,
Automotive Repair Manual
Ford Mustang Mercury Capri
Automotive Repair Manual by Larry Warren, Alan Ahlstrand and John H Haynes Member ollhe Guild at Motoring Wmers
Models covered : All Ford Mustang models - 1979 through 1992 All Mercury Capri models - 1979 through 1986
(lW6- 654)
Haynes Publishing Group Sparkford Nr Yeovil Somerset BA22 7JJ England Haynes North America, Inc 861 lawrence Drive Newbury Park California 91320 USA
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Acknowledgements We are grateful to the Ford Motor Company for assistance with technical information, certain illustrations and vehicle photos. The Champion Spark Plug Company supplied theillusirations of vari· ous spark plug conditions.
©
Haynes North America, Inc. 1990,1992 WIh~"""'JH ~ & Co.Ud.
A book in the Haynes Automotive Repair Manual Series Printed In the USA All rights rHef"Yed. No part of this boo« rNy be reproduced ortTansmined In any form or by any means, .-ctronlc or mechanical, Including photocopying, recording or by any Information storage or retrieval system, without permlulon In writing from the copyright holder.
ISBN 1 56392 026 3 library of Congress catalog card Number 92-70520 While every aHempt i. made to ensure that the information in Ihls rNrwalls correct, no Ilablltty can be accepted by the authors or pubIIshws for to.., ct.mage or Injury caused by any e"ora in, or omissions from, the Information gl~ .
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Contents Introductory pages About this manual InaoductJon to the Ford Mustang/Mercury Capri Vehicle Identification numbers
BUying parts Maintenance techniques, tools and working facilities Booster battery (jump) starting Jacking and towing Automollve chemicals and lubrICants
Salety IIrsll ConverSion factors TroobieshootlOg
0.. 0-6 0-7 0-8 0-8 0-15 0-16 0-18 0-19 0-2<1 0-21
Chapter 1 Tune-up and routine main tenance
1-1
Chapter 2 Part A Four-cylinder engine
2A·'
2A
28·'
2B
2C-l
2C
20-'
2D
2E·'
2E
Chapter 2 Part B Inhne six-cytinder engine
Chapter 2 Part C 2.8 hter V6 engine
Chapter 2 Part 0 3.8 liter V6 and all va engines
Chapter 2 Part E General engine overhaul procedures
Chapter 3 Cooling, heating and air conditioning systems
3-1
3
4-1
4
5-1
5
6-1
6
Chapter 4 Fuel and exhaust systems
Chapter 5 Engine electncal systems
Chapter 6 EmiSSions conuol syslems
Chapter 7 Part A Manual transmissions
7A·l
7A
78·1
78
Chapter 7 Part B AutomatIC transmiSSIOns
Chapter 8 CkJtch and dnlleline
8-1
8
9-1
9
Chapter 9 Brakes
Chapter 10 Suspension and steering systems
Chapter 11
Bod,
10·1
10
11·' 11
Chapter 12 ChaSSIS electncal system
1
12· '
WIring diagrams
12·16
Index
IND·l
12
IND
1980 Mercury Capri IiItback
..
About this manual Its purpose The purpose 01 this manual IS 10 help yoo get the best value from your
vehlCle.lIcan(losoin several ways.llean helpyou decide what work must be done. even it yOtJ choose to have II done by a dealer service department or a repair shop; it provides informatJon and procedures for routine malnte· nance and servicing; and 1\ offers diagl10stic and repair procedures to fol low when trouble occurs, We hope you use the manual 10 tackle the work yoursell. For many simpler jobs. doing il yourself may be quicker than arrangmg an appoint-
manito oe11he vehicle Into a shop and making the trips to leave It and pick II up More importantly, a lot 01 money can be saved by avoiding the expense the shop must pass on 10 you to coyer Its labor and overhead costs An added benefit is the sense 01 satisfactIOn and accomplishment that you leel aher doing Ihe job yoursell
Using the manual The manual IS divided mto Chapters, Each Chapter is divided into
numbered SeclJons, whICh are headed In bold type between hofIzontal lines. Each Section consists 01 consecutively numbered paragraphs At the beglnnu\g of each numbered Section you Will be rei erred to any Illustrations whICh apply to the procedures In that Section. The referellCe numbers used In Illustration captions PInpoint the per1lnent Section and the Step within that Section. That IS, illuslrallon 3.2 means the Illustration refers to Secllon 3 and Step (or paragraph) 2 within that Section, Procedures. ollCe described in the le~t. are not normally repeated . When irs necessary to refer to another Chapter, the referellCe Will be given as Chapter ilnd Seellon number. Cross references given without use of the word "Chapter" apply to Sections andlor paragraphs in the same Chapter For example. ·see SectIOn S" means In the same Chapter. RelerellCes to the left or nght Side of the vehlcte assume you are sitting In the dnver's seat, laCing lorward. Even though we have prepared Ihls manual With ex\feme care. neither the publisher nor the author can ateepl responsibility for any errors in, or omiSSions Irom, the Information given.
NOTE A Note provides Inlormatron necessary 10 property complete a procedure or Information which Will make the procedure easier to understand
CAUTION A Caution provides a special procedure or special steps which musl be taken while completing the procedure where the Caution is found Not heeding a Caution can result In damage to the assembly being wor1<.ed on.
WARNING A Warning proVides a Special procedure or special steps which must be taken while completing the procedure where the Warning IS found Not heeding a Warning can result in personal inJUry.
Introduction to the Ford Mustang/Mercury Capri The Ford Mustang and Mercury Caen, have the convenlJonal front en9,ne rear wheel dnve layout ''"!l'"''ha,~ been used over the long hie of these models. A
Va,,,.,,,
charged Power Irom the engine IS translerred through ei ther a four or frve-speed manual or three or four -speed automatic transmiSSion to the solid rear axle
by a tubular dnveshalt Incorporatrng.unrversal JOints SuspenSion at the tronlls Ford 's modilied MacPherson Slrut desrgn The rear suspension leatures COil SpringS With trailing arms used to locale the axle Rack and pinion steeflt"lg IS used, With power steenng optIOnal on early models and standard on later models The brakes are diSC at the Iront and drum at the rear (rear diSC brakes are used on the Mustang SVO), Vacuum assist IS optional onearly models and standard on .Ialer models
Vehicle identification numbers contains informatIOn such as where and when the vehicle was manufactured. the model year and the body style.
MoclificallOns are a continuing and unpubhclzed process in vehicle marn.Jlactunng Since spare parts manuals and liStS are compiled on a nu·
meocal basIs, the individual vehicle numbers are essential to coneclly ldentJly the component reQUIred
Vehicle Certification label The Vehicle CertifICation label (ve label) is attached to the Ironl ollhe
Vehicle Identification Number (VIN)
lett (driver's side) door pillar. The upper hall 01 the label contains the name of the manufacturer. the month and year 01 production. the Gross VehICle Weight Rating (GVWR). the Gross Axle Weight Rating (G AWR) and the certification statement (see illustration). The VC label also contains the VIN number, which is used lor warranty Idenlltication of the vehicle. and provides such information as manufactur· er.type 01 restraint system. body type. engine. transmission. model year and vehicle serial number.
This very Importanlloontllicauon number IS located on a plate attached to the leh Side dashboard Just InSide the Windshield (see lIIuslration). The VIN also appears on the Vehicle Certilicale 01 Title and Registration. It
Engine numbers Labelscontalning the engine code. ca~bra\lOn and serial numbers, as well as plant name. can be loond on the vatve cover. as well as stamped on the engine itself (see Illustration).
Manua' transmission numbers The manual transmission identificatIOn number and serial numbers can be found on a tag on the left side of the transmission extension hous· ing.
