engine LINCOLN ZEPHYR 2006 Repair Manual

EPA window sticker
Every new vehicle should have the EPA window sticker. Contact your
authorized dealer if the window sticker is not supplied with your vehicle.
The EPA window sticker should be your guide for the fuel economy
comparisons with other vehicles.
It is important to note the box in the lower left corner of the window
sticker. These numbers represent the Range of MPG (L/100 km)
expected on the vehicle under optimum conditions. Your fuel economy
may vary depending upon the method of operation and conditions.
EMISSION CONTROL SYSTEM
Your vehicle is equipped with various emission control components and a
catalytic converter which will enable your vehicle to comply with
applicable exhaust emission standards. To make sure that the catalytic
converter and other emission control components continue to work
properly:
• Use only the specified fuel listed.
• Avoid running out of fuel.
• Do not turn off the ignition while your vehicle is moving, especially at
high speeds.
• Have the items listed in scheduled maintenance information
performed according to the specified schedule.
The scheduled maintenance items listed in scheduled maintenance
information are essential to the life and performance of your vehicle
and to its emissions system.
If other than Ford, Motorcraft or Ford-authorized parts are used for
maintenance replacements or for service of components affecting
emission control, such non-Ford parts should be equivalent to genuine
Ford Motor Company parts in performance and durability.
Do not park, idle, or drive your vehicle in dry grass or other dry
ground cover. The emission system heats up the engine
compartment and exhaust system, which can start a fire.
Illumination of the indicator, charging system warning light or the
temperature warning light, fluid leaks, strange odors, smoke or loss of
engine power could indicate that the emission control system is not
working properly.
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Exhaust leaks may result in entry of harmful and potentially
lethal fumes into the passenger compartment.
Do not make any unauthorized changes to your vehicle or engine. By
law, vehicle owners and anyone who manufactures, repairs, services,
sells, leases, trades vehicles, or supervises a fleet of vehicles are not
permitted to intentionally remove an emission control device or prevent
it from working. Information about your vehicle’s emission system is on
the Vehicle Emission Control Information Decal located on or near the
engine. This decal identifies engine displacement and gives some tune up
specifications.
Please consult your Warranty Guide for complete emission warranty
information.
On board diagnostics (OBD-II)
Your vehicle is equipped with a computer that monitors the engine’s
emission control system. This system is commonly known as the On
Board Diagnostics System (OBD-II). This OBD-II system protects the
environment by ensuring that your vehicle continues to meet
government emission standards. The OBD-II system also assists your
authorized dealer in properly servicing your vehicle. When the
indicator illuminates, the OBD-II system has detected a malfunction.
Temporary malfunctions may cause the indicator to illuminate.
Examples are:
1. The vehicle has run out of fuel—the engine may misfire or run poorly.
2. Poor fuel quality or water in the fuel.
3. The fuel cap may not have been securely tightened. See Fuel filler
cap in this chapter.
These temporary malfunctions can be corrected by filling the fuel tank
with good quality fuel and/or properly tightening the fuel cap. After three
driving cycles without these or any other temporary malfunctions
present, the indicator should turn off—A driving cycle consists of a
cold engine startup followed by mixed city/highway driving. No additional
vehicle service is required.
If the indicator remains on, have your vehicle serviced at the first
available opportunity.
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Readiness for Inspection/Maintenance (I/M) testing
In some localities, it may be a legal requirement to pass an I/M test of
the on-board diagnostics system. If the
indicator is on, refer to the
description in the Warning lights and chimes section of the
Instrument Cluster chapter. Your vehicle may not pass the I/M test with
the
indicator on.
If the vehicle’s powertrain system or its battery has just been serviced,
the on-board diagnostics system is reset to a “not ready for I/M test”
condition. To ready the on-board diagnostics system for I/M testing, a
minimum of 30 minutes of city and highway driving is necessary as
described below:
• First, at least 10 minutes of driving on an expressway or highway.
• Next, at least 20 minutes driving in stop-and-go, city-type traffic with
at least four idle periods.
Allow the vehicle to sit for at least eight hours without starting the
engine. Then, start the engine and complete the above driving cycle. The
engine must warm up to its normal operating temperature. Once started,
do not turn off the engine until the above driving cycle is complete.
POWER STEERING FLUID
Refer to the scheduled maintenance information for the service
interval schedules. If adding fluid is necessary, use only MERCON
AT F.
1. Start the engine and let it run
until it reaches normal operating
temperature (the engine coolant
temperature gauge indicator will be
near the center of the normal area
between H and C).
2. While the engine idles, turn the
steering wheel left and right several
times.
3. Turn the engine off.
4. Check the fluid level in the reservoir. It should be between the MIN
and MAX lines. Do not add fluid if the level is in this range.
