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Engine - 3.0L 2V: Specifications Mercury Sable IV

Mechanical 93 illustrations ~1469 words

Torque Specifications

ApplicationFt. Lbs (N.m)
A/C Compressor Bolt18 (24)
A/C Compressor Bracket Stabilizer Bracket Bolt18 (24)
A/C Compressor Bracket-To-Cylinder Block Bolt35 (47)
A/C-To-Water Pump Bracket Bolts18 (24)
Accelerator Cable Bracket-To-Throttle Body Bolts13 (17)
Accessory Drive Belt Tensioner/Idler Assembly Cover Bolt35 (48)
Camshaft Sprocket-To-Camshaft Bolt46 (63)
Camshaft Synchronizer Clamp Bolt18 (24)
Camshaft Thrust Plate-To-Cylinder Block Bolt18 (24)
Connecting Rod Bolt26 (35)
Crankshaft Damper-To-Crankshaft Bolt107 (145)
Crankshaft Main Bearing Cap Stud Bolt(1) 59 (80)
Crankshaft Pulley-To-Crankshaft Damper Bolt35 (47)
Cylinder Head (2)
Stage 137 (50)
Stage 2(3)
Stage 322 (30)
Stage 4(4)
Stage 5(4)
EGR Tube-To-EGR Valve Nut
Stage 130 (41)
Stage 241 (55)
EGR Tube-To-Exhaust Manifold Nut30 (41)
EGR Valve-To-Upper Intake Manifold Bolt18 (24)
Engine Coolant Temperature Sender15 (20)
Engine Coolant Temperature Sensor15 (20)
Engine Ground Strap Nut18 (24)
Engine Oil Cooler Adapter Mounting Nut40 (54)
Engine Rear Insulator-To-Front Subframe Bolt65 (88)
Engine Rear Insulator-To-Transaxle Bracket Nut72 (98)
Engine Roll Restrictor Bolt35 (47)
Engine Roll Restrictor Brace Nut35 (47)
Engine Roll Restrictor Bracket-To-Engine Front Cover Nut18 (24)
Engine Roll Restrictor-To-Generator Bolt18 (24)
Engine Support Insulator
Stage 144 (60)
Stage 289 (120)
Stage 346 (62)
Stage 466 (90)
Exhaust Manifold Bolt-To-Cylinder Head (5)
Stage 1(6)
Stage 216 (22)
Exhaust Manifold-To-Y-Pipe Bolts30 (41)
Flywheel Bolt59 (80)
Front Cover/Water Pump Assembly Bolts/Studs(7) 18 (24)
Front Sub-Frame-To-Body Insulator Bolt76 (103)
Generator Bolt18 (24)
Ground Strap Bolt11 (15)
Halfshaft-To-Steering Knuckle Nut190 (257)
Knock Sensor Bolt13 (18)
Lower Control Arm-To-Steering Knuckle Nut59 (80)
Lower Intake Manifold-To-Cylinder Head Bolt (8)
Stage 111 (15)
Stage 224 (32)
Oil Pan Baffle24 (33)
Oil Level Indicator Tube-To-Exhaust Manifold Stud Bolt Nut13 (18)
Oil Filter Mounting Boss25 (34)
Oil Pan-To-Tranmission Bolts30 (40)
Oil Pressure Sensor14 (19)
Oil Pump Bolt35 (47)
Oil Pump-To-Crankshaft Main Bearing Cap Bolt35 (47)
Power Steering Pressure Line-To-Exhaust Manifold Stud Bolt Nut20 (27)
Power Steering Pressure Line-To-Transaxle Nut20 (27)
Power Steering Pump Bracket-To-Cylinder Head Bolt/Nut35 (47)
Power Steering Pump Bracket-To-Generator Stud Bolt35 (47)
Right Catalytic Converter Heat Shield Bolt15 (20)
Right Exhaust Manifold-To-Right Catalytic Converter Flange Bolt30 (41)
Rocker Arm
Stage 1(6)
Stage 224 (32)
Shifter Cable Nut13 (17)
Spark Plug11 (15)
Stabilizer Bar Link-To-Stabilizer Bar Nut41 (55)
Starter Motor Bolt18 (24)
