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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 CIII 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 .
    Fig 1: Crankshaft Upper Main Bearings
    G02155709Courtesy of FORD MOTOR CO.
  1. Install the crankshaft upper main bearings (6333).
    2. NOTE: Lubricate the crankshaft journals and the crankshaft main bearings with clean engine oil.
    Fig 2: Positioning Crankshaft
    G02155710Courtesy 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
    G02155711Courtesy of FORD MOTOR CO.
  3. Install the crankshaft rear oil seal (6701).
  4. Apply two dots of gasket maker between the rear bearing cap and the cylinder block (6010).
    Fig 4: Applying Gasket Maker
    G02155712Courtesy of FORD MOTOR CO.
  5. Install the crankshaft lower main bearings (6A338).
    Fig 5: Installing Crankshaft Lower Main Bearings
    G02155713Courtesy of FORD MOTOR CO.
  6. Install the main bearing caps.
    Fig 6: Installing Main Bearing Caps
    G02155714Courtesy 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 Bolts Torque Sequence
    G02155715Courtesy of FORD MOTOR CO.
  8. If removed, install the camshaft bearings (6261).
    Fig 8: Installing Camshaft Bearings
    G02155716Courtesy of FORD MOTOR CO.
    9. NOTE: Lubricate the camshaft (6250) and the camshaft bearings with clean engine oil.
    Fig 9: Installing Camshaft
    G02155717Courtesy of FORD MOTOR CO.
  9. Install the camshaft.
  10. Install the camshaft thrust plate (6269).
    Fig 10: Installing Camshaft Thrust Plate
    G02155718Courtesy 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
    G02155719Courtesy 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
    G02155720Courtesy of FORD MOTOR CO.
  14. Install the camshaft sprocket bolt.
    Fig 13: Installing Camshaft Sprocket Bolt
    G02155721Courtesy of FORD MOTOR CO.
    15. NOTE: Lubricate the piston and connecting rod assemblies with clean engine oil.
    Fig 14: Installing Piston & Connecting Rod Assemblies
    G02155722Courtesy 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 Caps
    G02155723Courtesy of FORD MOTOR CO.
  18. Install the oil pump (6600).
    Fig 16: Installing Oil Pump
    G02155724Courtesy of FORD MOTOR CO.
    19. NOTE: Lubricate the valve tappets (6500) with clean engine oil.
    Fig 17: Installing Valve Tappets
    G02155725Courtesy of FORD MOTOR CO.
  19. Install the valve tappets.
  20. Install the valve tappet guide plates (6K512).
    Fig 18: Installing Valve Tappet Guide Plates
    G02155726Courtesy of FORD MOTOR CO.
  21. Install the valve tappet guide plate retainer (6K564).
    Fig 19: Installing Valve Tappet Guide Plate Retainer
    G02155727Courtesy of FORD MOTOR CO.
  22. Install new head gaskets (6051).
    Fig 20: Installing New Head Gaskets
    G02155728Courtesy of FORD MOTOR CO.
  23. Position the cylinder heads (6049).
    Fig 21: Positioning Cylinder Heads
    G02155729Courtesy of FORD MOTOR CO.
    24. CAUTION: Cylinder head bolts are of a torque-to-yield design and cannot be reused. Always install new bolts.
    Fig 22: Cylinder Head Torque Sequence
    G02155730Courtesy of FORD MOTOR CO.
  24. Install new 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
  25. Install the oil filter (6714).
    • Advance the filter one half turn after the gasket contacts the sealing surface.
    Fig 23: Installing Oil Filter
    G02155731Courtesy of FORD MOTOR CO.
  26. Install a new engine front cover gasket (6020) and the engine front cover (6019).
    Fig 24: Installing New Engine Front Cover Gasket & Engine Front Cover
    G02155732Courtesy 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 Engine Front Cover & Water Pump Assembly
    G02155733Courtesy of FORD MOTOR CO.
  28. Install the oil pan baffle and the seven retaining nuts.
    Fig 26: Installing Oil Pan Baffle
    G02155734Courtesy of FORD MOTOR CO.
  29. Apply four beads of gasket maker as shown.
    Fig 27: Applying Gasket Maker
    G02155735Courtesy of FORD MOTOR CO.
  30. Position the oil pan gasket onto the oil pan.
    Fig 28: Positioning Oil Pan Gasket Onto Oil Pan
    G02155736Courtesy of FORD MOTOR CO.
  31. Position the oil pan (6675) and hand-start the bolts.
    Fig 29: Positioning Oil Pan & Hand-Starting Bolts
    G02155737Courtesy of FORD MOTOR CO.
  32. 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 30: Tightening Oil Pan Bolts
    G02155738Courtesy of FORD MOTOR CO.
