Engine - Exchange Program
Article No.95-25-6
12/18/95
ENGINE - 3.0L DURATEC - EXCHANGE PROGRAM
FORD:
1996 TAURUS
LINCOLN-MERCURY:
1996 SABLE
ISSUE:
An engine exchange program is being offered to provide early concern identification, high product quality, and customer satisfaction.
ACTION:
This exchange program is provided to dealers at NO COST. Refer to the following service/diagnosis procedures.
Generally, engines requiring replacement of the block and other major base repairs, including selected engine oil and coolant leaks, may qualify for a replacement assembly. Plant personnel will make the final decision whether to provide an exchange.
ENGINE IDENTIFICATION
Cleveland Engine Plant # 2 produces the 3.0L Duratec, which is a 24-Valve, DOHC, 60 Degree V-6, and is identified by the words "Duratec 24 Valve V-6" on the upper intake manifold. Lima Engine plant produces the 3.0L 12-Valve "Vulcan", push rod, OHV, 60 Degree V-6 engine which is also available in Taurus/Sable vehicles, and is identified by the words "3.0 V-6" on the upper intake manifold. This letter applies to the new 3.0L Duratec engine only. Each engine plant will respond to engine exchange inquiries for only those engines which it produces.
Before performing any type of repair, service personnel are requested to perform the diagnostics listed below on the original engine and record their findings.
NOTE:
DO NOT DISASSEMBLE THE ENGINE PRIOR TO CALLING THE TOLL-FREE NUMBER (LISTED AT THE END OF THIS ARTICLE).
1. Check and record engine fluid level and condition. If low, fill to the proper level and check for leaks.
2. Confirm customer concern and proceed to the following diagnostic steps.
DRIVEABILITY
1. Perform EEC-IV diagnostic quick test and record all codes. If codes are present, perform the required pinpoint test in the Powertrain Control/Emissions Diagnosis (PC/ED) Service Manual and repair all concerns.
2. Perform additional tests to assure other engine subsystems, such as fuel delivery and ignition, are performing within specifications.
3. If lack of compression is the suspected cause of a base engine concern, perform compression test both wet and dry. Confirm that compression is within the specification outlined in the 1996 Taurus/Sable Service Manual.
Prior to performing any repairs, call Cleveland Engine Plant # 2 at the phone number listed at the end of this article.
OIL LEAKS
1. If the source of oil leak is not obvious, determine source of the leak using Rotunda Oil Dye (164-R3705, or equivalent) and Rotunda Black Light (164-R0753, or equivalent).
2. In the event that an engine exchange is recommended by Cleveland Engine Plant # 2 for a leak concern, avoid separating any engine sealing surfaces.
Prior to performing any repairs, call Cleveland Engine Plant # 2 at the phone number listed at the end of this article.
OIL CONSUMPTION
1. Confirm the engine has been driven for at least 1,600 km (1,000 mi).
2. Start an oil consumption test to confirm oil consumption rate. Request the customer return to the dealership when the oil level is 1/2 L/qt low. The test will be complete when 1 L/qt has been added.
3. If the oil consumption is less than 1 L per 1,500 km (1 qt per 900 mi) (Ford standard), inform the customer the engine is operating properly.
4. If oil consumption is greater than 1 L per 1,500 km (1 qt per 900 mi), call (prior to performing any repairs) Cleveland Engine Plant # 2 at the phone number listed at the end of this article.
ENGINE NOISE
1. Attempt to isolate the source of the noise by removing the Front End Accessory Drive (FEAD) belt, keeping in mind that the water pump is driven by this belt. Run the engine for no more than 15 seconds with the FEAD belt removed, and note whether or not the noise was eliminated or changed in any way.
2. If this does not assist you in identifying the source of the noise, reinstall the FEAD belt and attempt to identify the noise by shorting the cylinders and/or using a technician's stethoscope.
3. In the event that an engine exchange is recommended by Cleveland Engine Plant # 2 for a noise concern, avoid separating any engine sealing surfaces.
Prior to performing any repairs, call Cleveland Engine Plant # 2 at the phone number listed at the end of this article.
INSTALLING A REPLACEMENT 3.0L DURATEC ENGINE
CAUTION:
3.0L DURATEC ENGINE LIFT BRACKETS SUPPLIED WITH THE ENGINE EXCHANGE ARE DESIGNED TO BE USED ONLY ONCE FOR ENGINE INSTALLATION AND THEN MUST BE SCRAPPED. DO NOT ATTEMPT TO REUSE THESE BRACKETS IN ANY WAY, OR SERIOUS INJURY COULD RESULT.
Transfer the necessary components from the original engine to the replacement engine as required. Replacement engines will be shipped full of engine oil and precautions should be taken to avoid spillage during installation. Remove the engine lift brackets supplied with the engine exchange after engine installation to avoid contact with the hood of the vehicle.
CAUTION:
FAILURE TO REMOVE THE ENGINE LIFT BRACKETS AFTER INSTALLATION OF THE ENGINE MAY RESULT IN HOOD DAMAGE.
NOTE:
CORRECT FLUID LEVEL SHOULD BE VERIFIED AFTER INSTALLATION. REFER TO THE FLUID LEVEL CHECK PROCEDURES IN THE 1996 TAURUS/SABLE SERVICE MANUAL.
Follow installation procedures found in the 1996 Taurus/Sable Service Manual. Special instructions will be included with the engine as required.
RETURNING THE ORIGINAL ENGINE
Do not disassemble the original engine beyond what is required to perform an exchange. The engine core must only be missing those parts which were transferred to the replacement engine, and must be fully assembled prior to return. Return the core immediately after the exchange is complete in the same shipping container in which the replacement engine was received. Shipping instructions will be provided with replacement assembly.
NOTE:
BEFORE SHIPPING THE ORIGINAL 3.0L DURATEC ENGINE, DRAIN ALL FLUIDS (OIL, COOLANT, GASOLINE) COMPLETELY AND INSERT THE SHIPPING PLUGS FROM THE REPLACEMENT ASSEMBLY.
PLANT PHONE INFORMATION
Call the engine plant and provide the information requested. The plant can also provide technical assistance.
CLEVELAND ENGINE PLANT # 2
^ Phone Number: 1-800-DURATEC (387-2832)
^ Operating 7:00 AM to 7:00 PM Eastern Time, Monday through Friday (excluding Ford-observed holidays)
FOR FURTHER INFORMATION
Refer to the Exchange Program guide for a complete listing of engines that are available for exchange and additional information.
OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: INFORMATION ONLY
OASIS CODES: 401000, 490000, 497000, 499000, 702000