Engine System - General Information: Other Mercury Sable V

Material

Material

Note. When repairing engines, all parts must be contamination free. If contamination/foreign material is present when repairing an engine, premature engine failure may occur.

Note. Specifications show the expected minimum or maximum condition. Refer to the appropriate Engine article for the procedure.

Note. If a component fails to meet the specifications, it is necessary to refinish it or install a new component. Wear limits are provided as an aid to determine if the component can be refinished. A new component must be installed when any component fails to meet specifications and cannot be refinished.

Note. This article contains information, steps and procedures that may not be specific to this engine.

This article covers general procedures and diagnosis and testing of the engine system, except for exhaust emission control devices, which are covered in the Introduction - Gasoline Engines article.

The engine incorporates the following features: Refer to the appropriate Engine article for the procedure.

1. Crankcase ventilation or breather system
2. Exhaust emission control system
3. Evaporative Emission (EVAP) control system

Some engines incorporate a fail-safe cooling system. Refer to the appropriate Engine article for the procedure.

The engine, fuel system, ignition system, emissions system and exhaust system all affect exhaust emission levels and must be maintained according to the maintenance schedule. Refer to the scheduled Maintenance Guide.

Correct engine identification is required to order parts. Refer to the appropriate Engine article for the procedure.

For complete vehicle and engine identification codes, refer to IDENTIFICATION CODES article.

Special Tools Illustration Tool Name Tool Number 12 Volt Master UV Diagnostic Inspection Kit 164-R0756 or equivalent (Leak Detector) Dial Indicator Gauge with Holding Fixture 100-002 (TOOL-4201-C) or equivalent Engine Cylinder Leak Detection/Air Pressurization Kit 014-00708 or equivalent EngineEAR 107-R2100 or equivalent EngineEAR/ChassisEAR 107-R2102 or equivalent Oil Pressure Gauge 303-088 (T73L-6600-A) Quick Disconnect Compression Tester 134-R0212 or equivalent Vacuum/Pressure Tester 164-R0253 or equivalent Vehicle Communication Module (VCM) and Integrated Diagnostic System (IDS) software with appropriate hardware, or equivalent scan tool

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Scheme 5

Material

There are 2 diagnostic paths that can be followed depending on the type of engine concern. Carry out Inspection and Verification - Engine Performance or Inspection and Verification - NVH.

Component Tests

The following component tests are used to diagnose engine concerns.

Engine Oil Leaks

Note. When diagnosing engine oil leaks, the source of the leak must be positively identified prior to repair. If the vehicle is driven extensively between adding the fluorescent additive and performing the leak test, fan air or wind can spread the leaking oil and make identifying the location of the leak difficult.

Prior to carrying out this procedure, clean the cylinder block, cylinder heads, valve covers, oil pan and flywheel with a suitable solvent to remove all traces of oil.

Engine Oil Leaks - Fluorescent Oil Additive Method

Use the 12 Volt Master UV Diagnostic Inspection Kit to carry out the following procedure for oil leak diagnosis.

1. Add 29.6 ml (1 oz) of gasoline engine oil dye to a minimum of 0.47L (1/2 qt) and a maximum of 0.95L (1 qt) engine oil and fill through the engine oil fill. Thoroughly premix the gasoline engine oil dye or it will not have enough time to reach the crankcase, oil galleries and seal surfaces during this particular 15 minute test. The additive must be mixed well with oil and added through the oil fill. Check the level on the oil level indicator to determine what amount of oil to premix. If it is in the middle of the crosshatch area or below the full mark, use 0.95L (1 qt). If it is at the full mark, use 0.47L (1/2 qt).
2. Run the engine for 15 minutes. Stop the engine and inspect all seal and gasket areas for leaks using the 12 Volt Master UV Diagnostic Inspection Kit. A clear bright yellow or orange area will identify the leak. For extremely small leaks, several hours may be required for the leak to appear.
3. At the end of test, make sure the oil level is within the upper and lower oil indicator marks. Remove oil as necessary if it registers above the full mark.