Starter Motor Ground Cable Bolt18 (24)
Steering Shaft Pinch Bolt18 (24)
Subframe-To-Body Bolts76 (103)
Throttle Body-To-Intake Manifold Bolts13 (17)
Tie Rod Nut41 (55)
Torque Converter Nut26 (35)
Transaxle-To-Engine Block30 (57)
Transaxle Manual Control Cable Nut13 (17)
Upper Intake Support Bracket Bolt35 (47)
Water Pump Bolt(9)
Water Pump Pulley Bolt18 (24)
Wheel Lug Nut95 (129)
Y-Pipe-To-Exhaust Manifold Nuts30 (40)
INCH Lbs. (N.m)
A/C Line Nut71 (8)
A/C Manifold & Tube Nut89 (10)
Belt Tensioner Bolt89 (10)
Camshaft Oil Seal Retainer Bolt89 (10)
Camshaft Position Sensor-To-Camshaft Synchronizer Bolts18 (2)
Camshaft Rear Oil Seal Retainer Bolts89 (10)
Coil-On-Plug Bolts53 (6)
Crankcase Cover Bolts89 (10)
Crankshaft Position Sensor Bolt89 (10)
EGR Vacuum Regulator Solenoid Nut53 (6)
Engine Control Sensor Wire Harness 42-Pin Connector Bolt89 (10)
Engine Cooling Fan89 (10)
Engine Rear Plate-To-Transaxle Bolt106 (12)
Exhaust Manifold Heat Shield-To-Right Exhaust Manifold Bolt89 (10)
Front Splash Shield Bolts62 (7)
Fuel Charging Harness Nut27 (3)
Fuel Injection Supply Manifold-To-Lower Intake Manifold Bolt89 (10)
Fuel Rail Bolt89 (10)
Fuel Supply Manifold Bolts89 (10)
Generator Output Nut71 (8)
Heater Hose Bracket Nuts89 (10)
Ignition Coil-On-Plug Bolts53 (6)
Intake Manifold Bolt89 (10)
Oil Drain Plug120 (13)
Oil Level Indicator & Tube Stud89 (10)
Oil Pan Bolt(10) 79 (9)
Oil Separator Bolts89 (10)
Power Steering Pressure Line Bracket Nut89 (10)
Powertrain Control Module Electrical Connector Bolt35 (4)
Starter Cable Positive Nut108 (12)
Thermostat Housing Bolt79 (9)
Transaxle-To-Oil Pan Bracket Nuts89 (10)
Upper Intake Manifold Bolt (11)
Stage 1(12)
Stage 289 (10)
Upper Intake Manifold Bracket Nut53 (6)
Valve Cover Bolt/Stud Bolt79 (9)
Valve Tappet Guide Plate Retainer Bolt79 (9)
Wire Harness Bolt89 (10)
(1) Tighten in sequence. (Scheme 1) (2) Tighten in sequence. (Scheme 2) (3) Loosen bolt 360 degrees. (4) Tighten an additional 90 degrees. (5) Tighten in sequence. (Scheme 3)and (Scheme 4). (6) Tighten to 89 INCH lbs. (10 N.m). (7) Apply pipe sealant with Teflon® to bolts as indicated. (Scheme 5) (8) Tighten in sequence. (Scheme 6) (9) Water pump is removed/installed with the front cover as an assembly. (10) Tighten in sequence. (Scheme 7) (11) Tighten in sequence. (Scheme 8) (12) Hand tighten.
(1)Tighten in sequence. (Scheme 1)
(2)Tighten in sequence. (Scheme 2)
(3)Loosen bolt 360 degrees.
(4)Tighten an additional 90 degrees.
(5)Tighten in sequence. (Scheme 3)and (Scheme 4).
(6)Tighten to 89 INCH lbs. (10 N.m).
(7)Apply pipe sealant with Teflon® to bolts as indicated. (Scheme 5)
(8)Tighten in sequence. (Scheme 6)
(9)Water pump is removed/installed with the front cover as an assembly.
(10)Tighten in sequence. (Scheme 7)
(11)Tighten in sequence. (Scheme 8)
(12)Hand tighten.

