Ford - Engine Builder Magazine
Contents
1. FIND ANY RING AND ANYTHING ABOUT RINGS AT HASTINGSMFG COM At Hastingsmfg com you can use our Online Ring Finder download our Master or Racing Ring TA read EEE of LOS HUGE ues or You ll receive a FREE Tough Gur Racing Rings Wall Chart and Sticker when you do Hastings stocks oil and compression rings in nearly every shape size and material for virtually every engine type including Cars Trucks Motorcycles Agriculture Compressors Marine and Performance Racing domestic and international 1 i ita dj Sets p l cil AL a LO LNE ifi i i Cast lron Premium Ductile lron and Steel Compression Rings Sign up today at Hastingsmfg com for a FREE Tough Guy Racing Rings Wall Chart and New Applications e Newsletter Flat and Barrel Face Reverse Twist Torsional Taper and Napier Shapes Chrome and Plasma Spray Molybdenum Moly Coatings Superior Oil Control Flex Vent Oil Rings Piston Rin S Anillos p ra Pist n Segments de Piston oo JA Winner 2008 Piston f i Polk inventory i Rings Efficiency Award F Le ee ee a Hastings Manufacturing Company LLC 325 N Hanover St Hastings MI 49058 Circle 111 in February Engine Builder for more information TECH SOLUTIONS guide Revised Cylinder Head Gasket and Head Bolts for 1983 92 Ford 2 3L OHC Oil leaks and broken cylinder head bolts may occur if the head bolts are not properly tightened The newest level of c2. 72 in Ibs 8 Nm then torque fastener 10 Figure 3 page 12 7 Install the left hand camshaft cover 8 Fully warm the engine to verify the repair From Mitchell 1 1997 2008 Ford 3 8L 3 9L and 4 2L Spark Knock Under Light Load and Acceleration Some Ford vehicles equipped with 3 8L 3 9L or 4 2L engines with Split Port Intake Manifold Runner Control IMRC may exhibit spark knock under light load and acceleration Follow the service steps to correct this condition Inspect for disconnected IMRC actuator rods 1 Check both right hand and left hand side IMRC rods to be sure they are properly attached to the actuator motor and intake manifold runner 2 It the IMRC actuator rods are found to be connected properly do not continue with information 3 If any IMRC actuator rods are dis connected refer to service manual 4 If any IMRC actuator rod linkages are found disconnected replace all four linkage rod retainers Figure 4 below LOWER INTAKE MRC LINKAGE TWO RETAINERS WHITE ACTUATOR SIDE REAR OF ENGINE TVD 2 RETAINERS RED RUNNCA SIDE Figure 4 If any actuator rod linkages are found disconnected replace all four linkage rod retainers Ford 4 6L 5 4L Engine Crank Trigger Wheel Interchangeability Back in 2001 on the 4 6L although this is a split year and in 2002 on the 5 4L Ford made some changes to the timing gear set specifically the crankshaft gear the two piece gears see
3. al 90 100 Diagnosing Ticking Noises in 2005 08 3 0L Ford Duratec Engines There have been some complaints of a ticking noise in the left bank cylinder head engine area in certain late model Ford Duratec engines Refer your engine installer to the following service proce dure to identify and resolve the issue Engines affected 2005 08 Ford 3 0L 4V Duratec with camshaft driven water pumps engine exhaust Service Procedure To diagnose with the engine running and warm at normal operating temper ature use a mechanic s stethoscope to determine if the ticking noise is coming from the left hand exhaust camshaft at cylinder 6 see Figure 1 below If the ticking noise can be verified refer to the following instructions For 2008 Escape and Mariner appli cations check the date on the left hand cam cover engine label If the engine build date is 5 16 2007 or before refer to the following to identify and resolve the engine ticking noise For engines built after this date this procedure does not apply For 2007 Fusion and Milan applica tions check the date on the front cover label If the engine build date is 5 9 2007 or before refer to the follow ing to identify and resolve the engine ticking noise For engines built after this date this procedure does not apply 1 Remove the left hand camshaft cover 2 Rotate the engine clockwise until the 6 cylinder exhaust cam lobes are pointing up and the valves are