  33. Install the camshaft synchronizer. Refer to CAMSHAFT SYNCHRONIZER (3.0L OHV) .
  34. Apply four beads of silicone gasket and sealant.
    Fig 31: Applying Silicone Gasket & Sealant
    G02155739Courtesy of FORD MOTOR CO.
  35. Position the intake manifold gaskets (9439) and end seals.
    Fig 32: Positioning Intake Manifold Gaskets & End Seals.
    G02155740Courtesy of FORD MOTOR CO.
  36. 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 33: Installing Lower Intake Manifold
    G02155741Courtesy of FORD MOTOR CO.
  37. 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 34: Installing Push Rods & Rocker Arms
    G02155742Courtesy of FORD MOTOR CO.
  38. Apply a bead of silicone gasket and sealant to the four intake-to-cylinder head seams.
    Fig 35: Applying Silicone Gasket & Sealant To Intake-To-Cylinder Head Seams
    G02155743Courtesy of FORD MOTOR CO.
  39. If removed, install the valve cover gaskets (6584).
    Fig 36: Installing Valve Cover Gaskets
    G02155744Courtesy of FORD MOTOR CO.
  40. Install the LH valve rocker arm cover (6582).
    • Install the two bolts.
    • Install the six stud bolts.
    Fig 37: Installing Left Side Valve Cover
    G02155745Courtesy of FORD MOTOR CO.
  41. Install the RH valve rocker arm cover.
    • Install the five bolts.
    • Install the three stud bolts.
    Fig 38: Installing Right Side Valve Cover
    G02155746Courtesy of FORD MOTOR CO.
  42. Position a new exhaust manifold gasket and install the RH exhaust manifold.
    Fig 39: Positioning New Exhaust Manifold Gasket & Installing Right Side Exhaust Manifold
    G02155747Courtesy of FORD MOTOR CO.
  43. 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 40: Exhaust Manifold Bolt Torque Sequence
    G02155748Courtesy of FORD MOTOR CO.
  44. Install the RH exhaust manifold heat shield.
    Fig 41: Installing Right Side Exhaust Manifold Heat Shield
    G02155749Courtesy of FORD MOTOR CO.
  45. Position and connect the RH spark plug wires.
    Fig 42: Connecting Right Side Spark Plug Wires
    G02155750Courtesy of FORD MOTOR CO.
  46. Position a new exhaust manifold gasket (9448) and install the LH exhaust manifold.
    Fig 43: Installing Left Side Exhaust Manifold
    G02155751Courtesy of FORD MOTOR CO.
  47. 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 44: Exhaust Manifold Bolt Torque Sequence
    G02155752Courtesy of FORD MOTOR CO.
  48. Coat the sealing surface of the oil level indicator tube with silicone gasket and sealant.
    Fig 45: Coating Oil Level Indicator Tube With Silicone Gasket & Sealant
    G02155753Courtesy of FORD MOTOR CO.
  49. Install the oil level indicator and tube.
    • Install the nut.
    Fig 46: Installing Oil Level Indicator & Tube
    G02155754Courtesy of FORD MOTOR CO.
  50. Position and connect the LH spark plug wires.
    Fig 47: Connecting Left Side Spark Plug Wires
    G02155755Courtesy of FORD MOTOR CO.
  51. Position the engine control sensor wiring harness and connect the fuel injectors electrical connectors.
    Fig 48: Positioning Engine Control Sensor Wiring Harness & Connecting Fuel Injectors Electrical Connectors
    G02155756Courtesy of FORD MOTOR CO.
  52. Connect the fuel injection pressure (IPR) sensor electrical and vacuum connectors.
    Fig 49: Connecting Fuel Injection Pressure Sensor Electrical & Vacuum Connectors
    G02155757Courtesy of FORD MOTOR CO.
  53. Position the wire harness along the cylinder block.
    • Install the pin-type retainers.
    Fig 50: Connecting Wire Harness Along Cylinder Block
    G02155758Courtesy of FORD MOTOR CO.
  54. Connect the camshaft position (CMP) sensor, engine coolant temperature sensor (ECT), water temperature sensor (WTS) and the oil pressure sensor electrical connectors.
    Fig 51: Connecting Camshaft Position Sensor, Engine Coolant Temperature Sensor, Water Temperature Sensor & Oil Pressure Sensor Electrical Connectors
    G02155759Courtesy of FORD MOTOR CO.
  55. Inspect the upper intake manifold gasket. Install new if required.
    Fig 52: Inspecting Upper Intake Manifold Gasket
    G02155760Courtesy of FORD MOTOR CO.
  56. 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 53: Inspecting Upper Intake Manifold
    G02155761Courtesy of FORD MOTOR CO.
