1997 Mercury Villager 3.0L Motor V6

1997 Mercury Villager GS
1997-98 ENGINES 3.0L SOHC V6 - VIN 1
1997-98 ENGINES
3.0L SOHC V6 - VIN 1
ENGINE IDENTIFICATION
This engine is of free wheeling design with a camshaft in each head, hydraulic valve lifters and two valves
per cylinder. Combustion chamber is cross-flow with pent-roof combustion chamber and squish area. Main
bearing cap is of one piece construction to increase rigidity and reduce vibration.
ENGINE IDENTIFICATION CODES

Engine Code
3.0L SOHC V6 1
ADJUSTMENTS
VALVE CLEARANCE ADJUSTMENT
Hydraulic lifters are used, and no valve adjustments are required.
TROUBLE SHOOTING
NOTE: For trouble shooting mechanical engine components, see appropriate table
in TROUBLE SHOOTING in GENERAL INFORMATION.
REMOVAL & INSTALLATION
CAUTION: When battery is disconnected, vehicle computer and memory systems

may lose memory data. Driveability problems may exist until computer
systems have completed a relearn cycle. See COMPUTER RELEARN
PROCEDURES article in GENERAL INFORMATION before
disconnecting battery.
NOTE: For reassembly reference, label all electrical connectors, vacuum hoses and
fuel lines before removal. Also place mating marks on engine hood and other
major assemblies before removal.
FUEL PRESSURE RELEASE
1. Remove fuel pump relay from left engine compartment relay block. Start engine.
2. After engine stalls, crank engine 2 or more revolutions to ensure pressure has been released.
3. Turn ignition OFF and install fuel pump relay. Using a rag to contain spray, disconnect fuel hoses.
Plug hoses.
COOLING SYSTEM DRAINING, FILLING & BLEEDING
WARNING: Electric cooling fan may come on at any time when ignition switch is in
ON position.
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Draining
1. Turn ignition on, and move front blower switch to 4. Set front temperature control to full WARM
position, and rear control switch to 4.
NOTE: For vehicles with rear heater, set rear heater blower switch to 4 and rear
temperature control knob to full WARM position.
2. Set mode selection switches to any mode except OFF. Turn ignition off. Remove right hand splash
shield.
3. Remove radiator pressure cap slowly, ensuring release of pressure before fully open. Position drain
pan under radiator. Open draincock at bottom of radiator.
CAUTION: DO NOT use a galvanized drain pan if coolant is to be reused. DO

NOT allow coolant to contact drive belts, or they will be damaged.
4. Remove coolant reservoir and drain. Clean reservoir and reinstall. Position drain pan under engine
prior to removing engine block drain plugs. Remove engine block drain plugs.
Filling & Bleeding
1. Ensure block drain plugs and radiator draincock are installed and tightened. Remove engine air relief
plug. Loosen radiator air relief plug 4 turns. DO NOT remove radiator air relief plug. Remove coolant
reservoir and support it above engine. Ensure coolant recovery hose is attached to reservoir and
radiator filler neck.
2. Place drain pan under radiator air relief plug opening. Slowly pour 50/50 mix of coolant and water
into radiator filler neck. Allow several minutes for air to escape. Fill radiator filler neck with coolant
only until coolant starts to drip from radiator air relief plug opening. When coolant starts to drip from
radiator air relief plug opening, close plug. Tighten plug to 15-19 ft. lbs. (20-26 N.m).
NOTE: When adding more coolant, fill to bottom of overflow tube. Allow
several minutes for air to escape.
3. Pour coolant into radiator while gently squeezing upper radiator hose. Install a wire under radiator
pressure cap negative pressure valve to allow flow of air and coolant regardless of pressure. See Fig.
1. Install cap on radiator at this time. Add 50/50 mix of coolant and water to MAX mark on coolant
reservoir.
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Fig. 1: Installing Wire Under Radiator Pressure Cap

Courtesy of FORD MOTOR CO.
4. With gear selector in Park, start and run engine at 2000 RPM for 15-30 minutes, allowing cooling
system to reach full operating temperature. Cooling fan will turn on and off indicating cooling system
has reached full operating temperature. Squeeze upper radiator hose to help burp air from cooling
system.
5. Stop engine and allow to cool completely. Ensure recovery reservoir fluid level does not drop below
MIN level. Lower recovery reservoir and reinstall. Remove radiator cap and remove wire. Reinstall
radiator cap. Fill radiator and coolant reservoir as necessary.
ENGINE
NOTE: Engine and transaxle are removed as a unit through bottom of engine
compartment.
Removal & Installation
1. Relieve fuel pressure. See FUEL PRESSURE RELEASE. Drain cooling system. See COOLING
SYSTEM DRAINING, FILLING & BLEEDING. Disconnect battery. Remove battery and fresh air
duct bracket bolt. Separate fresh air duct from air cleaner assembly. Remove and separate fresh air
duct and resonance chamber No. 1.
2. Drain engine oil. Disconnect overflow tube from radiator filler neck. Remove coolant reservoir.
3. Mark and disconnect following electrical connectors:
Vehicle speed sensor.

Valve body wiring harness.
Starter (wiring harness and positive battery cable).
Transmission Range (TR) switch.
Exhaust Gas Recirculation Control (EGRC) solenoid.
Throttle position sensor.
Idle switch.
Mass airflow sensor.
4. Disconnect and plug fuel lines. Disconnect carbon canister vacuum lines. Remove ignition coil dust
cover. Disconnect ignition coil connector, 2 mounting bolts and ignition coil.
CAUTION: DO NOT pull on high-tension lead when removing from ignition