Leakage Points - Underhood

Examine the following areas for oil leakage

1. Valve cover gaskets
2. Cylinder head gaskets
3. Oil cooler, if equipped
4. Oil filter adapter
5. Engine front cover
6. Oil filter adapter and filter body
7. Oil level indicator tube connection
8. Engine Oil Pressure (EOP) switch

Leakage Points - Under Engine, With Vehicle on Hoist

Examine the following areas for oil leakage

1. Oil pan gaskets
2. Oil pan sealer
3. Engine front cover gasket
4. Crankshaft front seal
5. Crankshaft rear oil seal
6. Oil filter adapter and filter body
7. Oil cooler, if equipped

Leakage Points - With Transmission and Flywheel Removed

Examine the following areas for oil leakage

1. Crankshaft rear oil seal
2. Rear main bearing cap parting line
3. Flexplate mounting bolt holes (with flexplate installed)
4. Pipe plugs at the end of oil passages

Oil leaks at crimped seams in sheet metal parts and cracks in cast or stamped parts can be detected when using the dye method.

Cylinder Leakage Detection

When a cylinder produces a low reading, use of the Engine Cylinder Leak Detection/Air Pressurization Kit will be helpful in pinpointing the exact cause.

The leakage detector is inserted in the spark plug hole, the piston is brought up to Top Dead Center (TDC) on the compression stroke, and compressed air is admitted.

Once the combustion chamber is pressurized, a special gauge included in the kit will read the percentage of leakage. Leakage exceeding 20% is excessive.

While the air pressure is retained in the cylinder, listen for the hiss of escaping air. A leak at the intake valve will be heard in the Throttle Body (TB). A leak at the exhaust valve can be heard at the tailpipe. Leakage past the piston rings will be audible at the PCV connection. If air is passing through a blown head gasket to an adjacent cylinder, the noise will be evident at the spark plug hole of the cylinder into which the air is leaking. Cracks in the cylinder block or gasket leakage into the cooling system may be detected by a stream of bubbles in the radiator.

Excessive Engine Oil Consumption

Nearly all engines consume oil, which is essential for normal lubrication of the cylinder bore walls and pistons and rings. Determining the level of oil consumption may require testing by recording how much oil is being added over a given set of miles.

Customer driving habits greatly influence oil consumption. Mileage accumulated during towing or heavy loading generates extra heat. Frequent short trips, stop-and-go type traffic or extensive idling, prevent the engine from reaching normal operating temperature. This prevents component clearances from reaching specified operating ranges.

The following diagnostic procedure may be utilized to determine internal oil consumption. Make sure that the concern is related to internal oil consumption, and not external leakage, which also consumes oil. Verify there are no leaks before carrying out the test. Once verified, the rate of internal oil consumption can be tested.

A new engine may require extra oil in the early stages of operation. Internal piston-to-bore clearances and sealing characteristics improve as the engine breaks in. Engines are designed for close tolerances and do not require break-in oils or additives. Use the oil specified in the Owner's Literature. Ambient temperatures may determine the oil viscosity specification. Verify that the correct oil is being used for the vehicle in the geographic region in which it is driven.