Automatic transmission numbers Tags With the automatic transmission serial number. build date and other information are atlached to the transmiSSion housing with a bah, usually at the edenSlon houSing.
Vehicle Emissions Contro/lnformatlon (VECI) label
The Vehicle IdenUflcaUon Number (VIN) Is visible through the
driver's side of the windshield
DAn ~IIDU
~I
"It
ThiS label is lound under the hood (Sse Chapter 6).
ENGINE lOENTIFI CATlON LAeEL
MFD . BY FORD MOTOR CO . IN U.S.A GVIIIR !>JIllI· 2"'~ U_RGAWII NUll
GAWII 2/1' II UlllG
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located on the front left door post, the vehicle certification label conlalns Important Informallon
18
FRONT
/' An engine identificatIon Isbel can usually be found on the v.lve cover
Buying parts Replacement parts are available from many sources, which generally fall inlo one of two categones - authorized dealer parts departments and Independent retail aula parts slores. Our advice concernU"lg Ihese parts is as follows R. tsll su lo parts stores; Good auto parts stores Will stock frequently needed components whICh wear 001 relatively last. such as clutch components, eMhaus\ systems. brake parts. tune-up parts, elc. "These stores al Ien supply new Of reconditioned parts on an exchange baSIS. whICh can save a conSIderable 3ff1OlJnt of money. Olscount auto partf slores are oflen very good places to boy malenals and parts needed fOf general vehicle maintenance such asoil,grease, hlters. spark plugs. belts,lauch-up paint.
bulbs. ele. They also usually sell tools and general aCCeSSOfl&S, have con -
venient hours, charge lower prices and can often be found nOI far from home.
Authorized dealer parts department: This IS the best source tor parts which are unique to the vehicle and not generally available else· where (such as major engine parts, transmiSSion parts, trim pieces. etc.). Wilrranty information : lithe vehICle IS still covered under warranty, be sure that any replacement parts purchased - regardless 01 the source - do not Invalidate the warranty l To be sure of obtaining the correct parts, have engine and chaSSIS numbers available and. it possible, take the old parts along lor positive Identification.
Maintenance techniques, tools and working facilities Maintenance techniques There are a numberot techniques Involved In maintenance and repair thai will be referred to throughout this manual. Application 01 these tech · nrques will enable the home mechaniC to be more elficient. beller orga· nrzed and capable of performing the various tasks properly, which Will ensure that the repair job is thorough and complete .
Fasteners Fasteners are nuts. bolts, studs and screws used to hold two or more parts together There are a lew things to k&ep In mind when WOrking With tasteners A lmost allot Ihem use a locking device 01 some type . either a Iockwasher, locknut. locking tab or thread adheSive. AU threaded tasten· ers should be clean and straight. With undamaged threads and undam aged corners on the hex head where the wrench fits. Develop the habtt 01 replaCing all damaged nuts and bolts With new ones. Special locknuts
Wllh nylon or fiber Inserts can onty be used once. II they are removed , they lose therr locking ability and must be replaced With new ones. Rusted nuts and bolts should be treated With a penetrating fluid to ease removal and prevent bre'lkage. Some mechanics use turpentine In a spout -type 011 can, which works quite well. Alter applYing the rust penetrant. let it work for a few minutes before trying to loosen the nut or bolt. Badly rusted fasteners may have 10 be chiseled or sawed olf or removed With a special nul breaker, available altool stores. II a bolt or stud breaksolf In an assembly, Ilcan be drilled and removed With a special tool commonly available for thiS purpose. Most automotive machine shops can perform thiS task , as wett as olher reparr procedures, such as the repair of threaded holes thaI have been strrpped out. Flat washers and Iockwashers, when removed from an assembly, should always be replaced exactly as removed Replace any damaged washers wllh new ones. Never use a lockwasher on any solt metal surlace (such as aluminum). thin sheet metal or plastlc_
Maintenance techniques, tools and working facilities
0- 9
Fastener sizes For a number of reasons. automobile manufacturers are making wider and wider use 01 melnc fasteners. Therefore, it is important to be able to
lell the difference between standard (sometimes called U.S. or SAE) and metric hardware, since they cannot be Interchanged. All bolts. whether standard or metric, are sized according to diameter. thread pitch and length. For example, a standard l f2 -13 x 1 bolt is 1/2 inch In diameter, has 131hreadsperinchandis 1 inch long. An MI2 - 1.75 )( 25 metric boll is 12 mm in diameter. has a thread ~Ich of 1.75 mm (the distance between threads) and is 25 mm long. The two bolts are nearly identical, and easily confused. but they are nol interchangeable. In addition \0 the differences in diameter, thread pitch and tength. metric and standard bolts can also be distinguished by examining the bolt heads. To begin wlth,lhedistance across the flats on a standard bolt head is measured in inches, while Ihe same dimension on a metnc bolt IS sized in millimeters (Ihe same IS Irue for nuls). As a resull. a slandard wrench should nol be used on a metric bolt and a mel ric wrench should not be
Grade 1 or 2
used on a standard bolt. Also , mosl slandard bolts have slashes radiallng out from the center of the head to denote the grade or strenglh of the bolt. which is an indication of the amount of torque thaI can be applied to It. The greater the number 01 slashes. the greater the strength 01 the bolt. Grades through 5 are commonly used on automobiles. Metric bolts have a property class (grade) number. rather than a slash, molded InlO their heads to indicate bolt strength. In this case, the higher the number, the strongerthe bolt. Property class numbers 8.8, 9.8 and 10.g are commonly used on automobiles. Strength markings can also be used to distinguish standard hex nuts from metric hex nuts. Many standard nuts have dots stamped Into one Side, while metric nuts are marked with a number. The greaterlhe number of dots, or the higher the number. the greater the strength 01 the nut MeIne studs are also marked on their ends according to property class (grade). Larger studs are numbered (the same as metric bolts), while smaller studs carry a geometric code to denote grade
°
Grade 5
Grade 8
Bolt strength markings (top - standardl SAEiUSS j bottom - metric)
Grade
Hex Nut Grade 5
Identification
@
Class
Hex Nut Property Class 9
@ 6 Dots
Standard hex nut strength markings
@ Arabic 9
3 Dots
Hex Nut Grade B
Identification
Hex Nut Property Class 10
@ Arabic 1 0
Melrlc hex nut strength markings
© E8 © CLASS
CLASS
CLASS
10.9
9.8
8.8
Metric slud length markings
Maintenance techniques, tools and working facilities
0-10
It should be ooled that many fa sleners, especially Grades 0 through 2, have nodlsllrIQuishing marks on them. When such is the case, the only way 10 determine whether It IS standard or metric IS to meaSIJre the thread PItch Of compare it to a known fastener 01 the same Size. Standard fasteners are ohen reteHed 10 as SAE. as opposed 10 melne. However. it sh~1d be nOled Ihat SAE technically refers to a non·metrlC fif16 threadlastener only. Coarse thread non-metric fasteners are referred to as USS sizes. SInce fasteners oIlhe same size (both slandardand metric) may have different strength ratings. be sure to reinstall any bolts, studs or nulS removed from your vehtcle In their ortglnal locations. Also, when replacing a fastener WIth a new one, make sure thai the new one has a strength rat· Ing equal to or greater than Ihe original.
Tightening sequences and procedures Most threaded fasteners should be ttghtened to a specific lorque value (torque IS the twiSting force applied to a Ihreaded componenl such as a nul or boll). Overtightening tna faslener can weaken 11 and cause it to break. while undertlghleningcan cause il to eventually come lOOse. Bolts, screws and studs. depending on the malerrallhey are made 01 and their thread diamelers, have specific torque values, many of which are noted in Ihe Speclflcalions at the beginning of each Chapter. Be sure to follow the torque recommendatIOns closely. For tasteners nol assigned a specifiC torque. a generallorque value chart IS presented here as a guide These torque values are for dry (untubflcaled) fasleners threaded inlO steel or cast iron (not aluminum). As was pl"evlously menlloned. the SIZE' and grade of a faslener determine the amount of torque that can safely be
Metric thread sizes M·S ....
