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Ford Escape 3.0L V6+engine

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13K views517 pages

Ford Escape 3.0L V6+engine

Uploaded by

nghia phan van
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape 2004 ENGINE Engine - 3.0L (4V) - Escape SPECIFICATIONS GENERAL SPECIFICATIONS GENERAL SPECIFICATIONS Item Specification] Lubricants and Sealants SAE SW-20 Premium Synthetic Blend Motor Oil XO-5W20-QSP WSS-M2C153-H] Silicone Gasket and Sealant F7AZ-19554- EA WSE-M4G323-A4] Metal Surface Cleaner F4AZ-19A536-RA WSE-MS5B392-A] Silicone Brake Caliper Grease and Dielectric Compound D7AZ-19A221 -A. ESE-MIC171 -Aj Engine Displacement No. cylinder 3.0L (4V) (182 CID) 6 Bore/stroke. 89.0 x 79.5 (3.5 x 3.13 in) Fire order 1-4-2-5-3-6] Oil pressure (Minimum at 1,500 RPM with] engine warmed up after 10 minutes of idling.) 76 kPa (II psi) Spark plug ‘AWSF-32F (F35E-12405-EA) Gap = 1.30-| 1.40 (.052-0.56 inch) Cylinder Head/Valve Train Cylinder head flatness a) Combustion chamber volume 52. cc 3.17 Ch} Valve seat width - intake 1.1-1.4 mm (0.043-0.055 in)} Valve seat width - exhaust 1.4-1.7 mm (0.055-0.066 in)| Valve seat angle 44.75 degrees| Valve seat runout (T.I.R.) 0.04 mm (0.001 in)} VALVE ARRANGEMENT (FRONT TO REAR) LH intake S-P-S-P-S-P| LH exhaust E-E-E-E-E-E} RH intake P-S-P-S-P-S| RH exhaust E-E-E-E-E-F} Valve stem guide clearance Intake 0.020-0.069 mm (0.0007-0.0027 in) 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape Exhaust 0.045-0.094 mm (0.0017-0.037 in)| Valve head diameter Intake 35 mm (1.38 in)| Exhaust 30 mm (1.18 in)| Gauge diameter 31 and 24.5 mm (1.22 and 0.96 in) Valve face runout (limit) 0.05 mm (0.001 in)} Valve face angle 45.5 degrees Valve stem diameter (std) Intake 5.975-5.995 mm (0.2350-0.2358 in)} Exhaust 5.950-5.970 mm (0.2343-0.2350 in)| Valve spring compression pressure Intake (n @ spec. length) 680 N @ 30.19 mm (153 Ibs @ 1.18 in)} Exhaust (n @ spec. length) 680 N @ 30.19 mm (153 Ibs @ 1.18 in)} Valve spring free length (approximate) Intake 46.8 mm (1.84 in)} Exhaust 46.8 mm (1.84 in) Valve spring installed pressure (n @ spec length) Intake 228 N @ 39.99 mm (51 Ibs @ 1.57 in) Exhaust 228 N @ 39.99 mm (51 Ibs @ 1.57 in) Valve sprin, alled pressure (n @ spec length - service limit) 10% Pressure loss @ 30.09] Valve springs - out of square limit 1%) Roller follower ratio 1.8:1 Hydraulic Valve Tappet Diameter (std) 16-15.988 mm (0.6290-0.6294 in)| Clearance to bore 0.018-0.069 mm (0.0007-0.0027 in)} Service limit 0.016 mm (0.0006 in) Hydraulic leakdown rate 7) 5-25 seconds| Collapsed valve tappet gap-desired 0.50-1.11 mm (0.019-0.043 in} Camshaft Lobe lift Intake (primary) 4.79 mm (0.188 in) Intake (secondary) 4.79 mm (0.188 in)} Exhaust 4.79 mm (0.188 inch)} Lobe lift - allowable lift loss 0.76 mm (0.03 in) Valve lift @ zero lash Intake (primary) 9.80 mm (0.388 in) Intake (secondary) 9.80 mm (0.388 in)} Exhaust 9.80 mm (0.388 inch) Camshaft end play 0.027-0.190 mm Standard 0.025-0.165 mm (0.001-0.0064 in)| Service limit 0.190 mm (0.00748 in)} Journal-to-bearing clearance Standard 0.025-0.076 mm (0.001-0.0029 in} 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape Service limit 0.121 mm (0.0047 in)| Journal diameters (all) 26.962-26.936 mm (1.061 -1.060 in) Journal inside diameter (cap assembled) 27.012-26.987 mm| Bearing inside diameter (all) 27.012-26.987 mm (1.063 -1.062 in) Cylinder Block Head gasket surface flatness 0.50 mm (0.02 in) for 150 x 150 mm (3x 5 in) area 0.25 mm (0.01 in) for 25 x 25 mm] (1x Lin) area 0.120 mm (0.005 in) overall Head gasket thickness 1.0 mm (0.40 in) Main bearing bore diameter 67.998-68.022 mm (2.677-2.6780 in)| Cylinder bore Diameter GB) Out-of-round limit 0.015 mm (.0005 in) Out-of-round service limit 0.020 mm (.0007 in)} ‘Taper service limit 0.020 mm (0.0008 in) Crankshaft Main bearing journal diameter 62.968-62.992 mm (2.479-2.480 in)| Connecting rod journal diameter 49.970-49.990 mm (1.967 -1.968 in)| Crankshaft free end play 0.110-0.232 mm (.004-.009 in)} Crankshaft runout to rear face of cylinder block 0,050 mm (in) max (0.001 in) Connecting rod bearings Clearance to crankshaft 0.028-0.066 mm (0.001-0.0025 in)} Bearing wall thickness (std) 1.503 mm (.059 in)} Main bearings Clearance to crankshaft - desired 0.025-0.045 mm (0.0009-0.0017 in)} Clearance to crankshaft-allowable 0.025- 0.050 mm (0.0009-0.0019 in) Bearing wall thickness - grade 1 2.497 mm (0.0983 in)| Bearing wall thickness - grade 2 2.501 mm (0.0985 in) Bearing wall thickness - grade 3 2.505 mm (0.0986 in) Connecting Rod Piston pin bore diameter 21.017-21.031 mm (0.827 -0.828 in) Crankshaft bearing bore diameter 53.015-53.035 mm (2.087: 1879 in)| Length (center to center) 138.06-138.14 mm (5.435-5.438 in)} Alignment (bore to bore max difference) ©) twist 0.050 mm per 25 (0.0019 per 0.984 in)} Bend 0.038 mm per 25 (0.0014 per 0.984 in)} 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape Side clearance (assembled to crank) Standard 0.100-0.30 mm (0.0039-0.0118 in)} Service limit 0.35 mm (0.0013in) max| Piston Piston diameter (6) Coated grade 1 88.990-89.010 mm (3.5035-3.5043 in)} Coated grade 2 88.998-89.022 mm (3.5039-3.5048 in)} Coated grade 3 89.010-89.030 mm (3.5043-3.5051 in)} Uncoated grade 1 88.970-88.980 mm (3.50275-3.50314 in)} Uncoated grade 2 88.978-88.992 mm (3.50306-3.50362 in)} Uncoated grade 3 89.010-89.030 mm (3.5043 S11 in)| Piston-to-bore clearance 0.012 to 0.022 mm (0.0005-0.0009 in)} Pin bore diameter (piston) 21.008-21.012 mm (0.8270-0.8272 in) Ring groove width Compression (top) 1,230-1.245 mm (0.0484-0.0490 in)| Compression (bottom) 1,530-1.545 mm (0.0602-0.0608 in)} Oil ring 3.030-3.055 mm (0.1192-0.1203 in)| Piston pin Length 60.51 -60.08 mm (2.382-2.365 in)} Diameter 21.011-21.013 mm (0.0013 in)} Pin-to-piston clearance 0.005 to +0.001 mm (0.0001 -0.00003 in)} Pin-to-rod clearance Standard 0.004-0.020 mm (0.0001 -0.0007 in)} Service limit 0.035 mm (0.0013 in) Piston Ring-To-Groove Clearance Compression (top) 0.040-0.075 mm (0.0015-0.0029 in)| Compression (bottom) 0.040-0.085 mm (0.0015-0.0033 in)} Oil ring Snug Fit Piston ring gap ‘) Compression (top) - gauge diameter 0.100-0.250 mm (0.0039-0.0098 in)} Compression (bottom) - gauge diameter 0.27-0.42 mm (0.0106-0.0165 in) Oil ring (steel rail) - gauge diameter 0.15-0.65 mm (0.0059-0.0255 in) Compression (top) - service limit 0.50 mm (0.0196 in) max} Compression (bottom) - service limit 0.65 mm (0.0255 in) max| Oil ring (Steel rail) - service limit 0.90 mm (0.0354 in) max| Lubrication System Oil capacity ® 5.5 Quarts 5.2 Liters} Drive Belt Tension Note: Drive belts have different tension specifications depending on whether they are newly installed 9) 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape Drive belt type 6 rib front end accessory Automatic Tensioners| drive (1) Refer to the procedure for specifications. (2) Time required for plunger to leak down 1.6 mm of travel with 222 N force and leak down fluid in tappet. (3) Cylinder Bore Diameter Grade 1: 89.000-89.010 mm (3.50393-3.504323 inch) Grade 