Basic Pre-checks

1. For persistent complaints of oil consumption, interview the customer to determine the oil consumption characteristics. If possible, determine the brand and grade of oil currently in the oil pan. Look at the oil filter or oil-change station tags to determine if Ford-recommended maintenance schedules have been followed. Make sure that the oil has been changed at the specified mileage intervals. If vehicle mileage is past the first recommended drain interval, the OEM production filter should have been changed.
2. Ask how the most current mileage was accumulated. That is, determine whether the vehicle was driven under the following conditions: Extended idling or curbside engine operation Stop-and-go traffic or taxi operation Towing a trailer or vehicle loaded heavily Frequent short trips (engine not up to normal operating temperature) Excessive throttling or high engine-RPM driving
3. Verify that there are no external leaks. If necessary, review the diagnostic procedure under Engine Oil Leaks in the Diagnosis and Testing portion of this article.
4. Inspect the crankcase ventilation system for: disconnected hoses at the valve cover or TB. loose or missing valve cover fill cap. missing or incorrectly seated engine oil level indicator. incorrect or dirty PCV valve. a PCV valve grommet unseated in the valve cover (if so equipped).
5. Inspect for signs of sludge. Sludge affects PCV performance and can plug or restrict cylinder head drainback wells. It can also increase oil pressure by restricting passages and reducing the drainback capability of piston oil control rings. Sludge can result from either excessive water ingestion in the crankcase or operation at extremely high crankcase temperatures.
6. Inspect the air filter for dirt, sludge or damage. A hole in the filter element will allow unfiltered air to bypass into the air induction system. This can cause premature internal wear (engine dusting), allowing oil to escape past rings, pistons, valves and guides.
7. If the engine is hot or was recently shut down, wait at least 5 minutes to allow the oil to drain back. Ask the customer if this requirement has been followed. Adding oil without this wait period can cause an overfill condition, leading to excessive oil consumption and foaming, which may cause engine damage.
8. Make sure the oil level indicator (dipstick) is correctly and fully seated in the indicator tube. Remove the oil level indicator and record the oil level.

Detailed Pre-checks

1. Check the thermostat opening temperature to make sure that the cooling system is operating at the specified temperature. If it is low, internal engine parts are not running at specified internal operating clearances.
2. Verify the spark plugs are not oil saturated. Oil leaking into one or more cylinders will appear as an oil soaked condition on the plug. If a plug is saturated, a compression check may be necessary at the conclusion of the oil consumption test.

Post Checks, Evaluation and Corrective Action

1. If test results indicate excessive oil consumption, carry out a cylinder compression test. The cylinder compression test should be carried out with a fully charged battery and all spark plugs removed. See the Compression Test Chart in this article for pressure range limits.
2. Compression should be consistent across all cylinders. Refer to the Compression Testing portion of this article. If compression tested within the specifications found in this article, the excessive oil consumption may be due to wear on the valve guides, valves or valve seals.
3. A cylinder leak detection test can be carried out using an Engine Cylinder Leak Detection/Air Pressurization Kit. This can help identify valves, piston rings, or worn valve guides/valve stems, inoperative valve stem seals or other related areas as the source of oil consumption.
4. If an internal engine part is isolated as the root cause, determine if the repair will exceed cost limits and proceed with a repair strategy as required.
5. Once corrective action to engine is complete and verifying that all pre-check items were eliminated in the original diagnosis, repeat the Oil Consumption Test as described above and verify consumption results.

Valve Train Analysis

The following component tests are used to diagnose valve train concerns.

Valve Train Analysis - Engine Off, Valve Cover Removed

Check for damaged or severely worn parts and correct assembly. Make sure correct parts are used with the static engine analysis as follows.

Valve Train Analysis - Camshafts and Valve Tappets

1. Check for broken or damaged parts.
2. Check for loose mounting bolts on camshaft caps.
3. Check for worn or damaged valve tappets.

Valve Train Analysis - Valve Springs, Valve Tappets Removed

1. Check for broken or damaged parts.

Valve Train Analysis - Valve Spring Retainer and Valve Spring Retainer Keys, Valve Tappets Removed

1. Check for correct seating of the valve spring retainer key on the valve stem and in valve spring retainer.
2. Check for correct seating on the valve stem.

Valve Train Analysis - Valves and Cylinder Head, Valve Tappets Removed

1. Check for plugged oil drain-back holes.
2. Check for worn or damaged valve tips.
3. Check for missing or damaged valve stem seals or guide-mounted valve stem seal.
4. Check for missing or worn valve spring seats.

Valve Train Analysis - Camshaft Lobe Lift

Check the lift of each camshaft lobe in consecutive order and make a note of the readings.

