Ford Taurus Service Manual: Installation

Engine

Special Tool(s)

Ford Taurus. Engine

Material

Ford Taurus. Engine

NOTICE: Whenever turbocharger air intake system components are removed, always cover open ports to protect from debris. It is important that no foreign material enter the system. The turbocharger compressor vanes are susceptible to damage from even small particles. All components should be inspected and cleaned, if necessary, prior to installation or reassembly.

  1. Using the Floor Crane and Spreader Bar, align the transaxle to the engine.

    Ford Taurus. Engine

  1. Install the 3 engine-to-transaxle bolts.
    • Tighten to 48 Nm (35 lb-ft).

    Ford Taurus. Engine

  1. Install the LH engine-to-transaxle bolt.
    • Tighten to 48 Nm (35 lb-ft).

    Ford Taurus. Engine

  1. Install the 2 LH bottom transaxle-to-engine bolts.
    • Tighten to 48 Nm (35 lb-ft).

    Ford Taurus. Engine

  1. Install the RH halfshaft support bracket and the 2 bolts.
    • Tighten to 40 Nm (30 lb-ft).

    Ford Taurus. Engine

  1. Install the intermediate shaft bracket 2 studs and the 2 nuts.
    • Tighten the studs to 10 Nm (89 lb-in).
    • Tighten the nuts to 25 Nm (30 lb-ft).

    Ford Taurus. Engine

  1. NOTE: LH shown, RH similar.

    Install the ratchet strap from the front subframe to the LH engine lift eye and from the rear of the subframe to the RH engine lift eye.

    Ford Taurus. Engine

  1. Using the Floor Crane and Spreader Bar, install the powertrain and subframe as an assembly on the powertrain lift table.

    Ford Taurus. Engine

  1. NOTE: LH shown, RH similar.

    Remove the ratchet strap from the front subframe to the LH engine lift eye and from the rear of the subframe to the RH engine lift eye.

    Ford Taurus. Engine

  1. Install the Adjustable Grip Arm.

    Ford Taurus. Engine

  1. Install a ratchet strap from the front of the subframe under the powertrain lift table to the rear of the subframe, to secure the subframe to the powertrain lift table.
  1. Attach the transaxle control wire harness retainer to the transaxle stud bolt.

    Ford Taurus. Engine

  1. Connect the transaxle control electrical connector.

    Ford Taurus. Engine

  1. Connect the generator electrical connector.

    Ford Taurus. Engine

  1. Connect the generator B+ cable and install the nut.
    • Tighten to 17 Nm (150 lb-in).

    Ford Taurus. Engine

  1. Connect the A/C electrical connector and attach the wiring harness retainer.

    Ford Taurus. Engine

  1. Install the ground wire and the bolt to the RH cylinder head.
    • Tighten to 10 Nm (89 lb-in).

    Ford Taurus. Engine

  1. Position the PTU support bracket in place and install the 3 bolts.
    1. Tighten the 2 bolts to 70 Nm (52 lb-ft).
    1. Tighten the bolt to 48 Nm (35 lb-ft).

    Ford Taurus. Engine

  1. Install the RH turbocharger lower bracket and the 3 bolts.
    1. Tighten the bolt to 19 Nm (168 lb-in).
    1. Tighten the 2 bolts to 48 Nm (35 lb-ft).

    Ford Taurus. Engine

  1. Install the starter, the stud bolt and bolt.
    • Tighten to 27 Nm (20 lb-ft).

    Ford Taurus. Engine

  1. Connect the wiring harness retainer to the starter motor stud bolt.

    Ford Taurus. Engine

  1. Attach the starter wire terminals and install the 2 nuts.
    1. Tighten the B+ terminal nut to 12 Nm (106 lb-in).
    1. Tighten the S-terminal nut to 5 Nm (44 lb-in).

    Ford Taurus. Engine

  1. Install the starter motor solenoid cover.

    Ford Taurus. Engine

  1. Remove the Heavy Duty Floor Crane and Spreader Bar.

    Ford Taurus. Engine

  1. Install the crankcase vent tube and connect the 2 quick connect couplings. For additional information, refer to Section 310-00.

    Ford Taurus. Engine

  1. Remove the Engine Lift Eye from the LH cylinder head.

    Ford Taurus. Engine

  1. Install the LH exhaust manifold heat shield and the 3 bolts.
    • Tighten to 12 Nm (106 lb-in).

    Ford Taurus. Engine

  1. Install the oil supply tube bracket on the LH valve cover stud bolt and install the nut.
    • Tighten to 8 Nm (71 lb-in).

    Ford Taurus. Engine

  1. Attach the 4 wiring harness retainer to the valve cover stud bolt.

    Ford Taurus. Engine

  1. Install the engine cover mounting stud to the LH valve cover stud bolt.
    • Tighten to 6 Nm (53 lb-in).

    Ford Taurus. Engine

  1. Remove the ratchet strap from the RH knuckle to subframe.
  1. NOTE: Make sure the struts go into the knuckles when raised.

    Raise the subframe and powertrain assembly into the vehicle.

  1. Install the engine mount and the 3 bolts.
    • Tighten to 90 Nm (66 lb-ft).

    Ford Taurus. Engine

  1. Install the 4 engine mount nuts.
    • Tighten to 63 Nm (46 lb-ft).

    Ford Taurus. Engine

  1. Install the bolt and the 3 nuts for the transaxle support insulator bracket-to-transaxle.
    • Tighten the bolt to 80 Nm (59 lb-ft).
    • Tighten the nuts to 63 Nm (46 lb-ft).

    Ford Taurus. Engine

  1. NOTE: RH shown, LH similar.

    Install the 2 front subframe bolts.

    • Tighten to 200 Nm (148 lb-ft).

    Ford Taurus. Engine

  1. NOTE: RH shown, LH similar.

    Position the subframe brackets and install the 4 bolts finger-tight.

    Ford Taurus. Engine

  1. NOTE: RH shown, LH similar.

    Install the 2 rear subframe bolts.

    • Tighten to 150 Nm (111 lb-ft).

    Ford Taurus. Engine

  1. NOTE: RH shown, LH similar.

    Tighten the 4 subframe bracket-to-body bolts to 55 Nm (41 lb-ft).

    Ford Taurus. Engine

  1. Remove the ratchet strap from the front of the subframe to the rear of the subframe.
  1. Remove the Adjustable Grip Arm and the powertrain lift table.

    Ford Taurus. Engine

  1. NOTE: LH shown, RH similar.

    Install the strut to the wheel knuckle and install the strut-to-wheel knuckle nuts and bolts.

    • Tighten to 250 Nm (184 lb-ft).

    Ford Taurus. Engine

  1. NOTE: LH shown, RH similar.

    Install the brake caliper and the guide pin bolts.

    • 432 mm (17 in) brakes: Tighten to 72 Nm (53 lb-ft).
    • 457 mm (18 in) brakes: Tighten to 75 Nm (55 lb-ft).

    Ford Taurus. Engine

  1. NOTICE: Do not tighten the wheel hub nut with the vehicle on the ground. The nut must be tightened to specification before the vehicle is lowered onto the wheels. Wheel bearing damage will occur if the wheel bearing is loaded with the weight of the vehicle applied.

    NOTE: LH shown, RH similar.

    NOTE: Apply the brake to keep the halfshaft from rotating.

    Using the previously removed wheel hub nut, seat the LH and RH halfshafts.
    • Tighten to 350 Nm (258 lb-ft).
    • Remove and discard the wheel hub nuts.

    Ford Taurus. Engine

  1. NOTICE: The wheel hub nut contains a one time locking chemical that is activated by the heat created when it is tightened. Install and tighten the new wheel hub nut to specification within 5 minutes of starting it on the threads. Always install a new wheel hub nut after loosening or when not tightened within the specified time or damage to the components can occur.