TORQUE SPECIFICATIONS

Scheme 1

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Scheme 1

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Scheme 8

The 3.0L engine has

  1. A V-Block With Six Cylinders And Splayed Crankpins
  2. A Distributorless Ignition System
  3. A Multiport, Sequential Fuel Injection (SFI) System
  4. Overhead Valves
  5. Hydraulic Valve Tappets (6500) For Automatic Lash Adjustment
  6. Connecting Rod Parting Faces That Are Unique With An Interference Fit

For removal and installation of the water pump, refer to ENGINE COOLING .

Major Upper Engine Components

Scheme 9

Scheme 9
Scheme 9

Cylinder Block - Lower

Scheme 10

Scheme 10
Scheme 10

Refer to DIAGNOSIS AND TESTING .

Scheme 11

Scheme 11: Removal
Scheme 11: Removal

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Scheme 12

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Scheme 24

Scheme 24
Scheme 24
  1. Disconnect the battery ground cable.
  2. Remove the air cleaner assembly and the air cleaner outlet tube.
  3. Remove the pin-type retainers and the snow shield.
  4. Disconnect the accelerator cable, speed control actuator cable and the throttle return spring from the throttle body.
  5. Remove the bolts, then position the accelerator cable bracket aside.
  6. Disconnect the hoses. Disconnect the vacuum hose. Disconnect the evaporative emissions return tube.
  7. Disconnect the electrical connectors. Disconnect the Idle Air Control (IAC). Disconnect the Throttle Position (TP) sensor.
  8. Disconnect the engine wiring harness from the intake manifold support bracket.
  9. Remove the upper intake manifold support bracket. Remove the bolts. Remove the nut.
  10. Disconnect the positive crankcase ventilation (PCV) tube from the upper intake manifold.
  11. Disconnect the Exhaust Gas Recirculation (EGR) tube from the EGR valve. Loosen the nut.
  12. Disconnect the vacuum hose from the EGR valve.
  13. Disconnect the vacuum tube from the upper intake manifold and vacuum regulator solenoid, and disconnect the electrical connector from the vacuum regulator solenoid.
  14. Disconnect the wire harness retaining clip.
  15. Disconnect the spark plug holder and the radio suppressor.
  16. Remove the upper intake manifold (9424). Remove the four bolts. Remove the intake manifold.

Scheme 25

Scheme 25: Installation
Scheme 25: Installation

Scheme 26

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Scheme 39

Scheme 39
Scheme 39
  1. Clean all the sealing surfaces.
  2. Inspect the upper intake manifold gaskets. Replace if required.
  3. Install the upper intake manifold. Install the bolts in the sequence shown. Tighten the bolts in two stages. Stage 1: Tighten hand tight. Stage 2: Tighten to 10 Nm (89 lb-in).
  4. Connect the radio suppressor and the spark plug holder.
  5. Connect the wire harness retaining clip.
  6. Connect the electrical connector and vacuum tube to the vacuum regulator solenoid and the vacuum tube to the intake manifold.
  7. Connect the vacuum hose to the EGR valve.
  8. Connect the EGR tube to the EGR valve.
  9. Connect the PCV tube to the upper intake manifold.
  10. Install the upper intake manifold support bracket.
  11. Connect the engine wiring harness to the intake manifold support bracket.
  12. Connect the IAC and TP sensor electrical connectors.
  13. Connect the evaporative emissions return tube and the vacuum hose.
  14. Position the accelerator cable bracket and install the bolts.
  15. Connect the accelerator control cable, speed control cable and the throttle return spring.
  16. Install the snow shield.
  17. Install the air cleaner assembly and the air cleaner outlet tube.
  18. Connect the battery ground cable.

