Engine - 3.0L 4V: Other Mercury Sable IV

Engine Compression

If one or more cylinders reads low, squirt approximately one tablespoon of engine oil on top of the pistons in the low-reading cylinders. Repeat the compression pressure check on these cylinders.

Compression Test-Interpreting Compression Readings If compression improves considerably, piston rings are faulty. If compression does not improve, valves are sticking or seating incorrectly. If two adjacent cylinders indicate low compression pressures and squirting oil on each piston does not increase compression, the head gasket may be leaking between cylinders. Engine oil or coolant in cylinders could result from this condition. Use the Compression Pressure Limit Chart when checking cylinder compression so that the lowest reading is within 75 percent of the highest reading.

Engine Compression

Cylinder Head

Special Tool(s)

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Piston

Materials

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1. Remove the top compression ring.
2. Remove the second compression ring.
3. Remove the first oil control ring.
4. Remove the oil control spacer ring.
5. Remove the second oil control ring.
6. Remove the clips.
7. Remove the piston pin and the connecting rod from the piston.
8. Clean and inspect the connecting rod and the piston. Refer to «GENERAL PROCEDURES»(ref-178685-S17002255352005062000000) .

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1. Lubricate the piston pin and piston bore with clean motor oil and install the piston pin.
2. Install the clips.
3. Check the piston ring end gap. Refer to «PISTON -- RING END GAP»(ref-178685-S37897000152005062000000) .
4. Lubricate the piston rings with clean motor oil.
5. Install the first oil control ring.
6. Install the oil control spacer ring.
7. Install the second oil control ring.
8. Install the second compression ring. The top of the second compression ring has a "0" on it. Position this side of the ring towards the top of the piston.
9. Install the top compression ring. The top compression ring can be installed with either side up.

Special Tool(s)

