Engine - 3.0L 4V: Specifications Mercury Sable IV

General Specifications

General Specifications (1 Of 7)

General Specifications (2 Of 7)

General Specifications (3 Of 7)

General Specifications (4 Of 7)

General Specifications (5 Of 7)

General Specifications (6 Of 7)

General Specifications (7 Of 7)

1. Cylinder bore diameter Grade 1:89.000-89.010 mm (3.50393-3.504323 in) Grade 2:89.010-89.020 mm (3.504323-3.504717 in) Grade 3:89.020-82.030 mm (3.504717-3.50511 in)
2. 0.250 mm undersize-add 0.125 mm to standard or grade 2 thickness.
3. Measured at 50 mm (1.9685 in) from outer perimeter top of piston to the pin axis.
4. Pin bore and crank bearing bore must be parallel and in same vertical plane within the specified total difference when measured at the ends of a 203 mm bar, 101.5 mm on each side of rod centerline.
5. Specification 82.4 mm (3.2441 in) diameter gauge.
6. With filter change.
7. Newly installed refers to the condition of the "new" drive belt before the engine has made no more than one rotation and before the drive belt has had a change to stretch or seat into the pulley grooves.

Torque Specifiations

TORQUE SPECIFICATIONS

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The 3.0L Duratec is a four-valve-per-cylinder, dual overhead camshaft engine. The engine uses a distributorless ignition system. The cylinder block is a two-piece design with the upper portion housing the cylinders, and a separate lower cylinder block containing the main bearing caps. Both sections are made of aluminum, with metal inserts for the bearing areas and caps. An aluminum oil pan bolts to the bottom of the lower cylinder block and to the transaxle to provide greater strength.

The camshaft are mounted in the cylinder heads and act against a roller follower to open and close the valves. A hydraulic last adjuster is located on one side of the roller follower and the valve tip on the opposite end. The camshafts are driven off the front of each cylinder head by two chains (one each side). Both of the chains are driven by a single sprocket that is located on the crankshaft, just in front of the oil pump.

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Refer to ENGINE SYSTEM GENERAL INFORMATION for basic mechanical concerns.

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1. Remove the air cleaner outlet tube. Remove the hoses. Loosen the clamps. Remove the air cleaner outlet tube.
2. Remove the pin-type retainers and the accelerator cable splash shield.
3. Disconnect the throttle cable and the cruise control cable.
4. Disconnect the throttle position sensor (TPS) and idle air control (IAC) valve electrical connectors.
5. Disconnect the harness from the throttle body stud.
6. Disconnect the exhaust gas recirculation (EGR) vacuum regulator and vacuum supply hoses.
7. Disconnect the positive crankcase ventilation (PCV) and evaporative emissions (EVAP) vacuum hoses.
8. Remove the EGR valve. Disconnect the vacuum hose. Remove the nuts. Remove the bolts. Remove the EGR valve.
9. Remove the EGR vacuum regulator (EVR) valve. Disconnect the vacuum hose. Disconnect the electrical connector. Remove the bolts. Remove the valve.
10. Remove the eight bolts and the upper intake manifold. Remove and discard the gaskets. Clean all mating surfaces.

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1. Position new gaskets in the upper intake manifold.
2. Position the upper intake manifold and install the bolts in the sequence shown.
3. Install the EGR vacuum regulator valve. Position the valve. Install the bolts. Connect the electrical connector. Connect the vacuum hose.
4. Install the EGR valve. Position the EGR. Install the bolts. Install the nuts Connect the vacuum hose.
5. Connect the PCV and EVAP vacuum hoses.
6. Connect the EGR vacuum regulator valve and vacuum supply hoses.
7. Connect the harness to the throttle body stud.
8. Connect the TPS and IAC valve electrical connectors.
9. Connect the throttle cable and the cruise control cable.
10. Install the pin-type retainers and the accelerator cable splash shield.
11. Install the air cleaner outlet tube. Position the air cleaner outlet tube. Install the clamps. Install the hoses.

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1. Remove the upper intake manifold. Refer to «UPPER INTAKE MANIFOLD»(ref-178953-S26818591092005062500000) .
2. Disconnect the fuel line spring lock coupling. Refer to «REMOVAL (SPRING LOCK COUPLING)»(ref-142370-S29761559572002101700000) .
3. Disconnect the fuel injector electrical connectors.
4. Remove the bolts in the sequence shown, and remove the lower intake manifold.
5. Remove and inspect the gaskets from the lower intake manifold.

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1. Install the gaskets in the lower intake manifold.
2. Install the lower intake manifold assembly and tighten the bolts in the sequence shown.
3. Connect the fuel injector electrical connectors.
4. Connect the fuel line spring lock coupling. Refer to «INSTALLATION (SPRING LOCK COUPLING)»(ref-142370-S40199006512002101700000) .
5. Install the upper intake manifold. Refer to «UPPER INTAKE MANIFOLD»(ref-178953-S26818591092005062500000) .

