Material — Part 1 Ford Taurus IV рестайлинг

Material

MATERIAL SPECIFICATION

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1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-233684) .
2. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-233724) .
3. Remove the LH valve cover. For additional information, refer to «VALVE COVER LH»(ref-233692-S01653174612006052600000) .
4. Remove the RH valve cover. For additional information, refer to «VALVE COVER RH»(ref-233692-S32098761522006052600000) .
5. Remove the power steering pump. For additional information, refer to «POWER STEERING»(ref-233694) .
6. Remove the retaining nut and position the power steering pressure line and muffler out of the way.
7. Remove the upper retaining bolts from the generator.
8. Remove the bolts, nuts and the engine-to-transaxle bracket.
9. Remove the torque converter inspection cover.
10. Remove the front pin-type retainers and position the front rocker panel moulding aside.
11. Remove the rear portion of the front fender splash shield. Remove the screws and the pin-type retainers.
12. Remove the two screws and the generator splash shield.
13. Install the special tool.
14. Remove the crankshaft damper pulley.
15. Remove the crankshaft damper bolt and washer.
16. Using the special tool, remove the crankshaft damper.
17. Disconnect the crankshaft position (CKP) sensor electrical connector. Remove the bolt and the CKP sensor.
18. Remove the generator bolt and position the generator to gain access to the electrical connector and terminal nut.
19. Disconnect the generator electrical connectors. Remove the nut and the B+ wire terminal. Disconnect the generator electrical connector.
20. Remove the bolts and the A/C compressor to front cover bracket.
21. Disconnect the camshaft position (CMP) sensor electrical connector. Remove the bolt and remove the CMP sensor.
22. Remove the tie strap from the power steering hose.
23. Remove the retaining nut and position the A/C low-pressure hose out of the way.
24. Remove the bolts and position the A/C high-pressure hose on top of the belt tensioner.
25. Remove the bolt and remove the belt tensioner.
26. Disconnect the engine cooling fan electrical connector and unclip the wiring harness.
27. Remove the bolt and the engine cooling fan.
28. Install the special tools to support the engine.
29. Remove the two upper A/C compressor bolts.
30. Remove the two lower A/C compressor bolts and position the A/C compressor aside.
31. Remove the bolts from the A/C bracket.
32. Raise the engine away from the A/C bracket using the engine support tool.
33. Remove the two oil pan-to-front cover bolts.
34. Remove the bolts, studs and the engine front cover.

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Scheme 555

1. Clean all sealing surfaces with metal surface cleaner.
2. Install three new gaskets in the front cover.
3. Apply a 6 mm (0.24 in) diameter dot of silicone gasket and sealer to the cylinder block, lower cylinder block, cylinder head and oil pan mating surfaces.
4. Position the cover and install the bolts in the sequence shown.
5. Install the two oil pan-to-front cover bolts.
6. Remove the oil pan plug and drain the engine oil. Install the plug and tighten to 26 Nm (19 lb-ft).
7. Using the engine support tool, lower the engine back together with the A/C bracket.
8. Install the bolts. Tighten the bolts in two stages. Stage 1: Tighten to 25 Nm (18 lb-ft). Stage 2: Tighten an additional 90 degrees.
9. Position the A/C compressor and install the two lower bolts.
10. Install the two upper A/C compressor bolts.
11. Position the engine cooling fan and install the bolt.
12. Connect the engine cooling fan electrical connector and clip the wiring harness.
13. Position the belt tensioner and install the bolt.
14. Position the A/C high-pressure hose and install the bolts.
15. Position the A/C low-pressure hose and install the retaining nut.
16. Install the tie strap to the power steering hose.
17. Install the CMP sensor and install the bolt. Connect the CMP sensor electrical connector.
18. Position the A/C compressor to front cover bracket and install the bolts.
19. Connect the generator. Install the B+ wire terminal and nut. Connect the generator electrical connector.
20. Install the generator and the lower bolt.
21. Install the CKP sensor. Connect the CKP sensor electrical connector.
22. Install the generator upper bolts.
23. Reposition the power steering line and muffler and install the retaining nut.
24. Tighten the generator lower bolt.
25. Install the special tool.
26. Apply silicone gasket and sealant to the end of the keyway slot.
27. Using the special tool, install the crankshaft damper.
28. Install the bolt and washer and tighten in four stages. Stage 1: Tighten to 120 Nm (89 lb-ft). Stage 2: Loosen 360 degrees. Stage 3: Tighten to 50 Nm (37 lb-ft). Stage 4: Tighten 90 degrees.
29. Install the crankshaft pulley.
30. Install the generator splash shield and the two screws.
31. Install the rear portion of the front fender splash shield. Install the screws and the pin-type retainers.
32. Position the front rocker panel moulding and install the pin-type retainers.
33. Install the torque converter inspection cover.
34. Position the engine-to-transaxle bracket and install the nuts and bolts.
35. Install the RH valve cover. For additional information, refer to «VALVE COVER RH»(ref-233692-S32098761522006052600000) .
36. Install the LH valve cover. For additional information, refer to «VALVE COVER LH»(ref-233692-S01653174612006052600000) .
37. Fill the engine with clean engine oil.
38. Connect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-233724) .
39. Install the power steering pump. For additional information, refer to «POWER STEERING»(ref-233694) .