Scheme 40

Scheme 40: Materials
Scheme 40: Materials

Scheme 41

Scheme 41: Removal
Scheme 41: Removal

Scheme 42

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Scheme 47

Scheme 48

Scheme 48
Scheme 48
  1. Disconnect the fuel supply line. Refer to «FUEL LINE CONNECTOR»(ref-142370-S39102991382002073100000) .
  2. Remove the upper intake manifold. Refer to «UPPER INTAKE MANIFOLD»(ref-178530-S34761484492005061600000) .
  3. Remove both the valve covers (6582). Refer to «VALVE COVER - RH»(ref-178530-S04144320292005061600000) or «VALVE COVER - LH»(ref-178530-S30561256242005061600000) .
  4. Disconnect the Fuel Injection Pressure (IPR) sensor electrical and vacuum connectors.
  5. Disconnect the fuel injector electrical connectors.
  6. Remove the fuel injection supply manifold (9F792) and fuel injectors as an assembly. Remove the four bolts.
  7. Disconnect the heater hose and Coolant Temperature Sender (CTS).
  8. Disconnect the engine coolant temperature (ECT) sensor and the degas bottle hose.
  9. Disconnect the upper radiator hose from the thermostat housing.
  10. Remove the camshaft position (CMP) sensor. Refer to «CAMSHAFT POSITION SENSOR»(ref-142370-S11644068292002101600000) .
  11. Remove the lower intake manifold (9424). Remove the bolts. Remove the manifold.
  12. Remove the intake manifold gaskets (9439) and the end seals.

Scheme 49

Scheme 49: Installation
Scheme 49: Installation

Scheme 50

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Scheme 57
  1. Clean all the sealing surfaces.
  2. Apply a drop of silicone gasket and sealant at the four cylinder block-to-cylinder head seams.
  3. Install the lower intake manifold gaskets and end seals. Position the intake manifold gaskets. Position the intake manifold end seals.
  4. Install the intake manifold. Tighten the bolts in the sequence shown in two stages: Stage 1: Tighten to 15 Nm (11 lb-ft). Stage 2: Tighten to 32 Nm (24 lb-ft).
  5. Install the camshaft position (CMP) sensor. Refer to «CAMSHAFT POSITION SENSOR»(ref-142370-S11644068292002101600000) .
  6. Connect the upper radiator hose. Connect the hose. Reposition the clamp.
  7. Connect the engine coolant temperature (ECT) sensor and the degas bottle hose.
  8. Connect the heater hose and the coolant temperature sender (CTS).
  9. Install the fuel injection supply manifold and fuel injectors as an assembly. Install the four bolts.
  10. Connect the fuel injector electrical connectors.
  11. Connect the fuel injection pressure (IPR) sensor electrical and vacuum connectors.
  12. Install both valve covers. Refer to «VALVE COVER - RH»(ref-178530-S04144320292005061600000) or «VALVE COVER - LH»(ref-178530-S30561256242005061600000) .
  13. Install the upper intake manifold. Refer to «UPPER INTAKE MANIFOLD»(ref-178530-S34761484492005061600000) .
  14. Connect the fuel line. Refer to «FUEL LINE CONNECTOR»(ref-142370-S39102991382002073100000) .
  15. Fill and bleed the engine cooling system. Refer to «BLEEDING»(ref-139103-S23703246542002042500000) .

Scheme 58

Scheme 58: Materials
Scheme 58: Materials

Scheme 59

Scheme 59: Removal
Scheme 59: Removal

Scheme 60

Scheme 60
Scheme 60

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Scheme 61

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Scheme 62
Scheme 62
  1. Remove the upper intake manifold (9424). Refer to «UPPER INTAKE MANIFOLD»(ref-178530-S34761484492005061600000) .
  2. Position the degas bottle hose aside. Lift the hose off the cover studs.
  3. Position fuel charging wire harness (12B637) aside. Lift the wire harness retainers off the valve cover studs.
  4. Position the spark plug wires aside (12280). Remove the wire harness retainers. Position the wires aside.
  5. Remove the valve cover (6582). Remove the five bolts. Remove the three stud bolts.

