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Home >> Ford >> 2002 >> Taurus SES, 3.0 S >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 2 (Engine - 3.0L 2V) >> Assembly >> Engine - with CII Power Steering System >> Engine Assembly

Engine Assembly

WARNING: This page is about a different variant/trim than selected.
    CAUTION: The crankshaft main bearings are precision fit. Refer to CRANKSHAFT MAIN BEARING JOURNAL - CLEARANCE for checking clearances.
    Fig 1: Installing Upper Crankshaft Main Bearing
    G02155630Courtesy of FORD MOTOR CO.
  1. Install the upper crankshaft main bearings (6333).
    2. NOTE: Lubricate the crankshaft journals and the crankshaft main bearings with clean engine oil.
    Fig 2: Positioning Crankshaft
    G02155631Courtesy of FORD MOTOR CO.
  2. Position the crankshaft (6303).
    3. NOTE: Lubricate the inner and outer sealing surfaces of the crankshaft rear oil seal with clean engine oil.
    Fig 3: Installing Crankshaft Rear Oil Seal
    G02155632Courtesy of FORD MOTOR CO.
  3. Install the crankshaft rear oil seal (6701).
  4. Apply two dots of gasket marker between the rear bearing cap and the cylinder block (6010).
    Fig 4: Marking Rear Bearing Cap & Cylinder Block
    G02155633Courtesy of FORD MOTOR CO.
  5. Install the lower crankshaft main bearings (6A338).
    Fig 5: Installing Lower Crankshaft Main Bearings
    G02155634Courtesy of FORD MOTOR CO.
  6. Install the main bearings caps.
    Fig 6: Installing Main Bearings Caps
    G02155635Courtesy of FORD MOTOR CO.
  7. Install the main bearing cap bolts in the sequence shown.
    • Tighten the bolts in pairs.
    Fig 7: Main Bearing Cap Bolt Torque Sequence
    G02155636Courtesy of FORD MOTOR CO.
  8. If removed, install the camshaft bearings (6261).
    Fig 8: Identifying Camshaft Bearing
    G02155637Courtesy of FORD MOTOR CO.
    9. NOTE: Lubricate the camshaft (6250) and the camshaft bearings with clean engine oil.
    Fig 9: Installing Camshaft
    G02155638Courtesy of FORD MOTOR CO.
  9. Install the camshaft.
  10. Install the camshaft thrust plate (6269).
    Fig 10: Installing Camshaft Thrust Plate
    G02155639Courtesy of FORD MOTOR CO.
  11. Inspect the camshaft end play. Refer to CAMSHAFT - END PLAY, PUSH ROD ENGINES .
  12. Align the timing marks.
    Fig 11: Aligning Timing Marks
    G02155640Courtesy of FORD MOTOR CO.
  13. Install the timing chain (6268), the camshaft sprocket (6256) and the crankshaft sprocket (6306) as an assembly.
    Fig 12: Installing Timing Chain, Camshaft Sprocket & Crankshaft Sprocket As An Assembly.
    G02155641Courtesy of FORD MOTOR CO.
  14. Install the camshaft sprocket bolt.
    Fig 13: Installing Camshaft Sprocket Bolt
    G02155642Courtesy of FORD MOTOR CO.
    15. NOTE: Lubricate the piston and connecting rod assemblies with clean engine oil.
    Fig 14: Installing Piston & Connecting Rod Assemblies
    G02155643Courtesy of FORD MOTOR CO.
  15. Install the piston and connecting rod assemblies (6100).
    16. NOTE: Lubricate the connecting rod bearings (6211) with clean engine oil.
  16. Install the connecting rod bearings (6211).
  17. Install the connecting rod caps (6210) and nuts.
    • Tighten the nuts in pairs.
    Fig 15: Installing Connecting Rod Bearings
    G02155644Courtesy of FORD MOTOR CO.
  18. Install the oil pump (6600).
    Fig 16: Installing Oil Pump
    G02155645Courtesy of FORD MOTOR CO.
    19. NOTE: Lubricate the valve tappets (6500) with clean engine oil.
    Fig 17: Installing Valve Tappets
    G02155646Courtesy of FORD MOTOR CO.
  19. Install the valve tappets.
  20. Install the valve tappet guide plates (6K512).
    Fig 18: Installing Valve Tappet Guide Plates
    G02155647Courtesy of FORD MOTOR CO.
  21. Install the valve tappet guide plate retainer (6K564).
    Fig 19: Installing Valve Tappet Guide Plate Retainer
    G02155648Courtesy of FORD MOTOR CO.