  57. Connect the spark plug holder and the radio suppressor.
    Fig 54: Connecting Spark Plug Holder & Radio Suppressor
    G02155762Courtesy of FORD MOTOR CO.
  58. Connect the Positive Crankcase Ventilation (PCV) valve.
    Fig 55: Connecting PCV Valve
    G02155763Courtesy of FORD MOTOR CO.
  59. Install and connect the oxygen sensor electrical connector.
    Fig 56: Connecting Oxygen Sensor Electrical Connector
    G02155764Courtesy of FORD MOTOR CO.
  60. Connect the EGR vacuum regulator solenoid electrical and vacuum hose connectors, and main vacuum harness connections.
    Fig 57: Connecting EGR Vacuum Regulator Solenoid Electrical & Vacuum Hose Connectors & Main Vacuum Harness Connection
    G02155765Courtesy of FORD MOTOR CO.
  61. Connect the EGR valve vacuum hose.
    Fig 58: Connecting EGR Valve Vacuum Hose
    G02155766Courtesy of FORD MOTOR CO.
  62. Install the upper intake manifold support bracket.
    • Install the bolt.
    • Install the nut.
    Fig 59: Installing Upper Intake Manifold Support Bracket
    G02155767Courtesy of FORD MOTOR CO.
  63. Position the wire harness and install the pin-type retainers.
    Fig 60: Positioning Wire Harness & Installing Pin-Type Retainers
    G02155768Courtesy of FORD MOTOR CO.
  64. Connect the Idle Air Control (IAC) valve and Throttle Position (TP) sensor electrical connectors.
    Fig 61: Connecting Idle Air Control Valve & Throttle Position Sensor Electrical Connectors
    G02155769Courtesy of FORD MOTOR CO.
  65. Install the EGR tube.
    • Connect the electrical connector.
    • Tighten the two compression nuts.
    Fig 62: Installing EGR Tube
    G02155770Courtesy of FORD MOTOR CO.
  66. Install the crankshaft damper and crankshaft pulley. Refer to CRANKSHAFT PULLEY .
  67. Install the Crankshaft Position (CKP) sensor (6C315).
    Fig 63: Installing Crankshaft Position Sensor
    G02155771Courtesy of FORD MOTOR CO.
  68. Connect the CKP sensor electrical connector.
    Fig 64: Connecting Crankshaft Position Sensor Electrical Connector
    G02155772Courtesy of FORD MOTOR CO.
  69. Install the water pump pulley.
    • Install the bolts.
    Fig 65: Installing Water Pump Pulley
    G02155773Courtesy of FORD MOTOR CO.
  70. Install the A/C compressor mounting bracket.
    • Install the bolts.
    Fig 66: Installing A/C Compressor Mounting Bracket
    G02155774Courtesy of FORD MOTOR CO.
  71. Install the A/C compressor.
    • Install the bolts.
    Fig 67: Installing A/C Compressor Mounting Bracket
    G02155775Courtesy of FORD MOTOR CO.
  72. Install the wire harness connectors on the bracket and connect the oxygen sensor electrical connector.
    Fig 68: Connecting Oxygen Sensor Electrical Connector
    G02155776Courtesy of FORD MOTOR CO.
  73. Connect the A/C compressor clutch coil electrical connector.
    Fig 69: Connecting A/C Compressor Clutch Coil Electrical Connector
    G02155777Courtesy of FORD MOTOR CO.
  74. Connect the A/C high pressure cutoff switch electrical connector.
    Fig 70: Connecting A/C High Pressure Cutoff Switch Electrical Connector
    G02155778Courtesy of FORD MOTOR CO.
  75. Install the front end accessory drive bracket assembly.
    Fig 71: Installing Front End Accessory Drive Bracket Assembly
    G02155779Courtesy of FORD MOTOR CO.
  76. Install the support bracket.
    • Install the nut.
    • Install the bolt.
    Fig 72: Installing Support Bracket
    G02155780Courtesy of FORD MOTOR CO.
  77. Install the accessory drive belt tensioner.
    • Install the bolts.
    Fig 73: Installing Accessory Drive Belt Tensioner
    G02155781Courtesy of FORD MOTOR CO.
  78. Install the generator and the bolts.
    Fig 74: Installing Generator
    G02155782Courtesy of FORD MOTOR CO.
  79. Install the generator support bracket.
    • Install the nut.
    • Install the bolt.
    Fig 75: Installing Generator Support Bracket
    G02155783Courtesy of FORD MOTOR CO.
  80. Install the accessory drive belt.
    Fig 76: Installing Accessory Drive Belt
    G02155784Courtesy of FORD MOTOR CO.
  81. Remove the engine from the stand.
  82. Install the flywheel and the bolts.
    Fig 77: Installing Flywheel
    G02155785Courtesy of FORD MOTOR CO.
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