    NOTE: LH shown, RH similar.

    NOTE: Apply the brake to keep the halfshaft from rotating.

    Install a new wheel hub nuts.
    • Tighten to 350 Nm (258 lb-ft).

    Ford Taurus. Engine

  1. NOTE: RH shown, LH similar.

    Install new upper stabilizer bar link nuts.

    • Tighten to 150 Nm (111 lb-ft).

    Ford Taurus. Engine

  1. NOTE: LH shown, RH similar.

    Install the wheel speed sensor and the bolt.

    • Tighten to 15 Nm (133 lb-in).

    Ford Taurus. Engine

  1. Install the 4 oil pan-to-transaxle bolts.
    • Tighten to 48 Nm (35 lb-ft).

    Ford Taurus. Engine

  1. Install 3 new torque converter bolts.
    • Tighten to 55 Nm (41 lb-ft).

    Ford Taurus. Engine

  1. Install the inspection cover and the 2 fasteners.

    Ford Taurus. Engine

  1. Connect the transaxle cooler tubes and install the 2 secondary latches.

    Ford Taurus. Engine

  1. If equipped, connect the 2 PTU coolant hoses.

    Ford Taurus. Engine

  1. If equipped, install the oil cooler hose retainer to the subframe.

    Ford Taurus. Engine

  1. If equipped, connect the oil cooler hoses.

    Ford Taurus. Engine

  1. Connect the lower radiator hose to the radiator.

    Ford Taurus. Engine

  1. Attach the lower radiator hose retainer to the cooling fan and shroud.

    Ford Taurus. Engine

  1. NOTE: Align the index marks for the LH Charge Air Cooler (CAC) tube.

    Connect the lower LH CAC tube to the LH turbocharger.

    • Tighten to 5 Nm (44 lb-in).

    Ford Taurus. Engine

  1. Using a new O-ring seal and gasket seal, install the upper A/C tube to the A/C compressor and install the nut.
    • Tighten to 15 Nm (133 lb-in).

    Ford Taurus. Engine

  1. Position the A/C tube bracket and install the bolt to the rear of the A/C compressor.
    • Tighten to 25 Nm (18 lb-ft).

    Ford Taurus. Engine

  1. Install a new engine oil filter.
    • Tighten to 5 Nm (44 lb-in) and then rotate an additional 180 degrees.

    Ford Taurus. Engine

  1. Line up the index marks on the rear driveshaft to the index marks on the PTU flange made during removal and install the 4 new bolts.
    • Tighten to 70 Nm (52 lb-ft).

    Ford Taurus. Engine

  1. NOTICE: Do not allow the intermediate shaft to rotate while it is disconnected from the gear or damage to the clockspring may occur. If there is evidence that the intermediate shaft has rotated, the clockspring must be removed and recentered. For additional information, refer to Section 501-20B.

    Install the steering intermediate shaft onto the steering gear and install a new bolt.

    • Tighten to 20 Nm (177 lb-in).

    Ford Taurus. Engine

  1. Install the RH and LH catalytic converters. For additional information, refer to Section 309-00.
  1. Install the 3 scrivets in the rubber shield.

    Ford Taurus. Engine

  1. Install the front splash shield, 3 pin-type retainers and the 7 bolts, when the cooling system or engine service is finished.

    Ford Taurus. Engine

  1. If equipped, install the skid plate and the 10 bolts.
    • Tighten to 70 Nm (52 lb-ft).

    Ford Taurus. Engine

  1. If equipped, install the underbody shield and the 4 retainers.

    Ford Taurus. Engine

  1. Install the front wheels and tires. For additional information, refer to Section 204-04.
  1. Connect the fuel supply tube. For additional information, refer to Section 310-00.

    Ford Taurus. Engine

  1. Install the Evaporative Emission (EVAP) tube assembly and connect the quick connect coupling to the intake manifold. For additional information, refer to Section 310-00.

    Ford Taurus. Engine

  1. Connect the EVAP valve electrical connector and attach to the intake manifold.

    Ford Taurus. Engine

  1. Connect the EVAP tube quick connect coupling. For additional information, refer to Section 310-00.

    Ford Taurus. Engine

  1. If equipped, attach the engine block heater harness to the radiator support wiring harness.
  1. Connect the upper radiator hose to the intake manifold coolant tube.

    Ford Taurus. Engine

  1. Install the ground wire and bolt to the engine front cover.
    • Tighten to 10 Nm (89 lb-in).

    Ford Taurus. Engine

  1. Connect the 2 heater hoses to the intake manifold.

    Ford Taurus. Engine

  1. NOTE: Align the index marks for the RH CAC tube.

    Install the RH CAC tube and tighten the clamps.

    • Tighten to 5 Nm (44 lb-in).

    Ford Taurus. Engine

  1. Attach the wiring harness pin-type retainer and connect the transaxle control cable to the shift cable bracket.

    Ford Taurus. Engine

  1. Connect the transaxle control cable to the control lever.

    Ford Taurus. Engine

  1. Connect the quick connect coupling to the intake manifold. For additional information, refer to Section 310-00.

    Ford Taurus. Engine

  1. Connect the battery power feed wire to the positive battery terminal and install the nut.
    • Connect the electrical connector.
    • Tighten to 6 Nm (53 lb-in).

    Ford Taurus. Engine

  1. Connect the engine wiring harness electrical connector.

    Ford Taurus. Engine

  1. Position back the ground wire and install the bolt.
    • Tighten to 6 Nm (53 lb-in).

    Ford Taurus. Engine

  1. Install the battery tray. For additional information, refer to Section 414-01.
  1. NOTE: Align the index marks for the CAC outlet pipe.

    Install the CAC outlet pipe and tighten the clamps.

    • Tighten to 5 Nm (44 lb-in).

    Ford Taurus. Engine

  1. Connect the Turbocharger Boost Pressure (TCBP)/Charge Air Cooler Temperature (CACT) sensor electrical connector.

    Ford Taurus. Engine

  1. If equipped, install the noise generator. For additional information, refer to Intake Air System Components - Exploded View in Section 303-12.
  1. Install the engine Air Cleaner (ACL) and ACL outlet pipe. For additional information, refer to Section 303-12.
  1. Install the degas bottle. For additional information, refer to Section 303-03.
  1. Using a new O-ring seal and gasket seal, install the A/C tube and the nut.
    • Tighten to 15 Nm (133 lb-in).

    Ford Taurus. Engine

  1. Using a new O-ring seal and gasket seal, connect the A/C tube and install the nut.
    • Tighten to 15 Nm (133 lb-in).

    Ford Taurus. Engine

  1. Install the engine wiring harness retainer to the bulkhead.
    1. Slide the wiring harness in the bulkhead.
    1. Make sure the wiring harness retainer tab is below the bulkhead lip.

    Ford Taurus. Engine

  1. Connect the PCM electrical connector.

    Ford Taurus. Engine

  1. Connect the engine harness electrical connector.

    Ford Taurus. Engine

  1. Install the strut tower brace and the 4 nuts.
    • Tighten to 30 Nm (22 lb-ft).

    Ford Taurus. Engine

  1. Attach the 2 brake booster vacuum hose retainers to the strut tower brace.

    Ford Taurus. Engine

  1. Install the cowl panel grille. For additional information, refer to Section 501-02.
  1. Connect the LH Heated Oxygen Sensor (HO2S) electrical connector.
    • Attach the HO2S connector retainer to the bracket.

    Ford Taurus. Engine

  1. Fill the engine with clean engine oil.
  1. Fill and bleed the cooling system. For additional information, refer to Section 303-03.
  1. Recharge the A/C system. For additional information, refer to Section 412-00.
  1. Perform the Misfire Monitor Neutral Profile Correction procedure following the on-screen instructions.