M·,
M· IO M· 12 M- 14
......... .
Nm
Fl·lbs SI09 141021 28 1040 50 10 71 8010140
9to 12 191028 381054 58 1096 10910154
5108 121018 221033 25 to 35
71010 171024 30 10 44 341047
6to 9 12to 18 14 to 20 22 to 32 27 to 38 40 to 55 40 to 60 55 to 80
91012 171024 191027 30 to 43 371051 55 to 74 55 to 81 75tol08
Pipe thread sizes 1/8 ............ . 1~
............. .
3/8 .... . 112 ....... .
U.S. thread sizes 1/4 - 20 5116-18 .. 5116 - 24 ..
3/8-1S .. . 3/8-24 .. . 7/16-14 . 7/16-20 . . 1/2- 13 . ...
T
T_ II _
- I o
G-
L
~
I
p -
~
Standard (SAE and USS) boll dimensions/grade malils
G
Grade marks (bolt length)
L
Length (in inches) Thread pilch (number of threads per inch) Nominal diameter (rn inches)
T D
o
Metric boil dimensions/grade marks P L
T D
Property class (bolt strength) Length (rn mll/lmelers) Thread Pitch (distance between threads
Diameter
In
mlllimelers)
Maintenance techniques, tools and working facilities applied to I\. The ligures listed here are approximate for Grade 2 and Grade 3 fasteners. Higher grades can tolerate higher torque values. Fasteners laid out In a pattern, such as cylinder head bolts, oil pan bolts. differential cover bol ts, etc .. must be loosened or lightened in sa·
quence 10 avoid warping the component. This sequence will normally be shown In the appropriate Chapter. II a specific pattern is not given. the 101lowing procedures can be used to prevent warping. Initially, the bolts or nuts should be assembled finger·llgh\ only. Next, they should be lightened one luillurn each. In a criss-cross or diagonal pattern. After each one has been tightened one fuillurn. relurn to the first one and tighten them all one-hailiurn. following Ihe same panern. Finally. ligh ten each of them one-quarter turn at a time until each fastener has been tightened to the proper torque. To loosen and remove the fasteners, the procedure would be reversed .
Component disassembly Component disassembly should be done with care and purpose to help ensure that the parts go back together properly. Always keep track of the sequence in which parts are removed. Make note of special characteristics or marks on parts thai can be Installed more than one way, such as a grooved thrust washer on a shah. It is a good idea to lay the disassembled parts out on a clean surface in the order that they were removed. It may also be helpful to make sketches or take instant photos of compo· nents before removal. When removing fasteners from a componen t. keep track of their locations, Sometimes threading a bolt back in a part. or putting the washers and nut back on a stUd, can prevent miK-ups later. If nu ts and bolts cannot be returned to their original k)callons, they should be kept in a compartmented bo)( or a series of small boKes. A cupcake or muffin tin is ideal for this purpose, since each cavity can hold Ihe boil s aQd nuts from a particular area (i.e. oil pan bolts, valve cover bolts, engme mount bolts. elc,). A pan 01 thiS type IS especially helpful when working on assemblies with very small parts. such as the carburetor, alternator. valve train or interior dash and trim pieces The cavIties can be marked with pamt or tape to Identify the contents. Whenever wifing looms. harnesses or connectors are separated. It IS a good idea to Identify the two halves with numbered pieces of masking tape so they can be easify reconnected.
Hose removal tips Warning : If the vehicle is equipped wifh air conditioning. cio not disconnect any of the Ale hoses Without firsf haVing the system depressurized by
a dealer service depanment or a service station. Hose removal precautions closely parallel gasket removal precautions. Avoid scratching or gouging the surlace Ihat the hose mates against or the connection may leak. This IS especially true for radiator hoses. Because of various chemical reactions, the rubber in hoses can bond itself to the metal spigot that the hose fits over. To remove a hose. first loosen the hose clamps that secure it to the spigot. Then, with slip-joint pliers, grab the hose at the clamp and rotate it around the spigot. Work it back and forth until it is completely free, then pull it off. Silicone or other lubricants will ease removal If they can be applied between the hose and the outside of the spigot. Apply the same lubricant to the inSide of the hose and the outside of the spigot to simplify installation. As a last resort (and if the hose is to be replaced With a new one anyway) , the rubber can be silt with aknile and the hose peeled from the spigot. II this must be done, be careful that the metal connection IS not damaged. II a hose clamp is broken or damaged, do nol reuse it. Wire-type clamps usually weaken With age. so itls a good idea to replace them with screw-type clamps whenever a hose is removed.
Tools A selection of good tools is a basic requirement for anyone who plans
to maintain and repair his or her own vehicle. For the owner who has few tools. the initial investment might seem high. but when compared to the spiraling costs of profeSSional auto maintenance and repair. it is a wise one.
Gasket sealing surfaces Throughout any vehicle, gaskets are used 10 seal the mating surfaces between two parts and keep lubricants, fluids, vacuum or pressure contained in an assembly. Many times these gaskets are coated with a liqUid or paste-type gasket sealing compound before assembly. Age. heat and pressure can some· times cause the two parts to stick together so tightly that they are very diffi· cult to separate. Often. the assembly can be loosened by striking it with a soft· face hammer near the mating sul1aces. A regular hammer can be used il a block of wood is placed between the hammer and the part. Do r.ot hammer on cast parts or parts thai could be easily damaged. With any particularly stubborn part, always recheck to make sure that every fastener has been removed. Avoid using a screwdriver or barto pry apart an assembly. as they can easily mar the gasket sealing SlJrfaces 01 the parts. which must remain smooth, If prying is absolutely necessary, use an old broom handle. but keep in mind that extra clean up will be necessary if the wood splinters. After the parts are separated, the old gasket must be carefully scraped off and the gasket suriaces cleaned. Stubborn gasket material can be soaked with rust penetrant or treated With a special chemical to soften it so it can be easily scraped off. A scraper can be fashioned from a piece of copper tubing by lIanening and sharpening one end. Copper is recom mended because it is usually softer than the sul1aces to be scraped, which reduces the chance of gouging the part. Some gaskets can be removed with a wire brush. but regardless of the method used. the mating surfaces must be left clean and smooth. If for some reason the gasket surface is gouged. then a gasket sealer thick enough to fill scratches Will have to be used during reassembly of the components. For most applications, a nondrying (or seml·drying) gasket sealer should be used
0- 11
Micrometer set
Diaf Indicator set
0-12
Maintenance techniques, tools and working facilities
Dial caliper
Hand-operated vacuum pump
TIming light
hole adapter
Damper/steering WhHI puller
General purpose puller
Hydraulic lifter remov.lloel
Vallie spring compressor
Valve spring compressor
Ridge reamer
Piston ring groov8 cleaning 1001
Compression gauge with spark plug
Ring femollalflnslallatlon tool
Maintenance techniques, tools and working facilities
0- 13
Rin g compressor
Cylinder hone
Brake hold-down spring tool
Brake cylind er ho ne
Clutc h plate alignment tool
Tap and die set
To help the owner decide which tools are needed to perform the tasks detailed in this manual, the following tool lists are oltered: Mamtenance and minor repair. Reparrloverhaul and Speeia/. The newcomer to practical mechanics should slarf off WI!h the maintenar'ICe and minor repair tool kit, which is adequate tor Ihe Simpler jobs pel10rmed on a vehicle. Then, as confidence and experience grow, Ihe owner can tackle more difficult tasks , buying additional tools as they are needed. Eventually the basic kit will be expanded into the repair and
Battery post and cable cleaning 1001
Oil filter wrench Funnel (medium size) Safety goggles Jac/{slands(2) Dram pan
cedures and Will add lools from Ihe special category when It is lelltha! the expense is justified by Ihe frequency of use.
