Engine - 3.0L 4V: Removal & Installation Mercury Sable IV

Removal and Installation

1. Remove the camshaft followers. Refer to «ROLLER FOLLOWERS»(ref-178953-S28317148392005062500000) .
2. Remove the hydraulic lash adjusters.
3. To install, reverse the removal procedure. Lubricate the hydraulic lash adjusters with clean motor oil.

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1. Raise and support the vehicle.
2. Remove the RH front wheel.
3. Remove the RH front inner fender splash shield. Remove the screws and the pin-type retainers.
4. Remove the alternator splash shield.
5. Rotate the accessory drive belt tensioner clockwise and remove the accessory drive belt from the crankshaft pulley.
6. Remove the torque converter inspection cover.
7. Install the flywheel holding tool.
8. Remove the crankshaft pulley.
9. To install, reverse the removal procedure.

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1. Remove the crankshaft pulley. Refer to «CRANKSHAFT PULLEY»(ref-178953-S34628305252005062500000) .
2. Remove the crankshaft damper bolt and washer.
3. Using the special tool, remove the crankshaft damper.

Scheme 1108

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. Refer to «CRANKSHAFT PULLEY»(ref-178953-S34628305252005062500000) .

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1. Remove the crankshaft vibration damper. Refer to «CRANKSHAFT VIBRATION DAMPER»(ref-178953-S25122215182005062500000) .
2. Using the special tool, remove the crankshaft front oil seal.

Scheme 1111

1. Using the special tool, install the crankshaft front oil seal.
2. Install the crankshaft vibration damper. Refer to «CRANKSHAFT VIBRATION DAMPER»(ref-178953-S25122215182005062500000) .

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1. Remove the hydraulic lash adjusters. Refer to «HYDRAULIC LASH ADJUSTER»(ref-178953-S34746699002005062500000) .
2. Pressurize the cylinder using compressed air.
3. Using the special tool, remove the key, retainer, and valve spring.
4. To install, reverse the removal procedure.

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Removal

1. Remove the valve spring. Refer to «VALVE SPRING»(ref-178953-S20714064872005062500000) .
2. Remove the valve seal.

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1. Using the special tool, install the valve seal.
2. Install the valve spring. Refer to «VALVE SPRING»(ref-178953-S20714064872005062500000) .

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1. Remove the LH exhaust manifold to pipe nuts.
2. Remove the coolant tube bracket bolt.
3. Disconnect and unclip the LH heated oxygen sensor (HO2S) electrical connector from the coolant tube.
4. Raise the support the vehicle.
5. Remove the pin-type retainers, bolts and the front splash shield.
6. Remove the lower exhaust manifold nuts.
7. Remove the coolant tube lower bracket bolt.
8. Lower the vehicle.
9. Remove the upper nuts and the exhaust manifold. Discard the gasket.

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1. Position a new gasket and install the exhaust manifold. Tighten the nuts in the sequence shown.
2. Position the coolant tubes and tighten the bolt.
3. Connect the LH HO2S electrical connector.
4. Install the LH exhaust manifold-to-pipe nuts.
5. Raise the vehicle.
6. Install the coolant tube lower bracket bolt.
7. Position the front splash shield and install the pin-type retainers and bolts.

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1. Remove the cowl panel grille.
2. Remove the RH valve cover. Refer to «VALVE COVER RH»(ref-178953-S26541368892005062500000) .
3. Disconnect the exhaust gas recirculation (EGR) tube from the exhaust manifold.
4. Raise and support the vehicle.
5. Remove the RH manifold-to-Y-pipe nuts.
6. Remove the engine support insulator nut.
7. Lower the vehicle.
8. Using the special tool, raise the engine until the exhaust manifold can be removed.
9. Remove the nuts in the sequence shown and remove the exhaust manifold. Discard the gasket.

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1. Position a new gasket and install the exhaust manifold nuts in the sequence shown.
2. Using the special tool, lower the engine.
3. Raise the vehicle.
4. Install the engine support insulator nut.
5. Install the RH exhaust manifold to pipe bolts.
6. Lower the vehicle.
7. Remove the special tools.
8. Install the RH valve cover. Refer to «VALVE COVER RH»(ref-178953-S26541368892005062500000) .
9. Install the cowl panel grille.

