Home ReviewsRefund
Home/Ford/Taurus X/Ford Taurus X I (2007-2009)/Repair manual/Mechanical/Engine - 3.5l
Contents Section: Mechanical All sections

Engine - 3.5l Ford Taurus X I

Mechanical 46 illustrations ~21329 words

Material

ItemSpecificationFill Capacity
Motorcraft High Performance Engine RTV Silicone TA-357WSE-M4G323-A6
Motorcraft Metal Surface Prep ZC-31-A
Motorcraft Premium Gold Engine Coolant with Bittering Agent (bittered in US only) VC-7-B (US); CVC-7-A (Canada); or equivalent (yellow color)WSS-M97B51-A1
Motorcraft SAE 5W-20 Premium Synthetic Blend Motor Oil XO-5W20-QSP (US); Motorcraft SAE 5W-20 Super Premium Motor Oil CXO-5W20-LSP12 (Canada); or equivalentWSS-M2C930-A5.2L (5.5 qt) includes filter change
Silicone Gasket Remover ZC-30
Thread Sealant with PTFE TA-24WSK-M2G350-A2

Material

GENERAL SPECIFICATIONS

ItemSpecification
Engine
Displacement3.5L (4V) (214 CID)
No. cylinders6
Bore/stroke92.5/86.7 mm (3.641/3.413 in)
Fire order1-4-2-5-3-6
Oil pressureMinimum 30 psi @ 1,500 RPM with engine at normal operating temperature
Compression ratio10.3:1
Spark plugAYSF-22FM Gap = 1.29-1.45 mm (0.051-0.057 in)
Engine weight (without accessory drive components)161 kg (355 lb)
Engine and transaxle assembly weight (without accessory drive components)260.8 kg (575 lb)
Cylinder Head and Valve Train
Cylinder head gasket surface flatness a
Combustion chamber volume55.84 cc (3.41 CI)
Valve tappet clearance - intake0.15-0.25 mm (0.006-0.01 in)
Valve tappet clearance - exhaust0.300-0.400 mm (0.0118-0.0157 in)
Valve guide bore inner diameter5.519-5.549 mm (0.217-0.218 in)
Valve stem diameter - intake5.479-5.497 mm (0.2157-0.2164 in)
Valve stem diameter - exhaust5.466-5.484 mm (0.2151-0.2159 in)
Valve stem-to-guide clearance - intake0.022-0.070 mm (0.0008-0.0027 in)
Valve stem-to-guide clearance - exhaust0.035-0.083 mm (0.0013-0.032 in)
Valve head diameter - intake36.82-37.18 mm (1.44-1.46 in)
Valve head diameter - exhaust30.82-31.18 mm (1.21-1.22 in)
Valve face runout0.05 mm (0.0001 in)
Valve face angle90.50-91.50 degrees
Valve seat width - intake1.3-1.5 mm (0.051-0.059 in)
Valve seat width - exhaust1.4-1.6 mm (0.055-0.062 in)
Valve seat runout0.04 mm (0.0001 in) MAX
Valve seat angle89.0-91.0 degrees
Valve spring free length (approx.)48.4 mm (1.90 in)
Valve spring compression pressure (N @ spec. length)510 N @ 27.32 mm (115 lbs @ 1.08 in)
Valve spring installed height37.0 mm (1.45 in)
Valve spring installed height pressure (N @ spec. length)235 N @ 37.0 mm (53 lbs @ 1.45 in)
Valve spring installed pressure - service limit10% force loss @ specified height
Camshaft
Theoretical valve lift @ 0 lash9.6798 mm (0.38 in)
Lobe lift - intake9.6798 mm (0.38 in)
Lobe lift - exhaust9.6798 mm (0.38 in)
Allowable lobe lift loss0.062 mm (0.0024 in)
Camshaft journal bore inside diameter - 1st journal31.0375-31.0625 mm (1.221-1.222 in)
Camshaft journal bore inside diameter - intermediate journals25.9875-26.0125 mm (1.023-1.024 in)
Camshaft bearing outside diameter - 1st journal30.993-31.013 mm (1.2202-1.2209 in)
Camshaft bearing outside diameter - intermediate journals25.937-25.963 mm (1.021-1.022 in)
Camshaft journal-to-bearing clearance, 1st journal - service limit0.070 mm (0.0027 in) MAX
Camshaft journal-to-bearing clearance, intermediate journals - service limit0.0755 mm (0.0029 in) MAX
Runout0.040 mm (0.0015 in) MAX
End play - standard0.032-0.170 mm (0.0012-0.0066 in)
End play - service limit0.190 mm (0.00748 in) MAX
Cylinder Block
Cylinder bore diameter - grade 1
Cylinder bore diameter - grade 2
Cylinder bore diameter - grade 3
Cylinder bore maximum taper
Cylinder bore maximum out-of-round - limit
Cylinder bore maximum out-of-round - service limit
Main bearing bore inside diameter72.400-72.424 mm (2.8503-2.8513 in)
Head gasket surface flatness
Head gasket surface finish
Crankshaft
Main bearing journal diameter67.5 mm (2.657 in)
Main bearing journal maximum taper0.004 mm (0.00015 in)
Main bearing journal maximum out-of-round0.006 mm (0.00023 in)
Main bearing journal-to-cylinder block clearance
Connecting rod journal diameter55.983-56.003 mm (2.204-2.205 in)
Connecting rod journal maximum taper0.004 mm (0.00015 in)
Connecting rod journal maximum out-of-round0.006 mm (0.00023 in)
Crankshaft maximum end play0.101-0.291 mm (0.0039-0.0114 in)
Piston and Connecting Rod
Piston diameter - single grade92.476-92.490 mm (3.6407-3.6413 in)
Piston-to-cylinder bore clearance0.010 to 0.044 mm (0.0003-0.0017 in)
Piston ring end gap - compression (top, gauge diameter)0.15-0.25 mm (0.0059-0.0098 in)
Piston ring end gap - compression (bottom, gauge diameter)0.30-0.55 mm (0.0118-0.0216 in)
Piston ring end gap - oil ring (steel rail, gauge diameter)0.15-0.45 mm (0.0059-0.0177 in)
Piston ring groove width - compression (top)1.230-1.25 mm (0.0484-0.0492 in)
Piston ring groove width - compression (bottom)1.530-1.55 mm (0.0602-0.0610 in)
Piston ring groove width - oil ring2.53-2.55 mm (0.0996-0.1003 in)
Piston ring width - upper comp ring1.17-1.19 mm (0.0460-0.0468 in)
Piston ring width - lower comp ring1.47-1.49 mm (0.0578-0.0586 in)
Piston ring-to-groove clearance (upper and lower compression rings)0.040-0.080 mm (0.0015-0.0031 in)
Piston pin bore diameter23.002-23.006 mm (0.9055-0.9057 in)
Piston pin diameter22.998-23.000 mm (0.9054-0.9055 in)
Piston pin length55.975 mm (2.203 in)
Piston pin-to-piston fit0.002 to 0.008 mm (0.00007-0.0003 in)
Piston-to-connecting rod clearance2.7 mm (0.1 in)
Connecting rod-to-pin clearance - standard0.007-0.021 mm (0.0002-0.0008 in)
Connecting rod-to-pin clearance - service limit
Connecting rod pin bore diameter23.007-23.019 mm (0.905-0.906 in)
Connecting rod length (center-to-center)152.68 mm (6.01 in)
Connecting rod maximum allowed bend0.038 mm (0.0014 in)
Connecting rod maximum allowed twist0.050 mm (0.0019 in)
Connecting rod bearing bore diameter - grade 159.866-59.872 mm (2.3569-2.3571 in)
Connecting rod bearing bore diameter - grade 259.873-59.879 mm (2.3572-2.3574 in)
Connecting rod bearing bore diameter - grade 359.880-59.886 mm (2.3574-2.3577 in)
Connecting rod bearing-to-crankshaft clearance
Connecting rod side clearance (assembled to crank) - standard0.175-0.425 mm (0.0068-0.0167 in)
Connecting rod side clearance (assembled to crank) - service limit

GENERAL SPECIFICATIONS

a Refer to the procedure in this article.

TORQUE SPECIFICATIONS TABLE

DescriptionNm
A/C compressor bolts and nut25
A/C compressor stud9
A/C tube bracket bolt10
A/C tube nut15
A/C tube retaining clamp bolt10
A/C tube-to-condenser nut15
A/C tube-to-evaporator bolt15
A/C tube-to-receiver/drier nut15
Accessory drive belt tensioner bolts10
Battery cable power feed cable nut6
Battery tray bolts9
Block drain plug (large)40
Block drain plug (small) a
Block heater40
Camshaft bearing cap bolts b
Camshaft position (CMP) sensor bolts10
Carrier bearing nuts40
Catalytic convertert-to-halfshaft bracket bolts20
Catalytic converter nuts40
Catalytic converter-to-exhaust manifold studs25
Coolant pump bolts b
Crankcase rear seal retainer plate bolts b
Crankshaft position (CKP) sensor bolt10
Crankshaft pulley bolt b
Cylinder head bolts b
Cylinder head M6 bolt10
Cylinder head temperature (CHT) sensor10
Driveshaft-to-power transfer unit (PTU) bolts70
Engine front cover bolts b
Engine lifting eye bolts24
Engine mount brace bolt and nut20
Engine mount bracket bolts b
Engine mount bracket-to-engine front cover bolts24
Engine mount studs18
Engine mount-to-engine nuts63
Engine mount-to-frame bolts90
Engine oil filter c
Engine oil pressure (EOP) switch18
Engine roll restrictor-to-subframe through bolt103
Engine roll restrictor-to-transaxle bolts103
Exhaust manifold heat shield bolts14
Exhaust manifold nuts b
Exhaust manifold studs12
Exhaust Y-pipe nuts40
Flexplate bolts80
Front halfshaft nut350
Fuel rail bolts10
Fuel tube bracket-to-upper intake manifold bolt6
Generator bolt and nut48
Generator B+ terminal nut6
Generator stud12
Ground cable-to-negative battery cable nut6
Ground cable bolt12
Ground wire-to-engine bolt10
Halfshaft nut350
Halfshaft support bracket bolts40
Halfshaft support bracket studs10
Heat shield nut and bolt10
Ignition coil-on-plug bolts7
Intermediate steering shaft bolt23
Knock sensor (KS) bolts20
Lower ball joint nuts115
Lower intake manifold bolts b
Oil filter adapter large bolt57
Oil filter adapter small bolt10
Oil pan bolts b
Oil pan drain plug27
Oil pan-to-transaxle bolts48
Oil pump bolts10
Oil pump screen and pickup tube bolts10
Power steering pressure (PSP) tube bracket-to-cylinder head bolt10
Power steering pump bolts25
PSP tube bracket-to-power steering pump bolt10
PSP tube bracket-to-steering gear bolt10
PSP tube bracket-to-valve cover stud bolt nut7
PSP tubes-to-power steering gear plate bolt25
PTU support bracket bolts70
RH cylinder head ground wire bolt10
Secondary timing exhaust camshaft bolt b
Secondary timing variable camshaft timing (VCT) bolt b
Secondary timing chain tensioner bolts b
Spark plugs15
Stabilizer bar link nuts55
Starter bolt and stud bolt27
Starter B+ terminal nut12
Starter S-terminal nut5
Subframe bolts150
Subframe bracket bolts103
Thermostat housing bolts10
Tie-rod end nuts115
Timing chain guide bolts10
Timing chain tensioner bolts10
Torque converter-to-flexplate bolts55
Transaxle mount bracket bolt and nuts80
Transaxle mount through bolt and nut175
Transaxle-to-engine bolts48
Upper intake manifold bolts b
Upper intake manifold bracket-to-engine bolt - long bracket (early build engines)24
Upper intake manifold bracket-to-engine bolt - short bracket10
Upper intake manifold-to-bracket bolt - long bracket (early build engines)10
Upper intake manifold-to-bracket bolt - short bracket10
Upper stablizer bar link nuts55
Valve cover bolts and stud bolts b
VCT housing bolts b
VCT solenoid bolts10
Wiring harness retainer bolt and stud bolt10

TORQUE SPECIFICATIONS TABLE

a Tighten to 20 Nm (15 lb-ft) plus an additional 180 degrees.

b Refer to the procedure in this article.

c Tighten to 5 Nm (44 lb-in) plus an additional 180 degrees.

The 3.5L (4V) is a V-6 engine with the following features

  1. Dual overhead camshafts
  2. Four valves per cylinder
  3. Sequential Multi-Port Fuel Injection (SFI)
  4. An aluminum lower intake manifold and a composite upper intake manifold
  5. Aluminum cylinder heads
  6. An aluminum, 60-degree V-cylinder block
  7. Timing chain driven coolant pump
  8. Variable Camshaft Timing (VCT) system
  9. The electronic ignition system with 6 ignition coils

Identification

For quick identification, refer to the safety certification decal.

  1. The decal is located on the LH front door lock face panel.
  2. An engine identification label is also attached to the engine.
  3. The symbol code on the identification tag identifies each engine for determining parts usage; for instance, engine displacement in liters or cubic inch displacement and model year.

Exhaust Emission Control System

Operation and required maintenance of the exhaust emission control devices used on this engine is covered in the Introduction - Gasoline Engines article.

Induction System

The SFI provides the fuel/air mixture needed for combustion in the cylinders. The 6 solenoid-operated fuel injectors

  1. are mounted between the fuel rail and the intake manifold.
  2. meter fuel into the air intake stream in accordance with engine demand.
  3. are positioned so that their tips direct fuel just ahead of the engine intake valves.

Valve Train

The valve train uses Direct Acting Mechanical Buckets (DAMB). The camshaft lobes are positioned directly above mechanical buckets which are positioned on top of the valves.

Variable Camshaft Timing (VCT) System

The VCT system changes intake camshaft timing dependent on engine speed, load and oil temperature. Oil pressure advances and retards camshaft timing to improve low-speed and high-speed engine performance, engine idle quality and exhaust emissions.

PCV System

All engines are equipped with a closed-type PCV system recycling the crankcase vapors to the upper intake manifold.

Lubrication System

The engine lubrication system is of the force-feed type in which oil is supplied under full pressure to the crankshaft, connecting rod bearings, timing chain tensioners and VCT solenoids. The flow of oil to the valve tappets and valve train is controlled by a restricting orifice located in the cylinder head, front camshaft cup.

Oil Pump

The lubrication system is designed to provide optimum oil flow to critical components of the engine through its entire operating range.

The heart of the system is a positive displacement internal gear oil pump.

Generically, this design is known as a gerotor pump, which operates as follows

  1. The oil pump is mounted on the front face of the cylinder block.
  2. The inner rotor is piloted on the crankshaft post and is driven through flats on the crankshaft.
  3. System pressure is limited by an integral, internally-vented relief valve which directs the bypassed oil back to the inlet side of the oil pump.
  4. Oil pump displacement has been selected to provide adequate volume to make sure of correct oil pressure both at hot idle and maximum speed.
  5. The relief valve calibration protects the system from excessive pressure during high-viscosity conditions.
  6. The relief valve is designed to provide adequate connecting rod bearing lubrication under high-temperature and high-speed conditions.

Cooling System

The engine cooling system includes the following

  1. Radiator
  2. Timing chain driven coolant pump
  3. Electric fan assembly(s)
  4. Degas bottle (aids in maintaining the correct volume of engine coolant)
  5. Coolant thermostat
  6. Coolant hoses

Scheme 7

Scheme 7: Engine Cylinder Identification
Scheme 7: Engine Cylinder Identification

For basic engine mechanical concerns, refer to ENGINE SYSTEM - GENERAL INFORMATION article. For driveability concerns, refer to the Introduction - Gasoline Engines article.

Valve Clearance Check

  1. Remove the valve covers. For additional information, refer to «Valve Cover - LH»(/ford/taurus-x/i-2007-2009/remont/mechanical/#engine-35l__valve-cover-lh) and «Valve Cover - RH»(/ford/taurus-x/i-2007-2009/remont/mechanical/#engine-35l__valve-cover-rh) .
  2. Use a feeler gauge to measure the clearance of each valve and record its location. A midrange clearance is the most desirable: Intake: 0.15-0.25 mm (0.006-0.01 in) Exhaust: 0.300-0.400 mm (0.0118-0.0157 in)
  3. If any of the valve clearances are out of specification, select new tappets using this formula: tappet thickness = measured clearance + the base tappet thickness - most desirable thickness. Select the tappets and mark the installation location.
  4. If required, install the new selected valve tappets in the marked locations. For additional information, refer to «Valve Tappets»(/ford/taurus-x/i-2007-2009/remont/mechanical/#engine-35l__valve-tappets) .

Upper Intake Manifold

Note. Early build shown, late build similar.

Scheme 8

Scheme 8: Upper Intake Manifold
Scheme 8: Upper Intake Manifold
ItemPart NumberDescription
1Evaporative emissions (EVAP) tube-to-upper intake manifold pin-type retainer
2W503274Upper intake manifold long support bracket bolt (early build engines)
314A464Heated PCV electrical connector (part of 12C508) (early build engines)
46K817PCV hose
514A464Throttle body (TB) electrical connector (part of 12C508)
6CS16140Brake booster-to-intake manifold vacuum hose clamp
76K817Brake booster-to-intake manifold vacuum hose
89D661EVAP-to-intake manifold tube
9W503274Upper intake manifold short support bracket bolt
10Engine control wiring harness retainer (part of 12C508)

Scheme 9

Scheme 9
Scheme 9
ItemPart NumberDescription
11Fuel tube bracket bolt
12W503282Upper intake manifold bolt (5 required)
13W707083Upper intake manifold bolt
149S455Upper intake manifold
159H486Upper intake manifold gasket (3 required)

REMOVAL

All engines

  1. Remove the air cleaner outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION AND FILTERING»(/ford/taurus-x/i-2007-2009/remont/removal-installation/#intake-air-distribution-system-and-filtering-system) article.
  2. Disconnect the throttle body (TB) electrical connector.
  3. Disconnect the evaporative emissions (EVAP) tube from the intake manifold.
  4. Detach the EVAP tube pin-type retainer from the upper intake manifold.
  5. Disconnect the brake booster vacuum hose from the intake manifold.
  6. Disconnect the PCV tube from the PCV valve.
  7. Disconnect the heated PCV electrical connector.
  8. Remove the upper intake manifold long support bracket bolt.
  9. Detach the wiring harness retainers from the upper intake manifold.
  10. Remove the upper intake manifold short support bracket bolt.
  11. Remove the fuel tube bracket bolt.
  12. Remove the 6 bolts and the upper intake manifold. Remove and discard the gaskets. Clean and inspect all of the sealing surfaces of the upper and lower intake manifold.

INSTALLATION

All engines

  1. Using new gaskets, install the upper intake manifold and the 6 bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
  2. Install the fuel tube bracket bolt. Tighten to 6 Nm (53 lb-in).
  3. Install the upper intake manifold short support bracket bolt. Tighten to 10 Nm (89 lb-in).
  4. Attach the wiring harness retainers to the upper intake manifold.
  5. Install the upper intake manifold long support bracket bolt. Tighten to 10 Nm (89 lb-in).
  6. Connect the heated PCV electrical connector.
  7. Connect the PCV tube to the PCV valve.
  8. Connect the brake booster vacuum hose to the intake manifold.
  9. Connect the EVAP tube to the intake manifold.
  10. Attach the EVAP tube pin-type retainer to the upper intake manifold.
  11. Connect the TB electrical connector.
  12. Install the air cleaner outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION AND FILTERING»(/ford/taurus-x/i-2007-2009/remont/removal-installation/#intake-air-distribution-system-and-filtering-system) article.

Scheme 10

Scheme 10: Lower Intake Manifold
Scheme 10: Lower Intake Manifold
ItemPart NumberDescription
1W503279Thermostat housing-to-lower intake manifold bolt (3 required)
28A571Thermostat housing gasket
3W503279Lower intake manifold bolt (10 required)
49K461Lower intake manifold
59439Lower intake manifold gasket (8 required)
CAUTIONDuring 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.
  1. Drain the cooling system. For additional information, refer to «ENGINE COOLING»(/ford/taurus-x/i-2007-2009/remont/cooling-system-mechanical/#engine-cooling-system) article.
  2. Remove the fuel rail. For additional information, refer to «FUEL CHARGING AND CONTROLS - 3.5L»(/ford/taurus-x/i-2007-2009/remont/fuel-system/#fuel-system-engine-control-system-35l) article.
  3. Remove the 3 thermostat housing-to-lower intake manifold bolts.
  4. Remove the 10 bolts and the lower intake manifold. Remove and discard the intake manifold and thermostat housing gaskets. Clean and inspect all sealing surfaces.
  1. Using new intake manifold and thermostat housing gaskets, install the lower intake manifold and the 10 bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
  2. Install the 3 thermostat housing-to-lower intake manifold bolts. Tighten to 10 Nm (89 lb-in).
  3. Install the fuel rail. For additional information, refer to «FUEL CHARGING AND CONTROLS - 3.5L»(/ford/taurus-x/i-2007-2009/remont/fuel-system/#fuel-system-engine-control-system-35l) article.
  4. Fill and bleed the cooling system. For additional information, refer to «ENGINE COOLING»(/ford/taurus-x/i-2007-2009/remont/cooling-system-mechanical/#engine-cooling-system) article.

