3.0l v6 - VIN [u] Mercury Sable II

ENGINE IDENTIFICATION

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

Engine may be identified by eighth character of Vehicle Identification Number (VIN), located on top of instrument panel, near lower left corner of windshield. VIN number is also stamped on Vehicle Certification (VC) label, mounted on left door pillar.

An engine identification label is located on engine. This label contains information for engine identification. An emission calibration number label is located on left door or pillar. Information from labels is required when ordering replacement parts.

ENGINE IDENTIFICATION CODES

VALVE CLEARANCE ADJUSTMENT

Note. Hydraulic valve lifters are used and no valve adjustment is required. When valve and/or valve seat is machined, valve clearance is reduced and may cause improper valve operation. Valve lifter must be collapsed and clearance checked.

1. Position piston No. 1 at TDC of compression stroke. Slowly apply pressure until valve lifter is completely collapsed on intake valve No. 1.
2. Measure clearance between rocker arm and tip of valve stem, holding lifter in collapsed position. If clearance is not within specification, replace valve, grind valve stem or replace other components as necessary. See COLLAPSED VALVE LIFTER SPECIFICATIONS table. COLLAPSED VALVE LIFTER SPECIFICATIONS Application In. (mm) All Valves .085-.185 (2.16-4.70)
3. Repeat procedure for exhaust valve No. 1, exhaust valve No. 2, intake valve No. 3, exhaust valve No. 4, and intake valve No. 6. Rotate crankshaft 360 degrees (one revolution). Repeat procedure for intake valve No. 2, exhaust valve No. 3, intake valve No. 4, exhaust valve No. 5, intake valve No. 5, and exhaust valve No. 6.

REMOVAL & INSTALLATION

Note. For reassembly reference, label all electrical connectors, vacuum hoses and fuel lines before removal. Place mating marks on engine hood and other major assemblies before removal.

FUEL PRESSURE RELEASE & FUEL LINE CONNECTIONS

Scheme 1

1. Remove fuel tank cap to release fuel tank pressure. Using EFI Pressure Gauge (T80L-9974-B), release fuel pressure from pressure relief valve on fuel rail. (Scheme 2)
2. Before disconnecting fuel lines, disconnect negative battery cable. To disconnect fuel lines, remove retaining clip from outside of fuel line coupling.
3. Use Spring Lock Coupling Remover (D87L-9280-A) for 3/8" line, or (D87L-9280-B) for 1/2" line. Install spring lock coupling remover on fuel line coupling so it enters cage opening. (Scheme 1)
4. Push spring lock coupling remover into cage opening to release female fitting from garter spring. Pull couplings apart. Remove spring lock coupling remover.
5. To install fuel lines, install new "O" rings on fuel lines. Use only specified fuel resistant "O" rings (Brown in color). Before installing, lightly coat "O" rings with clean engine oil. Clean fittings and replace garter spring (if necessary).
6. Install female fitting to male fitting and push until garter spring snaps over flared end of female fitting. Ensure lines are locked together and garter spring is over female fitting flared end.
7. Install retaining clip. Ensure horseshoe portion of clip is over coupling. DO NOT install retaining clip over rubber fuel line.

Note. Black retaining clip should be installed on fuel supply line and Gray clip on fuel return line.

ENGINE

Note. On Sable and Taurus vehicles, remove engine with transaxle remaining in vehicle.

Removal (Sable & Taurus)

1. Release fuel pressure and disconnect fuel lines. Refer to «FUEL PRESSURE RELEASE & FUEL LINE CONNECTIONS»(/mercury/sable/ii-1991-1995/remont/mechanical/#30l-v6-vin-u__fuel-pressure-release-fuel-line) under REMOVAL & INSTALLATION.
2. Remove battery and battery tray. Drain cooling system. Remove hood and air cleaner assembly. Discharge A/C system using approved refrigerant recovery/recycling equipment. Remove cooling fan and shroud. Remove harness bracket from right strut tower.
3. Disconnect necessary electrical connections, coolant hoses, vacuum hoses and ventilation hoses. Remove starter brace. Disconnect exhaust pipe at manifold.
4. Disconnect lines at power steering pump. Disconnect ground straps. Disconnect control cables at throttle body. On A/T equipped vehicles, remove torque converter-to-flexplate bolts.
5. On all vehicles, support front of transaxle with floor jack. Remove transaxle-to-cylinder block bolts. Remove engine mount bolts. Separate engine from transaxle and lift engine from vehicle.