2: 89.010-89.020 mm (3.504323-3.504717 inch) Grade 3: 89.020-82.030 mm (3.504717-3.50511 inch) (4) 0.250 mm Undersize - Add 0.125 mm to standard or grade 2 thickness. (5) Pin bore and crank bearing bore must be parallel and in same vertical plane within the specified total difference when measured at the ends of a 203 mm bar, 101.5 mm on each side of rod centerline. (6) Measured at 50 mm (1.9685 inch) from outer perimeter top of piston to the pin axis (7) Specification 82.4 mm (3.2441 inch) diameter gauge (8) With filter change. (9) Newly installed refers to the condition of the "new" drive belt before the engine has made no more than one rotation and before the drive belt has had a chance to stretch or seat into the pulley grooves. TORQUE SPECIFICATIONS TORQUE SPECIFICATIONS Description Nm | tb-ft | tb-in| AIC compressor bolts 25 | 18 | A/C compressor bracket bolts My]. | AVC line nut 8 : 71 A/C to water pump bracket bolts 25 | 18 -| Accessory drive belt tensioner bolt 25 | 18 | Camshaft cap bolts 10 : 89} 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape Camshaft oil seal retainer bolts 10 : 89} Camshaft position sensor bolt 10 - 89} Cooler tube bracket bolt 28 | 18 -| Crankshaft damper bolt aM]. | Crankshaft position sensor bolt 10 | - 89] Crankshaft pulley My. a Crankshaft pulley bracket nuts 25 | 18 + Cylinder head bolts a]. | Exhaust gas recirculation (EGR) tube nuts 40 | 30 + EGR valve bolts 25 | 18 -| EGR valve nuts | - | Engine front cover bolts and studs Oa | EGR vacuum regulator tube nuts 6 | - 33] Exhaust bracket nut 40 | 30 -| Flexplate bolts 80 | 59 -| Ball joint nuts 80 | 59 | Front splash shield bolts 7 | - 62 Fuel charging harness nut 6 | - 33 Fuel rail bolts 10 : 89} Generator bolts and studs 48 | 35 -| Ground strap bolt 15 | | Halfshaft nuts 258 | 191 + Halfshaft bracket bolts 48 | 35 -| Heater hose bracket nuts 7 : Ignition coil-on-plug bolts 6 |- LH engine support insulator bolts 70 | 52 | LH engine support insulator nut 90 | 66 -| LH exhaust manifold nuts 20 | 15 -| Lower cylinder block bolts and studs My. | Waiter pump belt cover 6 | - 53 Lower intake manifold bolts 10 - 89] Motor mount bracket bolts/nuts 103 | 76 | Oil level indicator and tube stud 10 : 89} Oil pan baffle nuts a] | Oil pan bolts and studs 25 | 18 + Oil pan to transaxle bolts 40 | 30 - 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape Oil pressure sensor 14 | 10 | Oil pump bolts 10 | - 80] il pump screen and pickup tube bolts Al- | Oil separator bolts 10 | - 89 Outer tie rod end nuts 55_| 41 -| Power steering pump bolts 25 | 18 -| Power steering pressure tube bracket nut 10 : 89 Power steering pressure tube nut 37 _| 27 -| Powertrain control module (PCM) electrical connector bolt 6 | - 53 Power distribution box cable nuts 12) 9 -| Radiator fan bolt 10 |_- 89] RH engine support insulator nut 90 | 66 | RH engine support insulator through bolt and nut 120 | 89 -| RH exhaust manifold nuts 20 | 15 -| RH radio ignition interference capacitor nut 10 | - Ey) Shifter cable nut 17 | 13 -| Starter motor ground cable bolt 25 | 18 -| Starter cable positive nut 12 | 9 -| Steering shaft pinch bolt 40 | 30 -| Strut to knuckle bolts 11s | 85 -| Subframe bolts 200 | 148 -| Subframe nuts 150 | 111 | Transaxle mount bolts 55 | 41 -| Transaxle mount through bolt 90 | 66 -| Sway bar end link nuts 48 | 35 + Throttle body bolt and stud 10 - 89} Timing chain guide bolts 25 | 18 {| Timing chain tensioner bolts 25 | 18 -| Torque converter-to-flexplate nuts 40 | 30 | Transaxle-to-oil pan bracket bolt 25 | 18 -| Transaxle to oil pan bracket nuts 10 : 89} Upper intake manifold bolts 10 | - 80] Valve cover bolts and studs 10 : 89] Water pump bolts 25 | 18 -| Wire harness bolt 5 : 44] Y-pipe nuts 40 | 30 + Y-pipe-to-exhaust manifold nuts 40 | 30 -| (1) Multiple step sequence. See procedure 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape DESCRIPTION AND OPERATION ENGINE The 3.0L Duratec is a four-valve-per-cylinder, dual overhead camshaft engine. The engine uses a distributorless ignition system with a separate coil located above each spark plug. The cylinder block is a two-piece design with the upper portion housing the cylinders, and a separate lower cylinder block containing the main bearing caps. Both sections are made of aluminum, with inserts for the bearing areas and caps. An aluminum oil pan bolts to the bottom of the lower cylinder block and to the transaxle to provide greater strength. The camshafts are mounted in the cylinder heads and act against a roller follower to open and close the valves. A hydraulic lash adjuster is located on one side of the roller follower and the valve tip on the opposite end. The camshafts are driven off the front of each cylinder head by two chains (one each side). Both of the chains are driven by a single sprocket that is located on the crankshaft, just in front of the oil pump. Upper Engine Components 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape 602739174 Fig. 1: Identifying Upper Engine C Courtesy of FORD MOTOR CO. 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape Go2790175, 2: Upper Engine Component Description Table Courtesy of FORD MOTOR CO. Lower Engine Components 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape G02739176 Fig. 3: Identifying Lower Engine Components Courtesy of FORD MOTOR CO. 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape Fig. 4: Lower Engine Component Description Table Courtesy of FORD MOTOR CO. DIAGNOSIS AND TESTING ENGINE 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape Refer to ENGINE SYSTEM-GENERAL INFORMATION for basic mechanical concerns. Refer to the appropriate INTRODUCTION - CNG, FLEX-FUEL & GASOLINE article for driveability concerns IN-VEHICLE REPAIR UPPER INTAKE MANIFOLD Removal 1. Remove the air cleaner outlet tube. 1, Remove the crankcase ventilation tube. 2. Loosen the clamps. 3, Remove the air cleaner outlet tube. Fig. 5: Removing Air Cleaner Outlet Tube Courtesy of FORD MOTOR CO. 2. Disconnect the cables. 1. Disconnect the throttle cable. 2. If equipped, disconnect the speed control cable. 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape 3. Remove the throttle cable bracket bolts. G02739179 Fig. 6: Disconnecting Cables Courtesy of FORD MOTOR CO. 3. Disconnect the throttle position (TP) sensor and idle air control (IAC) electrical connectors. 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape G02739180 Fis connecting Throttle Position (TP) Sensor And Idle Air Control (IAC) -al Connectors Courtesy of FORD MOTOR CO, 4. Disconnect the exhaust gas recirculation (EGR) valve vacuum hose and EGR tube nut. 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape G02739181 Fig. 8: Disconnecting Exhaust Gas Recirculation (EGR) Valve Vacuum Hose And EGR Tube Nut Courtesy of FORD MOTOR CO. 5. Disconnect the EGR vacuum regulator solenoid electrical connector and vacuum hose. 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape 6. G02739182 Fig. 9: Disconnecting EGR Vacuum Regulator Solenoid Electrical Connector And Vacuum Hose Courtesy of FORD MOTOR CO. Disconnect the three vacuum hoses on the back of the intake manifold. 