Engine - 3.0L (4V): Overhaul Ford Fusion I рестайлинг

DISASSEMBLY

Note. If the components are to be reinstalled, they must be installed in the same positions. Mark the components removed for locations. If not reassembled in their original positions, severe engine damage may occur.

1. Remove the hydraulic lash adjusters.
2. Using the Valve Spring Compressors, remove the keys, retainer and spring.
3. Remove the valve from the cylinder head.
4. Remove the valve stem seal.

ASSEMBLY

1. Using the Valve Stem Oil Seal Installer, install the valve stem seal.
2. Install the valve.
3. Using the Valve Spring Compressors, install the valve spring, retainer and key.
4. Install the hydraulic lash adjusters. Lubricate the hydraulic lash adjusters with clean engine oil.

Special Tools Illustration Tool Name Tool Number Engine Lifting Bracket Set 303-1140 Installer, Camshaft Oil Seal 303-464 (T94P-6256-BH) Installer, Camshaft Pulley 303-458 (T94P-6312-AH3), part of 303-S455 Installer, Crankshaft Rear Main Oil Seal 303-178 (T82L-6701-A) Installer, Crankshaft Vibration Damper 303-102 (T74P-6316-B) Installer, Front Cover Oil Seal 303-335 (T88T-6701-A) Installer, Power Steering Pump Pulley 211-185 (T91P-3A733-A) Installer Bolts, Crankshaft Rear Main Oil Seal 303-384 (T91P-6701-A) Lifting Brackets, Engine 134-00243 or equivalent Lifting Brackets, Engine 303-050 (T70P-6000) Protector, Camshaft Oil Seal 303-463 (T91P-6256-AH) Spacer, Water Pump Pulley 303-459 (T94P-6312-AH4), part of 303-S455 Spreader Bar 303-D089 (D93P-6001-A3) or equivalent Strap Wrench 303-D055 (D85L-6000-A) Universal Adapter Brackets 014-0001

Scheme 120

Material

Scheme 121

Scheme 122

Note. 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, can cause engine failure.

Note. If the oil pan was removed during engine disassembly, it must be installed after the engine and transaxle are assembled and the transaxle-to-engine bolts are installed. Failure to follow this assembly sequence can result in engine oil leaks.