Installation

1. To install, reverse removal procedure. Tighten all bolts to specification. See «TORQUE SPECIFICATIONS»(/mercury/sable/ii-1991-1995/remont/mechanical/#30l-v6-vin-u) .
2. When installing fuel lines, install new "O" rings on fuel lines. Use only specified fuel resistant "O" rings (Brown in color). Lightly coat "O" rings with clean engine oil before installing. Clean fittings and replace garter spring (if necessary).
3. Adjust all control cables and fluid levels. Refill cooling system. Evacuate and recharge A/C system.

Note. On Tempo and Topaz, engine and transaxle are removed as an assembly.

Removal (Tempo & Topaz)

1. Release fuel pressure and disconnect fuel lines. Refer to «FUEL PRESSURE RELEASE & FUEL LINE CONNECTIONS»(/mercury/sable/ii-1991-1995/remont/mechanical/#30l-v6-vin-u__fuel-pressure-release-fuel-line) under REMOVAL & INSTALLATION.
2. Remove battery and battery tray. Drain cooling system. Remove hood and air cleaner assembly. Discharge A/C system using approved refrigerant recovery/recycling equipment.
3. Disconnect necessary electrical connections, coolant hoses, vacuum hoses and ventilation hoses. Disconnect ground straps at intake manifold. Disconnect hoses from power steering pump. Remove power steering reservoir.
4. Disconnect refrigerant line from condenser, leaving line attached to A/C compressor. Disconnect control cables at throttle body. Disconnect cruise control servo and secure aside.
5. On A/T equipped vehicles, disconnect electrical connectors, control cable, oil cooler lines and speedometer cable from transaxle.
6. On M/T equipped vehicles, remove clutch cable. Remove shift control rod and extension bar from transaxle. Disconnect electrical connections at transaxle.
7. On all vehicles, remove radiator hoses, cooling fan and shroud. Raise and support vehicle. Remove front wheels. Disconnect exhaust pipe at exhaust manifold. Remove power steering lines from rear of engine above transaxle. Remove lower radiator hose and starter.
8. Remove stabilizer bar from lower control arm. Remove nut and disconnect tie rod and lower ball joint from steering knuckle.
9. Pull outward on spindle assemblies to disengage axle shafts from transaxle. Install plugs in transaxle openings to hold differential gears in place.
10. Disconnect lower transaxle mount. Lower vehicle. Support engine with hoist. Disconnect engine and transaxle mounts. Lift engine and transaxle assembly from vehicle.

1. To install, reverse removal procedure. Tighten all bolts to specification. See «TORQUE SPECIFICATIONS»(/mercury/sable/ii-1991-1995/remont/mechanical/#30l-v6-vin-u) .
2. Install new clip on end of axle shaft. DO NOT reuse original clip. Ensure opening of clip is toward top of axle shaft before installing. Lubricate axle shaft splines with Lubricant (C1AZ-1959-D) before installing.
3. When installing fuel lines, install new "O" rings on fuel lines. Use only specified fuel resistant "O" rings (Brown in color). Lightly coat "O" rings with clean engine oil before installing. Clean fittings and replace garter spring (if necessary).
4. Tighten nut on stabilizer bar bolt until bolt threads protrude through nut approximately .79" (20.1 mm). Adjust all control cables and fluid levels. Refill cooling system. Evacuate and recharge A/C system.

Scheme 2

1. Release fuel pressure and disconnect fuel lines. Refer to «FUEL PRESSURE RELEASE & FUEL LINE CONNECTIONS»(/mercury/sable/ii-1991-1995/remont/mechanical/#30l-v6-vin-u__fuel-pressure-release-fuel-line) under REMOVAL & INSTALLATION.
2. Disconnect negative battery cable and drain cooling system. Remove air cleaner flex hose. Disconnect necessary electrical connections, vacuum hoses and coolant hoses. Disconnect EGR pipe tube (if equipped) and rotate tube away from valve.
3. Remove accessories and/or brackets as necessary. Remove retaining bolts, upper intake manifold and throttle body assembly. (Scheme 2)
4. Remove spark plug wires and distributor cap. Align timing marks to TDC of cylinder No. 1. Place reference mark on distributor and cylinder block for reassembly reference. Remove distributor assembly. Remove ignition coil and bracket from left cylinder head.
5. Remove valve covers. Evenly remove lower intake manifold bolts. Remove lower intake manifold and gaskets.

