Engnie Ford Escape 2008 V6 3.0L

SECTION 303-01B: Engine — 3.
0L (4V) 2008 Escape/Mariner/Escape Hybrid/Mariner Hybrid Workshop Manual

SPECIFICATIONS Procedure revision date: 10/21/2008
Material
Item Specification Fill Capacity
High Temperature Nickel Anti- ESE-M12A4-A —
Seize Lubricant
XL-2 (US); CXG-2-B (Canada)
MERCON® Multi-Purpose MERCON® —
Automatic Transmission Fluid
XT-2-QDX (US); XT-2-LM12
(Canada)
Motorcraft Metal Surface Prep — —
ZC-31
Motorcraft SAE 5W-20 WSS- 5.7L (6.0 qt)
Premium Synthetic Blend Motor M2C930-A includes filter
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Oil change
XO-5W20-QSP (US);
Motorcraft SAE 5W-20 Super
Premium Motor Oil CXO-5W20-
LSP12 (Canada); or equivalent
Penetrating and Lock Lubricant — —
XL-1 (US); CXC-51-A (Canada)
Silicone Brake Caliper Grease ESE-M1C171- —
and Dielectric Compound A
XG-3-A
Silicone Gasket and Sealant WSE- —
TA-30 M4G323-A4
Thread Sealant with PTFE WSK- —
TA-24 M2G350-A2
General Specifications
Item Specification
Engine
Bore/stroke 89.0 x 79.5 mm (3.12 in)
Compression ratio 10.0:1
Displacement 3.0L (4V) (182 CID)
Engine and transaxle assembly weight 234 kg (516 lb)
(without accessory drive components)
Engine weight (without accessory drive 146 kg (322 lb)
components and flexplate)
Fire order 1-4-2-5-3-6
No. cylinders 6
Oil pressure (Minimum at 1,500 rpm 138 kPa (20 psi)
with engine warmed up after 10 minutes
of idling)
Spark plug AGSF-32M Gap = 1.30-1.40 mm
(0.052-0.056 in)
Cylinder Head and Valve Train
Combustion chamber volume 52 cc (3.17 CI)
Cylinder head gasket surface flatness 0.025 mm (0.001 in) in any 25 mm (1 in) x 25 mm (1 in) area,
0.05 mm (0.002 in) in any 150 mm (6 in) x 150 mm (6 in) area;
0.15 mm (0.005 in) overall
Roller follower ratio @ max. lift 2.0:1
Valve arrangement (front to rear) LH intake I-I-I-I-I-I
LH exhaust E-E-E-E-E-E
RH intake I-I-I-I-I-I
RH exhaust E-E-E-E-E-E
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Valve face angle 45.5 degrees
Valve face runout 0.05 mm (0.001 in)
Valve guide bore diameter 6.015-6.044 mm (0.236-0.237 in)
Valve head diameter — exhaust 30 mm (1.18 in)
Valve head diameter — intake 35 mm (1.38 in)
Valve head diameter (exhaust) — 28.0 mm (1.10236 in)
gauge diameter
Valve head diameter (intake) — gauge 33.5 mm (1.3189 in)
diameter
Valve seat angle 44.75 degrees
Valve seat runout 0.04 mm (0.001 in)
Valve seat width — exhaust 1.4-1.7 mm
(0.055-0.066 in)
Valve seat width — intake 1.1-1.4 mm
(0.043-0.055 in)
Valve spring compression pressure (N 693 N @ 30.09 mm
@ spec. length)
(156 lbs @ 1.18 in)
Valve spring free length (approx.) 46.6 mm (1.84 in)
Valve spring installed height (N @ spec. 39.89 mm (1.57 in)
length)
Valve spring installed pressure 240 N @ 39.89 mm (53.95 lbs @ 1.57 in)
Valve spring installed pressure — 10% force loss @ specified height
service limit
Valve spring squareness 2.5%
Valve stem diameter — exhaust 5.950-5.970 mm (0.2343-0.2350 in)
Valve stem diameter — intake 5.975-5.995 mm (0.2350-0.2358 in)
Valve stem-to-guide clearance — 0.045-0.094 mm (0.0017-0.037 in)
exhaust
Valve stem-to-guide clearance — intake 0.019-0.069 mm (0.0007-0.0027 in)
Hydraulic Lash Adjuster
Clearance to bore 0.018-0.069 mm (0.0007-0.0027 in)
Collapsed lash adjuster gap 0.50-1.11 mm (0.019-0.043 in)
Diameter (standard) 16-15.988 mm (0.6290-0.6294 in)
Hydraulic leakdown rate 5-25 seconds
Camshaft
Allowable lobe lift loss 0.76 mm (0.03 in)
Camshaft journal bore inside diameter 27.012-26.987 mm (1.063-1.062 in)
Camshaft journal-to-bearing clearance 0.121 mm (0.0047 in)
— service limit
Camshaft journal-to-bearing clearance 0.025-0.076 mm (0.001-0.0029 in)
— standard
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End play — service limit 0.190 mm (0.00748 in)
Journal diameter (all) 26.962-26.936 mm (1.061-1.060 in)
Lobe lift 4.80 mm (0.189 in)
Runout —
Theoretical valve lift @ 0 lash 9.80 mm (0.388 in)
Cylinder Block
Cylinder bore diameter — grade 1 89.000-89.010 mm (3.50393-3.504323 in)
Cylinder bore maximum out-of-round 0.015 mm (0.0005 in)
Cylinder bore maximum out-of-round — 0.020 mm (0.0007 in)
service limit
Cylinder bore maximum taper 0.020 mm (0.0008 in)
Head gasket surface flatness 0.025 mm (0.001 in) in any 25 mm (1 in) x 25 mm (1 in) area,
0.05 mm (0.002 in) in any 150 mm (6 in) x 150 mm (6 in) area;
0.15 mm (0.005 in) overall
Main bearing bore inside diameter 67.998-68.022 mm (2.677-2.6780 in)
Crankshaft
Connecting rod journal diameter 49.969-49.991 mm (1.967-1.968 in)
Connecting rod journal maximum out-of- 0.006 mm (0.0002 in)
round
Connecting rod journal maximum taper 0.008 mm (0.0003 in)
Crankshaft maximum end play 0.135-0.255 mm (0.005-0.010 in)
Main bearing journal diameter 62.968-62.992 mm (2.467-2.479 in)
Main bearing journal maximum out-of- 0.006 mm (0.0002 in)
round
Main bearing journal maximum taper 0.008 mm (0.0003 in)
Main bearing journal-to-cylinder block 0.024-0.072 mm (0.0009-0.003 in)
clearance
Piston and Connecting Rod
Connecting rod bearing bore diameter 53.015-53.035 mm (2.0872-2.0879 in)
Connecting rod bearing-to-crankshaft 0.028-0.066 mm (0.001-0.0025 in)
clearance
Connecting rod length (center-to-center) 138.06-138.14 mm (5.435-5.38 in)
Connecting rod maximum allowed bend 0.038 mm per 25
(0.0014 per 0.984 in)

Connecting rod maximum allowed twist 0.050 mm per 25
(0.0019 per 0.984 in)

Connecting rod pin bore diameter 21.017-21.031 mm (0.827-0.828 in)
Connecting rod side clearance 0.100-0.30 mm (0.0039-0.0118 in)
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Connecting rod-to-pin clearance — 0.035 mm (0.0013 in)
service limit
Connecting rod-to-pin clearance — 0.004-0.02 mm (0.0001-0.0007 in)
standard
Piston diameter — coated, grade 1 88.990-89.010 mm (3.5035-3.5043 in)
Piston diameter — uncoated, grade 1 88.970-88.980 mm (3.50275-3.50314 in)
Piston pin bore diameter 21.008-21.012 mm (0.8270-0.8272 in)
Piston pin diameter 21.011-21.013 mm (0.8271-0.8273 in)
Piston pin length 60.51-60.08 mm (2.382-2.365 in)
Piston ring end gap — compression 0.27-0.42 mm (0.0106-0.0165 in)
(bottom, gauge diameter)
Piston ring end gap — compression 0.65 mm (0.0255 in) max
(bottom, service limit)
Piston ring end gap — compression 0.100-0.250 mm (0.0039-0.0098 in)
(top, gauge diameter) a
Piston ring end gap — compression 0.50 mm (0.0196 in) max
(top, service limit)
Piston ring end gap — oil ring (steel rail, 0.15-0.65 mm (0.0059-0.0255 in)
gauge diameter)
Piston ring end gap — oil ring (steel rail, 0.90 mm (0.0354 in) max
service limit)
Piston ring groove width — compression 1.530-1.545 mm (0.0602-0.0608 in)
(bottom)
Piston ring groove width — compression 1.230-1.245 mm (0.0484-0.0490 in)
(top)
Piston ring groove width — oil ring 3.030-3.055 mm (0.1192-0.0120 in)
Piston ring-to-groove clearance —
Piston ring width —
Piston pin-to-piston fit 0.002 to 0.009 mm (0.00007-0.0003 in)
Piston-to-connecting rod clearance —
Piston-to-cylinder bore clearance 0.012 to 0.022 mm (0.0005-0.0009 in)
a Specification 82.4 mm (3.2441 in) diameter gauge
Torque Specifications
Description Nm lb-ft lb-in
Accelerator cable bracket bolts 10 — 89
Accelerator cable snow shield bolts 10 — 89
Accessory drive belt tensioner bolt 45 33 —
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Air conditioning compressor bracket bolts 25 18 —
Air conditioning compressor bolts 25 18 —
Battery cable nut 10 89
Block heater 21 15 —
Brake hose and wiring retainers 15 11
Camshaft journal and thrust cap bolts a — — —
Camshaft oil seal retainer bolts 10 — 89
Camshaft position (CMP) sensor bolt 10 — 89
Catalyst monitor sensor electrical connector bracket nut 10 89
Center accessory drive belt idler pulley bolt 25 18 —
Coil-on-plug bolts 6 — 53
Connecting rod cap bolts a — — —
Coolant bypass tube nut and bolt 10 — 89
Coolant pump bolts 10 — 89
Crankcase cover bolts 10 — 89
Crankshaft position (CKP) sensor bolt 10 — 89
Crankshaft pulley bolt a — — —
Cross brace bolts 90 66 —
Cross brace nut 175 129 —
Cylinder head bolts a — — —
Driveshaft-to-power takeoff bolts and washers 37 27 —
Engine control wiring harness (B+) shield nuts 6 — 53
Engine front cover bolts and studs a — — —
Engine lift bracket bolt 118 87 —
Engine oil filter a — — —
Engine oil pressure (EOP) switch 14 10 —
Engine support insulator bolts 48 35 —
Engine support insulator bracket bolt 90 66 —
Engine support insulator bracket nuts 55 41 —
Exhaust gas recirculation (EGR) tube 40 30 —
EGR tube nuts 40 30 —
EGR vacuum regulator stud bolt nut 6 — 53
Exhaust manifold nuts a — — —
Exhaust manifold studs 12 9 —
Exhaust Y-pipe flange nuts 29 21
Flexplate bolts 80 59 —
Front roll restrictor bolt 115 85

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Gearshift cable bracket bolts 23 17
Generator B+ wiring harness nut 6 53
Generator B+ wire nut 8 — 71
Generator bolt 47 35 —
Generator studs 8 — 71
Generator stud nuts 47 35 —
Ground strap bolt 10 — 89
Ground wire bolt 10 — 89
Ground wire eyelet nut 25 18 —
Halfshaft support bracket bolts 48 35 —
Heated oxygen sensor (HO2S) 47 35 —
Ignition coil-on-plug bolts 6 — 53
Intermediate shaft bearing retaining nuts 27 20
Lateral support crossmember bolts 115 85
LH accessory drive belt idler pulley bolt 47 35 —
LH transaxle support insulator through bolt 115 85 —
Lower ball joint pinch bolts and nuts 63 46
Lower cylinder block bolts a — — —
Lower intake manifold bolts a — — —
Oil level indicator tube stud bolt 10 — 89
Oil pan baffle nuts a — — —
Oil pan bolts and studs 25 18 —
Oil pan drain plug 26 19 —
Oil pan-to-transaxle bolts 40 30 —
Oil pump bolts 10 — 89
Oil pump screen and pickup tube bolts and nut 10 — 89
Output shaft speed (OSS) sensor bolt 13 10 —
Power distribution box cable nuts 12 9 —
Power transfer unit (PTU) bolts 45 33
PTU heat shield bolts 11 — 97
PTU vent tube bolt 14 10
Powertrain control module (PCM) wiring nut 8 71
Radio interference capacitor nut 6 — 53
Rear transaxle support insulator through bolt 103 76 —
RH accessory drive belt idler pulley and bracket bolts 25 18 —
RH and LH lower splash shield bolts 9 — 80
RH transaxle support insulator bracket nuts and bolt 80 59 —
RH radio ignition interference capacitor nut 6 — 53
RH transaxle support insulator through bolt 115 85 —
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Speed control actuator nuts 9 — 80
Stabilizer link-to-strut nuts 63 46
Tie-rod end nuts 55 41
Timing chain guide bolts 25 18 —
Timing chain tensioner bolts 25 18 —
Torque converter-to-flexplate nuts 40 30 —
Transaxle cooler tube bracket bolt 13 10
Transaxle cooler tube fitting nut 23 17
Transaxle-to-engine bolts 47 35 —
Transaxle-to-engine stud and nuts 48 35 —
Transaxle-to-oil pan bracket bolt 25 18 —
Upper intake manifold bolts a — — —
Upper radiator support bracket bolts 10 — 89
Valve cover bolts and stud bolts a — — —
Wiring harness-to-valve cover stud bolt nut 6 — 53
a Refer to the procedure in this section.

SECTION 303-01B: Engine — 3.0L (4V) 2008 Escape/Mariner/Escape Hybrid/Mariner Hybrid Workshop Manual
DESCRIPTION AND OPERATION Procedure revision date: 01/10/2007
Engine
The 3.0L (4V) is a V-6 engine has the following features:
 Dual overhead camshafts

 Four valves per cylinder
 Sequential multiport fuel injection (SFI)
 Composite lower intake manifold and composite upper intake manifold
 Aluminum cylinder heads
 Two-piece design aluminum cylinder block
 Electronic ignition system with 6 ignition coils
Identification
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For quick identification refer to the safety certification decal.
 The decal is located on the LH front door lock face panel.