Camshaft

Special Tool(s)

Ford Taurus. Engine

Ford Taurus. Engine

Ford Taurus. Engine

Material

Ford Taurus. Engine

Installation

 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.

NOTICE: Whenever turbocharger air intake system components are removed, always cover open ports to protect from debris. It is important that no foreign material enter the system. The turbocharger compressor vanes are susceptible to damage from even small particles. All components should be inspected and cleaned, if necessary, prior to installation or reassembly.

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.

All camshafts

  1. NOTICE: The crankshaft must remain in the freewheeling position (crankshaft dowel pin at 9 o'clock) until after the camshafts are installed and the valve clearance is checked/adjusted. Do not turn the crankshaft until instructed to do so. Failure to follow this process will result in severe engine damage.

    Rotate the crankshaft counterclockwise until the crankshaft dowel pin is in the 9 o'clock position.

    Ford Taurus. Engine

LH camshafts

  1. NOTICE: The camshafts must remain in the neutral position during installation or engine damage may occur.

    NOTE: Coat the camshafts with clean engine oil prior to installation.

    Position the camshafts onto the LH cylinder head in the neutral position as shown.

    Ford Taurus. Engine

  1. NOTE: Cylinder head camshaft bearing caps are numbered to verify that they are assembled in their original positions.

    Install the 8 camshaft caps and the 16 bolts. Tighten the bolts in the sequence shown in the following stages:

    • Stage 1: Tighten bolts 1, 2, 3 and 4 to 8 Nm (71 lb-in) then an additional 45 degrees.
    • Stage 2: Tighten bolts 5 and 6 to 8 Nm (71 lb-in).
    • Stage 3: Tighten bolts 7 and 8 to 8 Nm (71 lb-in) then an additional 45 degrees.
    • Stage 4: Loosen bolts 5 and 6.
      • Tighten bolts 5 and 6 to 8 Nm (71 lb-in) then an additional 45 degrees.
    • Stage 5: Tighten bolts 9, 10, 11 and 12 to 8 Nm (71 lb-in) then an additional 45 degrees.
    • Stage 6: Tighten bolts 13 and 14 to 8 Nm (71 lb-in).
    • Stage 7: Tighten bolts 15 and 16 to 8 Nm (71 lb-in) then an additional 45 degrees.
    • Stage 8: Loosen bolts 13 and 14.
      • Tighten bolts 13 and 14 to 8 Nm (71 lb-in) then an additional 45 degrees.

    Ford Taurus. Engine

RH camshafts

  1. NOTICE: The camshafts must remain in the neutral position during installation or engine damage may occur.

    NOTE: Coat the camshafts with clean engine oil prior to installation.

    Position the camshafts onto the RH cylinder head in the neutral position as shown.

    Ford Taurus. Engine

  1. NOTE: Cylinder head camshaft bearing caps are numbered to verify that they are assembled in their original positions.

    Install the 8 camshaft caps and the 16 bolts. Tighten the bolts in the sequence shown in the following stages:

    • Stage 1: Tighten bolts 1, 2, 3 and 4 to 8 Nm (71 lb-in) then an additional 45 degrees.
    • Stage 2: Tighten bolts 5 and 6 to 8 Nm (71 lb-in).
    • Stage 3: Tighten bolts 7 and 8 to 8 Nm (71 lb-in) then an additional 45 degrees.
    • Stage 4: Loosen bolts 5 and 6.
      • Tighten bolts 5 and 6 to 8 Nm (71 lb-in) then an additional 45 degrees.
    • Stage 5: Tighten bolts 9, 10, 11 and 12 to 8 Nm (71 lb-in) then an additional 45 degrees.
    • Stage 6: Tighten bolts 13 and 14 to 8 Nm (71 lb-in).
    • Stage 7: Tighten bolts 15 and 16 to 8 Nm (71 lb-in) then an additional 45 degrees.
    • Stage 8: Loosen bolts 13 and 14.
      • Tighten bolts 13 and 14 to 8 Nm (71 lb-in) then an additional 45 degrees.

    Ford Taurus. Engine

All camshafts

  1. NOTICE: If any components are installed new, the engine valve clearance must be checked/adjusted or engine damage may occur.

    NOTE: Use a camshaft sprocket bolt to turn the camshafts.

    Using a feeler gauge, confirm that the valve tappet clearances are within specification. If valve tappet clearances are not within specification, the clearance must be adjusted by installing new valve tappet(s) of the correct size. For additional information, refer to Valve Clearance Check in this section.

    Ford Taurus. Engine

LH camshafts

  1. NOTE: Use a camshaft sprocket bolt to turn the camshafts.

    Rotate the LH camshafts to the Top Dead Center (TDC) position and install the Camshaft Holding Tool on the flats of the camshafts.

    Ford Taurus. Engine

  1. Assemble the LH Variable Camshaft Timing (VCT) assembly, the LH exhaust camshaft sprocket and the LH secondary timing chain.
    • Align the colored links with the timing marks.

    Ford Taurus. Engine

  1. Position the LH secondary timing assembly onto the camshafts.

    Ford Taurus. Engine

  1. Install 2 new bolts and the original washer. Tighten in 4 stages.
    • Stage 1: Tighten to 40 Nm (30 lb-ft).
    • Stage 2: Loosen one full turn.
    • Stage 3: Tighten to 10 Nm (89 lb-in).
    • Stage 4: Tighten 90 degrees.

    Ford Taurus. Engine

  1. Remove the lockpin from the LH secondary timing chain tensioner.

    Ford Taurus. Engine

RH camshafts

  1. NOTE: Use a camshaft sprocket bolt to turn the camshafts.

    Rotate the RH camshafts to the TDC position and install the Camshaft Holding Tool on the flats of the camshafts.

    Ford Taurus. Engine

  1. Assemble the RH VCT assembly, the RH exhaust camshaft sprocket and the RH secondary timing chain.
    • Align the colored links with the timing marks.

    Ford Taurus. Engine

  1. Position the RH secondary timing assembly onto the camshafts.

    Ford Taurus. Engine

  1. Install 2 new bolts and the original washer. Tighten in 4 stages.
    • Stage 1: Tighten to 40 Nm (30 lb-ft).
    • Stage 2: Loosen one full turn.
    • Stage 3: Tighten to 10 Nm (89 lb-in).
    • Stage 4: Tighten 90 degrees.

    Ford Taurus. Engine

  1. Remove the lockpin from the RH secondary timing chain tensioner.

    Ford Taurus. Engine

All camshafts

  1. Rotate the crankshaft clockwise 60 degrees to the TDC position (crankshaft dowel pin at 11 o'clock).

    Ford Taurus. Engine

  1. NOTE: The crankshaft sprocket timing mark should be between the 2 colored links.

    Install the primary timing chain with the colored links aligned with the timing marks on the VCT assemblies and the crankshaft sprocket.

    Ford Taurus. Engine

  1. Install the lower LH primary timing chain guide and the 2 bolts.
    • Tighten to 10 Nm (89 lb-in).

    Ford Taurus. Engine

  1. Install the primary timing chain tensioner arm.

    Ford Taurus. Engine

  1. Reset the primary timing chain tensioner.
    1. Release the ratchet detent.
    1. Using a soft-jawed vise, compress the ratchet plunger.
    1. Align the hole in the ratchet plunger with the hole in the tensioner housing and install a suitable lockpin.

    Ford Taurus. Engine

  1. NOTE: It may be necessary to rotate the crankshaft slightly to remove slack from the timing chain and install the tensioner.

    Install the primary tensioner and the 2 bolts.

    • Tighten to 10 Nm (89 lb-in).
    • Remove the lockpin.

    Ford Taurus. Engine

  1. As a post-check, verify correct alignment of all timing marks.
    • There are 48 links between the RH intake VCT assembly colored link (1) and the LH intake VCT assembly colored link (2).
    • There are 35 links between the LH intake VCT assembly colored link (2) and the 2 crankshaft sprocket colored links (3).