All engines

1. Install the oil separator cover, a new gasket and the bolts. Tighten to 10 Nm (89 lb-in).
2. Position the new gaskets and the LH and RH cylinder heads. Install new bolts and tighten in the sequence shown in 6 stages: Stage 1: Tighten to 40 Nm (30 lb-ft). Stage 2: Tighten to 90 Nm (66 lb-ft). Stage 3: Loosen one full turn. Stage 4: Tighten to 40 Nm (30 lb-ft). Stage 5: Tighten 90 degrees. Stage 6: Tighten 90 degrees.
3. Position the oil pump and install the 4 bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
4. If removed, install the crankshaft key into the keyway on the crankshaft.
5. Install the crankshaft pulley bolt and washer and rotate the crankshaft keyway to the 11 o'clock position to locate Top Dead Center (TDC).
6. Apply clean engine oil to the LH and RH camshaft roller followers.
7. Install the LH and RH camshaft roller followers.
8. Position the Variable Camshaft Timing (VCT) actuators onto the intake camshafts. Install the bolts finger-tight.
9. Lubricate the RH camshafts with clean engine oil and carefully position the camshafts onto the cylinder head. Align the RH camshafts as shown.
10. Install the RH camshaft bearing caps. Loosely install the bolts.
11. Install the RH camshaft bearing thrust caps. Loosely install the bolts.
12. Tighten the RH camshaft bearing cap bolts in the sequence shown to 10 Nm (89 lb-in).
13. Tighten the RH VCT actuator bolt to 40 Nm (30 lb-ft) plus an additional 90 degrees.
14. Lubricate the LH camshafts with clean engine oil and carefully position the camshafts into the cylinder head. Align the LH camshafts as shown.
15. Install the LH camshaft bearing caps. Loosely install the bolts.
16. Install the LH camshaft bearing thrust caps. Loosely install the bolts.
17. Tighten the LH camshaft bearing cap bolts in the sequence shown to 10 Nm (89 lb-in).
18. Tighten the LH VCT actuator bolt to 40 Nm (30 lb-ft) plus an additional 90 degrees.
19. Install the camshaft oil seal retainer and the 2 bolts. Tighten to 10 Nm (89 lb-in).
20. Using the Camshaft Oil Seal Protector, Camshaft Oil Seal Installer and the Power Steering Pump Pulley Installer, install a new camshaft oil seal.
21. Remove the crankshaft pulley bolt and washer.
22. Install the crankshaft sprockets with the timing marks out.
23. Position the chain tensioner in a soft-jawed vise.
24. Hold the chain tensioner ratchet lock mechanism away from the ratchet stem with a small pick.
25. Slowly compress the timing chain tensioner.
26. Retain the tensioner piston with a 1.5 mm (0.05 in) wire or paper clip.
27. If timing marks in the timing chains are not evident, use a permanent-type marker to mark the crankshaft and camshaft timing marks on the LH and RH timing chains. Mark any link to use as the crankshaft timing mark. Starting with the crankshaft timing mark, count counterclockwise 29 links and mark the link. Continue counting counterclockwise to link 42 and mark the link.
28. Verify that the LH camshafts are correctly positioned.
29. Install the VCT assembly and the 4 bolts. Tighten to 25 Nm (18 lb-ft).
30. Install the LH timing chain. Align the marks on the timing chain with the marks on the camshaft and crankshaft sprockets.
31. Install the LH timing chain tensioner arm and the LH timing chain tensioner. Install the tensioner arm. Position the tensioner. Install the 2 bolts. Tighten to 25 Nm (18 lb-ft).
32. Install the crankshaft pulley bolt and washer and rotate the crankshaft clockwise 120 degrees until the crankshaft keyway is in the 3 o'clock position.
33. Verify that the RH camshafts are correctly positioned.
34. Install the RH VCT assembly and the 3 bolts. Tighten to 25 Nm (18 lb-ft).
35. Install the RH timing chain. Align the marks on the timing chain with the marks on the camshaft and crankshaft sprockets.
36. Install the RH timing chain tensioner and tensioner arm. Install the tensioner arm. Position the tensioner. Install the 2 bolts. Tighten to 25 Nm (18 lb-ft).
37. Remove the LH and RH timing chain tensioner piston retaining wires.
38. Rotate the crankshaft counterclockwise 120 degrees to TDC.
39. Verify the timing with the following steps. There should be 12 chain links between the camshaft timing marks. There should be 27 chain links between the camshaft and the crankshaft timing marks. There should be 30 chain links between the camshaft and the crankshaft timing marks.
40. Remove the crankshaft pulley bolt and washer.
