALLEN OFF, REMOVE THE COVER, RESEAT THE SEAL(S), REINSTALL CAM COVER AND VERIFY SEAL LOCATION. LOCTITE ADHESIVE # 414 CAN BE USED TO GLUE THE SEALS TO THE CAM COVER SPARK PLUG TOWERS.

f. Install cam cover retaining bolts and studs.

g. Torque cam cover bolts to 6-9 lb-ft (8-12 N-m).

3. Right Side Cam Cover Installation:

a. Carefully clean sealing surfaces of the cylinder head and cam cover (use a suitable solvent (e.g., D-Limonene) and, if needed, a plastic tipped scraper). Refer to TSB 93-23-14 for additional procedures/information.

b. Using Loctite Super Bonder # 414 adhesive (obtain locally), glue the new gasket onto the cam cover. Apply glue in drops spaced about 1" apart.

c. Apply RTV Silicone Gasket and Sealer (F1AZ-19562-A, or equivalent) where the front cover meets the cylinder head.

d. Install right side cam cover onto engine, being careful not to dislodge the spark plug tower seals when installing the cam cover.

NOTE :AFTER THE CAM COVER IS IN PLACE, VERIFY THAT THE SPARK PLUG TOWER SEALS ARE STILL IN PLACE BY LOOKING DOWN THE SPARK PLUG HOLES. IF THE SEALS HAVE FALLEN OFF, REMOVE THE COVER, RESEAT THE SEAL(S), REINSTALL CAM COVER AND VERIFY SEAL LOCATION. LOCTITE ADHESIVE # 414 CAN BE USED TO GLUE THE SEALS TO THE CAM COVER SPARK PLUG TOWERS.

e. Install cam cover retaining bolts and studs.

f. Torque cam cover bolts to 6-9 lb-ft (8-12 N-m).