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Section 457 (Engine - 3.0L 2V): Assembly: Engine

WARNING: This page is about a different car, the 2003 Mercury Sable and 2003 Ford Taurus. However, it is still accessible from the selected car via links, so may be relevant.
Fig 1: Identifying Special Tools
G01592502Courtesy of FORD MOTOR CO.
Fig 2: Identifying Material Specifications (1 Of 2)
G01592503Courtesy of FORD MOTOR CO.
Fig 3: Identifying Material Specifications (2 Of 2)
G01592504Courtesy of FORD MOTOR CO.
    CAUTION: The crankshaft main bearings are precision fit. For additional information, refer to ENGINE SYSTEM-GENERAL INFORMATION for checking clearances.
    Fig 4: Installing Crankshaft Upper Main Bearings
    G01592505Courtesy of FORD MOTOR CO.
  1. Install the crankshaft upper main bearings.
    2. NOTE: Lubricate the crankshaft journals and the crankshaft main bearings with clean engine oil.
    Fig 5: Positioning Crankshaft
    G01592506Courtesy of FORD MOTOR CO.
  2. Position the crankshaft.
    3. NOTE: Lubricate the inner and outer sealing surfaces of the crankshaft rear seal with clean engine oil.
    Fig 6: Installing Crankshaft Rear Seal
    G01592507Courtesy of FORD MOTOR CO.
  3. Install the crankshaft rear seal.
  4. Apply two dots of gasket maker between the rear bearing cap and the cylinder block.
    Fig 7: Applying Gasket Maker Between Rear Bearing Cap And Cylinder Block
    G01592508Courtesy of FORD MOTOR CO.
  5. Install the crankshaft lower main bearings.
    Fig 8: Installing Crankshaft Lower Main Bearings
    G01592509Courtesy of FORD MOTOR CO.
  6. Install the main bearing caps.
    Fig 9: Installing Main Bearing Caps
    G01592510Courtesy of FORD MOTOR CO.
  7. Install the main bearing cap bolts in the sequence shown.
    • Tighten the bolts in pairs.
    • Carry out the crankshaft and crankshaft bearing component tests. For additional information, refer to ENGINE SYSTEM-GENERAL INFORMATION .
    Fig 10: Installing Main Bearing Cap Bolts
    G01592511Courtesy of FORD MOTOR CO.
  8. If removed, install the camshaft bearings.
    Fig 11: Installing Camshaft Bearings
    G01592512Courtesy of FORD MOTOR CO.
    9. NOTE: Lubricate the camshaft and the camshaft bearings with clean engine oil.
    Fig 12: Installing Camshaft
    G01592513Courtesy of FORD MOTOR CO.
  9. Install the camshaft.
  10. Install the camshaft thrust plate.
    Fig 13: Installing Camshaft Thrust Plate
    G01592514Courtesy of FORD MOTOR CO.
  11. Inspect the camshaft end play. For additional information, refer to ENGINE SYSTEM-GENERAL INFORMATION .
  12. Align the timing marks.
    Fig 14: Aligning Timing Marks
    G01592515Courtesy of FORD MOTOR CO.
  13. Install the timing chain, the camshaft sprocket and the crankshaft sprocket as an assembly.
    Fig 15: Installing Timing Chain, Camshaft Sprocket And Crankshaft Sprocket
    G01592516Courtesy of FORD MOTOR CO.
  14. Install the camshaft sprocket bolt.
    Fig 16: Installing Camshaft Sprocket Bolt
    G01592517Courtesy of FORD MOTOR CO.
    15. NOTE: Lubricate the piston and connecting rod assemblies with clean engine oil.
    Fig 17: Installing Piston And Connecting Rod Assemblies
    G01592518Courtesy of FORD MOTOR CO.
  15. Install the piston and connecting rod assemblies.
    16. NOTE: Lubricate the connecting rod bearings with clean engine oil.
  16. Install the connecting rod bearings.
  17. Install the connecting rod caps and nuts.
    • Tighten the nuts in pairs.
    Fig 18: Installing Connecting Rod Caps And Nuts
    G01592519Courtesy of FORD MOTOR CO.
  18. Install the oil pump.
    Fig 19: Installing Oil Pump
    G01592520Courtesy of FORD MOTOR CO.
    19. NOTE: Lubricate the valve tappets with clean engine oil.
    Fig 20: Installing Valve Tappets
    G01592521Courtesy of FORD MOTOR CO.