  22. Install new head gaskets (6051).
    Fig 20: Installing New Head Gaskets
    G02155649Courtesy of FORD MOTOR CO.
  23. Position the cylinder heads (6049).
    Fig 21: Positioning Cylinder Heads
    G02155650Courtesy of FORD MOTOR CO.
  24. Install the bolts. Tighten the bolts in the sequence shown in five stages:
    • Stage 1: Tighten The Bolts To 50 Nm (37 Lb-In)
    • Stage 2: Loosen The Bolts One Full Turn
    • Stage 3: Tighten To 30 Nm (22 Lb-Ft)
    • Stage 4: Rotate 85-95 Degrees
    • Stage 5: Rotate An Additional 85-95 Degrees
    Fig 22: Cylinder Head Bolt Torque Sequence
    G02155651Courtesy of FORD MOTOR CO.
  25. Install the oil filter (6714).
    • Advance the filter one half turn after the gasket contacts the sealing surface.
    Fig 23: Installing Oil Filter
    G02155652Courtesy of FORD MOTOR CO.
  26. Install a new engine front cover gasket (6020) and the engine front cover (6019).
    Fig 24: Installing New Front Cover Gasket
    G02155653Courtesy of FORD MOTOR CO.
  27. Install the engine front cover and water pump assembly.
    1. Apply pipe sealant with Teflon® to the bolts indicated.
    2. Install the bolts.
    Fig 25: Installing Front Cover Assembly
    G02155654Courtesy of FORD MOTOR CO.
  28. Apply four beads of gasket maker as shown.
    Fig 26: Applying Gasket Maker
    G02155655Courtesy of FORD MOTOR CO.
  29. Position the oil pan gasket (6710).
    Fig 27: Positioning Oil Pan Gasket
    G02155656Courtesy of FORD MOTOR CO.
  30. Position the oil pan (6675) and hand-start the bolts.
    Fig 28: Installing Oil Pan Bolts
    G02155657Courtesy of FORD MOTOR CO.
  31. Install the bolts. Tighten the bolts in four stages:
    • Stage 1: Tighten The Four Corner Bolts To 12 Nm (9 Lb-In)
    • Stage 2: Tighten The Remaining Bolts To 12 Nm (9 Lb-In)
    • Stage 3: Loosen All The Bolts One Turn
    • Stage 4: Tighten All The Bolts To 12 Nm (9 Lb-In)
    Fig 29: Tightening Oil Pan Bolts
    G02155658Courtesy of FORD MOTOR CO.
  32. Install the camshaft synchronizer. Refer to CAMSHAFT SYNCHRONIZER (3.0L OHV) .
  33. Apply four beads of silicone gasket and sealant.
    Fig 30: Applying Silicone To Intake Manifold
    G02155659Courtesy of FORD MOTOR CO.
  34. Position the intake manifold gaskets (9439) and end seals.
    Fig 31: Positioning Intake Manifold Gaskets & End Seals
    G02155660Courtesy of FORD MOTOR CO.
  35. Install the lower intake manifold (9424). Tighten the bolts in two stages:
    • Stage 1: Tighten To 15 Nm (11 Lb-Ft)
    • Stage 2: Tighten To 32 Nm (24 Lb-Ft)
    Fig 32: Installing Lower Intake Manifold
    G02155661Courtesy of FORD MOTOR CO.
  36. Install the push rods (6565) and the rocker arms (6564).
    • Install the push rods.
    • Install the rocker arms.
    • Tighten the bolts in two stages:
      • Stage 1: Tighten To 10 Nm (89 Lb-In)
      • Stage 2: Tighten To 32 Nm (24 Lb-Ft)
    Fig 33: Installing Push Rods & Rocker Arms
    G02155662Courtesy of FORD MOTOR CO.
  37. Apply a bead of silicone gasket and sealant to the four intake-to-cylinder head seams.
    Fig 34: Identifying Silicone Gasket And Sealant
    G02155663Courtesy of FORD MOTOR CO.
  38. If removed, install the valve cover gaskets (6584).
    Fig 35: Installing Valve Cover Gaskets
    G02155664Courtesy of FORD MOTOR CO.
  39. Install the LH valve rocker arm cover (6582).
    • Install the two bolts.
    • Install the six stud bolts.
    Fig 36: Installing Left Side Valve Cover
    G02155665Courtesy of FORD MOTOR CO.
  40. Install the RH valve rocker arm cover.
    • Install the five bolts.