Valve Cover - LH

Special Tools Illustration Tool Name Tool Number Handle 205-153 (T80T-4000-W) Installer, Seal 303-1247/2 Remover, Seal 303-1247/1

Scheme 11

Scheme 11: Valve Cover - LH
Scheme 11: Valve Cover - LH

Scheme 12

Scheme 12
Scheme 12

Scheme 13

Scheme 13
Scheme 13
ItemSpecification
Motorcraft High Performance Engine RTV Silicone TA-357WSE-M4G323-A6
Motorcraft Metal Surface Cleaner ZC-21WSE-M5B392-A
Motorcraft Metal Surface Prep ZC-31
Silicone Gasket Remover ZC-30

Material

Scheme 14

Scheme 14
Scheme 14
ItemPart NumberDescription
114A464Engine control wiring harness electrical connector (part of 12C508)
214A464Engine control wiring harness electrical connector (part of 12C508)
314A464LH fuel injector electrical connector (3 required) (part of 12C508)
414A464LH variable camshaft timing (VCT) electrical connector (part of 12C508)
5W700497Engine control wiring harness retainer (part of 12C508)

Scheme 15

Scheme 15
Scheme 15
ItemPart NumberDescription
66750Oil level indicator
76C519Valve cover stud bolt (11 required)
86C535Spark plug tube seal (3 required)
96C535VCT seal
106A505LH valve cover
116A559LH valve cover gasket
CAUTIONDuring 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.
  1. Remove the LH ignition coils. For additional information, refer to «ENGINE IGNITION - 3.5L»(ref-293498) article.
  2. Remove the oil level indicator.
  3. Disconnect the LH variable camshaft timing (VCT) solenoid electrical connector.
  4. Detach and disconnect the 2 engine control wiring harness electrical connectors.
  5. Detach all of the wiring harness retainers from the LH valve cover stud bolts.
  6. Disconnect the 3 LH fuel injector electrical connectors.
  7. Loosen the 11 stud bolts and remove the LH valve cover. Discard the gasket.
  8. Inspect the VCT solenoid seals and the spark plug tube seals. Remove any damaged seals. Using the special tools, remove the seal(s).
  9. Clean the valve cover, cylinder head and engine front cover sealing surfaces with metal surface cleaner.
  1. Using the special tools, install new VCT solenoid and/or spark plug tube seals.
  2. Apply an 8 mm (0.31 in) bead of Motorcraft High Performance Engine RTV Silicone to the engine front cover-to-LH cylinder head joints.
  3. Using a new gasket, install the LH valve cover and 11 stud bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
  4. Connect the 3 LH fuel injector electrical connectors.
  5. Attach all of the wiring harness retainers to the LH valve cover stud bolts.
  6. Connect and attach the 2 engine control wiring harness electrical connectors.
  7. Connect the LH VCT solenoid electrical connector.
  8. Install the oil level indicator.
  9. Install the LH ignition coils. For additional information, refer to «ENGINE IGNITION - 3.5L»(ref-293498) article.

Valve Cover - RH

Special Tools Illustration Tool Name Tool Number Handle 205-153 (T80T-4000-W) Installer, Seal 303-1247/2 Remover, Seal 303-1247/1

ItemSpecification
Motorcraft High Performance Engine RTV Silicone TA-357WSE-M4G323-A6
Motorcraft Metal Surface Cleaner ZC-21WSE-M5B392-A
Motorcraft Metal Surface Prep ZC-31
Silicone Gasket Remover ZC-30

Material

Scheme 16

Scheme 16
Scheme 16
ItemPart NumberDescription
114A464RH heated oxygen sensor (HO2S) electrical connector (part of 12C508)
214A464RH variable camshaft timing (VCT) electrical connector (part of 12C508)
314A464RH catalyst monitor sensor electrical connector (part of 12C508)
414A464RH fuel injector electrical connector (3 required) (part of 12C508)
514A464Heated PCV electrical connector (part of 12C508) (early build engines)
6W700497Engine control wiring harness retainer (part of 12C508)
713A506Engine control wiring harness retainer (part of 12C508)
8W520100Power steering pressure (PSP) tube bracket-to valve cover stud bolt nut
9PSP tube bracket (part of 3A719)

Scheme 17

Scheme 17
Scheme 17
ItemPart NumberDescription
106C519Valve cover stud bolt (10 required)
116C520Valve cover bolt
126C535VCT seal
136C535Spark plug tube seal (3 required)
146582RH valve cover
156584RH valve cover gasket
CAUTIONDuring 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.

All engines

  1. Remove the RH ignition coils. For additional information, refer to «ENGINE IGNITION - 3.5L»(ref-293498) article.
  2. Detach and disconnect the RH catalyst monitor sensor electrical connector.
  3. Detach and disconnect the RH heated oxygen sensor (HO2S) electrical connector.
  4. Disconnect the RH variable camshaft timing (VCT) solenoid electrical connector.
  5. Disconnect the 3 RH fuel injector electrical connectors.
  6. Disconnect the heated PCV valve electrical connector.
  7. Detach all of the wiring harness retainers from the RH valve cover stud bolts.
  8. Remove the nut and the power steering pressure (PSP) tube bracket from the valve cover stud bolt.
  9. Loosen the bolt, the 10 stud bolts and remove the RH valve cover. Discard the gasket.
  10. Inspect the VCT solenoid seals and the spark plug tube seals. Remove any damaged seals. Using the special tools, remove the seal(s).
  11. Clean the valve cover, cylinder head and engine front cover sealing surfaces with metal surface cleaner.

All engines

  1. Using the special tools, install new VCT solenoid and/or spark plug tube seals.
  2. Apply an 8 mm (0.31 in) bead of Motorcraft High Performance Engine RTV Silicone to the engine front cover-to-RH cylinder head joints.
  3. Using a new gasket, install the RH valve cover, bolt and the 10 stud bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
  4. Install the PSP tube bracket on the valve cover stud bolt and install the nut. Tighten to 7 Nm (62 lb-in).
  5. Attach all of the wiring harness retainers to the RH valve cover stud bolts.
  6. Connect the heated PCV valve electrical connector.
  7. Connect the 3 RH fuel injector electrical connectors.
  8. Connect the RH VCT electrical connector.
  9. Connect the RH HO2S sensor electrical connector.
  10. Connect the RH catalyst monitor sensor electrical connector.
  11. Install the RH ignition coils. For additional information, refer to «ENGINE IGNITION - 3.5L»(ref-293498) article.

Scheme 18

Scheme 18: Lower End Components - Exploded View, Crankshaft Pulley and Crankshaft Front Seal
Scheme 18: Lower End Components - Exploded View, Crankshaft Pulley and Crankshaft Front Seal
ItemPart NumberDescription
1W701512Crankshaft pulley bolt
2N806165Washer
36316Crankshaft pulley
46700Crankshaft front seal
  1. For additional information, refer to the procedures in this article.

Crankshaft Pulley

Special Tools Illustration Tool Name Tool Number 3-Jaw Puller 303-D121 Installer, Front Cover Oil Seal 303-335 Replacer, Crankshaft Damper 303-102 (T74P-6316-B) Strap Wrench 303-D055 (D85L-6000-A)

Scheme 19

Scheme 19: Crankshaft Pulley
Scheme 19: Crankshaft Pulley

Scheme 20

Scheme 20
Scheme 20

Scheme 21

Scheme 21
Scheme 21

Scheme 22

Scheme 22
Scheme 22
ItemSpecification
Motorcraft SAE 5W-20 Premium Synthetic Blend Motor Oil XO-5W20-QSP (US); Motorcraft SAE 5W-20 Super Premium Motor Oil CXO-5W20-LSP12 (Canada); or equivalentWSS-M2C930-A

Material

  1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(/ford/taurus-x/i-2007-2009/remont/hoistjack/#jacking-and-lifting) article.
  2. Remove the accessory drive belt and the power steering belt. For additional information, refer to «ACCESSORY DRIVE»(/ford/taurus-x/i-2007-2009/remont/accessory-drive-belts/#accessory-drive-system) article.
  3. Using the special tool, remove the crankshaft bolt and washer. Discard the bolt.
  4. Using the special tool, remove the crankshaft pulley.
  1. Lubricate the crankshaft front seal inner lip with clean engine oil.
  2. Using the special tools, install the crankshaft pulley.
  3. Using the special tool, install the crankshaft pulley washer and new bolt and tighten 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.
  4. Install the accessory drive belt and the power steering belt. For additional information, refer to «ACCESSORY DRIVE»(/ford/taurus-x/i-2007-2009/remont/accessory-drive-belts/#accessory-drive-system) article.

Crankshaft Front Seal

Special Tools Illustration Tool Name Tool Number Installer, Crankshaft Vibration Damper 303-102 (T74P-6316-B) Installer, Front Crankshaft Seal 303-1251 Remover, Oil Seal 303-409 (T92C-6700CH)

Scheme 23

Scheme 23
Scheme 23

Scheme 24

Scheme 24
Scheme 24
ItemSpecification
Motorcraft Metal Surface Prep ZC-31-A
Motorcraft SAE 5W-20 Premium Synthetic Blend Motor Oil XO-5W20-QSP (US); Motorcraft SAE 5W-20 Super Premium Motor Oil CXO-5W20-LSP12 (Canada); or equivalentWSS-M2C930-A

Material

  1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(/ford/taurus-x/i-2007-2009/remont/hoistjack/#jacking-and-lifting) article.
  2. Remove the crankshaft pulley. For additional information, refer to «Crankshaft Pulley»(/ford/taurus-x/i-2007-2009/remont/mechanical/#engine-35l__crankshaft-pulley) .
  3. Using the Oil Seal Remover, remove and discard the crankshaft front seal. Clean all sealing surfaces with metal surface prep.
  1. Using the Front Crankshaft Seal Installer and Crankshaft Vibration Damper Installer, install a new crankshaft front seal.
  2. Install the crankshaft pulley. For additional information, refer to «Crankshaft Pulley»(/ford/taurus-x/i-2007-2009/remont/mechanical/#engine-35l__crankshaft-pulley) .

Scheme 25

Scheme 25: Lower End Components - Exploded View, Flexplate and Crankshaft Rear Seal
Scheme 25: Lower End Components - Exploded View, Flexplate and Crankshaft Rear Seal
ItemPart NumberDescription
1W701559Flexplate bolt (8 required)
26375Flexplate
312A227Crankshaft sensor ring
46701Crankshaft rear seal
  1. For additional information, refer to the procedures in this article.

REMOVAL AND INSTALLATION

  1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(/ford/taurus-x/i-2007-2009/remont/hoistjack/#jacking-and-lifting) article.
  2. Remove the transaxle. For additional information, refer to «AUTOMATIC TRANSAXLE/TRANSMISSION - 6F50»(/ford/taurus-x/i-2007-2009/remont/automatic-trans/#automatic-transmission-6f50) article.
  3. Remove the bolts and the flexplate. To install, tighten to 80 Nm (59 lb-ft).
  4. To install, reverse the removal procedure.

Crankshaft Rear Seal

Special Tools Illustration Tool Name Tool Number Handle 205-153 (T80T-4000-W) Installer, Rear Main Seal 303-1250 Remover, Crankshaft Rear Oil Seal 303-519 (T95P-6701-EH) Slide Hammer 307-005 (T59L-100-B)

Scheme 26

Scheme 26
Scheme 26

Scheme 27

Scheme 27
Scheme 27

Scheme 28

Scheme 28
Scheme 28
ItemSpecification
Motorcraft Metal Surface Prep ZC-31-A
Motorcraft SAE 5W-20 Premium Synthetic Blend Motor Oil XO-5W20-QSP (US); Motorcraft SAE 5W-20 Super Premium Motor Oil CXO-5W20-LSP12 (Canada); or equivalentWSS-M2C930-A

Material

  1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(/ford/taurus-x/i-2007-2009/remont/hoistjack/#jacking-and-lifting) article.
  2. Remove the flexplate. For additional information, refer to «Flexplate»(/ford/taurus-x/i-2007-2009/remont/mechanical/#engine-35l) .
  3. Remove the crankshaft sensor ring.
  4. Using the Crankshaft Rear Oil Seal Remover and Slide Hammer, remove and discard the crankshaft rear seal. Clean all sealing surfaces with metal surface prep.
  1. Position the Rear Main Seal Installer onto the end of the crankshaft and slide a new crankshaft rear seal onto the tool.
  2. Using the Rear Main Seal Installer and Handle, install the new crankshaft rear seal.
  3. Install the crankshaft sensor ring.
  4. Install the flexplate. For additional information, refer to «Flexplate»(/ford/taurus-x/i-2007-2009/remont/mechanical/#engine-35l) .

Engine Front Cover

Special Tools Illustration Tool Name Tool Number 3-Jaw Puller 303-D121 Alignment Pins 307-399 Installer, Crankshaft Front Seal 303-1251 Installer, Front Cover Seal 303-335 (T88T-6701-A) Engine Support 303-1295 Remover, Oil Seal 303-409 (T92C-6700CH) Replacer, Crankshaft Damper 303-102 (T74P-6312-B) Strap Wrench 303-D055 (D85L-6000-A)

Scheme 29

Scheme 29
Scheme 29

Scheme 30

Scheme 30
Scheme 30
ItemSpecification
Motorcraft High Performance Engine RTV Silicone TA-357WSE-M4G323-A6
Motorcraft Metal Surface Prep ZC-31
Motorcraft SAE 5W-20 Premium Synthetic Blend Motor Oil XO-5W20-QSP (US); Motorcraft SAE 5W-20 Super Premium Motor Oil CXO-5W20-LSP12 (Canada); or equivalentWSS-M2C930-A
Silicone Gasket Remover ZC-30

Material

CAUTIONDuring 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.
  1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(/ford/taurus-x/i-2007-2009/remont/hoistjack/#jacking-and-lifting) article.
  2. Recover the A/C system. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(/ford/taurus-x/i-2007-2009/remont/manual-hvac-system/#hvac-control-system-general-information-and-diagnostics) article.
  3. Remove the air cleaner outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION AND FILTERING»(/ford/taurus-x/i-2007-2009/remont/removal-installation/#intake-air-distribution-system-and-filtering-system) article.
  4. Remove the front wheels and tires. For additional information, refer to «WHEELS AND TIRES»(/ford/taurus-x/i-2007-2009/remont/wheel-tire-system/#wheels-tires) article.
  5. Remove the accessory drive belt, tensioner and the power steering belt. For additional information, refer to «ACCESSORY DRIVE»(/ford/taurus-x/i-2007-2009/remont/accessory-drive-belts/#accessory-drive-system) article.
  6. Remove the degas bottle. For additional information, refer to «ENGINE COOLING»(/ford/taurus-x/i-2007-2009/remont/cooling-system-mechanical/#engine-cooling-system) article.
  7. Remove the 2 nuts and disconnect the A/C tubes. Discard the O-ring seals.
  8. Remove the nut and the A/C tube-to-receiver/drier. Discard the O-ring seal.
  9. Disconnect the power steering cooler tube and drain the power steering fluid into a suitable container.
  10. Remove the RH inner fender splash shield. For additional information, refer to «FRONT END BODY PANELS»(/ford/taurus-x/i-2007-2009/remont/exterior-body-panels/#body-system-front-end-body-panels) article.
  11. Using the special tool, remove the crankshaft bolt and washer. Discard the bolt.
  12. Using the special tool, remove the crankshaft pulley.
  13. Using the special tool, remove and discard the crankshaft front seal.
  14. Remove the 4 nuts and the Y-pipe-to-catalytic converter nuts. Discard the nuts.
  15. Remove the 2 Y-pipe flange nuts. Detach the exhaust hanger and remove the Y-pipe. Discard the gaskets and nuts.
  16. Remove the drain plug and drain the engine oil. Install the drain plug and tighten to 27 Nm (20 lb-ft).
  17. Disconnect the hose from the power steering reservoir.
  18. Remove the RH and LH valve covers. For additional information, refer to «Valve Cover - LH»(/ford/taurus-x/i-2007-2009/remont/mechanical/#engine-35l__valve-cover-lh) and «Valve Cover - RH»(/ford/taurus-x/i-2007-2009/remont/mechanical/#engine-35l__valve-cover-rh) .
  19. Remove the bolt and the ground cable.
  20. Disconnect the fuel efficient power steering system solenoid electrical connector.
  21. Disconnect the power steering pressure (PSP) switch electrical connector.
  22. Remove the PSP tube bracket-to-power steering pump bolt.
  23. Remove the 3 bolts and position aside the power steering pump.
  24. Position a floor jack and the special tool under the oil pan.
  25. Remove the nut, bolt and engine mount brace.
  26. Remove the 4 engine mount nuts.
  27. Remove the 3 bolts and the engine mount.
  28. Remove the 2 bolts and the engine mount bracket.
  29. Remove the 2 engine mount studs.
  30. Remove the 2 upper engine mount bracket bolts.
  31. Loosen the lower engine mount bracket bolt and remove the engine mount bracket and bolt as an assembly.
  32. Remove the A/C tube bracket bolt.
  33. Remove the A/C tube retaining clamp bolt.
  34. Remove the A/C tube-to-evaporator bolt and the 2 A/C tubes. Discard the O-ring seals.
  35. Using the floor jack, raise the engine slightly.
  36. Remove the 22 engine front cover bolts.
  37. Install 6 of the engine front cover bolts (finger tight) into the 6 threaded holes in the engine front cover. Tighten the bolts one turn at a time in a criss-cross pattern until the engine front cover-to-cylinder block seal is released. Remove the engine front cover.
  1. Clean the engine front cover using a 3M Roloc® Bristle Disk (2-in white, part number 07528) in a suitable tool turning at the recommended speed of 15,000 RPM. Thoroughly wash the engine front cover to remove any foreign material, including any abrasive particles created during the cleaning process.
  2. Clean the sealing surfaces of the cylinder heads, the cylinder block and the oil pan in the following sequence. Remove any large deposits of silicone or gasket material. Apply silicone gasket remover and allow to set for several minutes. Remove the silicone gasket remover. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain. Apply metal surface prep to remove any remaining traces of oil or coolant and to prepare the surfaces to bond. Do not attempt to make the metal shiny. Some staining of the metal surfaces is normal. Make sure the 2 locating dowel pins are seated correctly in the cylinder block.
  3. Install the special tools.
  4. Apply a 3.0 mm (0.11 in) bead of Motorcraft High Performance Engine RTV Silicone to the engine front cover sealing surfaces including the 3 engine mount bracket bosses. Apply a 5.5 mm (0.21 in) bead of Motorcraft High Performance Engine RTV Silicone to the oil pan-to-cylinder block joint and the cylinder head-to-cylinder block joint areas of the engine front cover in 5 places as indicated.
  5. Install the engine front cover and bolts 17, 18, 19 and 20. Tighten in sequence to 3 Nm (27 lb-in).
  6. Remove the special tools (alignment pins).
  7. Install the engine mount bracket and lower bolt. Do not tighten at this time.
  8. Install the 2 upper engine mount bracket bolts. Do not tighten at this time.
  9. Install the remaining engine front cover bolts. Tighten all of the engine front cover bolts and engine mount bracket bolts in the sequence shown in 2 stages: Stage 1: Tighten bolts 1 thru 22 to 10 Nm (89 lb-in) and bolts 23, 24 and 25 to 15 Nm (11 lb-ft). Stage 2: Tighten bolts 1 thru 22 to 24 Nm (18 lb-ft) and bolts 23, 24 and 25 to 75 Nm (55 lb-ft).
  10. Using the floor jack, lower the engine to the installed position.
  11. Install the new O-ring seals and the A/C tubes-to-evaporator and the bolt. Tighten to 15 Nm (11 lb-ft).
  12. Install the A/C tube retaining clamp bolt. Tighten to 10 Nm (89 lb-in).
  13. Install the A/C tube bracket bolt. Tighten to 10 Nm (89 lb-in).
  14. Install the 2 engine mount studs. Tighten to 18 Nm (13 lb-ft).
  15. Install the engine mount bracket and the 2 bolts. Tighten to 24 Nm (18 lb-ft).
  16. Install the engine mount and the 3 bolts. Tighten to 90 Nm (66 lb-ft).
  17. Install the 4 engine mount nuts. Tighten to 63 Nm (46 lb-ft).
  18. Install the engine mount brace, nut and bolt. Tighten to 20 Nm (15 lb-ft).
  19. Position the power steering pump and install the 3 bolts. Tighten to 25 Nm (18 lb-ft).
  20. Install the power steering pressure (PSP) tube bracket-to-power steering pump bolt. Tighten to 10 Nm (89 lb-in).
  21. Connect the PSP switch electrical connector.
  22. Connect the fuel efficient power steering system solenoid electrical connector.
  23. Install the ground cable bolt. Tighten to 12 Nm (9 lb-ft).
  24. Install the RH and LH valve covers. For additional information, refer to «Valve Cover - LH»(/ford/taurus-x/i-2007-2009/remont/mechanical/#engine-35l__valve-cover-lh) and «Valve Cover - RH»(/ford/taurus-x/i-2007-2009/remont/mechanical/#engine-35l__valve-cover-rh) .
  25. Connect the hose to the power steering reservoir.
  26. Using a new gasket, install the exhaust Y-pipe and install the 2 new nuts. Tighten to 40 Nm (30 lb-ft). Attach the exhaust hanger.
  27. Install the exhaust Y-pipe assembly and 4 new nuts. Tighten to 40 Nm (30 lb-ft).
  28. Using the special tools, install a new crankshaft front seal.
  29. Using the special tools, install the crankshaft pulley.
  30. Using the special tool, install the crankshaft pulley washer and new bolt and tighten 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.
  31. Install the RH inner fender splash shield. For additional information, refer to «FRONT END BODY PANELS»(/ford/taurus-x/i-2007-2009/remont/exterior-body-panels/#body-system-front-end-body-panels) article.
  32. Connect the power steering cooler tube.
  33. Install a new O-ring seal and the A/C tube-to-receiver/drier and the nut. Tighten to 15 Nm (11 lb-ft).
  34. Using new O-ring seals, connect the A/C tubes and install the 2 nuts. Tighten to 15 Nm (11 lb-ft).
  35. Install the degas bottle. For additional information, refer to «ENGINE COOLING»(/ford/taurus-x/i-2007-2009/remont/cooling-system-mechanical/#engine-cooling-system) article.
  36. Install the accessory drive belt, tensioner and the power steering belt. For additional information, refer to «ACCESSORY DRIVE»(/ford/taurus-x/i-2007-2009/remont/accessory-drive-belts/#accessory-drive-system) article.
  37. Install the front wheels and tires. For additional information, refer to «WHEELS AND TIRES»(/ford/taurus-x/i-2007-2009/remont/wheel-tire-system/#wheels-tires) article.
  38. Install the engine air cleaner outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION AND FILTERING»(/ford/taurus-x/i-2007-2009/remont/removal-installation/#intake-air-distribution-system-and-filtering-system) article.
  39. Fill the engine with clean engine oil.
  40. Fill the power steering system. For additional information, refer to «STEERING SYSTEM - GENERAL INFORMATION»(/ford/taurus-x/i-2007-2009/remont/manual-power-steering/#steering-system-general-information) article.
  41. Recharge the A/C system. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(/ford/taurus-x/i-2007-2009/remont/manual-hvac-system/#hvac-control-system-general-information-and-diagnostics) article.