Scheme 3

1. Clean gasket mating surfaces. Lightly oil attaching bolts and stud threads prior to installation.
2. Apply Silicone Rubber Sealer (D6AZ-19562-AA) at cylinder block and cylinder head junction areas. (Scheme 3) When using silicone sealer, assembly must occur within 15 minutes after sealer is applied.
3. Install intake manifold front seal. When installing intake manifold rear seal, position seal with flat side toward distributor hole. Install lower intake manifold gaskets with locking tabs over tabs on cylinder head gaskets. CAUTION: Lower intake manifold gaskets must be installed with TO INTAKE MANIFOLD marking facing intake manifold.
4. Install lower intake manifold and retaining bolts. Tighten bolts to specification in sequence. (Scheme 4) See, in this article, «TORQUE SPECIFICATIONS»(/mercury/sable/ii-1991-1995/remont/mechanical/#30l-v6-vin-u). To complete installation, reverse removal procedure.
5. When installing fuel lines, install new "O" rings on fuel lines. Use only specified fuel resistant "O" rings (Brown in color). Lightly coat "O" rings with clean engine oil before installing. Clean fittings and replace garter spring (if necessary).
6. Adjust all control cables and fluid levels. Refill cooling system. Evacuate and recharge A/C system.

Scheme 4

Removal

1. Disconnect negative battery cable. On left manifold, remove exhaust manifold shield. Remove engine oil dipstick tube support bracket nut. Carefully rotate tube away from manifold.
2. On right manifold, remove EGR valve-to-exhaust manifold hoses, and EGR tube from exhaust manifold (if equipped). Remove water pump. See «WATER PUMP»(/mercury/sable/ii-1991-1995/remont/mechanical/#30l-v6-vin-u) . Remove heat shield.
3. On both manifolds, disconnect exhaust pipe from exhaust manifold. Remove retaining bolts and exhaust manifold.

To install, reverse removal procedure. Lightly oil threads of bolts and stud before installing. Tighten bolts to specification. See TORQUE SPECIFICATIONS .

1. Disconnect negative battery cable and drain cooling system. Remove intake manifolds. See «INTAKE MANIFOLD»(/mercury/sable/ii-1991-1995/remont/mechanical/#30l-v6-vin-u) under REMOVAL & INSTALLATION. Remove exhaust manifolds. See «EXHAUST MANIFOLD»(/mercury/sable/ii-1991-1995/remont/mechanical/#30l-v6-vin-u) under REMOVAL & INSTALLATION. Disconnect necessary electrical connections.
2. On left cylinder head, remove accessory drive belt and automatic tensioner. Remove power steering pump and bracket with hoses attached, and secure aside.
3. On both cylinder heads, remove valve covers. Loosen rocker arm bolts. Pivot rocker arms from push rods. Remove push rods. Mark component location for reassembly reference. Evenly remove cylinder head bolts and discard. Remove cylinder head and gasket.

Inspection

1. Inspect cylinder head for cracks or warpage. Machine cylinder head if warpage exceeds specification. See «CYLINDER HEAD»(/mercury/sable/ii-1991-1995/remont/mechanical/#30l-v6-vin-u) table under ENGINE SPECIFICATIONS. CAUTION: DO NOT machine more than .010" (.25 mm) from cylinder head original thickness.
2. Check cylinder block deck surface. Machine cylinder block if warpage exceeds specification. See «CYLINDER BLOCK»(/mercury/sable/ii-1991-1995/remont/mechanical/#30l-v6-vin-u) table under ENGINE SPECIFICATIONS.