  19. Install the valve tappets.
  20. Install the valve tappet guide plates.
    Fig 21: Installing Valve Tappet Guide Plates
    G01592522Courtesy of FORD MOTOR CO.
  21. Install the valve tappet guide plate retainer.
    Fig 22: Installing Valve Tappet Guide Plate Retainer
    G01592523Courtesy of FORD MOTOR CO.
  22. Install new cylinder head gaskets.
    Fig 23: Installing Cylinder Head Gaskets
    G01592524Courtesy of FORD MOTOR CO.
  23. Position the cylinder heads.
    Fig 24: Positioning Cylinder Heads
    G01592525Courtesy of FORD MOTOR CO.
  24. Install the bolts. Tighten the bolts in five stages in the sequence shown.
    • Stage 1: Tighten the bolts to 50 Nm (37 lb-in).
    • Stage 2: Loosen the bolts one full turn.
    • Stage 3: Tighten to 30 Nm (22 lb-ft).
    • Stage 4: Rotate 90 degrees.
    • Stage 5: Rotate an additional 90 degrees.
    Fig 25: Tightening Sequence Of Cylinder Head Bolts
    G01592526Courtesy of FORD MOTOR CO.
  25. Install the oil filter.
    Fig 26: Installing Oil Filter
    G01592527Courtesy of FORD MOTOR CO.
  26. Install a new engine front cover gasket and the engine front cover.
    Fig 27: Installing Engine Front Cover Gasket And Engine Front Cover
    G01592528Courtesy of FORD MOTOR CO.
  27. Install the engine front cover and water pump assembly.
    1. Apply pipe sealant with Teflon® to the bolts indicated.
    2. Install the bolts.
    Fig 28: Installing Engine Front Cover And Water Pump Assembly
    G01592529Courtesy of FORD MOTOR CO.
  28. Apply four beads of gasket maker as shown.
    Fig 29: Identifying Locations For Applying Gasket Maker
    G01592530Courtesy of FORD MOTOR CO.
  29. Position the oil pan gasket.
    Fig 30: Positioning Oil Pan Gasket
    G01592531Courtesy of FORD MOTOR CO.
  30. Position the oil pan and hand-start the bolts.
    Fig 31: Positioning Oil Pan And Hand-Start Bolts
    G01592532Courtesy of FORD MOTOR CO.
  31. Install the bolts. Tighten the bolts in four stages.
    • Stage 1: Tighten the four corner bolts to 12 Nm (9 lb-in).
    • Stage 2: Tighten the remaining bolts to 12 Nm (9 lb-in).
    • Stage 3: Loosen all the bolts one turn.
    • Stage 4: Tighten all the bolts to 12 Nm (9 lb-in).
    Fig 32: Installing Oil Pan Bolts
    G01592533Courtesy of FORD MOTOR CO.
  32. Install the camshaft synchronizer. For additional information, refer to REMOVAL & INSTALLATION .
    33. NOTE: If the lower intake manifold is not secured within four minutes, the sealant must be removed and the sealing area cleaned with metal surface cleaner. Allow to dry until there is no sign of wetness or four minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
    Fig 33: Identifying Locations For Applying Gasket Maker
    G01592534Courtesy of FORD MOTOR CO.
  33. Apply four beads of silicone gasket and sealant.
  34. Position the intake manifold gaskets and end seals.
    Fig 34: Positioning Intake Manifold Gaskets And End Seals
    G01592535Courtesy of FORD MOTOR CO.
  35. Install the lower intake manifold. Tighten the bolts in two stages in the sequence shown.
    • Stage 1: Tighten to 15 Nm (11 lb-ft).
    • Stage 2: Tighten to 32 Nm (24 lb-ft).
    Fig 35: Tightening Sequence Of Lower Intake Manifold Bolts
    G01592536Courtesy of FORD MOTOR CO.
  36. Install the push rods and the rocker arms. Tighten the rocker arm bolts in two stages
    • Stage 1: Tighten the bolts to 10 Nm (89 lb-in).
    • Stage 2: Tighten the bolts to 32 Nm (24 lb-ft).
    Fig 36: Installing Push Rods And Rocker Arms
    G01592537Courtesy of FORD MOTOR CO.
    37. NOTE: If the valve covers are not secured within four minutes, the sealant must be removed and the sealing area cleaned with metal surface cleaner. Allow to dry until there is no sign of wetness or four minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
    Fig 37: Applying Silicone Gasket And Sealant To Intake-To-Cylinder Head Seams
    G01592538Courtesy of FORD MOTOR CO.