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1. Remove the LH valve cover. Refer to «VALVE COVER LH»(ref-178953-S01843907352005062500000) .
2. Remove the RH valve cover. Refer to «VALVE COVER RH»(ref-178953-S26541368892005062500000) .
3. Remove the power steering pump. Refer to «POWER STEERING PUMP -- CII»(ref-178432-S19825361562005061500000) or «POWER STEERING PUMP -- 3.0L (4V) CIII»(ref-178432-S22150589032005061500000) .
4. Remove the oil pan. Refer to «OIL PAN»(ref-178953-S03297030382005062500000) .
5. Remove the generator. Refer to «REMOVAL & INSTALLATION»(ref-139460-S13057940422002050100000) .
6. Remove the crankshaft vibration damper. Refer to «CRANKSHAFT VIBRATION DAMPER»(ref-178953-S25122215182005062500000) .
7. Disconnect the crankshaft position (CKP) sensor electrical connector. Remove the bolt and the CKP sensor.
8. Remove the pin-type retainers, bolts and the front splash shield.
9. Lower the vehicle.
10. Remove the bolts and the A/C compressor-to-front cover bracket.
11. Remove the bolt and remove the CMP sensor.
12. Remove the belt tensioner.
13. Disconnect the engine cooling fan electrical connector and unclip the wiring harness.
14. Remove the bolt and the engine cooling fan.
15. Install the special tools to support the engine.
16. Remove the two upper A/C compressor bolts.
17. Raise the vehicle.
18. Remove the lower radiator mounting bolt.
19. Remove the two lower A/C compressor bolts and position the A/C compressor aside.
20. Lower the vehicle.
21. Remove the A/C bracket. Remove the bolts. Remove the engine mount bolts. Remove the bracket.
22. Remove the bolts, studs and the engine front cover.

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1. Clean all sealing surfaces with metal surface cleaner.
2. Install three new gaskets in the front cover.
3. Apply a 6 mm (0.24 in) diameter dot of gasket and sealer to the cylinder block-to-lower cylinder block and cylinder head mating surfaces.
4. Position the cover and install the bolts in the sequence shown.
5. Install the A/C bracket. Position the bracket. Install the bolts. Tighten the bolts in two stages. Stage 1: Tighten to 25 Nm (18 lb-ft). Stage 2: Tighten 90 degrees. Install the engine mount bolts.
6. Raise the vehicle.
7. Position the A/C compressor and install the two lower bolts.
8. Install the lower radiator mounting bolt.
9. Lower the vehicle.
10. Install the two upper A/C compressor bolts.
11. Remove the special tools.
12. Position the engine cooling fan and install the bolt.
13. Connect the engine cooling fan electrical connector and clip the wiring harness.
14. Install the belt tensioner.
15. Install the camshaft position (CMP) sensor and install the bolt. Connect the CMP sensor electrical connector.
16. Position the A/C compressor to front cover bracket, and install the bolts.
17. Raise the vehicle.
18. Position the front splash shield and install the pin-type retainers and bolts.
19. Install the crankshaft position (CKP) sensor. Connect the CKP sensor electrical connector.
20. Install the crankshaft vibration damper. Refer to «Crankshaft Vibration Damper»(ref-178953-S25122215182005062500000) .
21. Install the generator Refer to «REMOVAL & INSTALLATION»(ref-139460-S13057940422002050100000) .
22. Install the oil pan. Refer to «OIL PAN»(ref-178953-S03297030382005062500000) .
23. Install the power steering pump. Refer to «POWER STEERING PUMP -- CII»(ref-178432-S19825361562005061500000) or «POWER STEERING PUMP -- 3.0L (4V) CIII»(ref-178432-S22150589032005061500000) .
24. Install the RH valve cover. Refer to «VALVE COVER RH»(ref-178953-S26541368892005062500000) .
25. Install the LH valve cover. Refer to «VALVE COVER LH»(ref-178953-S01843907352005062500000) .
26. Fill the cooling system. Refer to ENGINE COOLING .

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1. Disconnect the crankcase ventilation tube from the valve cover.
2. Remove the water pump drive belt cover.
3. Remove the three LH spark plug wires. Disconnect the spark plug wire holder and position out of the way.
4. Disconnect the wiring harness from the valve cover studs. Position the wiring harness aside.
5. Remove the bolts, studs and the LH valve cover. Remove and discard the gasket.

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1. Position a new gasket on the valve cover.
2. Apply a 5 mm dot of silicone gasket and sealant to the front cover to cylinder head joints.
3. Position the valve cover and install the studs and the bolts in the sequence shown.
4. Connect the wiring harness to the valve cover studs.
5. Install the three LH spark plug wires. Connect the spark plug wire holder.
6. Install the water pump drive belt cover.
7. Connect the crankcase ventilation tube to the valve cover.