Note : If baSIC lune-ups are gOing to be part of routine maintenance, il will be necessary 10 purchase a good quality stroboscopic liming lighl and comOination tachometerldwell meter. AI/hough they are included in Ihe lisl of special tools, it is mentioned here because they are abwlule/y necessary for tuning most vehicles properly.
Maintenance and minor repair tool kit
Repair and overhaul tool set
The tools in this lisl should be considered the minimum required for pel1ormanceof routine maintenance. servicing and minor repair work. We recommend the purchase of combination wrenches (box-end and openend combined in one wrench ). While more expensive than open end wrenches , they oHer the advantages of both types of wrench.
These tools are essential for anyone who plans to perform mapr repairs and are in addition 10 those in the maintenance and minor repalr tool kit. Included is a comprehensive set of sockets which, though expensive, are invaluable because at their versatility, especially when various extensions and drives are available. We recommend the 1/2-inchdrive overthe 318·lnch drive. Although the larger drive is bulky and more expensive, it has the capacity of accepting a very wide range 01 large socI<.el$. Ideally, however, the mechanic should have a 318-inch drive sel and a 1f2-inch drive set.
overhaul tool set. Over a period 01 time, Ihe experienced dO-It-yourselfer will assemble a tool set complete enough for most repair and overhaul pro·
ComOination wrench sel (1/4-mch to I Inch oro mm 10 19 mm) Adjustable wrench. 8 inch Spark plug wrench wilh rubber Insert Spark plug gap adjusting tool Feeler gauge sel Brake bleeder wrench Slandard screwdflver (5Ito-mch x 0 inch) Phillips screwdriver (No.2 x 0 inch) Combination pliers - 6 inch Hacksaw and assortment of blades Tire pressure gauge Grease gun Oil can Fine emery cloth Wire brush
Socket set(s) Reversible ratchet Extension-tOinch Universal joint Torque wrench (same size drive as sockets) Ball peen hammer - 8 ounce Soh·face hammer (plas tic/rubber) Standard $crewdn"ver (1I4-inch x 6 inch) Standard screwdriver (stubby - 5!16·,nch) Phillips screwdriver (No.3 x 8 inch) Phi/lips screwdriver (stubby - No.2)
0-14
Maintenance techniques, tools and working facilities
Pliers - vise gnp Pliers - lineman's Pliers - needle nose Pliers - snap-ring (mternal and external) Cold chisel- II2·mch Scribe Scraper (made from lIattened copper tubing) Centerpunch Pm punches ( 1116, IIB,31f6-lnch) Steel rule/straightedge - t2 inch Allen wrench set (lIB to JlS-inch or 4 mm to 10 mm) A selection of flies Wire blush (large) Jackslands (second set) Jack (SCissor or hydraulic type) Nole: Another tool whICh IS otren useful IS an electnc dnll With a chuck caof 3,S·,nch and a set of good qualtty dnll bits
paCIty
SpecIal tools The tools In thiS !ISt Include those which are not used regularly. are expensive to buy. or which need 10 be used In accordance with their manufactuter"s instruClIOflS Unless these tools will be used frequently, it IS not very economICal to purchase many 01 them. A consideration would be to solitthe cost and use between yourself and a Inend or fnends. In addlllOn, moSt olthese tools can be obtained from a 1001 rental shop on a temporary basis This hst primarily contains only those tools and instruments widely available to the public, and not those special tools produced by the vehicle manutacturerfordistnootion to dealer service departments. Occasionally, references to the manufacturer's special tools are included in the te~1 of thiS manual. Generally. an alternative method 01 doing the JOb wrthout the special tool IS ollered. However. somellmes there is no alternative to thelf use Where this is the case, and the tool cannot be purchased Of borrowed, the work should be turned over to the dealer service department or an automotive repair shop. Valve spring compressor Piston ring groove cleaning tool PISton nng compressor PIston nng mslallallOfllooi Cylmder coffllXes$lOn gauge Cylinder ridge reamer Cylinder surfacing hone Cylinder bore gauge Micrometers andlor dial calipers Hydraulic litrer removal/ooi Bailloint separator Universal-type puller Impact screwdnvef DIal Indica/Of" set Stroboscopic tlmmg light (inductive plCk·up) Hand operated vacuum/pressure pump Tachometer/dWell meter Umversal electncal multlmeter Cable hoist Brake spong removal and ins tallatIOn 10015 F/oor~ck
Buying tools For Ihe dO-It-yourselfer who is just starting to gel involved In vehicle maintenance and repair. there are a number of options available when
purchasll'\gtools,ll maintenance and minor repair IS the exlent 01 the work to be done, the purchase 01 individual tools IS satislaClory. II, on the other hand, extensive work is planned, it would be a good idea to purchase a modest tool set Irom one 01 the large retail chain stores. A set can usually be bought at a substanual savings over the Individual 1001 prices, and they often come with a tool box. As addilionallools are needed, add-on sets, individual tools and a larger tool box can be purchased to ell:pand the tool selectIOn. Building a tool set gradually allows Ihe cost of the tools to be spread over a longer period 01 time and gives the mechanic the Ireedom to choose only those tools that will actually be used. Tool Stores Will ollen be Ihe only source of some 01the special tools that are needed, but regardless 01 where tools are bought, try to avoid cheap ones. especially when buYing screwdrivers and sockets. because they won't last very lOng The expense involved 11'\ replaCing cheap tools Will eventually be greater than Ihe initial cost of quality tools
Care and maintenance of tools Good tools are expenSive, so It makes sense to lIeatthem with respect. Keep them clean and in usable condilion and store them properly when not In use. Always Wipe of! any dirt, grease or metal chips before putling 'hem away. Never leave tools lying around In the work area. Upon completion 01 a JOb, always check closely under the hood for tools that may have been left there so they won·, gel lost dUring a test dnve Some tools, such as screwdrivers, pliers, wrenches and sockets, can be hung on a panel mounted on the garage or workshop wall, while others should be kept 11'\ a tool box or tray. Measunng instruments, gauges, meters, etc. musl be carefully stored where they cannot be damaged by weather or ImpaClfrom other tools. When tools are used with care and stored properly, they wlillasl a very long time. Even with the best of care, though, tools will wear out II used Irequently. When a tool IS damaged or worn out, replace It. Subsequent Jobs Will be safer and more enjoyable If you do
Working facilities Not to be overlooked when diSCUSSing \ools is the workshop If any· thing more Ihan rOUMe maintenance IS 10 be carned out, some sort of sunable work area IS esse"ntial. illS understood, and appreciated, that many home mechamcs do not have a good workshop or garage available. and end up removing an engme ordOlng major repairs outside It IS recommended, however, thatlhe overhaul 01 repalf be completed under the cover of a fOOf. A clean, flat workbench or table of comfortable working heIght IS an absolute necessity, The workbench should be eqUipped With a vise thaI has a jaw opening of al leasllour Inches, As menlloned preViously, some clean, dry storage space IS also reqUired for tools. as well as the lubncants, flUids, cleaning solvents, elc. whICh soon become necessary. Somellmes waste od and lIuids, draIned from the engine or cooling system dunng normal maintenance or repalfS, present a disposal problem. To avoid potInng them on the ground or Into a sewage system. pour the used lIulds Into large containers. seallhem With caps and take them to an authOrized disposal Slteor recycling center Plastic jugs, such as old antllreeze containers, are ideal tor this purpose Always keep a supply of old newspaper~ and clean rags available, Old towels are excellent for mopping up spills Many mechanics use rolls of paper towels for most work because they are readily available and dlspos· able. To help keep the alea underthe vehICle clean, a large cardboard box can be cut open and lIanefled \0 protect the garage Of shop floor, WheneverwOf1l.lng over a pamted surface, such as when leaning over a fender to service something under the hood. always cover it With an old blanket or bedspread to protect the finish. Vinyl covered pads, made especially tor this purpose, are available at ·auto parts stores.