Timing Drive Components

Special Tools Illustration Tool Name Tool Number Camshaft Alignment Tool 303-1248

Scheme 31

Scheme 31: Timing Drive Components
Scheme 31: Timing Drive Components

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 may cause engine failure.

  1. Remove the engine front cover. For additional information, refer to «Engine Front Cover»(/ford/taurus-x/i-2007-2009/remont/mechanical/#engine-35l__engine-front-cover) .
  2. Rotate the crankshaft clockwise and align the timing marks on the variable camshaft timing (VCT) assemblies as shown.
  3. Install the special tool onto the flats of the LH camshafts.
  4. Install the special tool onto the flats of the RH camshafts.
  5. Remove the 3 bolts and the RH VCT housing.
  6. Remove the 3 bolts and the LH VCT housing.
  7. Remove and discard the VCT housing seals.
  8. Remove the 2 bolts and the primary timing chain tensioner.
  9. Remove the primary timing chain tensioner arm.
  10. Remove the 2 bolts and the lower LH primary timing chain guide.
  11. Remove the primary timing chain.
  12. Remove the crankshaft timing chain sprocket.
  13. Remove the 2 bolts and the upper LH primary timing chain guide.
  14. Compress the LH secondary timing chain tensioner and install a suitable lockpin to retain the tensioner in the collapsed position.
  15. Remove and discard the LH VCT assembly bolt and the LH exhaust camshaft sprocket bolt. Remove the LH VCT assembly, secondary timing chain and the LH exhaust camshaft sprocket as an assembly.
  16. Remove the 2 bolts and the LH secondary timing chain tensioner.
  17. Compress the RH secondary timing chain tensioner and install a suitable lockpin to retain the tensioner in the collapsed position.
  18. Remove and discard the RH VCT assembly bolt and the RH exhaust camshaft sprocket bolt. Remove the RH VCT assembly, secondary timing chain and the RH exhaust camshaft sprocket as an assembly.
  19. Remove the 2 bolts and the RH secondary timing chain tensioner.
  20. Remove the 2 bolts and the RH primary timing chain guide.
  1. Install the RH primary timing chain guide and the 2 bolts. Tighten to 10 Nm (89 lb-in).
  2. Install the RH secondary timing chain tensioner and the 2 bolts. Tighten to 10 Nm (89 lb-in).
  3. Assemble the RH VCT assembly, the RH exhaust camshaft sprocket and the RH secondary timing chain. Align the colored links with the timing marks.
  4. Position the RH secondary timing assembly onto the camshafts.
  5. Install the new VCT bolt and new exhaust camshaft bolt and the original washers. Tighten in 4 stages. Stage 1: Tighten to 40 Nm (30 lb-ft). Stage 2: Loosen one full turn. Stage 3: Tighten to 10 Nm (89 lb-in). Stage 4: Tighten 90 degrees.
  6. Remove the lockpin from the RH secondary timing chain tensioner.
  7. Install the LH secondary timing chain tensioner and the 2 bolts. Tighten to 10 Nm (89 lb-in).
  8. Assemble the LH VCT assembly, the LH exhaust camshaft sprocket and the LH secondary timing chain. Align the colored links with the timing marks.
  9. Position the LH secondary timing assembly onto the camshafts.
  10. Install the new VCT bolt and new exhaust camshaft bolt and the original washers. Tighten in 4 stages. Stage 1: Tighten to 40 Nm (30 lb-ft). Stage 2: Loosen one full turn. Stage 3: Tighten to 10 Nm (89 lb-in). Stage 4: Tighten 90 degrees.
  11. Remove the lockpin from the LH secondary timing chain tensioner.
  12. Install the crankshaft timing chain sprocket.
  13. Install the primary timing chain with the colored links aligned with the timing marks on the VCT assemblies and the crankshaft sprocket.
  14. Install the upper LH primary timing chain guide and the 2 bolts. Tighten to 10 Nm (89 lb-in).
  15. Install the lower LH primary timing chain guide and the 2 bolts. Tighten to 10 Nm (89 lb-in).
  16. Install the primary timing chain tensioner arm.
  17. Reset the primary timing chain tensioner. Rotate the lever counterclockwise. Using a soft-jawed vise, compress the plunger. Align the hole in the lever with the hole in the tensioner housing. Install a suitable lockpin.
  18. Install the primary tensioner and the 2 bolts. Tighten to 10 Nm (89 lb-in). Remove the lockpin.
  19. As a post-check, verify correct alignment of all timing marks.
  20. Install new VCT housing seals.
  21. Install the LH VCT housing and the 3 bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
  22. Install the RH VCT housing and the 3 bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
  23. Install the engine front cover. For additional information, refer to «Engine Front Cover»(/ford/taurus-x/i-2007-2009/remont/mechanical/#engine-35l__engine-front-cover) .

Oil Filter Adapter

ItemSpecification
Motorcraft SAE 5W-20 Premium Synthetic Blend Motor Oil XO-5W20-QSP (US); Motorcraft SAE 5W-20 Super Premium Motor Oil CXO-5W20-LSP12 (Canada); or equivalentWSS-M2C930-A

Material

Scheme 32

Scheme 32
Scheme 32
ItemPart NumberDescription
16714Engine oil filter
2W708607Oil filter adapter bolt
36895Oil filter adapter bolt
46K649O-ring seal
56881Oil filter adapter
66A636Oil filter adapter gasket
  1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(/ford/taurus-x/i-2007-2009/remont/hoistjack/#jacking-and-lifting) article.
  2. Remove and discard the engine oil filter.
  3. Remove the 2 bolts and the oil filter adapter. Discard the gasket and O-ring seal. Clean and inspect all sealing surfaces.
  1. Using a new gasket and O-ring seal, install the oil filter adapter. Tighten the large bolt to 57 Nm (42 lb-ft). Tighten the small bolt to 10 Nm (89 lb-in).
  2. Install a new engine oil filter. Tighten to 5 Nm (44 lb-in) and then rotate an additional 180 degrees.

Engine Oil Pressure (EOP) Switch

ItemSpecification
Thread Sealant with PTFE TA-24WSK-M2G350-A2

Material

Scheme 33

Scheme 33
Scheme 33
ItemPart NumberDescription
114A464Engine oil pressure (EOP) switch electrical connector (part of 12C508)
29278EOP switch
  1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(/ford/taurus-x/i-2007-2009/remont/hoistjack/#jacking-and-lifting) article.
  2. Disconnect the engine oil pressure (EOP) switch electrical connector.
  3. Remove the EOP switch. To install, tighten to 18 Nm (13 lb-ft).
  4. To install, reverse the removal procedure. Apply thread sealant with PTFE to the EOP switch threads prior to installation.

Exhaust Manifold - LH

ItemSpecification
Motorcraft Metal Surface Prep ZC-31

Material

Scheme 34

Scheme 34
Scheme 34
ItemPart NumberDescription
1W713299LH exhaust manifold heat shield bolt (3 required)
29Y427LH exhaust manifold heat shield
3W701706LH exhaust manifold nut (6 required)
49431LH exhaust manifold
59448LH exhaust manifold gasket
6W701732LH exhaust manifold stud (6 required)
  1. Remove the LH catalytic converter. For additional information, refer to «EXHAUST SYSTEM»(/ford/taurus-x/i-2007-2009/remont/exhaust/#exhaust-system) article.
  2. Remove the LH heated oxygen sensor (HO2S). For additional information, refer to «ELECTRONIC ENGINE CONTROLS»(/ford/taurus-x/i-2007-2009/remont/removal-installation/#electronic-engine-control-system) article.
  3. Remove the 3 bolts and the LH exhaust manifold heat shield.
  4. Remove the 6 nuts and the LH exhaust manifold. Discard the nuts and gasket.
  5. Clean and inspect the LH exhaust manifold. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(/ford/taurus-x/i-2007-2009/remont/mechanical/#engine-system-general-information) article.
  6. Remove and discard the 6 LH exhaust manifold studs.
  7. Clean the exhaust manifold mating surface of the cylinder head with metal surface prep. Follow the directions on the packaging.
  1. Install 6 new LH exhaust manifold studs. Tighten to 12 Nm (9 lb-ft).
  2. Using a new gasket, install the LH exhaust manifold and 6 new nuts. Tighten in 2 stages in the sequence shown: Stage 1: Tighten to 20 Nm (15 lb-ft). Stage 2: Tighten to 20 Nm (15 lb-ft).
  3. Install the LH exhaust manifold heat shield and the 3 bolts. Tighten to 14 Nm (10 lb-ft).
  4. Install the LH HO2S. For additional information, refer to «ELECTRONIC ENGINE CONTROLS»(/ford/taurus-x/i-2007-2009/remont/removal-installation/#electronic-engine-control-system) article.
  5. Install the LH catalytic converter. For additional information, refer to «EXHAUST SYSTEM»(/ford/taurus-x/i-2007-2009/remont/exhaust/#exhaust-system) article.

Exhaust Manifold - RH

ItemSpecification
Motorcraft Metal Surface Prep ZC-31

Material

Scheme 35

Scheme 35
Scheme 35
ItemPart NumberDescription
114A464RH heated oxygen sensor (HO2S) electrical connector
2W701706RH exhaust manifold nut (6 required)
39430RH exhaust manifold
49448RH exhaust manifold gasket
5W701732RH exhaust manifold stud (6 required)
  1. Remove the RH catalytic converter. For additional information, refer to «EXHAUST SYSTEM»(/ford/taurus-x/i-2007-2009/remont/exhaust/#exhaust-system) article.
  2. Disconnect the RH heated oxygen sensor (HO2S) electrical connector.
  3. Remove the 6 nuts and the RH exhaust manifold. Discard the nuts and gasket.
  4. Clean and inspect the RH exhaust manifold. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(/ford/taurus-x/i-2007-2009/remont/mechanical/#engine-system-general-information) article.
  5. Remove and discard the 6 RH exhaust manifold studs.
  6. Clean the exhaust manifold mating surface of the cylinder head with metal surface prep. Follow the directions on the packaging.
  1. Install 6 new RH exhaust manifold studs. Tighten to 12 Nm (9 lb-ft).
  2. Using a new gasket, install the RH exhaust manifold and 6 new nuts. Tighten in 2 stages in the sequence shown: Stage 1: Tighten to 20 Nm (15 lb-ft). Stage 2: Tighten to 20 Nm (15 lb-ft).
  3. Connect the RH HO2S electrical connector.
  4. Install the RH catalytic converter. For additional information, refer to «EXHAUST SYSTEM»(/ford/taurus-x/i-2007-2009/remont/exhaust/#exhaust-system) article.

Engine Mount

Special Tools Illustration Tool Name Tool Number Oil Pan Holding Fixture 303-1295

Scheme 36

Scheme 36
Scheme 36
ItemPart NumberDescription
1W520102Engine mount brace nut
2W712511Engine mount brace bolt
36K075Engine mount brace
4W712334Engine mount-to-engine nut (4 required)
5W711914Engine mount stud (4 required)
6W712507Engine mount-to-frame bolt (3 required)
76F012Engine mount
  1. Remove the exhaust flexible pipe. For additional information, refer to «EXHAUST SYSTEM»(/ford/taurus-x/i-2007-2009/remont/exhaust/#exhaust-system) article.
  2. Position a floor jack and the special tool under the oil pan.
  3. Remove the engine coolant degas bottle. For additional information, refer to «ENGINE COOLING»(/ford/taurus-x/i-2007-2009/remont/cooling-system-mechanical/#engine-cooling-system) article.
  4. Remove the nut, bolt and engine mount brace. To install, tighten to 20 Nm (15 lb-ft).
  5. Remove the 4 engine mount nuts. To install, tighten to 63 Nm (46 lb-ft).
  6. Remove the 4 engine mount studs. To install, tighten to 18 Nm (13 lb-ft).
  7. Remove the 3 bolts and the engine mount. To install, tighten to 90 Nm (66 lb-ft).
  8. To install, reverse the removal procedure.

Special Tools Illustration Tool Name Tool Number Camshaft Alignment Tool 303-1248

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 may cause engine failure.

  1. Remove the engine front cover. For additional information, refer to «Engine Front Cover»(/ford/taurus-x/i-2007-2009/remont/mechanical/#engine-35l__engine-front-cover) .
  2. Rotate the crankshaft clockwise and align the timing marks on the variable camshaft timing (VCT) assemblies as shown.
  3. Install the special tool onto the flats of the LH camshafts.
  4. Install the special tool onto the flats of the RH camshafts.
  5. Remove the 3 bolts and the RH VCT housing.
  6. Remove the 3 bolts and the LH VCT housing.
  7. Remove and discard the VCT housing seals.
  8. Remove the 2 bolts and the primary timing chain tensioner.
  9. Remove the primary timing chain tensioner arm.
  10. Remove the 2 bolts and the lower LH primary timing chain guide.
  11. Remove the primary timing chain.
  12. Remove the crankshaft timing chain sprocket.
  13. Remove the 2 oil pump screen and pickup tube bolts.
  14. Remove the 3 oil pump bolts. Rotate the oil pump clockwise and separate the oil pump from the oil pump screen and pickup tube. Remove the oil pump. Discard the oil pump screen and pickup tube O-ring seal.
  1. Position the oil pump onto the crankshaft and rotate counterclockwise to position the pump onto the oil pump screen and pickup tube. Install the 3 bolts and tighten to 10 Nm (89 lb-in).
  2. Install the 2 oil pump screen and pickup tube bolts. Tighten to 10 Nm (89 lb-in).
  3. Install the crankshaft timing chain sprocket.
  4. Install the primary timing chain with the colored links aligned with the timing marks on the VCT assemblies and the crankshaft sprocket.
  5. Install the LH primary timing chain guide and the 2 bolts. Tighten to 10 Nm (89 lb-in).
  6. Install the primary timing chain tensioner arm.
  7. Reset the primary timing chain tensioner. Rotate the lever counterclockwise. Using a soft-jawed vise, compress the plunger. Align the hole in the lever with the hole in the tensioner housing. Install a suitable lockpin.
  8. Install the primary tensioner and the 2 bolts. Tighten to 10 Nm (89 lb-in). Remove the lockpin.
  9. As a post-check, verify correct alignment of all timing marks.
  10. Install new VCT housing seals.
  11. Install the LH VCT housing and the 3 bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
  12. Install the RH VCT housing and the 3 bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
  13. Install the engine front cover. For additional information, refer to «Engine Front Cover»(/ford/taurus-x/i-2007-2009/remont/mechanical/#engine-35l__engine-front-cover) .

Special Tools Illustration Tool Name Tool Number Disconnect Tool, Transmission Cooler Line 307-569 Engine Lifting Bracket 303-1245 Heavy Duty Floor Crane 014-00071 or equivalent Powertrain Lift 014-00765 Remover, Front Wheel Hub 205-D070 (D93P-1175-B) or equivalent Remover, Halfshaft (Extension) 205-243 (T89P-3415-A) Remover, Halfshaft (Plate) 205-290 (T89P-3415-B) Slide Hammer 100-001 (T50T-100-A) Spreader Bar 303-D089 (D93P-6001-A3) or equivalent Universal Adapter Brackets 014-0001

Scheme 37

Scheme 37: Engine
Scheme 37: Engine

Scheme 38

Scheme 38
Scheme 38

Scheme 39

Scheme 39
Scheme 39

Scheme 40

Scheme 40
Scheme 40

Scheme 41

Scheme 41
Scheme 41

Scheme 42

Scheme 42
Scheme 42

Scheme 43

Scheme 43
Scheme 43
WARNINGDo not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.

All vehicles

  1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(/ford/taurus-x/i-2007-2009/remont/hoistjack/#jacking-and-lifting) article.
  2. Release the fuel system pressure. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(/ford/taurus-x/i-2007-2009/remont/fuel-system/#fuel-system-general-information) article.
  3. Recover the A/C system. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(/ford/taurus-x/i-2007-2009/remont/manual-hvac-system/#hvac-control-system-general-information-and-diagnostics) article.
  4. Drain the cooling system. For additional information, refer to «ENGINE COOLING»(/ford/taurus-x/i-2007-2009/remont/cooling-system-mechanical/#engine-cooling-system) article.
  5. Remove the front wheels and tires. For additional information, refer to «WHEELS AND TIRES»(/ford/taurus-x/i-2007-2009/remont/wheel-tire-system/#wheels-tires) article.
  6. Remove the accessory drive belt and the power steering belt. For additional information, refer to «ACCESSORY DRIVE»(/ford/taurus-x/i-2007-2009/remont/accessory-drive-belts/#accessory-drive-system) article.
  7. Disconnect the power steering cooler tube and drain the power steering fluid into a suitable container.
  8. Remove the degas bottle. For additional information, refer to «ENGINE COOLING»(/ford/taurus-x/i-2007-2009/remont/cooling-system-mechanical/#engine-cooling-system) article.
  9. Remove the engine air cleaner and air cleaner outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION AND FILTERING»(/ford/taurus-x/i-2007-2009/remont/removal-installation/#intake-air-distribution-system-and-filtering-system) article.
  10. Remove the battery. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/taurus-x/i-2007-2009/remont/body-electrical/#battery-mounting-and-cables) article.
  11. Detach the 4 pin-type wiring harness fasteners from the side of the battery tray.
  12. Detach the 2 pin-type wiring harness fasteners from the front of the battery tray.
  13. Remove the 2 lower battery tray bracket bolts.
  14. Remove the nut, bolt and the battery tray and bracket.
  15. Disconnect the engine wiring harness electrical connector.
  16. Remove the nut and disconnect the power feed wire from the positive battery terminal.
  17. Remove the nut and disconnect the ground cable from the negative battery terminal.
  18. Disconnect the vacuum hose and the evaporative emissions (EVAP) tube from the upper intake manifold.
  19. Detach the EVAP tube pin-type retainer from the upper intake manifold.
  20. Disconnect the upper radiator hose, lower radiator hose and 2 heater hoses from the thermostat housing.
  21. Disconnect the transaxle control cable from the control lever.
  22. Disconnect the transaxle control cable from the shift cable bracket and detach the 2 wiring harness pin-type retainers.
  23. If equipped, detach the engine block heater harness from the radiator support and the power steering tube.
  24. Disconnect the A/C pressure switch and remove the nut and disconnect the upper A/C tube from the condenser. Discard the O-ring seal.
  25. Remove the 2 nuts and disconnect the A/C tubes. Discard the O-ring seals.
  26. Remove the nut and the A/C tube. Discard the O-ring seal.
  27. Disconnect the fuel supply tube from the fuel rail. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(/ford/taurus-x/i-2007-2009/remont/fuel-system/#fuel-system-general-information) article.
  28. Disconnect the 2 engine wiring harness electrical connectors. Detach the electrical connector from the LH valve cover.
  29. Detach the wire harness retainer from the RH valve cover stud bolt.
  30. Remove the bolt and the ground cable from the engine.
  31. Remove the oil level indicator.
  32. Disconnect the hose from the power steering reservoir.
  33. Disconnect the transaxle control electrical connector.
  34. Detach the transaxle control wire harness retainer from the transaxle stud bolt.
  35. Place the steering wheel in the straight-ahead position and the ignition key in the OFF position.
  36. Remove the bolt and disconnect the steering column shaft from the steering gear. Discard the bolt.
  37. Remove the 4 Y-pipe-to-catalytic converter nuts. Discard the nuts.
  38. Remove the 2 Y-pipe flange nuts. Detach the exhaust hanger and remove the Y-pipe. Discard the gaskets and nuts.
  39. Remove the 4 bolts (3 shown) and support the driveshaft with a length of mechanic's wire.
  40. Remove the drain plug and drain the engine oil. Install the drain plug and tighten to 27 Nm (20 lb-ft).
  41. Remove and discard the engine oil filter.
  42. Remove the power steering pressure (PSP) tube bracket-to-steering gear bolt.
  43. Remove the bolt, rotate the clamp plate clockwise and disconnect the PSP tube from the steering gear. Discard the O-ring seal.
  44. Remove the 2 engine roll restrictor-to-transaxle bolts.
  45. Remove and discard the upper stabilizer link nuts.
  46. Remove and discard the tie-rod end nuts. Separate the tie-rod ends from the wheel knuckles.
  47. Remove and discard the lower ball joint-to-wheel knuckle nuts. Separate the ball joints from the wheel knuckles.
  48. Position the special tool under the subframe assembly.
  49. Remove the subframe bracket-to-body bolts.
  50. Remove the rear subframe bolts and the subframe brackets.
  51. Remove the front subframe bolts.
  52. Lower the subframe assembly from the vehicle.
  53. Using the special tools, separate the LH halfshaft from the transaxle and support halfshaft with a length of mechanic's wire.
  54. Remove and discard the RH halfshaft nut.
  55. Using the special tool, separate the RH halfshaft from the hub.
  56. Remove the 2 RH halfshaft carrier bearing nuts. Remove the RH halfshaft.
  57. Remove the 2 RH halfshaft support bracket studs.
  58. Remove the 4 bolts and the RH halfshaft support bracket.
  59. Remove the 2 secondary latches from the transmission fluid cooler tubes at the transmission fluid cooler thermal bypass valve.
  60. Using the special tool, disconnect the transmission fluid cooler tubes from the transmission fluid cooler thermal bypass valve.
  61. Remove the 2 fasteners and the inspection cover.
  62. Remove and discard the 3 torque converter bolts.
  63. Remove the 4 oil pan-to-transaxle bolts.
  64. Disconnect the RH catalyst monitor electrical connector.
  65. Remove the 4 nuts and the RH catalytic converter. Discard the nuts and gasket.
  66. Remove the 5 bolts and the power transfer unit (PTU) support bracket.
  67. Remove the 5 bolts and the PTU.
  68. Install the special tools.
  69. Remove the transaxle mount through bolt and nut.
  70. Remove the bolt, 3 nuts and the transaxle mount bracket.
  71. Remove the nut, bolt and engine mount brace.
  72. Remove the 4 engine mount nuts.
  73. Remove the 3 bolts and the engine mount.
  74. Lower the engine and transaxle assembly from the vehicle.
  75. If equipped, remove the starter motor solenoid cover.
  76. Remove the 2 nuts and the starter motor wiring terminals.
  77. Disconnect the wiring harness retainer from the starter motor stud bolt.
  78. Remove the stud bolt, bolt and the starter.
  79. Install the special tool on the LH cylinder head.
  80. Using the special tools and a suitable engine crane, remove the engine and transaxle from the lift table.
  81. Remove the 2 engine-to-transaxle bolts.
  82. Remove the 5 transaxle-to-engine bolts. Separate the transaxle from the engine.