1, Disconnect the cha sis vacuum hose Disconnect the engine vacuum hose. Disconnect the positive crankcase ventilation (PCV) hose. wn 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape G02739183 Fig. 10: Disconnecting Vacuum Hoses Courtesy of FORD MOTOR CO. 7. Disconnect the vapor management valve (VMV) vacuum hose. 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape G02739184 Fig. 11: Disconnecting Vapor Management Valve (VMV) Vacuum Hose Courtesy of FORD MOTOR CO, 8. Disconnect the two electrical connectors attached to the left side of the upper intake manifold 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape G02739185 Fig. 12: Disconnecting Electri Ts i pper Intake Manifold Courtesy of FORD MOTOR CO. 9. Disconnect the power steering pressure (PSP) sensor electrical connector. 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape G02739186 Fig, 13: Disconnecting Power Steering Pressure (PSP) Sensor Electrical Connector Courtesy of FORD MOTOR CO. 10. Remove the bolt and position the transmission vent hose and bracket aside. 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape C G02739187 Fig, 14: Locating Bolt Courtesy of FORD MOTOR CO. 11. Remove the nut from the wire harness. 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape G02739188 Fig. 15: Removing Nut From Wire Harness Courtesy of FORD MOTOR CO. 12, Remove the eight bolts and the upper intake manifold. « Remove and discard the gaskets « Clean all sealing surfaces. 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape 02739189 Fig. 16: Removing Bolts And Upper Intake Manifold Courtesy of FORD MOTOR CO. Installation 1, Install new gaskets in the upper intake manifold. 2. Position the upper intake manifold and tighten the bolts in the sequence shown 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape 10 Nm ey En ae He AS 02739190 Fig. 17: Identifying Tightening Sequence And Torque Specification Of Upper Intake Manifold Bolts Courtesy of FORD MOTOR CO. 3. Connect the PSP electrical connector. 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape 02739191 Fig. 18: Connecting PSP Electrical Connector Courtesy of FORD MOTOR CO. 4. Position the transmission vent tube and bracket and install the bolt. 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape G02739192 : Identifying Transmission Vent Tube And Bracket Bolt Torque ication Courtesy of FORD MOTOR CO. 5. Position the wire harness and install the nut. 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape \ ween bf G02739193 Fig. 20: Identifying Wire Harness Nut Torque Specification Courtesy of FORD MOTOR CO. 6. Install the two electrical connectors on the left side of the intake manifold. 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape G02739194 Fig. 21: Installing Electrical Connectors Courtesy of FORD MOTOR CO. 7. Install the vapor management valve (VMY) vacuum hose. 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape 402739195 Fig. 22: Installing Vapor Management Valve (VMV) Vacuum Hose Courtesy of FORD MOTOR CO, 8. Connect the three vacuum h s on the back of the upper intake manifold. 1. Connect the chassis vacuum hose. 2. Connect the engine vacuum hose. 3. Connect the PCV hose. 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape G02739196 Fig. 23: Connecting Vacuum Hoses Courtesy of FORD MOTOR CO. 9. Connect the EGR vacuum regulator solenoid electrical connector and the vacuum hose. 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape Fig. 24: Connecting EGR Vacuum Regulator Solenoid Electrical Connector Courtesy of FORD MOTOR CO. 10. Install the EGR valve vacuum hose and EGR tube nut. 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape . G02739198 Fig. 25: Installing EGR Valve Vacuum Hose And EGR Tube Nut Courtesy of FORD MOTOR CO. 11. Connect the TP sensor and IAC electrical connectors. 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape G02739199 Fig. 26: Connecting TP Sensor & IAC Electrical Connectors Courtesy of FORD MOTOR CO. 12. Connect the throttle cables. 1. Install the throttle cable bracket bolts. 2. Connect the throttle cable. 3. If equipped, connect the speed control cable. 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape G02739200 Fig. 27: Connecting Throttle Cables Courtesy of FORD MOTOR CO. 13. Install the air cleaner outlet tube. 1. Position the air cleaner outlet tube. 2. Install the hoses. 3. Install the clamps. 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape 02739201 Fig. 28: Installing Air Cleaner Outlet Tube Courtesy of FORD MOTOR CO. LOWER INTAKE MANIFOLD. Material MATERIAL SPECIFICATION Trem Specification SAE 5W - 20 Premium Synthetic Blend Motor Oil XO-5W20-QSP_| WSS-M2C153-H| Removal 1. Disconnect the fuel hose spring lock coupling. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION 2. Remove the upper intake manifold. For additional information, refer to UPPER INTAKE MANIFOLD | 3. Disconnect the fuel rail 1, Disconnect the six fuel injector electrical connectors and wire harness locators. 2. Disconnect the fuel pressure damper vacuum hose: 3. Release the wire harness retainers from the fuel injection supply manifold 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape G02739202 Fig. 29: Disconnecting Fuel Rail Courtesy of FORD MOTOR CO. = Remove the bolts and the lower intake manifold. Remove and discard the gaskets. 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape G02739203 Fig. 30: Removing Bolts And Lower Intake Manifold Courtesy of FORD MOTOR CO. Installation 1. Clean and inspect all mating surfaces. 2. Install new gaskets in the lower intake manifold. 3. Install the lower intake manifold assembly and tighten the bolts in the sequence shown. 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape SET 10 Nm ie ibcinj) URS G02739204 Fig. 31: Identifying Tightening Sequence & Torque Specification Of Lower Intake Manifold Assembly Bolts Courtesy of FORD MOTOR CO. 4, Connect the fuel rail 1. Position the wire harness locators and connect the six fuel injector electrical connectors, 2. Connect the fuel pressure damper vacuum hose. Connect the fuel injection harness to the fuel supply manifold. 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape 02739205 Fig. 32: Connecting Fuel Rail Courtesy of FORD MOTOR CO. 5. Install the upper intake manifold. For additional information, refer to UPPER INTAKE MANIFOLD Connect the fuel hose spring lock coupling. For additional information, refer to FUEL SYSTEM-GENERAL (ORMATION 6. ENGINE FRONT COVER Material MATERIAL SPECIFICATION Ttem Specification Motocraft Metal Surface Cleaner ZC - 21 WSE-MS5B392-A] Silicone Gasket and Sealant TA-30 WSE -M4G323 -A4 Removal 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING & LIFTING 2. Disconnect the battery ground cable. For additional information, refer to BAT RY, 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape MOUNTING AND CABLES 3. Remove the RH and LH valve covers. For additional information, refer to VALVE COVER LH and VALVE COVER RH 4. Remove the generator. For additional information, refer to G! REGULATORS . . Remove the front engine support insulator. For additional information, refer to ENGINE SUPPORT INSULATORS - FRONT, RH 6. Remove the bolt and the camshaft position (CMP) s NERATORS & G02739206 Fig. 33: Removing Bolt And Camshaft Position (CMP) Sensor Courtesy of FORD MOTOR CO. 7. Remove the power steering pump. For additional information, refer to POWER STEERING 8. Remove the bolt and remove the belt tensioner. 