3.8l v6 - VIN [4] Ford Taurus I

ENGINE IDENTIFICATION

Note. For engine repair procedures not covered in this article, see ENGINE OVERHAUL PROCEDURES - GENERAL INFORMATION article in the GENERAL INFORMATION section.

Note. See TSB NUMBER 91-5B-9 for information on revised engine mount replacement procedures.

The engine may be identified by the Vehicle Identification Number (VIN) stamped on a metal tab attached to the instrument panel near the windshield on driver's side of vehicle. The VIN number is also stamped on both Safety Certification Decals, mounted on the left front door lock panel and on the Engine Identification Label, mounted on the valve cover. The VIN number contains 17 characters. The 8th character identifies the engine and the 10th character establishes the model year.

ENGINE IDENTIFICATION CODES

TROUBLE SHOOTING

Note. To trouble shoot mechanical components, see appropriate table in TROUBLE SHOOTING article in GENERAL INFORMATION.

ENGINE REMOVAL & INSTALLATION

Note. Information for Continental not available from manufacturer.

Removal (All Except Continental)

1. Drain cooling system. Disconnect negative battery cable. Disconnect under hood wiring connector retaining engine compartment light. Mark hinges for reinstallation and remove hood.
2. Remove air cleaner assembly, air intake duct and heat tube. Remove oil level indicator tube and fan shroud attaching screws. Remove fan/clutch assembly and shroud. Loosen accessory drive belt idler. Remove drive belt. Remove water pump pulley.
3. Disconnect upper and lower radiator hoses at radiator. Disconnect thermactor hose from downstream air tube check valve. Remove downstream air tube bracket bolt from rear of right cylinder head.
4. Remove coil secondary wire from coil. Remove power steering pump attaching bolts (if equipped). Place pump aside with hoses connected.
5. Remove A/C compressor attaching bolts (if equipped). Position compressor aside leaving refrigerant lines connected. Disconnect and remove alternator. Disconnect heater hoses from heater tube and water pump.
6. Remove cruise control servo and bracket (if equipped). Disconnect all vacuum hoses, electrical wiring and linkages from engine. Disconnect engine ground strap at dash panel. Disconnect transmission linkage at fuel charging assembly.
7. Remove crankshaft pulley assembly. Disconnect fuel lines connecting engine to vehicle body. Plug the hoses to prevent leakage.
8. Raise vehicle. Drain crankcase. Remove dust shield from converter housing. Remove flex plate-to-torque converter bolts. Disconnect battery cable from starter motor. Remove starter motor.
9. Remove transmission oil cooler line routing clip. Remove exhaust inlet pipe at exhaust manifold. Disconnect exhaust heat control valve vacuum line (if equipped). Remove valve from exhaust manifold studs.
10. Remove transmission-to-engine lower attaching bolts. Remove engine mount bolts. Lower vehicle. Support transmission with a jack.
11. Remove remaining bolts connecting transmission to engine. Slightly raise engine. Carefully pull engine away from transmission. Remove engine from engine compartment.

Installation

To install, reverse removal procedure. Check fluid levels. Start engine and check for leaks.

INTAKE MANIFOLDS

Note. Some models may differ in removal and installation of some components, due to location and accessories.

Scheme 18

1. Disconnect negative battery cable. Remove fuel cap to release fuel tank pressure. Drain cooling system. Remove air cleaner assembly and heat tube. Remove alternator and set aside. Disconnect throttle cable and transmission linkage (auto. trans.) at throttle body. Remove throttle mounting bracket. Disconnect cruise control unit (if equipped) and set aside.
2. Disconnect thermactor air supply hose at check valve. Disconnect flexible fuel line from steel line over valve cover. Disconnect fuel lines at injector fuel rail assembly. Remove upper radiator hose from thermostat housing. Disconnect coolant by-pass hose and heater tube at intake manifold.
3. Remove heater tube support bracket nut. Remove heater hose at rear of heater tube. Loosen hose clamp at heater elbow and remove heater tube assembly with hose and fuel lines attached. Mark and disconnect vacuum lines from fuel rail and intake manifold. Mark and disconnect necessary electrical connectors.
4. Remove A/C compressor support bracket at manifold (if equipped). Remove one PCV line from upper intake manifold. Remove second PCV line from left valve cover and lower intake manifold. Remove EGR valve assembly from upper intake manifold.
5. Mark left cylinder head spark plug wires and remove wires from spark plugs. Remove spark plug wiring retainer bracket at left front of intake manifold and set spark plug wires aside. Remove upper intake manifold bolts/studs. Remove upper intake manifold and gasket. (Scheme 18) (Scheme 18): Exploded View of Intake Components
6. Remove fuel pressure from fuel rail through relief valve on fuel rail. Disconnect fuel injector wiring harness at fuel injectors and remove wiring harness. Using Spring Lock Coupling Remover (D87L-9280-A), disconnect crossover fuel hose from fuel rail. NOTE: It may be easier to remove injectors with fuel rail assembly.
7. Remove 4 fuel rail retaining bolts. Using a side-to-side rocking motion, carefully disengage and remove fuel rail from injectors. Remove heater coolant outlet hose. Mark and remove lower intake manifold bolts. Remove lower intake manifold and gaskets.