0- 15
Booster battery (jump) starting Observe these precau tions when using a booster ban ery to start a vehicle:
a) Betare connecting the booster batlery. make sure the ignition
on
switch is in the poSition. oj Turn off the hghts, heater and other electrical loads.
e) Your eyes shoukl be shielded. Safety goggles are a good idea. d) Make sure the booster bauel)' IS the same voltage as the dead one In the vehicle. e) The two vehicles MUST NOT TOUCH each other! I) Make sure the transmiss ion is in Neutral {manual} Of Park (automatic). g) II the booster battery is not a maintenance-free type, remove the
vent caps and lay a cloth over the vent holes. Connect the red Jumper cable to the poSItive (-t) terminals of each bat-
tery. Connect one end of the black jumper cable to the negative (-) terminal of the booster battery. The other end of this cable should be connected to a good ground on the vehicle to be started, such as a boll or bracket on the engine block{see illustration). Make sure the cable Will not come into contact wilh the fan, drivebelts or other moving parts of the engine. Start the engine uSing the booster banery, then, With the engine running at idle speed, disconnect the jumper cables in the reverse order of connection.
Make the booster battery cable connections In the numerical order shown (note that the negative cable of the booster battery Is NOT attached to the negative terminal of the dead battery)
Jacking and towing Jacking Warning : The jack supphed WIth the vehicle should only be used lor changing a tire or plaC1f1Q jadl.stands under the frame. Never worlI under the vehICle or stal1 the engme while thiS Jack is being used as the only
means of SU{)fXJfl. The vehicle shOuld be on level ground. Place the shill lever in Park,
if you have an automalic, or Reverse it you have a manual l ransmlSSion Block the wheel diagonally opposite the wheel bemg changed. Set the parklngbrake. Warning : When one rear wheelis Itftedofflheground. mllther the automatic nor the manual tranSfTIISSIOfl WIll prevent the vehicle from moving and possibly slipping off the folck., even II " has been placed In Reverse or Park as described above. To prevent movement of the ve-
h1c1e while changmg a lire. always set the parkmg brake and blocli. the wheel diagonally opposite the wheel bemg changed. Remove lhe spare tire and Jack from stowage If equipped with anti-
theft wire wheel covers, pry 011 the center hub ornament and remove the Iockboll with the special 1001 (see illustration) Remove the wheel cover (if so equipped) with the tapered end of the lug nut wrench by Inserting it and tw isting the handle and then prying against the Inner wheel cover flange. Loosen, bI.Itdonot remove. the lug nuts (one-half turn IS suHlclenl). II eqUIpped with aluminum wheels. 008 01 the lug nuts Will be an antHheh type (see AnlHheh wheel lug nuts below) No l e: Some mode/shaveomamenla/lug nvlS; do not allemptlO remove them -Ihey are decoratIVe Items only! The entrre ornament assembly musl be removed
COVEA UUST 8E PAOP£RL Y 1HSTAL1.ED 8EFOfIE WSTALUNG LOCIC 80LT
'0" FOA LOcatiNG 'MAE COYtM
LOON COHOITIOH Of LOCK ~T.NOMlAL
It the vehicle is equipped with anti·then wire wheel covers , pry off the emblem and remove the lock bolt w ith the special wren ch
Jacking and towing
0- 17 ANTI -THEFT
LUG NUT
FRONT
3
fi ~O ~
•
TIG HTEN LUG NUTS I N THIS SE~UE N CE
""
NOTC ...
(~ ~
C'
","WARD
JACK ENGAGED IN NOTCH CLOSEST TO WHEEL OPENING
~~ . .!
-----
Jac king points
LUG NUT KEY
....t~~@Y
To remove or install the anti·theft lug nul, attach the key 10 the nut, then place the wrench on the key and turn the nut
Anti·theft wheel lug nuts II your vehicle is eqUipped with aluminum wheels, they have antHhett wheel lug nuts (one per wheel). The key and your registration card are attached to the lug wrench stowed with the spare ti re. Don't lose the ragistra\IOn card. You must send It to the manufacturer, not the dealer, to get a replacement key If yours IS lost. To remove or install the anti-theft lug nul, Insert the key Into the slot In the lug nut (see IIluslra\lon), Place the lug nul wrench on the key and, while applYing pressure on the key. remove or Inslall the lug nut. Mark the anlHhefllug nut ~at lon on the wheel before removing it. ThiS will allow you to Inslalll! in the same location_
Towing Place the SCissors-type jack under the side of the vehicle and adjust the jack height with the Jack handle so I[ fl\s into Ine notch in the vertical
rocker panel flange nearest the wheel to be changed. There IS a front and rear jacking notch on each side of the vehicle (see Illustration). When I,ft· ing the vehicle In any other way, special care must be exercised to aVOid damage to the fuel lank, tiller neck, exhaust system and underbody. Cau-
tion: Do no/ raise the vehicle With a bumper lack. The bumpercouJd be damaged. Also, lack slippage may occur. causing personal injury. Turn the jack handle clockWise until the tire clears the ground. Remove the lug nuts and the wheel. Pull the wheel off and replace It With the spare. Replace the lug nuts With the beveled edges facing In. Tighten them snugly Don't attempt to tighten them completely until the vehicle IS lOWered or It could slip off the jack. Turn the Jack handle counterclockwise to lower Ihe vehicle. Remove the lack and tighten the lug nuts In a criss-cross pattern Align the wheel cover (If so equipped) With Ihe valve Slem extension matching the hole In the cover Install Ihe cover and be sure that Irs snapped In place all the way around Stow Ihe \Ire. Jack and wrench. Unblock the wheels
As a general rule, the vehicle should be towed With the rear (dnve) wheels off the ground. II they can't be raised, either place them on a dolly or disconnect the driveshaU from the differential. When a vehicle IS lowed With Ihe rear wheels raised, Ihe steering wheel must be clamped in the straight ahead poSition with a special device deSigned lor use dunng tow· ing. Warning: Don'tuse the steering column lock to keep the frontwheels pomted straight ahead. Ir's not strong enough fOf purpose. Vehic les can be towed With all fourwheelsontheground, provided that speeds dan', exceed 35 mph and the distance is nol over 50 miles. When the rear wheels are off the ground there's no distance limitation, but don't exceed 50 mph. EqUipment specifically designed for towing should be used. It should be attached to the main structural members of the vehicle. not the bumpers or brackets. Safety IS a major consideration when towing and all applicable state and local laws must be obeyed. A safety chain syslem must be used at all times. WhIle towing. the parking brake should be released and Ihe transmission must be in Neu tral , The steering must be unloc.ked (ignition SWitch in the Off poSition). Remember that power steering and power brakes will not work with the erlgine off.
m,s
Automotive chemicals and lubricants A number of automotive chemicals and lubncants are available for use during vehicle maintenance and repai r. They include a wide variety of products ranging from cleaning solvents and degreasers to lubricants and protective sprays tor rubber. plastic and vinyl.