    Ford Taurus. Engine

  1. Inspect the VCT housing seals for damage and replace as necessary.

    Ford Taurus. Engine

  1. NOTE: RH shown, LH similar.

    NOTE: During removal, the O-ring seal may remain on the cylinder head. If so, remove the O-ring seal from the cylinder head, inspect the seal (replace as necessary) and install the O-ring seal on the VCT housing.

    Inspect the VCT housing-to-cylinder head O-ring seals for damage and replace as necessary.

    Ford Taurus. Engine

  1. NOTICE: Make sure the dowels on the Variable Camshaft Timing (VCT) housing are fully engaged in the cylinder head prior to tightening the bolts. Failure to follow this process will result in severe engine damage.

    Install the LH VCT housing and the 3 bolts.

    • Tighten in the sequence shown to 10 Nm (89 lb-in).

    Ford Taurus. Engine

  1. NOTICE: Make sure the dowels on the Variable Camshaft Timing (VCT) housing are fully engaged in the cylinder head prior to tightening the bolts. Failure to follow this process will result in severe engine damage.

    Install the RH VCT housing and the 3 bolts.

    • Tighten in the sequence shown to 10 Nm (89 lb-in).

    Ford Taurus. Engine

  1. Install the Alignment Pins.

    Ford Taurus. Engine

  1. NOTICE: Failure to use Motorcraft High Performance Engine RTV Silicone may cause the engine oil to foam excessively and result in serious engine damage.

    NOTE: The engine front cover and bolts 17, 18, 19 and 20 must be installed within 4 minutes of the initial sealant application. The remainder of the engine front cover bolts and the engine mount bracket bolts must be installed and tightened within 35 minutes of the initial sealant application. If the time limits are exceeded, the sealant must be removed, the sealing area cleaned and sealant reapplied. To clean the sealing area, use silicone gasket remover and metal surface prep. Failure to follow this procedure can cause future oil leakage.

    Apply a 3.0 mm (0.11 in) bead of Motorcraft High Performance Engine RTV Silicone to the engine front cover sealing surfaces including the 3 engine mount bracket bosses.
    • Apply a 5.5 mm (0.21 in) bead of Motorcraft High Performance Engine RTV Silicone to the oil pan-to-cylinder block joint and the cylinder head-to-cylinder block joint areas of the engine front cover in 5 places as indicated.

    Ford Taurus. Engine

  1. NOTE: Make sure the 2 locating dowel pins are seated correctly in the cylinder block.

    Install the engine front cover and bolts 17, 18, 19 and 20.

    • Tighten in sequence shown to 3 Nm (27 lb-in).

    Ford Taurus. Engine

  1. Remove the Alignment Pins.

    Ford Taurus. Engine

  1. NOTE: Do not tighten the bolts at this time.

    Install the engine mount bracket and the 3 bolts.

    Ford Taurus. Engine

  1. Install the remaining engine front cover bolts. Tighten all of the engine front cover bolts and engine mount bracket bolts in the sequence shown in 2 stages:
    • Stage 1: Tighten bolts 1 thru 22 to 10 Nm (89 lb-in) and bolts 23, 24 and 25 to 15 Nm (133 lb-in).
    • Stage 2: Tighten bolts 1 thru 22 to 24 Nm (18 lb-ft) and bolts 23, 24 and 25 to 75 Nm (55 lb-ft).

    Ford Taurus. Engine

  1. NOTICE: The thread sealer on the engine mount studs (including new engine mount studs if applicable) must be cleaned off with a wire brush and new Threadlock and Sealer applied prior to installing the engine mount studs. Failure to follow this procedure may result in damage to the engine mount studs or engine.

    Install the engine mount studs in the following sequence.

    1. Clean the front cover engine mount stud holes with pressurized air to remove any foreign material.
    1. Clean all the thread sealer from the engine mount studs (old and new studs).
    1. Apply new Threadlock and Sealer to the engine mount stud threads.
    1. Install the 2 engine mount studs.
      • Tighten to 20 Nm (177 lb-in).

    Ford Taurus. Engine

  1. Install the Heated Oxygen Sensor (HO2S) connector bracket and stud bolt to the engine front cover.
    • Tighten to 10 Nm (89 lb-in).

    Ford Taurus. Engine

  1. NOTE: Apply clean engine oil to the crankshaft front seal bore in the engine front cover.

    Using the Crankshaft Vibration Damper Installer and Front Crankshaft Seal Installer, install a new crankshaft front seal.

    Ford Taurus. Engine

  1. NOTE: Lubricate the outside diameter sealing surfaces with clean engine oil.

    Using the Crankshaft Vibration Damper Installer and Front Cover Oil Seal Installer, install the crankshaft pulley.

    Ford Taurus. Engine

  1. Using the Strap Wrench, install the crankshaft pulley washer and new bolt and tighten in 4 stages.
    • Stage 1: Tighten to 120 Nm (89 lb-ft).
    • Stage 2: Loosen one full turn.
    • Stage 3: Tighten to 50 Nm (37 lb-ft).
    • Stage 4: Tighten an additional 90 degrees.

    Ford Taurus. Engine

  1. Install the accessory drive belt tensioner and the 3 bolts.
    • Tighten to 11 Nm (97 lb-in).

    Ford Taurus. Engine

  1. Rotate the accessory drive belt tensioner clockwise and install the accessory drive belt.

    Ford Taurus. Engine

  1. NOTE: Installation of new seals is only required if damaged seals were removed during disassembly of the engine.

    NOTE: Spark plug tube seal installation shown, VCT solenoid seal installation similar.

    Using the VCT Spark Plug Tube Seal Installer and Handle, install new VCT solenoid and/or spark plug tube seals.

    Ford Taurus. Engine

  1. NOTICE: Failure to use Motorcraft High Performance Engine RTV Silicone may cause the engine oil to foam excessively and result in serious engine damage.

    NOTE: If the valve cover is not installed and the fasteners tightened within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Failure to follow this procedure can cause future oil leakage.

    Apply an 8 mm (0.31 in) bead of Motorcraft High Performance Engine RTV Silicone to the engine front cover-to-RH cylinder head joints.

    Ford Taurus. Engine

  1. Using a new gasket, install the RH valve cover and tighten the 11 stud bolts.
    • Tighten in the sequence shown to 10 Nm (89 lb-in).

    Ford Taurus. Engine

  1. NOTICE: Failure to use Motorcraft High Performance Engine RTV Silicone may cause the engine oil to foam excessively and result in serious engine damage.

    NOTE: If the valve cover is not installed and the fasteners tightened within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Failure to follow this procedure can cause future oil leakage.

    Apply an 8 mm (0.31 in) bead of Motorcraft High Performance Engine RTV Silicone to the engine front cover-to-LH cylinder head joints.

    Ford Taurus. Engine

  1. Using a new gasket, install the LH valve cover and tighten the 10 stud bolts.
    • Tighten in the sequence shown to 10 Nm (89 lb-in).

    Ford Taurus. Engine

  1. Install 3 RH ignition coil-on-plugs and the 3 bolts.
    • Tighten to 7 Nm (62 lb-in).

    Ford Taurus. Engine

  1. Install 3 LH ignition coil-on-plugs and the 3 bolts.
    • Tighten to 7 Nm (62 lb-in).

    Ford Taurus. Engine

  1. NOTE: The cam lobe for the fuel injection pump must be at Bottom Dead Center (BDC) for the fuel injection pump installation.

    Using the crankshaft pulley bolt, turn the crankshaft until the fuel injection pump cam lobe is at BDC.

    Ford Taurus. Engine

  1. NOTE: Valve cover is removed for clarity.

    NOTE: Apply clean engine oil to the fuel injection pump mounting pedestal bore.

    Install the fuel injection pump roller tappet.