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape 02739207 Fig. 34: Removing Power Steering Pump Bolt Courtesy of FORD MOTOR CO. 9. Remove the crankshaft front seal. For additional information, refer to CRANKSHAFT FRONT OIL SEAL 10. Remove the crankshaft position (CKP) sensor. « Disconnect the electrical connector. ¢ Remove the bolt and the sensor. 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape G02739208 Fig. 35: Removing Crankshaft Position (CKP) Sensor Courtesy of FORD MOTOR CO. 11. Remove the 2 oil pan-to-front cover bolts. 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape Fig. 36: Removing Oil Pan-To-Front Cover Bolts Courtesy of FORD MOTOR CO. 12. Remove the bolts, studs and the engine front cover. « Remove and discard the front cover gaskets. 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape G02739210 over Fig. 37: Removing Engine Front. Courtesy of FORD MOTOR CO. Installation CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surface. These tools cause scratches and gouges, which make leak paths. Use a plastic scraping tool to remove all traces of sealant. CAUTION: Do not damage the oil pan gasket while cleaning the sealant from the lower cylinder block-to-oil pan joint. 1. Clean all sealing surfaces with metal surface cleaner. 2. Install 3 new gaskets in the front cover. The engine front cover must be installed and the bolts NOTI 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape tightened within 4 minutes of applying the sealant. G02739211 Fig. 38: Applying Silicone Gasket & Sealer Courtesy of FORD MOTOR CO. 3. Apply a 6 mm (0.24 in) diameter dot of silicone gasket and sealer to the cylinder block, lower cylinder block, cylinder head and oil pan mating surfaces NOTE: Fasteners 1, 3, 4, 8, 10, 11, 14, 15 and 16 are studs. 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape G02739212 Fig. 39: Identifying Front Cover Bolt Tightening Sequence Courtesy of FORD MOTOR CO. 4. Position the cover and install the studs and bolts in the sequence shown. 5. Install the 2 oil pan-to-front cover bolts. « Tighten to 25 Nm (18 Ib-fi), 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape G02739213 Fig. 40: Installing Oil Pan-To-Front Cover Bolts Courtesy of FORD MOTOR CO. 6. Remove the oil pan plug and drain the engine oil « Install the plug and tighten to 26 Nm (19 Ib-ft) 7. Install the (CKP) sensor and connect the electrical connector. 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape G02739214 Fig. 41: Installing (CKP) Sensor Courtesy of FORD MOTOR CO. 8. Install the crankshaft front seal. For additional information, refer to CRANKSHAFT FRONT OIL SEAL 9. Install the tensioner and bolt. 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape 25 Nm (18 tb-t1)| =X SQA Ny Ny uv G02739215 Fig. 42: Identifying Tensioner Bolt Torque Specification Courtesy of FORD MOTOR CO. 10. Install the CMP and the bolt. « Connect the electrical connector. 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape 15 16. 17, G02739216 Fig. 43: Identifying CMP Bolt Torque Specification Courtesy of FORD MOTOR CO. Install the power steering pump. For additional information, refer to POWER STEERING . Install the front engine support insulator. For additional information, refer to ENGINE SUPPORT INSULATORS - FRONT, RH Install the generator. For additional information, refer to GENERATORS & REGULATORS . . Install the RH and LH valve cover. For additional information, refer to VALVE COVER RH and VALVE COVER LH Fill the engine with clean engine oil Connect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES . Fill and bleed the power st system. For additional information, refer to STEERING SYSTEM-GENERAL INFORMATION VALVE COVER LH Material MATERIAL SPECIFICATION 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape Item Specification Silicone Gasket and Sealant F7AZ-19554-EA WSE-MAG328 Silicone Brake Caliper Grease and Dielectric Compound D7AZ- 19A331-A ESE-MIC171-A| Metal Surface Cleaner F4AZ-19A536-RA WSE-M5B392-A| 1. Remove the water pump belt cover. 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape G02739217 Fig. 44: Removing Water Pump Belt Cover Courtesy of FORD MOTOR CO. 2. Disconnect the crankcase ventilation tube from the valve cover. 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape 02739218 Fig. 45: Disconnecting Crankease Ventilation Tube Courtesy of FORD MOTOR CO. CAUTION: When removing the coil-on-plugs, a slight twi: motion will break the seal and ease removal. ‘ing 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape G02739219 Fig. 46: Removing Three LH Coil-On-Plugs Courtesy of FORD MOTOR CO. 3. Remove the three LH coil-on-plugs. 1. Disconnect the electrical connectors. 2, Remove the bolts. 3. Remove the coils 4, Disconnect the wiring hamess from the valve cover studs. 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape Fig. 47: Disconnecting Wiring Harness From Valve Cover Studs Courtesy of FORD MOTOR CO. 5, Remove the engine lift bracket 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape 02739221 Fig. 48: Removing Engine Lift Bracket Courtesy of FORD MOTOR CO. 6. Position the power steering hose aside. + Remove the bolt 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape Fig. 49: Locating Bolt Courtesy of FORD MOTOR CO. 7. Remove the bolts, studs and the LH valve cover. « Remove and discard the gasket. 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape G02739223 Removing Bolts, Studs And LH Valve Cover Courtesy of FORD MOTOR CO. Installation NOTE: Clean the valve cover sealing area before installing a new gasket. 1. Install a new gasket on the valve cover. NOTE: Clean the head and the front cover sealing surfaces using metal surface cleaner before applying silicone gasket and sealant. NOTE: The valve cover must be installed and the bolts tightened within four minutes of applying the sealant. 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape ing Silicon Gasket Gap Courtesy of FORD MOTOR CO. 2. Apply a5 mm dot of silicone gasket sealant to the front cover to cylinder head joints. 3. Position the valve cover and install the studs and the bolts in the sequence shown 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape G02739225 Fig. 52: Identifying Tightening Sequence & Torque Specification Of Valve Cover Studs & Bolts Courtesy of FORD MOTOR CO. 4, Position the power steering hose and install the bolt 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape Wy WA Fig. 53: Identifying Power Steering Hose Bolt Torque Specification Courtesy of FORD MOTOR CO. 5. Position the engine lift bracket and install the bolt. 