coil.
5. Remove distributor cap dust cover. Disconnect distributor electrical connector. Unscrew 3 distributor
cap screws and distributor cap. Position cap and wire aside to gain access to main engine wiring
harness.
6. Disconnect main engine wiring harness clips from breather tube brackets. Disconnect fuel injector
electrical connectors. Remove 2 ground wire bolts from intake plenum, and position ground wires
aside.
7. Disconnect power transistor electrical connector, engine coolant temperature sensor connector,
temperature gauge sender electrical connector, magnetic clutch electrical connector, A/C high
pressure switch electrical connector and the 2 main harness connectors from right side of plenum
intake.
8. Disconnect cruise control cable (if equipped) from throttle lever. Disconnect accelerator cable from
throttle lever. Remove cruise control cable from hanging support (if equipped). Remove accelerator
cable from bracket at top of intake plenum. Remove 2 bolts holding accelerator cable/cruise control
cable bracket to intake plenum, and position aside.
9. Disconnect upper radiator hose from radiator. Disconnect lower radiator hose from radiator pipe.
Remove 2 upper A/C compressor-to-accessory bracket bolts. Disconnect heater hoses. Remove
ground from dipstick bracket. Disconnect brake booster vacuum hose from left side of intake plenum.
Loosen A/C compressor drive belt tensioner and remove A/C belt.
10. Raise and support vehicle. Remove splash shields. Remove shift cable nut from transmission range
switch, and slide shift cable off switch. Using a screwdriver, release locking pin from shift cable
bracket. Remove shift cable from shift cable bracket.
11. Disconnect oil level sensor electrical connector. Disconnect low oil level sensor electrical connector.
Disconnect generator electrical connector. Remove "B" terminal nut and generator ground wire nut
from generator, and position wires aside. Remove generator wiring bracket nut from back of
generator. Loosen generator lock bolt. Loosen generator adjustment bolt. Loosen front and rear
generator-to-accessory bracket bolts, and remove generator belt.
NOTE: Access front power steering-to-bracket bolts by inserting socket

through power steering pump pulley holes.
12. Loosen power steering pump tensioner center bolt. Loosen power steering pump adjustment bolt and
remove power steering pump belt. Remove 3 front power steering pump-to-bracket bolts from front of
power steering pump. Remove rear power steering pump-to-bracket bolt, and position power steering
pump aside.
13. Remove 2 lower A/C compressor-to-accessory bracket bolts, and position A/C compressor aside (if
equipped).
14. Remove 2 converter inlet pipe-to-three way catalytic converter nuts. (Discard nuts and gasket.)
Remove heated O2 sensor wire clips. Disconnect heated O2 sensor electrical connector.
15. Remove 4 front exhaust manifold flange cover bolts and front exhaust manifold flange cover. Remove
converter inlet pipe-to-exhaust bracket bolt. Remove 3 front exhaust manifold-to-catalytic converter
inlet pipe nuts. (Discard nuts and gasket.)
16. Remove 3 rear exhaust manifold-to-catalytic converter inlet pipe nuts. (Discard nuts and gasket.)
Remove catalytic converter inlet pipe from vehicle. Remove drive axles. See appropriate FWD AXLE
SHAFTS article in DRIVE AXLES.
17. Identify transaxle oil cooler hose-to-transaxle oil cooler line connections for reassembly. Disconnect
and plug transaxle cooler lines and hoses. Disconnect transaxle ground.
18. Position lift and wood blocks under engine/transaxle assembly. Remove 3 front transaxle mount bolts.
Remove 3 rear transaxle mount nuts. Remove 2 rear A/C and/or heater pipe brackets. Remove
transverse member bolts. Remove transverse member.
19. Lower engine/transaxle from engine compartment. Remove upper transaxle-to-engine bolts. Remove
2 exhaust bracket-to-transaxle nuts and the exhaust bracket. Remove 4 rear transaxle-to-engine brace
bolts. Remove 5 front transaxle-to-engine brace bolts.
20. Remove lower transaxle-to-engine bolt. Prevent crankshaft from spinning with a wrench, and remove
4 torque converter-to-flexplate bolts. Separate transaxle from engine assembly. To install, reverse
removal procedure using NEW gaskets and nuts as required.
INTAKE PLENUM
1. Drain cooling system. See COOLING SYSTEM DRAINING, FILLING & BLEEDING.
Disconnect negative battery cable. Remove air duct and resonance chamber. Disconnect TP sensor
electrical connector. Remove TP sensor electrical connector from EGR Control (EGRC) bracket.
2. Disconnect idle switch electrical connector. Disconnect and plug front throttle body coolant hose.
Disconnect and plug hose connected to top heater pipe. Disconnect EGRC solenoid-to-throttle body
vacuum hose. Disconnect EGR valve-to-EGRC solenoid vacuum hose. Remove 2 EGRC bracket
bolts, then lower EGRC bracket from intake plenum. Disconnect carbon canister-to-intake plenum
vacuum hose.
3. Disconnect No. 1, 3 and 5 spark plug wires from spark plugs, then remove spark plug wire boots from
between intake plenum runners. Remove the 2 spark plug wire bracket bolts and brackets from intake
plenum. Remove distributor dust cover.
4. Unscrew the 3 distributor cap screws. Remove distributor cap, and position cap and wires aside to
gain access to main engine wiring harness. Disconnect rear heater valve vacuum hose from right side
of plenum (if equipped). Remove wiring harness bracket from right side of plenum and set aside.
5. Disconnect cruise control cable (if equipped) from throttle lever. Disconnect accelerator cable from
throttle lever. Remove cruise control cable from hanging support (if equipped). Remove accelerator
cable from bracket attached to top of intake plenum. Remove cruise control cable (if equipped), then
accelerator cable from bracket on top of intake plenum and position aside.
6. Disconnect brake booster vacuum hose from left side of intake plenum. Remove EGR pipe from EGR
valve. Disconnect EGR temperature sensor electrical connector (if equipped). Disconnect bypass air
valve electrical connector. Disconnect Idle Air Control/Fast Idle Control assembly connectors.
7. Disconnect fuel pressure regulator-to-intake manifold vacuum line from fuel pressure regulator.
Disconnect main engine wiring harness clips from breather tube brackets. Remove 2 ground wire
bolts from intake plenum, and position ground wires and main wiring harness aside.
8. Remove the 2 front breather bracket-to-intake plenum bolts. Disconnect front breather hose from front
rocker arm cover. Remove 5 Allen-head intake plenum bolts. Remove intake plenum and discard
gasket.
9. To install, reverse removal procedure. Ensure gasket surfaces are clean before using a NEW intake
plenum gasket.
INTAKE MANIFOLD
1. Remove intake plenum. See INTAKE PLENUM. Disconnect 6 fuel injector electrical connectors.
Remove rear breather hose from rear rocker arm cover. Remove crossover breather tube from engine
front cover. Remove fuel rail and position fuel rail and insulators aside.
2. Disconnect engine coolant temperature sensor connector. Disconnect water temperature sender
connector. Remove upper radiator hose from intake manifold. Remove upper radiator hose bracket
bolt. Remove water bypass hose from intake manifold. Remove bolt attaching water hose connection
to engine front cover. Remove heater hose from top heater core pipe.
3. Remove 4 Allen-head intake manifold bolts and 4 intake manifold nuts in 2 steps in correct sequence.
See Fig. 2. Remove intake manifold washers. Remove intake manifold and discard gaskets. To install,
reverse removal procedure using NEW gaskets. Tighten 4 Allen-head bolts and 4 nuts in 3 steps and
in correct sequence. See Fig. 3. Step 1: 27-44 INCH lbs. (3-5 N.m). Step 2: 12-14 ft. lbs. (16-2 0
N.m). Step 3: repeat step 2.
Fig. 2: Intake Manifold Loosening Sequence