    • Install the three stud bolts.
    Fig 37: Installing Right Side Valve Cover
    G02155666Courtesy of FORD MOTOR CO.
  41. Position a new exhaust manifold gasket and install the RH exhaust manifold.
    Fig 38: Positioning New Exhaust Manifold Gasket & Installing Right Side Exhaust Manifold
    G02155667Courtesy of FORD MOTOR CO.
  42. Install the bolts.
    • Tighten the bolts in the sequence shown, in two stages:
      1. Stage 1: Tighten To 10 Nm (89 Lb-In)
      2. Stage 2: Tighten To 22 Nm (16 Lb-Ft)
    Fig 39: Exhaust Manifold Bolt Torque Sequence
    G02155668Courtesy of FORD MOTOR CO.
  43. Install the RH exhaust manifold heat shield.
    • Install the bolts.
    Fig 40: Installing Right Side Exhaust Manifold Heat Shield
    G02155669Courtesy of FORD MOTOR CO.
  44. Position and connect the RH spark plug wires.
    Fig 41: Installing Right Side Spark Plug Wires
    G02155670Courtesy of FORD MOTOR CO.
  45. Position a new exhaust manifold gasket (9448) and install the LH exhaust manifold.
    Fig 42: Installing Left Side Exhaust Manifold
    G02155671Courtesy of FORD MOTOR CO.
  46. Install the four bolts and two stud bolts. Tighten the bolts in sequence in two stages:
    1. Stage 1: Tighten To 10 Nm (89 Lb-In)
    2. Stage 2: Tighten To 22 Nm (16 Lb-Ft)
    Fig 43: Exhaust Manifold Torque Sequence
    G02155672Courtesy of FORD MOTOR CO.
  47. Coat the sealing surface of the oil level indicator tube with silicone gasket and sealant.
    Fig 44: Coating Oil Level Indicator Tube With Silicone Gasket & Sealant
    G02155673Courtesy of FORD MOTOR CO.
  48. Install the oil level indicator and tube.
    • Install the nut.
    Fig 45: Installing Oil Level Indicator & Tube
    G02155674Courtesy of FORD MOTOR CO.
  49. Position and connect the LH spark plug wires.
    Fig 46: Installing Left Side Spark Plug Wires
    G02155675Courtesy of FORD MOTOR CO.
  50. Position the engine control sensor wiring harness and connect the fuel injectors electrical connectors.
    Fig 47: Connecting Fuel Injector Connectors
    G02155676Courtesy of FORD MOTOR CO.
  51. Position the wire harness along the cylinder block.
    • Install the pin-type retainers.
    Fig 48: Positioning Wire Harness Along Cylinder Block
    G02155677Courtesy of FORD MOTOR CO.
  52. Connect the camshaft position (CMP) sensor, engine coolant temperature sensor (ECT), water temperature sensor (WTS) and the oil pressure sensor electrical connectors.
    Fig 49: Connecting Camshaft Position Sensor, Engine Coolant Temperature Sensor, Water Temperature Sensor & Oil Pressure Sensor Electrical Connectors
    G02155678Courtesy of FORD MOTOR CO.
  53. Inspect the upper intake manifold gasket. Install new if required.
    Fig 50: Inspecting Upper Intake Manifold Gasket
    G02155679Courtesy of FORD MOTOR CO.
  54. Install the upper intake manifold.
    • Tighten the bolts in the sequence shown in two stages:
      1. Stage 1: Tighten Hand Tight
      2. Stage 2: Tighten To 10 Nm (89 Lb-Ft)
    Fig 51: Installing Upper Intake Manifold
    G02155680Courtesy of FORD MOTOR CO.
  55. Connect the Positive Crankcase Ventilation (PCV) valve.
    Fig 52: Connecting PCV Valve
    G02155681Courtesy of FORD MOTOR CO.
  56. Connect the secondary air injection control solenoid.
    • Connect the electrical connector.
    • Connect the vacuum tube.
    Fig 53: Connecting Secondary Air Injection Control Solenoid
    G02155682Courtesy of FORD MOTOR CO.
  57. Install and connect the oxygen sensor electrical connector.
    Fig 54: Connecting Oxygen Sensor Electrical Connector
    G02155683Courtesy of FORD MOTOR CO.
  58. Connect the electronic vacuum regulator (EVR) and main vacuum harness connections.
    • Connect the vacuum harness to the upper intake manifold.
    • Connect the EVR vacuum tube.
    • Connect the EVR electrical connector.
