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Thorough Brake Inspections Are Comeback Preventers And Profit Builders

How many times have you seen a hand-painted sign in a shop window that advertised a menu-priced brake pad replacement for “$XX.95 per axle.” Of course, a menu-priced brake replacement would be good if a simple brake pad replacement would cure all...

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How many auto repair pet peeves are out there? Well, enough of them that one article wouldn’t hold them all. I’ve received so many emails, texts and phone calls about my article in the February issue that I thought: why not put everyone’s pet peeve...

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Air Filter Show & Tell: Seeing Is Believing

Air filters are normal wear items that ­require regular checks and ­replacement. Their role is to trap dirt particles that can cause damage to engine cylinders, walls, pistons and piston rings. In fuel-injected vehicles, the air filter also plays...

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ZF 8-Speed Transmission Replacement

The ZF 8HP transmission made its debut in 2009, and since its introduction, has been one of the top choices for international car manufacturers. BMW, one of ZF’s largest customers, uses the 8HP across its entire product portfolio. BMWs featuring...

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Shop Folds After Shoddy Brake Work Endangers Woman

A Florida woman was thankful to walk away without injury after her vehicle’s brakes went out for the second time in as many months due to negligence on the part of her local repair shop, ABC Action News reported. Shelly Darling of Zephyr Hills, FL,...

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Air Ride Diagnostics: Reservoirs and Compressors

Just about every Asian and European luxury import nameplate manufacturer has a 7- to 10-year-old vehicle on the road with an air-ride suspension at all four corners. Chances are one of these vehicles will be coming to your shop sooner rather than later. Regardless...

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Regulators Launch Investigation Into Jeep Grand Cherokee Brake Defect

Federal regulators are investigating whether the automatic braking systems in some 2014 Jeep Grand Cherokees may be defective after receiving a number of complaints from motorists about a potentially dangerous glitch that caused their vehicles to come...

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Electronic Proportioning Valve: Doing More With Less Hardware

Anti-lock brake systems (ABS) and the HCU are replacing proportioning, combination and other valves to change the braking forces in the front and rear. This is called Electronic Brake Distribution (EBD) and it can dynamically change the proportioning...

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NHTSA’s GM Brake Line Corrosion Investigation: Reading Between the Brake Lines

There will be no recalls on some GM vehicles for brake line corrosion. Instead, we received an advisory from the National Highway and Traffic Safety Administration (NHTSA) about brake line inspection and car washes. What was not discussed was the corrosion...

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Can Cordless Power Tools Replace Pneumatic Tools?

I recently attended Milwaukee Tool’s annual media tool preview event where they unveiled over 80 new products that will be available later this year and early next year. Milwaukee Tool is known primarily as a leading supplier of professional-grade power...

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OTC's Technician Challenge Tour Will Award Ultimate Diagnostics for Life

The OTC Technician Challenge is going on tour with dates in six states, showcasing the Encore with new Bravo 2.0 software. Technicians nationwide will compete to win one of three Ultimate Diagnostics for Life packages. Ultimate Diagnostics for Life winners...

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New Productivity Features Added To Coverage In Snap-on Software Upgrade 15.2

Snap-on has increased its vehicle coverage in the new Software Upgrade 15.2 for the Auto-ID, One-Touch Full Vehicle Code Scan and the One-Touch Code Clear features to provide effective, accurate and fast diagnostics out of the box and miles down the road. The...

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Home Cooling Tech Feature: Servicing Ford’s 3.0L Engine

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The 3.0L Duratec V6 was introduced in 1996 to replace the aging 3.8L V6 in the Ford Taurus and Mercury Sable. Unlike its conventional pushrod predecessor, the 3.0L V6 has dual overhead cams, four valves per cylinder and an aluminum block with cast-iron cylinder liners.

It is essentially a larger version of the 2.5L Duratec 60° V6 that was introduced in the 1994 Ford Contour and Jaguar X-Type. Both engines have the same 79.5 mm stroke crankshaft, but the 3.0L engine has larger cylinder bores (89 mm versus 82.4 mm in the 2.5L Duratec).

The 3.0L Duratec engine has Sequential Multiport Fuel Injection (SFI), and an upper and lower intake manifold with electronically controlled Intake Manifold Runner Control (IMRC) that varies intake air velocity for improved low-end torque, and a single coil distributorless ignition system (DIS) that fires two spark plugs simultaneously (waster spark).