Cleaners carburetor cleaner and choke c leaner is a strong solvent for gum. varnish and carbon. Most carburetor cleaners leave a dry·type lubricant lilm which will not harden or gum up. Because of this film it is not recommended lor use on electrical components. Brske system cleaner is used to remove grease and brake lIuld Irom the brake system. where clean surfaces are absolu tely necessary. It leaves no residue and otten eliminates brake squ eal caused by contami· nants. Electrical cleaner removes OXidation. corrosion and ca rbon deposits Irom electrical contacts. restoring full currentllow. It can also be used to clean spark plugs. carburetor jets, voltage regulators and other parts where an oil-free surface is deSIred. Demofsturants remove water and moisture from electrical compo· nents such as alternators. voltage regulators. electrical connectors and fuse blocks. They are non-conductive. non-corrosive and non·flammable.
Degreasers are heavy-duty solvents used to remove grease from the outside of the engine and from chassis components. They can be sprayed or brushed on and. depending on the type. are rinsed 011 either with water or salven\.
Lubricants Motoroi/ is the lubricant formulated lor use in engines. It normall y contains a wide variety of additives 10 p!"event corrosion and reduce loamlng and wear. Motor oil comes in various weights (viSCOSity ratings) from 5 to 80. The recommended weight of the oil depends on the season. temperature and the demands on the engine. Light oil is used in cold climates and under light load conditions. Heavy oil is used in hot climates and where high loads are encountered. Multi-VISCOSity oils are deSigned to have char· actenstics of both light and heavy oils and are available In a number of weights from 5W·20 to 20W·50. Gear all is designed to be used In dillerenllals. manual transmiSSions and other areas where high-temperature lubrication is required.
Chassfsand wheel bearing grease IS a heavy grease used where in· creased loads and friction are encountered. such as lor wheel bearings. balltoints. tle·rod ends and universal joints. Hlgh-tempersture wheel bearing grease is designed to withstand the extreme temperatures encountered by wheel bearings in disc brake equipped vehicles. It usually contains molybdenum disulfide (moly), which is a dry-type lubricant. Wh ite grease is a heavy grease lor metal-to·metal applicallons where water IS a problem, White grease stays soft under both low and high tem· peratures (usually from -100 to + tOO·degrees Fl, and will not wash 011 or dilute in the presence of water.
Assembly lube is a special extreme pressure lubflcant. usually containing moly. used to lubricate high-load parts (such as main and rod bearIngs and cam lobes) lorinitial start-up 01 a new engine_ The assembly lube lubricates the parts without being squeezed out or washed away until the engine Oiling system begins to function . Silicone lubricants are used to protect rubber. plastic. vinyl and nylon par1s.
Graphit" lubricants are used where oils cannot be used due to contaminationproblems. such as in locks. Thedrygraphite wililubrica te metal parts while remaining uncontaminated by dirt, water. ollar acids. It is elec· tricatty conductive and Will not foul electrical contacts In locks such as the ignition switch.
Moly penetrsnts loosen and tubricate frozen. rusted and corroded fasteners and prevent future ruSting or Ireezing .
Heat-sink greaseis a special electrically non-conductive grease that is used for mounting electrOniC igOilion modules where it is essential that heat is transferred away tram the module.
Sealants RTV sealant is one 01 the most Widely used gaskel compounds. Made from silicone. RTV is air curing. It seals. bonds, waterproofs. lills surface irregularities. remains lIexlble. doesn't shnnk. is relatively easy 10 remove. and is used as a supplemen tary sealer With almost all Jaw and medium temperature gaskets. Anaerobic sea/ant is much like RTV In that It can be used either to seal gaskets or to form gaskets by itsel!. It remains lIeKible. is solvent resistant and fills surface Imperlectlons. The dlllerence between an anaerobic sea· lant and an RTV·type sealant IS In the curing. RTV cures when exposed to air. while an anaerobIC sealanT cures only in the absence of air. This means tharan anaerobic sealant cures only alter The assembly of parts. sealing them together. Thread and pipe sea/ant IS used lor sealing hydraulic and pneumatiC liHings and vacuum lines. It is usually made from a tellon compound. and comes In a spray.. a paint-on liquid and as a wrap·around tape.
Chemicals Antl-se/ze compound prevenTs seizing. galling. cold welding. rust and corrosion in fasteners. High-temperature anti-seize. usually made With cOpPer and graphite lubricants. is used for exhaust system and exhaust manifold bolts. Anaerobic locking compounds are used to keep tasteners from vi· brating or working loose and cure only alter installation, In the absence of air. Medium strength locking compound IS used lor small nuts, bolls and screws that may be removed later. High·strength locking compound is for large nuts, bolts and 9(uds which aren't removed on a regular baSIS. Oi/additives range from viscosity index improvers to chemical treatmen ts that claim to reduce Internal engine inClion . It should be noted that most oil manu facturers cau tion against using additIves With their oils. Gas additives perform several functions, depending on their Chemical makeup. They usually contain solvents that help dissolve gum and varnish that build upon carburetor. fuel Injection and Intake parts. They also serve to break down carbon deposits that form on the InSIde surfaces of the combustion chambers. Some additives contain upper cy linder lubricants lor valves and piston rings. and others contain chemicals 10 remove condensation from the gas tank.
Miscellaneous Brake fluid ls specially formulated hydraulic IIUld that can Withstand the heat and pressure encoun tered In brake systems. Care must be taken so this lIuid does not come In contact With painted surlaces or plasllcs. An opened containe r should always be resea led to prevent contamination by water or dirt. Weatherstrip adhesive IS used to bond weatherstripping around doors. WIndows and trunk lids. It IS sometimes used to allach trim pieces. Undercoating IS a petroleum·based. tar·like substance that IS deSigned to protect metal surfaces on the underside of the vehicle from corrosion.1t also acts as a sound-deadening agent by Insula\lng the bottom 01 the vehicle. Waxes and polishes are used to help protect painted and plated sur· faces from the weaTher. Oillerent types of paint may reqUire the use of dlf· ferent types of wax and polish. Some polishes utIlize a chemica l or abraSIve cleaner to help remove the top layer of OXidiZed (dull) paint on older vehicles. In recen t years many non-wax polishes that contain a WIde vanety of chemicals such as polymers and silicones ha'l'e been intro· duced. These non-wax polishes are usually easier to apply and last longer than conventional waxes and polishes.
Safety fi rst! Regardless 01 how enthusiastic you may be about geltlng on with the JOb al hand. take the lime 10 ensure l hal your salely IS not ~pardlzed. A moment 5 lack 01 anenllon can result In an accident. as can failure to ab-
serve certain Simple salety precautions The posSIbility 01 an acCIdent Will always elUSt. and the lollowlng points should nOI be considered a compre-
hensIVe list 01 all dangers Rather, Ihey ale Intended 10 make you aware 01 the nsks and \0 encourage a safely conscIOUs approach 10 all wol1\ you carry out on your vehicle.
