Engine - 3.0L (4V): Removal & Installation Ford Taurus IV рестайлинг

Installation

1. Install the lower intake manifold and tighten the bolts in the sequence shown.
2. Connect the fuel injector electrical connectors.
3. Connect the fuel injection pressure and temperature sensor vacuum tube and the electrical connector.
4. Connect the fuel hose quick release coupling from the fuel supply manifold. For additional information, refer to «FUEL SYSTEM-GENERAL INFORMATION»(ref-233735) .
5. Install the upper intake manifold. For additional information, refer to «UPPER INTAKE MANIFOLD»(ref-233692-S35322932072006052600000) .

Removal

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1. Remove the engine front cover. For additional information, refer to «ENGINE FRONT COVER»(ref-233692-S02445666162006052600000) .
2. Remove the ignition pulse wheel.
3. Install the damper bolt.
4. Remove the LH and RH spark plugs.
5. Rotate the crankshaft clockwise to position the crankshaft keyway in the 11 o'clock position and position the camshafts in the correct position. This will position the number one cylinder at top dead center (TDC). Verify that the camshafts are correctly located. If not, rotate the crankshaft one additional turn and recheck.
6. Rotate the crankshaft clockwise 120 degrees to the 3 o'clock position to locate the RH camshafts in the neutral position.
7. Verify that the RH camshafts are in the neutral position.
8. Remove the RH timing chain tensioner arm. Remove the bolts. Remove the tensioner. Remove the tensioner arm.
9. Remove the bolts, RH timing chain guide and the timing chain.
10. Rotate the crankshaft clockwise 600 degrees (1-2/3 turns) to position the crankshaft keyway in the 11 o'clock position. This will position the LH camshafts in the neutral position.
11. Verify that the LH camshafts are in the neutral position.
12. Remove the LH timing chain and tensioner arm. Remove the bolts. Remove the tensioner. Remove the tensioner arm.
13. Remove the LH timing chain and timing chain guide.
14. Remove the damper bolt and the crankshaft sprockets.

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1. Install the crankshaft sprockets.
2. Position the chain tensioner in a soft-jawed vise.
3. Hold the chain tensioner ratchet lock mechanism away from the ratchet stem with a small pick.
4. Slowly compress the timing chain tensioner.
5. Retain the tensioner piston with a 1.5 mm (0.06 in) wire or paper clip.
6. If timing marks in the timing chains are not evident, use a permanent-type marker to mark the crankshaft and camshaft timing marks on the LH and RH timing chains. Mark any link to use as the crankshaft timing mark. Starting with the crankshaft timing mark, count 29 links and mark the link. Continue counting to 42 and mark the link.
7. Position the LH timing chain and guide and install the bolts. Align the marks on the timing chain with the marks on the camshaft and crankshaft sprockets.
8. Install the LH timing chain tensioner and tensioner arm. Install the tensioner arm. Position the tensioner. Install the bolts.
9. Install the crankshaft damper bolt and rotate the crankshaft clockwise 120 degrees until the crankshaft key way is in the 3 o'clock position.
10. Verify that the RH camshafts are correctly positioned.
11. Position the RH timing chain and chain guide and install the bolts. Align the marks on the timing chain with the marks on the camshaft and crankshaft sprockets.
12. Install the RH timing chain tensioner and tensioner arm. Install the tensioner arm. Position the tensioner. Install the bolts.
13. Remove the LH and RH timing chain tensioner piston retaining wires.
14. Rotate the crankshaft counterclockwise 120 degrees to top dead center (TDC)
15. Verify the timing with the following steps. There should be 12 chain links between the front camshaft timing marks. There should be 27 chain links between the camshaft and crankshaft timing marks. There should be 30 chain links between the camshaft and crankshaft timing marks.
16. Remove the crankshaft damper bolt.
17. Install the LH and RH spark plugs.
18. Install the ignition pulse wheel.
19. Install the engine front cover. For additional information, refer to «ENGINE FRONT COVER»(ref-233692-S02445666162006052600000) .

Removal and Installation

1. Remove the camshaft followers. For additional information, refer to «CAMSHAFT ROLLER FOLLOWER»(ref-233692-S36404606752006052600000) .
2. Remove the hydraulic lash adjusters.
3. To install, reverse the removal procedure. Lubricate the hydraulic lash adjusters with clean engine oil.

1. Remove the crankshaft pulley. For additional information, refer to «CRANKSHAFT PULLEY»(ref-233692-S34279120392006052600000) .
2. Remove the crankshaft damper bolt and washer.
3. Using the special tool, remove the crankshaft damper.

1. Apply silicone gasket and sealant to the end of the keyway slot.
2. Using the special tool, install the crankshaft damper.
3. Install the bolt and the 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.
4. Install the crankshaft pulley. For additional information, refer to «CRANKSHAFT PULLEY»(ref-233692-S34279120392006052600000) .