Fig. 3: Intake Manifold Tightening Sequence

EXHAUST MANIFOLD
Removal & Installation (Left)
1. Disconnect negative battery cable. Remove 2 nuts and 1 bolt attaching crossover tube-to-front exhaust
manifold, and discard gasket. Remove transmission fluid dipstick heat shield. Raise and support
vehicle. Loosen front exhaust manifold nuts in 2 steps in sequence. See Fig. 4. Remove top 3 nuts, but
DO NOT remove 3 lower nuts.
2. Remove front exhaust manifold mounting bracket bolt. Disconnect heated oxygen sensor electrical
connector. Remove 3 front exhaust manifold-to-converter inlet pipe nuts. Remove exhaust flex tube
bracket bolt. Remove left inner engine and transmission splash shield. Remove 3 lower front exhaust
manifold nuts. Remove front exhaust manifold and gasket from cylinder head. Discard gasket. To
install, reverse removal procedure using NEW gaskets. Tighten in sequence to 13-16 ft. lbs. (18-22
N.m). See Fig. 5.
Removal & Installation (Right)
1. Disconnect negative battery cable. Disconnect radiator overflow hose from radiator. Remove coolant
recovery reservoir. Remove air duct and resonance chamber. Remove 6 rear exhaust manifold
crossover tube heat shield bolts. Remove heat shields from crossover tube. Remove 2 nuts and one
bolt attaching rear exhaust manifold crossover tube-to-front exhaust manifold, and discard gasket.
2. Remove transmission fluid dipstick heat shield. Disconnect idle switch connector. Disconnect throttle
position sensor connector. Disconnect EGR control solenoid connector. Raise and support vehicle.
Remove EGR valve-to-backpressure transducer valve tube nut and position aside.
3. Remove EGR pipe from between EGR valve and rear exhaust manifold. Remove 6 rear exhaust
manifold nuts in sequence. See Fig. 4. Remove rear exhaust manifold and discard gasket. To install,
reverse removal procedure using NEW gasket. Tighten in sequence to 13-16 ft. lbs. (18-22 N.m). See
Fig. 5.
Fig. 4: Exhaust Manifold Loosening Sequence

Fig. 5: Exhaust Manifold Tightening Sequence

CYLINDER HEAD
Removal
Disconnect negative battery cable. Remove fresh air duct. Remove timing belt. See TIMING BELT.
Remove intake plenum. See INTAKE PLENUM.
NOTE: Mark spark plug wire locations for installation.
2. Disconnect spark plug wires and high-tension lead. Remove distributor. Mark and disconnect
following electrical connectors:

EGR control solenoid.
Mass airflow sensor.
Pulse signal generator.
Valve body wiring harness.
Park/Neutral position switch.
Magnetic clutch.
Power transistor.
A/C high-pressure switch.
Fuel injectors.
Ignition coil.
Temperature gauge sender.
Engine coolant temperature sensor.
3. Remove main wiring harness bracket from intake manifold coolant outlet. Remove fuel line bracket
bolt from EGRC solenoid bracket. Disconnect coolant bypass hose from intake manifold coolant
outlet. Remove 4 Allen-head fuel rail bolts, and position fuel rail and injectors aside. Disconnect
upper heater hose. Remove intake manifold. See INTAKE MANIFOLD.
4. Remove 9 rocker arm cover screws, rocker arm cover and gasket. Discard gasket. Using Camshaft
Pulley Holder (T92P-6312-AH), remove camshaft sprocket bolt. Using a small 3-leg gear puller,
remove camshaft sprocket. Remove 4 rear timing belt cover bolts and the rear timing cover. If
removing the front cylinder head, remove 2 dipstick bolts and dipstick bracket.
5. Raise and support vehicle. If removing front cylinder head, remove 4 front exhaust manifold flange
cover bolts and front exhaust manifold flange cover. Remove 3 front exhaust manifold-to-converter
inlet pipe nuts. Remove and discard gasket. Remove 2 nuts and one bolt attaching rear exhaust
manifold crossover tube-to-front exhaust manifold, and discard gasket. Remove front exhaust
manifold mounting bracket bolt. If removing front cylinder head, remove the 2 lower A/C
compressor-to-accessory bracket bolts. Lower vehicle.
NOTE: The upper A/C compressor-to-accessory bracket bolts are too long to
remove from A/C compressor. Remove them after compressor has
been moved aside.
6. If removing front cylinder head, loosen 2 upper A/C compressor-to-accessory bracket bolts, and wire
A/C compressor aside. If removing front cylinder head, remove the 2 upper accessory bracket bolts
and the 2 radiator/heater pipe bracket bolts.
CAUTION: Ensure that the first bolt in removal sequence is located in the No.
1 position outside of the cylinder head. This bolt is easily
forgotten and the tab can be broken off if cylinder head is moved
prior to bolt being removed. See Fig. 6. Be aware that the head
bolts stretch to yield on installation and may not be reused.
Discard head bolts on removal and replace with NEW bolts during
reassembly.
7. When removing cylinder head, remove head bolts in 2 steps in correct sequence. See Fig. 6. Remove
cylinder head bolt washers, noting which side of washer faces head. Remove cylinder head and
gasket. Discard bolts and gasket. If necessary, remove exhaust manifold from cylinder head. Remove
6 exhaust manifold nuts in sequence and discard gasket. See Fig. 4.
Inspection
Inspect cylinder head for damage, cracks and leakage of water and oil. Measure cylinder head for distortion.
Maximum distortion for cylinder head is 0.004" (0.10 mm). If distortion exceeds specification, grind
cylinder head surface. Cylinder head must be replaced if head height is not within 4.205-4.220" (106.8-
107.2 mm).
Installation
To install, reverse removal procedure using NEW gaskets and NEW cylinder head bolts. Tighten NEW
cylinder head bolts in sequence in 6 steps:
Step 1: Tighten bolts to 22 ft. lbs. (29 N.m).