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape 112 Nm (89 Ib-ft) G02739227 Fig. 54: Identifying Engine Lift Bracket Bolt Torque Specification Courtesy of FORD MOTOR CO. 6. Connect the wiring harness to the valve cover studs. 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape G02739228 Fig. 55: Connecting Wiring Harness Courtesy of FORD MOTOR CO. NOTE: Apply a light film of brake caliper grease and dielectric compound to the interior of the spark plug boot prior to installation. 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape G02739229 Fig. 56: Installing LH Coil-On-Plugs Courtesy of FORD MOTOR CO. 7. Install the three LH coil-on-plugs. 1, Position the coils, 2. Install the bolts. 3. Connect the electrical connectors. 8. Connect the crankcase ventilation tube to the valve cover, 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape G02739230 Fig. 57: Identifying Crankcase Ventilation Tube Courtesy of FORD MOTOR CO. 9. Install the water pump belt cover. 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape G02739231 Fig. 58: Identifying Water Pump Belt Cover Bolts Torque Specification Courtesy of FORD MOTOR CO. VALVE COVER RH Material MATERIAL SPECIFICATION Ttem Specification "i 2 Metal Surface Cleaner F4AZ-19A536-RA WSE-MSB392 Silicone Brake Caliper Grease and Dielectric Compound D7AZ~ 19A331-A ESE-MICITI-A ESC-MICI7I-A Silicone Gasket and Sealant FTAZ-19554-EA WSE-MAG325 Removal 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape 1. Remove the upper intake manifold, For additional information, refer to UPPER INTAKE MANIFOLD . CAUTION: When removing the coil-on-plugs, a slight twisting motion will break the seal and ease removal. 02739232 Fig. 59: Removing RH Coil-On-Plugs Courtesy of FORD MOTOR CO. 2. Remove the three RH coil-on-plugs. 1. Disconnect the electrical connectors. 2. Remove the bolts. 3. Remove the coils 3. Remove the wiring harness nuts and disconnect the oxygen sensor electrical connectors. 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape G02739233, Fig. 60: Removing Wiring Harness Nuts Courtesy of FORD MOTOR CO. 4. Remove the radio ignition interference capacitor. 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape Fig. 61: Removing Radio Ignition Interference Capacitor Courtesy of FORD MOTOR CO. 5. Separate the harness from the center locating pins and position aside. 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape 02739235 Fig, 62: Separating Harness From Center Locating Pins Courtesy of FORD MOTOR CO. 6. Disconnect the crankcase ventilation tube from the valve cover. 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape 602739236 Fig. 63: Disconnecting Crankcase Venti Courtesy of FORD MOTOR CO. 7. Remove the bolts, studs and the RH valve cover. « Remove and discard the gasket. 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape G02739237 64: Removing Bolts, Studs And RH Valve Cover Courtesy of FORD MOTOR CO. Installation NOTE: Clean the valve cover sealing area before installing a new gasket. 1. Install a new valve cover gasket. NOTE: Clean the head and front cover sealing surfaces using metal surface cleaner before applying silicone gasket and sealant. NOTE: The valve cover must be installed and the bolts tightened within four minutes of applying the sealant. 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape G02739238 Fig. 65: Applying Silicone Gasket Sealant To Front Cover To Cylinder Head Joints Courtesy of FORD MOTOR CO. 2. Apply a5 mm dot of silicone gasket sealant to the front cover to cylinder head joints. 3. Position the valve cover and install the bolt and the studs in the sequence shown, 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape om %) 7) GONm @9ib-in)) (5; G02739239 Fig. 66: Identifying Tightening Sequence & Torque Specification Of Valve Cover Bolt & Studs Courtesy of FORD MOTOR CO. 4, Connect the crankcase ventilation tube to the valve cover, 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape 02739240 Fig. 67: Connecting Crankcase Ventilation Tube Courtesy of FORD MOTOR CO. 5. Connect the radio ignition interference capacitor. 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape G02739241 Fig. 68: Connecting Radio Ignition Interference Capacitor Courtesy of FORD MOTOR CO. 6. Connect the O2 sensor electrical connectors and wiring harness to the RH valve cover stud. 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape G02739242 Fig. 69: Connecting O2 Sensor Electrical Connectors And Wiring Harness To RH Valve Cover Stud Courtesy of FORD MOTOR CO. NOTE: Apply a light film of brake caliper and grease compound to the interior of the spark plug boot prior to installation. 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape 4 - <8 micn® G02739243 Fig. 70: Identifying RH Coil-On-Plugs Courtesy of FORD MOTOR CO. 7. Install the three RH coil-on-plugs. 1. Position the coils. 2. Install the bolts. 3. Connect the electrical connectors. 8. Install the upper intake manifold. For additional information, refer to UPPER INTAKE MANIFOLD . CAMSHAFTS LH 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape Material [Service Sel, Water Pump Pulley [303-8456 (TO4P-6312-AH) Remover, Crankshallt Vibration 303-009 (T58P-6316-D) Remover, Oil Seat 303-409 (F92C-6700-CH) installer, Camshaft Oil Seat 203-464 (T94P-6256-BH) Protector, Camshaft OW Seal 303-463 (T94P.6256-aH) installer, Power Steering Pump [211-185 (T91P-SA73S-A) Courtesy of FORD MOTOR CO. MATERIAL SPECIFICATION 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape Item Specification SAE 5W-20 Premium Synthetic Blend Motor Oil XO-5W20-QSP_| WSS-M2C153-H| Metal Surface Cleaner F4AZ-19A536-RA WSE-M5B392-A] Removal 1. Remove the water pump belt. For additional information, refer to SPECIFICATIONS. & DRIVE BELT ROUTING . CAUTION: The OEM pulley is pressed on 4.74 mm (0.18 in) past flush of the end of the camshaft. The service pulley is pressed on flush to the end of the camshaft. G02739245, Fig. 72: Removing Water Pump Drive Pulley Using Special Tool Courtesy of FORD MOTOR CO. 3. Remove the timing drive components. For additional information, refer to TIMING DRIVE COMPONENTS . 2. Using the special tools, remove the water pump drive pulley and discard NOTE: To make sure of correct sealing, do not scratch the 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape camshaft. SI ‘th \ it oA SY a .\\ G02739246 Fig. 73: Removing Camshaft Oil Seal Using Special Tool Courtesy of FORD MOTOR CO. 4. Using the special tools, remove the camshaft oil seal and discard 5, Remove the bolts, the camshaft oil seal retainer and discard the press-in-place gasket. 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape G02739247 Fig. 74: Removing Camshaft Oil Seal Retainer Courtesy of FORD MOTOR CO. CAUTION: Cylinder head camshaft journal caps and cylinder heads are numbered to verify that they are assembled in their original positions. 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape 02739248 Fig. 75: Identifying Camshaft Journal Caps Loosening Sequence Courtesy of FORD MOTOR CO. Loosen the LH camshaft cap bolts evenly in the sequence shown to allow the camshafts to rise from the cylinder head and remove the caps 7. Remove the camshafts. 