MATERIAL SPECIFICATION

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Scheme 559

1. Disconnect the crankcase ventilation tube from the air cleaner outlet pipe.
2. Remove the nuts and the coolant pump drive belt cover.
3. Disconnect coil-on-plug electrical connectors. Detach the retainer and position the wiring harness aside.
4. Remove the bolts and the ignition coils.
5. Disconnect the wiring harness from the valve cover studs. Position the wiring harness aside.
6. Remove the stud bolts and the valve cover. Remove and discard the gasket.

Scheme 560

1. Tighten the valve cover studs in the sequence shown.
2. Connect the wiring harness to the valve cover studs.
3. Install the bolts and the ignition coils.
4. Position the wiring harness and retainer, and connect the coil-on-plug electrical connectors.
5. Install the coolant pump drive belt cover and the nuts.

MATERIAL SPECIFICATION

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1. Remove the upper intake manifold. For additional information, refer to «UPPER INTAKE MANIFOLD»(ref-233692-S35322932072006052600000) .
2. Disconnect the differential pressure feedback exhaust gas recirculation (EGR) sensor and the RH heated oxygen sensor (HO2S) electrical connectors.
3. Disconnect the coil-on-plug electrical connectors. Detach the wiring harness retainers and position the wiring harness aside.
4. Detach the wiring harness retainer from the stud.
5. Detach the pin-type retainer.
6. Remove the nuts from the valve cover studs. Position the radio interference capacitor and wiring harness conduit aside.
7. Remove the differential pressure feedback EGR sensor tube and bracket. Detach the electrical connector pin-type retainer. Remove the bolts from the differential pressure feedback EGR bracket. Disconnect and remove differential pressure feedback EGR and bracket from the vacuum tubes.
8. Remove the bolts and the ignition coils.
9. Remove the studs and the valve cover. Remove and discard the gaskets.

Scheme 569

Scheme 570

1. Tighten the valve cover studs in the sequence shown.
2. Install the bolts and the ignition coils.
3. Install the differential pressure feedback EGR valve sensor and bracket. Connect the differential pressure feedback EGR valve tube and bracket to the vacuum tubes. Install the differential pressure feedback EGR sensor and bracket and install the bolts. Attach the HO2S electrical connector pin-type retainer.
4. Connect the differential pressure feedback EGR sensor and the RH heated HO2S electrical connectors.
5. Position the radio interference capacitor and wiring harness conduit and install the nuts.
6. Attach the pin-type retainer.
7. Attach the wiring harness retainer to the stud.
8. Attach the wiring harness retainers and connect the coil-on-plug electrical connectors.
9. Install the upper intake manifold. For additional information, refer to «UPPER INTAKE MANIFOLD»(ref-233692-S35322932072006052600000) .