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Materials

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1. Clean gasket material, dirt and foreign material from the cylinder block. Wash the cylinder block with a suitable soap and water solution, and dry with compressed air.
2. If removed, install the crankshaft key into the keyway on the crankshaft.
3. Select the crankshaft main bearings for each crankshaft journal. Read the code on the crankshaft flange. Read the code on the cylinder block rear face. The first two numbers after the asterisk make up the code for main No. 1 and the next two numbers for main No. 2. The first two numbers after the second asterisk make up the code for main No. 3 and the last two numbers for main No. 4.
4. Using the chart, choose a bearing for each main. Match the block and crankshaft code with its corresponding column or row, by reading across the "crankshaft" row and down the "block" column. For example: If the block code is *0609*0711* and the crankshaft code is *8480*8082*, main No. 1 should use grade 1 bearings, as determined by the intersection of the 06 block column and the 84 crankshaft row. Mains 2, 3 and 4 should all be grade 2.
5. Install the main bearings into the cylinder block.
6. Install the main bearings into the lower cylinder block.
7. Install the crankshaft thrust bearing.
8. If removed, install the crankshaft key.
9. Apply gasket and sealant to the cylinder block as shown.
10. Apply engine oil to the crankshaft main and rod bearing journals.
11. Position the crankshaft in the cylinder block.
12. Position the lower cylinder block and install the bolts and studs. Tighten the bolts and studs in the sequence shown in four stages. Stage 1: Tighten fasteners 1-8 to 25 Nm (18 lb-ft). Stage 2: Tighten fasteners 9-19 to 40 Nm (30 lb-ft). Stage 3: Tighten fasteners 1-16 90 degrees. Stage 4: Tighten fasteners 17-22 to 25 Nm (18 lb-ft).
13. Using the special tool, measure crankshaft end play.
14. Using the special tools, install the crankshaft rear oil seal.
15. Position the flexplate and install the bolts.
16. Mount the engine on an engine stand.
17. Apply engine oil to the cylinder bores.
18. Using the special tool, install the piston and connecting rod assemblies.
19. Install the connecting rod caps and bolts. Tighten the bolts in two stages. Stage 1: Tighten to 23 Nm (17 lb-ft). Stage 2: Tighten to 43 Nm (32 lb-ft).
20. Position the oil pump and install the bolts in the indicated sequence.
21. 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.
22. Install a new O-ring seal on the oil pump screen and pick-up tube.
23. Install the oil pump screen and pick up tube. Position the oil pump screen and pick up tube. Install the bolts. Install the nut. Tighten the nut in two stages. Stage 1: Tighten to 10 Nm (89 lb-in). Stage 2: Tighten 45 degrees.
24. Position the oil separator, gasket, and install the bolts.
25. Position the LH and RH cylinder heads, gaskets, and install the bolts. Tighten the bolts in the sequence shown in six stages. Stage 1: Tighten to 40 Nm (30 lb-ft). Stage 2: Tighten to 90 Nm (66 lb-ft). 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.
26. Install the crankshaft damper bolt and rotate the crankshaft keyway to the 11 o'clock position to locate top dead center (TDC).
27. Apply engine oil to the LH and RH camshaft followers.
28. Install the LH and RH camshaft followers.
29. Apply engine oil to the LH and RH camshafts.
30. Install the LH and RH camshafts. Locate the camshafts as shown.
31. Position the RH camshaft caps and install the bolts in the sequence shown.
32. Position the LH camshaft caps and install the bolts in the sequence shown.
33. Verify that the camshaft bearing caps are in the correct locations.
34. Install the camshaft oil seal retainer.
35. Install a new camshaft oil seal. Using the special tools positioned over the oil seal, turn to install the seal.
36. Using the special tool, install the water pump drive pulley.
37. Remove the crankshaft damper bolt.
38. Install the crankshaft sprockets.
39. Position the chain tensioner in a soft-jawed vise.
40. Hold the chain tensioner ratchet lock mechanism away from the ratchet stem with a small pick.
41. Slowly compress the timing chain tensioner.
42. Retain the tensioner piston with a 1.5 mm (0.06 in) wire or paper clip.
43. 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 as the exhaust cam sprocket timing mark. Continue counting to 42. Mark the link as the intake sprocket timing mark.
44. 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.
45. Install the LH timing chain tensioner and tensioner arm. Install the tensioner arm. Position the tensioner. Install the bolts.
46. Install the crankshaft damper bolt and rotate the crankshaft clockwise 120 degrees until the crankshaft keyway is in the 3 o'clock position.
47. Verify that the RH camshafts are correctly positioned.
48. 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.
49. Install the RH timing chain tensioner and tensioner arm. Install the tensioner arm. Position the tensioner. Install the bolts.
50. Remove the LH and RH timing chain tensioner piston retaining wires.
51. 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.
52. Remove the crankshaft damper bolt.
53. Install the LH and RH spark plugs.