5. If the fluid is low, add fluid in small amounts, continuously checking
the level until it reaches the range between the MIN and MAX lines. Be
sure to put the cap back on the reservoir.
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BRAKE FLUID
The fluid level will drop slowly as
the brakes wear, and will rise when
the brake components are replaced.
Fluid levels between the “MIN” and
“MAX” lines are within the normal
operating range; there is no need to
add fluid. If the fluid levels are
outside of the normal operating
range the performance of your
brake system could be
compromised; seek service from
your authorized dealer immediately.
TRANSAXLE FLUID
Checking 6–speed automatic transmission fluid
Refer to your scheduled maintenance information for scheduled
intervals for fluid checks and changes. Your transaxle does not consume
fluid. However, the fluid level should be checked if the transaxle is not
working properly, i.e., if the transaxle slips or shifts slowly or if you
notice some sign of fluid leakage.
Checking automatic transmission fluid at normal operating
temperature (140°F-158°F [60°C-70°C])
Automatic transmission fluid expands when warmed. To obtain an
accurate fluid check, drive the vehicle until it is warmed up
(approximately 20 miles [30 km]) until the engine coolant gauge
indicates normal operating temperature. If your vehicle has been
operated for an extended period at high speeds, in city traffic
during hot weather or pulling a trailer, the vehicle should be turned
off for about 30 minutes to allow fluid to cool before checking.
1. Drive the vehicle 20 miles (30 km) or until the coolant guage indicates
normal operating temperature.
2. Park the vehicle on a level surface and engage the parking brake.
3. With the parking brake engaged and your foot on the brake pedal,
start the engine and move the gearshift lever through all of the gear
ranges. Allow sufficient time for each gear to engage (approximately
10–15 seconds in each position).
4. Move the gearshift lever to P (Park) and leave the engine running. MAX
MIN
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5. Remove the dipstick, wiping it clean with a clean, dry, lint-free rag. If
necessary, refer to Identifying components in the engine compartment
in this chapter for the location of the dipstick.
6. Install the dipstick making sure it is fully seated in the filler tube.
7. Remove the dipstick and inspect
the fluid level. The fluid should read
within the hot range on the dipstick
if at normal operating temperature
(140°F-158°F [60°C-70°C]).
Checking automatic transmission fluid at cool temperature
(59°F-77°F [15°C-25°C])
If a fluid check is necessary at a low
fluid temperature (59°F-77°F
[15°C-25°C]), perform the check
using the cold range on the dipstick.
However, the fluid must be
re-checked at the proper fluid temperature.
Low fluid level
Do not drive the vehicle if the fluid
level does not show at all on the
dipstick.
Driving the vehicle with less than
the recommended fluid level may result in transaxle failure. An under fill
condition of transmission fluid may cause shift and/or engagement
concerns and /or possible damage to the transaxle.
High fluid level
Fluid levels above the normal
operating range may result in
transaxle failure. An overfill
condition of transmission fluid may
cause shift and/or engagement
concerns and/or possible damage to
the transaxle.
High fluid levels can be caused by an overheating condition.
Adjusting automatic transmission fluid levels
Before adding any fluid, make sure the correct type is used. The type of
fluid used is normally indicated on the dipstick and also in the
Lubricant specifications section in this chapter.
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Note: Only one ATF fluid specification has been tested and approved for
use with the automatic 6-speed: Premium Automatic Transmission fluid.
Mercon fluids cannot be used with the automatic 6-speed without
damage or voiding warranty.
Use of a non-approved automatic transmission fluid may cause
internal transaxle component damage.
If necessary, add fluid in 1/2 pint (250 mL) increments through the filler
tube until the level is correct.
If an overfill occurs, excess fluid should be removed by an authorized
dealer.
An overfill condition of transmission fluid may cause shift and/or
engagement concerns and/or possible damage.
Do not use supplemental transmission fluid additives, treatments or
cleaning agents. The use of these materials may affect transmission
operation and result in damage to internal transaxle components.
AIR FILTER
Refer to scheduled maintenance information for the appropriate
intervals for changing the air filter element.
When changing the air filter element, use only the Motorcraft air filter
element listed. Refer to Motorcraft part numbers in this chapter.
To reduce the risk of vehicle damage and/or personal burn
injuries do not start your engine with the air cleaner removed
and do not remove it while the engine is running.
Changing the air filter element
1. Release the clamps that secure
the air filter housing cover.
2. Carefully separate the two halves
of the air filter housing.
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3. Remove the air filter element
from the air filter housing.
4. Wipe the air filter housing and
cover clean to remove any dirt or
debris and to ensure good sealing.
5. Install a new air filter element. Be
careful not to crimp the filter
element edges between the air filter
housing and cover. This could cause
filter damage and allow unfiltered
air to enter the engine if not properly seated.