Scheme 5

1. Ensure dowels are installed in cylinder block and cylinder head gaskets are installed with UP mark showing. Lightly oil cylinder head bolt threads before installing. CAUTION: Install new cylinder head bolts. DO NOT reuse bolts.
2. Install cylinder head. Tighten bolts to specification in 4 steps using proper sequence. (Scheme 5) See «TORQUE SPECIFICATIONS»(/mercury/sable/ii-1991-1995/remont/mechanical/#30l-v6-vin-u).
3. Coat ends of push rods with Assembly Lubricant (D9AZ-19579-D) before installing. Install push rods in original location. For each valve, rotate crankshaft until valve lifter and push rod are at lowest point on camshaft lobe.
4. Install rocker arm over push rod. Tighten rocker arm bolt to specification. See «TORQUE SPECIFICATIONS»(/mercury/sable/ii-1991-1995/remont/mechanical/#30l-v6-vin-u). NOTE: Rocker arms must be fully seated in cylinder head and push rods must be seated in rocker arm sockets prior to final tightening.
5. If valve train components have been changed, check valve clearance. See «VALVE CLEARANCE ADJUSTMENT»(/mercury/sable/ii-1991-1995/remont/mechanical/#30l-v6-vin-u__valve-clearance-adjustment) under ADJUSTMENTS. To complete installation, reverse removal procedure.

1. Disconnect negative battery cable. Remove accessory drive belts. Raise and support vehicle. Remove right front wheel.
2. Remove 4 retaining bolts and crankshaft pulley. Remove crankshaft damper retaining bolt. Using Crankshaft Damper Remover (T58P-6316-D) and Adapter (T28L-6316-B), remove crankshaft damper. Using a flat-blade screwdriver, pry seal from front cover, using care not to damage sealing surfaces.

1. To install, reverse removal procedure. Coat seal lip and crankshaft damper surface with engine oil before installing. Use Seal Installer (T70P-6B070-A) to install seal.
2. Apply Sealant (D6AZ-19562-BA) to crankshaft damper keyway before installing damper. Tighten bolts/nuts to specification. See «TORQUE SPECIFICATIONS»(/mercury/sable/ii-1991-1995/remont/mechanical/#30l-v6-vin-u) .

1. Remove engine. See «ENGINE»(/mercury/sable/ii-1991-1995/remont/mechanical/#30l-v6-vin-u__engine) under REMOVAL & INSTALLATION. Remove accessory drive belts.
2. Remove crankshaft damper bolt. Using Crankshaft Damper Remover (T58P-6316-D), and Adapter (T82L-6316-A), remove crankshaft damper from crankshaft. Using Seal Remover (T70P-6B070-B) or flat-blade screwdriver, remove seal from front cover.

1. To install, reverse removal procedure. Coat seal lip and crankshaft damper surface with engine oil before installing. Use Seal Installer (T70P-6B070-A) to install seal.
2. Apply Sealant (D6AZ-19562-AA) to crankshaft damper keyway before installing damper. Tighten bolts/nuts to specification. See «TORQUE SPECIFICATIONS»(/mercury/sable/ii-1991-1995/remont/mechanical/#30l-v6-vin-u) .

1. Disconnect negative battery cable and drain cooling system. Remove accessory drive belts. Disconnect coolant hoses from water pump.
2. Raise and support vehicle. Remove right front wheel. Remove 4 retaining bolts and crankshaft pulley. Remove crankshaft damper retaining bolt. Using Crankshaft Damper Remover (T58P-6316-D) and Adapter (T28L-6316-B), remove crankshaft damper.
3. Remove oil pan. See «OIL PAN»(/mercury/sable/ii-1991-1995/remont/mechanical/#30l-v6-vin-u) under REMOVAL & INSTALLATION. Remove retaining bolts, front cover (with water pump) and gasket. (Scheme 6)

Scheme 6

1. To install, reverse removal procedure. Use thread sealant on specified bolts. (Scheme 6) Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(/mercury/sable/ii-1991-1995/remont/mechanical/#30l-v6-vin-u).
2. Coat seal lip and crankshaft damper surface with engine oil before installing. Using Seal Installer (T70P-6B070-A), install seal.
3. Apply Sealant (D6AZ-19562-BA) to crankshaft damper keyway before installing damper. Tighten bolts/nuts to specification. See «TORQUE SPECIFICATIONS»(/mercury/sable/ii-1991-1995/remont/mechanical/#30l-v6-vin-u). Refill cooling system.

1. Remove engine. See «ENGINE»(/mercury/sable/ii-1991-1995/remont/mechanical/#30l-v6-vin-u__engine) under REMOVAL & INSTALLATION. Remove accessory drive belts and automatic tensioners.
2. Remove crankshaft damper bolt. Using Crankshaft Damper Remover (T58P-6316-D), remove crankshaft damper from crankshaft. Disconnect water pump connection from front cover. Remove oil pan. See «OIL PAN»(/mercury/sable/ii-1991-1995/remont/mechanical/#30l-v6-vin-u) under REMOVAL & INSTALLATION. Remove lower front cover bolts. Remove retaining bolts, front cover and gasket.