MATERIAL SPECIFICATION

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Scheme 573

1. Remove the timing drive components. For additional information, refer to «TIMING DRIVE COMPONENTS»(ref-233692-S22647073652006052600000) .
2. Remove the coolant pump belt. For additional information, refer to «ACCESSORY DRIVE»(ref-233714) .
3. Using the special tools, remove the coolant pump drive pulley and discard.
4. Using the special tools, remove the camshaft oil seal and discard.
5. Remove the intake camshaft oil seal retainer and discard the press-in-place gasket.
6. Loosen the bolts for the LH camshaft thrust caps.
7. Loosen the LH camshaft cap bolts in sequence to allow the camshafts to rise from the cylinder head and remove the caps.
8. Remove the camshafts.

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Scheme 575

1. Lubricate camshafts with engine oil and carefully position the camshafts into the cylinder head. Align the camshafts as shown.
2. Lubricate the bearing surfaces of the camshaft bearing caps with engine oil. Install the bearing caps and loosely install the bolts.
3. Lubricate the bearing surfaces of the camshaft bearing thrust caps with engine oil. Install the bearing thrust caps and loosely install the bolts.
4. Verify that the camshaft bearing caps are in the correct locations.
5. Tighten the bolts in the sequence shown.
6. Install a new press-in-place gasket and install the camshaft oil seal retainer.
7. Install the new camshaft oil seal. Using the special tools positioned over the oil seal, turn to install the seal.
8. Using the special tool, install the coolant pump drive pulley.
9. Install the coolant pump belt. For additional information, refer to «ACCESSORY DRIVE»(ref-233714) .
10. Install the timing drive components. For additional information, refer to «TIMING DRIVE COMPONENTS»(ref-233692-S22647073652006052600000) .

MATERIAL SPECIFICATION

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Scheme 577

1. Remove the timing drive components. For additional information, refer to «TIMING DRIVE COMPONENTS»(ref-233692-S22647073652006052600000) .
2. Loosen the RH camshaft thrust cap bolts.
3. Loosen the RH camshaft cap bolts in sequence to allow the camshafts to rise from the cylinder head and remove the caps.
4. Remove the camshafts.

Scheme 578

Scheme 579

1. Lubricate camshafts with engine oil and carefully position the camshafts into the cylinder head. Align the camshafts as shown.
2. Lubricate the bearing surfaces of the camshaft bearing caps with engine oil. Install the bearing caps and loosely install the bolts.
3. Lubricate the bearing surfaces of the camshaft bearing thrust caps with engine oil. Install the bearing thrust caps and loosely install the bolts.
4. Verify that the camshaft bearing caps are in the correct locations.
5. Tighten the bolts in the sequence shown.
6. Install the timing drive components. For additional information, refer to «TIMING DRIVE COMPONENTS»(ref-233692-S22647073652006052600000) .

MATERIAL SPECIFICATION

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1. Remove the LH and RH valve covers. For additional information, refer to «VALVE COVER LH»(ref-233692-S01653174612006052600000) and «VALVE COVER RH»(ref-233692-S32098761522006052600000) .
2. Remove the LH and RH spark plugs.
3. Remover the RH front wheel. For additional information, refer to «JACKING & LIFTING»(ref-233684) .
4. Remove the screws, the pin-type retainers, and the RH front inner fender splash shield.
5. Rotate the crankshaft until the camshaft lobe is pointing directly away from the follower.
6. Using the special tool, remove the follower.
7. To install, reverse the removal procedure. Lubricate the camshaft followers with clean engine oil.

MATERIAL SPECIFICATION

MATERIAL SPECIFICATION

MATERIAL SPECIFICATION

Scheme 582

1. Remove the crankshaft vibration damper. For additional information, refer to «CRANKSHAFT VIBRATION DAMPER»(ref-233692-S18033234982006052600000) .
2. Using the special tool, remove the crankshaft front oil seal and discard.

