Continental 2000-2002

Engine 2

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Overhaul



Keeping It Maintained

Now that you have just gone through all of that hard work, keep yourself from doing it all over again by thoroughly maintaining it. Not that you may not have maintained it before, heck you could have had one to two hundred thousand miles on it before doing this. However, you may have bought the vehicle used, and the previous owner did not keep up on maintenance. Which is why you just went through all of that hard work. See-



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Removal & Installation




NOTE
Disable the air suspension before raising the vehicle. The switch is located on the left side of the luggage compartment.

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Turn the air suspension switch to the OFF position.
  4.  
  5. Recover the A/C refrigerant.
  6.  
  7. Drain the cooling system.
  8.  
  9. Remove or disconnect the following:

    Negative battery cable
     
    Hood
     
    Steering column intermediate shaft
     
    Engine appearance cover
     
    Intake Air Temperature (IAT) sensor connector
     
    Air cleaner outlet tube
     
    Upper motor mount
     
    Fuel line
     
    Dash panel ground straps
     
    Powertrain Control Module (PCM) connector
     
    Mass Air Flow (MAF) sensor connector
     
    Traction control motor connector
     
    Throttle Position (TP) sensor connector
     
    Cruise control cable
     
    Accelerator cable and bracket
     
    Shift selector cable
     
    Engine control wiring harness (3 connectors) and bracket
     
    Intake manifold vacuum lines
     
    Transaxle cooler lines
     
    Power steering return hose at the fluid reservoir
     
    Alternator wiring harness
     
    Radiator splash shield
     
    Heater hoses
     
    Radiator hoses
     
    Front wheels
     
    Suspension height sensor links
     
    Lower ball joints
     
    Stabilizer bar links
     
    Outer tie rod ends
     
    Halfshafts
     
    Heated Oxygen (HO 2 S) sensor connectors
     
    Dual converter Y-pipe
     
    Block heater connector
     
    Power steering cooler lines
     
    A/C compressor lines
     
    Starter motor
     
    Subframe brackets
     
    Torque converter shield and torque converter
     

  10.  
  11. Support the powertrain from below and remove the subframe bolts.
  12.  
  13. Raise the vehicle away from the powertrain.
  14.  
  15. Attach an engine hoist to the powertrain.
  16.  
  17. Remove or disconnect the following:

    Power steering sensor connector
     
    Power steering return line from the steering gear
     
    Turbine shaft speed sensor connector
     
    Transaxle range sensor connector
     
    Transaxle control harness connector
     
    Left and right engine support insulators
     
    Right engine support insulator bracket
     

  18.  
  19. Remove the transaxle flange bolts and separate the engine from the transaxle.
  20.  

To install:


NOTE
When installing suspension components and halfshafts, use new nuts, bolts, circlips and split pins.

  1. Install or connect the following:

    Transaxle. Tighten the flange bolts to 25-34 ft. lbs. (34-46 Nm).
     
    Right engine support insulator bracket. Tighten the bolts to 16-21 ft. lbs. (22-29 Nm).
     
    Left and right engine support insulators. Tighten the through-bolts to 64-88 ft. lbs. (87-119 Nm).
     
    Transaxle control harness connector
     
    Transaxle range sensor connector
     
    Turbine shaft speed sensor connector
     
    Power steering return line from the steering gear
     
    Power steering sensor connector
     

  2.  
  3. Lower the vehicle on to the powertrain assembly. Use 2 pieces of 3 / 4 inch outside diameter pipe in the alignment holes behind the front subframe mounts to align the subframe to the body. Tighten the subframe mounting bolts to 57-76 ft. lbs. (77-103 Nm).
  4.  
  5. Install or connect the following:

    Torque converter shield and torque converter. Tighten the torque converter nuts to 20-34 ft. lbs. (27-46 Nm).
     
    Subframe brackets
     
    Starter motor
     
    A/C compressor lines
     
    Power steering cooler lines
     
    Block heater connector
     
    Dual converter Y-pipe
     
    HO 2 S sensor connectors
     
    Halfshafts. Tighten the hub retainer nuts to 170-202 ft. lbs. (230-275 Nm).
     
    Outer tie rod ends. Tighten the nuts to 35-46 ft. lbs. (47-63 Nm).
     
    Stabilizer bar links. Tighten the nuts to 30-40 ft. lbs. (40-55 Nm).
     