1. Remove the valve spring. For additional information, refer to «VALVE SPRING»(ref-233692-S36587493862006052600000) .
2. Remove the valve seal.

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1. Using the special tool, install the valve seal.
2. Install the valve spring. For additional information, refer to «VALVE SPRING»(ref-233692-S36587493862006052600000) .

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1. Remove the coolant tube bracket bolt.
2. Disconnect and unclip the LH heated oxygen sensor (HO2S) electrical connector from the coolant tube.
3. Remove the dual converter Y-pipe. For additional information, refer to «EXHAUST SYSTEM»(ref-233702) .
4. Remove the pin-type retainers, bolts and the front splash shield.
5. Remove the coolant tube lower bracket bolt.
6. Remove the nuts in the sequence shown and remove the exhaust manifold. Remove the studs. Discard the gasket, studs and nuts.
7. To install, reverse the removal procedure. Install the new exhaust manifold studs. Tighten to 12 Nm (9 lb-ft). Install the new exhaust manifold gasket, the exhaust manifold and the new nuts. Tighten the nuts in the sequence shown.

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1. Remove the wiper mounting arm and pivot shaft. For additional information, refer to «WIPERS AND WASHERS»(ref-233725) .
2. Remove the air cleaner outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(ref-233699) .
3. Remove the three retaining screws and the RH cowl top inner panel.
4. Remove the two retaining nuts and position the vacuum outlet manifold assembly aside.
5. Unseat the windshield wiper motor wiring harness grommet. Pull the wiring harness through the grommet.
6. Disconnect the cowl drain tube, remove the three retaining screws and the LH cowl top inner panel.
7. Remove the upper intake manifold. For additional information, refer to «UPPER INTAKE MANIFOLD»(ref-233692-S35322932072006052600000) .
8. Disconnect the differential pressure feedback exhaust gas recirculation (EGR) sensor and the RH heated oxygen sensor (HO2S) electrical connectors.
9. 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 the differential pressure feedback EGR and bracket from the vacuum tubes.
10. Remove the rear support brace. Remove the bolt. Remove the nut. Remove the rear support brace.
11. Remove the steering gear heat shield.
12. Remove the EGR tube. For additional information, refer to «ENGINE EMISSION CONTROL»(ref-233733) .
13. Remove the dual converter Y-pipe. For additional information, refer to «EXHAUST SYSTEM»(ref-233702) .
14. Remove the nuts in the sequence shown and remove the exhaust manifold. Remove the studs. Discard the gasket, studs and nuts.

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1. Install the new exhaust manifold studs. Tighten to 12 Nm (9 lb-ft).
2. Install the new exhaust manifold gasket, the exhaust manifold and the new nuts. Tighten the nuts in the sequence shown.
3. Install the dual converter Y-pipe. For additional information, refer to «EXHAUST SYSTEM»(ref-233702) .
4. Install the EGR tube. For additional information, refer to «ENGINE EMISSION CONTROL»(ref-233733) .
5. Install the steering gear heat shield.
6. Install the rear support brace. Position the rear support brace. Install the nut. Install the bolt.
7. Install the differential pressure feedback EGR valve sensor and bracket. Connect the differential pressure feedback EGR valve tube and bracket to the vacuum tubes. Position the differential pressure feedback EGR sensor and bracket and install the bolts. Attach the HO2S electrical connector pin-type retainer.
8. Connect the differential pressure feedback EGR sensor and the RH HO2S electrical connectors.
9. Install the upper intake manifold. For additional information, refer to «UPPER INTAKE MANIFOLD»(ref-233692-S35322932072006052600000) .
10. Install the LH cowl top inner panel and install the three retaining screws. Connect the cowl drain tube.
11. Install the windshield wiper motor wiring harness grommet.
12. Position the vacuum outlet manifold assembly and install the two retaining nuts.
13. Install the RH cowl inner panel and the three retaining screws.
14. Install the air cleaner outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(ref-233699) .
15. Install the wiper mounting arm and pivot shaft. For additional information, refer to «WIPERS AND WASHERS»(ref-233725) .

1. Raise and support the vehicle. For additional information, refer to «JACKING & LIFTING»(ref-233684) .
2. Position a drain pan and remove the oil filter.
3. Remove the oil pressure sender. Disconnect the electrical connector. Remove the sender.
4. To install, reverse the removal procedure.

1. Position the oil pan baffle and install the nuts. Tighten the nuts in two stages. Stage 1: Tighten to 10 Nm (89 lb-in). Stage 2: Tighten 45 degrees.
2. Install the oil pump screen cover and tube. For additional information, refer to «OIL PUMP SCREEN AND PICKUP TUBE»(ref-233692-S09936937992006052600000) .

1. Using the special tools, install the crankshaft rear oil seal.
2. Install the flexplate. For additional information, refer to «FLEXPLATE»(ref-233692-S13747979262006052600000) .