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1. Remove the coolant bypass tube. Refer to ENGINE COOLING .
2. Remove the LH exhaust manifold-to-pipe nuts.
3. Remove the water pump. Refer to ENGINE COOLING .
4. Remove the LH camshafts. Refer to «CAMSHAFTS LH»(ref-178953-S23591863292005062500000) .
5. Remove the camshaft followers.
6. Remove the hydraulic lash adjusters.
7. Remove the nuts and remove the exhaust manifold. Discard the gasket.
8. Remove the bolts in the sequence shown and remove the cylinder head. Discard the gasket and the bolts.

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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. Position a new gasket and install the exhaust manifold nuts in the sequence shown.
3. Install the hydraulic lash adjusters. Lubricate the hydraulic lash adjusters with clean motor oil.
4. Install the camshaft followers. Lubricate the camshaft followers with clean motor oil.
5. Install the LH camshafts. Refer to «CAMSHAFTS LH»(ref-178953-S23591863292005062500000) .
6. Install the water pump. Refer to ENGINE COOLING .
7. Install the LH exhaust manifold-to-pipe nuts.
8. Install the coolant bypass tube. Refer to ENGINE COOLING .

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1. Remove the coolant bypass tube. Refer to ENGINE COOLING .
2. Remove the RH camshafts. Refer to «CAMSHAFTS RH»(ref-178953-S23544687882005062500000) .
3. Raise and support the vehicle.
4. Remove the RH exhaust manifold-to-pipe bolts.
5. Lower the vehicle.
6. Disconnect the exhaust gas recirculation (EGR) tube from the exhaust manifold.
7. Remove the camshaft followers.
8. Remove the hydraulic lash adjusters.
9. Remove the nuts in the sequence shown and remove the exhaust manifold. Discard the gasket.
10. Remove the bolts in the sequence shown and remove the cylinder head. Discard the gasket and the bolts.

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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. Position a new gasket and install the exhaust manifold nuts in the sequence shown.
3. Install the hydraulic lash adjusters. Lubricate the hydraulic lash adjusters with clean motor oil.
4. Install the camshaft followers. Lubricate the camshaft followers with clean motor oil.
5. Connect the EGR tube to the exhaust manifold.
6. Raise and support the vehicle.
7. Install the RH exhaust manifold-to-pipe bolts.
8. Lower the vehicle.
9. Install the RH camshafts. Refer to «CAMSHAFTS RH»(ref-178953-S23544687882005062500000) .
10. Install the coolant bypass tube. Refer to ENGINE COOLING .

1. Raise and support the vehicle.
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.

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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 motor oil.

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1. Raise and support the vehicle.
2. Remove the front RH wheel.
3. Remove the RH front inner wheel splash shield. Remove the screws and the pin-type retainer.
4. Remove the dual converter Y-pipe.
5. Secure the exhaust system and remove the jackstand.
6. Drain the engine oil. Install a new drain plug gasket and tighten the drain plug to 27 Nm (20 lb-ft).
7. Remove the bolts, nuts and the engine-to-transaxle bracket.
8. Remove the torque converter inspection cover.
9. Remove the 18 bolts and the oil pan.

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1. Clean all sealing surfaces on the engines and the oil pan with metal surface cleaner.
2. Position a new gasket on the oil pan.
3. Apply a 10 mm (0.40 in) diameter dot of silicone gasket and sealer to the areas indicated.
4. Position the oil pan and hand tighten the oil pan-to-transaxle bolts.
5. Tighten the oil pan bolts in the sequence shown.
6. Tighten the oil pan-to-transaxle bolts.
7. Install the torque converter inspection cover.
8. Position the engine-to-transaxle bracket and install the nuts and the bolt.
9. Position a jackstand and release the exhaust system.
10. Install the dual converter Y-pipe.
11. Install the RH front inner wheel splash shield. Install the screws and the pin-type retainer.
12. Install the RH wheel.
13. Lower the vehicle.
14. Install the LH exhaust manifold-to-pipe nuts.
15. Fill crankcase to correct level with clean motor oil.

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1. Remove the oil pan. Refer to «OIL PAN»(ref-178953-S03297030382005062500000) .
2. Remove the nut, bolts and the oil pump screen and pick-up tube.
3. Remove and inspect the O-ring seal.