Scheme 7

1. To install, reverse removal procedure. Coat all front cover bolt threads with engine oil except bolts No. 1, 2 and 3. Apply thread sealant to threads of bolts No. 1, 2 and 3. (Scheme 7)
2. Tighten front cover bolts to specification in proper sequence. (Scheme 7) See «TORQUE SPECIFICATIONS»(/mercury/sable/ii-1991-1995/remont/mechanical/#30l-v6-vin-u). Coat seal lip and crankshaft damper surface with engine oil before installing. Using Seal Installer (T70P-6B070-A), install seal (if removed).
3. Apply Sealant (D6AZ-19562-AA) to crankshaft damper keyway before installing damper. Tighten bolts/nuts to specification. See «TORQUE SPECIFICATIONS»(/mercury/sable/ii-1991-1995/remont/mechanical/#30l-v6-vin-u). Refill cooling system.

1. Timing chain deflection (stretch) can be checked for wear before removing front cover. Remove left valve cover. Loosen cylinder No. 5 exhaust rocker arm and rotate to one side.
2. Position dial indicator on end of push rod. Rotate crankshaft clockwise to position cylinder No. 1 at TDC. Ensure crankshaft damper timing mark aligns with TDC mark on timing degree indicator. Zero dial indicator.
3. Rotate crankshaft counterclockwise until movement is detected by dial indicator. Note crankshaft damper timing mark for number of degrees of travel from TDC. If reading exceeds 6 degrees, replace timing chain and gears.

1. Remove front cover. See «FRONT COVER»(/mercury/sable/ii-1991-1995/remont/mechanical/#30l-v6-vin-u) under REMOVAL & INSTALLATION. Rotate crankshaft until cylinder No. 1 is on TDC of compression stroke and timing marks are aligned. (Scheme 8)
2. Remove camshaft gear retaining bolt and washer. Remove timing chain and gears as an assembly.

To install, reverse removal procedure. Ensure timing marks are aligned. (Scheme 8) Apply oil to timing chain and gears after installation.

Scheme 8

Remove intake manifolds. See INTAKE MANIFOLD under REMOVAL & INSTALLATION. Remove valve covers. Loosen rocker arm bolts. Pivot rocker arms from push rods. Remove push rods and valve lifters. Mark component location for reassembly reference.

Inspect components for damage. Ensure valve lifter bore diameter, valve lifter O.D. and oil clearance are within specification. See VALVE LIFTERS table under ENGINE SPECIFICATIONS. Replace components if not within specification.

1. To install, reverse removal procedure. Lubricate valve lifters and ends of push rods with Assembly Lubricant (D9AZ-19579-B) before installing.
2. Ensure components are installed in original location. When installing rocker arms on each valve, rotate crankshaft until valve lifter and push rod are at lowest point on camshaft lobe.
3. Install rocker arm over push rod. Tighten rocker arm bolt to specification. See «TORQUE SPECIFICATIONS»(/mercury/sable/ii-1991-1995/remont/mechanical/#30l-v6-vin-u) . NOTE: Rocker arms must be fully seated in cylinder head and push rods must be seated in rocker arm sockets prior to final tightening.
4. If valve train components have been changed, check valve clearance. See «VALVE CLEARANCE ADJUSTMENT»(/mercury/sable/ii-1991-1995/remont/mechanical/#30l-v6-vin-u__valve-clearance-adjustment) under ADJUSTMENTS. To complete installation, reverse removal procedure.

1. Remove engine from vehicle. See «ENGINE»(/mercury/sable/ii-1991-1995/remont/mechanical/#30l-v6-vin-u__engine) under REMOVAL & INSTALLATION. Remove intake manifolds. See «INTAKE MANIFOLD»(/mercury/sable/ii-1991-1995/remont/mechanical/#30l-v6-vin-u) . Remove valve lifters. See VALVE LIFTER. Remove timing chain. See, in this article, «TIMING CHAIN»(/mercury/sable/ii-1991-1995/remont/mechanical/#30l-v6-vin-u) .
2. Check camshaft end play. If camshaft end play is not within specification, replace thrust plate. See «CAMSHAFT»(/mercury/sable/ii-1991-1995/remont/mechanical/#30l-v6-vin-u) table under ENGINE SPECIFICATIONS.
3. Remove camshaft thrust plate retaining bolt. Remove camshaft. If replacing camshaft bearings, remove rear camshaft bore plug. Using Camshaft Bearing Set (T65L-6250-A), remove camshaft bearings.

