2005 Lincoln Aviator AWDFACTORY OEM SERVICE PROCEDURE

General Specifications

GENERAL SPECIFICATIONS

Item Specification
Lubricants and Sealants 
Metal Surface Cleaner ZC-21 WSE-M5B392-A
Silicone Gasket and Sealant F7AZ-19554-EA WSE-M4G323-A4
Motorcraft Premium Gold Engine Coolant VC-7-A (in California and Oregon VC-7-B, in Canada VC-7-C) or equivalent (yellow color) WSS-M97B51-A1
Thread Sealant with PTFE® TA-24 WSK-M2G350-A2
SAE 5W-20 Motorcraft Premium Synthetic Blend Motor Oil XO-5W20-QSP or equivalent WSS-M2C930-A
Motorcraft Silicone Brake Caliper Grease and Dielectric Compound XG-3-A or equivalent ESE-M1C171-A
Threadlock 262 TA-26 WSK-M2G351-A6
Engine 
Displacement 4.6L (4V) (281 CID)
Number of cylinders 8
Bore 90.2 mm (3.55 in)
Stroke 90.0 mm (3.54 in)
Firing order 1-3-7-2-6-5-4-8
Oil pressure (hot 1,500 rpm) 138--310 kPa
Oil capacity 6 +/- 0.25 (quarts U.S.)(1)
Compression ratio 10.1:1
Cylinder Head and Valve Train 
Cylinder head gasket surface flatness 0.10 mm (0.004 in) max. overall
Combustion chamber volume (cc) 53.0 +/- 1.5 cm3 (cc5 )
Valve arrangement (front to rear) - intake, LH All primary
Valve arrangement (front to rear) - exhaust, LH All primary
Valve arrangement (front to rear) - intake, RH All primary
Valve arrangement (front to rear) - exhaust, RH All primary
Valve clearance - intake 0.0445 mm (0.0018 in)
Valve clearance - exhaust 0.0705 mm (0.0028 in)
Valve guide bore diameter 7.015--7.044 mm (0.2762--0.2773 in)
Valve stem diameter - intake (standard) 6.975--6.995 mm (0.2754--0.2746 in)
Valve stem diameter - exhaust (standard) 6.949--6.970 mm (0.2744--0.2736 in)
Valve stem-to-guide clearance - intake 0.020--0.069 mm (0.00078--0.00272 in)
Valve stem-to-guide clearance - exhaust 0.046--0.095 mm (0.0018--0.0037 in)
Valve head diameter - intake 37 mm (1.46 in)
Valve head diameter - exhaust 30 mm (1.18 in)
Valve head diameter - gauge diameters 35.0 and 28.0 mm (1.378--1.102 in)
Valve face runout 0.05 mm (0.002 in)
Valve face angle 45.5 degrees
Valve seat width 1.8--2.2 mm (0.071--0.086 in)
Valve seat runout (TIR) max. 0.05 mm (0.002 in)
Valve seat angle 45 degrees
Valve spring free length (approx.) 45.5 mm (1.6598 in)
Valve spring squareness 2 degrees
Valve spring compression pressure 711.47 N @ 26.19 mm (159.9 lb-ft @ 1.031 in)
Valve spring installed height 36.14 mm (1.4228 in)
Valve spring installed pressure 289.1 N @ 36.14 mm (64.99 lb-ft @ 1.4228 in)
Valve spring installed pressure - service limit 10% pressure loss @ 28.02 mm (1.103 in)
Roller follower ratio 1.8:1
Hydraulic Lash Adjuster 
Diameter (standard) 16.000--15.988 mm (0.6299--0.6294 in)
Clearance to bore 0.018--0.069 mm (0.000709--0.002717 in)
Service limit 0.016 mm (0.0006299 in)
Hydraulic leakdown rate(2) 5--25 seconds
Collapsed lash adjuster gap - desired 0.45-0.85 mm (0.0177-0.0334 in)
Camshaft 
Theoretical valve lift @ 0 lash 10.0 mm (0.3937 in)
Lobe lift 5.54 mm (0.218 in)
Allowable lobe lift loss 0.130 mm (0.0051 in)
Journal diameter (all) 26.962-26.936 mm (1.0615-1.0605 in)
Camshaft journal bore inside diameter (all) 27.012-26.987 mm (1.0635-1.0625 in)
Camshaft journal-to-bearing clearance 0.025-0.076 mm (0.00098-0.002992 in)
Camshaft journal-to-bearing clearance - service limit 0.100 mm (0.003937 in) max.
Runout 0.025 mm (0.0010 in)
End play 0.025--0.165 mm (0.00098--0.00649 in)
End play - service limit 0.190 mm (0.007480 in)
Cylinder Block 
Cylinder bore diameter - surface finish (RMS)(3) 0.2--0.6 microns
Cylinder bore diameter - out-of-round limit(3) 0.015 mm (0.0006 in)
Cylinder bore diameter - out-of-round service limit(3) 0.020 mm (0.0008 in)
Cylinder bore diameter - taper service limit(3) 0.006 mm (0.0002 in)
Cylinder bore maximum taper 0.006 mm (0.0002 in)