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1. Install the O-ring seal.
2. Install the oil pump screen cover and 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.
3. Install the oil pan. Refer to «OIL PAN»(ref-178953-S03297030382005062500000) .

Scheme 1178

1. Remove the oil pump screen cover and tube. Refer to «OIL PUMP SCREEN AND PICKUP TUBE»(ref-178953-S10794452862005062500000) .
2. Remove the nuts and the oil pan baffle.

Scheme 1179

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. Refer to «OIL PUMP SCREEN AND PICKUP TUBE»(ref-178953-S10794452862005062500000) .

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1. Remove the timing drive components. Refer to «TIMING DRIVE COMPONENTS»(ref-178953-S35591184642005062500000) .
2. Remove the oil pump screen cover and tube. Refer to «OIL PUMP SCREEN AND PICKUP TUBE»(ref-178953-S10794452862005062500000) .
3. Remove the damper bolt and the crankshaft sprocket.
4. Remove the bolts in the indicated sequence and remove the oil pump.

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1. Position the oil pump and install the bolts in the sequence shown.
2. Install the crankshaft sprocket.
3. Install the oil pump screen cover and tube. Refer to «OIL PUMP SCREEN AND PICKUP TUBE»(ref-178953-S10794452862005062500000) .
4. Install the timing drive components. Refer to «TIMING DRIVE COMPONENTS»(ref-178953-S35591184642005062500000) .

Scheme 1184

1. Remove the transaxle. Refer to «REMOVAL & INSTALLATION - A/T»(ref-155920) .
2. Remove the bolts and the flexplate.
3. To install, reverse the removal procedure.

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1. Remove the flexplate. Refer to «FLEXPLATE»(ref-178953-S18220787832005062500000) .
2. Using the special tools, remove the crankshaft rear oil seal.

Installation

1. Using the special tools, install the crankshaft rear oil seal.
2. Install the flexplate. Refer to «FLEXPLATE»(ref-178953-S18220787832005062500000) .

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1. Raise and support vehicle.
2. Remove the right front wheel.
3. Remove the engine support insulator nut.
4. Lower the vehicle.
5. Remove the cowl panel grilles.
6. Install the 3-Bar Engine Support.
7. Using the special tools, raise the engine to gain clearance necessary to remove the mount.
8. Remove the RH front inner fender splash shield.
9. Remove the two upper bolts and remove the engine support insulator.
10. To install, reverse the removal procedure.

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1. Raise and support the vehicle.
2. Remove the right front wheel.
3. Remove the engine support insulator nut.
4. Lower the vehicle.
5. Remove the cowl panel grille.
6. Using the special tools, raise the engine to gain clearance to remove the engine support insulator.
7. Raise and support the vehicle.
8. Remove the nut and through bolt and the engine support insulator.
9. To install, reverse the removal procedure.