Camshaft

Special Tools Illustration Tool Name Tool Number 3-Jaw Puller 303-D121 Camshaft Alignment Tool 303-1248 Disconnect Tool, Transmission Cooler Tube 307-569 Handle 205-153 (T80T-4000-W) Powertrain Lift 014-00765 Remover, Front Hub 205-D070 (D93P-1175-B) or equivalent Remover, Halfshaft (Extension) 205-243 (T89P-3415-A) Remover, Halfshaft (Plate) 205-290 (T89P-3415-B) Remover, Oil Seal 303-409 (T92C-6700CH) Seal Remover 303-1247/1 Slide Hammer 100-001 (T50T-100-A) Strap Wrench 303-D055 (D85L-6000-A) Universal Adapter Brackets 014-0001

ItemSpecification
Motorcraft Metal Surface Prep ZC-31-A
Silicone Gasket Remover ZC-30

Material

CAUTIONDuring 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.

All camshafts

  1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(/ford/taurus-x/i-2007-2009/remont/hoistjack/#jacking-and-lifting) article.
  2. Release the fuel system pressure. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(/ford/taurus-x/i-2007-2009/remont/fuel-system/#fuel-system-general-information) article.
  3. Recover the A/C system. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(/ford/taurus-x/i-2007-2009/remont/manual-hvac-system/#hvac-control-system-general-information-and-diagnostics) article.
  4. Drain the cooling system. For additional information, refer to «ENGINE COOLING»(/ford/taurus-x/i-2007-2009/remont/cooling-system-mechanical/#engine-cooling-system) article.
  5. Remove the front wheels and tires. For additional information, refer to «WHEELS AND TIRES»(/ford/taurus-x/i-2007-2009/remont/wheel-tire-system/#wheels-tires) article.
  6. Remove the accessory drive belt and the power steering belt. For additional information, refer to «ACCESSORY DRIVE»(/ford/taurus-x/i-2007-2009/remont/accessory-drive-belts/#accessory-drive-system) article.
  7. Disconnect the power steering cooler hose and drain the power steering fluid into a suitable container.
  8. Remove the degas bottle. For additional information, refer to «ENGINE COOLING»(/ford/taurus-x/i-2007-2009/remont/cooling-system-mechanical/#engine-cooling-system) article.
  9. Remove the engine air cleaner and air cleaner outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION AND FILTERING»(/ford/taurus-x/i-2007-2009/remont/removal-installation/#intake-air-distribution-system-and-filtering-system) article.
  10. Remove the battery. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/taurus-x/i-2007-2009/remont/body-electrical/#battery-mounting-and-cables) article.
  11. Detach the 4 pin-type wiring harness fasteners from the side of the battery tray.
  12. Detach the 2 pin-type wiring harness fasteners from the front of the battery tray.
  13. Remove the 2 lower battery tray bracket bolts.
  14. Remove the nut, bolt and the battery tray and bracket.
  15. Disconnect the engine wiring harness electrical connector.
  16. Remove the nut and disconnect the power feed wire from the positive battery terminal.
  17. Remove the nut and disconnect the ground cable from the negative battery terminal.
  18. Disconnect the vacuum hose and the evaporative emissions (EVAP) tube from the upper intake manifold.
  19. Detach the EVAP tube pin-type retainer from the upper intake manifold.
  20. Disconnect the upper radiator hose, lower radiator hose and one heater hose from the thermostat housing.
  21. Disconnect the transaxle control cable from the control lever.
  22. Disconnect the transaxle control cable from the shift cable bracket.
  23. If equipped, detach the engine block heater wiring harness from the radiator support and the power steering tube.
  24. Disconnect the A/C pressure switch and remove the nut and disconnect the upper A/C tube from the condenser. Discard the O-ring seal.
  25. Remove the 2 nuts and disconnect the A/C tubes. Discard the O-ring seals.
  26. Remove the nut and the A/C tube. Discard the O-ring seal.
  27. Disconnect the fuel supply tube from the fuel rail. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(/ford/taurus-x/i-2007-2009/remont/fuel-system/#fuel-system-general-information) article.
  28. Disconnect the 2 engine wiring harness electrical connectors. Detach the electrical connector from the LH valve cover.
  29. Detach the wire harness retainer from the RH valve cover stud bolt.
  30. Remove the bolt and the ground cable.
  31. Remove the oil level indicator.
  32. Disconnect the hose from the power steering reservoir.
  33. Disconnect the transaxle control electrical connector.
  34. Detach the transaxle control wire harness retainer from the transaxle stud bolt.
  35. Place the steering wheel in the straight-ahead position and the ignition key in the OFF position.
  36. Remove the bolt and disconnect the steering column shaft from the steering gear. Discard the bolt.
  37. Remove the 4 Y-pipe-to-catalytic converter nuts. Discard the nuts.
  38. Remove the 2 Y-pipe flange nuts. Detach the exhaust hanger and remove the Y-pipe. Discard the gaskets and nuts.
  39. Remove the 4 bolts (3 shown) and support the driveshaft with a length of mechanic's wire.
  40. Remove the drain plug and drain the engine oil. Install the drain plug and tighten to 27 Nm (20 lb-ft).
  41. Remove and discard the engine oil filter.
  42. Remove the power steering pressure (PSP) tube bracket-to-steering gear bolt.
  43. Remove the bolt, rotate the clamp plate clockwise and disconnect the PSP tube from the steering gear. Discard the O-ring seal.
  44. Remove the 2 engine roll restrictor-to-transaxle bolts.
  45. Remove and discard the upper stabilizer link nuts.
  46. Remove and discard the tie-rod end nuts. Separate the tie-rod ends from the wheel knuckles.
  47. Remove and discard the lower ball joint-to-wheel knuckle nuts. Separate the ball joints from the wheel knuckles.
  48. Position the special tool under the subframe assembly.
  49. Remove the subframe bracket-to-body bolts.
  50. Remove the rear subframe bolts and the subframe brackets.
  51. Remove the front subframe bolts.
  52. Lower the subframe assembly from the vehicle.
  53. Using the special tools, separate the LH halfshaft from the transaxle and support halfshaft with a length of mechanic's wire.
  54. Remove and discard the RH halfshaft nut.
  55. Using the special tool, separate the RH halfshaft from the hub.
  56. Remove the 2 RH halfshaft carrier bearing nuts. Remove the RH halfshaft.
  57. Remove the 2 RH halfshaft support bracket studs.
  58. Remove the 4 bolts and the RH halfshaft support bracket.
  59. Remove the 2 secondary latches from the transmission fluid cooler tubes at the transmission fluid cooler thermal bypass valve.
  60. Using the special tool, disconnect the transmission fluid cooler tubes from the transmission fluid cooler thermal bypass valve.
  61. Install the special tools.
  62. Remove the transaxle mount through bolt and nut.
  63. Remove the bolt, 3 nuts and the transaxle mount bracket.
  64. Remove the nut, bolt and engine mount brace.
  65. Remove the 4 engine mount nuts.
  66. Remove the 3 bolts and the engine mount.
  67. Lower the engine and transaxle assembly from the vehicle.
  68. If equipped, disconnect the heated PCV electrical connector.
  69. Disconnect the PCV hose from the PCV valve.
  70. Disconnect the throttle body (TB) electrical connector.
  71. Detach the wiring harness retainers from the upper intake manifold.
  72. If equipped, remove the upper intake manifold long support bracket bolt.
  73. Remove the upper intake manifold short support bracket bolt.
  74. Remove the wire harness pin-type retainer and the fuel tube bracket bolt from the upper intake manifold.
  75. Remove the 6 bolts and the upper intake manifold. Discard the gaskets.
  76. Disconnect the RH catalyst monitor electrical connector.
  77. Disconnect the fuel efficient power steering system solenoid electrical connector.
  78. Disconnect the RH variable camshaft timing (VCT) solenoid electrical connector.
  79. Disconnect the 3 RH coil-on-plug electrical connectors.
  80. If equipped, disconnect the heated PCV valve electrical connector.
  81. Detach all of the wiring harness retainers from the RH valve cover and stud bolts.
  82. Disconnect the LH VCT solenoid electrical connector.
  83. Disconnect the 3 LH coil-on-plug electrical connectors.
  84. Detach all of the wiring harness retainers from the LH valve cover and stud bolts.
  85. Remove the 6 bolts and the 6 coil-on-plug assemblies.
  86. Disconnect the PSP switch electrical connector.
  87. Remove the PSP tube bracket-to-power steering pump bolt.
  88. Remove the nut and the PSP tube bracket from the RH valve cover stud bolt.
  89. Remove the 3 bolts and position aside the power steering pump.
  90. Remove the 3 bolts and the accessory drive belt tensioner.
  91. Remove the 11 stud bolts and the LH valve cover. Discard the gasket.
  92. Remove the bolt, the 10 stud bolts and the RH valve cover. Discard the gasket.
  93. Inspect the VCT solenoid seals and the spark plug tube seals. Install new seals if damaged. Using the special tools, remove the seal(s).
  94. Using the special tool, remove the crankshaft bolt and washer. Discard the bolt.
  95. Using the special tool, remove the crankshaft pulley.
  96. Using the special tool, remove and discard the crankshaft front seal.
  97. Remove the 2 bolts and the engine mount bracket.
  98. Remove the 2 engine mount studs.
  99. Remove the 3 bolts and the engine mount bracket.
  100. Remove the 22 engine front cover bolts.
  101. Install 6 of the engine front cover bolts (finger tight) into the 6 threaded holes in the engine front cover. Tighten the bolts one turn at a time in a criss-cross pattern until the engine front cover-to-cylinder block seal is released. Remove the engine front cover.
  102. Clean the engine front cover using a 3M Roloc® Bristle Disk (2-in white, part number 07528) in a suitable tool turning at the recommended speed of 15,000 RPM. Thoroughly wash the engine front cover to remove any foreign material, including any abrasive particles created during the cleaning process.
  103. Clean the sealing surfaces of the cylinder heads, the cylinder block and the oil pan in the following sequence. Remove any large deposits of silicone or gasket material. Apply silicone gasket remover and allow to set for several minutes. Remove the silicone gasket remover. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain. Apply metal surface prep, to remove any remaining traces of oil or coolant and to prepare the surfaces to bond. Do not attempt to make the metal shiny. Some staining of the metal surfaces is normal. Make sure the 2 locating dowel pins are seated correctly in the cylinder block.
  104. Rotate the crankshaft clockwise and align the timing marks on the VCT assemblies as shown.
  105. Install the special tool onto the flats of the LH camshafts.
  106. Install the special tool onto the flats of the RH camshafts.
  107. Remove the 3 bolts and the RH VCT housing.
  108. Remove the 3 bolts and the LH VCT housing.
  109. Remove and discard the VCT housing seals.
  110. Remove the 2 bolts and the primary timing chain tensioner.
  111. Remove the primary timing chain tensioner arm.
  112. Remove the 2 bolts and the lower LH primary timing chain guide.
  113. Remove the primary timing chain.
  114. Compress the LH secondary timing chain tensioner and install a suitable lockpin to retain the tensioner in the collapsed position.
  115. Remove and discard the LH VCT assembly bolt and the LH exhaust camshaft sprocket bolt. Remove the LH VCT assembly, secondary timing chain and the LH exhaust camshaft sprocket as an assembly.
  116. Remove the special tool from the LH camshafts.
  117. Verify the LH camshafts are in the neutral position.
  118. Remove the bolts and the LH camshaft bearing caps. Remove the LH camshafts.
  119. Compress the RH secondary timing chain tensioner and install a suitable lockpin to retain the tensioner in the collapsed position.
  120. Remove and discard the RH VCT assembly bolt and the RH exhaust camshaft sprocket bolt. Remove the RH VCT assembly, secondary timing chain and the RH exhaust camshaft sprocket as an assembly.
  121. Remove the special tool from the RH camshafts.
  122. Rotate the RH camshafts counterclockwise to the neutral position.
  123. Remove the bolts and the RH camshaft bearing caps. Remove the RH camshafts.

Valve Tappets

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, may cause engine failure.

  1. Depending on the valve tappets being serviced, remove the LH and/or the RH camshafts. For additional information, refer to «Camshaft»(/ford/taurus-x/i-2007-2009/remont/mechanical/#engine-35l__camshaft) .
  2. Remove the valve tappets from the cylinder head.

Valve Spring, Retainer and Seal

Special Tools Illustration Tool Name Tool Number Compressor, Valve Spring 303-300 (T87C-6565-A) Compressor, Valve Spring 303-350 (T89P-6565-A) Compressor, Valve Spring 303-1249

Scheme 44

Scheme 44: Valve Spring, Retainer and Seal
Scheme 44: Valve Spring, Retainer and Seal

Scheme 45

Scheme 45
Scheme 45

Scheme 46

Scheme 46
Scheme 46

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, may cause engine failure.

  1. Remove the valve tappets from the cylinder being serviced. For additional information, refer to «Valve Tappets»(/ford/taurus-x/i-2007-2009/remont/mechanical/#engine-35l__valve-tappets) .
  2. Rotate the crankshaft until the piston for the valve being serviced is at the top of its stroke.
  3. Pressurize the cylinder using compressed air.
  4. Using the Valve Spring Compressors, remove the keys, retainer and spring.
  5. Remove and discard the valve stem seal.

Cylinder Head - RH

ItemSpecification
Motorcraft Metal Surface Prep ZC-31-A
Silicone Gasket Remover ZC-30

Material

CAUTIONDuring 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.
  1. Remove the RH camshafts. For additional information, refer to «Camshaft»(/ford/taurus-x/i-2007-2009/remont/mechanical/#engine-35l__camshaft) .
  2. Disconnect the RH heated oxygen sensor (HO2S) electrical connector.
  3. Disconnect the RH camshaft position (CMP) sensor electrical connector.
  4. Remove the bolt and the RH CMP sensor.
  5. Remove the bolt and the power steering pressure (PSP) tube bracket from the RH cylinder head.
  6. Remove the bolt and the ground wire.
  7. Disconnect the 6 fuel injector electrical connectors (3 shown).
  8. Disconnect the cylinder head temperature (CHT) sensor electrical connector.
  9. Disconnect the LH catalyst monitor sensor electrical connector.
  10. Remove the 2 LH catalytic converter bracket bolts.
  11. Remove the 4 nuts (3 shown) and the LH catalytic converter. Discard the nuts and the gasket.
  12. Remove the LH cylinder block drain plug. Allow coolant to drain from the cylinder block.
  13. Remove the 4 nuts and the RH catalytic converter. Discard the nuts and gasket.
  14. If equipped, remove the heat shield and disconnect the block heater electrical connector. Remove the block heater wiring harness from the engine.
  15. Remove the RH cylinder block drain plug or, if equipped, the block heater. Allow coolant to drain from the cylinder block.
  16. Remove the 3 bolts and the RH exhaust manifold heat shield.
  17. Remove the 6 nuts and the RH exhaust manifold. Discard the nuts and exhaust manifold gaskets.
  18. Clean and inspect the RH exhaust manifold. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(/ford/taurus-x/i-2007-2009/remont/mechanical/#engine-system-general-information) article.
  19. Remove and discard the 6 RH exhaust manifold studs.
  20. Remove the 2 bolts and the RH primary timing chain guide.
  21. Remove the bolts and the RH secondary timing chain tensioner.
  22. Remove the 2 bolts and the engine lifting eye.
  23. If equipped, remove the bolt and the upper intake manifold long support bracket.
  24. Remove the bolt and the upper intake manifold short support bracket.
  25. Remove the coolant by-pass hose from the thermostat housing.
  26. Remove the 4 bolts and the fuel rail and injectors as an assembly.
  27. Remove the 3 thermostat housing-to-lower intake manifold bolts. Remove the thermostat housing and discard the gasket and O-ring seal.
  28. Remove the 10 bolts and the lower intake manifold. Discard the gaskets.
  29. Disconnect and remove the CHT sensor jumper harness.
  30. Remove the valve tappets from the cylinder head.
  31. Inspect the valve tappets. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(/ford/taurus-x/i-2007-2009/remont/mechanical/#engine-system-general-information) article.
  32. Remove and discard the M6 bolt.
  33. Remove and discard the 8 bolts from the cylinder head. Remove the cylinder head. Discard the cylinder head gasket.
  34. Clean the cylinder head-to-cylinder block mating surfaces of both the cylinder heads and the cylinder block in the following sequence. Remove any large deposits of silicone or gasket material with a plastic scraper. Apply silicone gasket remover, following package directions, and allow to set for several minutes. Remove the silicone gasket remover with a plastic scraper. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain. Apply metal surface prep, following package directions, to remove any remaining traces of oil or coolant and to prepare the surfaces to bond with the new gasket. Do not attempt to make the metal shiny. Some staining of the metal surfaces is normal.
  35. Support the cylinder head on a bench with the head gasket side up.
  36. Inspect all areas of the deck face with a straightedge and feeler gauge. The cylinder head must not have depressions deeper than 0.0254 mm (0.001 in) across a 38.1 mm (1.5 in) square area, or scratches more than 0.0254 mm (0.001 in).

Cylinder Head - LH

ItemSpecification
Motorcraft Metal Surface Prep ZC-31-A
Silicone Gasket Remover ZC-30

Material

CAUTIONDuring 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.
  1. Remove the LH camshafts. For additional information, refer to «Camshaft»(/ford/taurus-x/i-2007-2009/remont/mechanical/#engine-35l__camshaft) .
  2. Disconnect the 6 fuel injector electrical connectors (3 shown).
  3. Disconnect the cylinder head temperature (CHT) sensor electrical connector.
  4. Disconnect the LH camshaft position (CMP) sensor electrical connector.
  5. Remove the bolt and the LH CMP sensor.
  6. Disconnect the LH heated oxygen sensor (HO2S) electrical connector.
  7. Disconnect the LH catalyst monitor sensor electrical connector.
  8. Detach the wiring harness retainer from the rear of the LH cylinder head.
  9. Remove the nut and disconnect the generator B+ cable.
  10. Disconnect the generator electrical connector.
  11. Remove the nut, bolt and the generator. Remove the generator stud.
  12. Detach the engine oil pressure (EOP) switch wiring harness pin-type retainer.
  13. Remove the 2 LH catalytic converter bracket bolts.
  14. Remove the 4 nuts (3 shown) and the LH catalytic converter. Discard the nuts and the gasket.
  15. Remove the 3 bolts and the LH exhaust manifold heat shield.
  16. Remove the 6 nuts and the LH exhaust manifold. Discard the nuts and the exhaust manifold gasket.
  17. Clean and inspect the LH exhaust manifold. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(/ford/taurus-x/i-2007-2009/remont/mechanical/#engine-system-general-information) article.
  18. Remove and discard the 6 LH exhaust manifold studs.
  19. Remove the LH cylinder block drain plug. Allow coolant to drain from the cylinder block.
  20. Remove the 4 nuts and the RH catalytic converter. Discard the nuts and gasket.
  21. If equipped, remove the heat shield and disconnect the block heater electrical connector. Remove the block heater wiring harness from the engine.
  22. Remove the RH cylinder block drain plug or, if equipped, the block heater. Allow coolant to drain from the cylinder block.
  23. Remove the coolant bypass hose from the thermostat housing.
  24. Remove the 4 bolts and the fuel rail and injectors as an assembly.
  25. Remove the 3 thermostat housing-to-lower intake manifold bolts. Remove the thermostat housing and discard the gasket and O-ring seal.
  26. Remove the 10 bolts and the lower intake manifold. Discard the gaskets.
  27. Remove the 2 bolts and the upper LH primary timing chain guide.
  28. Remove the 2 bolts and the LH secondary timing chain tensioner.
  29. Remove the valve tappets from the cylinder head.
  30. Inspect the valve tappets. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(/ford/taurus-x/i-2007-2009/remont/mechanical/#engine-system-general-information) article.
  31. Remove and discard the M6 bolt.
  32. Remove and discard the 8 bolts from the cylinder head. Remove the cylinder head. Discard the cylinder head gasket.
  33. Clean the cylinder head-to-cylinder block mating surfaces of both the cylinder heads and the cylinder block in the following sequence. Remove any large deposits of silicone or gasket material with a plastic scraper. Apply silicone gasket remover, following package directions, and allow to set for several minutes. Remove the silicone gasket remover with a plastic scraper. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain. Apply metal surface prep, following package directions, to remove any remaining traces of oil or coolant and to prepare the surfaces to bond with the new gasket. Do not attempt to make the metal shiny. Some staining of the metal surfaces is normal.
  34. Support the cylinder head on a bench with the head gasket side up.
  35. Inspect all areas of the deck face with a straightedge and feeler gauge. The cylinder head must not have depressions deeper than 0.0254 mm (0.001 in) across a 38.1 mm (1.5 in) square area, or scratches more than 0.0254 mm (0.001 in).