1. Clean all gasket mating surfaces with a suitable solvent. Apply Contact Adhesive (D7AZ-19B508-A) on cylinder head intake gasket surfaces, to hold intake gaskets into place during installation. Position intake manifold gaskets on cylinder head. NOTE: Assembly must occur within 15 minutes after silicone sealer is applied. Lightly coat all bolts and stud threads with oil prior to installation.
2. Apply a bead of Silicone Sealer (D6AZ-19562-B) at each corner where cylinder head joins cylinder block. Install front and rear intake manifold end seals. Carefully lower intake manifold into position. Install intake manifold bolts in original location. Tighten to specifications in 3 steps. (Scheme 19) To complete installation, reverse removal procedure.

Intake Manifold Tightening Sequence. Scheme 19

EXHAUST MANIFOLDS

Note. Some models may differ in removal and installation of some components due to location and accessories.

Removal (Left Side)

Remove oil dipstick tube support bracket. Mark and disconnect spark plugs wires from spark plugs on left side. Raise vehicle. Remove exhaust pipe from exhaust manifold. Lower vehicle. Remove exhaust manifold bolts/studs. Remove exhaust manifold and gasket.

Note. Exhaust manifolds may warp slightly. Elongate necessary bolt holes, except for pilot hole.

Clean mating surfaces on both cylinder head and exhaust manifold. Lightly oil bolt and stud threads. Position new gasket and manifold onto cylinder head. Install the lower front bolt of No. 5 cylinder for pilot. Install remaining bolts. Tighten bolts to specifications. To complete installation, reverse removal procedure.

Removal (Right Side)

1. Remove air cleaner assembly and heat tube. Disconnect thermactor hose from check valve. Mark and remove spark plug wires from spark plugs on right side. Remove spark plugs. Remove outer heat shield. Disconnect EGR tube. Raise vehicle. Remove transmission/transaxle dipstick tube. Remove thermactor downstream air tube.
2. Remove exhaust pipe from exhaust manifold. Lower vehicle. Remove exhaust manifold bolts/studs. Remove exhaust manifold and inner heat shield as an assembly. Remove gasket.

Note. Exhaust manifolds may warp slightly. Elongate necessary bolt holes, except for pilot holes.

Clean mating surfaces on both cylinder head and exhaust manifold. Lightly oil bolt and stud threads. Position new gasket and manifold with inner heat shield onto cylinder head. Install the lower front bolt of No. 2 cylinder for pilot. Install remaining bolts. Tighten bolts to specifications. To complete installation, reverse removal procedure.

CYLINDER HEAD

Note. Some models may differ in removal and installation of some components due to location and accessories.

Removal

1. Disconnect negative battery. Drain cooling system. Remove air cleaner assembly with heat tube. Remove accessory drive belts. Remove oil filler cap, power steering pump/bracket assembly and A/C compressor/bracket assembly. Remove alternator assembly. Disconnect thermactor air valve from air pump. Remove accessory drive belt idler, thermactor pump assembly and PCV valve.
2. Remove upper and lower intake manifold. Refer to, in this article, «INTAKE MANIFOLDS»(/ford/taurus/i-1985-1991/remont/mechanical/#38l-v6-vin-4__intake-manifolds) . Remove valve covers. Remove exhaust manifolds. See «EXHAUST MANIFOLDS»(/ford/taurus/i-1985-1991/remont/mechanical/#38l-v6-vin-4__exhaust-manifolds) in this article. Loosen rocker arm bolts enough to move rocker arm off push rod. Mark and remove pushrods. Remove cylinder head bolts, noting location of different size bolts for installation. Discard cylinder head bolts. Remove cylinder head and gasket.