 An engine identification label is also attached to the engine.
 The symbol code on the identification tag identifies each engine for determining parts usage; for
instance, engine displacement in liters or cubic inch displacement and model year.
Exhaust Emission Control System
Operation and required maintenance of the exhaust emission control devices used on this engine are
covered in the Powertrain Control/Emissions Diagnosis (PC/ED) manual.
Induction System
The SFI provides the fuel/air mixture needed for combustion in the cylinders. The 6 solenoid-operated fuel
injectors:
 are mounted between the fuel rail and the intake manifold.
 meter fuel into the air intake stream in accordance with engine demand.
 are positioned so that their tips direct fuel just ahead of the engine intake valves.
Valve Train
The camshafts are mounted in the cylinder heads and act against a roller follower to open and close the
valves. A hydraulic lash adjuster is located on one side of the roller follower and the valve tip on the opposite
end. The camshafts are driven off the front of each cylinder head by 2 chains (one each side). Both of the
chains are driven by sprockets that are located on the crankshaft, just in front of the oil pump.
Positive Crankcase Ventilation System
All engines are equipped with a closed-type positive crankcase ventilation system recycling the crankcase
vapors to the upper intake manifold.
Lubrication System
The engine lubrication system is of the force-feed type in which oil is supplied under full pressure to the
crankshaft, connecting rod bearings and timing chain tensioners. The flow of oil to the valve tappets and
valve train is controlled by a restricting orifice located in the head gaskets.
Oil Pump
The lubrication system is designed to provide optimum oil flow to critical components of the engine through
its entire operating range.
The heart of the system is a positive displacement internal gear oil pump.
Generically this design is known as a gerotor pump, which operates as follows:
 The oil pump is mounted on the front face of the cylinder block.
 The inner rotor is piloted on the crankshaft post and is driven through flats on the crankshaft.
 System pressure is limited by an integral, internally-vented relief valve which directs the bypassed oil
back to the inlet side of the oil pump.
 Oil pump displacement has been selected to provide adequate volume to make sure of correct oil
pressure both at hot idle and maximum speed.
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 The relief valve calibration protects the system from excessive pressure during high viscosity
conditions.
 The relief valve is designed to provide adequate connecting rod bearing lubrication under high-
temperature and high-speed conditions.
Cooling System
The engine cooling system includes the following:
 Radiator
 Dual electric fan assemblies
 Degas bottle (aids in maintaining the correct volume of engine coolant)
 Coolant thermostat
 Coolant hoses
Engine Cylinder Identification

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DIAGNOSIS AND TESTING Procedure revision date: 01/10/2007
Engine
For basic engine mechanical concerns, refer to Section 303-00 . For driveability concerns, refer to the
Powertrain Control/Emissions Diagnosis (PC/ED) manual.

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IN-VEHICLE REPAIR Procedure revision date: 01/07/2009
Upper Intake Manifold
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Part
Item Number Description
1 W702251 Accelerator cable snow shield bolts (2 required)
2 9E776 Accelerator cable snow shield
3 9A825 Speed control cable to throttle body
4 9A758 Accelerator cable to throttle body
5 — Accelerator/speed control cable bracket bolt (3
required)
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Part
6 W52593 Evaporative emissions (EVAP) tube clamp
7 9D289 EVAP tube
8 — Exhaust gas recirculation (EGR) tube fitting (part of
9D477)
9 14A464 Throttle position (TP) sensor electrical connector (part
of 9H589)
10 W700497 Wiring retainer (part of 9H589)
11 — Transaxle vent tube pin-type retainer (part of 7034)
12 — Vacuum harness tube (part of 9E498)
13 14A464 Idle air control (IAC) valve electrical connector (part of
9H589)
14 14A464 EGR vacuum regulator electrical connector (part of
9H589)
15 — EGR vacuum regulator stud bolt nut
16 — Wiring retainer (part of 9H589)
17 — Positive crankcase ventilation (PCV) tube
18 — Vacuum harness tube fitting (part of 9E498)
19 392984 Brake booster vacuum hose clamp
20 2C053 Brake booster vacuum hose
21 14A464 Engine control wiring harness electrical connectors
(part of 9H589)
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Item Part Number Description
22 — Throttle body coolant hose clamps (2 required)
23 — Throttle body coolant hoses (2 required)
24 9Y450 Upper intake manifold bolt (8 required)
25 9424 Upper intake manifold
26 — Upper intake manifold gasket (6 required)
Removal
1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Section 100-02 .
2. Remove the air cleaner outlet pipe. For additional information, refer to Section 303-12B .
3. Remove the 2 bolts and the accelerator cable snow shield.
4. Detach the speed control and accelerator cables from the throttle body.
5. Remove the 3 accelerator/speed control cable bracket bolts.

 Position the cables and brackets aside.
6. Remove the EGR tube fitting from the EGR valve.
7. Detach the transaxle vent tube pin-type retainer from the throttle body.
8. Disconnect the throttle position (TP) sensor electrical connector and detach the wiring retainer.
9. Disconnect the vacuum harness tube fittings from the EGR valve and the EGR vacuum regulator.
10. Disconnect the evaporative emissions (EVAP) tube from the upper intake manifold.
11. Disconnect the idle air control (IAC) valve electrical connector.
12. Disconnect the EGR vacuum regulator electrical connector.
13. Remove the nut from the EGR vacuum regulator stud bolt and detach the wiring retainer.
14. Disconnect the PCV, brake booster and vacuum harness tubes from the upper intake manifold.
15. Detach the 2 main engine control wiring harness electrical connectors from the upper intake manifold.
16. Disconnect and plug the 2 throttle body coolant hoses.
17. Remove the 8 bolts and the upper intake manifold.
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 Remove and discard the gaskets.
Installation
1. NOTICE: If the engine is repaired or replaced because of upper engine failure, typically including
valve or piston damage, check the intake manifold for metal debris. If metal debris is found,
install a new intake manifold. Failure to follow these instructions can result in engine damage.
NOTE: Clean and inspect all sealing surfaces. Install new gaskets.
Position the upper intake manifold and install the bolts.

 Tighten in the sequence shown to 10 Nm (89 lb-in).
2. Connect the 2 throttle body coolant hoses.
3. Attach the 2 main engine control wiring harness electrical connectors to the upper intake manifold.
4. Connect the PCV, brake booster and vacuum harness tubes to the upper intake manifold.
5. Attach the wiring retainer to the EGR vacuum regulator stud bolt and install the nut.
 Tighten to 6 Nm (53 lb-in).
6. Connect the EGR vacuum regulator electrical connector.
7. Connect the IAC valve electrical connector and wiring harness retainer.
8. Connect the EVAP tube to the upper intake manifold.
9. Connect the vacuum harness tube fittings to the EGR valve and the EGR vacuum regulator.
10. Connect the TP sensor electrical connector and attach the wiring retainer.
11. Attach the transaxle vent tube pin-type retainer to the throttle body.
12. Install the EGR tube fitting to the EGR valve.

 Tighten to 40 Nm (30 lb-ft).
13. Position the accelerator/speed control cables and brackets and install the 3 bolts.
14. Attach the speed control and accelerator cables to the throttle body.
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15. Install the accelerator cable snow shield and the 2 bolts.
16. Install the air cleaner outlet pipe. For additional information, refer to Section 303-12B .

Lower Intake Manifold
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Part
1 W708187 Lower intake manifold bolt (8 required)
2 — Wire shield (part of 9H589)
3 — Wire shield pin-type retainer (2 required) (part of
9H589)
4 9E499 Fuel rail pressure and temperature sensor vacuum tube
fitting
5 14A464 Fuel injector electrical connector (6 required) (part of
9H589)
6 14A464 Fuel rail pressure and temperature sensor electrical
connector (part of 9H589)
7 9424 Lower intake manifold
8 9288 Fuel tube
9 9439 Lower intake manifold gasket (6 required)
10 14A464 Engine coolant temperature (ECT) sensor electrical
connector (part of 9H589)
Removal
WARNING: Do not smoke, carry lighted tobacco or have an open flame of any type when working
on or near any fuel-related component. Highly flammable mixtures are always present and may be
ignited. Failure to follow these instructions may result in serious personal injury.
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WARNING: Before working on or disconnecting any of the fuel tubes or fuel system components,
relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains
under high pressure, even when the engine is not running. Failure to follow this instruction may result
in serious personal injury.
1. Release the fuel system pressure. For additional information refer to Section 310-00 .
2. Disconnect the battery ground cable. For additional information, refer to Section 414-01 .
3. Remove the upper intake manifold. For additional information, refer to Upper Intake Manifold in this
section.
4. Disconnect the engine coolant temperature (ECT) sensor electrical connector.
5. Disconnect the fuel supply tube quick connect coupling at the fuel rail. For additional information, refer
to Section 310-00 .
6. Disconnect the fuel rail pressure and temperature sensor electrical connector and vacuum tube.
7. Disconnect the 6 fuel injector electrical connectors and the 2 wire shield pin-type retainers.
8. Remove the 8 lower intake manifold bolts and the lower intake manifold.
Installation
1. NOTICE: If the engine is repaired or replaced because of upper engine failure, typically including
valve or piston damage, check the intake manifold for metal debris. If metal debris is found,
install a new intake manifold. Failure to follow these instructions can result in engine damage.
NOTE: Clean and inspect all sealing surfaces. Install new gaskets.
Position the lower intake manifold and install the bolts.

2. Connect the 6 fuel injector electrical connectors and the 2 wire shield pin-type retainers.
3. Connect the fuel rail pressure and temperature sensor electrical connector and vacuum tube.
4. Connect the fuel supply tube quick connect coupling at the fuel rail. For additional information, refer to
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Section 310-00 .
5. Connect the ECT sensor electrical connector.
6. Install the upper intake manifold. For additional information, refer to Upper Intake Manifold in this
section.
7. Connect the battery ground cable. For additional information, refer to Section 414-01 .

Valve Cover — LH
Material
Item Specification
Motorcraft Metal Surface Prep —
ZC-31
Silicone Gasket and Sealant WSE-M4G323-A6
TA-30
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1 W702251 Accelerator cable snow shield bolts (2 required)
2 9E766 Accelerator cable snow shield
3 6853 Crankcase ventilation tube
4 17A084 Engine lift bracket
5 W701627 Engine lift bracket bolt
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6 — Upper radiator hose retainers (2 required)
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7 13A506 Wiring retainer (2 required) (part of 9H589)
8 W700497 Wiring retainer (2 required) (part of 9H589)
9 6C519 Valve cover stud bolt (9 required)
10 14A099 B+ cable wiring retainers (3 required)
11 6A505 Valve cover
12 6C519 Valve cover bolt (4 required)
13 6A559 Valve cover gasket
Removal
NOTICE: During engine repair procedures, cleanliness is extremely important. Any foreign material
(including any material created while cleaning gasket surfaces) that enters the oil passages, coolant
passages or the oil pan may cause engine failure.
1. Remove the LH ignition coil-on-plugs. For additional information, refer to Section 303-07B .
2. If equipped, remove the bolt and the engine lift bracket.
4. NOTICE: Do not disconnect the crankcase ventilation tube from the valve cover or damage to
the ventilation tube may occur.
Disconnect the crankcase ventilation tube from the air cleaner outlet pipe.
5. Detach the upper radiator hose from the 2 retainers on the cooling fan shroud and position the hose
aside.
6. Detach the 4 wiring retainers from the valve cover stud bolts.
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7. Detach the 3 wiring retainers from the valve cover stud bolts and position the B+ cable aside.
8. NOTE: Inspect the crankcase ventilation tube and valve cover sealing area. If either a new valve cover
or crankcase ventilation tube is required, both components must be installed new.
Remove the 5 bolts, 8 stud bolts and the valve cover.

 Remove and discard the gasket.
Installation
1. Install the new gasket in the valve cover in the following sequence.
1. Install the gasket at waffle pads and then the corners.
2. Install the gasket around bolt holes.
3. Install the remaining part of the gasket.
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2. NOTE: The valve cover must be installed and the bolts and studs tightened within 4 minutes of sealant
application.
NOTE: Clean cylinder head and front cover surface and the cam seal retainer-to-cylinder head surface
using metal surface prep before applying silicone gasket and sealant.
Apply an 8 mm (0.31 in) dot of silicone gasket and sealant at the cylinder block to front cover mating
surface and the cam seal retainer-to-cylinder head joints.
3. Position the valve cover and install the bolts and stud bolts.
4. Attach the 3 wiring (B+ cable) retainers onto the valve cover stud bolts.
5. Attach the 4 wiring retainers to the valve cover stud bolts.
6. Attach the upper radiator hose to the 2 retainers on the cooling fan shroud.
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7. Attach the crankcase ventilation tube to the air cleaner outlet pipe.
8. Install the accelerator cable snow shield and the 2 bolts.

9. If equipped, install the engine lift bracket and the bolt.

10. Install the LH ignition coil-on-plugs. For additional information, refer to Section 303-07B .

Valve Cover — RH
Material
Item Specification
ZC-31
Silicone Gasket and Sealant WSE-M4G323-A6
TA-30
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Part
1 6582 Valve cover
2 W700497 Wiring retainers (5 required)
3 6C519 Valve cover bolt (3 required)
4 6K817 Positive crankcase ventilation (PCV) tube
5 18801 Radio ignition interference capacitor electrical
connector
6 W520411 Radio ignition interference capacitor nut
7 W520411 Engine control wiring harness shield nut (2 required)
8 12B637 Engine control wiring harness shield
9 6C519 Valve cover stud bolt (10 required)
10 6584 Valve cover gasket
Removal
1. Remove the Air Cleaner (ACL) outlet pipe. For additional information, refer to Section 303-12B .
2. Remove the upper intake manifold. For additional information, refer to Upper Intake Manifold .
3. Remove the RH ignition coil-on-plugs. For additional information, refer to Section 303-07B .
4. Remove the PCV tube.
5. Disconnect the radio ignition interference capacitor electrical connector and detach the 5 wiring
retainers from the stud bolts.
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6. Remove the nut and the radio ignition interference capacitor.
7. Remove the 2 nuts and position the engine control wiring harness shield aside.
8. Remove the 3 bolts, 10 stud bolts and the valve cover.

 Remove and discard the gasket.
Installation
1. Install the new gasket in the valve cover in the following sequence.
1. Install the gasket at waffle pads and then corners.
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2. NOTE: The valve cover must be installed and the bolts and stud bolts tightened within 4 minutes of
sealant application.
NOTE: Clean cylinder head and front cover surface using metal surface prep before applying silicone
gasket and sealant.
Apply an 8 mm (0.31 in) dot of silicone gasket sealant to the front cover-to-cylinder head joints.
3. Position the valve cover and install the 3 bolts and 10 stud bolts.
4. Position the engine control wiring harness shield and install the 2 nuts.
5. Install the radio ignition interference capacitor and the nut.

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6. Attach the wiring retainers to the stud bolts and connect the radio ignition interference capacitor
electrical connector.
7. Install the PCV tube.
8. Install the RH ignition coil-on-plugs. For additional information, refer to Section 303-07B .
9. Install the upper intake manifold. For additional information, refer to Upper Intake Manifold .
10. Install the ACL outlet pipe. For additional information, refer to Section 303-12B .