54. Install the pulse wheel with the key way in the slot stamped 30 or 30RFF only. Install the ignition pulse wheel.
55. Install the special tool to hold the flexplate.
56. Install a new gasket in the front cover.
57. Apply a 6 mm (0.24 in) dot of gasket and sealant to the cylinder block to lower cylinder block and cylinder head mating surfaces.
58. Position the front cover and install the bolts and studs in the sequence shown.
59. Using the special tool, install the crankshaft front oil seal.
60. Apply a 10 mm (0.24 in) dot of gasket and sealant to the front cover-to-cylinder block mating surface.
61. Position the oil pan and gasket and loosely install the bolts and studs in the indicated sequence.
62. Align the transaxle face of the oil pan with the rear of the cylinder block. The pan should be 0.00 mm (0.0 in)-0.25 mm (0.009 in) under flush. Assemblies that are between 0.26 (0.01 in)-0.50 mm (0.019 in) should be shimmed using either one or two 0.25 mm (0.009 in) gold shims. Assemblies that are between 0.51 mm (0.20 in)-0.75 mm (0.029 in) should be shimmed using either one or two 0.50 mm (0.019 in) silver shims. If the pan measures greater than 0.75 mm (0.029 in) or the pan is over flush of the cylinder block, the entire pan assembly must be removed and a new one installed.
63. Tighten the oil pan bolts and studs in the sequence shown.
64. Install the oil pressure sensor.
65. Install a new seal on the oil level indicator tube.
66. Install the oil level indicator tube and install the bolt.
67. Install a new oil filter.
68. Apply gasket and sealant to the end of the crankshaft damper keyway slot.
69. Using the special tool, install the crankshaft vibration damper.
70. Install the crankshaft vibration damper washer and bolt. Tighten the bolt in four stages. Stage 1: Tighten to 120 Nm (89 lb-ft). Stage 2: Loosen one full turn (360 degrees). Stage 3: Tighten to 50 Nm (37 lb-ft). Stage 4: Tighten to 90 Nm (66 lb-ft).
71. Install new gaskets in the valve covers.
72. Apply a 8 mm (0.31 in) dot of gasket and sealant at the cylinder block-to-front cover mating surface of the LH and RH valve covers.
73. Position the RH valve cover and install the bolts and studs in the sequence shown.
74. Position the LH valve cover and install the bolts and studs in the sequence shown.
75. Install the water pump. Position the water pump and install the mounting bolts. Tighten the bolts in two stages. Step 1: Tighten to 10 Nm (89 lb-in). Step 2: Tighten an additional 90 degrees.
76. Connect the water pump outlet hose.
77. Install the water pump drive belt. Refer to «SABLE & TAURUS»(ref-139103-S33029127392002052400000) .
78. Position the evaporative emissions (EVAP) tube and install the nuts.
79. Position the RH exhaust manifold and gasket and install the nuts in the sequence shown.
80. Position the LH exhaust manifold and gasket and install the nuts in the sequence shown.
81. Position the fuel charging harness and install the nut.
82. Install new gaskets in the lower intake manifold.
83. Position the lower intake manifold and install the bolts in the sequence shown.
84. Connect the fuel injector electrical connectors.
85. Install the ignition coil, the stud and the nuts.
86. Connect the LH and RH spark plug wires.
87. Connect the LH HO2S electrical connector.
88. Clip the harness to the coolant tube.
89. Connect the coolant temperature sensor electrical connectors.
90. Position the knock sensor and install the bolt.
91. Connect the RH radio ignition interference capacitor, ignition coil electrical connector and HO2S electrical connectors. Clip the HO2S connectors into place.
92. Install new gaskets in the upper intake manifold, if required.
93. Position the upper intake manifold and install the bolts in the sequence shown.
94. Connect the exhaust gas recirculation (EGR) vacuum regulator solenoid electrical connector.
95. Connect the positive crankcase ventilation (PCV) and evaporative (EVAP) emissions hose from the upper intake manifold.
96. Connect the throttle position (TP) sensor and idle air control (IAC) valve electrical connectors.
97. Connect the exhaust gas recirculation (EGR) tube to the exhaust manifold.
98. Connect the differential pressure feedback exhaust gas recirculation (EGR) transducer electrical connector.
99. Install the crankshaft position (CKP) sensor. Install the sensor. Install the bolt. Connect the electrical connector and clip into place.
100. Install the crankshaft pulley.
101. Remove the special tool.
102. Connect the oil pressure sensor.
103. Connect the harness to the front LH valve cover studs.
104. Connect the camshaft position (CMP) sensor electrical connector.
105. Position the A/C compressor bracket and install the bolts. Tighten the bolts in two stages. Stage 1: Tighten bolts 1 through 5 to 25 Nm (18 lb-ft). Stage 2: Tighten bolts 1 through 4 an additional 90 degrees.
106. Position the A/C compressor and install the bolts.
107. Connect the A/C compressor. Connect the compressor electrical connector. Connect the pressure sensor electrical connector. Connect the harness to the bracket.
108. Position the power steering pump and install the bolts.
109. Install the generator. Position the generator. Install the studs. Install the bolt. Connect the electrical connector.
110. Install the power steering pressure hose.
111. Install the accessory drive belt.