4. fully closed 3 Remove all left hand exhaust cam caps individually and reinstall them fin ger tight 4 Torque bolts in sequence as shown in Figure 2 below to 72 in lbs 8 Nm excluding 4L camshaft cap 5 Using a screwdriver positioned on each side of the top of cam cap 4L see Figure 1 Verify the ticking noise is coming from Figure 2 Torque bolts in sequence to 72 Figure 3 Torque fastener 9 inboard first the left hand exhaust camshaft at cylinder 6 in lbs excluding cam cap 4L camshaft cap 12 ENGINE BUILDER TECH SOLUTIONS GUIDE February 2009 to 72 in lbs then torque fastener 10 MAHLE Driven by performance CLEVITE BEARINGS BUD DID Bud s all smiles after buying Clevite engine bearings for his car He knows in these tough times it s best to pick up quality parts he can rely on Now Bud can drive to the store and get all the bananas his family needs Lou bought bearings from the other guy It s a good thing Lou s single Clevite engine bearings Don t be a Lou www mahleclevite com NASCAR A NASCAR Performance is 4 registered Wademark of the National Association for Stook Gar Auto Racing i Circle 113 in February Engine Builder for more information Figure 2 page 12 apply hand pressure and shift cam cap 4L toward the exhaust side of the cylinder head 6 While holding cam cap 4L in the shifted position torque fastener 9 inboard first to
5. he exhaust temperatures are more intense than normal Without the special tips the exiting gases become hazardous to the paint on the truck s body dry grass that might catch fire or someone s legs who happens to be standing too close to the tail pipe Filter regeneration mode another new technology advancement that the independent tech needs to understand will be something you ll see more and more in your shops last Environmental ye the US Provection sx gency Starting EPA threw the diesel manufacturers a curve ball As part of the new regula tions these engines now have to be equipped with a particulate filter after the catalyst The job of the filter is to trap soot Periodically the PCM per forms a regeneration on the filter During regeneration mode raw fuel is injected into the filter to literally burn the soot out of the filter The soot is reduced to ash and drops to the bot tom of the filter The ash never leaves the particulate filter assembly and eventually the filters will need to be replaced In time this will open a new service market as these filters start needing replacement If your shop happens to do diesel work be advised also that these trucks are extremely tight under the hood and cab removal is required to do most repairs beyond basic maintenance on the Powerstroke V8 engines Tech Tip courtesy of Glen Beanard ASE certified master auto technician and ASE service consulta
6. n in the early years have all been replaced by the one piece There was a shorter gear set used prior to the dates listed above and a longer gear after those dates see Figure 5 below The crank position trigger wheel changed as well The early wheel that goes with the short gear is a PM trigger that has a spacer flange cast right into it The later wheel which is stamped steel is flat and used with the tall gear While they are identical to each other in location and number of cogs the stamped steel wheel is much less expen sive to manufacture than the PM unit Together they equal the same thing only one is cheaper to manufacture Anytime you re looking to purchase the timing components for a complex DOHC engine such as the 4 6L or 5 4L it 1s always less expensive to do so as a complete set However to this point we are unaware of anyone in the aftermarket manufacturing the timing set with the late tall crankshaft gear Therefore you need to buy the early set and substitute the new style tall crank gear into it which is still cheaper than buying all the parts separately However if you hit the Figure 5 A shorter gear set was used prior to 2001 02 and a longer gear after those dates 14 ENGINE BUILDERS TECH SOLUTIONS GUIDE February 2009 4 6L in 2001 the split year you could end up with the late gear and the early crank position trigger or vice versa nei ther of which will work in combination The later c
7. nt Diagnosing Oil Leaks on 7 3L Super Duty Diesel Engines You may have experienced an oil leak around the oil pump outlet fittings on Ford s 7 3L Super Duty diesel truck engines specifically some 1998 2003 ie Fil inn Figure 7 These exhaust tips should not be removed or covered with dress sleeves that will seal off the ports on the sides E Series 1999 2003 Super Duty 2000 03 Excursion and 2000 03 F 650 750 vehicles equipped with a 7 3L diesel engine may exhibit an oil leak at the high pressure oil pump outlet fittings TECH SOLUTIONS guide and or end plug According to Ford this type of leak may appear to bea rear miain Crankshait seal oil pan gasket or other engine oil leak due to the drain hole machined in the crankcase valley which allows any oil in the valley to run down the back of the engine see Figure 6 page 14 High pressure oil pump leaks at the outlet fittings and or end plug can be serviced without removing the pump assembly Replace the O rings on the fillings and the end plug using kit 2C3Z 9G804 AA All three O rings should be replaced Apply liquid thread sealer included in the kit prior to reinstallation Note Do not remove the bottom plug on the oil pump it is sealed in a different manner TSG The Best Solutions are available from Now order online at www epwi net with Traditional quality meets high technology Ordering online is a