Step 3: Loosen all bolts completely using loosening sequence. See Fig. 6.
Step 5: Tighten bolts to 40-47 ft. lbs. (54-64 N.m).
Step 6: Install bolt located at "A". See Fig. 7. Tighten bolt "A" to 80-104 INCH lbs. (9-12 N.m).
NOTE: Bolts in positions 4, 5, 12 and 13 are 5" (127 mm) in length. Remaining bolts
are 4.17" (106 mm) in length.
Fig. 6: Cylinder Head Bolt Loosening Sequence

Fig. 7: Cylinder Head Bolt Tightening Sequence

CRANKSHAFT FRONT SEAL
Removal
Disconnect negative battery cable. Remove timing belt. See TIMING BELT. Remove outer timing belt
guide. Remove crankshaft sprocket and inner timing belt guide. Using Seal Remover (T92C-6700-CH),
remove front seal.
Installation
Using Seal Replacer (T92P-6701-BH) with Sleeve, Nut, Bolt and Plate (T88T-6701-A), oil lip of NEW seal
and install until seal bottoms against oil pump body. To complete installation, reverse removal procedure.
TIMING BELT
Removal
Disconnect negative battery cable. Remove accessory drive belts. Remove 3 A/C compressor drive
belt tensioner bolts and tensioner.
2. Remove upper radiator hose bracket bolt. Loosen 2 upper radiator hose clamps, and remove upper
radiator hose and bracket from vehicle. Remove coolant bypass hose from between thermostat
housing and intake manifold coolant outlet.
3. Remove main wiring harness from upper timing belt cover. Remove 8 upper timing belt cover bolts
and upper timing belt cover.
4. Raise and support vehicle. Remove right front wheel. Remove right front outer splash shield. Remove
water pump pulley. Remove crankshaft pulley. Remove 5 lower timing belt cover bolts and lower
timing belt cover.
NOTE: If timing belt is to be reused, ensure direction of rotation is marked for

reinstallation.
5. Align timing marks between camshaft sprockets and rear timing belt cover. Ensure timing marks
between crankshaft timing belt sprocket and oil pump housing align. See Fig. 8. Loosen timing belt
tensioner nut. Remove timing belt.
Fig. 8: Identifying Timing Marks

Inspection
Inspect for damage, wear, peeling, cracks, hardening or contamination from oil or grease. Replace if
necessary.
Installation
1. Ensure all timing marks are properly aligned. See Fig. 8. Use an Allen wrench to turn timing belt
tensioner counterclockwise. Temporarily tighten tensioner nut. If installing NEW timing belt, ensure
white lines on belt align with camshaft and crankshaft sprocket timing marks, and that arrow on belt is
pointing away from engine block.
2. Install timing belt. Hold tensioner with Allen wrench and loosen tensioner nut. Allow tensioner to put
pressure on timing belt. With Allen wrench, turn timing belt tensioner clockwise 70-80 degrees and
tighten nut to 32-43 ft. lbs. (43-58 N.m).
3. Rotate crankshaft clockwise 2 revolutions and align No. 1 piston at TDC on compression stroke.
Apply 22 lbs. (9.98 kg) force on timing belt between rear camshaft sprocket and timing belt tensioner.
4. With assistance from a helper, adjust timing belt as follows:
Step 1: While holding timing belt tensioner steady with an Allen wrench, start a 0.0138" (0.35
mm) feeler gauge between belt and tensioner. See Fig. 9.
Step 2: Turn crankshaft clockwise until feeler gauge is positioned between tensioner and belt.
See Fig. 10. Tighten timing belt tensioner nut to 32-43 ft. lbs. (43-58 N.m).
Step 3: Rotate crankshaft clockwise 2 revolutions and align No. 1 piston at TDC on
compression stroke. Remove feeler gauge when beginning rotation.
5. Apply 22 lbs. (9.98 kg) force on timing belt between camshaft sprockets. Measure timing belt
deflection. Deflection should be 0.51-0.59" (13-15 mm). If deflection is not within specification,
repeat adjustment procedure. If timing belt cannot be adjusted to specification, replace belt. To
complete installation, reverse removal procedure. There should be 40 timing belt teeth between timing
marks on camshaft sprockets, and 43 timing belt teeth between left camshaft sprocket and crankshaft
timing belt sprocket timing mark.
Fig. 9: Starting Feeler Gauge Under Timing Belt

Fig. 10: Positioning Feeler Gauge Under Timing Belt

ROCKER ARM & HYDRAULIC VALVE LIFTER
1. Disconnect negative battery cable. If removing rear rocker arm shaft, rocker arms and valve lifters,
remove intake plenum. See INTAKE PLENUM. If removing front rocker arm shaft, rocker arms and
valve lifters, remove distributor. Remove rocker arm cover.
NOTE: Mark location of rocker arm shaft, rocker arms and valve lifters for
installation.
CAUTION: Removing rocker arm shaft bolts in one step may bend the rocker
arm shaft.
2. Loosen rocker arm shaft bolts in 2 steps. Remove rocker arm shaft assemblies from cylinder head.
Slide rockers off of the rocker arm shaft.
3. Secure valve lifters in valve lifter guide with mechanic's wire prior to removal. Remove valve lifter
guide with valve lifters. Remove lifters from valve lifter guide.
Inspection
Inspect rocker arms, rocker arm shafts and lifters for scratches, seizure and wear. See ROCKER ARM &
HYDRAULIC VALVE LIFTER SPECIFICATIONS table. Repair or replace as necessary.
ROCKER ARM & HYDRAULIC VALVE LIFTER SPECIFICATIONS