Inspect journal diameter, lobe lift, oil clearance and runout. Replace camshaft if not within specification. See CAMSHAFT table under ENGINE SPECIFICATIONS.

Note. Standard and .015" (.38 mm) oversize camshaft bearings are available.

1. To install, reverse removal procedure. Ensure oil holes in camshaft bearings and cylinder block are aligned. Front camshaft bearing must be installed .020-.035" (.51-.89 mm) below front face of cylinder block.
2. Apply sealant to rear camshaft bore plug before installing. Plug must be installed flush with cylinder block surface.
3. Lubricate camshaft lobes, journals and both sides of thrust plate with engine oil before installing.
4. Ensure camshaft end play is within specification. See «CAMSHAFT»(/mercury/sable/ii-1991-1995/remont/mechanical/#30l-v6-vin-u) table under ENGINE SPECIFICATIONS. To complete installation, reverse removal procedure.

1. Rear main seal is a one-piece seal. Either transaxle or engine must be removed to gain access. Remove flywheel (M/T) or drive plate (A/T). Using an awl, punch a hole in metal portion of seal. Using a slide hammer, remove seal.
2. Coat seal lip with engine oil before installing. Use Seal Installer (T88L-6701-A) to install seal. To complete installation, reverse removal procedure. Tighten bolts to specification. Refer to, «TORQUE SPECIFICATIONS»(/mercury/sable/ii-1991-1995/remont/mechanical/#30l-v6-vin-u) .

1. Disconnect negative battery cable. Remove dipstick. Raise and support vehicle. Drain engine oil. Remove starter and brace.
2. Disconnect low oil level sensor connector (if equipped). Disconnect oxygen sensor. Remove exhaust pipe located below oil pan. Remove flywheel/drive plate cover. Remove retaining bolts, oil pan and gasket.

1. To install, reverse removal procedure. Apply silicone sealant at rear main bearing cap and front cover-to-cylinder block areas before installing oil pan.
2. Apply Contact Adhesive (D7AZ-19B508-A) on gasket and install on oil pan. Tighten oil pan bolts to specification. See, in this aeticle, «TORQUE SPECIFICATIONS»(/mercury/sable/ii-1991-1995/remont/mechanical/#30l-v6-vin-u) . To install remaining components, reverse removal procedure. Fill crankcase with oil.

1. Disconnect negative battery cable. Raise and support vehicle. Drain engine oil and remove dipstick. Remove starter motor. Remove catalyst and pipe assembly.
2. Disconnect low oil level sensor connector at oil pan. On automatic transmission models, remove torque converter access plate. On manual transmission models, remove transaxle support plates.
3. Remove oil pan retaining bolts. Lower oil pan, ensuring oil pan baffle clears oil pump pick-up tube. Remove oil pan and gasket.

1. To install, reverse removal procedure. Apply silicone sealant at rear main bearing cap and front cover-to-cylinder block areas before installing oil pan. Insert oil pump intermediate drive shaft through hole in rear main bearing cap.
2. Apply Contact Adhesive (D7AZ-19B508-A) on gasket and install on oil pan. Tighten oil pan bolts to specification. See, in this article, «TORQUE SPECIFICATIONS»(/mercury/sable/ii-1991-1995/remont/mechanical/#30l-v6-vin-u) . Install remaining components. Fill crankcase with oil. Refill cooling system.

CYLINDER HEAD

Note. When valve and/or valve seat are machined, valve clearance is reduced and may cause improper valve operation. Valve lifter must be collapsed and clearance checked. See, in this article, VALVE CLEARANCE ADJUSTMENT under ADJUSTMENTS.

Check cylinder head warpage at deck surface. Resurface cylinder head if warpage exceeds specification. See CYLINDER HEAD table under ENGINE SPECIFICATIONS.