Lower End Components — Exploded View
Crankshaft Pulley and Front Seal
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1 W701512 Crankshaft pulley bolt
2 W701511 Washer
3 6316 Crankshaft pulley
4 6700 Crankshaft front seal
Flexplate and Rear Seal

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1 W701559 Flexplate bolt (8 required)
2 6375 Flexplate
3 6701 Crankshaft rear oil seal
1. For additional information, refer to the procedures in this section.

Crankshaft Pulley
Special Tool(s)
3 Jaw Puller
303-D121 (or equivalent)
Installer, Crankshaft Vibration

Damper
303-102 (T74P-6316-B)
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Material
Item Specification
Motorcraft® Metal Surface Prep —
ZC-31-A
Motorcraft® SAE 5W-20 Premium WSS-
Synthetic Blend Motor Oil M2C930-A
XO-5W20-QSP (US); Motorcraft®
SAE 5W-20 Super Premium Motor
Oil CXO-5W20-LSP12 (Canada); or
equivalent
Silicone Gasket and Sealant WSE-
TA-30 M4G323-A4
Removal
1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Section 100-
02 .
2. Remove the accessory drive belt. For additional information, refer to Section 303-05B .
3. Remove the crankshaft pulley bolt and washer.

 Discard the crankshaft pulley bolt.
4. Using the 3 Jaw Puller, remove the crankshaft pulley.

Installation
1. Lubricate the crankshaft front seal inner lip with clean engine oil.
2. NOTE: Clean the keyway and slot using metal surface prep before applying silicone gasket and
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sealant.
NOTE: The crankshaft pulley must be installed and the bolt tightened within 4 minutes of applying the
silicone gasket and sealant.
Apply silicone gasket and sealant to the end of the keyway slot.
3. NOTE: Lubricate the outside diameter sealing surface with clean engine oil.
Using the Crankshaft Vibration Damper Installer, install the crankshaft pulley.
4. Install the bolt and washer. Tighten the bolt in 4 stages:
 Stage 1: Tighten to 120 Nm (89 lb-ft).
 Stage 2: Loosen one full turn.
 Stage 4: Tighten an additional 90 degrees.
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5. Install the accessory drive belt. For additional information, refer to Section 303-05B .

Crankshaft Front Seal
Special Tool(s)
Installer, Front Cover Seal
303-335 (T88T-6701-A)
Replacer, Crankshaft Damper

303-102 (T74P-6316-B)
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Remover, Oil Seal
303-409 (T92C-6700CH)
Material
Item Specification
ZC-31
Motorcraft SAE 5W-20 Premium WSS-
XO-5W20-QSP (US); Motorcraft
equivalent
Removal
02 .
2. Remove the crankshaft pulley. For additional information, refer to Crankshaft Pulley in this section.
3. Using the special tool, remove and discard the crankshaft front seal.
Installation
1. NOTE: Clean all sealing surfaces with metal surface prep.
Apply clean engine oil to the seal lip and seal bore before installing the seal.
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2. Using the special tools, install a new crankshaft front seal.
3. Install the crankshaft pulley. For additional information, refer to Crankshaft Pulley in this section.

Flexplate
Removal and Installation
02 .
2. Remove the transmission. For additional information, refer to Section 307-01A .
3. Remove the bolts and the flexplate.

 To install, tighten to 80 Nm (59 lb-ft).
4. To install, reverse the removal procedure.
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Crankshaft Rear Seal
Special Tool(s)
Installer Bolts, Crankshaft Rear
Main Oil Seal
303-384 (T91P-6701-A)
Installer, Crankshaft Rear Main

Oil Seal
303-178 (T82L-6701-A)
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Remover, Crankshaft Rear Oil
Seal
303-519 (T95P-6701-EH)
Slide Hammer
307-005 (T59L-100-B)
Material
Item Specification
ZC-31-A
equivalent
Removal
02 .
2. Remove the flexplate. For additional information, refer to Flexplate in this section.
3. Using the Slide Hammer and the Crankshaft Rear Oil Seal Remover, remove and discard the
crankshaft rear oil seal.
Installation
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1. NOTE: Clean all sealing surfaces with metal surface prep.
NOTE: Apply clean engine oil to the seal lip and seal bore before installing the seal.
Using the Crankshaft Rear Main Oil Seal Installer Bolts and the Crankshaft Rear Main Oil Seal
Installer, install the crankshaft rear oil seal.
2. Install the flexplate. For additional information, refer to Flexplate in this section.

Engine Front Cover
Material
Item Specification
ZC-31
equivalent
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TA-30 M4G323-A6
Part
1 W709986 Generator bolt
2 10300 Generator
3 W710416 Generator stud
4 W520414 Generator stud nut (2 required)
5 15A024 Catalyst monitor sensor electrical connector bracket
6 W701542 Catalyst monitor sensor electrical connector bracket
nut
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Part
7 14A464 Crankshaft position (CKP) sensor electrical connector
(part of 9H589)
8 6C348 Center accessory drive belt idler pulley
9 — Center accessory drive belt idler pulley bolt (part of
6C348)
10 19A216 LH accessory drive belt idler pulley
11 — LH accessory drive belt idler pulley bolt (part of
19A216)
12 6B209 Accessory drive belt tensioner
13 W701625 Accessory drive belt tensioner bolt
14 14A464 Camshaft position (CMP) sensor electrical connector
(part of 9H589)
15 W706902 RH accessory drive belt idler pulley and bracket bolt (3
required)
16 3F671 RH accessory drive belt idler pulley and bracket
17 9H589 Wiring harness retainer
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Part
18 — Wire harness retainers (2 required) (part of 14290)
19 W707137 Speed control actuator nuts (3 required)
20 9C735 Speed control actuator
21 — A/C pressure switch electrical connector (part of
14290)
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22 W710030 Engine front cover stud bolt (2 required)
23 W708222 Engine front cover bolt (3 required)
25 6D081 Engine front cover gaskets (3 required)
27 6019 Engine front cover
28 W709678 Oil pan-to-front cover bolts (2 required)
Removal
passages or the oil pan can cause engine failure.
2. Release the fuel system pressure. For additional information, refer to Section 310-00 .
3. Disconnect the battery ground cable. For additional information, refer to Section 414-01 .
4. Remove the crankshaft front seal. For additional information, refer to Lower End Components —
Exploded View and Crankshaft Front Seal in this section.
5. Remove the generator bolt and the 2 nuts.

6. Remove the stud and position the generator away from the engine.
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7. Remove the bolt and the accessory drive belt tensioner.
8. Remove the bolt and the LH accessory drive belt idler pulley.
9. Remove the bolt and the center accessory drive belt idler pulley.
10. Remove the 3 RH accessory drive belt idler pulley and bracket bolts.
 Detach the wiring harness retainer and remove the idler pulley assembly.
11. Detach the wiring harness retainer, remove the nut and the catalyst monitor sensor electrical connector
bracket.
12. Disconnect the crankshaft position (CKP) sensor electrical connector.
13. Disconnect the camshaft position (CMP) sensor electrical connector.
14. Remove the LH and RH valve covers. For additional information, refer to Valve Cover — LH and Valve
Cover — RH in this section.
15. Remove the engine support insulator. For additional information, refer to Engine Support Insulators in
this section.
16. Disconnect the A/C pressure switch electrical connector.
17. Detach the 2 wire harness retainers from the speed control actuator mounting studs.
18. Remove the 3 nuts and position the speed control actuator aside.
19. Remove the 2 oil pan-to-front cover bolts.
20. Remove the 14 bolts, 2 stud bolts and the engine front cover.
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Installation
1. NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive
means to clean the sealing surfaces. These tools cause scratches and gouges which make leak
paths.
NOTICE: Do not damage the oil pan gasket while cleaning the sealant from the lower cylinder
block-to-oil pan joint.
Use a plastic scraping tool to remove all traces of sealant.

 Clean all sealing surfaces with metal surface prep and install new gaskets.
2. NOTE: The engine front cover must be installed and the bolts tightened within 4 minutes of applying
sealant.
Apply a 6 mm (0.23 in) diameter dot of silicone gasket and sealer to the cylinder block, lower cylinder
block, cylinder head and oil pan mating surfaces.
3. Position the engine front cover and install the bolts. Tighten in the sequence shown to 25 Nm (18 lb-ft).
1 W710030 Stud, Hex Flange Head Pilot, M6 x 1 x 20 / M8 x 1.25 x 47.5
2 W701525 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 47.5
3 W708222 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 64
13 W710030 Stud, Hex Flange Head Pilot, M6 x 1 x 20 / M8 x 1.25 x 47.5
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4. Install the 2 oil pan-to-front cover bolts.

5. Remove the oil pan drain plug and drain the engine oil.
 Install the plug and tighten to 26 Nm (19 lb-ft).
6. Install the speed control actuator and 3 nuts.

7. Attach the 2 wire harness retainers to the speed control actuator mounting studs.
8. Connect the A/C pressure switch electrical connector.
9. Install the engine support insulator. For additional information, refer to Engine Support Insulators in this
section.
10. Install the LH and RH valve covers. For additional information, refer to Valve Cover — LH and Valve
Cover — RH in this section.
11. Connect the CMP electrical connector.
12. Connect the CKP electrical connector.
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13. Install the catalyst monitor sensor electrical connector bracket and the nut.
 Attach the wiring harness retainer.
14. Position the RH accessory drive belt idler pulley and bracket and attach the wiring harness retainer.
 Install the 3 bolts and tighten to 25 Nm (18 lb-ft).
15. Install the center accessory drive belt idler pulley.

16. Install the LH accessory drive belt idler pulley.

17. Install the accessory drive belt tensioner and the bolt.
18. Position the generator and install the stud.

19. Install the generator bolt and 2 nuts.

20. Install the crankshaft front seal. For additional information, refer to Lower End Components — Exploded
View and Crankshaft Front Seal in this section.
21. Fill the engine with clean engine oil.
22. Connect the battery ground cable. For additional information, refer to Section 414-01 .

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Timing Drive Components
Removal
NOTICE: During engine repair procedures, cleanliness is extremely important. Any foreign material (including
any material created while cleaning gasket surfaces) that enters the oil passages, coolant passages or the oil
pan may cause engine failure.
NOTICE: Failure to verify correct timing drive component alignment will result in severe engine damage.
1. Remove the engine front cover. For additional information, refer to Engine Front Cover in this section.
2. NOTE: This pulse wheel is used in several different engines. Install the pulse wheel with the keyway in the slot
stamped "30" or "30RFF" (orange in color).
Remove the ignition pulse wheel.
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3. Install the crankshaft pulley bolt.
4. Remove the LH and RH spark plugs. For additional information, refer to Section 303-07B .
5. Rotate the crankshaft clockwise to position the crankshaft keyway in the 11 o'clock position and position the
camshafts in the correct position. This will position the No. 1 cylinder at top dead center (TDC).
 Verify that the camshafts are correctly located. If not, rotate the crankshaft one additional turn and
recheck.
6. Rotate the crankshaft clockwise 120 degrees to the 3 o'clock position to locate the RH camshafts in the neutral
position.
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7. Verify that the RH camshafts are in the neutral position.
8. Remove the RH timing chain tensioner arm.

1. Remove the bolts.
2. Remove the tensioner.
3. Remove the tensioner arm.
9. Remove the bolts, RH timing chain guide and the timing chain.
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10. Rotate the crankcase clockwise 600 degrees (1-2/3 turns) to position the crankcase keyway in the 11 o'clock
position. This will position the LH camshafts in the neutral position.
11. Verify the LH camshafts are in the neutral position.

12. Remove the LH timing chain and tensioner arm.
1. Remove the bolts.
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13. Remove the LH timing chain and timing chain guide.
14. Remove the crankshaft pulley bolt and the crankshaft sprockets.
Installation
1. NOTICE: Failure to verify correct timing drive component alignment will result in severe engine
damage.
Install the crankshaft sprocket with the timing mark facing out. The timing mark on the LH and RH timing chains
will be aligned to this mark during assembly.
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2. NOTE: LH shown, RH similar.
Position the chain tensioner in a soft-jawed vise.
Hold the chain tensioner ratchet lock mechanism away from the ratchet stem with a small pick.
4. NOTICE: During tensioner compression, do not release the ratchet stem until the tensioner piston is
fully bottomed in its bore or damage to the ratchet stem will result.
Slowly compress the timing chain tensioner.
5. Retain the tensioner piston with a 1.5 mm (0.05 in) wire or paper clip.
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6. If timing marks in the timing chains are not evident, use a permanent-type marker to mark the crankshaft and
camshaft timing marks on the LH and RH timing chains.
1. Mark any link to use as the crankshaft timing mark.
2. Starting with the crankshaft timing mark, count 29 links and mark the link.
3. Continue counting to link 42 and mark the link.
7. Verify that the LH camshafts are correctly positioned.

8. Position the LH timing chain and guide and install the bolts.
 Align the marks on the timing chain with the marks on the camshaft and crankshaft sprockets.
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9. Install the LH timing chain tensioner arm and the LH timing chain tensioner.
1. Install the tensioner arm.
2. Position the tensioner.
3. Install the bolts.
10. Install the crankshaft pulley bolt and rotate the crankshaft clockwise 120 degrees until the crankshaft keyway is
in the 3 o'clock position.
11. Verify that the RH camshafts are correctly positioned.
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12. Install the RH timing chain and chain guide and install the bolts.
13. Install the RH timing chain tensioner and tensioner arm.

14. Remove the LH and RH timing chain tensioner piston retaining wires.
15. Rotate the crankshaft counterclockwise 120 degrees to TDC.
damage.
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Verify the timing with the following steps.
1. There should be 12 chain links between the camshaft timing marks.
2. There should be 27 chain links between the camshaft and the crankshaft timing marks.
17. Remove the crankshaft pulley bolt.

stamped "30" or "30RFF" (orange in color).
Install the ignition pulse wheel.
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19. Install the LH and RH spark plugs. For additional information, refer to Section 303-07B .
20. Install the engine front cover. For additional information, refer to Engine Front Cover in this section.