1. Remove the spark plugs. Refer to «ENGINE IGNITION - 3.5L»(ref-293498) article.
2. Install the Dial Indicator Gauge with Holding Fixture so the rounded tip of the dial indicator is on top of the camshaft lobe and on the same plane as the valve tappet.
3. Rotate the crankshaft using a breaker bar and socket attached to the crankshaft pulley retainer bolt. Rotate the crankshaft until the base circle of the camshaft lobe is reached.
4. Zero the dial indicator. Continue to rotate the crankshaft until the high-lift point of the camshaft lobe is in the fully-raised position (highest indicator reading).
5. To check the accuracy of the original dial indicator reading, continue to rotate crankshaft until the base circle is reached. The dial indicator reading should be zero. If zero reading is not obtained, repeat Steps 1 through 6.
6. If the lift on any lobe is below specified service limits, install a new camshaft and camshaft valve tappets.
7. Install the spark plugs. Refer to «ENGINE IGNITION - 3.5L»(ref-293498) article.

Sprockets

1. Inspect the sprockets for cracks and worn or chipped teeth.

Camshaft Bearing Journal Diameter

Note. Refer to the appropriate Engine article for the specification.

1. Measure each camshaft journal diameter in 2 directions.

Camshaft Journal to Bearing Clearance - OHC Engines

Note. Refer to the appropriate Engine article for the specification.

1. Measure each camshaft bearing in 2 directions. Subtract the camshaft journal diameter from the camshaft bearing diameter.

Camshaft End Play - OHC Engines

Special Tools Illustration Tool Name Tool Number Dial Indicator Gauge with Holding Fixture 100-002 (TOOL-4201-C) or equivalent

Note. Refer to the appropriate Engine article for the specification.

1. Using the Dial Indicator Gauge with Holding Fixture, measure the camshaft end play.
2. Position the camshaft to the rear of the cylinder head.
3. Zero the Dial Indicator Gauge.
4. Move the camshaft to the front of the cylinder head. Note and record the camshaft end play. If camshaft end play exceeds specifications, install a new camshaft and recheck end play. If camshaft end play exceeds specification after camshaft installation, install a new cylinder head.

Camshaft Lobe Lift

Special Tools Illustration Tool Name Tool Number Dial Indicator Gauge with Holding Fixture 100-002 (TOOL-4201-C) or equivalent

Note. Refer to the appropriate Engine article for the specification.

1. Use the Dial Indicator Gauge with Holding Fixture to measure camshaft intake/exhaust lobe lift. Rotate the camshaft and subtract the lowest indicator reading from the highest indicator reading to figure the camshaft lobe lift.

Camshaft Runout

Special Tools Illustration Tool Name Tool Number Dial Indicator Gauge with Holding Fixture 100-002 (TOOL-4201-C) or equivalent

Note. Refer to the appropriate Engine article for the specification.

1. Using the Dial Indicator Gauge with Holding Fixture, measure the camshaft runout. Rotate the camshaft and subtract the lowest indicator reading from the highest indicator reading.

Crankshaft End Play

Special Tools Illustration Tool Name Tool Number Dial Indicator Gauge with Holding Fixture 100-002 (TOOL-4201-C) or equivalent

Note. Refer to the appropriate Engine article for the specification.

1. Install the Dial Indicator Gauge with Holding Fixture.
2. Position the crankshaft to the rear of the cylinder block.
3. Zero the Dial Indicator Gauge.
4. Move the crankshaft to the front of the cylinder block. Note and record the crankshaft end play.

Valve Stem Diameter

Note. Refer to the appropriate Engine article for the specification.

1. Measure the diameter of each intake and exhaust valve stem at the points shown. Verify the diameter is within specification.

Valve Guide Inner Diameter

Note. Refer to the appropriate Engine article for the specification.