Valve Springs

1. Inspect valve spring free length and pressure. Replace valve spring if not within specification. See «VALVES & VALVE SPRINGS»(/mercury/sable/ii-1991-1995/remont/mechanical/#30l-v6-vin-u) table under ENGINE SPECIFICATIONS.
2. Measure valve spring installed height from top of spring seat to underside of spring retainer. Installed height should be within specification. See «VALVES & VALVE SPRINGS»(/mercury/sable/ii-1991-1995/remont/mechanical/#30l-v6-vin-u) table.
3. If installed height is not within specification, a .030" (.76 mm) shim can be installed between cylinder head and valve spring to obtain correct height.

Valve Stem Oil Seals

Intake and exhaust valve stem seals are not interchangeable. Intake valve seal contains a Silver band, and exhaust valve contains a Red band around seal.

Valve Guides

1. Valve guides must be reamed for oversize valves if valve stem-to-guide oil clearance exceeds specification. See «CYLINDER HEAD»(/mercury/sable/ii-1991-1995/remont/mechanical/#30l-v6-vin-u) table under ENGINE SPECIFICATIONS. Valves are available in .015" (.38 mm) and .030" (.76 mm) oversize.
2. Valve guides may also be bored out and replaced with a service guide if oversized valves are not available or guide is damaged. Ream valve guides until proper valve stem-to-guide oil clearance exists.

Note. DO NOT ream valve guides from standard to maximum oversize in one step. Ream valve guides to oversize in gradual steps, so valve guides are reamed in relation to valve seat. Valve seats must be ground when valve guide is reamed or replaced.

Valve Seat

Valve seat angle, seat width and seat runout must be within specification. See CYLINDER HEAD table under ENGINE SPECIFICATIONS. Valve seats must be ground when valve guide is reamed or replaced. Replacement information is not available from manufacturer.

Valves

Ensure head diameter, valve face runout, stem diameter and valve margin are within specification. See VALVES & VALVE SPRINGS table under ENGINE SPECIFICATIONS.

Valve Seat Correction Angles

Use a 60-degree angle stone to remove stock from bottom of the seat (raise seat). A 30-degree stone will remove stock from top of the seat (lower seat).

Piston & Rod Assembly

Install piston on connecting rod with piston notch on same side as button on connecting rod. (Scheme 9) Install piston and connecting rod in engine with notch on top of piston toward front of engine.

Scheme 9

1. Standard size pistons are color coded Red, Blue and Yellow on piston dome. Measure piston skirt diameter at 90-degree angle to piston pin. Replace piston if piston diameter is not within specification.
2. Measure cylinder bore 1/2" below cylinder block head surface and 1/2" above piston when at bottom of cylinder bore. Use proper piston to obtain correct clearance. See «PISTONS PINS & RINGS»(/mercury/sable/ii-1991-1995/remont/mechanical/#30l-v6-vin-u) table under ENGINE SPECIFICATIONS.

Piston Rings

Ensure ring end gap and side clearance are within specification. See PISTONS PINS & RINGS table under ENGINE SPECIFICATIONS. Ensure piston ring gaps are not aligned.

Rod Bearings

Ensure piston and connecting rod are installed with notch on top of piston toward front of engine. (Scheme 9) Ensure bearing oil clearance and side play are within specification. See, in this article, CRANKSHAFT MAIN & CONNECTING ROD BEARINGS and CONNECTING RODS tables under ENGINE SPECIFICATIONS.

Crankshaft & Main Bearings

1. Main bearing caps are marked for location with No. 1 at front and No. 4 at rear of engine. Arrow on main bearing cap must point toward front of engine.
2. Apply silicone sealant at outer edges of rear main bearing cap before installing. DO NOT allow sealant to enter inner edges of main bearing cap.
3. When installing main bearing caps, thrust bearing must be aligned. Install all other main bearing caps. Install thrust bearing cap bolt (main bearing No. 3) finger tight.
4. Lightly pry crankshaft forward against thrust surface of upper half of bearing. Hold crankshaft forward and tighten bolts to specification. See «TORQUE SPECIFICATIONS»(/mercury/sable/ii-1991-1995/remont/mechanical/#30l-v6-vin-u) .
5. Ensure main bearing oil clearance and crankshaft end play are within specification. Refer to, at the end of this article, «CRANKSHAFT MAIN & CONNECTING ROD BEARINGS»(/mercury/sable/ii-1991-1995/remont/mechanical/#30l-v6-vin-u) table under ENGINE SPECIFICATIONS. Replace thrust bearing if end play is not within specification.