    Ford Taurus. Engine

  1. NOTE: Apply clean engine oil to the fuel injection pump mounting plate seal.

    Inspect the fuel injection pump mounting plate-to-valve cover gasket and replace if necessary.

    Ford Taurus. Engine

  1. NOTE: Apply clean engine oil to the fuel injection pump mounting plate O-ring seals.

    Inspect the 2 fuel injection pump mounting plate O-ring seals and replace if necessary.

    Ford Taurus. Engine

  1. NOTE: Apply clean engine oil to the fuel injection pump O-ring seal.

    Install the fuel injection pump on the fuel injection pump mounting plate.

    Ford Taurus. Engine

  1. NOTE: Clean the fuel injection pump bolts and apply Thread Sealant with PTFE to the bolts.

    Install the fuel injection pump and the 2 bolts finger-tight.

    • Tighten to 10 Nm (89 lb-in).
    • Tighten an additional 45 degrees.

    Ford Taurus. Engine

  1. NOTE: To install, apply clean engine oil to the threads of the 3 high-pressure fuel tube flare nuts.

    Install the high-pressure fuel tube and tighten the 3 flare nuts in the following 3 stages.

    • Stage 1: Tighten to 32 Nm (24 lb-ft).
    • Stage 2: Wait 10 minutes to minimize pre-stress.
    • Stage 3: Tighten to 32 Nm (24 lb-ft).

    Ford Taurus. Engine

  1. Install the high-pressure fuel tube bracket nut.
    • Tighten to 8 Nm (71 lb-in).

    Ford Taurus. Engine

  1. Attach the wiring harness retainers to the RH valve cover and stud bolt.
  1. Connect the 3 RH ignition coil-on-plug electrical connectors.

    Ford Taurus. Engine

  1. Connect the RH VCT solenoid electrical connector and attach the 2 wiring harness retainers.

    Ford Taurus. Engine

  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: Make sure the fuel rail wiring harnesses are routed correct.

    NOTE: Installing the 2 long bolts first will aid in installing the intake manifold.

    Using new intake manifold, coolant crossover and thermostat housing gaskets, install the intake manifold and the 12 bolts. Tighten in the sequence shown in 2 stages.
    • Stage 1: Tighten to 10 Nm (89 lb-in).
    • Stage 2: Tighten an additional 45 degrees.

    Ford Taurus. Engine

  1. Connect the 2 turbocharger coolant hoses to the intake manifold.

    Ford Taurus. Engine

  1. Position the fuel tube and install the fuel tube-to-engine front cover bracket bolt.
    • Tighten to 10 Nm (89 lb-in).

    Ford Taurus. Engine

  1. Attach the 2 wire harness-to-intake manifold retainers.

    Ford Taurus. Engine

  1. Connect the turbocharger wastegate regulating valve electrical connector.

    Ford Taurus. Engine

  1. Connect the Manifold Absolute Pressure (MAP)/Intake Air Temperature 2 (IAT2) sensor electrical connector.

    Ford Taurus. Engine

  1. Connect and attach the 2 fuel injector wiring harness electrical connectors.

    Ford Taurus. Engine

  1. Install the oil level indicator.

    Ford Taurus. Engine

  1. Install the oil supply tube bracket on the LH valve cover stud bolt and install the nut.
    • Tighten to 8 Nm (71 lb-in).

    Ford Taurus. Engine

  1. Attach all the wiring harness retainers to the LH valve cover and stud bolts.
  1. Install the engine cover mounting stud to the LH valve cover stud bolt.
    • Tighten to 6 Nm (53 lb-in).

    Ford Taurus. Engine

  1. Install the lower radiator hose to the thermostat housing.

    Ford Taurus. Engine

  1. Connect the 3 LH ignition coil-on-plug electrical connectors.

    Ford Taurus. Engine

  1. Connect the Engine Oil Pressure (EOP) electrical connector.
    • Attach the wiring harness retainer to the block.

    Ford Taurus. Engine

  1. Connect the LH VCT solenoid electrical connector.

    Ford Taurus. Engine

  1. Connect the Throttle Position (TP) and electronic Throttle Body (TB) electrical connectors.

    Ford Taurus. Engine

  1. Connect the fuel injection pump electrical connector and install the insulated cover.

    Ford Taurus. Engine

  1. NOTICE: The compression limiter bushing may fall out of the mounting bracket grommet on the Charge Air Cooler (CAC) tube during service. Make sure the bushing is in place when reinstalling the tube or damage to the tube may occur.

    Install the RH Charge Air Cooler (CAC) tube and turbocharger intake tube as an assembly and install the RH CAC tube nut to the intake manifold.

    • Tighten to 6 Nm (53 lb-in).

    Ford Taurus. Engine

  1. NOTICE: The compression limiter bushing may fall out of the mounting bracket grommet on the turbocharger intake tube during service. Make sure the bushing is in place when reinstalling the tube or damage to the tube may occur.

    Install the RH turbocharger intake tube to the valve cover stud bolt and install the nut.

    • Tighten to 6 Nm (53 lb-in).

    Ford Taurus. Engine

  1. NOTE: Align the index marks for the RH turbocharger intake pipe.

    Install the RH turbocharger intake pipe to the RH turbocharger and tighten the clamp.

    • Tighten to 5 Nm (44 lb-in).

    Ford Taurus. Engine

  1. NOTE: Align the index marks for the RH CAC tube.

    Install the RH CAC tube to the RH turbocharger and tighten the clamp.

    • Tighten to 5 Nm (44 lb-in).

    Ford Taurus. Engine

  1. Connect the RH turbocharger bypass valve electrical connector.

    Ford Taurus. Engine

  1. NOTE: Align the index marks for the LH turbocharger intake tube.

    Install the LH turbocharger intake tube to the LH turbocharger and tighten the clamp.

    • Tighten to 5 Nm (44 lb-in).

    Ford Taurus. Engine

  1. Install the turbocharger wastegate regulating valve hoses to the turbocharger wastegate regulating valve and to the RH CAC tube.

    Ford Taurus. Engine

  1. Connect the LH turbocharger bypass valve electrical connector.

    Ford Taurus. Engine

  1. Install the PCV tube and connect the 2 quick connect couplings. For additional information, refer to Section 310-00.

    Ford Taurus. Engine

  1. Using a new O-ring seal and gasket seal, connect the A/C tube to the compressor and install the nut.
    • Tighten to 15 Nm (133 lb-in).

    Ford Taurus. Engine

  1. Install the crankcase vent tube and connect the 2 quick connect couplings. For additional information, refer to Section 310-00.

    Ford Taurus. Engine

  1. NOTE: Make sure the struts go into the knuckles when raised.

    Raise the subframe and powertrain assembly into the vehicle.

  1. Install the engine mount and the 3 bolts.
    • Tighten to 90 Nm (66 lb-ft).

    Ford Taurus. Engine

  1. Install the 4 engine mount nuts.
    • Tighten to 63 Nm (46 lb-ft).

    Ford Taurus. Engine

  1. Install the bolt and the 3 nuts to the transaxle support insulator bracket-to-transaxle.
    • Tighten the bolt to 80 Nm (59 lb-ft).
    • Tighten the nuts to 63 Nm (46 lb-ft).

    Ford Taurus. Engine

  1. NOTE: RH shown, LH similar.

    Install the 2 front subframe bolts.

    • Tighten to 200 Nm (148 lb-ft).

    Ford Taurus. Engine

  1. NOTE: RH shown, LH similar.

    Position the subframe brackets and install the 4 bolts finger-tight.

    Ford Taurus. Engine

  1. NOTE: RH shown, LH similar.

    Install the 2 rear subframe bolts.

    • Tighten to 150 Nm (111 lb-ft).

    Ford Taurus. Engine

  1. NOTE: RH shown, LH similar.

    Tighten the 4 subframe bracket-to-body bolts to 55 Nm (41 lb-ft).