Oil Pan

Special Tools Illustration Tool Name Tool Number 3-Jaw Puller 303-D121 Handle 205-153 (T80T-4000-W) Seal Remover 303-1247/1 Remover, Oil Seal 303-409 (T92C-6700CH) Strap Wrench 303-D055 (D85L-6000-A)

ItemSpecification
Motorcraft Metal Surface Prep ZC-31-A
Silicone Gasket Remover ZC-30

Material

CAUTIONDuring 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.

All vehicles

  1. Remove the engine from the vehicle. For additional information, refer to «Engine»(/ford/taurus-x/i-2007-2009/remont/mechanical/#engine-35l) .
  2. Remove the 8 bolts and the flywheel.
  3. Remove the crankshaft sensor ring.
  4. Mount the engine on a suitable engine stand.
  5. If equipped, remove the heat shield and disconnect the block heater electrical connector. Detach all of the engine block heater harness retainers and remove the harness.
  6. If equipped, disconnect the heated PCV electrical connector.
  7. Disconnect the PCV hose from the PCV valve.
  8. Disconnect the throttle body (TB) electrical connector.
  9. Detach the wiring harness retainers from the upper intake manifold.
  10. If equipped, remove the upper intake manifold long support bracket bolt.
  11. Remove the upper intake manifold short support bracket bolt.
  12. Remove the fuel tube bracket bolt from the upper intake manifold.
  13. Remove the 6 bolts and the upper intake manifold. Discard the gaskets.
  14. Disconnect the fuel efficient power steering system solenoid electrical connector.
  15. Disconnect the power steering pressure (PSP) switch electrical connector.
  16. Disconnect the RH catalyst monitor sensor electrical connector.
  17. Disconnect the RH variable camshaft timing (VCT) solenoid electrical connector.
  18. Disconnect the 3 RH coil-on-plug electrical connectors.
  19. If equipped, disconnect the heated PCV valve electrical connector.
  20. Disconnect the RH heated oxygen sensor (HO2S) electrical connector.
  21. Detach all of the wiring harness retainers from the RH valve cover and stud bolts.
  22. Disconnect the LH catalyst monitor sensor electrical connector.
  23. Disconnect the LH VCT solenoid electrical connector.
  24. Disconnect the 3 LH coil-on-plug electrical connectors.
  25. Detach all of the wiring harness retainers from the LH valve cover and stud bolts.
  26. Remove the 6 bolts and the 6 coil-on-plugs.
  27. Remove the A/C compressor nut and stud.
  28. Remove the PSP tube bracket-to-power steering pump bolt.
  29. Remove the nut and the PSP tube bracket from the RH valve cover stud bolt.
  30. Remove the 3 bolts and position aside the power steering pump.
  31. Remove the 3 bolts and the accessory drive belt tensioner.
  32. Remove the 4 nuts (3 shown) and the LH catalytic converter. Discard the nuts and the gasket.
  33. Remove the 4 nuts and the RH catalytic converter. Discard the nuts and the gasket.
  34. Remove the RH cylinder block drain plug or, if equipped, the block heater. Allow coolant to drain from the cylinder block.
  35. Remove the LH cylinder block drain plug. Allow coolant to drain from the cylinder block.
  36. Remove the 11 stud bolts and the LH valve cover. Discard the gasket.
  37. Remove the bolt, the 10 stud bolts and the RH valve cover. Discard the gasket.
  38. Inspect the VCT solenoid seals and the spark plug tube seals. Remove any damaged seals. Using the special tools, remove the seal(s).
  39. Using the special tool, remove the crankshaft bolt and washer. Discard the bolt.
  40. Using the special tool, remove the crankshaft pulley.
  41. Using the special tool, remove and discard the crankshaft front seal.
  42. Remove the 2 bolts and the engine mount bracket.
  43. Remove the 2 engine mount studs.
  44. Remove the 3 bolts and the engine mount bracket.
  45. Remove the 22 engine front cover bolts.
  46. Install 6 of the engine front cover bolts (finger tight) into the 6 threaded holes in the engine front cover. Tighten the bolts one turn at a time in a criss-cross pattern until the engine front cover-to-cylinder block seal is released. Remove the engine front cover.
  47. Remove the 16 oil pan bolts.
  48. Install 2 of the oil pan bolts (finger tight) into the 2 threaded holes in the oil pan. Alternately tighten the 2 bolts one turn at a time until the oil pan-to-cylinder block seal is released. Remove the oil pan.
  49. Clean the engine front cover and oil pan using a 3M Roloc® Bristle Disk (2-in white, part number 07528) in a suitable tool turning at the recommended speed of 15,000 RPM. Thoroughly wash the engine front cover and oil pan to remove any foreign material, including any abrasive particles created during the cleaning process.
  50. Clean the sealing surfaces of the cylinder block in the following sequence. Remove any large deposits of silicone or gasket material. Apply silicone gasket remover and allow to set for several minutes. Remove the silicone gasket remover. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain. Apply metal surface prep to remove any remaining traces of oil or coolant and to prepare the surfaces to bond. Do not attempt to make the metal shiny. Some staining of the metal surfaces is normal. Make sure the 2 locating dowel pins are seated correctly in the cylinder block.

Oil Pump Screen and Pickup Tube

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, may cause engine failure.

  1. Remove the oil pan. For additional information, refer to «Oil Pan»(/ford/taurus-x/i-2007-2009/remont/mechanical/#engine-35l__oil-pan) .
  2. Remove the 3 bolts and the oil pump screen and pickup tube. Discard the O-ring seal.

Crankshaft Rear Seal with Retainer Plate

Special Tools Illustration Tool Name Tool Number Heavy Duty Floor Crane 014-00071 or equivalent Remover, Crankshaft Rear Oil Seal 303-519 (T95P-6701-EH) Slide Hammer 307-005 (T59L-100-B) Spreader Bar 303-D089 (D93P-6001-A3) or equivalent

ItemSpecification
Motorcraft Metal Surface Prep ZC-31-A
Silicone Gasket Remover ZC-30

Material

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, may cause engine failure.

Note. This procedure is for removal of the crankshaft rear seal and retainer plate and requires removal of the oil pan. If only removing the crankshaft rear seal, refer to Crankshaft Rear Seal .

  1. Remove the oil pan. For additional information, refer to «Oil Pan»(/ford/taurus-x/i-2007-2009/remont/mechanical/#engine-35l__oil-pan) .
  2. Using the Heavy Duty Floor Crane and Spreader Bar, remove the engine from the stand.
  3. Disconnect the Crankshaft Position (CKP) sensor electrical connector.
  4. Remove the bolt and the CKP sensor.
  5. Using the Crankshaft Rear Oil Seal Remover and Slide Hammer, remove and discard the rear crankshaft seal.
  6. Remove the 8 crankshaft rear seal retainer bolts.
  7. Install the 2 M6 oil pan bolts (finger tight) into the 2 threaded holes in the crankshaft rear seal retainer. Alternately tighten the 2 bolts one turn at a time until the crankshaft rear seal retainer-to-cylinder block seal is released. Remove the crankshaft rear seal retainer.
  8. Clean the crankshaft rear seal retainer plate using a 3M Roloc® Bristle Disk, (2-in white, part number 07528) in a suitable tool turning at the recommended speed of 15,000 RPM. Thoroughly wash the crankshaft rear seal retainer plate to remove any foreign material, including any abrasive particles created during the cleaning process.
  9. Clean the sealing surfaces of the cylinder block in the following sequence. Remove any large deposits of silicone or gasket material. Apply silicone gasket remover and allow to set for several minutes. Remove the silicone gasket remover. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain. Apply metal surface prep to remove any remaining traces of oil or coolant and to prepare the surfaces to bond. Do not attempt to make the metal shiny. Some staining of the metal surfaces is normal.

Special Tools Illustration Tool Name Tool Number 3-Jaw Puller 303-D121 Camshaft Alignment Tool 303-1248 Handle 205-153 (T80T-4000-W) Remover, Crankshaft Rear Oil Seal 303-519 (T95P-6701-EH) Remover, Oil Seal 303-409 (T92C-6700CH) Remover, Seal 303-1247/1 Slide Hammer 307-005 (T59L-100-B) Strap Wrench 303-D055 (D85L-6000-A)

ItemSpecification
Motorcraft Metal Surface Prep ZC-31-A
Silicone Gasket Remover ZC-30

Material

CAUTIONDuring 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.

Note. For additional information, refer to the exploded view under the Assembly procedure.

All vehicles

  1. Remove the 8 bolts and the flexplate.
  2. Remove the crankshaft sensor ring.
  3. Using the special tools, remove and discard the rear crankshaft seal.
  4. Mount the engine on a suitable engine stand.
  5. If equipped, remove the heat shield and disconnect the block heater electrical connector. Detach all of the engine block heater harness retainers and remove the harness.
  6. If equipped, disconnect the heated PCV electrical connector.
  7. Disconnect the PCV hose from the PCV valve.
  8. Disconnect the throttle body (TB) electrical connector.
  9. Detach the wiring harness retainers from the upper intake manifold.
  10. If equipped, remove the upper intake manifold long support bracket bolt.
  11. Remove the upper intake manifold short support bracket bolt.
  12. Remove the wire harness pin-type retainer and the fuel tube bracket bolt from the upper intake manifold.
  13. Remove the 6 bolts and the upper intake manifold. Discard the gaskets.
  14. Disconnect the fuel efficient power steering system solenoid electrical connector.
  15. Disconnect the power steering pressure (PSP) switch electrical connector.
  16. Disconnect the RH catalyst monitor sensor electrical connector.
  17. Disconnect the RH heated oxygen sensor (HO2S) electrical connector.
  18. Disconnect the RH variable camshaft timing (VCT) solenoid electrical connector.
  19. Disconnect the 3 RH coil-on-plug electrical connectors.
  20. If equipped, disconnect the heated PCV valve electrical connector.
  21. Detach all of the wiring harness retainers from the RH valve cover and stud bolts.
  22. Disconnect the RH camshaft position (CMP) sensor electrical connector.
  23. Disconnect the knock sensor (KS) electrical connector.
  24. Remove the bolt and the ground cable from the RH cylinder.
  25. Disconnect the 6 fuel injector electrical connectors (3 shown).
  26. Disconnect the cylinder head temperature (CHT) sensor electrical connector.
  27. Disconnect the LH CMP sensor electrical connector.
  28. Disconnect the LH catalyst monitor sensor electrical connector.
  29. Disconnect the LH HO2S electrical connector.
  30. Disconnect the 3 LH coil-on-plug electrical connectors.
  31. Disconnect the LH VCT solenoid electrical connector.
  32. Detach all of the wiring harness retainers from the LH valve cover and stud bolts.
  33. Remove the nut, the bolt and the heat shield.
  34. Remove the wiring harness retainer stud bolt.
  35. Remove the wiring harness grommet.
  36. Disconnect the crankshaft position (CKP) sensor electrical connector.
  37. Disconnect the A/C compressor electrical connector. Detach the A/C compressor wiring harness retainer.
  38. Remove the nut and disconnect the generator B+ cable.
  39. Disconnect the generator electrical connector.
  40. Disconnect the engine oil pressure (EOP) switch electrical connector and the wiring harness pin-type retainer. Remove the wiring harness from the engine.
  41. Remove the nut, 2 bolts and the A/C compressor.
  42. Remove the A/C compressor mounting stud from the oil pan.
  43. Remove the nut, bolt and the generator.
  44. Remove the PSP tube bracket-to-power steering pump bolt.
  45. Remove the nut and the PSP tube bracket from the RH valve cover stud bolt.
  46. Remove the bolt and the PSP tube bracket from the RH cylinder head.
  47. Remove the 3 bolts and position aside the power steering pump.
  48. Remove the 3 bolts and the accessory drive belt tensioner.
  49. Remove the 4 nuts (3 shown) and the LH catalytic converter. Discard the nuts and the gasket.
  50. Remove the 3 bolts and the LH exhaust manifold heat shield.
  51. Remove the 6 nuts and the LH exhaust manifold. Discard the nuts and exhaust manifold gaskets.
  52. Clean and inspect the LH exhaust manifold. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(/ford/taurus-x/i-2007-2009/remont/mechanical/#engine-system-general-information) article.
  53. Remove and discard the 6 LH exhaust manifold studs.
  54. Remove the 4 nuts and the RH catalytic converter. Discard the nuts and the gasket.
  55. Remove the 3 bolts and the RH exhaust manifold heat shield.
  56. Remove the 6 nuts and the RH exhaust manifold. Discard the nuts and exhaust manifold gaskets.
  57. Clean and inspect the RH exhaust manifold. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(/ford/taurus-x/i-2007-2009/remont/mechanical/#engine-system-general-information) article.
  58. Remove and discard the 6 RH exhaust manifold studs.
  59. Remove the RH cylinder block drain plug or, if equipped, the block heater. Allow coolant to drain from the cylinder block.
  60. Remove the LH cylinder block drain plug. Allow coolant to drain from the cylinder block.
  61. Remove the pin-type retainer and the cover.
  62. Remove the 2 bolts and the engine lifting eye.
  63. If equipped, remove the bolt and the upper intake manifold long support bracket.
  64. Remove the bolt and the upper intake manifold short support bracket.
  65. Remove the bolt and the RH CMP sensor.
  66. Remove the coolant by-pass hose from the thermostat housing.
  67. Remove the 4 bolts and the fuel rail and injectors as an assembly.
  68. Remove the 3 thermostat housing-to-lower intake manifold bolts. Remove the thermostat housing and discard the gasket.
  69. Remove the 10 bolts and the lower intake manifold. Discard the gaskets.
  70. Disconnect and remove the CHT sensor jumper harness.
  71. Remove the bolt and the LH CMP sensor.
  72. Remove the bolt and the CKP sensor.
  73. Remove the EOP switch.
  74. Remove the 2 bolts and the oil filter adapter. Discard the gasket and O-ring seal (on banjo bolt).
  75. Remove the 6 bolts and the 6 coil-on-plugs.
  76. Remove the 11 stud bolts and the LH valve cover. Discard the gasket.
  77. Remove the bolt, the 10 stud bolts and the RH valve cover. Discard the gasket.
  78. Inspect the VCT solenoid seals and the spark plug tube seals. Remove any damaged seals. Using the special tools, remove the seal(s).
  79. Remove the crankshaft bolt and washer. Discard the bolt.
  80. Using the special tool, remove the crankshaft pulley.
  81. Using the special tool, remove and discard the crankshaft front seal.
  82. Remove the 2 bolts and the engine mount bracket.
  83. Remove the 2 engine mount studs.
  84. Remove the 3 bolts and the engine mount bracket.
  85. Remove the 22 engine front cover bolts.
  86. Install 6 of the engine front cover bolts (finger tight) into the 6 threaded holes in the engine front cover. Tighten the bolts one turn at a time in a criss-cross pattern until the engine front cover-to-cylinder block seal is released. Remove the engine front cover.
  87. Rotate the crankshaft clockwise and align the timing marks on the VCT assemblies as shown.
  88. Install the special tool onto the flats of the LH camshafts.
  89. Install the special tool onto the flats of the RH camshafts.
  90. Remove the 3 bolts and the RH VCT housing.
  91. Remove the 3 bolts and the LH VCT housing.
  92. Remove and discard the VCT housing seals.
  93. Remove the 2 bolts and the primary timing chain tensioner.
  94. Remove the primary timing chain tensioner arm.
  95. Remove the 2 bolts and the lower LH primary timing chain guide.
  96. Remove the primary timing chain.
  97. Remove the crankshaft timing chain sprocket.
  98. Remove the 2 bolts and the upper LH primary timing chain guide.
  99. Compress the LH secondary timing chain tensioner and install a suitable lockpin to retain the tensioner in the collapsed position.
  100. Remove and discard the LH VCT assembly bolt and the LH exhaust camshaft sprocket bolt. Remove the LH VCT assembly, secondary timing chain and the LH exhaust camshaft sprocket as an assembly.
  101. Remove the special tool from the LH camshafts.
  102. Verify the LH camshafts are in the neutral position.
  103. Remove the 2 bolts and the LH secondary timing chain tensioner.
  104. Remove the bolts and the LH camshaft bearing caps. Remove the LH camshafts.
  105. Compress the RH secondary timing chain tensioner and install a suitable lockpin to retain the tensioner in the collapsed position.
  106. Remove and discard the RH VCT assembly bolt and the RH exhaust camshaft sprocket bolt. Remove the RH VCT assembly, secondary timing chain and the RH exhaust camshaft sprocket as an assembly.
  107. Remove the special tool from the RH camshafts.
  108. Rotate the RH camshafts counterclockwise to the neutral position.
  109. Remove the 2 bolts and the RH secondary timing chain tensioner.
  110. Remove the 2 bolts and the RH primary timing chain guide.
  111. Remove the bolts and the RH camshaft bearing caps. Remove the RH camshafts.
  112. Remove the valve tappets from the cylinder heads.
  113. Remove and discard the M6 bolt from each cylinder head.
  114. Remove and discard the 8 bolts from each cylinder head. Remove the cylinder heads. Discard the cylinder head gaskets.
  115. Clean the cylinder head-to-cylinder block mating surfaces of both the cylinder heads and the cylinder block in the following sequence. Remove any large deposits of silicone or gasket material with a plastic scraper. Apply silicone gasket remover, following package directions, and allow to set for several minutes. Remove the silicone gasket remover with a plastic scraper. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain. Apply metal surface prep, following package directions, to remove any remaining traces of oil or coolant and to prepare the surfaces to bond with the new gasket. Do not attempt to make the metal shiny. Some staining of the metal surfaces is normal.
  116. Support the cylinder heads on a bench with the head gasket side up.
  117. Inspect all areas of the deck face with a straightedge and feeler gauge. The cylinder heads must not have depressions deeper than 0.0254 mm (0.001 in) across a 38.1 mm (1.5 in) square area, or scratches more than 0.0254 mm (0.001 in).
  118. Remove the coolant tube. Remove and discard the O-ring seals.
  119. Remove the 2 bolts and the KS.
  120. Remove the 8 bolts and the coolant pump.
  121. Remove the 16 oil pan bolts.
  122. Install 2 of the oil pan bolts (finger tight) into the 2 threaded holes in the oil pan. Alternately tighten the 2 bolts one turn at a time until the oil pan-to-cylinder block seal is released. Remove the oil pan.
  123. Remove the 3 bolts and the oil pump screen and pickup tube. Discard the O-ring seal.
  124. Remove the 3 bolts and the oil pump.
  125. Remove the 8 crankshaft rear seal retainer bolts.
  126. Install the 2 M6 oil pan bolts (finger tight) into the 2 threaded holes in the crankshaft rear seal retainer. Alternately tighten the 2 bolts one turn at a time until the crankshaft rear seal retainer-to-cylinder block seal is released. Remove the crankshaft rear seal retainer.
  127. Clean the engine front cover, oil pan and crankshaft rear seal retainer plate using a 3M Roloc® Bristle Disk (2-in white, part number 07528) in a suitable tool turning at the recommended speed of 15,000 RPM. Thoroughly wash the engine front cover, oil pan and crankshaft rear seal retainer plate to remove any foreign material, including any abrasive particles created during the cleaning process.
  128. Clean the sealing surfaces of the cylinder block in the following sequence. Remove any large deposits of silicone or gasket material. Apply silicone gasket remover and allow to set for several minutes. Remove the silicone gasket remover. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain. Apply metal surface prep to remove any remaining traces of oil or coolant and to prepare the surfaces to bond. Do not attempt to make the metal shiny. Some staining of the metal surfaces is normal. Make sure the 2 engine front cover locating dowel pins are seated correctly in the cylinder block.

