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Home >> Ford >> 2011 >> Taurus AWD V6-3.5L Turbo >> Repair and Diagnosis >> Engine, Cooling and Exhaust >> Engine >> Service and Repair >> Overhaul >> Engine - Assembly >> Steps 161-200

Steps 161-200




Engine

















Engine Upper









Engine Upper - LH Cylinder Head









Engine Upper - RH Cylinder Head









Engine Front









Timing Drive Components - Roller Timing Chain

NOTE: Stamped steel RH timing chain guide shown, composite guide similar.









Timing Drive Components - Inverted Tooth Timing Chain









Lower Engine Block (View 1)









Lower Engine Block (View 2)









NOTICE: During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces that enters the oil passages, coolant passages or the oil pan, may cause engine failure.

NOTICE: Whenever turbocharger air intake system components are removed, always cover open ports to protect from debris. It is important that no foreign material enter the system. The turbocharger compressor vanes are susceptible to damage from even small particles. All components should be inspected and cleaned, if necessary, prior to installation or reassembly.

NOTE: The engine comes equipped with either a roller primary timing chain or an inverted tooth primary timing chain. The roller timing chain engine comes equipped with either a composite RH timing chain guide requiring the timing chain to ride on the outer side of the guide or a stamped steel RH timing chain guide requiring the timing chain to ride on the inner side of the guide. All roller timing chain engine replacement RH timing chain guides will be the stamped steel design.

NOTE: Early build engine cylinder heads and fuel injectors differ in design than late build engines. Although these parts are serviced in the same way, the parts are not interchangeable between early build and late build engines. The level of cylinder heads and fuel injectors can be determined by inspecting the engine code label. Early build engines are built through 09/14/2010 (0S 490 BA) and late build engines are built on or after 09/15/2010 (1S 490 BA).

NOTE: Assembly of the engine requires various inspections/measurements of the engine components (engine block, crankshaft, connecting rods, pistons and piston rings). These inspections/measurements will aid in determining if the engine components will require replacement. For additional information, refer to Engine System - General Information Procedures.

161. NOTE: Listen for audible click when installing the oil supply tube into the quick connect fitting.

Install the LH oil supply tube into the quick connect fitting.





162. Install the LH oil supply tube secondary latch.





163. NOTE: Lubricate the oil pan bore with clean engine oil.

Using 2 new O-ring seals, install the LH turbocharger oil return tube in the oil pan.





164. Install a new gasket, turbocharger oil return tube and the 2 bolts.
- Tighten to 10 Nm (89 lb-in).





165. NOTE: Make sure the turbocharger wastegate regulating valve hose does not contact the exhaust manifold heat shield.

Connect the turbocharger wastegate regulating valve hose to the LH turbocharger assembly.





166. Install LH Camshaft Position (CMP) sensor and the bolt.
- Tighten to 10 Nm (89 lb-in).





167. Connect the LH CMP sensor electrical connector.





168. Connect the Cylinder Head Temperature (CHT) sensor electrical connector.





169. Install the radio capacitor and the bolt to the RH cylinder head.
- Tighten to 10 Nm (89 lb-in).





170. Install the RH CMP sensor and the bolt.
- Tighten to 10 Nm (89 lb-in).





171. Connect the RH CMP sensor electrical connector.





172. Attach all of the wiring harness retainers to the RH valve cover and stud bolts.

173. Connect the 3 RH ignition coil-on-plug electrical connectors.





174. Connect the RH VCT solenoid electrical connector and attach the 2 wiring harness retainers.





175. NOTICE: If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions can result in engine damage.

NOTE: Make sure the fuel rail wiring harnesses are routed correct.

NOTE: Installing the 2 long bolts first will aid in installing the intake manifold.

Using new intake manifold, coolant crossover and thermostat housing gaskets, install the intake manifold and the 12 bolts.

- Tighten in the sequence shown to 10 Nm (89 lb-in).





176. Connect the 2 turbocharger coolant hoses to the intake manifold.





177. Position the fuel tube and install the fuel tube-to-engine front cover bracket bolt.
- Tighten to 10 Nm (89 lb-in).





178. Attach the 2 wire harness-to-intake manifold retainers.





179. Connect the turbocharger wastegate regulating valve electrical connector.





180. Connect the Manifold Absolute Pressure (MAP)/Intake Air Temperature 2 (IAT2) sensor electrical connector.





181. Connect and attach the 2 fuel injector wiring harness electrical connectors.





182. Connect the KS sensor electrical connector.





183. Install the oil level indicator.





184. Attach all the wiring harness retainers to the LH valve cover and stud bolts.

185. Connect the 3 LH ignition coil-on-plug electrical connectors.





186. NOTE: Apply thread sealant with PTFE to the Engine Oil Pressure (EOP) switch threads.

Install the EOP switch.

- To install, tighten to 14 Nm (124 lb-in) plus an additional 180 degrees.





187. Using a new gasket, install the oil filter adapter and the 3 bolts.
- Tighten to 10 Nm (89 lb-in) plus an additional 45 degrees.





188. Connect the EOP electrical connector.
- Attach the EOP wiring harness retainer to the engine block.





189. Install the stud, generator and the nut and bolt.
- Tighten the stud to 8 Nm (71 lb-in).

- Tighten the nut and bolt to 47 Nm (35 lb-ft).





190. Connect the generator electrical connector.





191. Connect the generator B+ cable and install the nut.
- Tighten to 17 Nm (150 lb-in).





192. Connect the A/C compressor electrical connector.
- Attach the wiring harness retainer from the to the A/C stud bolt.





193. Attach the CMS electrical connector to the A/C compressor bracket.





194. Connect the LH camshaft VCT solenoid electrical connector.





195. Connect the Throttle Position (TP) sensor and electronic Throttle Body (TB) electrical connectors.





196. Connect the electrical connector and install the noise insulator shield for the fuel injection pump.





197. Install the PCV tube and connect the 2 quick connect couplings. For additional information, refer to Fuel System - General Information Service and Repair.





198. Install the lower radiator hose to the thermostat housing.





199. NOTICE: The compression limiter bushing may fall out of the mounting bracket grommet on the Charge Air Cooler (CAC) tube during service. Make sure the bushing is in place when reinstalling the tube or damage to the tube may occur.

Install the RH Charge Air Cooler (CAC) tube and turbocharger intake tube as an assembly and install the RH CAC tube nut to the intake manifold.

- Tighten to 6 Nm (53 lb-in).





200. NOTICE: The compression limiter bushing may fall out of the mounting bracket grommet on the turbocharger intake tube during service. Make sure the bushing is in place when reinstalling the tube or damage to the tube may occur.

Install the RH turbocharger intake tube nut.

- Tighten to 6 Nm (53 lb-in).




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