  37. Apply a bead of silicone gasket and sealant to the four intake-to-cylinder head seams.
  38. If removed, install the valve cover gaskets.
    Fig 38: Installing Valve Cover Gaskets
    G01592539Courtesy of FORD MOTOR CO.
  39. Install the LH valve cover.
    Fig 39: Installing LH Valve Cover
    G01592540Courtesy of FORD MOTOR CO.
  40. Install the RH valve cover.
    Fig 40: Installing RH Valve Cover
    G01592541Courtesy of FORD MOTOR CO.
  41. Position a new exhaust manifold gasket and install the RH exhaust manifold.
    Fig 41: Positioning Exhaust Manifold Gasket And Installing RH Exhaust Manifold
    G01592542Courtesy of FORD MOTOR CO.
  42. Install the bolts. Tighten the exhaust manifold bolts in two stages in the sequence shown.
    • Stage 1: Tighten to 10 Nm (89 lb-in).
    • Stage 2: Tighten to 22 Nm (16 lb-ft).
    Fig 42: Tightening Sequence Of Exhaust Manifold Bolts
    G01592543Courtesy of FORD MOTOR CO.
  43. Install the RH exhaust manifold heat shield.
    Fig 43: Installing RH Exhaust Manifold Heat Shield
    G01592544Courtesy of FORD MOTOR CO.
  44. Position and connect the RH spark plug wires.
    Fig 44: Positioning And Connecting RH Spark Plug Wires
    G01592545Courtesy of FORD MOTOR CO.
  45. Position a new exhaust manifold gasket and install the LH exhaust manifold.
    Fig 45: Positioning Exhaust Manifold Gasket And Installing LH Exhaust Manifold
    G01592546Courtesy of FORD MOTOR CO.
  46. Install the four bolts and two stud bolts. Tighten the exhaust manifold bolts in two stages in the sequence shown.
    • Stage 1: Tighten to 10 Nm (89 lb-in).
    • Stage 2: Tighten to 22 Nm (16 lb-ft).
    Fig 46: Tightening Sequence Of Exhaust Manifold Bolts
    G01592547Courtesy of FORD MOTOR CO.
    47. NOTE: If the oil level indicator tube is not secured within four minutes, the sealant must be removed and the sealing area cleaned with metal surface cleaner. Allow to dry until there is no sign of wetness or four minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
    Fig 47: Coating Sealing Surface Of Oil Level Indicator Tube With Silicone Gasket And Sealant
    G01592548Courtesy of FORD MOTOR CO.
  47. Coat the sealing surface of the oil level indicator tube with silicone gasket and sealant.
  48. Install the oil level indicator and tube.
    Fig 48: Installing Oil Level Indicator And Tube
    G01592549Courtesy of FORD MOTOR CO.
  49. Position and connect the LH spark plug wires.
    Fig 49: Positioning And Connecting LH Spark Plug Wires
    G01592550Courtesy of FORD MOTOR CO.
  50. Position the engine control sensor wiring harness and connect the fuel injector electrical connectors.
    Fig 50: Connecting Fuel Injector Electrical Connectors
    G01592551Courtesy of FORD MOTOR CO.
  51. Position the wire harness along the cylinder block and install the pin-type retainers.
    Fig 51: Installing Pin-Type Retainers
    G01592552Courtesy of FORD MOTOR CO.
  52. Connect the camshaft position (CMP) sensor, engine coolant temperature (ECT) sensor, ECT sender and the oil pressure switch electrical connectors.
    Fig 52: Connecting CMP Sensor, ECT Sensor, ECT Sender And Oil Pressure Switch Electrical Connectors
    G01592553Courtesy of FORD MOTOR CO.
  53. Inspect the upper intake manifold gasket. Install a new gasket, if required.
    Fig 53: Inspecting Upper Intake Manifold Gasket
    G01592554Courtesy of FORD MOTOR CO.
  54. Install the upper intake manifold. Tighten the bolts in two stages in the sequence shown.
    1. Stage 1: Tighten hand tight.
    2. Stage 2: Tighten to 10 Nm (89 lb-ft).
    Fig 54: Tightening Sequence Of Upper Intake Manifold Bolts
    G01592555Courtesy of FORD MOTOR CO.
  55. Connect the positive crankcase ventilation (PCV) valve.
    Fig 55: Connecting Positive Crankcase Ventilation Valve
    G01592556Courtesy of FORD MOTOR CO.
  56. Connect the secondary air injection control solenoid electrical and vacuum connections.
    Fig 56: Connecting Secondary Air Injection Control Solenoid Electrical And Vacuum Connections
    G01592557Courtesy of FORD MOTOR CO.