Cylinder Head

Special Tools Illustration Tool Name Tool Number Compressor, Valve Spring 303-300 (T87C-6565-A) Compressor, Valve Spring 303-350 (T89P-6565-A) Compressor, Valve Spring 303-1249 Installer, Valve Stem Oil Seal 303-470 (T94P-6510-CH)

ItemSpecification
Motorcraft SAE 5W-20 Premium Synthetic Blend Motor Oil XO-5W20-QSP (US); Motorcraft SAE 5W-20 Super Premium Motor Oil CXO-5W20-LSP12 (Canada); or equivalentWSS-M2C930-A

Material

Scheme 47

Scheme 47
Scheme 47
ItemPart NumberDescription
16518Intake valve spring retainer key (12 required)
26514Intake valve spring retainer (6 required)
36513Intake valve spring (6 required)
46A517Intake valve stem seal (6 required)
56505Intake valve (6 required)
66507Exhaust valve (6 required)
76A517Exhaust valve stem seal (6 required)
86513Exhaust valve spring (6 required)
96514Exhaust valve spring retainer (6 required)
106518Exhaust valve spring retainer key (12 required)
116G004Cylinder Head Temperature (CHT) sensor

DISASSEMBLY

All cylinder heads

Note. If the components are to be reinstalled, they must be installed in the same positions. Mark the components for installation into their original locations.

  1. Using the Valve Spring Compressors, remove the keys, retainer and spring.
  2. Remove the valve from the cylinder head.
  3. Remove and discard the valve stem seal.
  4. Repeat the above steps for each valve.
  5. Remove and discard the Cylinder Head Temperature (CHT) sensor.

ASSEMBLY

All cylinder heads

  1. Using the Valve Stem Oil Seal Installer, install a new valve stem seal.
  2. Install the valve.
  3. Using the Valve Spring Compressors, install the valve spring, retainer and key.
  4. Repeat the above steps for each valve.
  5. Install a new CHT sensor. Tighten to 10 Nm (89 lb-in).

Special Tools Illustration Tool Name Tool Number Alignment Pins 307-399 Camshaft Alignment Tool 303-1248 Engine Lifting Bracket 303-1245 Handle 205-153 (T80T-4000-W) Heavy Duty Floor Crane 014-00071 or equivalent Installer, Crankshaft Front Seal 303-1251 Installer, Crankshaft Rear Seal 303-1250 Installer, Crankshaft Vibration Damper 303-102 (T74P-6316-B) Installer, Front Cover Oil Seal 303-335 Installer, Seal 303-1247/2 Spreader Bar 303-D089 (D93P-6001-A3) or equivalent Strap Wrench 303-D055 (D85L-6000-A)

ItemSpecification
Motorcraft High Performance Engine RTV Silicone TA-357WSE-M4G323-A6
Motorcraft Metal Surface Prep ZC-31-A
Motorcraft Premium Gold Engine Coolant with Bittering Agent (bittered in US only) VC-7-B (US); CVC-7-A (Canada); or equivalent (yellow color)WSS-M97B51-A1
Motorcraft SAE 5W-20 Premium Synthetic Blend Motor Oil XO-5W20-QSP (US); Motorcraft SAE 5W-20 Super Premium Motor Oil CXO-5W20-LSP12 (Canada); or equivalentWSS-M2C930-A
Silicone Gasket Remover ZC-30
Thread Sealant with PTFE TA-24WSK-M2G350-A2

Material

Scheme 48

Scheme 48
Scheme 48
ItemPart NumberDescription
112C508Engine control harness
29S455Upper intake manifold
39J444Upper intake manifold long support bracket (early build engines)
49F797Fuel rail
59J444Upper intake manifold short support bracket
69K461Lower intake manifold
78A856Thermostat housing
89N271Coolant tube
99N271Knock sensor (KS)
106010Cylinder block

Scheme 49

Scheme 49
Scheme 49
ItemPart NumberDescription
16A0003Engine mount bracket
2W701512Crankshaft pulley bolt
3N806165Crankshaft pulley washer
46316Crankshaft pulley
56700Crankshaft front seal
66C086Engine front cover
76268Timing chain
86306Crankshaft timing sprocket
96K254Primary timing chain tensioner
106K255Primary timing chain tensioner arm
116B274LH lower primary timing chain guide
126M256RH primary timing chain guide
136K297LH upper primary timing chain guide
148501Coolant pump
156010Cylinder block

Scheme 50

Scheme 50
Scheme 50
ItemPart NumberDescription
16675Oil pan
26622Oil pump screen and pickup tube
36621Oil pump
46010Cylinder block
56D327Crankshaft rear seal retainer
612A227Crankshaft sensor ring
76375Flexplate
86881Oil filter adapter
99278Engine oil pressure (EOP) switch

Scheme 51

Scheme 51
Scheme 51
ItemPart NumberDescription
16083LH cylinder head gasket
26C261LH variable camshaft timing (VCT) housing
3W12244LH exhaust manifold stud (6 required)
46500Valve tappet (32 required)
56050LH cylinder head
66279LH camshaft bolt (2 required)
7W710738LH exhaust camshaft sprocket washer
86C524LH VCT assembly
96256LH exhaust camshaft sprocket
106C256LH secondary timing chain
116A258LH camshaft cap (8 required)
126A505LH valve cover
136A267LH intake camshaft
146A269LH exhaust camshaft
156C271LH secondary timing chain tensioner

Scheme 52

Scheme 52
Scheme 52
ItemPart NumberDescription
1W712244RH exhaust manifold stud (6 required)
26051RH cylinder head gasket
36G004Cylinder head temperature (CHT) sensor
414B485CHT sensor jumper harness
56B288Camshaft position sensor (2 required)
66049RH cylinder head
717A084Engine lift eye
86C260RH variable camshaft timing (VCT) housing
96279RH camshaft bolt (2 required)
10W710738RH exhaust camshaft sprocket washer
116256RH exhaust camshaft sprocket
126C524RH VCT assembly
136C256RH secondary timing chain
146A266RH intake camshaft
156A268RH exhaust camshaft
1612405Spark plug (6 required)
176A258RH camshaft cap (8 required)
186582RH valve cover
1912A375Coil-on-plug (6 required)
206C270RH secondary timing chain tensioner
CAUTIONDuring 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.

All vehicles

  1. Apply a 3 mm (0.11 in) bead of Motorcraft High Performance Engine RTV Silicone to the sealing surface of the crankshaft rear seal retainer.
  2. Install the crankshaft rear seal retainer and the 8 bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
  3. Install the oil pump and the 3 bolts. Tighten to 10 Nm (89 lb-in).
  4. Using a new O-ring seal, install the oil pump screen and pickup tube and the 3 bolts. Tighten to 10 Nm (89 lb-in).
  5. Install the A/C compressor and the 2 bolts. Tighten to 25 Nm (18 lb-ft).
  6. Apply a 3 mm (0.11 in) bead of Motorcraft High Performance Engine RTV Silicone to the sealing surface of the oil pan. Apply a 5.5 mm (0.21 in) bead of Motorcraft High Performance Engine RTV Silicone to the 2 crankshaft seal retainer plate-to-cylinder block joint areas on the sealing surface of the oil pan.
  7. Install the oil pan and bolts 10, 11, 13 and 14. Tighten the bolts in the sequence shown to 3 Nm (27 lb-in). Loosen the bolts 180 degrees.
  8. Align the oil pan to the cylinder block and A/C compressor. Position the oil pan so the mounting boss is against the A/C compressor and using a straightedge, align the oil pan flush with the rear of the cylinder block at the 2 areas shown.
  9. Tighten bolts 10, 11, 13 and 14 in the sequence shown to 3 Nm (27 lb-in).
  10. Install the remaining oil pan bolts. Tighten all the oil pan bolts in the sequence shown. Tighten the large bolts (1-14) to 20 Nm (15 lb-ft). Tighten the small bolts (15 and 16) to 10 Nm (89 lb-in).
  11. Install the A/C compressor mounting stud and nut. Tighten the stud to 9 Nm (80 lb-in) and the nut to 25 Nm (18 lb-ft).
  12. Install the coolant pump and the 8 bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
  13. Install the knock sensor (KS) and the 2 bolts. Tighten to 20 Nm (15 lb-ft).
  14. Using new O-ring seals, install the coolant tube.
  15. Install a new gasket, the RH cylinder head and 8 new bolts. Tighten in the sequence shown in 5 stages: Stage 1: Tighten to 20 Nm (15 lb-ft). Stage 2: Tighten to 35 Nm (26 lb-ft). Stage 3: Tighten 90 degrees. Stage 4: Tighten 90 degrees. Stage 5: Tighten 90 degrees.
  16. Install the bolt. Tighten to 10 Nm (89 lb-in).
  17. Install a new gasket, the LH cylinder head and 8 new bolts. Tighten in the sequence shown in 5 stages: Stage 1: Tighten to 20 Nm (15 lb-ft). Stage 2: Tighten to 35 Nm (26 lb-ft). Stage 3: Tighten 90 degrees. Stage 4: Tighten 90 degrees. Stage 5: Tighten 90 degrees.
  18. Install the bolt. Tighten to 10 Nm (89 lb-in).
  19. Position the crankshaft dowel pin in the 9 o'clock position.
  20. Install the valve tappets.
  21. Position the camshafts onto the RH cylinder head in the neutral position as shown.
  22. Install the 8 camshaft caps and the 16 bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
  23. Position the camshafts onto the LH cylinder head in the neutral position as shown.
  24. Install the 8 camshaft caps and the 16 bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
  25. Using a feeler gauge, confirm that the valve tappet clearances are within specification. For additional information, refer to «Valve Clearance Check»(/ford/taurus-x/i-2007-2009/remont/mechanical/#engine-35l__valve-clearance-check) .
  26. Install the RH primary timing chain guide and the 2 bolts. Tighten to 10 Nm (89 lb-in).
  27. Install the RH secondary timing chain tensioner and the 2 bolts. Tighten to 10 Nm (89 lb-in).
  28. Rotate the RH camshafts to the top dead center (TDC) position and install the special tool on the flats of the camshafts.
  29. Assemble the RH variable camshaft timing (VCT) assembly, the RH exhaust camshaft sprocket and the RH secondary timing chain. Align the colored links with the timing marks.
  30. Position the RH secondary timing assembly onto the camshafts.
  31. Install the new VCT bolt and the exhaust camshaft bolt and the original washers. Tighten in 4 stages. Stage 1: Tighten to 40 Nm (30 lb-ft). Stage 2: Loosen one full turn. Stage 3: Tighten to 10 Nm (89 lb-in). Stage 4: Tighten 90 degrees.
  32. Remove the lockpin from the RH secondary timing chain tensioner.
  33. Install the LH secondary timing chain tensioner and the 2 bolts. Tighten to 10 Nm (89 lb-in).
  34. Rotate the LH camshafts to the TDC position and install the special tool on the flats of the camshafts.
  35. Assemble the LH VCT assembly, the LH exhaust camshaft sprocket and the LH secondary timing chain. Align the colored links with the timing marks.
  36. Position the LH secondary timing assembly onto the camshafts.
  37. Install the new VCT bolt and the exhaust camshaft bolt and the original washers. Tighten in 4 stages. Stage 1: Tighten to 40 Nm (30 lb-ft). Stage 2: Loosen one full turn. Stage 3: Tighten to 10 Nm (89 lb-in). Stage 4: Tighten 90 degrees.
  38. Remove the lockpin from the LH secondary timing chain tensioner.
  39. Rotate the crankshaft clockwise 60 degrees to the TDC position (crankshaft dowel pin at 11 o'clock).
  40. Install the crankshaft timing chain sprocket.
  41. Install the primary timing chain with the colored links aligned with the timing marks on the VCT assemblies and the crankshaft sprocket.
  42. Install the upper LH primary timing chain guide and the 2 bolts. Tighten to 10 Nm (89 lb-in).
  43. Install the lower LH primary timing chain guide and the 2 bolts. Tighten to 10 Nm (89 lb-in).
  44. Install the primary timing chain tensioner arm.
  45. Reset the primary timing chain tensioner. Rotate the lever counterclockwise. Using a soft-jawed vise, compress the plunger. Align the hole in the lever with the hole in the tensioner housing. Install a suitable lockpin.
  46. Install the primary tensioner and the 2 bolts. Tighten to 10 Nm (89 lb-in). Remove the lockpin.
  47. As a post-check, verify correct alignment of all timing marks.
  48. Install new VCT housing seals.
  49. Install the LH VCT housing and the 3 bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
  50. Install the RH VCT housing and the 3 bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
  51. Install the special tools.
  52. Apply a 3.0 mm (0.11 in) bead of Motorcraft High Performance Engine RTV Silicone to the engine front cover sealing surfaces including the 3 engine mount bracket bosses. Apply a 5.5 mm (0.21 in) bead of Motorcraft High Performance Engine RTV Silicone to the oil pan-to-cylinder block joint and the cylinder head-to-cylinder block joint areas of the engine front cover in 5 places as indicated.
  53. Install the engine front cover and bolts 17, 18, 19 and 20. Tighten in sequence to 3 Nm (27 lb-in).
  54. Remove the special tools (alignment pins).
  55. Install the engine mount bracket and the 3 bolts.
  56. Install the remaining engine front cover bolts. Tighten all of the engine front cover bolts and engine mount bracket bolts in the sequence shown in 2 stages: Stage 1: Tighten bolts 1 thru 22 to 10 Nm (89 lb-in) and bolts 23, 24 and 25 to 15 Nm (11 lb-ft). Stage 2: Tighten bolts 1 thru 22 to 24 Nm (18 lb-ft) and bolts 23, 24 and 25 to 75 Nm (55 lb-ft).
  57. Install the 2 engine mount studs. Tighten to 18 Nm (13 lb-ft).
  58. Install the engine mount bracket and the 2 bolts. Tighten to 24 Nm (18 lb-ft).
  59. Using the special tools, install a new crankshaft front seal.
  60. Using the special tools, install the crankshaft pulley.
  61. Using the special tool, install the crankshaft pulley washer and new bolt and tighten 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.
  62. Using the special tools, install new VCT solenoid and/or spark plug tube seals.
  63. Apply an 8 mm (0.31 in) bead of Motorcraft High Performance Engine RTV Silicone to the engine front cover-to-RH cylinder head joints.
  64. Using a new gasket, install the RH valve cover, bolt and the 10 stud bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
  65. Apply an 8 mm (0.31 in) bead of Motorcraft High Performance Engine RTV Silicone to the engine front cover-to-LH cylinder head joints.
  66. Using a new gasket, install the LH valve cover and 11 stud bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
  67. Install the 6 coil-on-plug assemblies and the 6 bolts. Tighten to 7 Nm (62 lb-in).
  68. Using a new gasket and O-ring seal, install the oil filter adapter and the 2 bolts. Tighten the large bolt to 57 Nm (42 lb-ft). Tighten the small bolt to 10 Nm (89 lb-in).
  69. Install the EOP switch. Tighten to 18 Nm (13 lb-ft).
  70. Install the crankshaft position (CKP) sensor and install the bolt. Tighten to 10 Nm (89 lb-in).
  71. Install LH camshaft position (CMP) sensor and the bolt. Tighten to 10 Nm (89 lb-in).
  72. Install and connect the CHT sensor jumper harness.
  73. Using new gaskets, install the lower intake manifold and the 10 bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
  74. Using a new gasket, install the thermostat housing and the 3 bolts. Tighten to 10 Nm (89 lb-in).
  75. Install new fuel injector O-ring seals. Remove the retaining clips and separate the fuel injectors from the fuel rail. Remove and discard the O-ring seals. Install new O-ring seals and lubricate with clean engine oil. Install the fuel injectors and the retaining clips onto the fuel rail.
  76. Install the fuel rail and injectors as an assembly and install the 4 bolts. Tighten to 10 Nm (89 lb-in).
  77. Install the coolant bypass hose to the thermostat housing.
  78. Install the RH CMP sensor and the bolt. Tighten to 10 Nm (89 lb-in).
  79. Install the upper intake manifold short support bracket and the bolt. Tighten to 10 Nm (89 lb-in).
  80. If equipped, install the upper intake long support manifold bracket and the bolt. Tighten to 10 Nm (89 lb-in).
  81. Install the engine lifting eye and the 2 bolts. Tighten to 24 Nm (18 lb-ft).
  82. Install the cover and the pin-type retainer.
  83. Install the LH cylinder block drain plug. Tighten to 20 Nm (15 lb-ft) plus an additional 180 degrees.
  84. Install the RH cylinder block drain plug or, if equipped, the block heater. Tighten to 40 Nm (30 lb-ft).
  85. Install 6 new RH exhaust manifold studs. Tighten to 12 Nm (9 lb-ft).
  86. Using a new gasket, install the RH exhaust manifold and 6 new nuts. Tighten in 2 stages in the sequence shown: Stage 1: Tighten to 20 Nm (15 lb-ft). Stage 2: Tighten to 20 Nm (15 lb-ft).
  87. Install the RH exhaust manifold heat shield and the 3 bolts. Tighten to 14 Nm (10 lb-ft).
  88. Using a new gasket, install the RH catalytic converter and the 4 new nuts. Tighten to 40 Nm (30 lb-ft).
  89. Install 6 new LH exhaust manifold studs. Tighten to 12 Nm (9 lb-ft).
  90. Using a new gasket, install the LH exhaust manifold and 6 new nuts. Tighten in 2 stages in the sequence shown: Stage 1: Tighten to 20 Nm (15 lb-ft). Stage 2: Tighten to 20 Nm (15 lb-ft).
  91. Install the LH exhaust manifold heat shield and the 3 bolts. Tighten to 14 Nm (10 lb-ft).
  92. Using a new gasket, install the LH catalytic converter and 4 new nuts (3 shown). Tighten to 40 Nm (30 lb-ft).
  93. Install the accessory drive belt tensioner and the 3 bolts. Tighten to 10 Nm (89 lb-in).
  94. Install the power steering pump and the 3 bolts. Tighten to 25 Nm (18 lb-ft).
  95. Install the power steering pressure (PSP) tube bracket and the bolt to the RH cylinder head. Tighten to 10 Nm (89 lb-in).
  96. Install the PSP tube bracket and nut to the RH valve cover stud bolt. Tighten to 7 Nm (62 lb-in).
  97. Install the PSP tube bracket bolt. Tighten to 10 Nm (89 lb-in).
  98. Install the generator, the bolt and the nut. Tighten to 48 Nm (35 lb-ft).
  99. Position the wiring harness onto the engine.
  100. Connect the EOP switch electrical connector and the wiring harness pin-type retainer.
  101. Connect the generator electrical connector.
  102. Connect the generator B+ cable and install the nut. Tighten to 6 Nm (53 lb-in).
  103. Connect the A/C compressor electrical connector. Attach the A/C compressor wiring harness retainer.
  104. Connect the CKP sensor electrical connector.
  105. Install the wiring harness grommet.
  106. Install the wiring harness retainer stud bolt. Tighten to 10 Nm (89 lb-in).
  107. Install the heat shield, the nut and the bolt. Tighten to 10 Nm (89 lb-in).
  108. Attach all of the wiring harness retainers to the LH valve cover and stud bolts.
  109. Connect the LH camshaft VCT solenoid electrical connector.
  110. Connect the 3 LH coil-on-plug electrical connectors.
  111. Connect the LH HO2S electrical connector.
  112. Connect the LH catalyst monitor sensor electrical connector.
  113. Connect the LH CMP sensor electrical connector.
  114. Connect the CHT sensor electrical connector.
  115. Connect the 6 fuel injector electrical connectors (3 shown).
  116. Install the ground cable and the bolt. Tighten to 10 Nm (89 lb-in).
  117. Connect the KS electrical connector.
  118. Connect the RH CMP sensor electrical connector.
  119. Attach all of the wiring harness retainers to the RH valve cover and stud bolts.
  120. If equipped, connect the heated PCV valve electrical connector.
  121. Connect the 3 RH coil-on-plug electrical connectors.
  122. Connect the RH VCT solenoid electrical connector.
  123. Connect the RH HO2S electrical connector.
  124. Connect the RH catalyst monitor sensor electrical connector.
  125. Connect the PSP switch electrical connector.
  126. Connect the fuel efficient power steering system solenoid electrical connector.
  127. Using a new gasket, install the upper intake manifold and the 6 bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
  128. Install the fuel tube bracket bolt to the upper intake manifold and install the wiring harness pin-type retainer. Tighten to 6 Nm (53 lb-in).
  129. Install the upper intake manifold short support bracket and the 2 bolts (1 shown). Tighten to 10 Nm (89 lb-in).
  130. If equipped, install the upper intake manifold long support bracket and the 2 bolts (1 shown). Tighten the upper bolt 10 Nm (89 lb-in). Tighten the lower bolt 24 Nm (18 lb-ft).
  131. Attach the wiring harness retainers to the upper intake manifold.
  132. Connect the throttle body (TB) electrical connector.
  133. Connect the PCV hose to the PCV valve.
  134. If equipped, connect the heated PCV electrical connector.
  135. If equipped, position the block heater wiring harness onto the engine and attach all of the harness retainers.
  136. If equipped, connect the block heater electrical connector and install the heat shield.
  137. Install the special tool on the LH cylinder head.
  138. Using the special tools, remove the engine from the stand.
  139. Position the special tool onto the end of the crankshaft and slide a new crankshaft rear seal onto the tool.
  140. Using the special tools, install the new crankshaft rear seal.
  141. Install the crankshaft sensor ring.
  142. Install the flexplate and the 8 bolts. Tighten to 80 Nm (59 lb-ft).