Valve Train Components — Exploded View
Valve Train Components — LH
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1 6A266 LH intake camshaft
2 6B280 Intake camshaft thrust bearing cap
3 W710702 Intake camshaft thrust bearing cap bolt (2 required)
4 6A258 Intake camshaft bearing cap (3 required)
5 W710702 Intake camshaft bearing cap bolt (6 required)
6 6A266 LH exhaust camshaft
7 6B280 Exhaust camshaft thrust bearing cap
8 W710702 Exhaust camshaft thrust bearing cap bolt (2 required)
9 6B280 Exhaust camshaft bearing cap (4 required)
10 W710702 Exhaust camshaft bearing cap bolt (8 required)
11 6A359 Coolant pump drive pulley
12 6K292 Camshaft oil seal
13 W701242 Camshaft oil seal retainer bolt (2 required)
14 6B293 Camshaft oil seal retainer
15 6B295 Camshaft oil seal retainer gasket
16 6529 Roller follower (12 required)
17 6518 Valve spring retainer key (24 required)
18 6514 Valve spring retainer (12 required)
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19 6513 Valve spring (12 required)
20 6A517 Valve stem seal (12 required)
21 6C501 Hydraulic lash adjuster (12 required)
Valve Train Components — RH

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1 6529 Roller follower
2 6518 Valve spring retainer key
3 6514 Valve spring retainer
4 6513 Valve spring
5 6A517 Valve stem seal
6 6C501 Hydraulic lash adjuster
7 W710702 Camshaft bearing cap bolt (16 required)
8 6B280 Camshaft bearing thrust cap (2 required)
9 6A258 Camshaft bearing cap (6 required)
10 6A266 Exhaust camshaft
11 6A266 Intake camshaft

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Camshafts — LH
Special Tool(s)
Installer, Camshaft Oil Seal
303-464 (T94P-6256-BH)
Installer, Camshaft Pulley

303-458 (T94P-6312-AH3), part of
303-S455
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Installer, Power Steering Pump
Pulley
211-185 (T91P-3A733-A)
Plate, Water Pump Pulley

303-456 (T94P-6312-AH1), part of
303-S455
Protector, Camshaft Oil Seal

303-463 (T94P-6256-AH)
Protector, Water Pump Shaft

303-457 (T94P-6312-AH2), part of
303-S455
Remover, Crankshaft Vibration

Damper
303-009 (T58P-6316-D)
Remover, Oil Seal
303-409 (T92C-6700-CH)
Spacer, Water Pump Pulley

303-459 (T94P-6312-AH4), part of
303-S455
Material
Item Specification
ZC-31
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equivalent
Removal
1. Remove the coolant pump belt. For additional information refer to Section 303-05B .
2. Remove the timing drive components. For additional information, refer to Timing Drive Components in
this section.
3. NOTICE: Failure to use the correct special tools, assembled as shown in the illustration, will
result in damage to the coolant pump pulley and/or special tools.
Using the special tools, remove the coolant pump pulley.

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4. NOTICE: Do not scratch the camshaft sealing surface while removing the camshaft oil seal. If
scratched, camshaft oil seal leakage may occur.
Using the special tools, remove and discard the camshaft oil seal.
5. Remove the 2 bolts and the camshaft oil seal retainer.

 Discard the press-in-place gasket.
6. NOTICE: Cylinder head camshaft bearing caps must be assembled in their original positions.
Some engines have factory markings on the camshaft bearing caps (as shown in illustration).
Engines that do not have the factory markings must be marked for correct position and
orientation prior to removal. Failure to install the camshaft bearing caps in their original
position may result in severe engine damage.
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If necessary, mark the camshaft bearing cap position and orientation as shown in the illustration.
7. NOTICE: After loosening all of the camshaft bearing cap bolts, remove the camshaft bearing
thrust caps (1L and 6L) first, or damage to the thrust caps may occur.
NOTE: Make sure the camshaft bearing caps are marked as instructed in the previous step.
Loosen the bolts evenly in the sequence shown.
1. Remove the camshaft bearing thrust caps (1L and 6L).
2. Remove the remaining camshaft bearing caps.
3. Remove the camshafts from the cylinder head.
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Installation
1. Lubricate the camshafts with clean engine oil and carefully position the camshafts into the cylinder
head.
 Align the camshafts as shown.
2. NOTICE: The camshaft caps must be installed in their original positions or damage to the
engine may occur.
NOTICE: Do not install the camshaft journal thrust caps until all of the camshaft bearing caps
have been installed, or damage to the thrust caps may occur.
Lubricate the bearing surfaces of the camshaft bearing caps with clean engine oil and install the
bearing caps.
 Loosely install the bolts.
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3. Lubricate the bearing surfaces of the camshaft bearing thrust caps with clean engine oil and install
the bearing thrust caps.
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5. NOTE: Clean the sealing surfaces with metal surface prep before installing a new press-in-place
gasket.
Install the camshaft oil seal retainer and the 2 bolts.

6. NOTE: Lubricate the camshaft oil seal with clean engine oil.
Using the special tools, install the camshaft oil seal.
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Install the special tool in the camshaft as shown in the illustration.
 Adjust the collar on the special tool screw to get the best thread engagement in the rear of the
camshaft.
NOTE: Only the roller collared nut from the Power Steering Pump Pulley Installer (211-185) is used
on Camshaft Pulley Installer (303-485).
Position the coolant pump pulley over the previously installed special tool and on the end of the
camshaft. Install the special tools as shown in the illustration.
 Using the special tools, install a new service coolant pump pulley flush with the end of the
camshaft.
9. Install the timing drive components. For additional information, refer to Timing Drive Components in
this section.
10. Install the coolant pump belt. For additional information refer to Section 303-05B .
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Camshafts — RH
Material
Item Specification
equivalent
Removal
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this section.
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thrust caps (5R and 1R) first, or damage to the thrust caps may occur.

1. Remove the camshaft bearing thrust caps (5R and 1R).
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Installation
1. Lubricate the camshafts with clean engine oil and carefully position the camshafts into the cylinder
head.
 Align the camshafts as shown.
2. NOTICE: The camshaft caps must be installed in their original positions or damage to the
engine may occur.
NOTICE: Do not install the camshaft bearing thrust caps until all of the camshaft bearing caps
have been installed, or damage to the thrust caps may occur.
Lubricate the bearing surfaces of the camshaft bearing caps with clean engine oil and install the
bearing caps.
3. Lubricate the bearing surfaces of the camshaft bearing thrust caps with clean engine oil and install
the bearing thrust caps.

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this section.

Camshaft Roller Follower
Special Tool(s)
Compressor, Valve Spring
303-473 (T94P-6565-BH)
Material
Item Specification
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equivalent
02 .
2. Remove the LH and RH valve covers. For additional information, refer to Valve Cover — LH and
Valve Cover — RH in this section.
3. Remove the LH and RH spark plugs. For additional information, refer to Section 303-07B .
4. Remove the RH splash shield.

 To install, tighten to 9 Nm (80 lb-in).
5. Rotate the crankshaft until the camshaft lobe is pointing directly away from the roller follower.
6. Using the Valve Spring Compressor, remove the roller followers.

7. NOTE: Lubricate the camshaft followers with clean engine oil.
To install, reverse the removal procedure.
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Hydraulic Lash Adjuster
Material
Item Specification
SAE 5W-20 Super Premium Motor Oil
CXO-5W20-LSP12 (Canada); or
equivalent
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1. Remove the camshaft roller followers. For additional information, refer to Camshaft Roller Follower in this
section.
2. NOTE: Mark the positions of the hydraulic lash adjusters to make sure they are assembled in their original
positions.
Remove the hydraulic lash adjusters.
3. NOTE: Inspect the hydraulic lash adjusters for scoring marks and uneven wear in the bore. Install new
lash adjusters if necessary.

 Lubricate the hydraulic lash adjusters with clean engine oil.

Valve Spring, Retainer, and Seal
Special Tool(s)
303-473 (T94P-6565-BH)
Installer, Valve Stem Oil Seal

303-470 (T94P-6510-CH)
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Material
Item Specification
equivalent
Removal
1. Remove the camshaft roller followers. For additional information, refer to Camshaft Roller Follower in
this section.
2. NOTE: If air pressure has forced the piston to the bottom of the cylinder, any loss of air pressure will
allow the valve(s) to fall into the cylinder. A rubber band, tape or string wrapped around the end of the
valve stem will prevent this from happening.
Pressurize the cylinder using compressed air.
3. Using the Valve Spring Compressor, remove the key, retainer and the valve spring.
4. NOTE: Camshaft removed for clarity.
Remove the valve seal.
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Installation
1. NOTE: Lubricate the valve guide with clean engine oil.
Using the Valve Stem Oil Seal Installer, install the valve seal.
2. Using the Valve Spring Compressor, install the valve spring, retainer and key.
3. Install the camshaft roller followers. For additional information, refer to Camshaft Roller Follower in
this section.
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Cylinder Head — RH
Material
Item Specification
ZC-31-A
equivalent
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1 6065 Cylinder head bolt (8 required)
2 6529 Camshaft roller follower (12 required)
4 6049 Cylinder head
5 6051 Cylinder head gasket
Removal
2. Remove the lower intake manifold. For additional information, refer to Lower Intake Manifold in this
section.
3. Remove the coolant pump housing. For additional information, refer to Section 303-03A .
4. Remove the RH camshafts. For additional information, refer to Valve Train Components — Exploded
View and Camshafts — RH in this section.
5. NOTICE: The camshaft roller followers must be installed in their original positions. If not
reassembled in their original positions, severe engine damage may occur.
Remove the camshaft roller followers.
6. NOTICE: The hydraulic lash adjusters must be installed in their original positions. If not
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7. Remove the RH exhaust manifold. For additional information, refer to Section 309-00 .
8. NOTE: New cylinder head bolts must be installed. They are a torque-to-yield design and cannot be
reused.
Remove the bolts in the sequence shown.

 Remove the cylinder head.
 Discard the bolts and gasket.
9. Support the cylinder head on a bench with the head gasket side up. Check the cylinder head distortion
and the cylinder block distortion. For additional information, refer to Section 303-00 .
Installation
paths.
Use a plastic scraping tool to remove all traces of the head gasket.
 Clean all surfaces with metal surface prep.
2. Position a new gasket and the cylinder head.
reused.
Install the bolts and tighten in 6 stages in the sequence shown.

 Stage 2: Tighten 90 degrees.
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4. Install the RH exhaust manifold. For additional information, refer to Section 309-00 .
Install the hydraulic lash adjusters.

Install the camshaft roller followers.

 Lubricate the camshaft roller followers with clean engine oil.
7. Install the RH camshafts. For additional information, refer to Valve Train Components — Exploded View
and Camshafts — RH in this section.
8. Install the coolant pump housing. For additional information, refer to Section 303-03A .
9. Install the lower intake manifold. For additional information, refer to Lower Intake Manifold in this
section.

Cylinder Head — LH
Material
Item Specification
ZC-31-A
equivalent
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LH Cylinder Head
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1 6065 Cylinder head bolt (8 required)
2 6529 Camshaft roller follower (12 required)
4 6050 Cylinder head
5 6750 Oil level indicator
6 6754 Oil level indicator tube
7 W701822 Oil level indicator tube stud bolt
8 110282 Oil level indicator tube O-ring
9 6083 Cylinder head gasket
Upper Radiator Support Brackets
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1 W707399 Upper radiator support bracket bolts
Removal
2. Remove the lower intake manifold. For additional information, refer to Lower Intake Manifold in this
section.
3. Remove the coolant pump housing. For additional information, refer to Section 303-03A .
4. Remove the LH camshafts. For additional information, refer to Valve Train Components — Exploded
View and Camshafts — LH in this section.
Remove the camshaft roller followers.

7. Remove the LH catalytic converter. For additional information, refer to Section 309-00 .
8. Remove the 4 upper radiator support bracket bolts.
9. Remove the oil level indicator.
10. Remove the stud bolt and then remove the oil level indicator tube by guiding it between the radiator
support and the cooling fan.
 Remove and discard the O-ring seal.
reused.
Remove the bolts in the sequence shown.
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paths.
Clean the cylinder head gasket surfaces with a plastic scraping tool and metal surface prep.
13. Support the cylinder head on a bench with the head gasket side up. Check the cylinder head distortion
and the cylinder block distortion. For additional information, refer to Section 303-00 .
Installation
1. Position a new gasket and the cylinder head.
reused.
Install the bolts and tighten in 6 stages in the sequence shown.

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3. NOTE: Installation of the oil level indicator may require the assistance of a second technician to align
the tube with the orifice.
NOTE: Install a new O-ring seal and lubricate with clean engine oil.
Guide the oil level indicator tube between the radiator support and the cooling fan and install it in the
orifice, install the stud bolt.
4. Install the oil level indicator.
5. Install the 4 upper radiator support bracket bolts.

6. Install the LH catalytic converter. For additional information, refer to Section 309-00 .

Install the camshaft roller followers.

 Lubricate the camshaft roller followers with clean engine oil.
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9. Install the camshafts. For additional information, refer to Valve Train Components — Exploded View
and Camshafts — LH in this section.
10. Install the coolant pump housing. For additional information, refer to Section 303-03A .
11. Install the lower intake manifold. For additional information, refer to Lower Intake Manifold in this
section.

Engine Lubrication Components — Exploded View

Oil Pan, Oil Pump Screen and Pickup Tube and Oil Pan Baffle
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1 W701605 Oil pan-to-engine bolt (10 required)
2 W701606 Oil pan-to-engine stud bolt (5 required)
3 W500120 Oil pan-to-transaxle bolt (2 required)
4 6675 Oil pan
5 6710 Oil pan gasket
6 W701582 Oil pump screen and pickup tube nut
7 W700005 Oil pump screen and pickup tube bolts (2 required)
8 6622 Oil pump screen and pickup tube
9 6625 Oil pump screen and pickup tube O-ring seal
10 W701542 Oil pan baffle nut (7 required)
11 6687 Oil pan baffle

Oil Pump

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1 W500300 Oil pump bolt (4 required)
2 6621 Oil pump

Oil Pan
Material
Item Specification
ZC-31
equivalent
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TA-30 M4G323-A4
Removal
02 .
2. Remove the exhaust Y-pipe. For additional information, refer to Section 309-00 .
3. Drain the engine oil and install the drain plug.

4. Remove and discard the oil filter.
5. Remove the 2 oil pan-to-transaxle bolts.
6. NOTE: For reference during installation, mark the location of the stud bolts.
Remove the 10 bolts, 5 stud bolts and the oil pan.

 Remove and discard the oil pan gasket.
Installation
means to clean the sealing surfaces. These tools cause scratches and gouges which make
leak paths.
Use a plastic scraping tool to remove all traces of the oil pan gasket.
 Clean all sealing surfaces with metal surface prep and install a new oil pan gasket.
2. NOTE: The oil pan must be installed and the bolts tightened within 4 minutes of sealant application.
Apply a 10 mm (0.40 in) diameter dot of silicone sealant to the areas indicated.
3. Position the oil pan and loosely install the bolts and stud bolts.
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4. Install the 2 oil pan-to-transaxle bolts.
5. Tighten the oil pan-to-engine bolts and stud bolts in the sequence shown to 25 Nm (18 lb-ft).
6. NOTE: Lubricate the engine oil filter gasket with clean engine oil prior to installing.
Install a new oil filter.

 Tighten to 5 Nm (44 lb-in) and then rotate an additional 180 degrees.
7. Install the exhaust Y-pipe. For additional information, refer to Section 309-00 .