41. Install the ignition pulse wheel.
42. Install 3 new gaskets in the front cover.
43. Apply a 6 mm (0.23 in) dot of silicone gasket and sealant to the cylinder block to lower cylinder block and cylinder head mating surfaces.
44. Position the engine front cover and install the 14 bolts and 2 stud bolts. Tighten in the sequence shown to 25 Nm (18 lb-ft).
45. Apply clean engine oil to the seal lip and seal bore before installing the seal.
46. Using the Front Cover Oil Seal Installer and the Crankshaft Vibration Damper Installer, install a new crankshaft front seal.
47. Apply silicone gasket and sealant to the end of the keyway slot.
48. Using the Front Cover Oil Seal Installer and the Crankshaft Vibration Damper Installer, install the crankshaft pulley.
49. Install the bolt and washer. Using the Strap Wrench to hold the crankshaft pulley, tighten the bolt in 4 stages: Stage 1: Tighten to 120 Nm (89 lb-ft). Stage 2: Loosen one full turn. Stage 3: Tighten to 50 Nm (37 lb-ft). Stage 4: Tighten an additional 90 degrees.
50. Install the accessory drive belt tensioner and the 2 idler pulleys. Tighten the tensioner bolt to 45 Nm (33 lb-ft). Tighten the idler pulley bolts to 25 Nm (18 lb-ft).
51. Install the oil pan baffle and the 8 nuts. Tighten the oil pan baffle nuts in 2 stages. Stage 1: Tighten the 4 smaller nuts to 5 Nm (44 lb-in) and the larger nuts to 15 Nm (133 lb-in). Stage 2: Tighten all 8 nuts an additional 45 degrees.
52. Install a new O-ring seal on the oil pump screen and pickup tube. Lubricate with clean engine oil.
53. Install the oil pump screen and pickup tube and the 2 bolts. Tighten to 10 Nm (89 lb-in).
54. Install the LH and RH spark plugs. Tighten to 15 Nm (133 lb-in).
55. Apply a an 8 mm (0.31 in) dot of silicone gasket sealant to the front cover-to-cylinder head joints and the cam seal retainer-to-cylinder head joints.
56. Position the LH valve cover and install the bolts and stud bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
57. Install the 3 LH coil-on-plug assemblies and the 3 bolts. Tighten to 7 Nm (62 lb-in).
58. Apply an 8 mm (0.31 in) dot of silicone gasket sealant to the front cover-to-cylinder head joints.
59. Position the RH valve cover and install the bolts and stud bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
60. Install the 3 RH coil-on-plug assemblies and the 3 bolts. Tighten to 7 Nm (62 lb-in).
61. If equipped, install the block heater. Tighten to 40 Nm (30 lb-ft).
62. Install the EOP switch. Tighten to 14 Nm (124 lb-in).
63. Install the KS and the bolt. Tighten to 20 Nm (177 lb-in).
64. Install the coolant pump and the 3 bolts. Tighten to 10 Nm (89 lb-in) then rotate 90 degrees.
65. Install the Camshaft Pulley Installer on the camshaft as shown in the illustration. Adjust the collar on the Camshaft Pulley Installer screw to get the best thread engagement in the rear of the camshaft.
66. Position the coolant pump pulley over the previously installed Camshaft Pulley Installer, Water Pump Pulley Spacer and the Power Steering Pump Pulley Installer, and on the end of the camshaft. Install the Camshaft Pulley Installer, Water Pump Pulley Spacer and the Power Steering Pump Pulley Installer, as shown in the illustration. Using the Camshaft Pulley Installer, Water Pump Pulley Spacer and the Power Steering Pump Pulley Installer, install the coolant pump pulley flush with the end of the camshaft.
67. Install the coolant pump belt on the coolant pump pulley and position it on the coolant pump drive pulley.
68. Rotate the crankshaft clockwise to seat the coolant pump belt on the coolant pump drive belt pulley.
69. Connect the coolant pump hose to the cylinder block outlet.
70. Install new O-ring seals, the coolant bypass tube, bolt and stud bolt. Tighten to 10 Nm (89 lb-in).
71. Install the thermostat housing.
72. Position the lower intake manifold and install the 8 bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
73. Install a new O-ring on the oil level indicator tube. Apply clean engine oil to the O-ring.
74. Position the oil level indicator and tube and install the stud bolt. Tighten to 9 Nm (80 lb-in).
75. Install the LH catalytic converter bracket and the 2 bolts. Tighten to 35 Nm (26 lb-ft).
76. Install 6 new RH catalytic converter studs. Tighten to 12 Nm (106 lb-in).
77. Install a new gasket, the RH exhaust manifold and 6 new nuts. Tighten to 20 Nm (177 lb-in) in the sequence shown.