  57. Install and connect the oxygen sensor electrical connector.
    Fig 57: Installing And Connecting Oxygen Sensor Electrical Connector
    G01592558Courtesy of FORD MOTOR CO.
  58. Connect the following:
    • Connect the vacuum harness connection to the upper intake manifold.
    • Connect the EGR vacuum regulator solenoid electrical and vacuum connections.
    Fig 58: Connecting EGR Vacuum Regulator Solenoid Electrical And Vacuum Connections
    G01592559Courtesy of FORD MOTOR CO.
  59. Connect the EGR valve vacuum hose.
    Fig 59: Connecting EGR Valve Vacuum Hose
    G01592560Courtesy of FORD MOTOR CO.
  60. Install the upper intake manifold support bracket.
    Fig 60: Installing Upper Intake Manifold Support Bracket
    G01592561Courtesy of FORD MOTOR CO.
  61. Connect the vacuum tube to the secondary air injection valve.
    Fig 61: Connecting Vacuum Tube To Secondary Air Injection Valve
    G01592562Courtesy of FORD MOTOR CO.
  62. Position the wiring harness and install the pin-type retainers.
    Fig 62: Positioning Wiring Harness And Installing Pin-Type Retainers
    G01592563Courtesy of FORD MOTOR CO.
  63. Connect the idle air control (IAC) valve and throttle position (TP) sensor electrical connectors.
    Fig 63: Connecting Idle Air Control Valve And Throttle Position Sensor Electrical Connectors
    G01592564Courtesy of FORD MOTOR CO.
  64. Install the EGR tube.
    • Connect the electrical connector.
    • Tighten the two compression nuts.
    Fig 64: Installing EGR Tube
    G01592565Courtesy of FORD MOTOR CO.
  65. Install the crankshaft damper and crankshaft pulley. For additional information, refer to CRANKSHAFT PULLEY .
  66. Install the crankshaft position (CKP) sensor.
    Fig 65: Installing Crankshaft Position Sensor
    G01592566Courtesy of FORD MOTOR CO.
  67. Connect the CKP sensor electrical connector.
    Fig 66: Connecting CKP Sensor Electrical Connector
    G01592567Courtesy of FORD MOTOR CO.
  68. Install the water pump pulley.
    Fig 67: Installing Water Pump Pulley
    G01592568Courtesy of FORD MOTOR CO.
  69. Install the A/C compressor mounting bracket.
    Fig 68: Installing A/C Compressor Mounting Bracket
    G01592569Courtesy of FORD MOTOR CO.
  70. Install the A/C compressor.
    Fig 69: Installing A/C Compressor
    G01592570Courtesy of FORD MOTOR CO.
  71. Install the wiring harness connectors on the bracket and connect the oxygen sensor electrical connector.
    Fig 70: Connecting Oxygen Sensor Electrical Connector
    G01592571Courtesy of FORD MOTOR CO.
  72. Connect the A/C compressor clutch coil electrical connector.
    Fig 71: Connecting A/C Compressor Clutch Coil Electrical Connector
    G01592572Courtesy of FORD MOTOR CO.
  73. Connect the A/C high pressure cutoff switch electrical connector.
    Fig 72: Connecting A/C High Pressure Cutoff Switch Electrical Connector
    G01592573Courtesy of FORD MOTOR CO.
  74. Install the power steering pump and bracket assembly.
    Fig 73: Installing Power Steering Pump And Bracket Assembly
    G01592574Courtesy of FORD MOTOR CO.
  75. Install the support bracket.
    Fig 74: Installing Support Bracket
    G01592575Courtesy of FORD MOTOR CO.
  76. Install the drive belt tensioner.
    Fig 75: Installing Drive Belt Tensioner
    G01592576Courtesy of FORD MOTOR CO.
  77. Install the drive belt idler pulley.
    Fig 76: Installing Drive Belt Idler Pulley
    G01592577Courtesy of FORD MOTOR CO.
  78. Install the generator.
    Fig 77: Installing Generator
    G01592578Courtesy of FORD MOTOR CO.
  79. Install the generator support bracket.
    Fig 78: Installing Generator Support Bracket
    G01592579Courtesy of FORD MOTOR CO.
  80. Connect the generator electrical connections.
    Fig 79: Connecting Generator Electrical Connections
    G01592580Courtesy of FORD MOTOR CO.
  81. Install the drive belt.
    Fig 80: Installing Drive Belt
    G01592581Courtesy of FORD MOTOR CO.
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