Operation CHARM: Car repair manuals for everyone.
Home >> Mercury >> 1998 >> Sable V6-3.0L DOHC VIN S >> Repair and Diagnosis >> Engine, Cooling and Exhaust >> Engine >> Service and Repair >> Assembly >> Steps 66-130

Steps 66-130












66. Remove lock pins from LH and RH timing chain tensioners.
67. Install crankshaft position (CKP) sensor pulse ring onto crankshaft. Align crankshaft key with orange point stripe on CKP sensor pulse ring.
68. Clean engine front cover to cylinder block and cylinder head sealing surfaces using a clean shop towel and Metal Surface Cleaner F4AZ-19A536-RA or equivalent meeting Ford specification WSE-M5B392-A to remove all residues that may interfere with the sealer's ability to adhere.

69. NOTE: Install engine front over and retaining bolts and stud bolts in the locations and sequence shown in no more than six minutes after applying sealer.

Sealer Locations:





Apply a 3 mm (0.118 inch) diameter bead, approximately 12 mm (0.472 inch) long, of Silicone Gasket and Sealant F7AZ-19554-EA or equivalent sealant meeting Ford specification WSK-M2G343-A4 in six locations on cylinder block as shown.
70. Install engine front cover with new engine front cover gaskets over alignment dowels to cylinder block and cylinder heads.





71. Install engine front cover retaining bolts and stud bolts in locations and sequence as shown finger tight then a quarter turn in no more than six minutes after applying sealer.

Engine Front Cover Installation Sequence:





72. Install remaining engine front cover retaining bolts and stud bolts.
73. Tighten all engine front cover retaining bolts and stud bolts in sequence shown to 20-30 Nm (15-22 ft. lbs.)
74. If removed, install drive belt tensioner onto RH side of engine front cover. Tighten retaining bolt to 20-30 Nm (15-22 ft. lbs.).
75. Lubricate engine front cover crankshaft front oil seal bore with Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford specification ESR-M99C80-A. Using Crankshaft Damper Replacer 303-102 (T74P-6316-B), install crankshaft front seal into engine front cover.
76. Turn engine assembly upside down on engine stand.

77. WARNING: EYE PROTECTION IS REQUIRED TO BE WORN DURING USE OF COMPRESSED AIR. FAILURE TO WEAR EYE PROTECTION COULD RESULT IN PERSONAL INJURY.

Clean oil pan with suitable soap and water solution. Dry completely with compressed air.
78. Clean oil pan to cylinder block sealing surfaces on oil pan and cylinder block with shop towel and Metal Surface Cleaner F4AZ-19A536-RA or equivalent meeting Ford specification WSE-M513392-A to remove all residues that may interfere with the sealer's ability to adhere.
79. Install new oil pan gasket and apply 8 mm (0.31 inch) diameter bead of Silicone Gasket and Sealant F7AZ-19554-EA or equivalent sealant meeting Ford specification WSK-M2G343-A4 at two places as shown in the following illustration.
80. Install oil pan and oil pan retaining bolts and studs to cylinder block loosely in locations shown.
81. Align oil pan to rear of cylinder block using a straightedge to 0.0-0.25 mm (0.0-0.010 inch). Install or remove shims from rear of oil pan as required.

Oil Pan Installation Sequence (1 Of 2):




Oil Pan Installation Sequence (2 Of 2):





82. With oil pan aligned to rear of cylinder block, tighten oil pan retaining bolts and studs in sequence to 20-30 Nm (15-22 ft. lbs.) no more than six minutes after applying sealer.
83. Turn engine right side up on engine stand.
84. Install oil pressure sensor into cylinder block. Apply Pipe Sealant with Teflon&circle; D8AZ-19554-A or equivalent meeting Ford specifications WSK-M2G350-A2 to oil pressure sensor prior to installation. Tighten oil pressure sensor to 12-16 Nm (9-12 ft. lbs.)
85. Lubricate oil bypass filter rubber seal with Motorcraft Super Premium 5W30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G and install oil bypass filter. Tighten oil bypass filter three-quarter turn after rubber seal contacts sealing surface.

86. NOTE: Inspect oil level indicator tube to lower cylinder block O-ring for damage or wear. Replace O-ring as necessary.






Lubricate oil level indicator tube O-ring with Motorcraft Super Premium 5W30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G. Install oil level indicator tube, oil level dipstick and oil level indicator tube retaining bolt. Tighten retaining stud bolt to 8-12 Nm (71-106 inch lbs.)

87. NOTE: Inspect sensor O-ring prior to installation of sensors. Replace O-ring as necessary if damaged or worn.

NOTE: Camshaft position sensor has 90 degree angled exhaust manifold connector end.