78. Install a new gasket, the RH catalytic converter and 6 new nuts. Tighten to 20 Nm (177 lb-in) in the sequence shown.
79. Install the A/C compressor bracket and the 3 bolts. Tighten to 25 Nm (18 lb-ft).
80. Install the A/C compressor and the 3 bolts. Tighten to 25 Nm (18 lb-ft).
81. Install the generator and the 3 bolts. Tighten to 48 Nm (35 lb-ft).
82. Position the wiring harness onto the engine.
83. Attach the wiring harness to the cylinder block.
84. Install the wiring harness retainer bolt. Tighten to 10 Nm (89 lb-in).
85. Position the power steering pump and reservoir assembly onto the engine and install the 3 bolts. Tighten to 25 Nm (18 lb-ft).
86. Install the 3 power steering reservoir nuts. Tighten to 9 Nm (80 lb-in).
87. Rotate the accessory drive belt tensioner counterclockwise and install the accessory drive belt.
88. Attach the wiring harness retainer to the coolant bypass stud bolt.
89. Position the wiring harness onto the engine and connect the ECT sensor electrical connector.
90. Connect the KS electrical connector.
91. Connect the PCV valve electrical connector.
92. Connect the Power Steering Pressure (PSP) switch electrical connector.
93. Connect the Crankshaft Position (CKP) sensor electrical connector.
94. Attach the 2 wiring harness retainers.
95. Connect the RH Heated Oxygen Sensor (HO2S) electrical connector.
96. Attach the wiring harness retainer to the power steering stud bolt.
97. Connect the RH catalyst monitor sensor electrical connector.
98. Install the radio frequency interference capacitor and the nut. Tighten to 6 Nm (53 lb-in).
99. Connect the RH VCT solenoid and LH Camshaft Position (CMP) sensor electrical connectors. If equipped, attach the 2 wiring harness retainers to the valve cover stud bolts.
100. Connect the 3 RH coil-on-plug electrical connectors. Attach the 2 wiring harness pin-type retainers to the valve cover.
101. Attach the 2 wiring harness retainers to the fuel rail.
102. Connect the 6 fuel injector electrical connectors (3 shown).
103. If equipped, attach the wiring harness retainer to the LH valve cover stud bolt.
104. Connect the 3 LH coil-on-plug electrical connectors. Attach the 2 wiring harness pin-type retainers to the valve cover.
105. Attach the 3 wiring harness retainers to the valve cover stud bolts.
106. Connect the LH VCT solenoid and LH CMP sensor electrical connectors. Attach the 2 wiring harness retainers to the valve cover stud bolts.
107. Connect the generator B+ cable and electrical connector and install the nut. Tighten to 6 Nm (53 lb-in).
108. Connect the EOP switch electrical connector and wiring harness retainer.
109. If equipped, attach the block heater wiring harness retainers to the oil level indicator tube and remove the harness.
110. If equipped, connect the block heater electrical connector.
111. Connect the A/C compressor electrical connector and the wiring harness retainer.
112. Position the upper intake manifold and install the 8 bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
113. Connect the Throttle Body (TB) coolant hose.
114. Connect the electronic TB electrical connector.
115. Connect the crankcase vent hose to the upper intake manifold.
116. Attach the wiring harness pin-type retainer to the upper intake manifold.
117. Connect the Manifold Absolute Pressure (MAP) sensor electrical connector and the pin-type retainer.
118. Install the lower half of the Engine Lifting Bracket Set.
119. Install the upper half of the Engine Lifting Bracket Set.
120. Install the Engine Lifting Bracket.
121. Install the Engine Lifting Bracket and the Universal Adapter Bracket.
122. Using the Spreader Bar, Engine Lifting Brackets, Engine Lifting Bracket Set and a suitable engine crane, remove the engine from the engine stand.
123. Using the Crankshaft Rear Main Oil Seal Installer and the Crankshaft Rear Main Oil Seal Installer Bolts, install the crankshaft rear seal.
124. Install the engine-to-transaxle separator plate.
125. Position the flexplate and install the 8 bolts. Tighten to 80 Nm (59 lb-ft).

Special Tools Illustration Tool Name Tool Number Engine Lifting Bracket Set 303-1140 Heavy Duty Floor Crane 014-00071 or equivalent Lifting Bracket, Engine 303-050 (T70P-6000) Lifting Brackets, Engine 134-00243 or equivalent Powertrain Lift 014-00765 Socket, Exhaust Gas Oxygen Sensor 303-476 Spreader Bar 303-D089 (D93P-6001-A3) or equivalent Universal Adapter Brackets 014-0001

Material