Component In. (mm)
Rocker Arm Shaft Diameter 0.7078-0.7087 (17.979-18.000)
Rocker Arm Bore 0.7089-0.7098 (18.007-18.028)
Oil Clearance (Maximum) 0.0017-0.0026 (0.043-0.066)
Lifter Diameter 0.6278-0.6282 (15.947-15.957)
Valve Lifter Guide Bore 0.6299-0.6304 (16.00-16.013)
Valve Lifter Bore Oil Clearance 0.0017-0.0026 (0.043-0.066)
Installation
To install, reverse removal procedure. Tighten rocker arm shaft bolts in 2 stages to 13-16 ft. lbs. (18-22
N.m).
CAMSHAFT
1. Remove cylinder head. See CYLINDER HEAD . Remove rocker arm shaft, rocker arms and valve
lifters. See ROCKER ARM & HYDRAULIC VALVE LIFTER. Install cylinder head on Head
Holding Fixture (D83L-500-A).
2. Remove camshaft oil seal using Seal Remover (T92C-6700-CH). Discard seal. Remove 3 camshaft
end-plate bolts, bracket and camshaft end plate.
3. Temporarily install camshaft sprocket on end of camshaft. Hold camshaft with Camshaft Pulley
Holder (T92P-6312-AH), and remove camshaft thrust plate bolt. Remove camshaft thrust plate.
Remove camshaft sprocket. Remove camshaft from front of cylinder head. To install, reverse removal
procedure.
CRANKSHAFT REAR OIL SEAL
1. Rear main seal is a one-piece seal. Remove transaxle. See TRANSMISSION REMOVAL &
INSTALLATION article in TRANSMISSION SERVICING. Remove flywheel (M/T) or flexplate
plate (A/T).
2. Using an awl, punch a hole in metal portion of seal. Using Jet Plug Remover (T77L-9533-B), remove
seal. Coat seal lip with engine oil before installing. Use Seal Installer (T88L-6701-A) to install seal.
To complete installation, reverse removal procedure. Tighten bolts to specification. See TORQUE
SPECIFICATIONS.
WATER PUMP
Removal
Drain cooling system. See COOLING SYSTEM DRAINING, FILLING & BLEEDING. Disconnect
negative battery cable. Remove accessory drive belts. Raise and support vehicle. Remove water pump
pulley. Remove crankshaft pulley. Remove lower timing belt cover. Remove 6 water pump bolts. Remove
water pump.
NOTE: For installation reference, mark location of bolt having threads in bolt head.
CAUTION: Ensure there is no gasket residue on pump or block before installation.
Installation
Using Gasket Maker E2AZ-19562-B (WSK-M2G348-A5), lay a continuous bead 0.079-0.118" (2-3 mm)
wide on water pump gasket surface. Position pump on engine block and install 6 bolts, noting placement of
bolt with threads in bolt head. To complete installation, reverse removal procedure.
OIL PAN
Removal
1. Raise and support vehicle. Drain engine oil. Install a support (screw-type jack) under crankshaft
pulley. Remove both engine mount through-bolts.
2. Remove 2 rear refrigerant/heater pipe bracket bolts. Remove transverse member nuts and bolts.
Remove transverse member from vehicle.
3. Remove 4 front exhaust manifold flange cover bolts and front manifold flange cover. Remove
converter inlet pipe-to-exhaust bracket bolt. Remove 2 exhaust bracket-to-transaxle nuts and exhaust
bracket.
4. Remove 3 front exhaust manifold-to-catalytic converter inlet pipe nuts. Discard nuts and gasket.
Remove 3 rear exhaust manifold-to-catalytic converter inlet pipe nuts. Discard nuts and gasket.
Position catalytic converter inlet pipe aside.
5. Remove 4 rear transaxle-to-engine brace bolts. Remove 5 front transaxle-to-engine brace bolts.
Disconnect oil level sensor electrical connector.
6. Remove 18 oil pan bolts in correct sequence. See Fig. 11. Remove oil pan and discard oil pan end
gaskets.
Installation
Ensure gasket surfaces are clean. Apply Loctite Ultra Gray (599) Silicone Sealant (WSE-M4G320-A2) to oil
pan end gaskets and a bead around oil pan. See Fig. 12. Install oil pan to engine block. Tighten 18 bolts in
correct sequence to 62-71 INCH lbs. (7-8 N.m). See Fig. 13. To complete installation, reverse removal
procedure.
Fig. 11: Oil Pan Loosening Sequence

Fig. 12: Sealing Oil Pan End Gaskets & Oil Pan
Fig. 13: Oil Pan Tightening Sequence

OVERHAUL
CYLINDER HEAD
CAUTION: Replace cylinder head if warpage exceeds specification.
Cylinder Head
Check cylinder head warpage at cylinder block and manifold mating surfaces. Replace head if warpage
exceeds specification. See CYLINDER HEAD table under ENGINE SPECIFICATIONS.
Valve Springs
Inspect valve spring free length and pressure. Replace valve spring if not within specification. See
VALVES & VALVE SPRINGS table under ENGINE SPECIFICATIONS.
Valve Stem Oil Seals
Using Slide Hammer (T50T-100-A) and Seal Remover (T89P-6510-D), remove valve stem oil seal from
cylinder head. Using Seal Installer (T92P-6510-AH), press seal in by hand until it is fully seated.
Valve Guides
To replace valve guide, drive valve guide from camshaft side of cylinder head using Valve Guide
Remover/Installer (T89P-6510-A). Using valve guide remover/installer, install valve guide until its top is
seated in cylinder head 0.520-0.528" (13.2-13.4 mm) from lower valve spring seat. See Fig. 14.
Valve Seat
Valve seat angle and seat width must be within specification. See CYLINDER HEAD table under ENGINE
SPECIFICATIONS. Replacement information is not available from manufacturer.
Valves
Ensure head diameter, stem diameter, stem length and valve margin are within specification. See VALVES
& VALVE SPRINGS table under ENGINE SPECIFICATIONS.
Valve Seat Correction Angles
Use a 30-degree wheel to lower seat or a 45-degree wheel to raise seat. Use a 60-degree wheel to narrow
seat width.
Fig. 14: Installing Valve Guide

CYLINDER BLOCK ASSEMBLY
Piston & Rod Assembly
Ensure rod, piston and rod cap are marked with matching cylinder number before removing. Install piston
with indent on top of piston toward front of engine. Ensure connecting rod is installed with front mark ("W")
toward front of engine. See Fig. 15.
Fig. 15: Installing Piston & Connecting Rod

Fitting Pistons
Ensure piston-to-bore clearance is as specified. See PISTONS, PINS & RINGS table under ENGINE
SPECIFICATIONS.
Piston Rings
Ensure ring end gap and side clearance are within specification. See PISTONS, PINS & RINGS table
under ENGINE SPECIFICATIONS. Piston rings must be properly installed. Position piston rings so end
gaps are placed 120 degrees apart, but DO NOT align with piston pin.
Rod Bearings
1. Ensure rod, piston and rod cap are marked with matching cylinder number before removing. Coat rod
bearings with Assembly Lubricant (D9AZ-19579-D) before installing. Before installation, place
rubber or plastic tube over rod bolt threads to protect crankshaft bearing surfaces. Coat rod bolts with
oil before installing nuts.
2. Install piston with indent on top of piston toward front of engine. Ensure connecting rod is installed
with front mark "W" toward front of engine. See Fig. 15.
3. Ensure bearing oil clearance and side clearance are within specification. See CRANKSHAFT, MAIN
& CONNECTING ROD BEARINGS and CONNECTING RODS tables under ENGINE
SPECIFICATIONS.
4. When tightening connecting rod nuts, it must be done in 2 steps. Step 1: Tighten connecting rod nuts
to 10-12 ft. lbs. (14-16 N.m). Step 2: Turn connecting rod nuts 60-65 degrees. If no degree wrench is
available, tighten to 28-32 ft. lbs. (38-44 N.m).
Crankshaft & Main Bearings
1. Four main bearings are retained by a single bearing cap which also stiffens the crankcase. Loosen
main bearing cap bolts in 2 steps following correct sequence. See Fig. 16.
2. Coat main bearings with Assembly Lubricant (D9AZ-19579-D) before installing. Apply oil to main
bearing cap bolts.
3. Tighten main bearing cap in 2 or 3 steps in correct sequence to 66-74 ft. lbs. (90-100 N.m). See Fig.
17.
Fig. 16: Main Bearing Cap Bolt Loosening Sequence