The coil is mounted on the front valve cover, and the firing order is 1-4-2-5-3-6. The plugs are gapped at 1.3-1.4 mm (0.052-0.56”).

The dual overhead cams on the Duratec engine are chain driven, so there’s no timing belt to replace.
Over the years, this engine has undergone continual evolution and has been produced in several variations, including:
• A 208 horsepower version with roller finger followers for the Taurus and Sable, and the 2001 and later Ford Escape and Mazda Tribute.

• A more powerful 232 hp version for the 2000-’05 Lincoln LS, Jaguar AJ30 and S-Type, Mazda 6 and MPV, and 2005 Ford Five Hundred, Mercury Montego and Ford Freestyle with direct-acting mechanical bucket tappets.

• A Variable Valve Timing (VVT) with electronic throttle control for the 2003-’06 Lincoln LS, 2003-’06 Jaguar X-Type applications, 2006 Ford Fusion, Mercury Milan and Lincoln Zephyr, and 2009 Ford Escape. On the 2009 Fusion, a new type of VVT system called “Cam Torque Actuated” (CTA) is used to advance cam timing. The cam phaser generates its own internal pressure rather than relying on oil pump pressure to move the cams. The result is more advance (47°) and better fuel economy.

Though the 3.0L Duratec V6 has had a relatively long production run, its successor is the larger displacement 265 hp 3.5L Duratec V6, which powers the 2007 Ford Edge, Lincoln MKX and MKZ, and 2008 and later Taurus and Sable, and 2009 Ford Flex. An even larger 275 hp 3.7L Duratec V6 with a 95.5 mm bore is used in the 2008 Mazda CX-9 and Lincoln MKS, and 2009 Mazda 6. Ford says it will continue making the 3.0L V6 for several more years with additional improvements to reduce emissions and improve fuel economy.

3.0L Variants
The first-generation 3.0L Duratec blocks produced from 1996 through 1998 can be identified by the “F5DE” casting number on the engine block. In 1999, Ford changed to a slightly different casting (XW4E) which has different coolant passages on the right side that require a different head gasket. Install an old style head gasket on this  engine and it will leak coolant.

The following year, Ford revised the block casting slightly and reduced the size of the knock sensor threads from 12 mm to 8 mm. Other than that, the 1999 and newer blocks are interchangeable. The 2000-’04 blocks use casting number XW4E-BA.

The cast iron liners in the aluminum block can be bored to oversize if the cylinders are worn or tapered. Flat-top pistons with a slight dome are used without valve reliefs in the older 3.0L Duratec engines that do not have variable valve timing, but pistons with four valve reliefs are required for additional valve clearance in the newer versions with VVT. The compression ratio is the same, so the newer pistons can be used in the older applications.

All the Duratec engines use powder metal connecting rods with cracked (fracture-split) caps. Rod lengths and weights are all the same, and can be interchanged from one year to the next. If the big end of the rod is worn or stretched, though, the rod has to be replaced because cracked caps cannot be ground to resize the bearing opening.

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Larry Carley

Larry Carley has more than 30 years of experience in the automotive aftermarket, including experience as an ASE-certified technician, and has won numerous awards for his articles. He has written 12 automotive-related books and developed automotive training software, available at www.carleysoftware.com.
  • Jodi

    I own a 2006 ford escape 3.0 and I am having a problem finding out if the water pump is exhaust driven or I take driven. I need to replace the engine. The engine sits sideways so I do not know if the front of the engine is on the right or left side. I read online that if the 8th digit of the vin is 1 then it is exhaust. Need help

  • Dale Noel

    Have a 2005 ford f150 v8 4.6 timing chain cover do you think it would work on a 2000 gt mustang v8 4.6 if I get the 2005 ford belt

  • David Utley

    Can I install a conventional 3.0 out of an 2001 Mercury Sable in a 2002 Mazda Tribute with a DOHC 3.0?

  • Stan McCowen

    I can’t find the bolt size for the holes on the 2002 3.0 Duratec engine in a Lincoln LSE that you bolt the brackets to, to support the engine while changing the oil pan gasket. Does anyone know what size they are?

    • Ryan puckett

      M12x1.75

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