    Lower ball joints. Tighten the nuts to 50-68 ft. lbs. (68-92 Nm).
     
    Suspension height sensor links
     
    Front wheels
     
    Radiator hoses
     
    Heater hoses
     
    Radiator splash shield
     
    Alternator wiring harness
     
    Power steering return hose at the fluid reservoir
     
    Transaxle cooler lines
     
    Intake manifold vacuum lines
     
    Engine control wiring harness (3 connectors) and bracket
     
    Shift selector cable
     
    Accelerator cable and bracket
     
    Cruise control cable
     
    TP sensor connector
     
    Traction control motor connector
     
    MAF sensor connector
     
    PCM connector
     
    Dash panel ground straps
     
    Fuel line
     
    Upper motor mount
     
    Air cleaner outlet tube
     
    IAT sensor connector
     
    Engine appearance cover
     
    Steering column intermediate shaft
     
    Hood
     
    Negative battery cable
     

  6.  
  7. Fill the cooling system.
  8.  
  9. Check and adjust fluid levels as necessary.
  10.  
  11. Recharge the A/C system.
  12.  
  13. Turn the air suspension switch to the ON position.
  14.  
  15. Run the engine and check for leaks.
    NOTE
    Whenever the subframe is removed or lowered, the wheel alignment should be checked.

  16.  

In the process of removing the engine, you will come across a number of steps which call for the removal of a separate component or system, such as "disconnect the exhaust system" or "remove the radiator." In most instances, a detailed removal procedure can be found elsewhere in this product.

It is virtually impossible to list each individual wire and hose which must be disconnected, simply because so many different model and engine combinations have been manufactured. Careful observation and common sense are the best possible approaches to any repair procedure.

Removal and installation of the engine can be made easier if you follow these basic points:



If you have to drain any of the fluids, use a suitable container.
 
Always tag any wires or hoses and, if possible, the components they came from before disconnecting them.
 
Because there are so many bolts and fasteners involved, It is wise to store, and label the retainers from components separately in marked containers, jars, or coffee cans. This will prevent confusion during installation.
 
After unbolting the transmission or transaxle, always make sure it is properly supported.
 
If it is necessary to disconnect the air conditioning system, have this service performed by a qualified technician using a recovery/recycling station. If the system does not have to be disconnected, unbolt the compressor and set it aside.
 
When unbolting the engine mounts, always make sure the engine is properly supported. When removing the engine, make sure that any lifting devices are properly attached to the engine. It is recommended that if your engine is supplied with lifting hooks, your lifting apparatus be attached to them.
 
Lift the engine from its compartment slowly, checking that no hoses, wires, or other components are still connected.
 
After the engine is clear of the compartment, place it on an engine stand or workbench.
 
After the engine has been removed, you can perform a partial or full teardown of the engine using the procedures outlined herein.
 


NOTE
Label all wiring, vacuum hoses, fuel lines, etc. before disconnecting them; making installation much easier. Be sure to disable the air suspension systems where applicable.


NOTE
If your vehicle is equipped with air conditioning, refer to Section 1 for information regarding the implications of servicing your A/C system yourself. Only an MVAC-trained, EPA-certified, automotive technician should service the A/C system or its components.


CAUTION
Never open, service, or drain the radiator or cooling system when hot; serious burns can occur from the steam and hot coolant. In addition, when draining engine coolant, keep in mind that cats and dogs are attracted to ethylene glycol antifreeze and could drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantities. Always drain coolant into a sealable container. Coolant should be reused unless it is contaminated or is several years old.


CAUTION
Observe all applicable safety precautions when working around fuel. Whenever servicing the fuel system, always work in a well-ventilated area. Do not allow fuel spray or vapors to be exposed to a spark or open flame. Keep a dry chemical fire extinguisher near the work area. Always keep fuel in a container specifically designed for fuel storage; also, always properly seal fuel containers to avoid the possibility of fire or explosion.

3.8L Engine

NOTE
If your vehicle is equipped with air conditioning, refer to Section 1 for information regarding the implications of servicing your A/C system yourself. Only an MVAC-trained, EPA-certified, automotive technician should service the A/C system or its components.