Inspection

1. Thoroughly clean all gasket mating surfaces. A cleaning solvent for intake manifold gasket surfaces is required. Check dowels in cylinder block and replace if necessary. Check cylinder head(s) for cracks and warpage. Replace head if cracked.
2. Machine head if warpage exceeds .007" (.18 mm) overall. DO NOT machine more than .010" (.25 mm) from cylinder head. Clean and tap cylinder head bolt holes in cylinder block. Check cylinder block surface for warpage. See CYLINDER BLOCK ASSEMBLY in this article.

Note. Always use NEW cylinder head bolts. The 3.8L engine has aluminum cylinder heads and requires Ford Cooling System Fluid (E2FZ-19549-A) at 50/50 mixture.

1. Perform inspection before installing cylinder head(s). Place head gasket on cylinder block using dowels for guides. Install cylinder head on block. Apply a thin coat of Teflon Pipe Sealant (D8AZ-19554-A) to threads of NEW short cylinder head bolts. DO NOT apply sealant to long cylinder head bolts.
2. Install cylinder head bolts. Tighten cylinder head bolts to specifications and in sequence. See «TORQUE SPECIFICATIONS»(/ford/taurus/i-1985-1991/remont/mechanical/#38l-v6-vin-4__torque-specifications) table at end of this article. (Scheme 20) Dip each push rod in Oil Conditioner (D9AZ-19579-C) and install push rods in original position. Before each rocker arm is installed on push rod, rotate crankshaft until push rod is in full down position. Position rocker arm on push rod and tighten bolt to 43 INCH lbs. (5 N.m) maximum.
3. Repeat procedure for remaining push rods and rocker arms. Final tightening of rocker arms may be done with camshaft in any position. To complete installation, reverse removal procedure. Tighten all bolts/nuts to specifications. Change oil and filter. Fill cooling system with specified coolant. Check for leakage.

Cylinder Head Tightening Sequence. Scheme 20

CAMSHAFT FRONT COVER & TIMING CHAIN

Note. Some models may differ in removal and installation of some components due to location and accessories.

1. Disconnect negative battery cable. Drain cooling system. Drain engine oil. Remove oil filter. Remove air cleaner assembly with heat tube. Remove accessory belts. Remove fan shroud, fan and clutch assembly. Remove water pump pulley. Leave hoses attached and remove power steering pump/bracket assembly. Leave hoses attached and remove A/C compressor/bracket assembly.
2. Disconnect coolant by-pass hose and heater hose at water pump. Remove radiator hose from thermostat housing. Mark and remove spark plug wires from spark plugs. Disconnect coil wire. Remove distributor cap and wires as an assembly. Position No. 1 cylinder at TDC on compression stroke. Ignition rotor should be at No. 1 cylinder. CAUTION: Special care must be taken when removing crankshaft pulley and damper. They are initially balanced as a unit from the factory.
3. Mark distributor to engine and remove distributor. Raise vehicle. Mark crankshaft pulley-to-damper to ensure installation to original position. If sufficient room is available, DO NOT separate crankshaft pulley and damper. Using Crankshaft Damper Remover (T58P-6316-D) and Adapter (T82L-6316-B), remove crankshaft damper.
4. Remove lower radiator hose. Remove oil pan. See «OIL PAN REMOVAL & INSTALLATION»(/ford/taurus/i-1985-1991/remont/mechanical/#38l-v6-vin-4__oil-pan-removal-installation) in this article. Lower vehicle. Remove front cover bolts. One front cover bolt is hid behind oil filter adapter. Remove front cover and water pump as an assembly. Remove gasket. Check timing chain deflection. See INSPECTION under «CAMSHAFT FRONT COVER & TIMING CHAIN»(/ford/taurus/i-1985-1991/remont/mechanical/#38l-v6-vin-4__camshaft-front-cover-timing-chain) in this article.
5. Remove camshaft sprocket bolt and washer. Remove distributor drive gear. Remove camshaft sprocket, crankshaft sprocket and timing chain as an assembly. Pry evenly on crankshaft sprocket with 2 screwdrivers if necessary.