Essential DOs and DON'Ts DON 'T rely on a Jack when working under Ihe vehicle Always use ap -
proved jackslands to support the weight 01 the vehicle and place them un· der Ihe recommended lilt or support points DON 'T altempl to loosen extremely tight fasleners (i.e. wheel lug nuts)
while the vehICle IS on a lack - II may lall DON' T Start the engine withoul lirst making sure Ihat the transmission IS In Neutral (or Park where applICable) and the parking brake IS set. DON'T remove the radiator cap from a hot cooling system -let It cool or COVer It With a cloth and retease Ihe pressure gradually. DON'T anemplto dram the engine 011 unlll you are sure It has cooled to the polnlIhalII Will not burn you, DON'T louch any pan of the engine or exhaust sySlem untlt II has cooled sulliclenUy 10 aVOid burns, DON'T siphon tOXIC liqUids such as gasoline, anllfreeze and brake fluid by mouth, or allow them 10 remain on your Skin, DON'T Inhale brake lining dust - IllS potenIJaJly hazardous (see Asbestos below) DON'T allow sptlled 011 or grease to remain on the floor -Wipe il upbetore someone slips on II DON'T use loose lining wrenches or other tools which may slip and cause in)Ury DON'T push on wrenches when loosening or lightening nuts or bolts. AI· ways Iry 10 pull the wrench toward you. lithe slluatlon calls for pushing the wrench away, push With an open hand to avoid scraped knuckles I' the wrench should shp DON'T anempt to hft a heavy component alone - get someone to help you DON'T rush or take unsafe shortcuts to finish a job, DON'T allow Children or animals In or around Ihe vehicte while you are wor1ung on it ..cc..wear eye protection when uSing power tools such as a drill, sander. bench grinder, etc. and when WDfking under a vehICle DO keep loose clothing and tong hair well oul 01 the way of moVing parts. 'l5'()make sure thai any hOist used has a sate workmg load laong adequate 'iOr"1he pcb. DO get someone to check on you penodlCalty when working alone on a Yeii'lCle .,£2carry out work In a logical sequence and make sure that everything IS col1'ectly assembled and lightened. DO keep chemicals and fluids tightly capped and out of the reach 01chil· 'Orin and pelS. ....~emembel thaI your vehicle 's safety affects thaI of yoursell and others Inn doubt on any POint, get profeSSIOnal advice.
Fire Remember at all limes that gasoline IS hlQhly flammable. Never smoke 01 have any kind 01 open llame around when working on a vehicle. But the riSk does not end there. A spark caused by an electncal short cirCUIt. by two metal surfaces contactlOg each other, or even by statIC eleclncrty built up In your bOdy under certam conditions, can IQnIle gasoline vapors, which In a conlined space are highly exploSive Do not, under any Circum· stances, use gasoline for cleaning parts Use an approved salety solvent Always dlsconneclthe battery ground H cable at the battery before workmgon any part of the fuel system or electrical syslem. Never fisk spill· Ing fuel on a hot engine or exhaust component It IS strongly recommended that a fire extinguisher SUitable for use on fuel and electncal fires be kept handy in the garage or workshop at all times Never try 10 extinguish a luel or elactncal fire With water.
Fumes Certam lurnes are highly tOXIC and can quickly cause unconscrousness and even death If Inhaled to any exlen\. Gasoline vaporlalls Into thiScategory, as do the vapors from some cleaning solvents. Any draJnlng or pour· Ing of such volatile fluids should be done In a well venlilated area When using cleaning flUids and solvents, read the instructions on the cOnlalner carefully. Never use matenals from unmarked containers. Never run the engine in an enclosed space. such as a garage, Exhaust tumes contain carbon monoxide. which is extremely poisonous, " you need to run the engine. always do so in the open all, or at least have the rear of the vehicle outside the work area II you are lortunale enough 10 have the use of an Inspection Pit, never drain or pour gasolme and never run the engine white the VehICle IS over the pit The fumes , being heaVier than all, will concentrate In the ptt wllh poSSibly lethal results
The battery Nevercreate a spark or allow a bare light bulb near a banery. They nor· mally give off a certain amoun t of hydrogen gas. which is highly explOSive. Always disconnect the battery ground H cable at the barrery belore working on the fuel or electrical systems If poSSible, loosen the filler caps or cover when charging the battery from an external source (thiS does not apply to sealed or malnlenancelree banenes). Do not charge at an excessIVe rale or the battery may burst Take care when addll'IQ water to a non mamtenance--tree banery and when carrying a battery. The electrolyte, even when diluted, IS very corrosIVe and should not be allowed to contact clothing or skin Always wear eye protection when cleaning the battery to prevenlthe caushc depoSits from enlenng your eyes.
Household current When using an electric power 1001 , mspection light. etc. , which oper· ates on household CUffent. always make sure Ihat the tool is correctly con nected to lIs plug and that. where necessary, It IS properly grounded Do not use such Items in damp conditions and, again, do not create a spark or apply excessive heal in the VIClnlly olluel or fuel vapor
Asbestos
Secondary ignition system voltage
Certain InCllon, Insulating. sealing, and other prodUCIS - such as btake linings, brake bands. clutch linings. torque converters, gaskets. etc. - con· tain asbestos. Extreme care must be taken to avoid mhalatlon of dust from such products. since It IS hazardous to health II In doubt, assume thatthey Oocontain asbestos
A severe electnc shock can result from touching cellaln parts of the IQnIllOn system (such as the spark plug wiles) when the engine IS running or being cranked, particularly if components are damp or the insulation is defec\IVe. In the case of an eleClronic ignition system, the secondary sys tem voltage Is much higher and could prove latal
Conversion factors Length (distance) _ Inche. (in)
X X X
0.0394
X X X X X X X X
0.061 1.76 0.88 0.8 33 1.057 0.22 0.833 0.264
.. Cubic inches Icu in; in')
X 28.35 - Grlms Ig) X 0.454 .. Kllogrlms (kg)
X X
0.035 2.205
_ Ounces 10z) .. Pounds UbI
X 0.278 .. Newtons IN) X 4.448 .. Newtons IN) X 0 .1 '"' Kilogrems-Iorce Ikgf; kg)
X X X
3 .6 0 .225 9 .81
.. Ounces-Iorce lod; 01) .. Pounds-force IIbl; 11:1+ ,. Newtons INI
X
14.223
inch
X 0.070 '"' Kllograms-Iorce per squ8Te centimetre Ikgl/cm' ; kW'cm') X 0 .068 .. Atmospheres (.,m)
X
14.696
inch
X 0.069 .. B.rs
X
14.5
inch
X 6.895
.. Kllaplsc.ls (kP.)
