Attachment III - Technical Information

[NEW] CERTAIN 2003-2005 MODEL YEAR LINCOLN LS AND FORD THUNDERBIRD
VEHICLES EQUIPPED WITH 3.9L ENGINE - EXTENDED WARRANTY
COVERAGE ON IGNITION COIL COVER AND WIPER MOTOR BRACKET SEAL

OVERVIEW

This program (07N09) is a one-time repair for the replacement of the ignition coil covers and wiper motor bracket seal when evidence of water contamination is found on the ignition coil assemblies or in the spark plug wells.

NOTE:
On the affected vehicles, water contamination may cause internal damage to the ignition coil assembly, resulting in premature failure of the ignition coil assemblies. Therefore, if water contamination is identified on a cylinder bank, all 4 ignition coil assemblies and associated spark plugs must be replaced on the affected engine bank(s).

Follow instructions in the Lincoln LS or Ford Thunderbird Workshop Manual Section 303-04B for ignition coil and spark plug replacement.

REMOVE WATER CONTAMINATION AND INSTALL NEW SPARK PLUGS AND IGNITION COILS

1. Remove all ignition coils from the water contaminated engine bank(s).

2. Using shop air, blow (dry) out water from the spark plug wells.

3. Install new spark plugs in contaminated engine bank(s).

4. Install new ignition coils in contaminated engine bank(s).

CLEAN VALVE COVER AND INSTALL NEW IGNITION COIL COVERS





1. Remove all silicone sealant and residue from the valve cover surface and ignition coil wiring harness. See Figure 1.





2. Apply a bead of silicone sealant above and below the area of the notch where the ignition coil harness enters the valve cover. See Figure 2.

3. Install the new ignition coil covers (XW4Z-12025-AD) on both engine banks and tighten the bolts to 5 Nm (44 lb-in).

4. Install the EVAP canister purge valve bracket and nuts.

INSTALL NEW WIPER MOTOR BRACKET SEAL

1. Remove the cowl panel grille (refer to Section 501-00 or 501-02 of the Lincoln LS or Ford Thunderbird Workshop Manual).





2. Remove the wiper motor bracket seal and discard. See Figure 3.

3. Clean the wiper motor bracket sealing area using Bug and Tar Remover (ZC-42), or equivalent.

4. Install a new wiper motor bracket seal (5W4Z-54021A46-A), centering the seal on the hole of the cowl panel grille. See Figure 3.

5. Reinstall the cowl panel grille.