1. Check timing chain deflection by removing right valve cover. Loosen No. 3 exhaust rocker arm and move off of push rod. Install dial indicator with pointer on tip of push rod. To eliminate slack on right side of timing chain, rotate crankshaft clockwise until No. 1 cylinder is on TDC. Zero dial indicator.
2. Slowly rotate crankshaft counterclockwise until initial dial indicator movement is noted. Note the number of degrees the crankshaft rotated. If the number of degrees exceeds 6 degrees replace timing chain and sprockets.
3. Clean and check all gasket mating surfaces thoroughly. Replace front cover oil seal before installing front cover. Place No. 1 cylinder on TDC before installing components.

1. Place crankshaft sprocket, camshaft sprocket and timing chain to engine block as an assembly. Timing marks on crankshaft and camshaft sprocket should be aligned at closest point. (Scheme 21) If not aligned, rotate camshaft or crankshaft as necessary.
2. With timing chain assembly installed, install distributor drive gear. Install washer and bolt. Tighten to specifications. Thoroughly coat timing chain and sprockets with Oil Conditioner (D9AZ-19579-C). Lubricate front cover oil seal with engine oil. Apply Contact Adhesive (D7AZ-19B508-A) to engine side of front cover gasket and place gasket on engine.
3. Position front cover assembly to engine. Use dowels to help align if necessary. Install front cover bolts and tighten to specifications. To complete installation, reverse removal procedure. Tighten all bolts/nuts to specifications. Fill cooling system with specified coolant only. Check for leakage.

Timing Chain Sprocket Alignment. Scheme 21

Timing Chain Gear Alignment W/Balance Shafts (FWD). Scheme 22

CAMSHAFT FRONT COVER OIL SEAL

1. Remove fan shroud and fan clutch assembly. Loosen accessory drive belt idler. Raise vehicle. Disengage accessory drive belt from crankshaft pulley. Mark crankshaft pulley-to-damper and remove pulley. CAUTION: Special care must be taken when removing crankshaft pulley and damper. They are initially balanced as a unit from the factory.
2. Using Crankshaft Damper Remover (T58P-6316-D) and Adapter (T82L-6316-B), remove crankshaft damper. Pry oil seal out of front cover. Lubricate new oil seal with engine oil. Install seal with Seal Installer (T82L-6316-A and T70P-6B070-A). To complete installation, reverse removal procedure. Tighten all bolts/nuts to specifications.

Removal (Cougar & Thunderbird)

1. Drain cooling system and remove radiator. Remove A/C condenser (if equipped). Remove grille. Remove accessory belts. Remove intake manifolds. See «INTAKE MANIFOLDS»(/ford/taurus/i-1985-1991/remont/mechanical/#38l-v6-vin-4__intake-manifolds) in this article. Remove valve covers. Loosen rocker arm bolts. Rotate rocker arms off of push rods. Mark and remove push rods. Mark and remove lifters. Remove oil pan.
2. Remove front cover/water pump assembly. Refer to «CAMSHAFT FRONT COVER & TIMING CHAIN»(/ford/taurus/i-1985-1991/remont/mechanical/#38l-v6-vin-4__camshaft-front-cover-timing-chain) in this article. Remove balance shaft gear and spacer. (Scheme 23) Remove thrust plate. Pull camshaft out front of engine. Use care not to damage camshaft bearings.

Clean all components and gasket mating surfaces. Check clearance of camshaft-to-bearings. Check lift of each lobe in consecutive order and record each reading. See CAMSHAFT LOBE LIFT in this article. Repair or replace as necessary.

Lubricate camshaft lobes and bearing surfaces with Oil Conditioner (D9AZ-19579-C). Install camshaft using care not to damage bearings and journal surfaces. To complete installation, reverse removal procedure. Ensure marked components are installed to original position. Change oil and filter. Fill cooling system with specified coolant only.

Exploded View of Timing Chain Assembly. Scheme 23

Removal & Installation (Continental, Sable, Taurus)

1. Remove engine and transaxle from vehicle. See «ENGINE REMOVAL & INSTALLATION»(/ford/taurus/i-1985-1991/remont/mechanical/#38l-v6-vin-4__engine-removal-installation) in this article. Remove intake manifold. See «INTAKE MANIFOLD»(/ford/taurus/i-1985-1991/remont/mechanical/#38l-v6-vin-4__intake-manifolds) in this article. Remove valve covers. Loosen rocker arm bolts. Rotate rocker arms off of push rods. Mark and remove push rods. Mark and remove lifters.
2. Remove oil pan. Remove front cover and water pump as an assembly. Remove timing chain and sprockets. See «CAMSHAFT FRONT COVER & TIMING CHAIN»(/ford/taurus/i-1985-1991/remont/mechanical/#38l-v6-vin-4__camshaft-front-cover-timing-chain) in this article. Remove balance shaft gear and spacer. (Scheme 23) Remove thrust plate. Pull camshaft out front of engine. Use care not to damage camshaft bearings.