Oil Pump Screen and Pickup Tube
Material
Item Specification
equivalent
Removal
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NOTICE: During engine repair procedures, cleanliness is extremely important. Any foreign material,
including any material created while cleaning gasket surfaces that enters the oil passages, coolant
passages or the oil pan, may cause engine failure.
02 .
2. Remove the oil pan. For additional information, refer to Engine Lubrication Components — Exploded
View and Oil Pan in this section.
3. Remove the bolts, nut and the oil pump screen and pickup tube.
Installation
1. Install a new O-ring seal on the oil pump screen and pickup tube.
 Lubricate the O-ring seal with clean engine oil.
2. Install the oil pump screen and pickup tube.

1. Position the oil pump screen and pickup tube.
2. Install the bolts and tighten to 10 Nm (89 lb-in).
3. Install the nut and tighten in 2 stages.
 Stage 1: Tighten to 5 Nm (44 lb-in).
 Stage 2: Tighten 45 degrees.
3. Install the oil pan. For additional information, refer to Oil Pan in this section.
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Oil Pan Baffle
NOTICE: During engine repair procedures, cleanliness is extremely important. Any foreign material,
including any material created while cleaning gasket surfaces that enters the oil passages, coolant
passages or the oil pan, may cause engine failure.
02 .
2. Remove the oil pump screen and pickup tube. For additional information, refer to Engine Lubrication
Components — Exploded View and Oil Pump Screen and Pickup Tube in this section.
3. Remove the 7 nuts and the oil pan baffle.
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 To install tighten the oil pan baffle nuts in 2 stages.
 Stage 2: Tighten an additional 45 degrees.

Oil Pump
Removal
02 .
this section.
3. Remove the oil pump screen and pickup tube. For additional information, refer to Engine Lubrication
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4. Remove the bolts in the sequence shown.
Installation
1. Position the oil pump and install the bolts.

2. Install the oil pump screen and pickup tube. For additional information, refer to Engine Lubrication
this section.
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Engine Oil Pressure (EOP) Switch
Material
Item Specification
Thread Sealant with PTFE WSK-M2G350-A2
TA-24
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Part
1 16102 RH lower splash shield
2 W706713 RH lower splash shield pin-type retainer
3 W707257 RH lower splash shield bolt (5 required)
4 14A464 Engine oil pressure (EOP) switch electrical connector
(part of 9H589)
5 9278 EOP switch
6 6714 Engine oil filter
2. Remove the pin-type retainer, 5 bolts and the RH lower splash shield.
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3. NOTE: Lubricate the engine oil filter gasket with clean engine oil prior to installing.
Remove the engine oil filter.

 To install, tighten to 5 Nm (44 lb-in) and then rotate an additional 180 degrees.
4. Disconnect the engine oil pressure (EOP) switch electrical connector.
5. Remove the EOP switch.


 Apply Thread Sealant with PTFE to the EOP switch threads.

Oil Level Indicator and Tube
Material
Item Specification
XO-5W20-QSP (US); Motorcraft SAE
5W-20 Super Premium Motor Oil
CXO-5W20-LSP12 (Canada); or
equivalent
1
Item Part Number
6750
Description
Oil level indicator
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2 W701822 Oil level indicator tube stud bolt
4 110282 Oil level indicator O-ring seal
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Part
5 W707399 Upper radiator support bracket bolts (4 required)
6 — Upper radiator hose retaining clips (2 required) (part of
8B274)
7 8B274 Upper radiator hose
1. Detach the upper radiator hose from the 2 retaining clips on the cooling fan shroud.
 Position the hose aside.
2. Remove the 4 upper radiator support bracket bolts.

3. Remove the oil level indicator.
4. Remove the stud bolt and then remove the oil level indicator tube by guiding it between the radiator
support and the cooling fan.
5. NOTE: Install a new O-ring seal and lubricate with clean engine oil.
NOTE: Installation of the oil level indicator may require the assistance of a second technician to align
the tube with the orifice.

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Engine Support Insulators
Special Tool(s)
3-Bar Engine Support Kit
303-F072
Lifting Brackets, Engine

303-050 (T70P-6000)
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Universal Adapter Brackets
014-0001
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1 N621942 Ground wire eyelet nut
2 — Ground wire eyelet
3 N621942 Engine support insulator bracket nuts (3 required)
4 W709667 Engine support insulator bracket bolt
5 6061 Engine support insulator bracket
6 W500233 Engine support insulator bolts (3 required)
7 6068 Engine support insulator
1. Remove the lower intake manifold. For additional information, refer to Lower Intake Manifold in this section.
2. Remove the engine support insulator bracket bolt.

3. Install the special tools.
1. Position the 2 universal adapter brackets on top of the cylinder block.
2. Install 2 M8 x 1.25 x 36 mm (1.41 in) bolts and tighten to 10 Nm (89 lb-in).
3. Position the universal lifting bracket onto the 2 universal adapter brackets.
4. Fasten the universal lifting bracket to the 2 universal adapter brackets with a suitable nut and bolt.
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4. Using the special tools, lift the engine 12 mm (0.47 in).
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5. Remove the nut and ground wire eyelet from the engine support insulator bracket stud.
6. Remove the 3 nuts and the engine support insulator bracket.

7. Remove the 3 bolts and the engine support insulator.


REMOVAL Procedure revision date: 10/21/2008
Engine
Special Tool(s)
Engine Lifting Bracket Set
303-1140
Front Drive Halfshaft Remover

205-241 (T86P-3514-A)
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303-050 (T70P-6000)
Powertrain Lift with Tilting Plate

014-00765
Slide Hammer
101-001
Spreader Bar
303-D089 (D93P-6001-A3) or
equivalent
Tie-Rod End Remover

211-105 (T85M-3395-A)
014-0001
Removal
All vehicles
02 .
2. Release the fuel system pressure. For additional information, refer to Section 310-00 .
3. Remove the battery tray. For additional information, refer to Section 414-01 .
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4. Remove the air cleaner outlet pipe and air cleaner. For additional information, refer to Section 303-
12B .
5. Remove the front wheels and tires. For additional information, refer to Section 204-04 .
6. Remove the lower splash shields.
7. Disconnect the catalyst monitor sensor electrical connector and the 2 wiring harness retainers.
8. Remove the 4 bolts and the lateral support crossmember.
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9. Remove and discard the 6 exhaust Y-pipe-to-catalytic converter nuts.
10. Detach the exhaust hanger and remove the exhaust Y-pipe.
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Remove the LH and RH brake hose retainers and ABS sensor wiring harness bolts.
Remove the LH and RH stabilizer link-to-strut nuts.

Remove the LH and RH tie-rod end nuts.
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Using the special tool, separate the LH and RH tie-rod ends from the steering knuckles.
Remove the LH and RH lower ball joint pinch bolts and nuts.
 Separate the steering knuckles from the lower ball joints.
16. Using the Halfshaft Remover and Slide Hammer, remove the LH front drive halfshaft from the
differential and secure aside.
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17. Using a brass drift to strike the RH halfshaft in the indicated area, separate the halfshaft from the
intermediate shaft and secure aside.
18. NOTE: A new power transfer unit (PTU) intermediate shaft seal must be installed whenever the
intermediate shaft or PTU is removed from the vehicle.
Remove the 2 intermediate shaft retaining nuts.

 Remove the intermediate shaft.
All wheel drive (AWD) vehicles
19. NOTICE: Do not reuse the driveshaft flange bolts and washers. Install new bolts and washers
or damage to the vehicle may occur.
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NOTE: Index-mark the drive shaft flange and power transfer unit (PTU) flange for installation.
Remove and discard the 6 front driveshaft-to-PTU bolts and washers.

 Position the driveshaft aside and support with mechanic's wire.
All vehicles
20. Rotate the accessory drive belt tensioner counterclockwise and remove the accessory drive belt.
21. Drain the engine coolant. For additional information, refer to Section 303-03A .
22. Drain the engine oil and install the drain plug.
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23. Disconnect the A/C clutch field coil electrical connector.
24. Remove the 3 bolts and position the A/C compressor aside.
25. Remove the 3 accessory drive belt idler pulley assembly bolts.
 Detach the wiring harness retainer and remove the idler pulley assembly.
26. Remove the front roll restrictor bolt and the 2 bolts for the engine support cross brace.
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27. Remove the rear nut and the engine support crossmember.
 Discard the nut.
28. Disconnect the 2 transmission cooler tubes (1 shown).

29. Loosen the transaxle cooler tube fitting.
 Remove the bracket bolt and the transaxle cooler tube.
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30. Disconnect the EGR tube fitting from the converter.
32. Disconnect the accelerator cable and the speed control actuator cable.
 Remove the 2 accelerator cable bracket bolts.
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33. Remove the bolt and position the cables and brackets aside.
34. Disconnect the upper and lower radiator hoses.

35. Disconnect the heater hoses and the throttle body coolant hose.
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36. Detach the transaxle vent tube retainer from the throttle body.
37. Disconnect the fuel supply tube quick connect coupling. For additional information, refer to Section
310-00 .
38. Disconnect the gearshift cable from the transaxle.

39. Disconnect the wire harness retainer from the shift cable bracket, remove the 2 remaining bolts, and
position the cable and bracket aside.
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40. Disconnect the differential pressure feedback EGR sensor electrical connector and detach the pin-
type retainer.
41. Disconnect the EGR tube fitting and remove the EGR tube and the differential pressure feedback
EGR sensor as an assembly.
42. Disconnect the evaporative emissions (EVAP) canister purge valve tube from the intake manifold.
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43. Disconnect the brake booster vacuum tube from the intake manifold.
44. Disconnect the manifold absolute pressure (MAP) sensor vacuum tube and electrical connector.
45. Disconnect the PCM electrical connectors and remove the nut.
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46. Remove the bolt and detach the ground wire.
47. Remove the nut and disconnect the cable from the power distribution box.
48. Disconnect the electrical connector from the power distribution box.
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49. Remove the bolt and disconnect the ground wire and the electrical connector.
50. Detach the wiring harness retainers from the battery tray bracket.
51. Remove the nut and disconnect the wire from the battery cable.
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52. Remove the nut and the ground wire from the engine mount stud.
53. If equipped, disconnect the engine block heater electrical connector.

54. Disconnect the output shaft speed (OSS) sensor electrical connector and remove the bolt and the
OSS sensor.
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55. Remove the torque converter inspection cover.
56. Remove the 4 torque converter nuts.

57. Remove the 2 oil pan-to-transaxle bolts.
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58. Remove the 2 nuts and the transaxle-to-engine stud.
59. NOTICE: Do not allow the engine oil pan to rest on the powertrain lift. Doing so may cause
damage to the oil pan.
Using the special tools, secure the engine and transaxle to the powertrain lift.
NOTE: The next 5 steps must be carried out with the vehicle raised and the powertrain lift in position.
60. Remove the RH transaxle support insulator bolt.
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61. Remove the bolt, nuts and the RH transaxle support insulator.
62. Remove the rear transaxle support bolt.

63. Remove the 3 engine support bracket nuts and the bolt.
 Remove the engine support bracket.
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64. Lower the powertrain from the vehicle.
65. Disconnect the LH heated exhaust gas oxygen (HEGO) sensor and LH catalyst monitor sensor
electrical connectors.
 Detach the 3 pin-type retainers from the transaxle support bracket.
66. Disconnect the transmission range (TR) sensor electrical connector.

67. Disconnect the transaxle electronic control switch electrical connector.
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68. Detach the wiring harness from the bracket.
69. Disconnect the turbine speed sensor (TSS) electrical connector.

 Detach the 2 wiring harness retainer.
AWD vehicles
70. Disconnect the RH HO2S electrical connector.
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71. Remove the 6 RH exhaust manifold nuts and the manifold.
 Discard the nuts and gasket.
72. Remove and discard the 6 RH exhaust manifold studs.

73. Remove the 6 bolts and the halfshaft support bracket.
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74. Remove the bolt, detach the pin-type retainer and position the power transfer unit (PTU) vent tube
aside.
75. Remove the 3 PTU bolts.

76. Remove the bolt and the PTU.
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77. Remove the 3 bolts and the PTU heat shield.
78. Using the Halfshaft Oil Seal Remover and Slide Hammer, remove the intermediate shaft seal.
All vehicles
79. Remove the nut and detach wiring harness retainer.
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80. Remove the 2 stud bolts and position the EGR regulator aside.
81. NOTE: When installing the lower half of the lifting bracket it will be easier to loosely install the upper
bolt first then install the lower bolt.
Install the lower half of the special tool.

82. Install the upper half of the special tool.
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83. Install the special tools to the front of the RH cylinder head.
84. Install the special tools to the rear of the LH cylinder head.
85. Using the special tools and a suitable engine crane, remove the engine and transaxle from the lift
table.
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86. Remove the 5 remaining transaxle-to-engine bolts (3 shown).
87. Using the special tools and a suitable engine crane, separate the engine and transaxle.

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DISASSEMBLY Procedure revision date: 01/07/2009
Engine
Special Tool(s)
Installer, Connecting Rod
303-462 (T94P-6136-AH)
Plate, Water Pump Pulley

303-456 (T94P-6312-AH1), part of
303-S455
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Protector, Water Pump Shaft
303-457 (T94P-6312-AH2), part of
303-S455
Remover, Crankshaft Rear Oil

Seal
303–519 (T95P-6701-EH)
Remover, Crankshaft Vibration

Damper
303–009 (T58P-6316-D)
Remover, Oil Seal

303-409 (T92C-6700CH)
Remover, Stretchy Belt

303-1419
Slide Hammer
307-005 (T59L-100-B)
Socket, Exhaust Gas Oxygen

Sensor
303–476 (T94P-9472-A)
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Strap Wrench
303-D055 (D85L-6000-A)
Material
Item Specification
ZC-31-A
Penetrating and Lock Lubricant —
XL-1 (US); CXC-51-A (Canada)
NOTE: For additional information, refer to the exploded view under the assembly procedure in this section.
All vehicles
1. Remove the bolts and the flexplate.

2. Remove the engine-to-transaxle separator plate.
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3. Using the special tools, remove and discard the crankshaft rear oil seal.
4. Mount the engine on a suitable stand.
5. Detach the wiring harness connectors from the upper intake manifold.
6. Detach the wiring harness retainer, remove the nut and the catalyst monitor sensor electrical
connector bracket.
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7. Disconnect the crankshaft position (CKP) sensor electrical connector and detach the wiring harness
retainers.
8. Disconnect the exhaust gas recirculation (EGR) vacuum regulator electrical connector.
9. Remove the 2 wiring harness retaining nuts.
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10. Disconnect the idle air control (IAC) valve and the throttle position (TP) sensor electrical connectors.
 Detach the wiring harness retainer.
11. Remove the PCV tube.

12. Disconnect the fuel rail pressure and temperature sensor electrical connector and vacuum tube.
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13. Disconnect the throttle body coolant hose.
14. NOTICE: If the engine is repaired or replaced because of upper engine failure, typically
including valve or piston damage, check the intake manifold for metal debris. If metal debris is
found, install a new intake manifold. Failure to follow these instructions can result in engine
damage.
Remove the bolts and upper intake manifold.