    Fig 55: Connecting Electronic Vacuum Regulator & Main Vacuum Harness Connections
    G02155684Courtesy of FORD MOTOR CO.
  59. Connect the EGR valve vacuum tube.
    Fig 56: Connecting EGR Valve Vacuum Tube
    G02155685Courtesy of FORD MOTOR CO.
  60. Install the upper intake manifold support bracket.
    • Install the bolt.
    • Install the nut.
    Fig 57: Installing Upper Intake Manifold Support Bracket
    G02155686Courtesy of FORD MOTOR CO.
  61. Connect the vacuum tube to the secondary air injection valve.
    Fig 58: Connecting Vacuum Tube To Secondary Air Injection Valve
    G02155687Courtesy of FORD MOTOR CO.
  62. Position the wire harness and install the pin-type retainers.
    Fig 59: Positioning Wire Harness & Installing Pin-Type Retainers
    G02155688Courtesy of FORD MOTOR CO.
  63. Connect the Idle Air Control (IAC) valve and Throttle Position (TP) sensor electrical connectors.
    Fig 60: Connecting Idle Air Control Valve & Throttle Position Sensor Electrical Connectors
    G02155689Courtesy of FORD MOTOR CO.
  64. Install the EGR tube.
    • Connect the electrical connector.
    • Tighten the two compression nuts.
    Fig 61: Installing EGR Tube
    G02155690Courtesy of FORD MOTOR CO.
  65. Install the crankshaft damper and crankshaft pulley. Refer to CRANKSHAFT PULLEY .
  66. Install the Crankshaft Position (CKP) sensor (6C315).
    Fig 62: Installing Crankshaft Position Sensor
    G02155691Courtesy of FORD MOTOR CO.
  67. Connect the CKP sensor electrical connector.
    Fig 63: Connecting Crankshaft Position Sensor
    G02155692Courtesy of FORD MOTOR CO.
  68. Install the water pump pulley.
    • Install the bolts.
    Fig 64: Installing Water Pump Pulley
    G02155693Courtesy of FORD MOTOR CO.
  69. Install the A/C compressor mounting bracket.
    • Install the bolts.
    Fig 65: Installing A/C Compressor Mounting Bracket
    G02155694Courtesy of FORD MOTOR CO.
  70. Install the A/C compressor.
    • Install the bolts.
    Fig 66: Installing A/C Compressor
    G02155695Courtesy of FORD MOTOR CO.
  71. Install the wire harness connectors on the bracket and connect the oxygen sensor electrical connector.
    Fig 67: Installing Wire Harness Connectors On Bracket
    G02155696Courtesy of FORD MOTOR CO.
  72. Connect the A/C compressor clutch coil electrical connector.
    Fig 68: Connecting A/C Compressor Clutch Coil Electrical Connector
    G02155697Courtesy of FORD MOTOR CO.
  73. Connect the A/C high pressure cutoff switch electrical connector.
    Fig 69: Connecting A/C High Pressure Cutoff Switch Electrical Connector
    G02155698Courtesy of FORD MOTOR CO.
  74. Install the power steering pump and bracket assembly.
    • Install the nuts.
    • Install the bolt.
    Fig 70: Installing Power Steering Pump & Bracket Assembly
    G02155699Courtesy of FORD MOTOR CO.
  75. Install the support bracket.
    • Install the nut.
    • Install the bolt.
    Fig 71: Installing Support Bracket
    G02155700Courtesy of FORD MOTOR CO.
  76. Install the accessory drive belt tensioner.
    • Install the bolt.
    Fig 72: Installing Accessory Drive Belt Tensioner
    G02155701Courtesy of FORD MOTOR CO.
  77. Install the accessory drive belt idler pulley.
    • Install the bolt.
    Fig 73: Installing Accessory Drive Belt Idler Pulley
    G02155702Courtesy of FORD MOTOR CO.
  78. Install the generator.
    • Install the stud bolt.
    Fig 74: Installing Generator
    G02155703Courtesy of FORD MOTOR CO.
  79. Install the generator support bracket.
    • Install the nut.
    • Install the bolt.
    Fig 75: Installing Generator Support Bracket
    G02155704Courtesy of FORD MOTOR CO.
  80. Connect the generator electrical connectors.
    Fig 76: Connecting Generator Electrical Connectors
    G02155705Courtesy of FORD MOTOR CO.
  81. Install the accessory drive belt.
    Fig 77: Installing Accessory Drive Belt
    G02155706Courtesy of FORD MOTOR CO.
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