6. 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape Go27ge249 Fig. 76: Removing Camshafts Courtesy of FORD MOTOR CO. Be sure camshaft bearing caps are installed in the original positions. 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape 02739250 Fig. 77: Aligning Camshafts Courtesy of FORD MOTOR CO. Lubricate camshafts with clean engine oil and carefully position the camshafts into the cylinder head. « Align the camshafts as shown. CAUTION: Do not install the camshaft journal thrust caps until all of the camshaft bearing caps have been installed, or damage to the thrust caps can occur. 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape 02739251 Fig. 78: Lubricating Bearing Surfaces Courtesy of FORD MOTOR CO. . Lubricate the bearing surfaces of the camshaft bearing caps with clean engine oil Install the bearing caps and loosely install the bolts . Lubricate the bearing surfaces of the camshaft bearing thrust caps with clean engine oil. Install the bearing thrust caps and loosely install the bolts. 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape G02739252 Fig. 79: Installing Bearing Thrust Caps Courtesy of FORD MOTOR CO. 4. Tighten the bolts in the sequence shown. 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape G02739253, g Sequence g Bolt Tightenin Courtesy of FORD MOTOR CO. Fig, 80: Identifyin Clean and degrease the sealing surfaces with metal surface cleaner. NOTE: 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape 02739254 Fig. 81: Identifying Camshaft Oil Seal Retainer Bolts Torque Specification Courtesy of FORD MOTOR CO. 5. Install a new press-in-place gasket and install the camshaft oil seal retainer, 6. Install the timing drive components. For additional information, refer to TIMING DRIVE COMPONENTS . NOTE: Lubricate the camshaft oil seal with clean engine oil. 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape 4 ‘ ae f Ui 02739255 Fig, 82: Installing Camshaft Oil Seal Courtesy of FORD MOTOR CO. 7. Using special tools, install a new camshaft oil seal CAUTION: The OEM pulley is pressed on 4.74 mm (0.18 in) past flush of the camshaft. The service pulley is pressed on flush to the end of the camshaft. 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape 02739256 Fig. 83: Installing Service Water Pump Drive Pulley Courtesy of FORD MOTOR CO. 8. Using the special tool, install a new service water pump drive pulley. 9. Install the water pump belt. For additional information, refer to SPECIFICATIONS & DRIVE BELT ROUTING CAMSHAFTS RH Material MATERIAL SPECIFICATION Item Specification SAE 5W - Premium Synthetic Blend Motor Oil W XO-5W20-QSP- WSS-M2C153-H] Removal 1. Remove the timing drive mponents. For additional information, refer to TIMING CAUTION: Cylinder head camshaft journal caps and cylinder heads are numbered to verify that they are assembled 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape in their original positions. Fig. 84: Identifying RH Camshaft Cap Bolts Loosening Sequence Courtesy of FORD MOTOR CO. 2. Loosen the RH camshaft cap bolts evenly in the sequence shown to allow the camshafts to rise from the cylinder head and remove the caps. 3. Remove the camshafts. 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape 02739258 Fig. 85: Removing Camshafts Courtesy of FORD MOTOR CO. Installation NOTE: Be sure camshaft bearing caps are installed in the original positions. 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape G02739259 Fig. 86: Aligning Camshafts Courtesy of FORD MOTOR CO. Lubricate camshafts with clean engine oil and carefully position the camshafts into the cylinder head « Align the camshafts as shown CAUTION: Do not install the camshaft journal thrust caps until all of the camshaft bearing caps have been installed, or damage to the thrust caps may occur. 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape G02739260 Fig. 87: Lubricating Bearing Surfaces Of Camshaft Bearing Caps Courtesy of FORD MOTOR CO. 2. Lubricate the bearing surfaces of the camshaft bearing caps with clean engine oil and install the bearing caps and loosely install the bolts. 3. Lubricate the bearing surfaces of the camshaft bearing thrust caps with clean engine oil. Install the bearing thrust caps and loosely install the bolts. 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape 02739261 ig. 88: Installing Bearing Thrust Caps Courtesy of FORD MOTOR CO. 4. Tighten the bolts in the sequence shown. 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape Goz7a9262 Fig. 89: Identifying Bolt Tightening Sequence Courtesy of FORD MOTOR CO. 5. Install the timing drive components. For additional information, refer to TIMING DRIVE COMPONENTS . TIMING DRIVE COMPONENTS 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape Removal CAUTION: Failure to verify correct timing drive component alignment will result in severe engine damage. 1. Remove the engine front cover. For additional information, refer to ENGINE FRONT COVER CAUTION: This pulse wheel is used in several different engines. Install the pulse wheel with the keyway in the slot stamped "20-25-34Y-30M" (color blue). G02739263 ig. 90: Identifying Ignition Pulse Wheel Courtesy of FORD MOTOR CO. 2. Remove the ignition pulse wheel 3. Install the damper bolt 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape G02739264 Fig. 91: Installing Damper Bolt Courtesy of FORD MOTOR CO. NOTE: LH shown, RH similar. 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape G02739265 Fig. 92: Locating LH And RH Spark Plugs Courtesy of FORD MOTOR CO. |. Remove the LH and the RH spark plugs. . Rotate the crankshaft clockwise to position the crankshaft keyway in the 1 o'clock position and position the camshafts in the correct position. This will position the number I cylinder at top dead center (TDC) « Verify that the camshafts are correctly located, If not, rotate the crankshaft one additional turn and recheck 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape frowning SLY 02739266 Fig. 93: Locating Camshaft Pulley Courtesy of FORD MOTOR CO. 6. Rotate the crankshaft clockwise 120 degrees to the 3 o'clock position to locate the RH camshafts in the neutral position. 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape G02739267 Fig. 94: Identifying Camshaft Aligning Mark Courtesy of FORD MOTOR CO. 7. Verify that the RH camshafts are in the neutral position. 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape G02739268 Fig. 95: Identifying RH Camshafts Are In Neutral Position Courtesy of FORD MOTOR CO. 8. Remove the RH timing chain and tensioner arm Remove the bolts. 1 2. Remove the tensioner. 3. Remove the tensioner arm. 