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1. Disconnect the battery ground cable.
2. Remove the steering shaft pinch bolt.
3. Remove the cowl vent screen.
4. Remove the ground strap bolt.
5. Loosen the bolt and disconnect the powertrain control module (PCM) electrical connector.
6. Disconnect the evaporative emission system hoses.
7. Disconnect the mass air flow (MAF) sensor electrical connector.
8. Remove the air cleaner outlet tube. Disconnect the crankcase ventilation hoses. Loosen the clamps. Remove the tube.
9. Release the clamps and remove the air cleaner cover.
10. Remove the pin-type retainers and the accelerator cable splash shield.
11. Disconnect and unclip the accelerator and cruise control cables.
12. Disconnect the throttle position (TP) sensor and idle air control (IAC) valve electrical connectors.
13. Disconnect the transaxle range sensor electrical connector.
14. Remove the nut and unclip the shifter cable from the bracket.
15. Loosen the bolt and disconnect the harness connector.
16. Drain the cooling system. Refer to ENGINE COOLING .
17. Recover the A/C system. Refer to «REFRIGERANT SYSTEM RECOVERY»(ref-178710-S17932127632005062100000) .
18. Relieve the fuel pressure. Refer to «FUEL SYSTEM PRESSURE RELEASE»(ref-142370-S36646181352002073100000) .
19. Disconnect the low pressure A/C line spring lock coupling at the accumulator/drier. Refer to «SPRING LOCK COUPLING»(ref-178710-S38808236292005062100000) .
20. Remove the heater hose bracket nut.
21. Disconnect the heater hoses.
22. Remove the heater hose bracket nut.
23. Disconnect the coolant recovery bottle hose.
24. Remove the nut and disconnect the starter motor ground cable.
25. Disconnect the upper radiator hose.
26. Disconnect the power steering fluid hose from the reservoir.
27. Remove the two LH exhaust manifold-to-pipe nuts.
28. Raise and support the vehicle.
29. Drain the engine oil.
30. Remove the LH and RH front wheels.
31. Remove the pin-type retainers, bolts, and the front splash shield.
32. Remove the LH and RH inner fender splash shield pin-type retainers and remove the splash shield.
33. Remove the starter cable cover.
34. Remove the nut and disconnect the cable from the starter.
35. Remove the LH and RH sway bar end link nuts.
36. 36. NOTE: Insert a steel rod to prevent the rotor from turning. Remove the halfshaft nut and washer. Discard the nut.
37. 37. NOTE: RH shown, LH similar. Remove the LH and RH ball joint nuts.
38. 38. Using the special tool, separate the control arm from the ball joint.
39. 39. NOTE: RH shown, LH similar. Remove the LH and RH tie rod end cotter pin and castle nut.
40. 40. Using the special tool, separate the tie rod end from the knuckle.
41. 41. Using the special tools, push the halfshaft out of the hub.
42. 42. Remove the RH exhaust manifold-to-pipe bolts.
43. 43. Remove the nuts and the dual converter Y-pipe.
44. 44. Disconnect the power steering and transaxle hoses from the cooler.
45. 45. Disconnect the transaxle cooler line.
46. 46. Remove the nut and disconnect the A/C high pressure line at the condenser.
47. 47. Remove four bolts and remove the radiator support bracket.
48. 48. Disconnect the lower radiator hose and the reservoir supply hose.
49. 49. Disconnect the engine block heater electrical connector.
50. 50. Unclip the engine block heater harness.
51. 51. Remove the torque converter inspection cover.
52. 52. NOTE: Index the flexplate and torque converter by marking one stud. Remove the four torque converter-to-flexplate nuts.
53. 53. Using the special tool, support the subframe.
54. 54. Remove the four subframe bolts and lower the subframe engine/transaxle assembly.
55. 55. Remove the coolant tube lower mounting bolt.
56. 56. Remove the coolant tube mounting bolt and position the tube away from the cylinder head.
57. 57. Remove the engine support brace.
58. 58. Install the special tool.
59. 59. Using the special tools, support the engine and transaxle at the LH and RH cylinder heads.
60. 60. Disconnect the power steering pressure line and remove the clamp bolt.
61. 61. Remove the LH engine mount-to-frame nut.
62. 62. Remove the RH engine mount-to-frame nut.
63. 63. Remove the engine-to-transaxle bracket bolt.
64. 64. Remove the bolts and separate the engine from transaxle.
65. 65. Mount the engine on a suitable engine stand.

Special Tool(s)