Special Tools Illustration Tool Name Tool Number Heavy Duty Floor Crane 014-00071 or equivalent Powertrain Lift 014-00765 Spreader Bar 303-D089 (D93P-6001-A3) or equivalent Universal Adapter Brackets 014-0001

ItemSpecification
Motorcraft SAE 5W-20 Premium Synthetic Blend Motor Oil XO-5W20-QSP (US); Motorcraft SAE 5W-20 Super Premium Motor Oil CXO-5W20-LSP12 (Canada); or equivalentWSS-M2C930-A

Material

All vehicles

  1. Using the special tools, align the transaxle to the engine.
  2. Install the 5 transaxle-to-engine bolts. Tighten to 48 Nm (35 lb-ft).
  3. Install the 2 engine-to-transaxle bolts. Tighten to 48 Nm (35 lb-ft).
  4. Using the special tools, position the engine and transaxle onto the lift table.
  5. Install the special tools.
  6. Install the starter, the stud bolt and bolt. Tighten to 27 Nm (20 lb-ft).
  7. Connect the wiring harness retainer to the starter motor stud bolt.
  8. Attach the starter wire terminals and install the 2 nuts. Tighten to 12 Nm (9 lb-ft). Tighten to 5 Nm (44 lb-in).
  9. If equipped, install the starter motor solenoid cover.
  10. Raise the engine and transaxle assembly into the vehicle.
  11. Install the engine mount and the 3 bolts. Tighten to 90 Nm (66 lb-ft).
  12. Install the 4 engine mount nuts. Tighten to 63 Nm (46 lb-ft).
  13. Install the engine mount brace, nut and bolt. Tighten to 20 Nm (15 lb-ft).
  14. Install the transaxle mount bracket and the 4 nuts. Tighten to 80 Nm (59 lb-ft).
  15. Install the transaxle mount through bolt and nut. Tighten to 175 Nm (129 lb-ft).
  16. Position the power transfer unit (PTU) in place and install the 5 bolts. Tighten to 90 Nm (66 lb-ft).
  17. Position the PTU support bracket in place and install the 5 bolts. Tighten to 70 Nm (52 lb-ft).
  18. Install a new PTU seal. For additional information, refer to «TRANSFER CASE - POWER TRANSFER UNIT (PTU)»(/ford/taurus-x/i-2007-2009/remont/transfer-case/#transfer-case-power-transfer-unit-ptu) article.
  19. Using a new gasket, install the RH catalytic converter and 4 new nuts. Tighten to 40 Nm (30 lb-ft).
  20. Connect the RH catalyst monitor electrical connector.
  21. Install the RH halfshaft support bracket and the 4 bolts. Tighten the halfshaft support-to-cylinder block bolts to 40 Nm (30 lb-ft). Tighten the catalytic converter-to-halfshaft support bolts to 20 Nm (15 lb-ft).
  22. Install the 2 halfshaft support bracket studs. Tighten to 10 Nm (89 lb-in).
  23. Install the RH halfshaft into the transaxle and the wheel hub and install the 2 carrier bearing nuts. Tighten to 40 Nm (30 lb-ft).
  24. Install the 4 oil pan-to-transaxle bolts. Tighten to 48 Nm (35 lb-ft).
  25. Install 3 new torque converter bolts. Tighten to 55 Nm (41 lb-ft).
  26. Install the inspection cover and the 2 fasteners.
  27. Connect the transaxle cooling tubes and install the safety clips.
  28. Install the LH halfshaft into the transaxle.
  29. Using the special tool, raise the subframe into the installed position.
  30. Install the 2 front subframe bolts. Tighten to 150 Nm (111 lb-ft).
  31. Position the subframe brackets and install the 4 bolts finger-tight.
  32. Install the 2 rear subframe bolts. Tighten to 150 Nm (111 lb-ft).
  33. Tighten the 4 subframe bracket-to-body bolts to 103 Nm (76 lb-ft).
  34. Install new lower ball joint-to-wheel knuckle nuts. Tighten to 115 Nm (85 lb-ft).
  35. Install new tie-rod end nuts. Tighten to 115 Nm (85 lb-ft).
  36. Install new upper stabilizer bar link nuts. Tighten to 55 Nm (41 lb-ft).
  37. Install the new halfshaft nut. Tighten to 350 Nm (258 lb-ft).
  38. Install the 2 engine roll restrictor-to-transaxle bolts. Tighten to 103 Nm (76 lb-ft).
  39. Using a new O-ring seal, install the PSP tube onto the steering gear, rotate the clamp plate and install the bolt. Tighten to 25 Nm (18 lb-ft).
  40. Install the PSP tube bracket-to-steering gear bolt. Tighten to 10 Nm (89 lb-in).
  41. Install a new engine oil filter. Tighten to 5 Nm (44 lb-in) and then rotate an additional 180 degrees.
  42. Line up the index marks on the rear driveshaft to the index marks on the PTU flange made during removal and install the 4 bolts (3 shown). Tighten to 70 Nm (52 lb-ft).
  43. Using a new gasket, install the Y-pipe and install the 2 new nuts. Tighten to 40 Nm (30 lb-ft). Attach the exhaust hanger.
  44. Install the Y-pipe assembly and 4 new nuts. Tighten to 40 Nm (30 lb-ft).
  45. Install the steering intermediate shaft onto the steering gear and install a new bolt. Tighten to 23 Nm (17 lb-ft).
  46. Connect the transaxle control electrical connector.
  47. Attach the transaxle control wire harness retainer to the transaxle stud bolt.
  48. Connect the hose to the power steering reservoir.
  49. Install the oil level indicator.
  50. Install the ground cable and bolt. Tighten to 12 Nm (9 lb-ft).
  51. Attach the wire to the RH valve cover stud bolt.
  52. Connect the 2 engine wiring harness electrical connectors. Attach the electrical connector to the LH valve cover.
  53. Connect the fuel supply tube to the fuel rail. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(/ford/taurus-x/i-2007-2009/remont/fuel-system/#fuel-system-general-information) article.
  54. Using a new O-ring seal, install the A/C tube and the nut. Tighten to 15 Nm (11 lb-ft).
  55. Using new O-ring seals, connect the A/C tubes and install the 2 nuts. Tighten to 15 Nm (11 lb-ft).
  56. Using a new O-ring seal, connect the upper A/C tube to the condenser and install the nut and connect the A/C pressure switch electrical connector. Tighten to 15 Nm (11 lb-ft).
  57. If equipped, attach the engine block heater harness to the radiator support and the power steering tube.
  58. Connect the transaxle control cable to the shift cable bracket and attach the 2 wiring harness pin-type retainers.
  59. Connect the transaxle control cable to the control lever.
  60. Connect the upper radiator hose, lower radiator hose and 2 heater hoses to the thermostat housing.
  61. Disconnect the vacuum hose and the evaporative emissions (EVAP) tube from the upper intake manifold.
  62. Attach the EVAP tube pin-type retainer to the upper intake manifold.
  63. Connect the ground cable to the negative battery terminal and install the nut. Tighten to 6 Nm (53 lb-in).
  64. Connect the power feed wire to the positive battery terminal and install the nut. Tighten to 6 Nm (53 lb-in).
  65. Connect the engine wiring harness electrical connector.
  66. Install the battery tray and bracket and the nut and bolt. Tighten to 9 Nm (80 lb-in).
  67. Install the 2 lower battery tray bracket bolts. Tighten to 9 Nm (80 lb-in).
  68. Attach the 2 pin-type wiring harness fasteners to the front of the battery tray.
  69. Attach the 4 pin-type wiring harness fasteners to the side of the battery tray.
  70. Install the battery. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/taurus-x/i-2007-2009/remont/body-electrical/#battery-mounting-and-cables) article.
  71. Install the engine air cleaner and air cleaner outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION AND FILTERING»(/ford/taurus-x/i-2007-2009/remont/removal-installation/#intake-air-distribution-system-and-filtering-system) article.
  72. Install the degas bottle. For additional information, refer to «ENGINE COOLING»(/ford/taurus-x/i-2007-2009/remont/cooling-system-mechanical/#engine-cooling-system) article.
  73. Connect the power steering cooler tube.
  74. Install the accessory drive belt and the power steering belt. For additional information, refer to «ACCESSORY DRIVE»(/ford/taurus-x/i-2007-2009/remont/accessory-drive-belts/#accessory-drive-system) article.
  75. Install the front wheels and tires. For additional information, refer to «WHEELS AND TIRES»(/ford/taurus-x/i-2007-2009/remont/wheel-tire-system/#wheels-tires) article.
  76. Fill the engine with clean engine oil.
  77. Fill and bleed the cooling system. For additional information, refer to «ENGINE COOLING»(/ford/taurus-x/i-2007-2009/remont/cooling-system-mechanical/#engine-cooling-system) article.
  78. Fill the power steering system. For additional information, refer to «STEERING SYSTEM - GENERAL INFORMATION»(/ford/taurus-x/i-2007-2009/remont/manual-power-steering/#steering-system-general-information) article.
  79. Recharge the A/C system. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(/ford/taurus-x/i-2007-2009/remont/manual-hvac-system/#hvac-control-system-general-information-and-diagnostics) article.

Special Tools Illustration Tool Name Tool Number Alignment Pins 307-399 Camshaft Alignment Tool 303-1248 Handle 205-153 (T80T-4000-W) Installer, Crankshaft Front Seal 303-1251 Installer, Crankshaft Vibration Damper 303-102 (T74P-6316-B) Installer, Front Cover Oil Seal 303-335 Installer, Seal 303-1247/2 Powertrain Lift 014-00765 Strap Wrench 303-D055 (D85L-6000-A)

ItemSpecification
Motorcraft High Performance Engine RTV Silicone TA-357WSE-M4G323-A6
Motorcraft Metal Surface Prep ZC-31-A
Motorcraft SAE 5W-20 Premium Synthetic Blend Motor Oil XO-5W20-QSP (US); Motorcraft SAE 5W-20 Super Premium Motor Oil CXO-5W20-LSP12 (Canada); or equivalentWSS-M2C930-A
Silicone Gasket Remover ZC-30

Material

WARNINGDo not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.
CAUTIONDuring 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.

All camshafts

  1. Rotate the crankshaft counterclockwise until the crankshaft dowel pin is in the 9 o'clock position.
  2. Position the camshafts onto the LH cylinder head in the neutral position as shown.
  3. Install the 8 camshaft caps and the 16 bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
  4. Position the camshafts onto the RH cylinder head in the neutral position as shown.
  5. Install the 8 camshaft caps and the 16 bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
  6. Using a feeler gauge, confirm that the valve tappet clearances are within specification. If valve tappet clearances are not within specification, the clearance must be adjusted by installing new valve tappet(s) of the correct size. For additional information, refer to «Valve Clearance Check»(/ford/taurus-x/i-2007-2009/remont/mechanical/#engine-35l__valve-clearance-check) .
  7. Rotate the LH camshafts to the top dead center (TDC) position and install the special tool on the flats of the camshafts.
  8. Assemble the LH variable camshaft timing (VCT) assembly, the LH exhaust camshaft sprocket and the LH secondary timing chain. Align the colored links with the timing marks.
  9. Position the LH secondary timing assembly onto the camshafts.
  10. Install 2 new bolts and the original washer. Tighten in 4 stages. Stage 1: Tighten to 40 Nm (30 lb-ft). Stage 2: Loosen one full turn. Stage 3: Tighten to 10 Nm (89 lb-in). Stage 4: Tighten 90 degrees.
  11. Remove the lockpin from the LH secondary timing chain tensioner.
  12. Rotate the RH camshafts to the TDC position and install the special tool on the flats of the camshafts.
  13. Assemble the RH VCT assembly, the RH exhaust camshaft sprocket and the RH secondary timing chain. Align the colored links with the timing marks.
  14. Position the RH secondary timing assembly onto the camshafts.
  15. Install 2 new bolts and the original washer. Tighten in 4 stages. Stage 1: Tighten to 40 Nm (30 lb-ft). Stage 2: Loosen one full turn. Stage 3: Tighten to 10 Nm (89 lb-in). Stage 4: Tighten 90 degrees.
  16. Remove the lockpin from the RH secondary timing chain tensioner.
  17. Rotate the crankshaft clockwise 60 degrees to the TDC position (crankshaft dowel pin at 11 o'clock).
  18. Install the primary timing chain with the colored links aligned with the timing marks on the VCT assemblies and the crankshaft sprocket.
  19. Install the lower LH primary timing chain guide and the 2 bolts. Tighten to 10 Nm (89 lb-in).
  20. Install the primary timing chain tensioner arm.
  21. Reset the primary timing chain tensioner. Rotate the lever counterclockwise. Using a soft-jawed vise, compress the plunger. Align the hole in the lever with the hole in the tensioner housing. Install a suitable lockpin.
  22. Install the primary tensioner and the 2 bolts. Tighten to 10 Nm (89 lb-in). Remove the lockpin.
  23. As a post-check, verify correct alignment of all timing marks.
  24. Install new VCT housing seals.
  25. Install the LH VCT housing and the 3 bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
  26. Install the RH VCT housing and the 3 bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
  27. Install the special tools.
  28. Apply a 3.0 mm (0.11 in) bead of Motorcraft High Performance Engine RTV Silicone to the engine front cover sealing surfaces including the 3 engine mount bracket bosses. Apply a 5.5 mm (0.21 in) bead of Motorcraft High Performance Engine RTV Silicone to the oil pan-to-cylinder block joint and the cylinder head-to-cylinder block joint areas of the engine front cover in 5 places as indicated.
  29. Install the engine front cover and bolts 17, 18, 19 and 20. Tighten in sequence shown to 3 Nm (27 lb-in).
  30. Remove the special tools (alignment pins).
  31. Install the engine mount bracket and the 3 bolts.
  32. Install the remaining engine front cover bolts. Tighten all of the engine front cover bolts and engine mount bracket bolts in the sequence shown in 2 stages: Stage 1: Tighten bolts 1 thru 22 to 10 Nm (89 lb-in) and bolts 23, 24 and 25 to 15 Nm (11 lb-ft). Stage 2: Tighten bolts 1 thru 22 to 24 Nm (18 lb-ft) and bolts 23, 24 and 25 to 75 Nm (55 lb-ft).
  33. Install the 2 engine mount studs. Tighten to 18 Nm (13 lb-ft).
  34. Install the engine mount bracket and the 2 bolts. Tighten to 24 Nm (18 lb-ft).
  35. Using the special tools, install a new crankshaft front seal.
  36. Using the special tools, install the crankshaft pulley.
  37. Using the special tool, install the crankshaft pulley washer and new bolt and tighten 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.
  38. Install the accessory drive belt tensioner and the 3 bolts. Tighten to 10 Nm (89 lb-in).
  39. Install the power steering pump and the 3 bolts. Tighten to 25 Nm (18 lb-ft).
  40. Using the special tools, install new VCT solenoid and/or spark plug tube seals.
  41. Apply an 8 mm (0.31 in) bead of Motorcraft High Performance Engine RTV Silicone to the engine front cover-to-RH cylinder head joints.
  42. Using a new gasket, install the RH valve cover, bolt and the 10 stud bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
  43. Apply an 8 mm (0.31 in) bead of Motorcraft High Performance Engine RTV Silicone to the engine front cover-to-LH cylinder head joints.
  44. Using a new gasket, install the LH valve cover and 11 stud bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
  45. Install the power steering pressure (PSP) tube bracket and nut to the RH valve cover stud bolt. Tighten to 7 Nm (62 lb-in).
  46. Install the PSP tube bracket bolt. Tighten to 10 Nm (89 lb-in).
  47. Connect the PSP switch electrical connector.
  48. Install the 6 coil-on-plug assemblies and the 6 bolts. Tighten to 7 Nm (62 lb-in).
  49. Attach all of the wiring harness retainers to the LH valve cover and stud bolts.
  50. Connect the 3 LH coil-on-plug electrical connectors.
  51. Connect the LH VCT solenoid electrical connector.
  52. Attach all of the wiring harness retainers to the RH valve cover and stud bolts.
  53. If equipped, connect the heated PCV valve electrical connector.
  54. Connect the 3 RH coil-on-plug electrical connectors.
  55. Connect the RH VCT solenoid electrical connector.
  56. Connect the fuel efficient power steering system solenoid electrical connector.
  57. Connect the RH catalyst monitor sensor electrical connector.
  58. Using a new gasket, install the upper intake manifold and the 6 bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
  59. Install the fuel tube bracket bolt to the upper intake manifold and install the wiring harness pin-type retainer. Tighten to 6 Nm (53 lb-in).
  60. Install the upper intake manifold short support bracket and the bolt. Tighten to 10 Nm (89 lb-in).
  61. If equipped, install the upper intake manifold long support bracket and the bolt. Tighten to 10 Nm (89 lb-in).
  62. Attach the wiring harness retainers to the upper intake manifold.
  63. Connect the throttle body electrical connector.
  64. Connect the PCV hose to the PCV valve.
  65. If equipped, connect the heated PCV electrical connector.
  66. Raise the engine and transaxle assembly into the vehicle.
  67. Install the engine mount and the 3 bolts. Tighten to 90 Nm (66 lb-ft).
  68. Install the 4 engine mount nuts. Tighten to 63 Nm (46 lb-ft).
  69. Install the engine mount brace, the nut and the bolt. Tighten to 20 Nm (15 lb-ft).
  70. Install the transaxle support insulator bracket and the 4 nuts. Tighten the nuts to 80 Nm (59 lb-ft).
  71. Install the transaxle support insulator through bolt and nut. Tighten to 175 Nm (129 lb-ft).
  72. Install a new PTU seal. For additional information, refer to «TRANSFER CASE - POWER TRANSFER UNIT (PTU)»(/ford/taurus-x/i-2007-2009/remont/transfer-case/#transfer-case-power-transfer-unit-ptu) article.
  73. Install the RH halfshaft support bracket and the 4 bolts. Tighten the halfshaft support-to-cylinder block bolts to 40 Nm (30 lb-ft). Tighten the catalytic converter-to-halfshaft support bolts to 20 Nm (15 lb-ft).
  74. Install the 2 halfshaft support bracket studs. Tighten to 10 Nm (89 lb-in).
  75. Install the RH halfshaft into the transaxle and the wheel hub and install the 2 carrier bearing nuts. Tighten to 40 Nm (30 lb-ft).
  76. Install the LH halfshaft into the transaxle.
  77. Connect the transaxle cooling tubes and install the safety clips.
  78. Using the special tool, raise the subframe into the installed position.
  79. Install the 2 front subframe bolts. Tighten to 150 Nm (111 lb-ft).
  80. Position the subframe brackets and install the 4 bolts finger-tight.
  81. Install the 2 rear subframe bolts. Tighten to 150 Nm (111 lb-ft).
  82. Tighten the 4 subframe bracket-to-body bolts to 103 Nm (76 lb-ft).
  83. Install new lower ball joint-to-wheel knuckle nuts. Tighten to 115 Nm (85 lb-ft).
  84. Install new tie-rod end nuts. Tighten to 115 Nm (85 lb-ft).
  85. Install new upper stabilizer bar link nuts. Tighten to 55 Nm (41 lb-ft).
  86. Install the new halfshaft nut. Tighten to 350 Nm (258 lb-ft).
  87. Install the 2 engine roll restrictor-to-transaxle bolts. Tighten to 103 Nm (76 lb-ft).
  88. Using a new O-ring seal, install the PSP tube onto the steering gear, rotate the clamp plate and install the bolt. Tighten to 25 Nm (18 lb-ft).
  89. Install the PSP tube bracket-to-steering gear bolt. Tighten to 10 Nm (89 lb-in).
  90. Install a new engine oil filter. Tighten to 5 Nm (44 lb-in) and then rotate an additional 180 degrees.
  91. Line up the index marks on the rear driveshaft to the index marks on the PTU flange made during removal and install the 4 bolts (3 shown). Tighten to 70 Nm (52 lb-ft).
  92. Using a new gasket, install the Y-pipe and install the 2 new nuts. Tighten to 40 Nm (30 lb-ft). Attach the exhaust hanger.
  93. Install the Y-pipe assembly and 4 new nuts. Tighten to 40 Nm (30 lb-ft).
  94. Install the steering intermediate shaft onto the steering gear and install a new bolt. Tighten to 23 Nm (17 lb-ft).
  95. Connect the transaxle control electrical connector.
  96. Attach the transaxle control wire harness to the transaxle stud bolt.
  97. Connect the hose to the power steering reservoir.
  98. Install the oil level indicator.
  99. Install the ground cable and bolt. Tighten to 12 Nm (9 lb-ft).
  100. Attach the wire harness retainer to the RH valve cover stud bolt.
  101. Connect the 2 engine wiring harness electrical connectors. Attach the electrical connector to the LH valve cover.
  102. Connect the fuel supply tube to the fuel rail. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(/ford/taurus-x/i-2007-2009/remont/fuel-system/#fuel-system-general-information) article.
  103. Using a new O-ring seal, install the A/C tube and the nut. Tighten to 15 Nm (11 lb-ft).
  104. Using new O-ring seals, connect the A/C tubes and install the 2 nuts. Tighten to 15 Nm (11 lb-ft).
  105. Using a new O-ring seal, connect the upper A/C tube to the condenser and install the nut and connect the A/C pressure switch electrical connector. Tighten to 15 Nm (11 lb-ft).
  106. If equipped, attach the block heater wiring harness retainer to the radiator and power steering tube.
  107. Connect the transaxle control cable to the shift cable bracket.
  108. Connect the transaxle control cable to the control lever.
  109. If equipped, connect the heater hose to the auxiliary coolant pump.
  110. Connect the upper radiator hose, lower radiator hose and heater hose to the thermostat housing.
  111. Connect the vacuum hose and the evaporative emissions (EVAP) tube to the upper intake manifold.
  112. Attach the EVAP tube pin-type retainer to the upper intake manifold.
  113. Connect the ground cable to the negative battery terminal and install the nut. Tighten to 6 Nm (53 lb-in).
  114. Connect the power feed wire to the positive battery terminal and install the nut. Tighten to 6 Nm (53 lb-in).
  115. Connect the engine wiring harness electrical connector.
  116. Install the battery tray and bracket and the nut and bolt. Tighten to 9 Nm (80 lb-in).
  117. Install the 2 lower battery tray bracket bolts. Tighten to 9 Nm (80 lb-in).
  118. Attach the 2 pin-type wiring harness fasteners to the front of the battery tray.
  119. Attach the 4 pin-type wiring harness fasteners to the side of the battery tray.
  120. Install the battery. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/taurus-x/i-2007-2009/remont/body-electrical/#battery-mounting-and-cables) article.
  121. Install the engine air cleaner and air cleaner outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION AND FILTERING»(/ford/taurus-x/i-2007-2009/remont/removal-installation/#intake-air-distribution-system-and-filtering-system) article.
  122. Install the degas bottle. For additional information, refer to «ENGINE COOLING»(/ford/taurus-x/i-2007-2009/remont/cooling-system-mechanical/#engine-cooling-system) article.
  123. Connect the power steering cooler tube.
  124. Install the accessory drive belt and the power steering belt. For additional information, refer to «ACCESSORY DRIVE»(/ford/taurus-x/i-2007-2009/remont/accessory-drive-belts/#accessory-drive-system) article.
  125. Install the front wheels and tires. For additional information, refer to «WHEELS AND TIRES»(/ford/taurus-x/i-2007-2009/remont/wheel-tire-system/#wheels-tires) article.
  126. Fill the engine with clean engine oil.
  127. Fill and bleed the cooling system. For additional information, refer to «ENGINE COOLING»(/ford/taurus-x/i-2007-2009/remont/cooling-system-mechanical/#engine-cooling-system) article.
  128. Fill the power steering system. For additional information, refer to «STEERING SYSTEM - GENERAL INFORMATION»(/ford/taurus-x/i-2007-2009/remont/manual-power-steering/#steering-system-general-information) article.
  129. Recharge the A/C system. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(/ford/taurus-x/i-2007-2009/remont/manual-hvac-system/#hvac-control-system-general-information-and-diagnostics) article.
ItemSpecification
Motorcraft SAE 5W-20 Premium Synthetic Blend Motor Oil XO-5W20-QSP (US); Motorcraft SAE 5W-20 Super Premium Motor Oil CXO-5W20-LSP12 (Canada); or equivalentWSS-M2C930-A

Material

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, may cause engine failure.