Cylinder bore maximum out-of-round 0.015 mm (0.0006 in)
Main bearing bore inside diameter 72.400--72.424 mm (2.8504--2.8513 in)
Camshaft bearing bore inside diameter 26.987--27.012 mm (1.0625--1.0635 in)
Head gasket surface flatness 0.15 mm (0.006 in) max. overall
Crankshaft 
Main bearing journal diameter 67.481--67.505 mm (2.6567269--2.6576718 in)
Main bearing journal maximum taper 0.004 mm (0.0002 in)
Main bearing journal maximum out-of-round 0.006 mm (0.0002 in)
Main bearing journal-to-cylinder block clearance - desired 0.025--0.045 mm (0.00098--0.00177 in)
Main bearing journal-to-cylinder block clearance - allowable 0.025--0.050 mm (0.00098--0.00197 in)
Connecting rod journal diameter 52.983--53.003 mm (2.085941--2.086728 in)
Connecting rod journal maximum taper 0.004 mm (0.0002 in)
Connecting rod journal maximum out-of-round 0.004 mm (0.0002 in)
Crankshaft maximum end play 0.130--0.301 mm (0.005118--0.011850 in)
Piston and Connecting Rod 
Piston diameter - standard(4) 0.028 mm (0.0010 in)
Piston diameter - coded red 1(4) 90.167--90.188 mm (3.299--3.5505 in)
Piston diameter - coded blue 2(4) 90.180--90.195 mm (3.5504--3.5510 in)
Piston diameter - coded yellow 3(4) 90.198--90.208 mm (3.5511--3.5515 in)
Piston-to-cylinder bore clearance -0.010/+0.026 mm (-0.0003937/+0.0010236 in)
Piston ring end gap - compression (top)(3) 0.150--0.300 mm (0.006--0.0018 in)
Piston ring end gap - compression (bottom)(5) 0.300--0.550 mm (0.0018--0.0022 in)
Piston ring end gap - oil ring (steel rail)(5) 0.15--0.66 mm (0.00591--0.02598 in)
Piston ring groove width - compression (top) 1.230--1.250 mm (0.0484--0.0492 in)
Piston ring groove width - compression (bottom) 1.520--1.540 mm (0.05984--0.06062 in)
Piston ring groove width - oil ring 3.030--3.055 mm (0.1193--0.1203 in)
Piston ring width - compression (top and bottom) 1.00 mm (0.03937 in) max.
Piston ring width - oil ring 1.15 mm (0.04528 in) max.
Piston ring-to-groove clearance - compression (top) 0.0090--0.0235 mm (0.000354--0.000925 in)
Piston ring-to-groove clearance - compression (bottom) 0.030--0.080 mm (0.00118--0.00315 in)
Piston ring-to-groove clearance - oil ring snug fit
Piston pin bore diameter 21.9985--22.0035 mm (0.8661--0.8663 in)
Piston pin diameter 22.0005--22.0030 mm (0.8661596--0.8662581 in)
Piston pin length 61.601--62.030 mm (2.42523--2.44212 in)
Piston pin-to-piston fit(6) -0.0045/+0.002 mm (-0.000177/+0.0000787 in)
Connecting rod-to-pin clearance - standard 0.004--0.0175 mm (0.000157--0.00689 in)
Connecting rod-to-pin clearance - service limit 0.35 mm (0.01378 in)
Connecting rod pin bore diameter 21.9985--22.0025 mm (0.866081--0.866238 in)
Connecting rod length (center-to-center) 150.7 mm (5.933 in)
Connecting rod maximum allowed bend 0.038 per 25 mm (0.00150 per 0.9843 in)
Connecting rod maximum allowed twist 0.050 per 25 mm (0.00197 per 0.9843 in)
Connecting rod bearing bore diameter 56.866--56.886 mm (2.23881--2.23960 in)
Connecting rod bearing-to-crankshaft clearance - desired and allowable 0.027--0.069 mm (0.0010629--0.0027165 in)
Connecting rod side clearance (assembled to crank) - standard 0.15--0.45 mm (0.00591--0.01772 in)
Connecting rod side clearance (assembled to crank) - service limit 0.50 mm (0.01969 in) max.
(1) With installation of a new filter.
(2) Time necessary for plunger to leak down 1.6 mm of travel with 222 N force and leak down fluid in tappet.
(3) Cylinder bore diameter Red - 90.200-90.213 Blue - 90.213-90.226 Yellow - 90.226-90.239
(4) Measured at 42 mm from piston dome, at 90 degrees to the piston pin.
(5) Specification in 90.200 mm diameter gauge.
(6) Piston pin outer diameter is larger than piston pin bore, providing a possible interference fit.
Factory Service Tools

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.