Clean all components and gasket mating surfaces. Check clearance of camshaft-to-bearings. Check lift of each lobe in consecutive order and record each reading. See CAMSHAFT LOBE LIFT in this article. Repair or replace as necessary.

Lubricate camshaft lobes and bearing surfaces with Oil Conditioner (D9AZ-19579-C). Install camshaft using care not to damage bearings and journal surfaces. To complete installation, reverse removal procedure. Ensure marked components are installed to original position. Change oil and filter. Fill cooling system with specified coolant only.

BALANCE SHAFT REMOVAL & INSTALLATION

1. Remove front cover and timing chain assembly. Refer to «CAMSHAFT FRONT COVER & TIMING CHAIN»(/ford/taurus/i-1985-1991/remont/mechanical/#38l-v6-vin-4__camshaft-front-cover-timing-chain) in this article. Mark balance shaft drive gear-to-driven gear. Remove balance shaft drive gear and spacer from camshaft. (Scheme 23)
2. Remove balance shaft thrust plate bolts. Slide balance shaft out front of engine. To install, reverse removal procedure. Ensure marks made at removal on drive and driven gears are aligned. (Scheme 22) Coat gears with Lubricant (ESE-M2C39-F).

1. Remove engine and transaxle from vehicle. See «ENGINE REMOVAL & INSTALLATION»(/ford/taurus/i-1985-1991/remont/mechanical/#38l-v6-vin-4__engine-removal-installation) at the end of this article. Remove transmission/transaxle. Remove clutch disc and pressure plate (if equipped). Remove flywheel/flexplate and rear cover plate. Remove camshaft. See CAMSHAFT in this article.
2. Remove crankshaft and push pistons to top of cylinder. Remove engine rear camshaft core plug. Using Camshaft Bearing Set (T65L-6250-A), remove camshaft bearings. Remove front camshaft bearing by install bearing set through rear of engine.

Camshaft bearings are available prefinished to size for standard and .015" (.38 mm) undersize journal diameters. Bearings are not interchangeable from one bore to another. Use Camshaft Bearing Set (T65L-6250-A) to install camshaft bearings. Ensure bearing hole and cylinder block hole are aligned. To complete installation, reverse removal procedure.

BALANCE SHAFT BEARINGS

Remove balance shaft. See BALANCE SHAFT REMOVAL & INSTALLATION in this article. Use Camshaft Bearing Set (T65L-6250-A) to remove and install balance shaft bearings.

CAMSHAFT LOBE LIFT

1. Loosen rocker arm bolt and rotate rocker arm off of push rod. Check lift of each lobe in consecutive order. Using a dial indicator, position point to end of push rod, in the same plane as push rod movement.
2. Rotate crankshaft until push rod is at lowest position. Zero indicator. Rotate crankshaft slowly until push rod is in fully raised position. Ensure that total lift recorded is within specifications. If any lobe is not within specifications, replace camshaft and lifters.

Valve Arrangement

Right Side - I-E-I-E-I-E.

Left Side - E-I-E-I-E-I.

Note. "Right" and "Left" refer to right and left side of the engine NOT the vehicle.

VALVE SEATS

Note. Valve seat replacement information not available at this time. Repair valve guides if necessary, prior valve seat refacing.

Refacing

Valve seat must be a true 44.5 degree finished angle. Use only a 60 degree angle grinding stone to remove stock from bottom of all seats. Use only a 30 degree angle grinding stone to remove stock from top of all seats. Intake and exhaust seat width should be .06-.08" (1.5-2.0 mm).

Note. Lubricate valves and valve guides with heavy SF oil prior to installation. Apply Ford Polyethylene Grease (DOAZ-19584-A) to tip of valve stem prior to installation.