Fig. 17: Main Bearing Cap Bolt Tightening Sequence

Thrust Bearing
1. Thrust bearing is integral with main bearing No. 4. Apply a liberal amount of clean oil to main
bearings, thrust bearings and main journals. Install crankshaft and main bearing cap.
2. Tighten main bearing cap in 2 or 3 steps in correct sequence. See CRANKSHAFT, MAIN &
CONNECTING ROD BEARINGS. Using a dial indicator and a screwdriver, measure crankshaft
end play. See Fig. 18. End play should be 0.0020-0.0067" (0.050-0.17 mm). If end play exceeds
0.0118" (0.30 mm), replace thrust bearing with one of oversize thickness.
Fig. 18: Measuring Crankshaft End Play

Cylinder Block
Cylinder bore diameter is measured at top, middle and bottom of bore. Check cylinder bore diameter, taper,
out-of-round and deck warpage. Repair or replace if not within specification. See CYLINDER BLOCK
table under ENGINE SPECIFICATIONS.
CAUTION: DO NOT remove more than .008" (.20 mm) from combined cylinder
block deck and cylinder head thickness when resurfacing.
ENGINE OILING
ENGINE LUBRICATION SYSTEM
Oil pump is positive displacement, crankshaft driven. Oil is drawn from oil pan through an oil pickup tube
and strainer. Pump sends oil to oil filter, and from there it is directed to cylinder heads and engine block
under pressure. The oil then drains back to oil pan. See Fig. 19.
Crankcase Capacity
Oil capacity is 4.2 qts. (4.0L) with filter and 3.7 qts. (3.5L) without filter.
Fig. 19: View Of Engine Oil Circuit

OIL PUMP
Removal & Disassembly
1. Disconnect negative battery cable. Remove accessory drive belts. Remove timing belt. See TIMING
BELT under REMOVAL & INSTALLATION. Raise and support vehicle.
2. Drain engine oil. Remove generator bracket-to-oil pump bolt and position bracket aside. Remove
power steering pump bracket bolts, and position power steering pump aside. Remove crankshaft
pulley. Remove outer timing belt guide. Remove crankshaft sprocket and inner timing belt guide.
3. Disconnect low oil pressure switch electrical connector. Remove 3 oil filter adapter bolts and the oil
filter adapter. Discard the 2 "O" rings. Remove oil pan. See OIL PAN under REMOVAL &
INSTALLATION.
4. Remove 2 oil pickup tube bolts and oil pickup tube. Discard "O" ring. Remove 6 oil pump bolts.
Remove oil pump from engine block. Discard gasket.
5. Carefully pry crankshaft front seal out of oil pump body. Discard seal. Remove 6 oil pump cover
screws and the oil pump cover. See Fig. 20.
6. Remove inner rotor from outer rotor. Remove outer rotor from pump body. Unscrew pressure
regulator cap from oil pump body.
Fig. 20: Exploded View Of Oil Pump

Inspection
1. With a feeler gauge, measure inner rotor tooth tip clearance. Maximum clearance is 0.0071" (0.18
mm). If measurement is above specification, replace oil pump.
2. With a feeler gauge, measure outer rotor-to-pump body clearance. Maximum outer rotor-to-pump
body clearance is 0.0045-0.0079" (0.114-0.200 mm). If measurement is above specification, replace
oil pump.
3. Using a straightedge and feeler gauge, inspect oil pump inner rotor clearance. Maximum inner rotor
clearance is 0.0020-0.0035" (0.05-0.09 mm). If measurement is above specification, replace oil pump.
4. Using a straightedge and feeler gauge, inspect oil pump outer rotor clearance. Maximum outer rotor
clearance is 0.0020-0.0043" (0.05-0.11 mm). If measurement is above specification, replace oil pump.
5. Measure inner rotor ridge. Measure pump body. See Fig. 21 and Fig. 22 . Subtract inner ridge
measurement from pump body measurement to obtain inner rotor ridge-to-oil pump body clearance.
Maximum inner rotor ridge-to-oil pump body clearance is 0.0018-0.0036" (0.045-0.91 mm). If
measurement is above specification, replace oil pump.
Fig. 21: Measuring Rotor Ridge

Fig. 22: Measuring Pump Body

6. Visually inspect pressure regulator valve and valve spring for wear or damage. Check pressure
regulator housing for nicks or scratches. Coat pressure regulator valve with clean engine oil and
ensure the valve slides smoothly in the housing. Replace as necessary.
7. Measure pressure regulator valve housing bore. Measure pressure regulator valve O.D. Subtract valve
diameter from housing bore diameter to obtain pressure regulator valve-to-pressure regulator housing
clearance. Maximum clearance is 0.0016-0.0038" (0.040-0.097 mm). If measurement is above
specification, replace oil pump.
Reassembly & Installation
For reassembly and installation, reverse disassembly and removal procedures using NEW seal, gasket and
"O" rings. Tighten nuts and bolts to proper specifications. See TORQUE SPECIFICATIONS.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application Ft. Lbs. (N.m)

A/C Compressor Drive Belt Tensioner Bolts 15 (21)
A/C Compressor-To-Accessory Bracket Bolts 17-20 (23-27)
Camshaft Sprocket Bolt 58-65 (78-88)
Camshaft Thrust Plate Bolt 58-65 (78-88)
Catalytic Converter Inlet Pipe-To-Exhaust Bracket Bolt 32-40 (44-54)
Catalytic Converter Inlet Pipe-To-Three Way Catalytic 32-40 (44-54)
Converter Nuts
Connecting Rod Nuts (1)
Crankshaft Pulley Bolt 141-156 (191-211)

Cylinder Head Bolts (2)
Distributor Hold-Down Bolt 10-13 (14-17)