 Discard the gaskets.
15. Disconnect the engine coolant temperature (ECT) sensor electrical connector.
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16. Disconnect the RH coil-on-plug electrical connectors.
 Detach the 2 wiring harness retainers.
17. Disconnect the radio interference capacitor electrical connector.

 Detach the wiring harness retainers.
18. Disconnect the LH coil-on-plug electrical connectors.
 Detach the 2 wiring harness retainers.
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19. Disconnect the camshaft position sensor (CMP) and engine oil pressure (EOP) switch electrical
connectors.
 Detach the wiring harness retainers.
20. Disconnect the generator electrical connector.

21. Remove the nut and the B+ wire from the generator.
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22. Disconnect the 6 fuel injector electrical connectors.
23. Detach the 2 wiring harness retainers (1 shown).

 Remove the fuel charging wiring harness from the engine.
24. Remove the nut and detach the 4 wiring harness retainers.
 Remove the B+ harness from the engine.
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25. NOTICE: If the engine is repaired or replaced because of upper engine failure, typically
including valve or piston damage, check the intake manifold for metal debris. If metal debris is
found, install a new intake manifold. Failure to follow these instructions can result in engine
damage.
Remove the bolts and the lower intake manifold.

26. NOTE: When removing the coil-on-plugs, a slight twisting motion will break the seal and ease
removal.
NOTE: LH shown, RH similar.
Remove the bolts and the 6 coil-on-plugs.
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Front wheel drive (FWD) vehicles
27. Disconnect the RH heated oxygen sensor (HO2S) electrical connector.
28. Remove the 6 nuts, the RH exhaust manifold and the gasket.
 Discard the gasket and nuts.
29. Remove and discard the 6 RH exhaust manifold studs.
30. Remove the bolts and the halfshaft support bracket.
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All vehicles
31. Remove the bolt, 2 nuts and the generator.
32. Remove the 3 bolts and the A/C compressor bracket.

33. Remove the EOP switch and, if equipped, the block heater.
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34. Remove the stud bolt and the oil level indicator and tube.
35. NOTE: If necessary, lubricate the sensor threads with penetrating and lock lubricant to assist in
removal.
Using the special tool, remove the HO2S.

36. Remove the nuts, the LH exhaust manifold and the gasket.
 Discard the gasket and nuts.
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37. Remove and discard the 6 LH exhaust manifold studs.
38. Remove and discard the oil filter.

39. Position the Stretchy Belt Remover under the coolant pump belt as shown.
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40. NOTE: Feed the Stretchy Belt Remover on to the camshaft coolant pump pulley approximately 90
degrees.
Turn the crankshaft clockwise and feed the Stretchy Belt Remover evenly on the camshaft coolant
pump pulley as shown.
41. Remove the coolant pump belt.

 Fold the Stretchy Belt Remover over the top of the coolant pump belt.
 In one quick motion, pull the Stretchy Belt Remover up and toward the front of the engine,
removing the coolant pump belt.
Using the special tools, remove the coolant pump pulley.
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43. Disconnect the 2 hoses and remove the thermostat housing.
44. Remove the nut, stud bolt and the coolant bypass tube.
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45. Disconnect the coolant pump hose from the cylinder block outlet.
46. Remove the 3 bolts and the coolant pump.

47. Remove the nut and the radio interference capacitor.
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48. Remove the bolts and the RH valve cover.
 Discard the gasket.
49. Remove the bolts and the LH valve cover.

50. Remove the bolts, studs and the oil pan.
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51. Remove the bolts, nut and the oil pump screen and pickup tube.
52. Remove and discard the O-ring seal.

53. Remove the nuts and the oil pan baffle.
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54. Remove the 3 bolts and the accessory drive belt tensioner, LH and center idler pulley.
55. Use the special tool to hold the crankshaft pulley and remove the bolt.
56. Using the special tool, remove the crankshaft pulley.
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57. Remove and discard the crankshaft front seal.
means to clean the sealing surface. These tools cause scratches and gouges, which make
leak paths. Use a plastic scraping tool to remove all traces of sealant.
Remove the 14 bolts, 2 stud bolts and the front cover.

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59. NOTE: This pulse wheel is used in several different engines. Install the pulse wheel with the keyway
in the slot stamped "30" or "30RFF" (orange in color).
Remove the ignition pulse wheel.
60. NOTICE: Only use hand tools when removing or installing the spark plugs or damage can
occur to the cylinder head or spark plug.
NOTE: LH shown, RH similar.
Remove the LH and RH spark plugs.

61. Install the crankshaft pulley bolt.
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62. Rotate the crankshaft clockwise to position the crankshaft keyway in the 11 o'clock position and
position the camshafts in the correct position. This will position the No. 1 cylinder at top dead center
(TDC).
 Verify that the camshafts are correctly located. If not, rotate the crankshaft one additional turn
and recheck.
63. Rotate the crankshaft clockwise 120 degrees to the 3 o'clock position to position the RH camshafts in
the neutral position.
64. Verify that the RH camshafts are in the neutral position.
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65. Remove the RH timing chain tensioner arm.
1. Remove the 2 bolts.
66. Remove the bolts, RH timing chain guide and the timing chain.
67. Rotate the crankcase clockwise 600 degrees (1-2/3 turns) to position the crankcase keyway in the 11
o'clock position. This will position the LH camshafts in the neutral position.
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68. Verify the LH camshafts are in the neutral position.
69. Remove the LH timing chain and tensioner arm.

1. Remove the 2 bolts.
70. Remove the LH timing chain and timing chain guide.
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71. Remove the crankshaft pulley bolt and the crankshaft sprocket.
72. Remove the 4 bolts in the sequence shown.

 Remove the oil pump.
73. NOTICE: Do not scratch the camshaft sealing surface while removing the camshaft oil seal. If
scratched, camshaft oil seal leakage may occur.
Using the special tools, remove the camshaft oil seal and discard.
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74. Remove the 2 bolts and the camshaft oil seal retainer.
 Discard the press-in-place gasket.
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thrust caps (1L and 6L) first, or damage to the thrust caps may occur.

1. Remove the camshaft bearing thrust caps (1L and 6L).
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thrust caps (5R and 1R) first, or damage to the thrust caps may occur.

1. Remove the camshaft bearing thrust caps (5R and 1R).
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NOTE: RH shown, LH similar.
Remove the LH and RH camshaft roller followers.

 Mark the location of the roller followers, using a permanent-type marker.

81. NOTE: RH shown, LH similar.
Loosen the bolts in the indicated sequence and remove the LH and RH cylinder heads.
 Discard the bolts and the gaskets.
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means to clean the sealing surfaces. These tools cause scratches and gouges which make
leak paths.
Clean the cylinder head gasket surfaces with a plastic scraping tool and metal surface prep.
83. Support the cylinder head on a bench with the head gasket side up. Check the cylinder head
distortion and the cylinder block distortion. For additional information, refer to Section 303-00 .
84. Remove the bolts and the oil separator cover.

85. Remove the crankshaft key.

86. Before removing the pistons, inspect the top of the cylinder bores. If necessary, remove the ridge or
carbon deposits from each cylinder using an abrasive pad or equivalent, following manufacturer's
instructions.
87. NOTE: Clearly mark the position and orientation of the pistons, connecting rods, connecting rod caps
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and connecting rod bearings for reassembly.
Remove the connecting rod cap bolts and cap.

 Discard the connecting rod cap bolts.
88. NOTICE: Do not scratch the cylinder walls or crankshaft journals with the connecting rod.
Using the Connecting Rod Installer, remove the piston/rod assembly from the engine block.
 Repeat these 2 steps until all the piston/rod assemblies are removed from the engine block.
89. Remove the engine block from the stand and place on a workbench.
90. Remove the bolts and studs in the indicated sequence.

 Discard the lower cylinder block bolts.
 Remove the lower cylinder block.
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91. Remove the crankshaft rear main seal.
 Remove the crankshaft.
92. Remove the crankshaft thrust bearing from the cylinder block.
93. NOTE: If the main bearings are being reused, mark them for correct position and orientation for
reassembly.
Remove the bearings from the lower cylinder block.
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94. NOTE: If the main bearings are being reused, mark them for correct position and orientation for
reassembly.
Remove the crankshaft main bearings from the cylinder block.
95. Inspect the cylinder block, lower cylinder block, pistons and connecting rods. For additional
information, refer to Section 303-00 .
2008 Escape/Mariner/Escape Hybrid/Mariner Hybrid Workshop
SECTION 303-01B: Engine — 3.0L (4V)
Manual
DISASSEMBLY AND ASSEMBLY OF
Procedure revision date: 07/10/2007
SUBASSEMBLIES
Cylinder Head
Special Tool(s)
303-300 (T87C-6565-A)

303-350 (T89P-6565-A)
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303-1418
Installer, Valve Stem Oil Seal

303-470 (T94P-6510-CH)
Cylinder Head
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1 6518 Valve spring retainer key (24 required)
2 6514 Valve spring retainer (12 required)
3 6513 Valve spring (12 required)
4 6A517 Valve stem seal (12 required)
5 6505 Intake valve (6 required)
6 6507 Exhaust valve (6 required)
Disassembly
NOTICE: If the components are to be reinstalled, they must be installed in the same positions. Mark the
components removed for locations. If not reassembled in their original positions, severe engine
damage may occur.
1. Using the Valve Spring Compressors, remove the keys, retainer and spring.
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2. Remove the valve from the cylinder head.
3. Remove the valve stem seal.
Assembly
1. Using the Valve Stem Oil Seal Installer, install the valve stem seal.
2. Install the valve.
3. Using the Valve Spring Compressors, install the valve spring, retainer and keys.
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2008 Escape/Mariner/Escape Hybrid/Mariner Hybrid Workshop
SECTION 303-01B: Engine — 3.0L (4V)
Manual
DISASSEMBLY AND ASSEMBLY OF
Procedure revision date: 05/08/2009
SUBASSEMBLIES
Piston
Material
Item Specification
equivalent
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1 6150 Piston compression upper ring
2 6152 Piston compression lower ring
3 6159 Piston oil control upper segment ring
4 6161 Piston oil control spacer
5 6159 Piston oil control lower segment ring
6 6140 Piston pin retainer
7 6140 Piston pin retainer
8 6135 Piston pin
9 6200 Connecting rod
10 6110 Piston
Disassembly
1. Remove the piston rings from the piston.

 Discard the piston rings.
2. Remove the 2 piston pin retainers and the piston pin.
3. NOTE: If the piston and connecting rod are to be reinstalled, they must be assembled in the same
orientation. Mark the piston orientation to the connecting rod for reassembly.
Separate the piston from the connecting rod.
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4. Clean and inspect the piston and connecting rod. For additional information, refer to Section 303-00 .
Assembly
1. Align the piston-to-connecting rod orientation marks and position the connecting rod in the piston.
2. Lubricate the piston pin and pin bore with clean engine oil.
3. Install the piston pin in the piston and connecting rod assembly.
4. Install the piston pin retaining clips in the piston.
5. Lubricate the piston and the new piston rings with clean engine oil.
6. NOTE: The piston compression lower ring should be installed with the "O" mark on the ring face
pointing up toward the top of the piston.
NOTE: When installing the piston oil control spacer, orient the gap such that the cut ends are pointed
toward the top of the piston.
Install the piston rings onto the piston as shown.

1. Center line of the piston parallel to the wrist pin bore
2. Upper compression ring gap location
3. Upper oil control segment ring gap location
4. Lower oil control segment ring gap location
5. Expander ring and lower compression ring gap location

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ASSEMBLY Procedure revision date: 01/28/2010
Engine
Special Tool(s)
Compressor, Piston Ring
303-D032 (D81L-6002-C)
Dial Indicator Gauge with Holding

Fixture
100-002 (TOOL-4201-C)
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Installer, Camshaft Oil Seal
303-464 (T94P-6256-BH)
Installer, Camshaft Pulley

303-458 (T94P-6312-AH3), part of
303-S455
Installer, Connecting Rod

303-462 (T94P-6136-AH)
Installer, Crankshaft Rear Main Oil

Seal
303-178 (T82L-6701-A)
Installer, Crankshaft Vibration Damper

303-102 (T74P-6316-B)
Installer, Front Cover Oil Seal

303-335 (T88T-6701-A)
Installer, Power Steering Pump Pulley
211-185 (T91P-3A733-A)
Installer Bolts, Crankshaft Rear Main

Oil Seal
303-384 (T91P-6701-A)
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303-050 (T70P-6000)
Protector, Camshaft Oil Seal

303-463 (T94P-6256-AH)
Socket, Exhaust Gas Oxygen Sensor

303-476 (T94P-9472-A)
Spacer, Water Pump Pulley

303-459 (T94P-6312-AH4), part of
303-S455
Spreader Bar
303-D089 (D93P-6001-A3) or
equivalent
Material
Item Specification
High Temperature Nickel Anti-Seize ESE-M12A4-A
Lubricant
XL-2 (US); CXG-2-B (Canada)
ZC-31
XO-5W20-QSP (US); Motorcraft SAE
5W-20 Super Premium Motor Oil CXO-
5W20-LSP12 (Canada); or equivalent
Silicone Brake Caliper Grease and ESE-M1C171-
Dielectric Compound A
XG-3-A
TA-30 M4G323-A4

Lower Engine Block (View 1)
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1 12A227 Ignition pulse wheel
2 6L266 RH timing chain tensioner
3 6K255 RH timing chain tensioner arm
4 6268 RH timing chain
5 6M256 RH timing chain guide
6 6306 Crankshaft sprocket
7 6L266 LH timing chain tensioner
8 6K255 LH timing chain tensioner arm
9 6268 LH timing chain
10 6B297 LH timing chain guide
11 6621 Oil pump
12 W701923 Cup plug
13 6B752 Oil separator gasket
14 — Cover
15 8A505 Water inlet tube
16 6701 Crankshaft rear oil seal
17 — Spacer plate
18 6375 Flexplate
19 — Engine oil pressure (EOP) switch
20 W705934 Woodruff key
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21 6622 Oil pickup tube and screen
22 6687 Oil pan baffle
23 6714 Oil filter
24 6675 Oil pan
25 10300 Generator
26 19A216 LH accessory drive belt idler pulley
27 6B209 Accessory drive belt tensioner
28 6700 Crankshaft front seal
29 6316 Crankshaft vibration damper
30 W701511 Crankshaft vibration damper washer
31 W701512 Crankshaft vibration damper bolt
32 6B288 Crankshaft position (CKP) sensor
33 6C315 Camshaft position (CMP) sensor
34 6C348 Center accessory drive belt idler pulley
35 6019 Front cover

Lower Engine Block (View 2)