  1. Turn off or disable the air suspension system.
  2.  
  3. Drain the cooling system, then disconnect the negative battery cable.
  4.  
  5. Properly relieve the fuel system pressure. For details, please refer to the procedure located in Section 5 of this manual.
  6.  
  7. Disengage the underhood light wiring connector. Matchmark the position of the hood hinges, then remove the hood.
  8.  
  9. Remove the oil level indicator tube.
  10.  
  11. Disconnect the alternator-to-voltage regulator wiring assembly if equipped.
  12.  
  13. Remove the radiator upper sight shield.
  14.  
  15. Remove the Integrated Relay Controller Module (IRCM) and the bracket retaining bolts, then position the IRCM and bracket out of the way.
  16.  



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Fig. Pointing to the IRCM, partially hidden under the radiator frame near the battery

  1. Remove the air cleaner assembly.
  2.  



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Fig. One screw at the base of the air cleaner holds the entire assembly in place



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Fig. Lifting the air cleaner assembly out as an assembly

  1. Disconnect the cooling fan motor and the front center radiator primary-crash-sensor wire connectors, if equipped.
  2.  
  3. Remove the cooling fan motor/fan blade and fan shroud assembly.
  4.  



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Fig. The fan shroud and fan comes out as an assembly

  1. Remove the upper radiator hose.
  2.  
  3. Disconnect and plug the transaxle oil cooler inlet and outlet tubes to prevent dirt and grease from entering the tubes. Disconnect the heater hoses.
  4.  
  5. Disconnect the power steering pressure hose assembly.
  6.  
  7. Disconnect the engine control sensor wiring from the A/C clutch field coil. Discharge the A/C system using the proper equipment, then disconnect the compressor-to-condenser discharge line.
  8.  
  9. Remove the radiator coolant recovery reservoir assembly. Remove the wiring shield from the throttle body.
  10.  
  11. Remove the accelerator cable-mounting bracket.
  12.  
  13. Disconnect the fuel supply and return lines.
  14.  
  15. Disconnect the power steering pump pressure hose from the bracket.
  16.  
  17. Disconnect the fuel charging wiring from the engine control sensor wiring assembly.
  18.  
  19. Identify, tag, and disconnect all necessary vacuum hoses.
  20.  
  21. Disconnect the ground wire assembly. Remove the air cleaner outlet tube.
  22.  
  23. Disconnect one end of the throttle control valve cable. Detach the bulkhead electrical connector and transaxle pressure switches.
  24.  
  25. Remove the transaxle support assembly retaining bolts, then remove the transaxle support assembly from the vehicle.
  26.  
  27. Raise and safely support the vehicle. Remove the wheel and tire assemblies.
  28.  
  29. Position a drain pan under the car's oil pan, then drain the engine oil and remove the filter. Move the drain pan out of the way.
  30.  
  31. Disconnect the heated oxygen sensor.
  32.  
  33. Loosen and remove the drive belt. Remove the crankshaft pulley and drive belt tensioner assemblies.
  34.  
  35. Remove the starter motor. For details, please refer to the procedure located earlier in this section.
  36.  
  37. Remove the dual converter Y-pipe retaining bolts, then remove the Y-pipe.
  38.  
  39. Remove the left and right front engine support (motor mount) insulator-to-front subframe retaining nuts.
  40.  
  41. If equipped, remove the engine rear cover, then remove the converter-to-flywheel nuts.
  42.  
  43. Disconnect the engine control sensor wiring from the low oil level sensor. Remove the crankshaft pulley and damper assembly.
  44.  
  45. Disconnect the lower radiator hose.
  46.  
  47. Remove the engine-to-transaxle bolts and partially lower the vehicle. Remove the front wheel and tire assemblies.
  48.  
  49. Unfasten the water pump pulley retaining bolts.
  50.  
  51. Remove the distributor cap and position aside, then pull out the distributor rotor.
  52.  
  53. Remove the radiator.
  54.  
  55. Unfasten the exhaust manifold bolt lock retaining bolts. Remove the thermactor air pump retaining bolts and the thermactor air pump.
  56.  
  57. Disconnect the engine control sensor wiring from the oil pressure sensor.
  58.  
  59. Install Engine Lifting Eyes, then position, and install suitable engine lifting equipment.
  60.  



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Fig. Be sure to use a block of wood to protect the bottom of the engine

  1. Position a suitable jack under the transaxle and raise the transaxle slightly, then remove the water pump pulley.
  2.  