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1. Remove the accessory drive belt.
2. Remove the power steering pressure hose.
3. Remove the generator. Disconnect the electrical connector. Remove the bolt. Remove the studs. Remove the generator.
4. Remove the bolts and the power steering pump.
5. Disconnect the A/C compressor. Disconnect the compressor electrical connector. Disconnect the pressure sensor electrical connector. Disconnect the harness from the bracket.
6. Remove the bolts and the A/C compressor.
7. Remove the bolts and the A/C compressor bracket.
8. Disconnect the camshaft position (CMP) sensor electrical connector.
9. Disconnect the harness from the front LH valve cover studs.
10. Disconnect the oil pressure sensor.
11. Install the special tool to hold the flywheel.
12. Remove the crankshaft pulley.
13. Remove the crankshaft damper bolt and washer.
14. Using the special tool, remove the crankshaft vibration damper.
15. Remove the special tool.
16. Remove the crankshaft position (CKP) sensor. Disconnect the electrical connector. Remove the bolt. Remove the sensor.
17. Disconnect the differential pressure feedback exhaust gas recirculation (EGR) transducer electrical connector.
18. Loosen and disconnect the EGR tube from the manifold.
19. Disconnect the throttle position sensor (TPS) and idle air control (IAC) valve electrical connectors.
20. Disconnect the positive crankcase ventilation (PCV) and evaporative emissions (EVAP) hose from the upper intake.
21. Disconnect the exhaust gas recirculation (EGR) vacuum regulator solenoid electrical connector.
22. Remove the bolts and the upper intake manifold. Inspect the gaskets. Discard if damaged.
23. Disconnect the RH radio ignition interference capacitor, heated oxygen sensor (HO2S) electrical connectors and ignition coil electrical connector.
24. Remove the knock sensor bolt.
25. Disconnect the coolant temperature sensor electrical connectors.
26. Disconnect the harness from the coolant tube.
27. Disconnect and unclip the LH HO2S electrical connector from the coolant tube.
28. Disconnect the LH and RH spark plug wires.
29. Remove the stud nuts, and the ignition coil.
30. Disconnect the fuel injector electrical connectors.
31. Remove the bolts and the lower intake manifold.
32. Remove the fuel charging harness. Disconnect the harness from the stud. Remove the harness nut.
33. Remove the nuts and the LH exhaust manifold. Discard the gasket.
34. Remove the nuts and the RH exhaust manifold. Discard the gasket.
35. Remove the nuts and the EVAP tube from the RH valve cover.
36. Remove the water pump drive belt.
37. Disconnect the water pump outlet hose.
38. Remove the bolts and the water pump.
39. Remove the bolts and studs and the RH and LH valve cover. Remove and discard the gaskets.
40. Remove the bolt and stud and the coolant tube.
41. Remove the bolts and studs and the oil pan. Discard the gasket.
42. Remove the bolts, nut and the oil pick-up tube and screen.
43. Remove the nuts and the oil pan baffle.
44. Remove the oil filter.
45. Remove the stud and the oil level indicator and tube.
46. Remove the oil pressure sensor.
47. Remove the bolts, studs, and the front cover.
48. Remove the crankshaft front seal from the front cover.
49. Remove the ignition pulse wheel.
50. Install the damper bolt.
51. Remove the LH and RH spark plugs.
52. 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 re-check.
53. Rotate the crankshaft clockwise 120 degrees to the 3 o'clock position to locate the RH camshafts in the neutral position.
54. Verify that the RH camshafts are correctly positioned.
55. Remove the RH timing chain tensioner arm. Remove the bolts. Remove the tensioner. Remove the tensioner arm.
56. Remove the bolts, RH timing chain guide and the timing chain.
57. 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.
58. Remove the LH timing chain and tensioner arm. Remove the bolts. Remove the tensioner. Remove the tensioner arm.
59. Remove the LH timing chain and timing chain guide.
60. Remove the damper bolt and the crankshaft sprockets.
61. Using the special tools, remove the water pump drive pulley.
62. Using the special tools, remove the camshaft oil seal.
63. Remove the intake camshaft oil seal retainer.
64. Loosen the LH camshaft cap bolts in the indicated sequence and remove the camshaft caps. Tap the caps lightly with a soft faced mallet to loosen the camshaft caps.
65. Loosen the RH camshaft cap bolts in the indicated sequence and remove the camshaft caps. Tap the caps lightly with a soft faced mallet to loosen the camshaft caps.
66. Remove the LH and RH camshafts.
67. Remove the LH and RH camshaft followers. Mark the location of the followers using a permanent-type marker.
68. Loosen the bolts in the indicated sequence and remove the LH and RH cylinder heads. Discard the gaskets.
69. Remove the bolts and the oil separator. Discard the gaskets.
70. Remove the bolts in the indicated sequence and remove the oil pump.
71. Using the special tool, remove the cylinder ridge.
72. Remove the connecting rod cap bolts. Hold the piston/rod assembly to keep it from falling from the engine block.
73. Using the special tool, remove the piston/rod assembly from the engine block.
74. Remove the engine block from the stand and place on a workbench.
75. Remove the bolts and the flexplate.
76. Remove the bolts and studs in the indicated sequence and remove the lower cylinder block.
77. Remove the crankshaft rear main seal and remove the crankshaft.
78. Remove the crankshaft key.
79. Remove the crankshaft thrust bearing from the cylinder block.
80. Remove the bearings from the lower cylinder block.
81. Remove the crankshaft main bearings from the cylinder block.
82. Inspect the cylinder block, lower cylinder block, cylinder heads, pistons and connecting rods. Refer to ENGINE COOLING .