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Home >> Mercury >> 1998 >> Sable V6-3.0L DOHC VIN S >> Repair and Diagnosis >> Engine, Cooling and Exhaust >> Engine >> Cylinder Head Assembly >> Rocker Arm Assembly >> Service and Repair

Rocker Arm Assembly: Service and Repair





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.

REMOVAL

1. Remove upper intake manifold Service and Repair
and valve covers. Service and Repair

2. Remove crankshaft pulley. Service and Repair

3. Remove crankshaft damper retaining bolt from front of crankshaft allowing key way to be referenced.

4. CAUTION:Rotate crankshaft clockwise 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 and rocker arms or damage to camshafts may occur.

Rotate crankshaft clockwise to top dead center (TDC) No. 1 cylinder.

5. Verify the alignment flags (marked RFF) on the camshafts are aligned. If the arrows on the camshaft are not aligned, rotate the crankshaft clockwise one complete revolution.

6. Rotate crankshaft clockwise to position crankshaft keyway to the 3 o'clock position. This will position the RH cylinder head camshafts to the neutral position (base circle).

7. CAUTION:Cylinder head camshaft journal caps and cylinder heads should be identified to verify 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 cap first to ensure that damage to the cylinder head camshaft journal thrust cap does not occur.

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

8. 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.






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

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

10. Rotate crankshaft and position crankshaft keyway to the 11 o'clock location. This will position the LH cylinder head camshafts to neutral position (base circle).

11. Verify the alignment flags (marked RFF) on the camshafts are aligned.

12. Remove cylinder head camshaft journal thrust cap retaining bolts and thrust caps from LH cylinder head.

13. 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.






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

Camshafts, Rocker Arms And Valve Tappets - LH Cylinder Head Shown, RH Similar (1 Of 2):





Camshafts, Rocker Arms And Valve Tappets - LH Cylinder Head Shown, RH Similar (2 Of 2):






INSTALLATION

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

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

Lubricate rocker arms by immersing rocker arm in Engine Assembly Lubricant D9AZ-1 9579-D or equivalent meeting Ford specification ESR-M99C80-A and install rocker arms onto LH cylinder head under camshafts.

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

Align camshaft end play in LH cylinder head with thrust caps. 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. Install LH cylinder head camshaft journal thrust caps and tighten retaining bolts to 8-12 Nm (71-106 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).

5. 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 camshaft damage.

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

Lubricate rocker arms by immersing rocker arm in Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford specification ESR-M99C80-A and install rocker arms onto RH cylinder head under camshafts.

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

Align camshaft end play in RH cylinder head with thrust caps. 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. Install RH cylinder head camshaft journal thrust caps and tighten retaining bolts to 8-12 Nm (71-106 inch lbs.).






8. Install the crankshaft damper retaining bolt. Tighten bolt as follows:
Step 1: Tighten to 120 Nm (88 ft. lbs.).
Step 2: Loosen minimum of one full turn (360°).
Step 3: Tighten to 47-53 Nm (35-39 ft. lbs.).
Step 4: Rotate 85-95°.

9. Install crankshaft pulley. Service and Repair

10. Install valve covers Service and Repair

and upper intake manifolds. Service and Repair

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