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Fig. With the engine slightly raised the water pump pulley is removable

  1. Carefully remove the engine from the vehicle.
  2.  



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Fig. Flex sockets are a big help here. Only remove the lower nut to remove the engine



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Fig. Just remove the lower nut to pull the engine. Once the engine is out you can easily get the top bolt on the motor mount

To install:


NOTE
Lightly oil all bolt and stud threads before installation, except those specifying special sealant.

  1. Position the engine assembly in the vehicle.
  2.  
  3. Install the engine-to-transaxle bolts, then remove the jack from under the transaxle, and remove the engine lifting equipment. Remove the engine lifting eyes. Place all lifting equipment aside and out of the way.
  4.  
  5. Tighten the engine-to-transaxle bolts to 41-50 ft. lbs. (55-68 Nm).
  6.  
  7. Engage the engine control sensor wiring to the oil pressure sensor.
  8.  
  9. Install the air conditioning compressor and tighten the retaining bolts to 30-45 ft. lbs. (41-61 Nm). Connect the compressor-to-condenser discharge line.
  10.  
  11. Connect the A/C clutch field coil to the engine control sensor wiring.
  12.  
  13. Fasten the heater hoses and the fuel supply and return hoses, then connect the vacuum hoses.
  14.  
  15. Connect the engine control module wiring assembly.
  16.  
  17. Attach the transaxle oil cooler inlet and outlet tubes.
  18.  
  19. Install the radiator assembly.
  20.  
  21. Partially raise and safely support the vehicle.
  22.  
  23. Install the converter-to-flywheel nuts/bolts and tighten to 20-34 ft. lbs. (27-46 Nm).
  24.  
  25. Install the left and right front engine supports, then install the engine rear plate.
  26.  
  27. Install the starter motor. For details, please refer to the procedure located earlier in this section.
  28.  
  29. Connect the lower radiator hose.
  30.  
  31. Install the drive belt-tensioner assembly and the crankshaft pulley and vibration damper assembly. Tighten the crankshaft pulley retaining bolts to 20-28 ft. lbs. (27-38 Nm).
  32.  
  33. Install the dual converter Y-pipe, then connect the engine control sensor wiring to the heated exhaust gas oxygen sensor.
  34.  
  35. Install the oil filter, and then connect the engine control sensor wiring to the low oil level sensor.
  36.  
  37. Carefully lower the vehicle.
  38.  
  39. Position the thermactor air supply pump and install the retaining bolts.
  40.  
  41. Connect the vacuum pump and install the exhaust air supply pump pulley assembly.
  42.  
  43. Install the wiring shield.
  44.  
  45. Install the distributor cap and rotor.
  46.  
  47. Install the radiator reservoir /coolant recovery assembly, upper radiator hose, and water pump pulley.
  48.  
  49. Connect the alternator-to-voltage regulator wiring assembly, then fasten the fuel charging wiring to the engine control sensor wiring.
  50.  
  51. Connect the wiring assembly ground.
  52.  
  53. Install the accelerator cable-mounting bracket.
  54.  
  55. Connect the power steering pressure hose assembly and the power steering return hose.
  56.  
  57. Install the cooling fan motor/fan blade and the fan shroud assembly.
  58.  
  59. Connect the cooling fan motor and the front center radiator primary crash-sensor wire connectors.
  60.  
  61. Install the IRCM relay and bracket. Make sure to tighten the retainers securely.
  62.  
  63. Install the drive belts.
  64.  
  65. Position and install the engine and transaxle support assembly.
  66.  
  67. Install the radiator upper sight shield.
  68.  
  69. Partially raise and safely support the vehicle. Install the wheel and tire assemblies, then tighten the lug nuts to 85-105 ft. lbs. (115-142 Nm).
  70.  
  71. Carefully lower the vehicle.
  72.  
  73. Install the hood, using the aligning marks made during removal, and connect the negative battery cable.
  74.  
  75. Fill the cooling system with the proper type and quantity of coolant. Fill the crankcase with the proper type and viscosity of motor oil to the required level.
  76.  
  77. Have a MVAC certified evacuate, pressure test and recharge the A/C system, using the proper equipment.
  78.  
  79. Start the engine and check for leaks.
  80.  

4.6L Engine

NOTE
The Front Wheel Drive 4.6L Engine has to be removed with the transaxle intact mounted onto the sub-frame as an assembly. It requires the use of a hoist and a special lifting platform to lower the assembly from the body.


NOTE
Your vehicle is equipped with air conditioning, refer to Section 1 for information regarding the implications of servicing your A/C system yourself. Only an MVAC-trained, EPA-certified, automotive technician should service the A/C system or its components.

