FREE REPAIR MANUALS & LABOR GUIDES 1982-2013 Vehicles
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Home >> Mercury >> 1998 >> Sable V6-183 3.0L VIN U FI >> Repair and Diagnosis >> Engine, Cooling and Exhaust >> Engine >> Camshaft, Lifters and Push Rods >> Camshaft >> Service and Repair >> Installation

Installation


Rocker Arm & Valve Locations:






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 rubber sealant. Clean gasket mating surfaces of engine front cover to cylinder block and oil pan to cylinder block.

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

NOTE: Lightly oil all bolt and stud bolt threads with clean engine oil meeting Ford specification WSS-M2C153-G before installation except those specified for special sealant.

2. Inspect camshaft bearings for wear.
3. Clean and inspect all components before installation.
4. Lubricate camshaft lobes, distributor drive gear and bearing surfaces liberally with Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford specification ESR-M99C80-A. Coat entire camshaft drive gear with Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford specification ESR-M99C80-A. Carefully slide camshaft through camshaft bearings into cylinder block. Keep camshaft in line with front camshaft bearing.

CAUTION: If a new camshaft and/or a camshaft position sensor housing is installed, ALWAYS add the rest of the Engine Assembly Lubricant D9AZ-19579-D or equivalent (pint) meeting Ford specification ESR-M99C80-A to the engine oil by pouring it through the distributor hole onto the camshaft drive gear. Run engine at idle for five minutes prior to driving vehicle.





5. Lubricate camshaft thrust plate with Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford specification ESR-M99C80-A and install with two retaining bolts. Tighten bolts to 10 Nm (88 inch. lbs.).
6. If installing a new camshaft, check endplay. If clearance is excessive, replace camshaft thrust plate.





7. Lubricate timing chain, crankshaft sprocket and camshaft sprocket with Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford specification ESR-M99C80-A. Align marks as illustrated. Inspect camshaft sprocket bolt for blockage of drilled oil passages and clean as required. Install bolt and washer and tighten to 50-70 Nm (37-51 ft. lbs.).

CAUTION: Do not replace camshaft sprocket bolt with a standard bolt or severe engine damage will occur. This bolt is an oil carrying, precision component.

8. Lubricate valve tappets and bore with Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford specification ESR-M99C80-A.
9. Install valve tappets into original bores.
10. Aligning valve tappet flats, install valve tappet guide plate.

NOTE: Install plate with the word "UP" and or button visible.

11. Install tappet guide plate and retainer over valve tappet guide plate. Hand-start two retaining bolts. Tighten bolts to 10-14 Nm (89-123 inch. lbs.).
12. Apply a 6 mm (1/4 inch) drop of Silicone Gasket and Sealant F6AZ-19562-AA or equivalent meeting Ford specification WSE-M4G323-A6 to intersection of cylinder block and cylinder head at four corners as shown.

NOTE: Prior to applying sealer, clean sealing surfaces with Metal Surface Cleaner F4AZ-19A536-RA or equivalent meeting Ford specification WSE-M5B392-A, to remove all residues that may interfere with the sealer's ability to adhere.

13. Position intake manifold gaskets onto cylinder heads. Align intake manifold gasket locking tabs to the provisions on the head gaskets as shown.
14. Install front and rear intake manifold end seals as shown. Secure with retaining features.
15. Carefully lower intake manifold into position aligning intake manifold bolt holes to those in the cylinder head.
- Install bolts No. 1, 2, 3 and 4 and hand-tighten.
- Install remaining bolts and tighten in sequence in two steps:
- Tighten in numerical sequence to 20-30 Nm (15-22 ft. lbs.).
- Then tighten again to 26-32 Nm (20-23 ft. lbs.).

NOTE: Use care to prevent disturbing the silicone sealer which can cause sealing voids.

16. Coat camshaft position sensor housing drive gear teeth with Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford specification ESR-M99C80-A. Install Camshaft Position Sensor (CMP sensor).
17. Apply Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford specification ESR-M99C80-A to removed push rods and rocker arms. Install rocker arms. Move rocker arms into position with push rod and valve stem.
18. Rotate crankshaft to align camshaft and crankshaft timing marks as shown to camshaft position A. Tighten rocker arm seat retaining bolts of specified rocker arms to 7-15 Nm (6-11 ft. lbs.) to seat rocker arm seats into cylinder head. Rotate crankshaft to camshaft position B. Tighten rocker arm seat retaining bolts of remaining rocker arms to 7-15 Nm (6-11 ft. lbs.). Final-tighten rocker arm seat retaining bolts to 26-38 Nm (20-28 ft. lbs.) in any position. If new valve tappets are being installed check collapsed tappet gaps.

19. Inspect crankshaft front seal for damage and replace if required. Install new engine front cover gasket on alignment dowels on cylinder block. Install engine front cover and tighten retaining bolts to 20-30 Nm (15-22 ft. lbs.). Install water pump and new water pump housing gasket if removed.

NOTE: Rocker arm seat 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.

20. Install new oil pan gasket to cylinder block and secure with Gasket and Trim Adhesive F3AZ-19B508-B or equivalent meeting Ford specifications ESR-M11P17-A and ESE-M2G52-A. Make sure the oil pan gasket retaining tab features are properly installed on cylinder block, rear crankshaft main bearing cap and engine front cover. Install oil pan and all retaining bolts.
- Tighten four corner bolts to 10-14 Nm (89-123 inch. lbs.).
- Then tighten the remaining bolts to the same value.
- Back off all 16 retaining bolts and retighten to 10-14 Nm (89-123 inch. lbs.).

21. Install crankshaft damper and crankshaft pulley.
22. Install generator, brackets, drive belt tensioner and drive belt.
23. Install valve covers.
24. Install engine control sensor wiring to each fuel injector. Secure retainers to valve cover stud bolts.
25. Install ignition coil to rear of LH cylinder head. Tighten retaining bolts to 40-55 Nm (30-40 ft. lbs.).
26. Install upper intake manifold and new intake manifold upper gasket.
27. Install ignition wire harness retainers to valve cover stud bolts and connect ignition wires to spark plugs and ignition coil.
28. Install engine in vehicle.
29. Fill and bleed engine cooling system.
30. Fill crankcase to proper level with clean engine oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G.
31. Start engine and check for coolant, oil, exhaust, vacuum and fuel leaks. Check and, if necessary, adjust base ignition timing as described in the Powertrain Control/Emissions Diagnosis Manuals (unleaded gasoline only).
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