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape 02739269 Fig. 96: Removing RH Tensioner Arm Courtesy of FORD MOTOR CO. 9, Remove the bolts, RH timing chain guide and the timing chain 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape G02739270 Fig, 97: Removing Bolts, RH Timing Chain Guide & Timing Chain Courtesy of FORD MOTOR CO. 10. Rotate the crankshaft clockwise 600 degrees (1 -2/3 times) to position the crankshaft keyway in the 11 o'clock position. This will position the LH camshafts in the neutral position NS 8 oN 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape 02739271 Fig. 98: Identifying Crankshaft Aligning Mark Courtesy of FORD MOTOR CO, Verify that the LH camshafts are in the neutral position. ll 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape G02739272 Fig. 99: Identifying LH Camshafts Are In Neutral Position Courtesy of FORD MOTOR CO. 12. Remove the LH timing chain and tensioner arm Remove the bolts. 1 2. Remove the tensioner. 3. Remove the tensioner arm. 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape AAA G02739273 Fig. 100: Removing LH Timing Chain And Tensioner Arm Courtesy of FORD MOTOR CO. 13. Remove the LH timing chain and the timing chain guide. 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape G02739274 Fig. 101: Removing LH Timing Chain And Timing Chain Guide Courtesy of FORD MOTOR CO. 14, Remove the damper bolt and the crankshaft sprockets. 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape G02739275 Fig. 102: Removing Damper Bolt And Crankshaft Sprockets Courtesy of FORD MOTOR CO. Installation CAUTION: Failure to verify correct timing drive component alignment will result in severe engine damage. NOTE: Install the sprockets with the timing marks out. 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape 02739276 Fig, 103: Installing Crankshaft Sprockets Courtesy of FORD MOTOR CO. 1. Install the crankshaft sprockets. NOTE: LH shown, RH similar. 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape G02739277 Fig. 104: Positioning Chain Tensioner In A Soft-Jawed Vise Courtesy of FORD MOTOR CO. 2. Position the chain tensioner in a soft-jawed vise. NOTE: LH shown, RH similar. 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape G02739278 Fig. 105: Holding Chain Tensioner Ratchet Lock Mechanism Courtesy of FORD MOTOR CO. 3. Hold the chain tensioner ratchet lock mechanism away from the ratchet stem with a small pick. CAUTION: During tensioner compression, do not release the ratchet stem until the tensioner piston is fully bottomed in its bore or damage to the ratchet stem will result. 4. Slowly compress the timing chain tensioner, 5. Retain the tensioner piston with a 1.5 mm (0.06 in) wire or paper clip. 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape G02739279 Fig. 106: Retaining Tensioner Piston Courtesy of FORD MOTOR CO. 6 If the timing marks on the timing chains are not evident, use a permanent-type marker to mark on the LH and the RH timing chains. 1 2. 3, Mark any link to use as the crankshaft timing mark. Starting with the crankshaft timing mark, count 29 links and mark the link. Continue counting to 42 and mark the link 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape G02739280 Fig. 107: Identifying Timing Chain Courtesy of FORD MOTOR CO. 7. Position the LH timing chain and guide and install the bolts. « Align the marks on the timing chain with the marks on the camshaft and crankshaft sprockets. 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape A : f Z) \ [25 Nim (168 1b-fi | me G02739281 : Installing LH Timing Chain y of FORD MOTOR CO. 8. Install the LH timing chain tensioner and tensioner arm. 1. Install the tensioner arm. 2. Position the tensioner. 3. Install the bolts, 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape wet BLA CSO RAB G02739282 ig. 109: Installing LH Timing Chain Tensioner & Tensioner Arm Courtesy of FORD MOTOR CO. 9, Install the crankshaft damper bolt and rotate the crankshaft clockwise 120 degrees until the crankshaft keyway is in the 3 o'clock position. 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape G02739283 Fig. 110: Identifying Crankshaft Keyway Courtesy of FORD MOTOR CO. 10. Verify that the RH camshafts are correctly positioned. 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape G02739284 Fig. 111: Identifying RH Camshafts Position Courtesy of FORD MOTOR CO. 11. Position the RH timing chain and chain guide and install the bolts. # Align the marks on the timing chain with the marks on the camshaft and crankshaft sprockets. 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape G02739285 Fig. 112: Aligning Marks On Timing Chain Courtesy of FORD MOTOR CO. 12. Install the RH timing chain tensioner and tensioner arm. 1. Install the tensioner arm. 2. Position the tensioner. 3. Install the bolts, 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape 02739286 Fig. 113: Installing RH Timing Chain Tensioner & Tensioner Arm Courtesy of FORD MOTOR CO. 13. Remove the LH and RH timing chain tensioner piston retaining wires. 14. Rotate the crankshaft counterclockwise 120 degrees to top dead center (TDC). CAUTION: Failure to verify correct timing drive component alignment will result in severe engine damage. 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape Fig. 114: Checking Timing Chain Courtesy of FORD MOTOR CO. 15. Verify the timing with the following steps. 1. There should be 12 chain links between the front camshaft timing marks. 2. There should be 27 chain links between the camshaft and crankshaft timing marks. 3. There should be 30 chain links between the camshaft and crankshaft timing marks. 16. Remove the crankshaft damper bolt. 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape Fig. 115: Removing Crankshaft Damper Bolt Courtesy of FORD MOTOR CO. NOTE: LH shown, RH similar. 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape G02739289 Fig. 116: Identifying Spark Plug Torque Specification Courtesy of FORD MOTOR CO. 17. Install the LH and RH spark plugs. CAUTION: This pulse wheel is used in several different engines. Install the pulse wheel with the keyway in the slot stamped "20-25-34Y-30M" (color blue). 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape Fig. 117: Installing Ignition Pulse Wheel Courtesy of FORD MOTOR CO. 18, Install the ignition pulse wheel 19. Install the engine front cover. For additional information, refer to ENGINE FRONT COVER. ROLLER FOLLOWERS Special Tool(s) 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape Compressor, Valve Spring 303-473 (T94P-6565-BH) G02739291 118: Identifying Roller Followers Special Tool Courtesy of FORD MOTOR CO. Material MATERIAL SPECIFICATION Item Specification SAE 5W - 20 Premium Synthetic Blend Motor Oil XO-5W20-QSP WSS-M2C153-H| Removal and Installation 1, Remove the LH and RH valve covers. For additional information, refer to VALVE COVER LH and VALVE COVER RH 2. Remove the LH and RH spark plugs. 