  1. Disconnect the negative battery cable.
  2.  
  3. Disconnect the steering coupling at the pinch bolt joint inside the passenger compartment
  4.  
  5. Remove the engine appearance cover retainers and remove the engine appearance cover from the vehicle.
  6.  
  7. Disconnect the engine control sensor wiring from the intake air temperature sensor and the crankcase ventilation tube from the air cleaner outlet tube. Loosen the clamps on the air cleaner outlet tube to the engine air cleaner and the throttle body. Remove the air cleaner outlet tube.
  8.  
  9. Drain and recycle the engine coolant.
  10.  
  11. Properly relieve the fuel system pressure.
  12.  
  13. Disconnect the fuel tubes from the fuel injection supply manifold.
  14.  
  15. Disconnect the chassis vacuum supply hose at the connection on the intake manifold. Position the hose out of the way.
  16.  
  17. Remove the ground straps from the dash panel.
  18.  
  19. Disconnect the engine control sensor wiring from the powertrain control module and position the engine control sensor wiring out of the way.
  20.  
  21. Remove the connectors for the engine control sensor wiring from the retaining bracket on the power brake booster. Disconnect the engine control sensor wiring at the two connectors
  22.  
  23. Disconnect the engine control sensor wiring from the mass air flow sensor, and the wiring from the evaporative emission canister purge valve.
  24.  
  25. Disconnect the evaporative emission hose at the crankcase vent connector and position it out of the way.
  26.  
  27. Remove the shield and disconnect the throttle and speed control cables from the throttle body and from the cable bracket. Move them out of the way.
  28.  
  29. Disconnect the manual lever control at the transmission range sensor.
  30.  
  31. Remove and disconnect the connectors from the engine control sensors wiring bracket from the top of the transaxle
  32.  
  33. Disconnect the main emission vacuum control connector at the connection near the fan shroud
  34.  
  35. Disconnect the oil cooler inlet tube from the transaxle. Remove the dipstick.
  36.  
  37. Disconnect the heater hoses and upper radiator hose.
  38.  
  39. Remove the power steering return hose and drain the reservoir.
  40.  
  41. Disconnect the wiring harness from the generator, and remove the retaining clip.
  42.  
  43. Partially raise the vehicle on a hoist, and remove the front tire assemblies
  44.  
  45. Disconnect the ride height sensors, if equipped, from the lower suspension arms.
  46.  
  47. Remove the stabilizer bar links from the front stabilizer bar.
  48.  
  49. Separate the RH and LH front suspension lower arms from the knuckles at the ball-joints.
  50.  
  51. Separate the tie rod ends from the steering knuckles.
  52.  
  53. Remove the RH and LH front axle wheel hub retainers from the halfshaft ends, and remove the halfshafts from the front wheel knuckle.
  54.  
  55. Raise the vehicle and remove the splash shield from the radiator support and from the front sub-frame.
  56.  
  57. Drain the engine oil.
  58.  
  59. Remove the dual converter Y pipe.
  60.  
  61. Disconnect the power steering pressure hose from the cooler connection and position it out of the way. Be sure to catch any fluid that may leak from the hose.
  62.  
  63. Disconnect the lower radiator hose at the thermostat housing and remove the lower hose.
  64.  
  65. Disconnect the starter wiring and remove the starter.
  66.  
  67. Disconnect the lower oil cooler from the transaxle.
  68.  
  69. Disconnect the retaining clips and the A/C compressor lines.
  70.  
  71. Support the front sub-frame, (engine and transaxle assembly), using a suitable powertrain lift.
  72.  
  73. Remove the front sub-frame retaining bolts, and lower the engine transaxle and front sub-frame from the vehicle.
  74.  
  75. Disconnect the power steering pressure hose from the power steering pump.
  76.  
  77. Install the necessary engine lifting brackets to the engine, and using a suitable crane, support the engine and transaxle assembly.
  78.  
  79. Remove the front engine support insulator, rear engine support insulator, (motor mounts) and the engine and transmission support.
  80.  
  81. Lift the engine and transaxle from the front sub-frame.
  82.  
  83. Lower the engine and transaxle support the transaxle on a level, stationary surface. Remove the transaxle-to-cylinder block mounting bolts and separate the engine from the transaxle assembly.
  84.  

To install:

Installation is the reversal of the removal procedures

 
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