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1 6150 Piston compression upper ring (6 required)
2 6152 Piston compression lower ring (6 required)
3 6159 Piston oil control upper segment ring (6 required)
4 6161 Piston oil control spacer (6 required)
5 6159 Piston oil control lower segment ring (6 required)
6 6140 Piston pin retainer (12 required)
7 6135 Piston pin (6 required)
8 6110 Piston (6 required)
9 6200 Connecting rod (6 required)
10 6211 Connecting rod upper bearing (6 required)
11 6211 Connecting rod lower bearing (6 required)
12 6210 Connecting rod cap (6 required)
13 6010 Cylinder block
14 6333 Cylinder block crankshaft main bearing (4 required)
15 6A341 Crankshaft upper thrust bearing
16 6303 Crankshaft
17 6333 Lower cylinder block crankshaft main bearings (3 required)
18 6337 Lower cylinder block crankshaft main thrust bearing
19 6F095 Lower cylinder block

Intake Manifold and Cylinder Heads
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1 6582 RH valve cover
2 18801 Radio ignition interference capacitor
3 12B637 Engine control sensor and fuel charging wiring harness
4 — PCV valve
5 — PCV tube
6 9424 Upper intake manifold
7 9J472 EGR vacuum regulator
8 9D460 EGR valve
9 9E498 Vacuum harness
10 9F715 Idle air control (IAC) valve
11 9E926 Throttle body (TB)
12 4682 Fuel rail pressure and temperature sensor
13 9F792 Fuel rail
14 9J477 Lower intake manifold
15 12A366 Coil-on-plug (6 required)
16 6A505 LH valve cover
17 6A359 Coolant pump drive pulley
18 6B293 Rear seal retainer
19 6A258 Camshaft journal cap
20 6B280 Camshaft bearing cap
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21 6A269 LH exhaust camshaft
22 8548 Coolant bypass tube
23 6A267 LH intake camshaft
24 12405 Spark plug
25 6C501 Hydraulic lash adjuster
26 6514 Valve spring retainer
27 6529 Camshaft follower
28 6518 Valve spring retainer key
29 6513 Valve spring
30 6A517 Valve stem seal
31 8501 Coolant pump
32 8K543 Coolant pump belt
33 — LH engine lifting eye (if equipped)
34 — Oil level indicator
36 6083 LH cylinder head gasket
37 6507 Intake valve
38 6505 Exhaust valve
39 6049 LH cylinder head
40 6051 RH cylinder head gasket
41 6050 RH cylinder head
42 6A266 RH intake camshaft
43 6A268 RH exhaust camshaft
44 6B280 Camshaft bearing cap
45 6A258 Camshaft journal cap
NOTICE: During engine repair procedures, cleanliness is extremely important. All parts must be thoroughly
cleaned and any foreign material, including any material created while cleaning gasket surfaces, that enters
the oil passages, coolant passages or the oil pan, can cause engine failure.
NOTICE: If the oil pan was removed during engine disassembly, it must be installed after the engine and
transaxle are assembled and the transaxle-to-engine bolts are installed. Failure to follow this assembly
sequence can result in engine oil leaks.
NOTE: Assembly of the engine requires various inspections/measurements of the engine components (engine block,
crankshaft, connecting rods, pistons and piston rings). These inspections/measurements will aid in determining if the
engine components will require replacement. For additional information, refer to Section 303-00 .
All vehicles
1. NOTE: This procedure is for selecting bearings using a new crankshaft.
Select the crankshaft main bearings for each crankshaft journal.

1. Read the code on the crankshaft flange.
2. Read the code on the cylinder block rear face.
 The first 2 numbers after the asterisk make up the code for main No. 1 and the next 2 numbers for
main No. 2.
 The first 2 numbers after the second asterisk make up the code for main No. 3 and the last 2
numbers for main No. 4.
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2. Using the chart, choose a bearing for each main. Match the block and crankshaft code with its corresponding
column or row, by reading across the "crankshaft" row and down the "block" column.
 For example: If the block code is *0609*0711* and the crankshaft code is *8580*8082*, main No. 1
should use grade 1 bearings, as determined by the intersection of the 06 block column and the 85
crankshaft row. Mains 2, 3 and 4 should all be grade 2.
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3. NOTE: Before assembling the cylinder block, all sealing surfaces must be free of chips, dirt, paint and foreign
material. Also, make sure the coolant and oil passages are clear.
Lubricate the upper crankshaft main bearings with clean engine oil and install the 4 crankshaft main bearings in
the cylinder block.
4. Lubricate the lower crankshaft main bearings with clean engine oil and install the 4 crankshaft main bearings in
the lower cylinder block.
5. Lubricate the crankshaft thrust bearing with clean engine oil and install in the cylinder block.
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6. Install the crankshaft key.
7. Apply clean engine oil to the crankshaft main and rod bearing journals.
8. Position the crankshaft in the cylinder block.

9. NOTICE: The lower cylinder block must be installed and the bolts tightened within 4 minutes of
applying the sealant.
NOTE: Clean and degrease both surfaces using metal surface prep before applying sealant.
Apply gasket and sealant to the cylinder block as shown.
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10. NOTICE: Fasteners No. 5 through 8 are studs. Fasteners No. 18 through 22 are M8 x 1.25 mm x 79.3 mm
(0.05 in x 3.12 in) bolts. Fasteners No. 1 through 4, 17 are M8 x 1.25 mm x 96 mm (0.05 in x 3.75 in) bolts.
Fasteners 9 through 12 are M10 x 1.5 mm x 106.8 mm (0.06 in x 4.20 in) /M8 x 1.25 mm x 21.5 mm (0.05
in x 0.84 in) studs. Fasteners 13 through 16 are M10 x 1.5 mm x 106.5 mm (0.06 in x 4.17 in) bolts. The
bolts and studs must be installed in the correct position or engine damage can result.
Position the lower cylinder block and install the new bolts and new studs.
 Tighten the bolts and studs in the sequence shown in 4 stages.
 Stage 1: Tighten fasteners 1 through 8 to 25 Nm (18 lb-ft).
 Stage 3: Tighten fasteners 1 through 16 an additional 90 degrees.
11. Using the Dial Indicator Gauge with Holding Fixture, measure crankshaft end play.
 Position the crankshaft to the rear of the cylinder block.
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 Zero the Dial Indicator Gauge with Holding Fixture.
 Move the crankshaft to the front of the cylinder block. Note and record the crankshaft end play.
 Acceptable crankshaft end play is 0.100-0.255 mm (0.003-0.010 in). If the crankshaft end play exceeds
the specified range, install new parts as necessary.
12. Using the Crankshaft Rear Main Oil Seal Installer and the Crankshaft Rear Main Oil Seal Installer Bolts, install
the crankshaft rear oil seal.
13. Install the engine-to-transaxle separator plate.

14. Position the flexplate and install the bolts.
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15. Mount the engine on an engine stand.
16. Using the chart, select the correct piston grade size for the cylinder bores.
 Measure the cylinder block bore diameter.
 Mark the outside of the block with the appropriate number(s) to identify bore grade size.
 Choose the correct piston grade size for the cylinder bore.
17. NOTICE: Be sure not to scratch the cylinder wall or crankshaft journal with the connecting rod. Push
the piston down until the connecting rod bearing seats on the crankshaft journal.
NOTE: Lubricate the pistons, piston rings, connecting rod bearings and the entire cylinder bores with clean
engine oil.
NOTE: Make sure the piston rings are positioned to specifications for installation. For additional information,
refer to Disassembly and Assembly of Subassemblies - Piston in this section.
NOTE: Make sure the piston arrow on top is facing toward the front of the engine.
NOTE: After installation of each piston and connecting rod, rotate the crankshaft to verify smooth operation.
Using the Piston Ring Compressor and the Connecting Rod Installer, install the piston and connecting rod
assemblies.
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18. NOTICE: The rod cap installation must keep the same orientation as marked during disassembly or
engine damage may occur.
Install the connecting rod caps and the new bolts.

 Tighten the bolts in 2 stages.
19. Install the crankcase cover, a new gasket and the bolts.
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Position the new LH and RH cylinder heads and gaskets. Install new bolts and tighten in the sequence shown
in 6 stages.
21. Install the crankshaft pulley bolt and rotate the crankshaft keyway to the 11 o'clock position to locate top dead
center (TDC).
22. NOTICE: The hydraulic lash adjusters must be installed in their original positions. If not reassembled in
their original positions, severe engine damage may occur.

23. Apply clean engine oil to the LH and RH camshaft roller followers.
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24. NOTICE: The camshaft roller followers must be installed in their original positions. If not reassembled
in their original positions, severe engine damage may occur.
NOTE: RH shown, LH similar.
Install the LH and RH camshaft roller followers.
25. Apply clean engine oil to the LH and RH camshafts.
26. Install the LH and RH camshafts.

 Locate the camshafts as shown.
27. NOTICE: Cylinder head camshaft journal caps and cylinder heads are numbered to verify that they are
assembled in their original positions. If not reassembled in their original positions, severe engine
damage may occur.
NOTICE: Do not install the camshaft journal thrust caps until all of the camshaft bearing caps have
been installed, or damage to the thrust caps can occur.
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Lubricate the bearing surfaces of the LH camshaft bearing caps with clean engine oil and install the bearing
caps.
28. Lubricate the bearing surfaces of the LH camshaft bearing thrust caps with clean engine oil and install the
bearing thrust caps.
30. NOTICE: Cylinder head camshaft journal caps and cylinder heads are numbered to verify that they are
assembled in their original positions. If not reassembled in their original positions, severe engine
damage may occur.
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NOTICE: Do not install the camshaft journal thrust caps until all of the camshaft bearing caps have
been installed, or damage to the thrust caps can occur.
Lubricate the bearing surfaces of the RH camshaft bearing caps with clean engine oil and install the bearing
caps.
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31. Lubricate the bearing surfaces of the RH camshaft bearing thrust caps with clean engine oil and install the
bearing thrust caps.

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33. NOTE: Clean the sealing surface with metal surface prep before installing a new press-in-place gasket.
Install the camshaft oil seal retainer and the 2 bolts.

34. NOTE: Apply clean engine oil to the seal lip and seal bore before installing the seal.
Using the special tools, install a new camshaft oil seal.

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damage.
Install the crankshaft sprocket with the timing mark facing out. The timing mark on the LH and RH timing chains
will be aligned to this mark during assembly.
Position the chain tensioner in a soft-jawed vise.

Hold the chain tensioner ratchet lock mechanism away from the ratchet stem with a small pick.
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39. NOTICE: During tensioner compression, do not release the ratchet stem until the tensioner piston is
fully bottomed in its bore or damage to the ratchet stem will result.
Slowly compress the timing chain tensioner.
40. Retain the tensioner piston with a 1.5 mm (0.06 in) wire or paper clip.
41. If timing marks in the timing chains are not evident, use a permanent-type marker to mark the crankshaft and
camshaft timing marks on the LH and RH timing chains.
1. Mark any link to use as the crankshaft timing mark.
2. Starting with the crankshaft timing mark, count 29 links and mark the link.
3. Continue counting to link 42 and mark the link.
42. Position the LH timing chain and guide and install the bolts.
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43. Install the LH timing chain tensioner arm and the LH timing chain tensioner.
44. Install the crankshaft pulley bolt and rotate the crankshaft clockwise 120 degrees until the crankshaft keyway is
in the 3 o'clock position.
45. Verify that the RH camshafts are correctly positioned.
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46. Install the RH timing chain and chain guide and install the bolts.
47. Install the RH timing chain tensioner and tensioner arm.

48. Remove the LH and RH timing chain tensioner piston retaining wires.
49. Rotate the crankshaft counterclockwise 120 degrees to TDC.
damage.
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Verify the timing with the following steps.
1. There should be 12 chain links between the camshaft timing marks.

stamped "30" or "30RFF" only (orange in color).
Install the ignition pulse wheel.
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53. Install 3 new gaskets in the front cover.
54. NOTE: Clean and degrease the sealing surfaces with metal surface prep before applying gasket and sealant.
NOTE: The front cover must be installed and the bolts tightened within 4 minutes of sealant application.
Apply a 6 mm (0.24 in) dot of silicone gasket and sealant to the cylinder block to lower cylinder block and
cylinder head mating surfaces.
55. NOTE: Fasteners 1 and 13 are stud bolts.
Position the front cover and install the bolts and stud bolts.
 Tighten in the sequence shown to 25 Nm (18 lb-ft).
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56. NOTE: Apply clean engine oil to the seal lip and seal bore before installing the seal.
Using the special tools, install the crankshaft front oil seal.
57. NOTE: Clean the keyway and slot using metal surface prep before applying silicone gasket and sealant.
NOTE: Sealing surfaces must be free of dirt and oil.
NOTE: The crankshaft pulley must be installed and the bolt tightened within 4 minutes of sealant application.
Apply silicone gasket and sealant to the end of the crankshaft pulley keyway slot.
58. NOTE: Lubricate the outside diameter sealing surface with clean engine oil.
Using the special tool, install the crankshaft pulley.
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59. Install the crankshaft pulley washer and tighten the bolt in 4 stages.
 Stage 2: Loosen one full turn (360 degrees).
60. Install the belt tensioner and the bolt.

61. Install the LH idler pulley and the bolt.
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62. Install the center idler pulley and the bolt.
63. Position the oil pan baffle. Install the nuts and tighten in 2 stages.
 Stage 1: Tighten to 5 Nm (44 lb-in).
64. Install a new O-ring seal on the oil pump screen and pickup tube. Lubricate with clean engine oil.
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65. Install the oil pump screen and pickup tube.
1. Position the oil pump screen and pickup tube.
3. Install the nut and tighten in 2 stages.
 Stage 2: Tighten 45 degrees.
66. Install the new gasket in the LH valve cover in the following sequence.
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application.
NOTE: Clean cylinder head and front cover surface and the cam seal retainer-to-cylinder head surface using
metal surface prep before applying silicone gasket and sealant.
Apply an 8 mm (0.31 in) dot of silicone gasket and sealant at the cylinder block to front cover mating surface
and the cam seal retainer-to-cylinder head joints.
68. Position the LH valve cover and install the bolts and stud bolts.
69. Install the new gasket in the RH valve cover in the following sequence.
application.
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NOTE: Clean cylinder head and front cover surface using metal surface prep before applying silicone gasket
and sealant.
Apply an 8 mm (0.31 in) dot of silicone gasket and sealant at the cylinder block to front cover mating surface of
the LH and RH valve covers.
71. Position the RH valve cover and install the bolts and stud bolts.
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72. Install the radio interference capacitor and the nut.
73. Install the coolant pump and the bolts.

74. Connect the coolant pump hose to the cylinder block outlet.
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75. Install the bypass tube and the nut and bolt.
76. Position the coolant tube and connect the hoses.

77. NOTICE: Failure to use the correct special tools, assembled as shown in the illustration, will result in
damage to the coolant pump pulley and/or special tools.
Install the special tool in the camshaft as shown in the illustration.