  1. Install the valve tappets.
  2. Depending on the valve tappets being serviced, install the LH and/or the RH camshafts. For additional information, refer to «Camshaft»(/ford/taurus-x/i-2007-2009/remont/mechanical/#engine-35l) .

Special Tools Illustration Tool Name Tool Number Compressor, Valve Spring 303-300 (T87C-6565-A) Compressor, Valve Spring 303-350 (T89P-6565-A) Compressor, Valve Spring 303-1249 Installer, Valve Stem Oil Seal 303-470 (T94P-6510-CH)

ItemSpecification
Motorcraft SAE 5W-20 Premium Synthetic Blend Motor Oil XO-5W20-QSP (US); Motorcraft SAE 5W-20 Super Premium Motor Oil CXO-5W20-LSP12 (Canada); or equivalentWSS-M2C930-A

Material

  1. Using the Valve Stem Oil Seal Installer, install a new valve stem seal.
  2. Using the Valve Spring Compressors, install the valve spring, retainer and key.
  3. Install the valve tappets. For additional information, refer to «Valve Tappets»(/ford/taurus-x/i-2007-2009/remont/mechanical/#engine-35l) .
ItemSpecification
Motorcraft SAE 5W-20 Premium Synthetic Blend Motor Oil XO-5W20-QSP (US); Motorcraft SAE 5W-20 Super Premium Motor Oil CXO-5W20-LSP12 (Canada); or equivalentWSS-M2C930-A

Material

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, may cause engine failure.

  1. Install a new gasket, the RH cylinder head and 8 new bolts. Tighten in the sequence shown in 5 stages: Stage 1: Tighten to 20 Nm (15 lb-ft). Stage 2: Tighten to 35 Nm (26 lb-ft). Stage 3: Tighten 90 degrees. Stage 4: Tighten 90 degrees. Stage 5: Tighten 90 degrees.
  2. Install the bolt. Tighten to 10 Nm (89 lb-in).
  3. Install the valve tappets.
  4. Install and connect the cylinder head temperature (CHT) sensor jumper harness.
  5. Using new gaskets, install the lower intake manifold and the 10 bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
  6. Using a new gasket and O-ring seal, install the thermostat housing and the 3 bolts. Tighten to 10 Nm (89 lb-in).
  7. Install new fuel injector O-ring seals. Remove the retaining clips and separate the fuel injectors from the fuel rail. Remove and discard the O-ring seals. Install new O-ring seals and lubricate with clean engine oil. Install the fuel injectors and the retaining clips onto the fuel rail.
  8. Install the fuel rail and injectors as an assembly and install the 4 bolts. Tighten to 10 Nm (89 lb-in).
  9. Install the coolant bypass hose to the thermostat housing.
  10. Install the upper intake manifold short support bracket and the bolt. Tighten to 10 Nm (89 lb-in).
  11. If equipped, install the upper intake manifold long support bracket and the bolt. Tighten to 10 Nm (89 lb-in).
  12. Install the engine lifting eye and the 2 bolts. Tighten to 24 Nm (18 lb-ft).
  13. Install the RH secondary timing chain tensioner and the 2 bolts. Tighten to 10 Nm (89 lb-in).
  14. Install the RH primary timing chain guide and the 2 bolts. Tighten to 10 Nm (89 lb-in).
  15. Install 6 new RH exhaust manifold studs. Tighten to 12 Nm (9 lb-ft).
  16. Using a new gasket, install the RH exhaust manifold and 6 new nuts. Tighten in 2 stages in the sequence shown: Stage 1: Tighten to 20 Nm (15 lb-ft). Stage 2: Tighten to 20 Nm (15 lb-ft).
  17. Install the RH exhaust manifold heat shield and the 3 bolts. Tighten to 14 Nm (10 lb-ft).
  18. Install the RH cylinder block drain plug or, if equipped, the block heater. Tighten to 40 Nm (30 lb-ft).
  19. If equipped, install the block heater wiring harness onto the engine. Connect the block heater electrical connector and install the heat shield.
  20. Using a new gasket, install the RH catalytic converter and 4 new nuts. Tighten to 40 Nm (30 lb-ft).
  21. Install the LH cylinder block drain plug. Tighten to 20 Nm (15 lb-ft) plus an additional 180 degrees.
  22. Using a new gasket, install the LH catalytic converter and 4 new nuts (3 shown). Tighten to 40 Nm (30 lb-ft).
  23. Install the 2 LH catalytic converter bracket bolts. Tighten to 20 Nm (15 lb-ft).
  24. Connect the LH catalyst monitor sensor electrical connector.
  25. Connect the CHT sensor electrical connector.
  26. Connect the 6 fuel injector electrical connectors (3 shown).
  27. Install the ground wire and the bolt. Tighten to 10 Nm (89 lb-in).
  28. Install the Power Steering Pressure (PSP) tube bracket and the bolt to the RH cylinder head. Tighten to 10 Nm (89 lb-in).
  29. Install the RH camshaft position (CMP) sensor and the bolt. Tighten to 10 Nm (89 lb-in).
  30. Connect the RH CMP sensor electrical connector.
  31. Connect the RH heated oxygen sensor (HO2S) electrical connector.
  32. Install the RH camshafts. For additional information, refer to «Camshaft»(/ford/taurus-x/i-2007-2009/remont/mechanical/#engine-35l) .
ItemSpecification
Motorcraft SAE 5W-20 Premium Synthetic Blend Motor Oil XO-5W20-QSP (US); Motorcraft SAE 5W-20 Super Premium Motor Oil CXO-5W20-LSP12 (Canada); or equivalentWSS-M2C930-A

Material

CAUTIONDuring 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.
  1. Install a new gasket, the LH cylinder head and 8 new bolts. Tighten in the sequence shown in 5 stages: Stage 1: Tighten to 20 Nm (15 lb-ft). Stage 2: Tighten to 35 Nm (26 lb-ft). Stage 3: Tighten 90 degrees. Stage 4: Tighten 90 degrees. Stage 5: Tighten 90 degrees.
  2. Install the bolt. Tighten to 10 Nm (89 lb-in).
  3. Install the valve tappets.
  4. Install the LH secondary timing chain tensioner and the 2 bolts. Tighten to 10 Nm (89 lb-in).
  5. Install the upper LH primary timing chain guide and the 2 bolts. Tighten to 10 Nm (89 lb-in).
  6. Using new gaskets, install the lower intake manifold and the 10 bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
  7. Using a new gasket and O-ring seal, install the thermostat housing and the 3 bolts. Tighten to 10 Nm (89 lb-in).
  8. Install new fuel injector O-ring seals. Remove the retaining clips and separate the fuel injectors from the fuel rail. Remove and discard the O-ring seals. Install new O-ring seals and lubricate with clean engine oil. Install the fuel injectors and the retaining clips onto the fuel rail.
  9. Install the fuel rail and injectors as an assembly and install the 4 bolts. Tighten to 10 Nm (89 lb-in).
  10. Install the coolant bypass hose to the thermostat housing.
  11. Install the RH cylinder block drain plug or, if equipped, the block heater. Tighten to 40 Nm (30 lb-ft).
  12. If equipped, install the block heater wiring harness onto the engine. Connect the block heater electrical connector and install the heat shield.
  13. Using a new gasket, install the RH catalytic converter and 4 new nuts. Tighten to 40 Nm (30 lb-ft).
  14. Install the LH cylinder block drain plug. Tighten to 20 Nm (15 lb-ft) plus an additional 180 degrees.
  15. Install 6 new LH exhaust manifold studs. Tighten to 12 Nm (9 lb-ft).
  16. Using a new gasket, install the LH exhaust manifold and 6 new nuts. Tighten in 2 stages in the sequence shown: Stage 1: Tighten to 20 Nm (15 lb-ft). Stage 2: Tighten to 20 Nm (15 lb-ft).
  17. Install the LH exhaust manifold heat shield and the 3 bolts. Tighten to 14 Nm (10 lb-ft).
  18. Using a new gasket, install the LH catalytic converter and 4 new nuts (3 shown). Tighten to 40 Nm (30 lb-ft).
  19. Install the LH catalytic converter bracket bolts. Tighten to 20 Nm (15 lb-ft).
  20. Attach the engine oil pressure (EOP) switch wiring harness pin-type retainer.
  21. Install the stud, generator and the nut and bolt. Tighten the stud to 12 Nm (9 lb-ft). Tighten nut and bolt to 48 Nm (35 lb-ft).
  22. Connect the generator electrical connector.
  23. Connect the generator B+ cable and install the nut. Tighten to 6 Nm (53 lb-in).
  24. Attach the pin-type wire harness retainer to the rear of LH cylinder head.
  25. Connect the LH catalyst monitor sensor electrical connector.
  26. Connect the LH heated oxygen sensor (HO2S) electrical connector.
  27. Install LH camshaft position (CMP) sensor and the bolt. Tighten to 10 Nm (89 lb-in).
  28. Connect the LH CMP sensor electrical connector.
  29. Connect the cylinder head temperature (CHT) sensor electrical connector.
  30. Connect the 6 fuel injector electrical connectors (3 shown).
  31. Install the LH camshafts. For additional information, refer to «Camshaft»(/ford/taurus-x/i-2007-2009/remont/mechanical/#engine-35l) .

Special Tools Illustration Tool Name Tool Number Alignment Pins 307-399 Handle 205-153 (T80T-4000-W) Heavy Duty Floor Crane 014-00071 or equivalent Installer, Crankshaft Front Seal 303-1251 Installer, Crankshaft Vibration Damper 303-102 (T74P-6316-B) Installer, Front Cover Oil Seal 303-335 Installer, Seal 303-1247/2 Spreader Bar 303-D089 (D93P-6001-A3) or equivalent Strap Wrench 303-D055 (D85L-6000-A)

ItemSpecification
Motorcraft High Performance Engine RTV Silicone TA-357WSE-M4G323-A6
Motorcraft Metal Surface Prep ZC-31-A
Motorcraft SAE 5W-20 Premium Synthetic Blend Motor Oil XO-5W20-QSP (US); Motorcraft SAE 5W-20 Super Premium Motor Oil CXO-5W20-LSP12 (Canada); or equivalentWSS-M2C930-A
Silicone Gasket Remover ZC-30

Material

CAUTIONDuring 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.

All vehicles

  1. Apply a 3 mm (0.11 in) bead of Motorcraft High Performance Engine RTV Silicone to the sealing surface of the oil pan. Apply a 5.5 mm (0.21 in) bead of Motorcraft High Performance Engine RTV Silicone to the 2 crankshaft seal retainer plate-to-cylinder block joint areas on the sealing surface of the oil pan.
  2. Install the oil pan and bolts 10, 11, 13 and 14. Tighten in the sequence shown to 3 Nm (27 lb-in). Loosen the bolts 180 degrees.
  3. Align the oil pan to the cylinder block and A/C compressor. Position the oil pan so the mounting boss is against the A/C compressor and using a straightedge, align the oil pan flush with the rear of the cylinder block at the 2 areas shown.
  4. Tighten bolts 10, 11, 13 and 14 in the sequence shown, to 3 Nm (27 lb-in).
  5. Install the remaining oil pan bolts. Tighten all the oil pan bolts in the sequence shown. Tighten the large bolts (1-14) to 20 Nm (15 lb-ft). Tighten the small bolts (15 and 16) to 10 Nm (89 lb-in).
  6. Install the A/C compressor mounting stud and nut. Tighten the stud to 9 Nm (80 lb-in) and the nut to 25 Nm (18 lb-ft).
  7. Install the special tools.
  8. Apply a 3.0 mm (0.11 in) bead of Motorcraft High Performance Engine RTV Silicone to the engine front cover sealing surfaces including the 3 engine mount bracket bosses. Apply a 5.5 mm (0.21 in) bead of Motorcraft High Performance Engine RTV Silicone to the oil pan-to-cylinder block joint and the cylinder head-to-cylinder block joint areas of the engine front cover in 5 places as indicated.
  9. Install the engine front cover and bolts 17, 18, 19 and 20. Tighten in sequence shown to 3 Nm (27 lb-in).
  10. Remove the special tools (alignment pins).
  11. Install the engine mount bracket and the 3 bolts.
  12. Install the remaining engine front cover bolts. Tighten all of the engine front cover bolts and engine mount bracket bolts in the sequence shown in 2 stages: Stage 1: Tighten bolts 1 thru 22 to 10 Nm (89 lb-in) and bolts 23, 24 and 25 to 15 Nm (11 lb-ft). Stage 2: Tighten bolts 1 thru 22 to 24 Nm (18 lb-ft) and bolts 23, 24 and 25 to 75 Nm (55 lb-ft).
  13. Install the 2 engine mount studs. Tighten to 18 Nm (13 lb-ft).
  14. Install the engine mount bracket and the 2 bolts. Tighten to 24 Nm (18 lb-ft).
  15. Using the special tools, install a new crankshaft front seal.
  16. Using the special tools, install the crankshaft pulley.
  17. Using the special tool, install the crankshaft pulley washer and new bolt and tighten 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.
  18. Using the special tools, install new VCT solenoid and/or spark plug tube seals.
  19. Apply an 8 mm (0.31 in) bead of Motorcraft High Performance Engine RTV Silicone to the engine front cover-to-RH cylinder head joints.
  20. Using a new gasket, install the RH valve cover, bolt and the 10 stud bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
  21. Apply an 8 mm (0.31 in) bead of Motorcraft High Performance Engine RTV Silicone to the engine front cover-to-LH cylinder head joints.
  22. Using a new gasket, install the LH valve cover and 11 stud bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
  23. Install the 6 coil-on-plug assemblies and the 6 bolts. Tighten to 7 Nm (62 lb-in).
  24. Install the LH cylinder block drain plug. Tighten to 20 Nm (15 lb-ft) plus an additional 180 degrees.
  25. Install the RH cylinder block drain plug or, if equipped, the block heater. Tighten to 40 Nm (30 lb-ft).
  26. Using a new gasket, install the RH catalytic converter and 4 new nuts. Tighten to 40 Nm (30 lb-ft).
  27. Using a new gasket, install the LH catalytic converter and 4 new nuts (3 shown). Tighten to 40 Nm (30 lb-ft).
  28. Install the accessory drive belt tensioner and the 3 bolts. Tighten to 10 Nm (89 lb-in).
  29. Install the power steering pump and the 3 bolts. Tighten to 25 Nm (18 lb-ft).
  30. Install the power steering pressure (PSP) tube bracket bolt. Tighten to 10 Nm (89 lb-in).
  31. Install the PSP bracket and nut to the RH valve cover stud bolt. Tighten to 7 Nm (62 lb-in).
  32. Attach all of the wiring harness retainers to the LH valve cover and stud bolts.
  33. Connect the 3 LH coil-on-plug electrical connectors.
  34. Connect the LH camshaft VCT solenoid electrical connector.
  35. Connect the LH catalyst monitor sensor electrical connector.
  36. Attach all of the wiring harness retainers to the RH valve cover and stud bolts.
  37. Connect the RH heated oxygen sensor (HO2S) electrical connector.
  38. If equipped, connect the heated PCV valve electrical connector.
  39. Connect the 3 RH coil-on-plug electrical connectors.
  40. Connect the RH VCT solenoid electrical connector.
  41. Connect the RH catalyst monitor sensor electrical connector.
  42. Connect the PSP switch electrical connector.
  43. Connect the fuel efficient power steering system solenoid electrical connector.
  44. Using new gaskets, install the upper intake manifold and the 6 bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
  45. Install the fuel tube bracket bolt to the upper intake manifold. Tighten to 6 Nm (53 lb-in).
  46. Install the upper intake manifold short support bracket bolt. Tighten to 10 Nm (89 lb-in).
  47. If equipped, install the upper intake manifold long support bracket bolt. Tighten to 10 Nm (89 lb-in).
  48. Attach the wiring harness retainers to the upper intake manifold.
  49. Connect the throttle body (TB) electrical connector.
  50. Connect the PCV hose to the PCV valve.
  51. If equipped, connect the heated PCV electrical connector.
  52. If equipped, connect the block heater electrical connector and install the heat shield. Attach all the engine block heater wiring harness retainer.
  53. Using the special tools, remove the engine from the stand.
  54. Install the crankshaft sensor ring.
  55. Install the flexplate and the 8 bolts. Tighten to 80 Nm (59 lb-ft).
  56. Install the engine in the vehicle. For additional information, refer to «Engine»(/ford/taurus-x/i-2007-2009/remont/mechanical/#engine-35l) .

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.

  1. Using a new O-ring seal, install the oil pump screen and pickup tube and the 3 bolts. Tighten to 10 Nm (89 lb-in).
  2. Install the oil pan. For additional information, refer to «Oil Pan»(/ford/taurus-x/i-2007-2009/remont/mechanical/#engine-35l) .

Special Tools Illustration Tool Name Tool Number Handle 205-153 (T80T-4000-W) Heavy Duty Floor Crane 014-00071 or equivalent Installer, Rear Main Seal 303-1250 Spreader Bar 303-D089 (D93P-6001-A3) or equivalent

ItemSpecification
Motorcraft High Performance Engine RTV Silicone TA-357WSE-M4G323-A6
Motorcraft SAE 5W-20 Premium Synthetic Blend Motor Oil XO-5W20-QSP (US); Motorcraft SAE 5W-20 Super Premium Motor Oil CXO-5W20-LSP12 (Canada); or equivalentWSS-M2C930-A

Material

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.

  1. Apply a 3 mm (0.11 in) bead of Motorcraft High Performance Engine RTV Silicone to the sealing surface of the crankshaft rear seal retainer.
  2. Install the rear seal retainer and the 8 bolts in the sequence shown. Tighten in the sequence shown to 10 Nm (89 lb-in).
  3. Position the Rear Main Seal Installer onto the end of the crankshaft and slide a new crankshaft rear seal onto the tool.
  4. Using the Rear Main Seal Installer and Handle, install the new crankshaft rear seal.
  5. Install the Crankshaft Position (CKP) sensor and install the bolt. Tighten to 10 Nm (89 lb-in).
  6. Connect the CKP sensor electrical connector.
  7. Using the Heavy Duty Floor Crane and Spreader Bar, install the engine onto the stand.
  8. Install the oil pan. For additional information, refer to «Oil Pan»(/ford/taurus-x/i-2007-2009/remont/mechanical/#engine-35l) .

See also:
• Introduction - Gasoline Engines
• ENGINE SYSTEM - GENERAL INFORMATION
• INTAKE AIR DISTRIBUTION AND FILTERING
• ENGINE COOLING
• FUEL CHARGING AND CONTROLS - 3.5L
• JACKING AND LIFTING
• ACCESSORY DRIVE
• AUTOMATIC TRANSAXLE/TRANSMISSION - 6F50
• CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS
• WHEELS AND TIRES
• FRONT END BODY PANELS
• STEERING SYSTEM - GENERAL INFORMATION
• EXHAUST SYSTEM
• ELECTRONIC ENGINE CONTROLS
• FUEL SYSTEM - GENERAL INFORMATION
• BATTERY, MOUNTING AND CABLES
• SUPPLEMENTAL RESTRAINT SYSTEM
• TRANSFER CASE - POWER TRANSFER UNIT (PTU)
• Valve Cover - LH
• Valve Cover - RH
• Valve Tappets
• Crankshaft Pulley
• Flexplate
• Engine Front Cover
• Camshaft
• Cylinder Head - RH
• Cylinder Head - LH
• Oil Pan
• Crankshaft Rear Seal
• Valve Clearance Check

More articles — Engine