    Ford Taurus. Engine

  1. Remove the ratchet strap from the front of the subframe to the rear of the subframe.
  1. Remove the Adjustable Grip Arm and the powertrain lift table.

    Ford Taurus. Engine

  1. NOTE: LH shown, RH similar.

    Install the strut to the wheel knuckle and install the strut-to-wheel knuckle nuts and bolts.

    • Tighten to 250 Nm (184 lb-ft).

    Ford Taurus. Engine

  1. NOTE: LH shown, RH similar.

    Install the brake caliper and the guide pin bolts.

    • 432 mm (17 in) brakes: Tighten to 72 Nm (53 lb-ft).
    • 457 mm (18 in) brakes: Tighten to 75 Nm (55 lb-ft).

    Ford Taurus. Engine

  1. NOTICE: Do not tighten the wheel hub nut with the vehicle on the ground. The nut must be tightened to specification before the vehicle is lowered onto the wheels. Wheel bearing damage will occur if the wheel bearing is loaded with the weight of the vehicle applied.

    NOTE: LH shown, RH similar.

    NOTE: Apply the brake to keep the halfshaft from rotating.

    Using the previously removed wheel hub nut, seat the LH and RH halfshafts.
    • Tighten to 350 Nm (258 lb-ft).
    • Remove and discard the wheel hub nuts.

    Ford Taurus. Engine

  1. NOTICE: The wheel hub nut contains a one time locking chemical that is activated by the heat created when it is tightened. Install and tighten the new wheel hub nut to specification within 5 minutes of starting it on the threads. Always install a new wheel hub nut after loosening or when not tightened within the specified time or damage to the components can occur.

    NOTE: LH shown, RH similar.

    NOTE: Apply the brake to keep the halfshaft from rotating.

    Install a new wheel hub nuts.
    • Tighten to 350 Nm (258 lb-ft).

    Ford Taurus. Engine

  1. NOTE: RH shown, LH similar.

    Install new upper stabilizer bar link nuts.

    • Tighten to 150 Nm (111 lb-ft).

    Ford Taurus. Engine

  1. NOTE: LH shown, RH similar.

    Install the wheel speed sensor and the bolt.

    • Tighten to 15 Nm (133 lb-in).

    Ford Taurus. Engine

  1. Connect the transaxle cooler tubes and install the 2 secondary latches.

    Ford Taurus. Engine

  1. If equipped, connect the 2 PTU coolant hoses.

    Ford Taurus. Engine

  1. If equipped, install the oil cooler hose retainer to the subframe.

    Ford Taurus. Engine

  1. If equipped, connect the oil cooler hoses.

    Ford Taurus. Engine

  1. Connect the lower radiator hose to the radiator.

    Ford Taurus. Engine

  1. Attach the lower radiator hose retainer to the cooling fan and shroud.

    Ford Taurus. Engine

  1. NOTE: Align the index marks for the LH CAC tube.

    Connect the lower LH CAC tube to the LH turbocharger and tighten the clamp.

    • Tighten to 5 Nm (44 lb-in).

    Ford Taurus. Engine

  1. Using a new O-ring seal and gasket seal, install the upper A/C tube to the A/C compressor and install the nut.
    • Tighten to 15 Nm (133 lb-in).

    Ford Taurus. Engine

  1. Position the A/C tube bracket and install bolt to the rear of the A/C compressor.
    • Tighten to 25 Nm (18 lb-ft).

    Ford Taurus. Engine

  1. Install a new engine oil filter.
    • Tighten to 5 Nm (44 lb-in) and then rotate an additional 180 degrees.

    Ford Taurus. Engine

  1. Line up the index marks on the rear driveshaft to the index marks on the PTU flange made during removal and install the 4 new bolts.
    • Tighten to 70 Nm (52 lb-ft).

    Ford Taurus. Engine

  1. NOTICE: Do not allow the intermediate shaft to rotate while it is disconnected from the gear or damage to the clockspring may occur. If there is evidence that the intermediate shaft has rotated, the clockspring must be removed and recentered. For additional information, refer to Section 501-20B.

    Install the steering intermediate shaft onto the steering gear and install a new bolt.

    • Tighten to 20 Nm (177 lb-in).

    Ford Taurus. Engine

  1. Install the RH and LH catalytic converters. For additional information, refer to Section 309-00.
  1. Install the 3 scrivets in the rubber shield.

    Ford Taurus. Engine

  1. Install the front splash shield, 3 pin-type retainers and the 7 bolts, when the coolant system or engine service is finished.

    Ford Taurus. Engine

  1. If equipped, install the skid plate and the 10 bolts.
    • Tighten to 70 Nm (52 lb-ft).

    Ford Taurus. Engine

  1. If equipped, install the underbody shield and the 4 retainers.

    Ford Taurus. Engine

  1. Install the front wheels and tires. For additional information, refer to Section 204-04.
  1. Connect the fuel supply tube. For additional information, refer to Section 310-00.

    Ford Taurus. Engine

  1. Install the Evaporative Emission (EVAP) tube assembly and connect the quick connect coupling to the intake manifold. For additional information, refer to Section 310-00.

    Ford Taurus. Engine

  1. Connect the EVAP valve electrical connector and attach to the intake manifold.

    Ford Taurus. Engine

  1. Connect the EVAP tube quick connect coupling. For additional information, refer to Section 310-00.

    Ford Taurus. Engine

  1. If equipped, attach the engine block heater harness to the radiator support wiring harness.
  1. Connect the upper radiator hose to the intake manifold coolant tube.

    Ford Taurus. Engine

  1. Install the ground wire and bolt to the engine front cover.
    • Tighten to 10 Nm (89 lb-in).

    Ford Taurus. Engine

  1. Connect the 2 heater hoses to the intake manifold.

    Ford Taurus. Engine

  1. NOTE: Align the index marks for the RH CAC tube.

    Install the RH CAC tube and tighten the clamps.

    • Tighten to 5 Nm (44 lb-in).

    Ford Taurus. Engine

  1. Connect the transaxle control cable to the shift cable bracket.

    Ford Taurus. Engine

  1. Connect the transaxle control cable to the control lever.

    Ford Taurus. Engine

  1. Connect the quick connect coupling to the intake manifold. For additional information, refer to Section 310-00.

    Ford Taurus. Engine

  1. Connect the battery power feed wire to the positive battery terminal and install the nut.
    • Connect the electrical connector.
    • Tighten to 6 Nm (53 lb-in).

    Ford Taurus. Engine

  1. Connect the engine wiring harness electrical connector.

    Ford Taurus. Engine

  1. Position back the ground wire and install the bolt.
    • Tighten to 6 Nm (53 lb-in).

    Ford Taurus. Engine

  1. Install the battery tray. For additional information, refer to Section 414-01.
  1. NOTE: Align the index marks for the CAC outlet pipe.

    Install the CAC outlet pipe and tighten the clamps.

    • Tighten to 5 Nm (44 lb-in).

    Ford Taurus. Engine

  1. Connect the Turbocharger Boost Pressure (TCBP)/Charge Air Cooler Temperature (CACT) sensor electrical connector.

    Ford Taurus. Engine

  1. If equipped, install the noise generator. For additional information, refer to Intake Air System Components - Exploded View in Section 303-12.
  1. Install the engine Air Cleaner (ACL) and ACL outlet pipe. For additional information, refer to Section 303-12.
  1. Install the degas bottle. For additional information, refer to Section 303-03.
  1. Using a new O-ring seal and gasket seal, install the A/C tube and the nut.
    • Tighten to 15 Nm (133 lb-in).

    Ford Taurus. Engine

  1. Using a new O-ring seal and gasket seal, connect the A/C tube and install the nut.
    • Tighten to 15 Nm (133 lb-in).