Scheme 24

1. Mark all components prior to removal for installation reference. Clean carbon from cylinder head, using care not to damage surfaces. Remove valves. Check valve-to-guide clearance of each valve in its respective valve guide.
2. Install a valve and hold against seat. Install Valve Stem Clearance Tool (T65T-6505-H) on valve stem, until fully seated. Tighten tool set screw firmly. Allow valve to drop away from seat and tool to contact upper guide surface.
3. Install dial indicator with pointer against center portion of tool. (Scheme 24) Move clearance tool back and forth in-line with dial indicator pointer. Keep clearance tool on upper guide surface. Record dial indicator reading.
4. Divide dial indicator reading by 2. This total is the valve-to-guide clearance. If not within specifications, replace valve(s) with next available oversize valve. Ream valve guide until clearance with valve is within specifications. See ENGINE SPECIFICATIONS tables at end of this article. (Scheme 24): Checking Valve-to-Guide Clearance NOTE: Always reface valve seat after valve guide has been serviced.
5. Check valve face for pitting, cracks and runout. Reface or replace valve as necessary. Ensure valve face angle is a true 45.8 degrees. Ensure proper seat width is achieved. See ENGINE SPECIFICATIONS tables at end of this article.

1. Inspect valve springs for cracks or damage. Measure out-of-square. Maximum out-of-square is.060" (1.52 mm). Check free length. Check spring tension at specified length. See ENGINE SPECIFICATIONS tables at end of this article. Replace springs as necessary. CAUTION: DO NOT install spacers unless necessary. Spacers used in excess of recommendations will cause premature failure.
2. Measure installed height from top of spring seat to bottom of spring retainer. (Scheme 25) Install height should be 2.02" (51.3 mm). If assembled height is greater than specifications, install necessary.030" (.76 mm) thick spacer between cylinder head spring pad and spring seat.

Measuring Valve Spring Installed Height. Scheme 25

Lifter parts are not interchangeable and are serviced as assemblies. Mark location of each lifter to ensure lifter is installed in its original location and position. After cleaning and reassembling lifters, they should be tested for leak-down rate. Leak-down rate is 20-60 seconds to travel .125" (3.18 mm) under a 50 lb. (23 kg) load. Replace lifter assembly as necessary.

HYDRAULIC LIFTER CLEARANCE

1. Valve stem-to-rocker arm clearance should meet specifications with lifter totally collapsed. Valve and/or valve seat refacing can diminish clearance and allow valve to be held open.
2. To determine rocker arm-to-valve stem clearance, attach auxiliary starter switch to staring circuit. With ignition switch in "OFF" position, crank engine until No. 1 piston is on TDC of compression stroke. Completely collapse No. 1 intake valve lifter.
3. Measure clearance between rocker arm and tip of valve stem, holding lifter in collapsed position. Repeat procedure for No. 1 exhaust, No. 2 exhaust, No. 3 intake, No. 4 exhaust and No. 6 intake.
4. Rotate crankshaft 360 degrees (one revolution). Repeat procedure for No. 2 intake, No. 3 exhaust, No. 4 intake, No. 5 exhaust, No. 5 intake and No. 6 exhaust. If not within specifications, replace or grind valve stem as necessary. See COLLAPSED LIFTER CLEARANCE table in this article.

COLLAPSED LIFTER CLEARANCE

1. Using a feeler gauge and straightedge, check cylinder block head gasket surface for flatness. Surface should be flat within .003" (.08 mm) over 6" surface. Check cylinder bore for wear, taper, out-of-round and piston fit. See «CYLINDER BORE SPECIFICATIONS»(/ford/taurus/i-1985-1991/remont/mechanical/#38l-v6-vin-4) table in this article.
2. Install all main bearing caps and tighten to specifications prior to cylinder bore honing. Use only equal parts of kerosene and SAE 20 motor oil for honing cylinder bores. Use ONLY a spring-loaded type cylinder hone. After honing, allow cylinders to cool. Thoroughly clean bore with detergent and water solution.
3. Rinse solution from bore thoroughly with clean water. Wipe bore clean with lint free cloth. Lubricate cylinder bores with engine oil. Tap cylinder head bolt threads in cylinder block.

CYLINDER BORE SPECIFICATIONS

OIL PAN REMOVAL & INSTALLATION

Disconnect negative battery cable. Raise and support vehicle. Drain crankcase. Remove oil filter. Remove converter assembly. Remove starter motor. Remove converter housing cover. Remove bolts retaining oil pan assembly. Remove oil pan assembly.