6. Replace the air filter housing cover and secure the clamps.
Note: Failure to use the correct air filter element may result in severe
engine damage. The customer warranty may be void for any damage to
the engine if the correct air filter element is not used.
MOTORCRAFT PART NUMBERS
Component 3.0L DOHC V6 Duratec engine
Engine air filter element FA-1771
Battery BXT-40R
Oil filter FL-820-S
PCV valve 1
Spark plugs 2
1
The PCV valve is a critical emission component. It is one of the items
listed in scheduled maintenance information and is essential to the
life and performance of your vehicle and to its emissions system.
For PCV valve replacement, see your authorized dealer. Refer to
scheduled maintenance information for the appropriate intervals for
changing the PCV valve.
Replace the PCV valve with one that meets Ford material and
design specifications for your vehicle, such as a Motorcraft or
equivalent replacement part. The customer warranty may be void
for any damage to the emissions system if such a PCV valve is not
used. 2
For spark plug replacement, see your authorized dealer. Refer to
scheduled maintenance information for the appropriate intervals for
changing the spark plugs.
Replace the spark plugs with ones that meet Ford material and
design specifications for your vehicle, such as Motorcraft or
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equivalent replacement parts. The customer warranty may be
void for any damage to the engine if such spark plugs are not
used.
REFILL CAPACITIES
Fluid Ford Part
Name Application Capacity
Brake fluid Motorcraft High
Performance
DOT 3 Motor
Vehicle Brake
Fluid All Fill between Min
and Max on
reservoir
Engine oil
(including filter
change) 1
Motorcraft SAE
5W-20 Premium
Synthetic Blend
Motor Oil (US)
Motorcraft SAE
5W-20 Super
Premium Motor
Oil (Canada) All 6.0 quarts
(5.7L)
Fuel tank N/A All 17.5 gallons
(66.2L)
Power steering
fluid Motorcraft
MERCON
AT F All Between MIN
and MAX on
reservoir
Engine coolant 2
Motorcraft
Premium Gold
Engine Coolant
(yellow-colored) All 9.72 quarts
(9.2L)
Transmission
fluid Premium
Automatic
Transmission
Fluid 6–speed
automatic
transaxle 7.4 quarts
(7.0L) 3
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Fluid Ford Part
Name Application Capacity
Windshield
washer fluid Motorcraft
Premium
Windshield
Washer
Concentrate All 4.75 quarts
(4.5L)1
Use of synthetic or synthetic blend motor oil is not mandatory. Engine
oil need only meet the requirements of Ford specification
WSS-M2C930-A and the API Certification mark. 2
Add the coolant type originally equipped in your vehicle. 3
Indicates only approximate dry-fill capacity. Some applications may vary
based on cooler size and if equipped with an in-tank cooler. The amount
of transmission fluid and fluid level should be set by the indication on
the dipstick’s normal operating range.
LUBRICANT SPECIFICATIONS
Item Ford part
name Ford part
number Ford
specification
Brake fluid Motorcraft High
Performance
DOT 3 Motor
Vehicle Brake
Fluid PM-1 or PM-1-C ESA-M6C25-A
or
WSS-M6C62-A
Door
weatherstrips Silicone Spray
Lubricant XL-6 ESR-M13P4-A
Door latch, hood
latch, auxiliary
hood latch, door
hinges, striker
plates, seat
tracks and fuel
filler door hinge Multi-Purpose
Grease XG-4 or XL-5 ESB-M1C93–B
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Item Ford part
name Ford part
number Ford
specification
Engine coolant Motorcraft
Premium Gold
Engine Coolant
(yellow-colored) VC-7-A (U.S.,
except CA, OR
and NM),
VC-7-B (CA, OR
and NM) WSS-M97B51–A1
Cooling system
stop leak pellets Motorcraft
Cooling System
Stop Leak
Pellets VC-6 WSS-M99B37-B6
Engine oil Motorcraft SAE
5W-20 Premium
Synthetic Blend
Motor Oil (US)
Motorcraft SAE
5W-20 Super
Premium Motor
Oil (Canada) XO-5W20-QSP
(US)
CXO-5W20–LSP12
(Canada) WSS-M2C930-A
with API
Certification
Mark
Lock cylinders Motorcraft
Penetrating and
Lock Lubricant XL-1 none
Power steering
fluid Motorcraft
MERCON
AT F XT-2-QDX MERCON

Automatic
transaxle fluid Motorcraft
Premium
Automatic
Transmission
Fluid XT-8-QAW WSS-M2C924-A
Windshield
washer fluid Premium
Windshield
Washer
Concentrate ZC-32-A WSB-M8B16–A2
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