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1. Using the special tools, support the engine and assemble with the transaxle.
2. Install the engine-to-transaxle bolts.
3. Install the LH engine mount nut.
4. Install the RH engine mount nut.
5. Install the engine-to-transaxle bracket bolt.
6. Connect the power steering pressure line and install the clamp bolt.
7. Remove the special tools from the engine.
8. Install the engine support brace.
9. Position the coolant tube to the head, and install the coolant tube mounting bolt.
10. Install the coolant tube lower mounting bolt.
11. Using the special tool, raise the engine/transaxle assembly into the vehicle and loosely install the four subframe bolts.
12. Align the subframe with the body. Install a 19 mm (0.75 in) rod into the front LH sub frame-to-body alignment hole. Hand-tighten the bolt.
13. Align the subframe with the body. Install a 19 mm (0.75 in) rod into the front RH sub frame-to-body alignment hole. Hand-tighten the bolt.
14. Verify the subframe-to-body alignment at both of the alignment holes.
15. Tighten the four subframe bolts.
16. Remove the special tool.
17. Install the four torque converter-to-flexplate nuts.
18. Install the torque converter inspection cover.
19. Clip the engine block heater harness to the engine block.
20. Connect the engine block heater electrical connector.
21. Connect the lower radiator hose and reservoir supply hose.
22. Install the radiator support bracket and bolts.
23. Connect the A/C high pressure line to the condenser and install the nut.
24. Connect the transaxle cooler line.
25. Connect the power steering and transaxle hoses to the cooler.
26. Position the dual converter Y-pipe and install the nuts.
27. Install the RH exhaust manifold-to-pipe bolts.
28. Connect the RH and LH tie rod ends. Install the castle nut. Install the cotter pin.
29. Install the RH and LH ball joint nuts.
30. Install the RH and LH sway bar end link nuts.
31. Position the halfshaft in the hub and install the washer and a new nut.
32. Position the starter cable and install the nut.
33. Install the starter cable cover.
34. Position the inner fender splash shield and install the pin-type retainers.
35. Position the front splash shield and install the bolts and pin-type retainers.
36. Install the LH and RH wheels.
37. Lower the vehicle.
38. Install the two LH exhaust manifold-to-pipe nuts.
39. Connect the power steering fluid hose to the reservoir.
40. Connect the upper radiator hose.
41. Position the starter motor ground cable and install the bolt.
42. Connect the coolant recovery bottle hose.
43. Install the heater hose bracket nut.
44. Connect the heater hoses.
45. Install the heater hose bracket nut.
46. Connect the low pressure A/C line spring lock coupling at the accumulator/drier. Refer to «SPRING LOCK COUPLING»(ref-178710-S38808236292005062100000) .
47. Recharge the A/C system. Refer to «REFRIGERANT SYSTEM CHARGING»(ref-178710-S24401265432005062100000) .
48. Connect the harness and tighten the bolt.
49. Clip the shifter cable to the bracket and install the nut.
50. Connect the transaxle range sensor electrical connector.
51. Connect the throttle position (TP) sensor and idle air control (IAC) valve electrical connectors.
52. Connect the accelerator and cruise control cables.
53. Position the accelerator cable splash shield and install the pin-type retainers.
54. Position the air cleaner cover and clamp into place.
55. Install the air cleaner outlet tube. Install the tube. Tighten the clamps. Connect the crankcase ventilation hoses.
56. Connect the mass air flow (MAF) sensor electrical connector.
57. Connect the evaporative emission system hoses.
58. Connect the powertrain control module (PCM) electrical connector and tighten the bolt.
59. Position the ground strap and install the bolt.
60. Install the cowl vent screen.
61. Install the steering shaft pinch bolt.
62. Fill the engine with clean motor oil.
63. Connect the battery ground cable.
64. Fill the cooling system. Refer to ENGINE COOLING .
65. Fill and bleed the power steering system. Refer to «POWER STEERING SYSTEM FILLING»(ref-178350-S42156665562005061400000) .