Scheme 583

1. Apply clean engine oil to the seal before installing the seal.
2. Using the special tool, install the crankshaft front oil seal.
3. Install the crankshaft vibration damper. For additional information, refer to «CRANKSHAFT VIBRATION DAMPER»(ref-233692-S18033234982006052600000) .

MATERIAL SPECIFICATION

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1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-233684) .
2. Release the fuel system pressure. For additional information, refer to «FUEL SYSTEM-GENERAL INFORMATION»(ref-233735) .
3. Remove the coolant pump bypass tube. For additional information, refer to «ENGINE COOLING»(ref-233700) .
4. Remove the LH exhaust manifold-to-pipe nuts.
5. Remove the coolant pump. For additional information, refer to «ENGINE COOLING»(ref-233700) .
6. Remove the lower intake manifold. For additional information, refer to «LOWER INTAKE MANIFOLD»(ref-233692-S34132369242006052600000) .
7. Remove the LH camshafts. For additional information, refer to «CAMSHAFTS LH»(ref-233692-S21749774132006052600000) .
8. Using the special tools, lower the engine until it is aligned with the A/C compressor bracket, and finger-tighten the four bolts.
9. Remove the three-bar engine support.
10. Remove the camshaft followers.
11. Remove the hydraulic lash adjusters.
12. Disconnect the LH heated oxygen sensor (HO2S) electronic connector.
13. Remove the nuts in the sequence shown and remove the LH exhaust manifold. Remove the studs. Discard the gasket, studs and nuts.
14. Remove the oil level indicator.
15. Remove the nut and the oil level indicator tube. Inspect and, if necessary, install a new O-ring seal.
16. Remove the LH cylinder block drain plug.
17. Remove the bolts in the sequence shown and remove the cylinder head. Discard the gasket and the bolts.
18. Support the cylinder head on a bench with the head gasket side up. 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) deep.

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Scheme 590

1. Position the LH cylinder head, gasket and install the bolts in the sequence shown in six stages. Tighten the bolts in six stages. Stage 1: Tighten to 40 Nm (30 lb-ft). Stage 2: Tighten bolts 90 degrees. Stage 3: Loosen one full turn. Stage 4: Tighten to 40 Nm (30 lb-ft). Stage 5: Tighten 90 degrees. Stage 6: Tighten 90 degrees.
2. Install the LH cylinder block drain plug.
3. Install the oil level indicator tube and the nut.
4. Install the new LH exhaust manifold studs. Tighten to 12 Nm (9 lb-ft).
5. Install the new LH exhaust manifold gasket, the exhaust manifold and the new nuts. Tighten the nuts in the sequence shown.
6. Connect the LH HO2S electrical connector.
7. Install the hydraulic lash adjusters. Lubricate the hydraulic lash adjusters with clean engine oil.
8. Install the camshaft followers. Lubricate the camshaft followers with clean engine oil.
9. Install the three-bar engine support.
10. Remove the four A/C compressor bracket bolts.
11. Using the special tools, raise the engine away from the A/C compressor bracket.
12. Install the LH camshafts. For additional information, refer to «CAMSHAFTS LH»(ref-233692-S21749774132006052600000) .
13. Install the lower intake manifold. For additional information, refer to «LOWER INTAKE MANIFOLD»(ref-233692-S34132369242006052600000) .
14. Install the coolant pump. For additional information, refer to «ENGINE COOLING»(ref-233700) .
15. Install the LH exhaust manifold-to-pipe nuts.
16. Install the coolant pump bypass tube. For additional information, refer to «ENGINE COOLING»(ref-233700) .