Engine Mount Bracket Bolts (Rear) 30-38 (41-52)
Engine Mount Through-Bolts 58-65 (78-88)
Engine-To-Transaxle Bolts 22-30 (30-40)
Exhaust Bracket-To-Transaxle Nuts 22-30 (30-40)
Exhaust Manifold Nuts 13-16 (18-22)
Exhaust Manifold-To-Catalytic Converter Inlet Pipe Nuts 32-40 (44-54)
Flexplate Bolts 61-69 (83-93)
Fuel Rail Bolts 18-20 (24-27)
Generator Bracket-To-Oil Pump Bolt 15 (21)
Generator Lock Bolt 12-15 (16-20)
Generator-To-Accessory Bracket Bolts 17-19 (23-36)
Intake Manifold Bolts & Nuts (3)
Intake Plenum Bolts 13-16 (18-22)

Main Bearing Bolts (4) 66-74 (90-100)
Oil Drain Plug 21-29 (29-39)
Oil Filter (5)
Oil Filter Adapter Bolts 12-15 (16-21)

Oil Pickup Tube Bolts 12-15 (16-21)
Oil Pump Bolts (Long) 9-12 (12-16)
Pressure Regulator Cap 29-51 (39-69)
Power Steering Pump-To-Bracket Bolts 11-15 (15-20)
Power Transistor Bracket-To-Cylinder Head Bolt 18 (25)
Radiator/Heater Pipes Bracket Bolts 15 (21)
Rocker Arm Shaft Bolts 13-16 (18-22)
Thermostat Housing Bolts 12-15 (16-21)
Timing Belt Tensioner Nut 32-43 (43-58)
Transaxle Mount Bolts (Front) 30-38 (41-52)
Transaxle Mount Nuts (Rear) 32-41 (43-55)
Transaxle-To-Engine Bolt (Lower) 22-30 (30-40)
Transaxle-To-Engine Bolt (Upper) 29-36 (39-49)
Transaxle-To-Engine Brace Bolts 22-30 (30-40)
Torque Converter-To-Flexplate Bolts 32-44 (44-59)
Transverse Member Bolts & Nuts 58-65 (78-88)

Upper Radiator Hose Bracket Bolt 38-48 (46-65)
Upper Radiator Hose Clamps 14-17 (19-23)
Water Pump Bolts 12-15 (16-21)
Water Pump Pulley Bolts 12-15 (16-21)
Wheel Lug Nuts 72-87 (98-118)
INCH Lbs. (N.m)
Exhaust Manifold Flange Cover Bolts (Front) 48-59 (5.4-6.7)
Cylinder Head Bolt "A" 71 (8)
Dipstick Tube Bracket Bolts 71 (8)
Ignition Coil Bolts 71 (8)
Oil Pan Bolts 62-71 (7-8)
Oil Pump Bolts (Short) 53-62 (6-7)
Oil Pump Cover Screws 35-44 (4-5)
Rear Main Seal Housing Bolts 71 (8)
Rocker Arm Cover Screws 9-27 (1-3)
Timing Belt Cover Bolts (All) 27-44 (3-5)
(1) Tighten in 2 stages: first to 10-12 ft. lbs. (14-16 N.m), then to 28-32 ft. lbs. (38-44 N.m).
(2) See CYLINDER HEAD under REMOVAL & INSTALLATION.

(3) See INTAKE MANIFOLD under REMOVAL & INSTALLATION.
(4) See CRANKSHAFT & MAIN BEARINGS in CYLINDER BLOCK ASSEMBLY under
OVERHAUL.
(5) Tighten 1 1/6 turns after gasket touches mounting surface.
ENGINE SPECIFICATIONS
GENERAL SPECIFICATIONS
GENERAL SPECIFICATIONS
Application Specification
Displacement 181 Cu. In. (3.0L)
Bore 3.43" (87 mm)
Stroke 3.27" (83 mm)
Compression Ratio 9.0:1
Fuel System SFI
CRANKSHAFT, MAIN BEARINGS & CONNECTING ROD BEARINGS SPECIFICATIONS
CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS

Application In. (mm)
Crankshaft
End Play 0.002-0.007 (0.005-0.18)
Runout
Standard .0010 (.025)
Limit 0.00339 (0.086)

Main Bearings
Journal Diameter
Grade No. 0 2.4790-2.4793 (62.984-
62.975)
Grade No. 1 2.4787-2.4790 (62.959-
62.967)
Grade No. 2 2.4784-2.4787 (62.951-
62.959)
Journal Out-Of-Round 0.0002 (0.005)
Journal Taper 0.0002 (0.005)
Oil Clearance
Standard 0.0011-0.0022 (0.028-
0.055)
Limit .0035 (.089)
Connecting Rod Bearings
Journal Diameter 1.9667-1.9675 (49.955-
49.974)
Journal Out-Of-Round 0.0002 (0.005)
Journal Taper 0.0002 (0.005)
Oil Clearance 0.0006-0.0021 (0.015-
0.053)
CONNECTING RODS SPECIFICATIONS
CONNECTING RODS
Bore Diameter
Pin Bore 0.8261-0.8265" (20.982-20.994
mm)
Crankpin Bore 1.9669-1.9682" (49.960-49.991
mm)
Maximum Bend 0.0039" Per 3.94" (0.10 mm Per 100
mm)
Side Clearance 0.0079-0.0138 (0.20-0.35 mm)
ENGINE PISTONS, PISTON PINS & PISTON RINGS SPECIFICATIONS
PISTONS, PINS & RINGS

Pistons
Clearance 0.0010-0.0018 (0.025-0.046)
Standard Diameter
Grade No. 1 3.4238-3.4242 (86.965-86.975)
Grade No. 2 3.4242-3.4246 (86.975-86.985)
Grade No. 3 3.4246-3.4250 (86.985-86.995)
Oversize Diameter
First Oversize 0.0098 (0.25) 3.4337-3.4356 (87.215-87.265)
Second Oversize 0.0197 (0.50) 3.4435-3.4455 (87.465-87.515)
Pins
Pin Diameter 0.8256-0.8261 (20.971-20.983)
Piston Pin Hole Diameter 0.8255-0.8260 (20.969-20.981)
Pin-To-Piston Clearance -0.0002-0.0 (-0.0005-0.0)
Rings
No. 1
End Gap 0.0083-0.0173 (0.21-0.44)
Side Clearance 0.0016-0.0029 (0.041-0.074)
No. 2
End Gap 0.0071-0.0173 (0.18-0.44)
Side Clearance 0.0012-0.0025 (0.030-0.064)
No. 3 (Oil)
End Gap 0.0079-0.0299 (0.20-0.76)
Side Clearance .0006-.0075 (.015-.19)
CYLINDER BLOCK SPECIFICATIONS
CYLINDER BLOCK
Cylinder Bore
Grade No. 1 3.4252-3.4256 (87.000-
87.010)
Grade No. 2 3.4256-3.4260 (87.010-
87.020)
Grade No. 3 3.4260-3.4264 (87.020-
87.030)
Maximum Taper 0.0006 (0.015)
Maximum Out-Of-Round 0.0006 (0.015)
Minimum Deck Height 8.9606-8.9645 (227.6-
227.7)
Maximum Deck Warpage (Combined Head & Block) 0.008 (0.2)
ENGINE VALVES & VALVE SPRINGS SPECIFICATIONS
VALVES & VALVE SPRINGS