If removed, install crankshaft position (CKP) sensor and camshaft position sensor into engine front cover. Install and tighten sensor retaining bolts to 8-12 Nm (71-106 inch lbs.)
88. Install LH and RH exhaust manifold gaskets, exhaust manifolds and exhaust manifold retaining nuts onto cylinder head. tighten exhaust manifold retaining nuts to 18-22 Nm (13-16 ft. lbs.)





89. Install power steering pump onto engine front cover Tighten retaining bolts to 20-30 Nm (15-22 ft. lbs.)
90. Install spark plugs into cylinder heads. Tighten spark plugs to 9-20 Nm (80-177 inch lbs.)
91. Using a shop towel and Metal Surface Cleaner F4AZ-19A536-A or equivalent meeting Ford specification WSE-M5B392-A, clean cylinder head to valve cover sealing surfaces to remove all residues that may interfere with the sealer's ability to adhere.

Valve Cover Sealing:





92. Apply 8 mm (0.31 inch) diameter bead of Silicone Gasket and Sealant F7AZ-1 9554-EA or equivalent sealant meeting Ford specification WSK-M2G343-A4 at two places on the valve cover sealing surfaces where the engine front cover and cylinder heads contact each valve cover.

APPLY 8 mm DIAMETER DROP OF SILICONE GASKET AND SEALANT F7AZ-19554-EA OR EQUIVALENT MEETING FORD SPECIFICATION WSK-M2G343-A4 SEALER TO FRONT COVER GASKET INTERSECTION FOUR PLACES (TWO PER VALVE COVER)

NOTE: TIGHTEN ALL VALVE COVER FASTENERS WITHIN SIX MINUTES OF APPLYING SILICONE GASKET AND SEALANT F7AZ-19554-EA OR EQUIVALENT MEETING FORD SPECIFICATION WSK-M2G343-A4 AA0182-C

Valve Cover Installation Sequence, LH Side:




Valve Cover Installation Sequence, RH Side:





93. Install new valve cover gaskets, valve covers and retaining bolts and studs. Verify bolts and studs are in their proper locations. Tighten in sequence to 8-12 Nm (71-106 inch lbs.)
94. Install ignition coil, radio ignition interference capacitor, ignition coil ground cable and ignition coil retaining bolts to RH valve cover. Tighten retaining bolts to 8 Nm (70 inch lbs.)
95. Install evaporative emission return tube to the RH valve cover stud bolts. Tighten retaining nuts to 5-7 Nm (45-61 inch lbs.)

96. NOTE: Lubricate crankshaft front oil seal lip prior to installation of crankshaft damper.





Install crankshaft damper using Crankshaft Damper Replacer 303-102 (T74P-6316-B) and washer from retaining bolt.
97. Install Flywheel Holding Tool 303-103 (T74P-6375-A) to cylinder block and engage teeth on flywheel. Use suitable spacers for proper alignment of tool to flywheel.

98. NOTE: Prior to applying sealer, clean sealing surfaces with Metal Surface Cleaner F4AZ-19A536-RA or equivalent meeting Ford specification WSE-M5B392-A to remove all residues that may interfere with the sealer's ability to adhere.

NOTE: Silicone Gasket and Sealant F6AZ-19562-AA or equivalent meeting Ford specification WSE-M4G23-A6 must be applied to front of crankshaft on inside diameter of crankshaft damper at keyway prior to installing crankshaft damper retaining bolt.





Install crankshaft damper retaining bolt and washer. Tighten retaining bolt as follows:
- Tighten retaining bolt to 120 Nm (88 ft. lbs.)
- Loosen retaining bolt a minimum of one full turn.
- Tighten retaining bolt to 47-53 Nm (35-39 ft. lbs.)
- Rotate retaining bolt an additional 85-95 degrees.
99. Install accessory drive crankshaft pulley and bracket. Using a 34 mm socket tighten pulley counterclockwise to 95-105 Nm (70-77 ft. lbs.)
100. Remove Flywheel Holding Tool 303-10 (T74P-6375-A) from cylinder block.
101. Install and tighten crankshaft pulley bracket retaining nuts to 20-30 Nm (15-22 ft. lbs.)
102. Install water pump and water pump retaining nuts onto engine front cover. Tighten water pump retaining nuts to 20-30 Nm (15-22 ft. lbs.)





103. Install generator and retaining bolt to engine front cover and cylinder block. Tighten retainer bolts to 20-30 Nm (15-22 ft. lbs.)

104. CAUTION: A/C compressor mounting bracket must engage the front cover dowels or engine vibration may occur.

CAUTION: A/C compressor mounting bracket bolts are torque to yield and cannot be reused.

1 Of 2:




2 Of 2:





Install A/C compressor mounting bracket. Tighten retaining bolts to 25 Nm (18 ft. lbs.) then tighten an additional 90 degrees.