PISTON & ROD ASSEMBLY

Note. Following procedure is with cylinder head, oil pan and oil pump pick-up tube removed. Ensure components are marked for installation to original location and position.

1. Ensure pistons and rods are measured and installed in cylinder from which it was removed. Ensure notch on piston top and hole on connecting rod faces front of engine. (Scheme 26) Check piston fit before assembling piston on rod. See «FITTING PISTONS»(/ford/taurus/i-1985-1991/remont/mechanical/#38l-v6-vin-4__fitting-pistons) in this article.
2. Check piston pin fit. If not within specifications, remove pin and measure pin bore in piston and rod. Replace as necessary. If piston pin is to be replaced, replace piston and pin as an assembly. See ENGINE SPECIFICATIONS tables at end of this article.

Piston & Rod Position. Scheme 26

FITTING PISTONS

1. Check piston-to-bore clearance. See ENGINE SPECIFICATIONS tables at end of this article. Standard size pistons are color coded Red, Blue or Yellow on the piston dome. See «PISTON SIZE CODE»(/ford/taurus/i-1985-1991/remont/mechanical/#38l-v6-vin-4) table in this article.
2. If bore diameter is in lower one-third of specifications, use a Red coded piston. If bore diameter is in middle one-third of specifications, use a Blue coded piston. If bore diameter is in upper one-third of specifications, use Yellow coded piston. The Yellow coded piston is .004" (.10 mm) oversize. Use proper size piston to acquire specified clearance. See «PISTON SELECTION»(/ford/taurus/i-1985-1991/remont/mechanical/#38l-v6-vin-4) table in this article.

PISTON SIZE CODES

PISTON SELECTION

FITTING RINGS

1. Select proper rings for bore diameter. Place ring square in cylinder bore, below normal ring wear area. Measure the ring end gap. If ring end gap is less than specifications, remove necessary amount from end of ring. If ring gap is greater than specifications, use a different set of rings. Ensure rings are installed in cylinder bore in which they were measured.
2. Check side clearance of rings after installing on piston. Ensure clearance is within specifications around entire circumference. If lower lands of piston have high steps, replace piston. Replace piston and rings if side clearance is not within specifications. Properly set ring ends on piston before installing pistons into cylinder. (Scheme 27) See ENGINE SPECIFICATIONS tables at end of this article.

Piston Ring End Gap Spacing. Scheme 27

MAIN BEARING INSPECTION

Note. Following procedures are with oil pan and oil pump pick-up tube removed. Only one bearing at a time should be checked or replaced.

Use Plastigage method and check clearance between main bearing and crankshaft journal. Check crankshaft for nicks, scratches, scores and wear. If not within specifications, replace bearings. Machine or replace crankshaft as necessary. See ENGINE SPECIFICATIONS tables at end of this article. Check crankshaft end play. Refer to THRUST BEARING ALIGNMENT in this article. Replace thrust bearing as necessary.

CONNECTING ROD BEARINGS INSPECTION

Use Plastigage method and check clearance between rod bearing and crankshaft. If specified clearance cannot be obtained with standard bearings, try a standard bearing in combination with an undersize bearing. Standard bearings may be used with a .001" (.025 mm) or .002" (.050 mm) undersize bearing. Tighten all bolts/nuts to specifications. Desired clearance is the minimum of the specified clearance. See ENGINE SPECIFICATIONS tables at end of this article.

THRUST BEARING ALIGNMENT INSPECTION

Install dial indicator on front of engine with pointer on end of crankshaft. Pry crankshaft fully rear and zero indicator. Pry crankshaft fully forward and note reading. If end play exceeds specifications, replace thrust bearing. If end play is less than specifications, remove thrust bearing and inspect surfaces. Replace as necessary. See ENGINE SPECIFICATIONS tables at end of this article.

1. Remove transaxle. On manual transaxle models, remove clutch disc, pressure plate and flywheel. See appropriate CLUTCHES article in this section. On automatic transaxle models, remove flexplate. See appropriate TRANSMISSION SERVICING article in this section.
2. Use an awl and punch a hole into the metal surface of the seal. Use care not to damage sealing surfaces. Install Jet Plug Remover (T77L-9533-B) and remove oil seal.

Check crankshaft seal surface for wear and replace as necessary. Coat crankshaft seal area and lip of oil seal with engine oil. Using Rear Crankshaft Seal Replacer (T81P-6701-A), install oil seal. Tighten bolts on seal replacer evenly, to ensure seal is installed squarely. To complete installation, reverse removal procedure.