8. rank trigger ring is only available from Ford and costs about 26 and the later timing gear is around 20 However the early crank trigger rings seem to be floating around everywhere So why bother with the later gears at all The crank position sensor only knows air gaps not stamped steel or PM trigger wheels If you have an abundance of the early crank position sensor trigger wheels then you don t have to buy the later tim ing gear at all if you provide the trigger ring with the engine upon selling it So if youre having this issue in your facility go on a treasure hunt and see what you can find in the way of the early crank position sensor trigger ring From Roy Berndt s EngINtel Column 2008 Up 6 4L Ford Powerstroke Diesel Exhaust Service Tips Another issue that an installer should be aware of pertains to the exhaust tips found on the 2008 and up F Super Duty diesels These exhaust tips should not be removed or covered with dress sleeves that will seal off the ports on the sides see Figure 7 page 15 As you can see the new generation of diesel engines from all makes will have some odd Oulet Fittings gt Figure 6 7 3L engines may leak at the high pressure oil pump outlet fittings and or end plug looking exhaust tips on them The tips are designed to draw cool air into the tip by use of venturi action to cool the exiting gases during filter regeneration During filter regeneration mode t
9. s easy as Just click on Select type Click n Engine Kits of kit oversizes amp add to order and you re done the vehicle make amp your kit number undersizes amp warranty option in as little as 30 seconds Getting the best engine kits and parts in the business is now even faster branch Sa oe a ae T a ry Find out more at www epwi net or call an EPWI warehouse convenient to you I WIZARD is the newest customer convenience and it s only available from Engine amp Performance Warehouse ENGINE amp PERFORMANCE WAREHOUSE ALBUQUERQUE B77 767 0100 i5 505 761 0100 DALLAS B00 284 5348 214 637 3301 HOUSTON 800 288 6548 713 862 2929 ANCHO yarei 800 288 5573 907 563 7278 DENVER 800 888 8970 303 572 8844 OAKLAND B00 234 1410 510 569 9802 OKLAHOMA CITY DE ERE PORTLAND 800 937 3652 00 76 5152 ane e a te Seek aI Aa 405 942 8435 503 232 2270 TACOMA B00 876 5152 SAN ANTONIO B00 423 2707 210 224 8424 PHOENIX B88 272 0191 602 272 0191 Circe 115 in February Engine Builder for more information www enginebuildermag com ENGINE BUILDER 15
10. ylinder head gasket and cylinder head bolts are recommended any time cylin der head service is performed The new cylinder head gasket and bolts require a different service procedure for all 1992 and earlier 2 3L engines If cylinder head service is required refer to the following procedures for cylinder head gasket replacement and cylinder head bolt Torque Plus Angle steps to provide more uniform sealing The new head gasket and bolts are uniquely different from the production designed parts Because of the difference the new cylinder head bolts are the only bolts that can be used with the new head gasket If a previous head gasket is to be used or if head bolts are not available for the new gasket the previous head gasket and bolts must be used Failure to prop erly torque the cylinder head gasket can lead to an improper sealing surface which can result in a leaking condition and broken head bolts e With the cylinder block and head properly prepared install the new head gasket The camshaft must be properly positioned to ensure proper timing alignment e Install all 10 head bolts into the block finger tight e Use the new Torque Plus Angle procedure as follows only for new head gasket and bolts Tighten all 10 cylinder head bolts in sequence shown in service manual to 51 ft lbs 70 Nm e Retighten all 10 head bolts in sequence to 51 ft Ibs 70 Nm Tighten all 10 head bolts in sequence an addition
Download Pdf Manuals
Related Search