MATERIAL SPECIFICATION

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1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-233684) .
2. Release the fuel system pressure. For additional information, refer to «FUEL SYSTEM-GENERAL INFORMATION»(ref-233735) .
3. Remove the coolant pump bypass tube. For additional information, refer to «ENGINE COOLING»(ref-233700) .
4. Remove the rear support brace. Remove the bolt. Remove the nut. Remove the rear support brace.
5. Remove the lower intake manifold. For additional information, refer to «LOWER INTAKE MANIFOLD»(ref-233692-S34132369242006052600000) .
6. Remove the RH camshafts. For additional information, refer to «CAMSHAFTS RH»(ref-233692-S23586958042006052600000) .
7. Using the special tools, lower the engine until it is aligned with the A/C compressor bracket, and finger-tighten the four bolts.
8. Remove the three-bar engine support.
9. Remove the RH exhaust manifold-to-pipe bolts.
10. Disconnect the exhaust gas recirculation (EGR) tube from the exhaust manifold.
11. Remove the bolt and the ground wire.
12. Remove the camshaft followers.
13. Remove the hydraulic lash adjusters.
14. Disconnect the RH heated oxygen sensor (HO2S) electrical connector.
15. Remove the nuts in the sequence shown and remove the RH exhaust manifold. Remove the studs. Discard the gasket, studs and nuts.
16. Remove the RH cylinder block drain plug.
17. Remove the bolts in the sequence shown and remove the cylinder head. Discard the gasket and the bolts.
18. Support the cylinder head on a bench with the head gasket side up. 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) deep.

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Scheme 602

1. Position the RH cylinder head, gasket and install the bolts in the sequence shown in six stages. Tighten the bolts in six stages. Stage 1: Tighten to 40 Nm (30 lb-ft). Stage 2: Tighten bolts 90 degrees. Stage 3: Loosen one full turn. Stage 4: Tighten to 40 Nm (30 lb-ft). Stage 5: Tighten 90 degrees. Stage 6: Tighten 90 degrees.
2. Install the RH cylinder block drain plug.
3. Install the new RH exhaust manifold studs. Tighten to 12 Nm (9 lb-ft).
4. Install the new RH exhaust manifold gasket, the exhaust manifold and the new nuts. Tighten the nuts in the sequence shown.
5. Connect the RH HO2S electrical connector.
6. Install the hydraulic lash adjusters. Lubricate the hydraulic lash adjusters with clean engine oil.
7. Install the camshaft followers. Lubricate the camshaft followers with clean engine oil.
8. Install the ground wire and bolt.
9. Connect the EGR tube to the exhaust manifold.
10. Install the RH exhaust manifold-to-pipe bolts.
11. Install the three-bar engine support.
12. Remove the four A/C compressor bracket bolts.
13. Using the special tools, raise the engine away from the A/C compressor bracket.
14. Install the RH camshafts. For additional information, refer to «CAMSHAFTS RH»(ref-233692-S23586958042006052600000) .
15. Install the lower intake manifold. For additional information, refer to «LOWER INTAKE MANIFOLD»(ref-233692-S34132369242006052600000) .
16. Install the rear support brace. Install the rear support brace. Install the bolt. Install the nut.
17. Install the coolant pump bypass tube. For additional information, refer to «ENGINE COOLING»(ref-233700) .

MATERIAL SPECIFICATION

Scheme 603

Scheme 604

1. Remove the oil level indicator.
2. Remove the oil level indicator tube. Remove the stud. Remove the oil level indicator tube.
3. Inspect the O-ring seal at the end of the oil level indicator tube and install a new O-ring seal if necessary.
4. To install, reverse the removal procedure. Lubricate the O-ring seal with clean engine oil.

MATERIAL SPECIFICATION

Scheme 605

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-233684) .
2. Remove the RH front inner wheel splash shield. Remove the screws and the pin-type retainer.
3. Remove the dual converter Y-pipe. For additional information, refer to «EXHAUST SYSTEM»(ref-233702) .
4. Secure the exhaust system and remove the jackstand.
5. Drain the engine oil.
6. Install and tighten the drain plug to 27 Nm (20 lb-ft).
7. Remove and discard the oil filter.
8. Remove the bolts, nuts and the engine-to-transaxle bracket.
9. Remove the torque converter inspection cover.
10. Remove the 18 bolts and the oil pan.

Scheme 606