    Ford Taurus. Engine

  1. Install the engine wiring harness retainer to the bulkhead.
    1. Slide the wiring harness in the bulkhead.
    1. Make sure the wiring harness retainer tab is below the bulkhead lip.

    Ford Taurus. Engine

  1. Connect the PCM electrical connector.

    Ford Taurus. Engine

  1. Connect the engine harness electrical connector.

    Ford Taurus. Engine

  1. Install the strut tower brace and the 4 nuts (2 shown).
    • Tighten to 30 Nm (22 lb-ft).

    Ford Taurus. Engine

  1. Attach the 2 brake booster vacuum hose retainers to the strut tower brace.

    Ford Taurus. Engine

  1. Install the cowl panel grille. For additional information, refer to Section 501-02.
  1. Connect the LH Heated Oxygen Sensor (HO2S) electrical connector.
    • Attach the HO2S connector retainer to the bracket.

    Ford Taurus. Engine

  1. NOTICE: Do not expose the Motorcraft High Performance Engine RTV Silicone to engine oil for at least 90 minutes after installing the engine front cover. Failure to follow this instruction may cause oil leakage.

    Fill the engine with clean engine oil.

  1. Fill and bleed the cooling system. For additional information, refer to Section 303-03.
  1. Recharge the A/C system. For additional information, refer to Section 412-00.
  1. Perform the Misfire Monitor Neutral Profile Correction procedure following the on-screen instructions.

Valve Tappets

Material

Ford Taurus. Engine

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. NOTE: The valve tappets must be installed in their original positions.

    NOTE: Coat the valve tappets with clean engine oil prior to installation.

    Install the valve tappets.

    Ford Taurus. Engine

  1. Depending on the valve tappets being serviced, install the LH and/or the RH camshafts. For additional information, refer to Camshaft in this section.

Valve Spring, Retainer and Seal

Special Tool(s)

Ford Taurus. Engine

Material

Ford Taurus. Engine

  1. NOTE: Lubricate the valve stem seal with clean engine oil prior to installation.

    Using the Valve Stem Oil Seal Installer, install a new valve stem seal.

    Ford Taurus. Engine

  1. Using the Valve Spring Compressors, install the valve spring, retainer and key.

    Ford Taurus. Engine

  1. Install the valve tappets. For additional information, refer to Valve Tappets in this section.

Cylinder Head - RH

Material

Ford Taurus. Engine

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: Whenever turbocharger air intake system components are removed, always cover open ports to protect from debris. It is important that no foreign material enter the system. The turbocharger compressor vanes are susceptible to damage from even small particles. All components should be inspected and cleaned, if necessary, prior to installation or reassembly.

  1. Install a new gasket, the RH cylinder head and 8 new bolts. Tighten in the sequence shown in 5 stages:
    • Stage 1: Tighten to 20 Nm (177 lb-in).
    • Stage 2: Tighten to 35 Nm (26 lb-ft).
    • Stage 3: Tighten 90 degrees.
    • Stage 4: Tighten 90 degrees.
    • Stage 5: Tighten 45 degrees.

    Ford Taurus. Engine

  1. Install the cylinder head M6 bolt.
    • Tighten to 10 Nm (89 lb-in).

    Ford Taurus. Engine

  1. NOTE: The valve tappets must be installed in their original positions.

    NOTE: Coat the valve tappets with clean engine oil prior to installation.

    Install the valve tappets.

    Ford Taurus. Engine

  1. Install the RH engine lifting eye and the 2 bolts.
    • Tighten to 24 Nm (18 lb-ft).

    Ford Taurus. Engine

  1. Install the RH secondary timing chain tensioner and the 2 bolts.
    • Tighten to 10 Nm (89 lb-in).

    Ford Taurus. Engine

  1. Install the RH timing chain guide and bolt.
    • Tighten to 10 Nm (89 lb-in).

    Ford Taurus. Engine

  1. Install the RH cylinder block drain plug or, if equipped, the block heater.
    • Tighten the cylinder block drain plug to 10 Nm (89 lb-in) plus an additional 720 degrees.
    • Tighten the block heater to 40 Nm (30 lb-ft).

    Ford Taurus. Engine

  1. If equipped, install the block heater wiring harness onto the engine.
    • Connect the block heater electrical connector and install the heat shield.

    Ford Taurus. Engine

  1. Install the LH cylinder block drain plug.
    • Tighten to 16 Nm (142 lb-in) plus an additional 180 degrees.

    Ford Taurus. Engine

  1. Install 8 new RH exhaust manifold studs.
    • Tighten to 12 Nm (106 lb-in).

    Ford Taurus. Engine

  1. NOTICE: Failure to tighten the exhaust manifold nuts to specification a second time will cause the exhaust manifold to develop an exhaust leak.

    Install a new gasket, RH exhaust manifold and 8 new nuts. Tighten in 2 stages in the sequence shown:

    • Stage 1: Tighten to 15 Nm (133 lb-in).
    • Stage 2: Tighten to 20 Nm (177 lb-in).

    Ford Taurus. Engine

  1. Install the oil supply tube filter, washer and bolt.
    1. Install a new oil supply tube filter in the oil supply tube block.
    1. Slide the new washer onto the oil supply tube block.
    1. Instal the banjo bolt into the oil supply tube block.

    Ford Taurus. Engine

  1. Install the RH turbocharger oil supply tube.
    • Tighten the bolt to 40 Nm (30 lb-ft).

    Ford Taurus. Engine

  1. Install a new gasket, the turbocharger and the 3 new exhaust manifold-to-turbocharger bolts.
    • Tighten to 45 Nm (33 lb-ft).

    Ford Taurus. Engine

  1. Install the upper turbocharger-to-cylinder block bracket and the 3 bolts and position the bracket as far clockwise as possible and tighten the bolts in the following sequence:
    1. Tighten the lower bolt to 26 Nm (19 lb-ft).
    1. Tighten the upper bolt to 26 Nm (19 lb-ft).
    1. Tighten the turbocharger bolt to 19 Nm (168 lb-in).

    Ford Taurus. Engine

  1. Using 2 new sealing washers, install the 2 RH turbocharger coolant tubes and banjo bolts.
    • Tighten to 40 Nm (30 lb-ft).

    Ford Taurus. Engine

  1. Install the coolant tube bracket-to-cylinder head bolt.
    • Tighten to 10 Nm (89 lb-in).

    Ford Taurus. Engine

  1. If necessary, install the RH cylinder head turbocharger oil supply quick connect fitting.
    • Tighten to 16 Nm (142 lb-in).

    Ford Taurus. Engine

  1. NOTE: Listen for audible click when installing the oil supply tube into the quick connect fitting.

    Install the RH oil supply tube into the quick connect fitting.

    Ford Taurus. Engine

  1. Install the oil supply tube secondary latch.

    Ford Taurus. Engine

  1. Install a new gasket and the RH turbocharger oil return tube and the 2 bolts.
    • Tighten to 10 Nm (89 lb-in).

    Ford Taurus. Engine

  1. NOTE: Make sure the turbocharger wastegate regulating valve hose does not contact the exhaust manifold heat shield.

    Connect the turbocharger wastegate regulating valve hose to the RH turbocharger assembly.

    Ford Taurus. Engine

  1. NOTE: Make sure the heat shield does not contact the wastegate arm.

    Install the 2 upper RH exhaust manifold heat shield and the 5 bolts.

    • Tighten to 12 Nm (106 lb-in).

    Ford Taurus. Engine

  1. Connect the Cylinder Head Temperature (CHT) sensor electrical connector to the rear of the RH cylinder head.

    Ford Taurus. Engine

  1. Install the ground wire and the bolt.
    • Tighten to 10 Nm (89 lb-in).

    Ford Taurus. Engine

  1. Install the RH Camshaft Position (CMP) sensor and the bolt.
    • Tighten to 10 Nm (89 lb-in).

    Ford Taurus. Engine

  1. Connect the RH CMP sensor electrical connector.

    Ford Taurus. Engine

  1. Install the RH camshafts. For additional information, refer to Camshaft in this section.
  1. Install the fuel rails. For additional information, refer to Section 303-04B.

