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Home >> Mercury >> 1997 >> Sable V6-3.0L VIN U >> Repair and Diagnosis >> Engine, Cooling and Exhaust >> Engine >> Camshaft, Lifters and Push Rods >> Lifter / Lash Adjuster >> Service and Repair >> Removal and Installation

Removal and Installation



NOTE: Ford does not provide a TDC (Top Dead Center) mark or determination procedure for this engine in this vehicle.
ALLDATA users have reported success using aftermarket tools to determine TDC on this engine.






CAUTION
Before replacing a valve tappet for noisy operation, make sure the noise is not caused by:
- improper valve-to-rocker arm clearance.
- worn rocker arms.
- loose rocker arm mounting nuts or studs.
- worn push rods.

REMOVAL
1. Rotate crankshaft to zero degrees top dead center (0° TDC) on the compression stroke.
2. Disconnect battery ground cable. Refer to Starting and Charging.
3. Drain engine cooling system.
4. Remove crankcase ventilation hose from valve cover and air cleaner outlet tube. Refer to Powertrain Management.
5. Remove aspirator hose from air cleaner outlet tube. Remove air cleaner outlet tube from throttle body and engine air cleaner (ACL). Refer to Powertrain Management.

WARNING: COVER THE FUEL PRESSURE RELIEF VALVE WITH A SHOP CLOTH TO PREVENT ACCIDENTAL FUEL SPRAY INTO THE EYES.

6. Carefully relieve fuel pressure at fuel pressure relief valve (Schrader valve). Refer to Powertrain Management.
7. Disconnect fuel tubes. Refer to Powertrain Management.
8. Mark location and remove vacuum lines.
9. Disconnect engine control sensor wiring from camshaft position sensor (CMP sensor), throttle position sensor (TP sensor), idle air control valve (IAC valve), engine coolant temperature sensor (ECT sensor), ignition coil, water temperature indicator sender unit, EGR backpressure transducer and EGR vacuum regulator solenoid electrical connectors.
10. Disconnect upper radiator hose from water hose connection. After loosening retaining clamp, use a twisting motion on upper radiator hose to loosen from water hose connection.
11. Remove brace from generator mounting bracket to throttle body stud bolt.
12. Remove EGR valve to exhaust manifold tube. Refer to Exhaust System.
13. Remove upper intake manifold.
14. Disconnect engine control sensor wiring retainers from valve cover stud bolts. Carefully disconnect engine control sensor wiring from each fuel injector and remove engine control sensor wiring from engine.
15. Disconnect heater water hoses. Refer to Cooling System.
16. Remove ignition wires from spark plugs. Refer to Powertrain Management. Remove wire harness retainers from valve cover bolts.
17. Remove ignition coil from rear of LH cylinder head.
18. Remove valve covers.
19. Loosen cylinder No.3 intake valve rocker arm seat retaining bolt and rotate rocker arm off of push rod and away from top of valve stem. Remove push rod.

NOTE: Lower intake manifold may be removed with fuel injection supply manifold and fuel injectors in place as an assembly.

20. Remove lower intake manifold retaining bolts using a Torx head socket. Before attempting to remove intake manifold, break seal between intake manifold and cylinder block:
a. Wedge a large pry bar or similar tool between intake manifold and cylinder block.
b. Pry upward on tool using area between water hose connection and transaxle as a leverage point.
21. Loosen rocker arm seat retaining bolt of valve tappet to be replaced enough to allow rocker arm to be lifted off the push rod and rotated to one side.

NOTE: Push rods should be installed in their original location and position during reassembly.

22. Remove push rods. If more than one is removed, identify the location of each push rod.
23. Loosen two valve tappet guide plate and retainer bolts. Remove tappet guide plate and retainer from valve tappet valley.
24. Remove valve tappet guide plate from valve tappets by lifting straight up.

NOTE: If the valve tappets are stuck in the bore(s) due to excessive varnish or gum deposits, it may be necessary to use a claw-type tool to aid removal. Rotate the valve tappet back and forth to loosen it from the deposits.

25. To remove, grasp valve tappet and pull in line with bore.

INSTALLATION

CAUTION: Aluminum components gouge easily which may cause gasket leaks. Always use care when scraping aluminum gasket surfaces.

NOTE: Lightly oil all retaining bolt and stud bolt threads before installation.

1. Clean mating gasket surfaces of lower intake manifold and cylinder head. Lay a clean cloth or shop cloth in the valve tappet valley to catch any gasket material. After scraping, carefully lift cloth from valve tappet valley to prevent any particles from entering oil drain holes or cylinder head. Use a suitable solvent to remove old silicone sealant.
2. Lubricate valve tappets and bore with Engine ASSEMBLY Lubricant D9AZ-19579-D or equivalent meeting Ford specification ESR-M99C80-A.
3. Install valve tappet into bore.
4. Aligning valve tappet flats, install valve tappet guide plate. Install valve tappet guide plate with word "UP" and/or button visible.
5. Install tappet guide plate and retainer over valve tappet guide plate. Retainer orientation is not important. Loosely install two retaining bolts. Tighten bolts to 10-14 Nm (89-123 inch lbs.).
6. Install the lower intake manifold.

NOTE: Rocker arm seats must be fully seated into cylinder head and push rod must be fully seated in rocker arm and valve tappet sockets prior to final tightening.

7. Lubricate removed push rods with Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford specification ESR-M99C80-A.
8. Position push rod into engine block and center on valve tappet.
9. Lubricate removed rocker arms with Engine Assembly Lubricant.
10. Move rocker arms into position with push rods and snug rocker arm seat retaining bolt. Rotate crankshaft to position camshaft lobes straight down and away from valve tappet. Tighten rocker arms in two steps:
A. Tighten retaining bolt for rocker arm seats into cylinder head to 7-15 Nm (6-11 ft. lbs.).
B. Final tighten rocker arm seat retaining bolt to 26-38 Nm (20-28 ft. lbs.) in any position.
11. Install valve covers.
12. Install engine control sensor wiring to each fuel injector. Secure wire harness retainers to valve cover stud bolts.
13. Install ignition coil to rear of LH cylinder head. Tighten retaining bolts to 40-55 Nm (30-40 ft. lbs.).
14. Install ignition wire harness retainers to valve cover stud bolts and connect ignition wires to spark plugs and ignition coil.
15. Install upper intake manifold.
16. Install EGR valve to exhaust manifold tube from intake manifold to EGR valve. Refer to Exhaust System.
17. Install and connect fuel tubes. Refer to Powertrain Management.
18. Install fuel tube safety retaining clips.
19. Install upper radiator hose and heater water hoses. Tighten retaining clamps securely.
20. Connect vacuum lines to premarked locations.
21. Connect electrical connections to idle air control valve, engine coolant temperature sensor, throttle position sensor, EGR backpressure transducer, EGR vacuum regulator solenoid, ignition coil and water temperature indicator sender unit.
22. Fill and bleed cooling system with specified coolant mixture.

NOTE: Engine coolant is corrosive to all engine bearing material. Replacing oil after removal of a coolant carrying component prevents damage.

23. Fill crankcase with the correct viscosity and amount of engine oil.
24. Install air cleaner outlet tube to throttle body and engine air cleaner.
25. Install crankcase ventilation tube to valve cover and air cleaner outlet tube. Install aspirator hose to air cleaner outlet tube.
26. Connect battery ground cable.
27. Start engine and check for coolant, oil, fuel and vacuum leaks.
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