105. Install A/C compressor and retaining bolts. Tighten retaining bolts to 20-30 Nm (15-22 ft. lbs.)
106. Install A/C compressor mounting bracket to water pump brace. Tighten retaining nuts to 20-30 Nm (15-22 ft. lbs.)

107. NOTE: Inspect water bypass tube to cylinder block O-rings for damage or wear. Replace as necessary.





Lubricate O-rings with Premium Cooling System Fluid E2FZ-19549-AA or B (in Oregon, F5Z-19549-CC, in Canada, Motorcraft CXC-8-B) or equivalent meeting Ford specification ESE-M97B44-A and install O-rings, water bypass tube and retainers onto RH cylinder head. Install retaining stud bolt in the upper water bypass tube bolt hole and bolt in lower hole. Tighten retainers to 8-12 Nm (71-106 inch lbs.)
108. Lubricate heater water hose with Silicone Lubricant COAZ-19553-AA or equivalent meeting Ford specification ESR-M13P4-A. Install heater water hose onto water bypass tube. Install heater water hose spring clamp securely.
109. Install crankcase ventilation tube onto oil separator and water bypass stud bolt. Install crankcase ventilation tube retaining nut. Tighten nut to 5-7 Nm (45-61 inch lbs.)
110. Correctly position the engine control sensor wiring and install two retaining bolts and four retaining nuts. Tighten bolts to 8-12 Nm (71-107 inch lbs.), tighten nuts to 5-7 Nm (45-61 inch lbs.)
111. Install new intake manifold gaskets onto cylinder heads using locating pins to position intake manifold gaskets.





112. Install lower intake manifold, fuel injectors and fuel injection supply manifold as an assembly onto cylinder heads.





113. Install lower intake manifold retaining bolts to 8-12 Nm (71-106 inch lbs.) in sequence shown.
114. Install the IMRC actuator onto the RH valve cover. Tighten retainers to 8-12 Nm (71-106 inch lbs.)

115. NOTE: Do not loosen or bend intake manifold runner control actuator cable retainer bracket. Bracket alignment is critical and potential damage to the intake manifold runner control actuator may occur.

Connect the IMRC actuator cable to the IMRC lever and bracket.
116. Connect ignition wires to spark plugs and ignition coil. Install ignition wire separators onto valve cover stud bolts.
117. Connect engine control sensor wiring to the following components:
- engine coolant temperature sensor
- ignition coil
- radio ignition interference capacitor
- fuel injectors
- oil pressure sensor
- crankshaft position sensor
- A/C compressor
- generator
- EGR backpressure transducer
- water temperature indicator sender unit
- IMRC Actuator
118. Install new intake manifold upper gaskets onto lower intake manifold using locating pins to position intake manifold upper gaskets.

Intake Manifold Installation Sequence (1 Of 2):




Intake Manifold Installation Sequence (2 Of 2):





119. Install upper intake manifold and upper intake manifold retaining bolts onto lower intake manifold. Tighten retaining bolts in sequence shown to 8-12 Nm (71-106 inch lbs.)
120. If removed, install idle air control valve gasket, idle air control valve and retaining bolts onto upper intake manifold. Tighten retaining bolts to 8-12 Nm (71-106 inch lbs.).
121. If removed, install EGR vacuum solenoid control and retaining bolts onto upper intake manifold. Tighten retaining bolts to 5-7 Nm (45-61 inch lbs.).
122. If removed, install throttle body gasket, throttle body and throttle body retaining bolts and stud bolt to upper intake manifold. Position stud bolt in lower RH bolt hole. Tighten throttle body retaining bolts to 8-12 Nm (71-106 inch lbs.).
123. Connect engine control sensor wiring to idle air control valve, EGR vacuum solenoid control and throttle position sensor.
124. If removed, install EGR valve gasket, EGR valve and EGR valve retainers. Tighten retainers to 20-30 Nm (15-22 ft. lbs.).
125. Install EGR valve to exhaust manifold tube to RH exhaust manifold and EGR valve.
126. Connect main emission vacuum control connector to the EGR valve and fuel pressure regulator.
127. Install and connect positive crankcase ventilation valve into oil separator crankcase ventilation tube and upper intake manifold vacuum port.
128. Connect the evaporative emission tube to the upper intake manifold vacuum port connector.
129. Rotate accessory drive belt tensioner clockwise and install accessory drive belt. Carefully release drive belt tensioner.
130. Install the lower radiator hose tube and retaining bracket to the LH cylinder head. Tighten retainers to 8-12 Nm (71-106 inch lbs.)
131. Remove engine from engine stand using Rotunda Powertrain Lift 014-00765, Universal Removal Bracket 014-0766, Rotunda Spreader Bar 303-F054 (014-00793), or equivalents and Engine Lifting Brackets 303-050 (T70P-6000) and a suitable floor crane, and install engine.
pro multis · About Operation CHARM