 Adjust the collar on the special tool screw to get the best thread engagement in the rear of the camshaft.
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78. NOTICE: Failure to use the correct special tools, assembled as shown in the illustration, will result in
damage to the coolant pump pulley and/or special tools.
NOTE: Only the roller collared nut from the Power Steering Pump Pulley Installer (211-185) is used on
Camshaft Pulley Installer (303-485).
Position the coolant pump pulley over the previously installed special tool and on the end of the camshaft.
Install the special tools as shown in the illustration.
 Using the special tools, install a new service coolant pump pulley flush with the end of the camshaft.
79. Install the coolant pump belt on the coolant pump pulley and position it on the camshaft pulley.
80. NOTICE: Do not use any screwdrivers, pliers or other metal objects that could cause damage to the belt
or camshaft pulley while installing the belt.
Rotate the crankshaft clockwise to seat the water pump belt on the camshaft pulley.
81. Lubricate the O-ring seal and install the oil filter.
 Tighten to 5 Nm (44 lb-in) and then rotate an additional 180 degrees.
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82. Install 6 new LH exhaust manifold studs.
83. Install a new gasket and the LH exhaust manifold and new nuts.
84. NOTE: Make sure to apply anti-seize lubricant to the threads of the heated oxygen sensor (HO2S) before
installation.
Using the special tool, install the LH HO2S.

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85. Install a new O-ring on the oil level indicator tube. Apply clean engine oil to the O-ring.
86. Position the oil level indicator and tube and install the stud bolt.
87. Install the engine oil pressure (EOP) switch and, if equipped, the block heater.
 Tighten the EOP switch to 14 Nm (10 lb-ft).
 Tighten the block heater to 21 Nm (15 lb-ft).
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88. Install the 3 bolts and the A/C compressor bracket.
89. Position the generator and install the bolt and 2 nuts.
Front wheel drive (FWD) vehicles
90. Install the halfshaft support bracket and the bolts.

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91. Install 6 new RH exhaust manifold studs.
92. Install a new gasket and the RH exhaust manifold and new nuts.
93. Connect the RH HO2S electrical connector.
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All vehicles
Apply a light film of silicone brake caliper grease and dielectric compound to the interior of the spark plug boot
prior to installation.
Install the 6 coil-on-plugs and the bolts.

95. NOTICE: If the engine is repaired or replaced because of upper engine failure, typically including valve
or piston damage, check the intake manifold for metal debris. If metal debris is found, install a new
intake manifold. Failure to follow these instructions can result in engine damage.
NOTE: Install new gaskets.

Install the lower intake manifold and the bolts.
96. Install the B+ wiring harness on the engine.

 Attach the 4 wiring harness retainers, and install the nut.
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97. Position the fuel charging wiring harness on the engine.
 Attach the 2 wiring harness retainers (1 shown) to the engine.
98. Connect the fuel injector electrical connectors.

99. Install the B+ wire and nut on the generator.
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100. Connect the generator electrical connector.
101. Connect the camshaft position sensor (CMP) and EOP switch electrical connectors.
 Attach the wiring retainers.
102. Connect the LH coil-on-plug electrical connectors.
 Attach the 2 wiring retainers.
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103. Connect the radio interference capacitor electrical connector.
 Attach the wiring retainers.
104. Connect the RH coil-on-plug electrical connectors.

 Attach the 2 wiring harness retainers.
105. Connect the engine coolant temperature (ECT) sensor electrical connector.
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106. NOTICE: If the engine is repaired or replaced because of upper engine failure, typically including valve
or piston damage, check the intake manifold for metal debris. If metal debris is found, install a new
intake manifold. Failure to follow these instructions can result in engine damage.
NOTE: Install new gaskets.
Install the upper intake manifold and the bolts.

107. Connect the throttle body (TB) coolant hose.

108. Connect the fuel rail pressure and temperature sensor electrical connector and vacuum tube.
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109. Install the PCV tube.
110. Connect the idle air control (IAC) valve and the throttle position (TP) sensor electrical connectors.
 Attach the wiring retainer.
111. Position the engine control wiring harness and install the nuts.
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112. Connect the EGR vacuum regulator electrical connector.
113. Connect the crankshaft position (CKP) sensor electrical connector and attach the wiring retainers.
114. Position the catalyst monitor sensor electrical connector bracket. Install the nut and attach the wiring retainer.
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115. Attach the engine control sensor wiring connectors to the upper intake manifold.
116. Using the special tools, remove the engine from the engine stand.

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INSTALLATION Procedure revision date: 10/21/2008
Engine
Special Tool(s)
Engine Lifting Bracket Set
303-1140
Lifting Bracket, Engine

303-050 (T70P-6000)
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Powertrain Lift with Tilting Plate
014-00765
Spreader Bar
303-D089 (D93P-6001-A3) or
equivalent

014-0001
Material
Item Specification
equivalent
TA-30 M4G323-A4
Installation
NOTICE: If the oil pan was removed during engine disassembly, it must be installed after the engine
and transaxle are assembled and the transaxle-to-engine bolts are installed. Failure to follow this
assembly sequence can result in engine oil leaks.
All vehicles
1. Using the special tools, align the engine with the transaxle.
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2. Install the 5 transaxle-to-engine bolts (3 shown).
3. Using the special tools, secure the engine and transaxle to the powertrain lift.
4. Install the EGR regulator and the 2 stud bolts.
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5. Attach the wiring harness retainer and install the nut.
All wheel drive (AWD) vehicles
6. Using the Handle and PTO Driven Gear Oil Seal Installer, install the intermediate shaft seal.
7. Install the PTU heat shield and the 3 bolts.
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8. Position the power transfer unit (PTU) and install the bolt.
9. Install the 3 PTU bolts.

10. Install the PTU vent tube, the pin-type retainer and the bolt.
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11. Install the halfshaft support bracket and the 6 bolts.
12. Install 6 new RH exhaust manifold studs.

13. Using a new gasket, install the RH exhaust manifold and 6 new nuts.
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14. Connect the RH heated oxygen sensor (HO2S) electrical connector.
All vehicles
15. Connect the turbine speed sensor (TSS) electrical connector.

 Attach the wiring harness retainer.
16. Attach the transaxle control harness to the bracket.
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17. Connect the transaxle wiring harness electronic control switch electrical connector.
18. Connect the transmission range (TR) sensor electrical connector.

19. Attach the pin-type retainers to the transaxle support bracket and connect the HO2S and catalyst
monitor sensor electrical connectors.
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20. Position the powertrain into the vehicle.
21. Install the engine support bracket, the bolt and the 3 nuts.
 Tighten the nuts to 55 Nm (41 lb-ft) and the bolt to 90 Nm (66 lb-ft).
22. Install the rear transaxle support through bolt.
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23. Position the RH transaxle support insulator and install the bolt and nuts.
24. Install the RH transaxle support insulator through bolt.

25. Install the transaxle-to-engine stud and 2 nuts.
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26. NOTE: Clean and degrease all sealing surfaces with metal surface cleaner.
NOTE: The oil pan must be installed and the bolts tightened within 4 minutes of the sealant
application.
Apply a 10 mm (0.39 in) dot of silicone gasket and sealant to the front cover-to-cylinder block sealing
surface.
27. NOTE: Install a new oil pan gasket.

Position the oil pan and gasket and loosely install the bolts and stud bolts.
28. Install the 2 oil pan-to-transaxle bolts.

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29. Tighten the oil pan bolts in the sequence shown to 25 Nm (18 lb-ft).
30. Install the 4 torque converter nuts.

31. Install the torque converter inspection cover.
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32. Install the output shaft speed (OSS) sensor and the bolt and connect the electrical connector.
33. If equipped, connect the engine block heater electrical connector.

34. Install the ground wire eyelet and nut to the engine mount stud.
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35. Install the wire and nut to the battery cable.
36. Attach the wiring harness retainers from the battery tray bracket.
37. Position the ground strap and the electrical connector and install the bolts.
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38. Connect the electrical connector to the power distribution box.
39. Install the cable and the nut.

40. Attach the ground wire and install the bolt.
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41. Position the wiring and install the nut. Connect the PCM electrical connectors.
42. Connect the manifold absolute pressure (MAP) sensor electrical connector and vacuum tube.
43. Connect the brake booster vacuum tube.
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44. Connect the evaporative emissions (EVAP) purge valve tube to the intake manifold.
45. Position the EGR tube and loosely install the fittings.
 Tighten the EGR tube-to-EGR valve fitting to 40 Nm (30 lb-ft).
46. Connect the differential pressure feedback EGR sensor electrical connector and attach the pin-type
retainer.
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47. Position the shift cable and bracket in place, install the bolts and install the wiring harness retainer.
48. Connect the gearshift cable to the transaxle.

49. Attach the wiring harness pin-type retainer to the gearshift cable bracket.
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50. Connect the fuel supply tube quick connect coupling at the fuel rail. For additional information, refer to
Section 310-00 .
51. Attach the transaxle vent tube retainer to the throttle body.
52. Connect the heater hoses and the throttle body coolant hose.
53. Connect the upper and lower radiator hoses.
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54. Position the accelerator and speed control cables and bracket. Install the nut.
55. Position the bracket and install the bolts.

 Connect the accelerator cable and the speed control actuator cable.
56. Position the accelerator cable snow shield and install the bolts.
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57. Tighten the EGR tube-to-RH catalytic converter fitting to 40 Nm (30 lb-ft).
58. Install the transaxle cooler tube and the bracket bolt.
 Tighten the bolt to 13 Nm (10 lb-ft), tighten the fitting to 23 Nm (17 lb-ft).
59. Connect the 2 transmission cooler tubes (1 shown).
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60. Install the cross brace and the new nut finger tight.
61. Install the 2 bolts for the cross brace and the bolt for the front roll restrictor.
 Tighten the 2 cross brace bolts to 90 Nm (66 lb-ft).
 Tighten the front roll restrictor bolt to 115 Nm (85 lb-ft).
62. Tighten the cross brace nut to 175 Nm (129 lb-ft).
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63. Position the RH accessory drive belt idler pulley and bracket and attach the wiring harness retainer.
 Install the 3 bolts and tighten to 25 Nm (18 lb-ft).
64. Install the A/C compressor and the bolts.

65. Connect the A/C clutch field coil electrical connector.
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66. Rotate the accessory drive belt tensioner counterclockwise and install the accessory drive belt.
AWD vehicles
67. NOTICE: Do not reuse the driveshaft flange bolts and washers. Install new bolts and washers
or damage to the vehicle may occur.
Align the index-marks made during removal and install 6 new front driveshaft-to-PTU bolts and
washers.
All vehicles
68. Install the intermediate shaft and the 2 nuts.

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69. Install the RH halfshaft onto the intermediate shaft.
70. Install the LH halfshaft into the transaxle.

Attach the LH and RH lower ball joints to the steering knuckles and install the pinch bolts and nuts.
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Install the LH and RH tie-rod ends and nuts.


Install the LH and RH stabilizer link-to-strut nuts.
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Install the LH and RH brake hose retainers and ABS sensor wiring harness bolts.
75. Install the Y-pipe and the 2 new exhaust flange-to-RH catalytic converter nuts.
76. Install the 2 new exhaust flange-to-LH catalytic converter nuts.
77. Attach the Y-pipe to the rear catalytic converter.

1. Attach the exhaust hanger.
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2. Install the 2 new exhaust flange-to-rear catalytic converter nuts.
 Tighten to 29 Nm (21 lb-ft).
78. Install the lateral support crossmember and the 4 bolts.

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79. Connect the catalyst monitor sensor electrical connector and the 2 wiring harness retainers.
80. Install the lower splash shields.

81. Install the front wheels and tires. For additional information, refer to Section 204-04 .
82. Install the air cleaner outlet pipe and air cleaner. For additional information, refer to Section 303-12B .
83. Install the battery tray. For additional information, refer to Section 414-01 .
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85. Fill and bleed the cooling system. For additional information refer to Section 303-03A .

Engnie Ford Escape 2008 V6 3.0L

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Engnie Ford Escape 2008 V6 3.0L

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SECTION 303-01B: Engine — 3.

0L (4V) 2008 Escape/Mariner/Escape Hybrid/Mariner Hybrid Workshop Manual

(0.0014 per 0.984 in)

(0.0019 per 0.984 in)

The 3.0L (4V) is a V-6 engine has the following features:

 Dual overhead camshafts

 The decal is located on the LH front door lock face panel.

Exhaust Emission Control System

Positive Crankcase Ventilation System

Generically this design is known as a gerotor pump, which operates as follows:

The engine cooling system includes the following:

Engine Cylinder Identification

Upper Intake Manifold

3. Remove the 2 bolts and the accelerator cable snow shield.

5. Remove the 3 accelerator/speed control cable bracket bolts.

6. Remove the EGR tube fitting from the EGR valve.

12. Disconnect the EGR vacuum regulator electrical connector.

16. Disconnect and plug the 2 throttle body coolant hoses.

17. Remove the 8 bolts and the upper intake manifold.

Position the upper intake manifold and install the bolts.

2. Connect the 2 throttle body coolant hoses.

8. Connect the EVAP tube to the upper intake manifold.

12. Install the EGR tube fitting to the EGR valve.

Lower Intake Manifold

4. Disconnect the engine coolant temperature (ECT) sensor electrical connector.

Position the lower intake manifold and install the bolts.

5. Connect the ECT sensor electrical connector.

2. If equipped, remove the bolt and the engine lift bracket.

3. Remove the 2 bolts and the accelerator cable snow shield.

Remove the 5 bolts, 8 stud bolts and the valve cover.

5. Attach the 4 wiring retainers to the valve cover stud bolts.

8. Install the accelerator cable snow shield and the 2 bolts.

9. If equipped, install the engine lift bracket and the bolt.

4. Remove the PCV tube.

8. Remove the 3 bolts, 10 stud bolts and the valve cover.

5. Install the radio ignition interference capacitor and the nut.

7. Install the PCV tube.

Lower End Components — Exploded View

Crankshaft Pulley and Front Seal

Flexplate and Rear Seal

1. For additional information, refer to the procedures in this section.

Installer, Crankshaft Vibration

3. Remove the crankshaft pulley bolt and washer.

4. Using the 3 Jaw Puller, remove the crankshaft pulley.

Crankshaft Front Seal

Replacer, Crankshaft Damper

1. NOTE: Clean all sealing surfaces with metal surface prep.

Removal and Installation

2. Remove the transmission. For additional information, refer to Section 307-01A .

3. Remove the bolts and the flexplate.

4. To install, reverse the removal procedure.

Crankshaft Rear Seal

Installer, Crankshaft Rear Main

Engine Front Cover

5. Remove the generator bolt and the 2 nuts.

13. Disconnect the camshaft position (CMP) sensor electrical connector.

16. Disconnect the A/C pressure switch electrical connector.

19. Remove the 2 oil pan-to-front cover bolts.

Use a plastic scraping tool to remove all traces of sealant.