Intake Valves
Face Angle 45°
Head Diameter 1.654-1.661" (42.0-42.2 mm)
Minimum Margin 0.0453-0.0571" (1.15-1.45 mm)
Minimum Refinish Length 4.933-4.957" (125.3-125.9 mm)
Stem Diameter 0.2742-0.2748" (6.965-6.980 mm)
Exhaust Valves
Face Angle 45°

Head Diameter 1.378-1.386" (35.0-35.2 mm)
Minimum Margin 0.0531-0.0650" (1.35-1.65 mm)
Minimum Refinish Length 4.890-4.913" (124.2-124.8 mm)
Stem Diameter 0.3136-0.3138" (7.965-7.970 mm)
Valve Springs
Outer
Free Length 2.016" (51.2 mm)
Out-Of-Square 0.087" (2.2 mm)
Inner
Free Length 1.736" (44.1 mm)
Out-Of-Square 0.075" (1.9 mm)
Lbs. @ In. (kg @ mm)
Pressure
Inner (Valve Open) 57.3 @ 0.984 (26 @ 25)
Outer (Valve Open) 117.7 @ 1.181 (53.4 @ 30)
CYLINDER HEAD SPECIFICATIONS
CYLINDER HEAD
Cylinder Head Height 4.205-4.220" (106.8-107.2
mm)
Maximum Warpage 0.004" (0.10 mm)
Valve Seat Angle 45°
Valve Seat Width
Intake 0.0689" (1.75 mm)
Exhaust 0.067" (1.7 mm)
Valve Guides
Intake Valve
Guide I.D. 0.2756-0.2763" (7.000-
7.018 mm)
Guide Installed Height 0.520-0.528" (13.2-13.4
mm)
Stem-To-Guide Oil Clearance 0.0008-0.0021" (0.020-
0.053 mm)
Exhaust Valve
Guide I.D. 0.3150-0.3154" (8.000-
8.011 mm)
Guide Installed Height 0.520-0.528" (13.2-13.4
mm)
Stem-To-Guide Oil Clearance 0.0016-0.0029" (0.041-
0.074 mm)
CAMSHAFT SPECIFICATIONS
CAMSHAFT
Bore Diameter
Journal A 1.8504-1.8514 (47.000-47.026)
Journal B 1.6732-1.6742 (42.500-42.525)
Journal C 1.8898-1.8907 (48.000-48.024)
End Play 0.0012-0.0024 (0.03-0.06)
Journal Diameter
Journal A 1.8472-1.8480 (46.920-46.940)
Journal B 1.6701-1.6709 (42.421-42.440)
Journal C 1.8866-1.8874 (47.920-47.940)
Journal Runout 0.004 (0.1)
Lobe Height 1.5331-1.5460 (38.941-39.268)
Oil Clearance 0.0059 (0.15)
VALVE LIFTERS SPECIFICATIONS
VALVE LIFTERS
Bore Diameter 0.6299-0.6304 (16.000-16.012)
Lifter Diameter 0.6278-0.6282 (15.946-15.956)
Oil Clearance
Standard .0018-.0035 (.046-.089)
Limit 0.0017-0.0026 (0.043-0.066)

1997 Mercury Villager 3.0L Motor V6

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1997 Mercury Villager 3.0L Motor V6

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1997 Mercury Villager GS

1997-98 ENGINES 3.0L SOHC V6 - VIN 1

3.0L SOHC V6 - VIN 1

ENGINE IDENTIFICATION CODES

Hydraulic lifters are used, and no valve adjustments are required.

REMOVAL & INSTALLATION

CAUTION: When battery is disconnected, vehicle computer and memory systems

FUEL PRESSURE RELEASE

COOLING SYSTEM DRAINING, FILLING & BLEEDING

jueves, 01 de octubre de 2020 10:16:27

CAUTION: DO NOT use a galvanized drain pan if coolant is to be reused. DO

Filling & Bleeding

Fig. 1: Installing Wire Under Radiator Pressure Cap

Removal & Installation

Vehicle speed sensor.

Starter (wiring harness and positive battery cable).

Transmission Range (TR) switch.

Exhaust Gas Recirculation Control (EGRC) solenoid.

Throttle position sensor.

Mass airflow sensor.

CAUTION: DO NOT pull on high-tension lead when removing from ignition

NOTE: Access front power steering-to-bracket bolts by inserting socket

Removal & Installation

Removal & Installation

Fig. 2: Intake Manifold Loosening Sequence

Fig. 3: Intake Manifold Tightening Sequence

Removal & Installation (Left)

Removal & Installation (Right)

Fig. 4: Exhaust Manifold Loosening Sequence

Fig. 5: Exhaust Manifold Tightening Sequence

NOTE: Mark spark plug wire locations for installation.

following electrical connectors:

Mass airflow sensor.

Pulse signal generator.

Valve body wiring harness.

Park/Neutral position switch.

A/C high-pressure switch.

Temperature gauge sender.

Engine coolant temperature sensor.

6 exhaust manifold nuts in sequence and discard gasket. See Fig. 4.

Step 1: Tighten bolts to 22 ft. lbs. (29 N.m).

Fig. 6: Cylinder Head Bolt Loosening Sequence

Fig. 7: Cylinder Head Bolt Tightening Sequence

CRANKSHAFT FRONT SEAL

NOTE: If timing belt is to be reused, ensure direction of rotation is marked for

Fig. 8: Identifying Timing Marks

Fig. 9: Starting Feeler Gauge Under Timing Belt

Fig. 10: Positioning Feeler Gauge Under Timing Belt

ROCKER ARM & HYDRAULIC VALVE LIFTER

ROCKER ARM & HYDRAULIC VALVE LIFTER SPECIFICATIONS

Removal & Installation

CRANKSHAFT REAR OIL SEAL

Removal & Installation

CAUTION: Ensure there is no gasket residue on pump or block before installation.

Fig. 11: Oil Pan Loosening Sequence

Fig. 13: Oil Pan Tightening Sequence

CAUTION: Replace cylinder head if warpage exceeds specification.

Valve Stem Oil Seals

Valve Seat Correction Angles