Thrust Bearing

Thrust bearing is located on main bearing No. 3. Replace bearing if crankshaft end play is not within specification. See CRANKSHAFT MAIN & CONNECTING ROD BEARINGS table under ENGINE SPECIFICATIONS.

Cylinder Block

1. Using a straightedge and feeler gauge, check for cylinder block deck surface warpage. Machine cylinder block if warpage exceeds specification. See «CYLINDER BLOCK»(/mercury/sable/ii-1991-1995/remont/mechanical/#30l-v6-vin-u) table under ENGINE SPECIFICATIONS. CAUTION: DO NOT machine more than .010" (.25 mm) of material from original cylinder block head surface.
2. Check cylinder bore diameter, out-of-round, taper and scoring. Cylinder bore is measured 1/2" below cylinder block deck and1/2" above piston when at bottom of cylinder bore. Cylinder block must be bored if not within specification. See «CYLINDER BLOCK»(/mercury/sable/ii-1991-1995/remont/mechanical/#30l-v6-vin-u) table under ENGINE SPECIFICATIONS.

ENGINE OILING SYSTEM

Lubrication system is a force-feed type. Oil is supplied under full pressure to crankshaft, connecting rods, camshaft bearings 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. Oil pump is driven by an intermediate shaft connected to distributor.

Crankcase Capacity

Oil capacity is 4.5 qts. (4.26L) with filter.

Oil Pressure

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

Removal & Disassembly

Remove oil pan. See OIL PAN under REMOVAL & INSTALLATION. Remove oil pump retaining bolts, oil pump and shaft. Disassemble oil pump. Note component relationships for reassembly reference.

Inspect components for damage. Ensure oil pump is within specification. See OIL PUMP SPECIFICATIONS table.

OIL PUMP SPECIFICATIONS

Reassembly & Installation

To reassemble, reverse disassembly procedure. Ensure components are installed in original location. To install, reverse removal procedure. Tighten bolts to specification. See TORQUE SPECIFICATIONS. Fill crankcase.

1. Disconnect negative battery cable. Drain cooling system. Loosen water pump pulley bolts. Remove accessory drive belts.
2. Remove automatic tensioner. Disconnect coolant hoses from water pump. Remove retaining bolts, water pump and gasket. (Scheme 10)

Scheme 10

1. To install, reverse removal procedure. Lightly oil all bolt and stud threads before installing, except bolt requiring Thread Sealant (EST-M4G208-B). (Scheme 10) Apply Contact Adhesive (D7AZ-19B508-A) on gasket and install on water pump.
2. Tighten bolts/nuts to specification. See, in this article, «TORQUE SPECIFICATIONS»(/mercury/sable/ii-1991-1995/remont/mechanical/#30l-v6-vin-u). Refill cooling system.

Drain cooling system. Remove accessory drive belts. Disconnect coolant hoses from water pump. Remove nut and bolts from mounting bracket. Remove pump mounting bolts and water pump. (Scheme 11)

To install, reverse removal procedure. Tighten bolts to specification. See TORQUE SPECIFICATIONS . Refill cooling system.

Scheme 11

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

GENERAL ENGINE SPECIFICATIONS

GENERAL SPECIFICATIONS

CRANKSHAFT MAIN & CONNECTING ROD BEARINGS SPECIFICATIONS

CRANKSHAFT MAIN & CONNECTING ROD BEARINGS

CONNECTING RODS SPECIFICATIONS

CONNECTING RODS

PISTONS PINS & RINGS SPECIFICATIONS

PISTONS PINS & RINGS

CYLINDER BLOCK SPECIFICATIONS

CYLINDER BLOCK

VALVES & VALVE SPRINGS SPECIFICATIONS

VALVES & VALVE SPRINGS

CYLINDER HEAD SPECIFICATIONS

CYLINDER HEAD

CAMSHAFT SPECIFICATIONS

CAMSHAFT

VALVE LIFTERS SPECIFICATIONS

VALVE LIFTERS

See also:
• ENGINE OVERHAUL PROCEDURES - GENERAL INFORMATION
• FUEL PRESSURE RELEASE & FUEL LINE CONNECTIONS
• TORQUE SPECIFICATIONS
• VALVE CLEARANCE ADJUSTMENT
• ENGINE
• CRANKSHAFT MAIN & CONNECTING ROD BEARINGS