1. Use a ball gauge to determine the inside diameter of the valve guides in 2 directions at the top, middle and bottom of the valve guide.
2. Measure the ball gauge with a micrometer.
3. If the valve guide is not within specifications, install a new cylinder head assembly.

Valve Stem to Valve Guide Clearance

Special Tools Illustration Tool Name Tool Number Clearance Gauge, Valve Guide 303-004 (TOOL-6505-E) or equivalent Dial Indicator Gauge with Holding Fixture 100-002 (TOOL-4201-C) or equivalent

Scheme 6

Note. Refer to the appropriate Engine article for the specification.

Note. The valve stem diameter must be within specifications before checking valve stem-to-valve guide clearance.

1. Install a Valve Guide Clearance Gauge on the valve stem and install a Dial Indicator Gauge with Holding Fixture. Lower the valve until the clearance gauge contacts the upper surface of the valve guide.
2. Move the Valve Guide Clearance Gauge toward the Dial Indicator Gauge with Holding Fixture and zero the Dial Indicator Gauge. Move the Valve Guide Clearance Gauge away from the Dial Indicator Gauge with Holding Fixture and note the reading. The reading will be DOUBLE the valve stem-to-valve guide clearance.

Valve Spring Installed Length

Note. Refer to the appropriate Engine article for the specification.

1. Measure the installed length of each valve spring.

Valve Spring Free Length

Note. Refer to the appropriate Engine article for the specification.

1. Measure the free length of each valve spring.

Valve Spring Squareness

1. Measure the out-of-square on each valve spring. Turn the valve spring and observe the space between the top of the valve spring and the square.

Valve Spring Strength

Special Tools Illustration Tool Name Tool Number Pressure Gauge, Valve/Clutch Spring 303-006 (TOOL-6513-DD) or equivalent

Note. Refer to the appropriate Engine article for the specification.

1. Use the Valve/Clutch Spring Pressure Gauge to check the valve spring for correct strength at the specified valve spring length.

Valve and Seat Refacing Measurements

Note. Refer to the appropriate Engine article for the specification.

Note. After grinding valves or valve seats, check valve clearance.

1. Check the valve head and seat. Check valve angles. Check margin width. Be sure margin width is within specification.
2. Inspect for abnormalities on the valve face and seat. Install a new cylinder head assembly if abnormalities are found.

Valve Seat Width

Note. Refer to the appropriate Engine article for the specification.

1. Measure the valve seat width. If necessary, grind the valve seat to specification. Measure the intake valve seat width. Measure the exhaust valve seat width. Recheck the valve spring installed length after the seats have been ground, and shim the valve springs as necessary to achieve the correct installed spring length.

Valve Seat Runout

Note. Refer to the appropriate Engine article for the specification.

1. Use a valve seat runout gauge to check valve seat runout.

Cylinder Head Distortion

Special Tools Illustration Tool Name Tool Number Feeler Gauge Set 303-D027 (D81L-4201-A) or equivalent

Note. Refer to the appropriate Engine article for the specification.

1. Using a Straightedge and a Feeler Gauge Set, inspect the cylinder head for flatness in the sequence shown.

Cylinder Block Distortion

Special Tools Illustration Tool Name Tool Number Feeler Gauge Set 303-D027 (D81L-4201-A) or equivalent

Note. Refer to the appropriate Engine article for the specification.

1. Use a Straightedge and a Feeler Gauge Set to inspect the cylinder block for flatness.

Powertrain/Drivetrain Mount Neutralizing

Note. Refer to the appropriate article and procedure for special instructions on loosening and tightening mount fasteners.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-293448) article.
2. Loosen, but do not remove, the powertrain/drivetrain mount fasteners.
3. Lower the vehicle.
4. Start the vehicle and move it in forward 0.6-1.2 m (2-4 ft). Then move the vehicle in reverse the same distance.
5. Raise and support the vehicle.
6. Tighten the powertrain/drivetrain mount fasteners.
7. Lower the vehicle.
8. Test the system for normal operation.