Scheme 63

Scheme 63: Installation
Scheme 63: Installation

Scheme 64

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Scheme 68
  1. Clean all the mating surfaces.
  2. Apply a bead of silicone gasket and sealant in two places where the cylinder head (6049) and intake manifold meet.
  3. Install the valve cover gasket, if removed.
  4. Install the valve cover. Position the valve cover. Install the five bolts. Install the three stud bolts.
  5. Reposition the spark plug wires. Position the wires. Install the wire harness retainers.
  6. Install the fuel charging wire harness.
  7. Install the degas bottle hose.
  8. Install the upper intake manifold. Refer to «UPPER INTAKE MANIFOLD»(ref-178530-S34761484492005061600000) .
  9. Connect the battery ground cable.

Scheme 69

Scheme 69: Materials
Scheme 69: Materials

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Scheme 70: Removal
Scheme 70: Removal

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Scheme 75
  1. Disconnect the battery ground cable (14301).
  2. Remove the ignition coil. Refer to «IGNITION COIL»(ref-142370-S27081734332002101700000) .
  3. Disconnect the crankcase ventilation hose.
  4. Position the engine wiring harness from the front of the valve cover aside. Remove the wiring retainers from the studs.
  5. Position the engine wiring harness from the back of the valve cover aside. Remove the wiring retainers from the studs.
  6. Remove the spark plug wire retainers, then position the spark plug wires aside.
  7. Remove the LH valve cover. Remove the six stud bolts. Remove the two bolts.
  8. Remove the valve cover gasket, if required.

Scheme 76

Scheme 76: Installation
Scheme 76: Installation

Scheme 77

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Scheme 77

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Scheme 82
  1. Clean all mating surfaces.
  2. Apply a bead of silicone gasket and sealant in two places where the cylinder head (6049) and intake manifold meet.
  3. If removed, install the valve cover gasket.
  4. Install the valve cover. Install the six stud bolts. Install the two bolts.
  5. Reposition the spark plug wires. Install the spark plug wire retainers.
  6. Install the engine wiring harness. Position back over valve cover. Connect the retainers to the studs.
  7. Install the engine wiring harness. Position back over valve cover. Connect the retainers to the studs.
  8. Connect the crankcase vent tube.
  9. Install the ignition coil. Refer to «IGNITION COIL»(ref-142370-S27081734332002101700000) .
  10. Connect the battery ground cable.

Scheme 83

Scheme 83: Special Tool(s)
Scheme 83: Special Tool(s)

Scheme 84

Scheme 84: Materials
Scheme 84: Materials

Scheme 85

Scheme 85: Removal
Scheme 85: Removal

Scheme 86

Scheme 86
Scheme 86

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Scheme 87

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Scheme 88
Scheme 88
  1. Remove the accessory drive belt (8020). Refer to «DRIVE BELT ROUTING»(ref-139103-S33285511932002042500000) .
  2. Raise the vehicle on a hoist.
  3. Remove the RH front wheel (1007).
  4. Remove the splash shield (16B560).
  5. Disconnect and remove the crankshaft position (CKP) sensor. Remove the bolts
  6. Remove the crankshaft pulley (6312). Remove the bolts.
  7. Remove the crankshaft damper bolt.
  8. Using the special tool, remove the crankshaft damper (6316).

Scheme 89

Scheme 89: Installation
Scheme 89: Installation

Scheme 90

Scheme 90
Scheme 90

Scheme 91

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Scheme 91

Scheme 92

Scheme 92
Scheme 92
  1. Install the crankshaft damper. Coat the sealing surfaces of the crankshaft damper with clean engine oil. Coat the crankshaft damper keyway with silicone gasket and sealant. Install the crankshaft damper.
  2. Install the crankshaft damper bolt and the washer.
  3. Install and connect the crankshaft position (CKP) sensor.
  4. Install the crankshaft pulley.
  5. Install the splash shield.
  6. Install the RH front wheel.
  7. Lower the vehicle.
  8. Install the accessory drive belt. Refer to «DRIVE BELT ROUTING»(ref-139103-S33285511932002042500000) .

Scheme 93

Scheme 93: Materials
Scheme 93: Materials

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