Cylinder Head - LH

Material

Ford Taurus. Engine

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: Whenever turbocharger air intake system components are removed, always cover open ports to protect from debris. It is important that no foreign material enter the system. The turbocharger compressor vanes are susceptible to damage from even small particles. All components should be inspected and cleaned, if necessary, prior to installation or reassembly.

  1. Install a new gasket, the LH cylinder head and 8 new bolts. Tighten in the sequence shown in 5 stages:
    • Stage 1: Tighten to 20 Nm (177 lb-in).
    • Stage 2: Tighten to 35 Nm (26 lb-ft).
    • Stage 3: Tighten 90 degrees.
    • Stage 4: Tighten 90 degrees.
    • Stage 5: Tighten 45 degrees.

    Ford Taurus. Engine

  1. Install the cylinder head M6 bolt.
    • Tighten to 10 Nm (89 lb-in).

    Ford Taurus. Engine

  1. NOTE: The valve tappets must be installed in their original positions.

    NOTE: Coat the valve tappets with clean engine oil prior to installation.

    Install the valve tappets.

    Ford Taurus. Engine

  1. Install the LH secondary timing chain tensioner and the 2 bolts.
    • Tighten to 10 Nm (89 lb-in).

    Ford Taurus. Engine

  1. Install the upper LH primary timing chain guide and the bolt.
    • Tighten to 10 Nm (89 lb-in).

    Ford Taurus. Engine

  1. Install the RH cylinder block drain plug or, if equipped, the block heater.
    • Tighten the cylinder block drain plug to 10 Nm (89 lb-in) plus an additional 720 degrees.
    • Tighten the block heater to 40 Nm (30 lb-ft).

    Ford Taurus. Engine

  1. If equipped, install the block heater wiring harness onto the engine.
    • Connect the block heater electrical connector and install the heat shield.

    Ford Taurus. Engine

  1. Install the LH cylinder block drain plug.
    • Tighten to 16 Nm (142 lb-in) plus an additional 180 degrees.

    Ford Taurus. Engine

  1. Install 8 new LH exhaust manifold studs.
    • Tighten to 12 Nm (106 lb-in).

    Ford Taurus. Engine

  1. NOTICE: Failure to tighten the exhaust manifold nuts to specification a second time will cause the exhaust manifold to develop an exhaust leak.

    Install a new gasket, LH exhaust manifold and turbocharger assembly and 8 new nuts. Tighten the nuts in 2 stages in the sequence shown:

    • Stage 1: Tighten to 15 Nm (133 lb-in).
    • Stage 2: Tighten to 20 Nm (177 lb-in).

    Ford Taurus. Engine

  1. Install the upper turbocharger bracket-to-cylinder block and the 2 bolts.
    • Do not tighten the bolts at this time.

    Ford Taurus. Engine

  1. Install the lower turbocharger-to-cylinder block bracket and the 2 bolts.
    • Do not tighten the bolts at this time.

    Ford Taurus. Engine

NOTICE: The next 4 steps must be performed in order or damage to the turbocharger may occur.

  1. Tighten the upper turbocharger bracket-to-turbocharger bolt.
    • Tighten to 19 Nm (168 lb-in).

    Ford Taurus. Engine

  1. Tighten the upper turbocharger bracket-to-cylinder block bolt.
    • Tighten to 25 Nm (18 lb-ft).

    Ford Taurus. Engine

  1. Tighten the lower turbocharger bracket-to-turbocharger bolt.
    • Tighten to 19 Nm (168 lb-in).

    Ford Taurus. Engine

  1. Tighten the lower turbocharger bracket-to-cylinder block bolt.
    • Tighten to 11 Nm (97 lb-in).

    Ford Taurus. Engine

  1. Install the oil supply tube filter, washer and bolt.
    1. Install a new oil supply tube filter in the oil supply tube block.
    1. Slide the new washer onto the oil supply tube block.
    1. Install the banjo bolt into the oil supply tube block.

    Ford Taurus. Engine

  1. Install the LH turbocharger oil supply tube.
    • Tighten the bolt to 40 Nm (30 lb-ft).

    Ford Taurus. Engine

  1. Using 2 new sealing washers, install the 2 LH turbocharger coolant tubes and the banjo bolts.
    • Tighten to 40 Nm (30 lb-ft).

    Ford Taurus. Engine

  1. If necessary, install the LH cylinder head turbocharger oil supply quick connect fitting.
    • Tighten to 16 Nm (142 lb-in).

    Ford Taurus. Engine

  1. NOTE: Listen for audible click when installing the oil supply tube into the quick connect fitting.

    Install the LH oil supply tube into the quick connect fitting.

    Ford Taurus. Engine

  1. Install the LH oil supply tube secondary latch.

    Ford Taurus. Engine

  1. Install a new gasket, turbocharger oil return tube and the 2 bolts.
    • Tighten to 10 Nm (89 lb-in).

    Ford Taurus. Engine

  1. NOTE: Make sure the turbocharger wastegate regulating valve hose does not contact the exhaust manifold heat shield.

    Connect the turbocharger wastegate regulating valve hose to the LH turbocharger assembly.

    Ford Taurus. Engine

  1. Install the LH exhaust manifold heat shield and the 3 bolts.
    • Tighten to 12 Nm (106 lb-in).

    Ford Taurus. Engine

  1. Install the stud, generator and the nut and bolt.
    • Tighten the stud to 8 Nm (71 lb-in).
    • Tighten the nut and bolt to 47 Nm (35 lb-ft).

    Ford Taurus. Engine

  1. Connect the generator electrical connector.

    Ford Taurus. Engine

  1. Connect the generator B+ cable and install the nut.
    • Tighten to 17 Nm (150 lb-in).

    Ford Taurus. Engine

  1. Install the LH coolant tube bracket-to-cylinder head nut.
    • Tighten to 10 Nm (89 lb-in).

    Ford Taurus. Engine

  1. Attach the pin-type wire harness retainer to the rear of LH cylinder head.

    Ford Taurus. Engine

  1. Install the LH Camshaft Position (CMP) sensor and the bolt.
    • Tighten to 10 Nm (89 lb-in).

    Ford Taurus. Engine

  1. Connect the LH CMP sensor electrical connector.

    Ford Taurus. Engine

  1. Install the LH camshafts. For additional information, refer to Camshaft in this section.
  1. Install the fuel rails. For additional information, refer to Section 303-04B.
    Assembly
    Engine Special Tool(s) Material Engine Upper Engine Upper - LH Cylinder Head Engine Upper - RH Cylinder Head Engine Front Timing Drive Components Lower Engine Block (View 1) Lowe ...

    Other materials:

    Specifications, Description and Operation
    SPECIFICATIONS Torque Specifications DESCRIPTION AND OPERATION Safety Belt System  WARNING: All safety belt components must be inspected and corrected as part of any collision repair. Inspect all safety belt components as prescribed by Safety Belt Inspection and Repair After a Collision fou ...

    Power windows
    WARNING: Do not leave children unattended in your vehicle and do not let children play with the power windows. They may seriously injure themselves. WARNING: When closing the power windows, you should verify they are free of obstructions and make sure that children and pets are not in the proxi ...

    Cleaning products
    For best results, use the following products or products of equivalent quality: Motorcraft Bug and Tar Remover (ZC-42) Motorcraft Custom Bright Metal Cleaner (ZC-15) Motorcraft Detail Wash (ZC-3-A) Motorcraft Dusting Cloth (ZC-24) Motorcraft Engine Shampoo and Degreaser (United States only) (Z ...