FREE REPAIR MANUALS & LABOR GUIDES 1982-2013 Vehicles
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Home >> Mercury >> 1997 >> Mystique V6-153 2.5L DOHC VIN L SFI >> Repair and Diagnosis >> Engine, Cooling and Exhaust >> Engine >> Cylinder Head Assembly >> Rocker Arm Assembly >> Service and Repair

Rocker Arm Assembly: Service and Repair






REMOVAL
1. Remove valve covers (6582) and valve cover gaskets t6584).
2. Remove crankshaft pulley retaining bolt from front of crankshaft t6303).

CAUTION: Rotate crankshaft to position the crankshaft keyway to the 11 o'clock position and engine to top dead center (TDC) No. 1 cylinder prior to removal and installation of camshafts (6250) and rocker arms (6564) or damage to engine may occur.

3. Rotate crankshaft to TDC No. 1 cylinder.
4. Verify the alignment arrows on the camshafts are aligned. If the arrows on the camshaft are not aligned, rotate the crankshaft one complete revolution.
5. Rotate crankshaft to position crankshaft keyway to the 3 o'clock location. This will position the RH cylinder head camshafts to the neutral position these circle).
6. Rotate water pump drive belt tensioner (6B209) clockwise to release water pump drive belt tension and remove water pump drive belt (8620). Carefully release drive belt tensioner.
7. Remove battery (10655).





8. Using Crankshaft Damper Remover T58P-6316-D and Water Pump Pulley Remover/Replacer T94P-6312-AH with Shaft Protector and Screw, remove water pump drive pulley from LH intake camshaft





9. Remove camshaft rear oil seal retainer bolts and camshaft rear oil seal retainer and gasket from LH cylinder head t6049).

CAUTION: Cylinder head camshaft journal caps and cylinder heads are numbered to make sure that they are assembled in their original position. When removed, keep camshaft journal caps from each cylinder head with the head they were removed from. Do not mix with camshaft journal caps from another cylinder head.

CAUTION: Remove cylinder head camshaft journal thrust caps first to make sure that damage to the cylinder head camshaft journal thrust caps does not occur.

10. Remove cylinder head camshaft journal thrust cap retaining bolts and thrust caps from RH cylinder head.

Camshaft journal cap bolt removal sequence:





11. Loosen remaining RH cylinder head camshaft journal cap bolts 7-8 turns in sequence shown in several passes (approximately 1-2 turns each pass) to allow camshafts to be raised from RH cylinder head. Do not remove retaining bolts completely.

CAUTION: If roller rocker arms are to be reused, mark position of rocker arms to make sure that they are assembled in their original positions.

12. With RH cylinder head camshaft journal caps and camshafts loose on RH cylinder head, remove rocker arms.
13. Rotate crankshaft two revolutions and position crankshaft keyway to the 11 o'clock location. This will position the LH cylinder head camshafts to the neutral position these circle).
14. Verify the alignment arrows on the camshafts are aligned.

CAUTION:
^ Cylinder head camshaft journal caps and cylinder heads are numbered to make sure that they are assembled in their original position. When removed, keep camshaft journal caps from each cylinder head with the head they were removed from Do not mix with camshaft journal caps from another cylinder head.
^ Remove cylinder head camshaft journal thrust caps first to make sure that damage to the cylinder head camshaft journal thrust caps does not occur.

15. Remove cylinder head camshaft journal thrust cap retaining bolts and thrust caps from LH cylinder head.
16. Loosen remaining LH cylinder head camshaft journal cap bolts 7-8 turns in sequence shown in several passes (approximately 1-2 turns each pass) to allow camshafts to be raised from LH cylinder head. Do not remove retaining bolts completely.

CAUTION: If roller rocker arms are to be reused, mark position of rocker arms to make sure that they are assembled in their original positions.

17. With LH cylinder head camshaft journal caps and camshafts loose on LH cylinder head, remove rocker arms.

INSTALLATION

CAUTION: Crankshaft keyway must be at the 11 o'clock location prior to installation of the rocker arms. Failure to do so may lead to engine damage.

NOTE: Make sure rocker arms are installed in their original locations.

1. Lubricate rocker arms with Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford specification ESR-M99C80-A and install rocker arms onto LH cylinder head under camshafts.

CAUTION: Install cylinder head camshaft journal thrust caps last to make sure that damage to camshaft journal thrust caps does not occur.





2. With LH cylinder head rocker arms installed under camshafts, tighten LH cylinder head camshaft journal cap bolts in sequence shown in several passes to 8-12 Nm (71-106 inch lbs.).
3. Align camshafts in LH cylinder head with thrust caps. Install LH cylinder head camshaft journal thrust caps and tighten retaining bolts to 8-12 Nm (71-206 inch lbs.).
4. Rotate crankshaft two revolutions and position crankshaft keyway to the 3 o'clock location. This will position the RH cylinder head camshafts to the neutral position (base circle).

CAUTION: Crankshaft keyway must be at the 3 o'clock location. This will position the camshafts in neutral position prior to installation of the RH cylinder head rocker arms. Failure to do so may lead to engine damage.

NOTE: Ensure rocker arms are installed in their original locations

5. Lubricate rocker arms with Engine Assembly Lubricant and install rocker arms onto RH cylinder head under camshafts.

CAUTION: Install cylinder head camshaft journal thrust caps last to make sure that damage to 1 camshaft journal thrust caps does not occur.

6. With RH cylinder head rocker arms installed under camshafts, tighten RH cylinder head camshaft journal cap bolts in sequence shown in several passes to 8-12 Nm (71-106 inch lbs.)
7. Align camshafts in RH cylinder head with thrust caps Install RH cylinder head camshaft journal thrust caps and tighten retaining bolts to 8-12 Nm (71-206 inch lbs.).
8. Install camshaft rear oil seal and retainer and gasket onto LH cylinder head. Tighten camshaft rear oil seal retainer bolts to 8-12 Nm (71-106 inch lbs.).





9. Using Power Steering Pump Pulley Replacer TO1P-3A733-A, Screw T94P-6312-AH and Replacer Cup T94P-6312-AH, install water pump drive pulley on LH intake camshaft.
10. Rotate water pump drive belt tensioner clockwise and install water pump drive belt. Carefully release drive belt tensioner.
11. Install battery.
12. install the crankshaft pulley retaining bolt. Tighten bolt as follows:
Step ... Tighten to 120 Nm (89 ft. lbs.).
Step ... Loosen minimum of one full turn (360°).
Step ... Tighten to 47-53 Nm (35-39 ft. lbs.).
Step ... Rotate 85-95°.
13. Install valve covers and valve cover gaskets.
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