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape G02739292 Fig. 119: Removing LH And RH Spark Plugs Courtesy of FORD MOTOR CO. 3. Remove the RH front wheel, 4, Remove the splash shield 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape 402739293 Fig. 120; Removing Splash Shield Bol: Courtesy of FORD MOTOR CO. 5. Rotate the crankshaft until the camshaft lobe is pointing directly away from the follower, 6. Using the special tool, remove the followers 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape G02739294 ig. 121: Removing Followers Courtesy of FORD MOTOR CO. 7. To install, reverse the removal procedure « Lubricate the camshaft followers with clean engine oil HYDRAULIC LASH ADJUSTERS Material MATERIAL SPECIFICATION Item Specification SAE SW-20 Premium Synthetic Blend Motor Oil XO-5W20-QSP WSS-M2C153-H| Removal and Installation 1. Remove the camshaft followers. For additional information, refer to ROLLER FOLLOWERS NOTE: Mark the positions of the hydraulic lash adjusters to make sure they are assembled in their original positions. 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape Fig. 122: Removing Hydraulic Lash Adjusters Courtesy of FORD MOTOR CO. 2. Remove the hydraulic lash adjusters. NOTE: Inspect the hydraulic lash adjusters for scoring marks and uneven wear in the bore. Install new lash adjusters if necessary. 3. To install, reverse the removal procedure. + Lubricate the hydraulic lash adjusters with clean engine oil CRANKSHAFT PULLEY Special Tool(s) 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape Strap Wrench 303-D055 (D85L-6000-A), or equivalent Remover, Crankshaft Vibration Damper 303-009 (T58P-6316-D) Installer, Crankshaft Vibration Damper 303-102 (T74P-6316-B) G02739296 Fig. 123: Identifying Special Tools Courtesy of FORD MOTOR CO. Material MATERIAL SPECIFICATION Item Specification SAE 5W-20 Premium Synthetic Blend Motor Oil XO-5W20-QSP | _WSS-M2C153-H| Silicone Gasket and Sealant F7AZ-19554-EA. WSE-M4G323-A4| Metal Surface Cleaner F4AZ-19A536-RA -M5B392-A| Removal and Installation 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape 1. Remove the accessory drive belt. For additional information, refer to SPECIFICATIONS & DRIVE BELT ROUTING 2. Remove the splash shield. 02739297 Fig. 124: Removing Splash Shield Bolts Courtesy of FORD MOTOR CO. 3. Install the special tool 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape G02739298 Fig. 125: Installing Special Tool Courtesy of FORD MOTOR CO. 4. Remove the crankshaft pulley bolt and washer. 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape G02739299 Fig. 126: Removing Crankshaft Pulley Bolt And Washer Courtesy of FORD MOTOR CO. 5. Using the special tool, remove the crankshaft pulley 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape Fig. 127: Removing Crankshaft Pulley Courtesy of FORD MOTOR CO. Installation NOTE: Clean the keyway and slot using metal surface cleaner before applying silicone gasket and sealer. NOTE: Seal surfaces must be free of dirt and oil. NOTE: The crankshaft pulley must be installed within four minutes of applying the silicone gasket and sealer. 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape 602739301 Fig, 128: Identifying End Of Keyway Slot Courtesy of FORD MOTOR CO. 1. Apply silicone gasket and sealant to the end of the keyway slot NOTE: Lubricate the outside diameter sealing surface of the crankshaft pulley with clean engine oil. 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape Fig. 129: Installing Crankshaft Pulley Courtesy of FORD MOTOR CO. 2. Using the special tool, install the crankshaft pulley. NOTE: Use an appropriate strap wrench to hold the crankshaft pulley. 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape Fig. 130: Installing Bolt And Washer Courtesy of FORD MOTOR CO. 3. Install the bolt and the washer and tighten in four stages. * Stage 1: Tighten to 120 Nm (86 Ib-ft). Stage 2: Loosen 360 degrees. Stage 3: Tighten to 50 Nm (37 Ib-ft) « Stage 4: Tighten an additional 90 degrees. 4. Install RH front inner splash shield. 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape = ae ra an 9 Nm (80 Ib-iny PNY G02739304 Fig. 131: Identifying RH Front Inner Splash Shield Bolts Torque Specification Courtesy of FORD MOTOR CO. 5. Install the accessory drive belt. For additional information, refer to SPECIFICATIONS & DRIVE BELT ROUTING CRANKSHAFT FRONT OIL SEAL Special Tool(s) 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape Installer, Front Oil Seal 303-335 (T88T-6701—A) Remover, Oil Seal 303-409 (T92C-6700-CH) 02739305 Fig. 132: Identifying Special Tools Courtesy of FORD MOTOR CO. Material MATERIAL SPECIFICATION Item Specification SAE SW-20 Premium Synthetic Blend Motor Oil XO-5W20-QSP WSS-M2C153-H] Metal Surface Cleaner F4AZ-19A536-RA WSE-MSB392-A] Removal 1, Remove the crankshaft pulley. For additional information, refer to CRANKSHAFT PULLEY . 2. Using the special tool, remove the crankshaft front oil seal and discard. 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape G02739306 Fig. 133: Removing Crankshaft Front Oil Seal Courtesy of FORD MOTOR CO. Installation NOTE: Clean all sealing surfaces with metal surface cleaner. 1. Apply clean engine oil to the seal before installing the seal 2. Using the special tool, install the crankshaft front oil seal 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape G02739307 Fig. 134: Installing Crankshaft Front Oil Seal Courtesy of FORD MOTOR CO. 3. Install the crankshaft pulley. For additional information, refer to CRANKSHAFT PULLEY VALVE SPRING Special Tool(s) Valve Spring Compressor 303-473 (T94P-6565—BH) 02739308 Fig, 135: Identifying Speci Courtesy of FORD MOTOR CO. 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape Removal and Installation 1. Remove the roller followers. For additional information, refer to ROLLER FOLLOWERS NOTE: If air pressure has forced the piston to the bottom of the cylinder, any loss of air pressure will allow the valve(s) to fall into the cylinder. A rubber band, tape or string wrapped around the end of the valve stem will prevent this from happening. 2. Pres 3. Using the special tool, remove the key, retainer, and valve spring. urize the cylinder using compressed air. G02739309 Fig. 136: Removing Key, Retainer, And Valve Spring Courtesy of FORD MOTOR CO. 4, To install, reverse the removal procedure VALVE SEALS Special Tool(s) 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape Installer, Valve Stem Oil Seal 303-470 (T94P-6510-CH) 02739310 137: Identifying Special Tool “ourtesy of FORD MOTOR CO. Material MATERIAL SPECIFICATION Trem Specification SAESW-20 Premium Synthetic Blend Motor Oil XO-5W20-QSP WSS-M2C153-H| Removal 1. Remove the valve spring. Refer to VALVE SPRING NOTE: Camshaft removed for clarity. 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape G02739311 Fig. 138: Removing Valve Seal Courtesy of FORD MOTOR CO. 2. Remove the valve seal. Installation NOTE: Lubricate the valve guide with clean engine oil. 1. Using the special tool, install the valve seal. 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape G02739312 Fig. 139: Installing Valve Seal Courtesy of FORD MOTOR CO. 2. Install the valve spring. Refer to VALVE SPRING EXHAUST MANIFOLD LH Removal 1. Remove the LH heated oxygen sensor (HO2S) and the LH catalyst monitor. For additional information, refer to ELECTRONIC ENGINE CONTROLS . 2. Remove the bolts and the splash shield 2004 Ford Escape 2004 ENGINE Engine - 3.0L (4V) - Escape KE

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