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1. Remove the upper intake manifold. Refer to «Upper Intake Manifold»(ref-178953-S26818591092005062500000) .
2. Remove the ignition coil and bracket. Refer to «IGNITION COIL»(ref-142370-S27081734332002101700000) .
3. Remove the RH spark plug wires.
4. Disconnect the differential pressure feedback exhaust gas recirculation (EGR) electrical connector.
5. Remove the wiring harness nut. Disconnect the wiring retainer and position the wiring aside.
6. Disconnect the crankcase ventilation tube from the valve cover.
7. Remove the nut and position the EVAP tube aside.
8. Remove the bolts, studs and the RH valve cover. Remove and discard the gasket.

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1. Remove a new valve cover gasket on the valve cover.
2. Position the valve cover and install the bolt and the studs in the sequence shown.
3. Position the EVAP tube and install the nuts.
4. Connect the crankcase ventilation tube to the valve cover.
5. Position the wiring harness and install the nut. Connect the wiring retainer.
6. Connect the differential pressure feedback EGR electrical connector.
7. Install the RH spark plug wires.
8. Install the upper intake manifold. Refer to «UPPER INTAKE MANIFOLD»(ref-178953-S26818591092005062500000) .

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1. Remove the timing drive components. Refer to «Timing Drive Components»(ref-178953-S35591184642005062500000) .
2. Remove the water pump belt.
3. Using the special tools, remove the water pump drive pulley.
4. Using the special tools, remove the camshaft oil seal.
5. Remove the intake camshaft oil seal retainer.
6. Loosen the bolts for the LH camshaft thrust caps.
7. Loosen the LH camshaft cap bolts in sequence to allow the camshafts to rise from the cylinder head and remove the caps.
8. Remove the camshafts.

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1. Lubricate camshafts with engine oil and carefully position the camshafts into the cylinder head. Align the camshafts as shown.
2. Lubricate the bearing surfaces of the camshaft bearing caps with engine oil. Install the bearing caps and loosely install the bolts.
3. Lubricate the bearing surfaces of the camshaft bearing thrust caps with engine oil. Install the bearing thrust caps and loosely install the bolts.
4. Verify that the camshaft bearing caps are in the correct locations.
5. Tighten the bolts in the sequence shown.
6. Install the camshaft oil seal retainer.
7. Install the new camshaft oil seal. Using the special tools positioned over the oil seal, turn to install the seal.
8. Using the special tool, install the water pump drive pulley.
9. Install the water pump belt.
10. Install the timing drive components. Refer to «Timing Drive Components»(ref-178953-S35591184642005062500000) .

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1. Remove the timing drive components. Refer to «Timing Drive Components»(ref-178953-S35591184642005062500000) .
2. Loosen the bolts for the RH camshaft thrust caps.
3. Loosen the RH camshaft cap bolts in sequence to allow the camshafts to rise from the cylinder head and remove the caps.
4. Remove the camshafts.

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1. Lubricate camshafts with engine oil and carefully position the camshafts into the cylinder head. Align the camshafts as shown.
2. Lubricate the bearing surfaces of the camshaft bearing caps with engine oil and install the bearing caps and loosely install the bolts.
3. Lubricate the bearing surfaces of the camshaft bearing thrust caps with engine oil. Install the bearing thrust caps and loosely install the bolts.
4. Verify that the camshaft bearing caps are in the correct locations.
5. Tighten the bolts in the sequence shown.
6. Install the timing drive components. Refer to «Timing Drive Components»(ref-178953-S35591184642005062500000) .

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1. Remove the engine front cover. Refer to «ENGINE FRONT COVER»(ref-178953-S30531150902005062500000) .
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 re-check.
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 correctly positioned.
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 correctly positioned.
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 as the exhaust cam sprocket timing mark. Continue counting to 42. Mark the link as the intake sprocket timing mark.
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 keyway 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. 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.
15. Remove the crankshaft damper bolt.
16. Install the LH and RH spark plugs.
17. Install the ignition pulse wheel.
18. Install the engine front cover. Refer to «ENGINE FRONT COVER»(ref-178953-S30531150902005062500000) .

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1. Remove the LH and RH valve covers. Refer to «VALVE COVER LH»(ref-178953-S01843907352005062500000) and «VALVE COVER RH»(ref-178953-S26541368892005062500000) .
2. Remove the LH and RH spark plugs.
3. Remover the RH front wheel.
4. Remove the screws, the pin-type retainers, and the RH front inner fender splash shield.
5. Rotate the crankshaft until the camshaft lobe is pointing directly away from the follower.
6. Using the special tool, remove the follower.
7. To install, reverse the removal procedure. Lubricate the camshaft followers with clean motor oil.

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