FRONT CRANKSHAFT OIL SEAL

See CAMSHAFT FRONT COVER & TIMING CHAIN in this article.

ENGINE OILING SYSTEM

The lubrication is a force-feed type. The oil is supplied under full pressure to crankshaft, connecting rods, camshaft bearing and valve lifters. A controlled volume of oil is supplied to rocker arms and push rods. All other moving parts are lubricated by splash or gravity flow.

Crankcase Capacity

Crankcase capacity is 4 qts. (3.8L) without filter and 4.5 qts. (4.3L) with filter change. DO NOT change oil without filter.

Normal Oil Pressure (Hot)

Normal oil pressure is 40-60 psi (2.8-4.2 kg/cm 2 ) at 2500 RPM.

Removal & Installation

Remove oil filter. Remove oil pump-to-front cover bolts. Remove oil pump assembly. Replace "O" ring and lubricate with engine oil. Position oil pump to front cover. Install oil pump mounting bolts and tighten to specifications.

With oil pump removed, place a straightedge across surface of housing. Use a feeler gauge and check clearance to the gears. Measure thickness of gear with micrometer. Measure depth of gear pocket in the housing. Measure diameter of gear with micrometer. Measure gear pocket diameter. Measure clearance between gear and pocket wall. If not within specifications, replace components as necessary. See OIL PUMP SPECIFICATIONS table in this article.

OIL PUMP SPECIFICATIONS

ENGINE COOLING

Removal & Installation (Cougar & Thunderbird)

1. Drain cooling system. Disconnect negative battery cable. Remove air cleaner and heater tube assembly. Remove fan clutch assembly and shroud. Loosen accessory drive belt idler. Remove accessory belts and water pump pulley. Remove power steering pump and bracket assembly with hoses attached (if equipped).
2. Remove A/C compressor front support bracket (if equipped). Leave A/C compressor in place. Disconnect coolant by-pass and heater hose from water pump. Remove water pump attaching bolts. Remove water pump assembly.
3. Clean gasket mating surfaces and replace gasket. To complete installation, reverse removal procedure. Tighten all bolts/nuts to specifications. Fill cooling system with specified coolant only. Check for leakage.

Removal & Installation (Continental, Sable & Taurus)

1. Drain cooling system. Disconnect negative battery cable. Remove lower nut on both right-hand engine mounts. Carefully raise engine. Loosen accessory belt idler. Remove accessory belts and water pump pulley. Remove air suspension pump (if equipped).
2. Remove power steering pump and bracket assembly with hoses attached (if equipped). Remove A/C compressor front support bracket and leave compressor in place. Disconnect coolant by-pass and heater hose from water pump. Remove water pump attaching bolts. Remove water pump and gasket.
3. Clean gasket mating surfaces and replace gasket. To complete installation, reverse removal procedure. Tighten all bolts/nuts to specifications. Fill cooling system with specified coolant only. Check for leakage.

Note. For further information on cooling system capacities and other cooling system components, see ENGINE COOLING SYSTEMS article in this section.

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

GENERAL ENGINE SPECIFICATIONS

GENERAL SPECIFICATIONS

VALVE SPECIFICATIONS

VALVE SPECIFICATIONS

PISTON/PIN/RING SPECIFICATIONS

PISTONS, PINS & RINGS SPECIFICATIONS

BEARING SPECIFICATIONS

CRANKSHAFT MAIN & CONNECTING ROD BEARINGS SPECIFICATIONS

VALVE SPRING SPECIFICATIONS

VALVE SPRINGS SPECIFICATIONS

CAMSHAFT SPECIFICATIONS

CAMSHAFT SPECIFICATIONS

See also:
• ENGINE OVERHAUL PROCEDURES - GENERAL INFORMATION
• INTAKE MANIFOLDS
• EXHAUST MANIFOLDS
• TORQUE SPECIFICATIONS
• OIL PAN REMOVAL & INSTALLATION
• CAMSHAFT FRONT COVER & TIMING CHAIN
• CAMSHAFT LOBE LIFT
• ENGINE REMOVAL & INSTALLATION
• BALANCE SHAFT REMOVAL & INSTALLATION
• CYLINDER BORE SPECIFICATIONS
• FITTING PISTONS
• THRUST BEARING ALIGNMENT