X
0.145
= Kilograms-Iorce per sqUire centimetre (kgl/cm'; kg/cm')
X
98.1
.. Pounds-Iorce per squere (psi; Ibllin'; Ib/in') _ Pounds-force per squ.re (psi; Ibl/in'; Iblin') .. Pounds-Ion::e per squire (psi; Ibf/in'; IbAn') .. Pounds-Iorce per square (psi; Ibl/in'; lb1ln') .. Kiloplscals (kP,)
X 25.4 .. Millimetre. ("1m) X 0 .305 .. Metres (m) X 1.609 _ Kilometres IkmJ
Inchea IInl Feet (h) Miles
3.281
0.621
.. F•• t 1ft) .. Mile,
Volume (capacity) Cubic inches (cu In; inl) Imperial pints /Imp pt) Imperial qUirt. (Imp qt) Imperiel qUIrts (Imp qt) US quartt IUS qtl Imperial gallon. (Imp gal) Imperial gallons limp gal) US gll10ns IUS gin
X X X X X X X X
16.387 _ Cubic centlmeHII Icc: em') 0.568 .. Litr" (I) 1.137 .. Lltr" (I) 1.201 .. US qUIrts IUS qt)
0.946 .. Lhret II) 4 .546 .. Lltres (I) 1.201 .. US gallons (US gall 3.185 .. Lltr•• (II
. Imperill pinl8 (Imp pt) _ Imperial qUirts (Imp CIt! .. Imperial qUirts (Imp qt)
.. US qUirts (US qt)
_ Imperial gallons limp gall '"' Imperial gallon. limp gel) .. US gallons (US gall
Mess (weight) Ounces lod Pounds lib)
Force Ounces-Iorce (od ; od Pounds-force Ubf; Ib) Newtons IN)
Pressure Pounds-Iorce per square (psi; Ibl/in' ; IbIln') Pouncls-Iorce per sqUire (psi; Ibf/in'; lb/in') Pounds-force per squ.re (psi; Ibl/in'; IbIln') Pounds -Iorce per squ8Te (psi: Ibl/in'; Ib/in') Kilopascals (kPa)
Inch
inch inch inch inch
X
0.01
inChes
X
1.152 .. Kilogrlms-force centimetre
X
0 .868
Inches
(kgl cm: kg cm) X 0.113 .. Newlon me"es (Nm)
X
8.85
inches
X 0.083 .. Pounds-Iorce lilt Ubf It; Ib 11)
X
12
feet Ubi 11 : Ib hI
X 0.138 "" Kilograms-force metres (kgl m ; kg m) X 1.356 _ Newton metres INm) X 0 .102 .. Kilograms-force metres (kgl m: kg m)
X
7.233
.. Pounds-Iorce IIbl in: Ib in) .. Pounds-force Ubi In: Ib in) .. Pounds-force UbI in; Ib in) .. Pounds-Iorce
X X
0.738 9.804
.. Pounds-Iorce leel Ubi ft; Ib It) .. Newton metres (NmJ
X
0 .0013
Torque (moment of force) Pounds-Ion:e Obi in; Ib inl Pounds-Iorce UbI in; Ib InJ Pounds-force IIbl in; Ib in) Pounds-Iorce
Pounds-force leet UbI h ; Ib III Newton metres (Nm)
Inches inches InChe, lilt Obi h; Ib h)
Power Horsepower (hp)
X
745.7 _ Witts {WI
.. Horsepower (hpj
X
1.609 .. Kilometres per hour (km/hr; kph) X
0.621
.. Miles per hour (miles/hr; mph)
X X
2 .825 2.352
.. Miles per gIllon, Imperill (mpgl .. Miles per gallon. US (mpg)
Velocity (speed) Miles per hour Imlles/hr: mph)
Fuel consumptionMiles per gillon, Imperial (mpg) M iles per glHon, US (mpgl
X 0 .354 "" Kilometres per litre (kmlll X 0 .425 .. Kilometres per liTre (kmll)
Tempersture Degrees Fahrenheit
= (OC x 1.8 ) + 32
Degrees Cel,iu, lOegrees Centlgrede; °C)
"It is common prlJerice fa convert from miles per glJflon (mpg) fa lirr"s/ IOO kilom"tfls (UlOOIun), where mpg I1mperilJl) x 1/100 km _ 282 lind mpg (US) J/ 1/100 km .. 235
.. (OF _ 32) x 0.56
Troubleshooting Contents
Symptom
Section
Engine and performance Engine backfires .. Engine diesels (continues to run)
13
after switching oft Engine hard to sian when cold Engme hard to stan when hOI. . . ..
15
,
NOISy In Neutral WIth engine running ..... . NOISy In one particular gear Lubricant teakage Slips oul of high gear ..... .
33
3' 38 36
4
..
Engine tacks power Engine lopes while Idling or Idles erratically ...... . . ......... . Engine misses throughout driVIng speed range .•, .. . EngIne rOlales but Will not start . , ........ .. ...... .
12 8 9 10 2
Engine stalls
11
Engine misses at Idle speed . .
. . .. . .. , ..... .
7
Engine starts but stops immediately.. . ... , ..... . Engine WIll nol rOlale when attempting to stan . .• ••
Automatic transmission Fluid leakage . . ........ General shih mechanism problems . . . . . Transmission slips. shifts rough. is noisy or has no drive in forward or reverse gears .... ................... Transmission will not downshift With accelerator pedal pressed . . .. . . .. to the :Ioor ..
42 39 4t 40
Driveshaft
Pinging or knocking engine sounds dunng acceleration or uphill Starler molor noisy or e~cesslvely rough in engagement . Starter motor operates Without rolallng engine.
14
6
3
Eng ine electrical system Batlery will 1'101 hold a charge Alternator light lalls to come on when key IS turned on A~ernator light stays on ......... .
16 18 17
Fuel system 19
E_cesslve fuel consumption Fl.l8lleakage andlor 11.191 odor
Knock or clunk when the transmission is under initial load (just after transmission is put into gear) ............ Metallic grating sound consistent with vehicle speed Oil leak at front 01 driveshaft . . . .. ... .... Vibrabon
44 45 43 46
Axles . .........................
47 48 49
Brake pedalleels spongy when depressed . . . . . . .. . Brake pedal pulsates during brake application Excessive brake pedal travel .... ExceSSive effort reqUIred to slop vehICle . . . . . . . . . . .. .. NOise (high'Pltched squeal WIth brakes applied) . . ... .. . . .. Pedal travels to the floor With little reslSlance . Vehicle PlJIIS 10 one side during braking
53 56 52 54 5t 55 50
Noise ....... . Vibration .. Oil leakage
20
Brakes
Cooling system Coolant loss E_lernal cool ani leakage .. Internal coolant leakage Overcooling Overheating Poor coolant Circulation.
Section
Symptom
.... ... ..
25
23 24 22 21
26
Clutch Clutch slips (engine speed increases With no increase In vehICle speed) Clutch pedal slays on floor when disengaged .. . FailS 10 release (pedal pmssed to lloor·shlft lever does not move freely in and out 01 Reverse) . ... . . . . . . . .. Grabbing (cha\1enng) as clutch is engaged ........ Squeal or rumble With clutch lully disengaged (pedal depressed) Squeal or rumble With clutch fully engaged (pedal released)
Suspension and steering systems 28 32 27 29 3t 30
Manual transm ission OIIIiculty In engaging gears . NOISy In all gears
37 34
ExceSSIVe pitching and/or rolling around corners or dunng brakmg .............. ... ... . ExceSSive play in steenng .. . . .. . . .. . .. . . . . E~cessive tire wear (!lOt specific to one area) . . . . . .. .. ....... Exces!liva tire wear on insida edge . E~cessive tlra wear on outside edge . . . . . . . . . . . . . E~cess ively sllff steering. . . . . . . . . . . . . .. .... ........ Lack of power assistance .... .... . . .. ....... Shimmy. shake or vibration . ........... nre tread worn in ooe place . . . . . . . . . . . . . . . . . . . .. ... Vehicle PlJlls 10 one side ... . . . . . . . . . . . . . . . . . . . . . . ..
59 61 63 65 64 60 62 58 66 57
0-22
Troubleshooting
ThiS section provides an easy relerence guide to the more common problems which may occur dUring the opera tion of your veh icle These problems and poSSible causes are grouped under various components or systems, suchas Engine. Cooling system. etc .. and also relertotheChap· ter andlor Section which deals wiH1 the problem Remember that successlultroubleshooting IS not a mysterious black an practiced only by profeSSional mechaniCS. Irs simply the result 01 a bit of knowledge combined With an intelligent. systematic approach to the problem. Always work by a process of elimination. staning With the simplest solution and working through \0 the most complex - and never overlook. the obVIOUS. Anyone can torget to till the gas tank or leave the lights on overnight. so don't assume that you are above such oversigh ts Finally. always get clear in your mind why a problem has occurred and take steps to ensure that It doesn't happen again. II the electrical system lalls because 01a poor connection, check all other connections in the system to make sure they don't tall as well. II a panlcular fuse continues to blow. find out why - don't just go on replacing luses. Remember. lailure 01 a small component can often be Indicative of potential failure or incor· rect lunctiOnl(lg 01 a more Imponant component or system.
Engine and performance Engi ne will not rotate when attempting to start Battery terminal connecllons are loose or corrode
2 Battery discharged or laulty. II the cable connecliOns are clean and tight on the battery posts, turn the key to the On position and SWi tch on the headlights and/or Windshield wipers. 11 they tall to function. the battery is discharged 3 AutomatlctransmlSSIOn not completely engaged in Park or clutch not completely depressed ( t984 and later models). 4 Broken. loose or disconnected wiring in the stanlng Circuit. Inspect all wifing and connectors at the battery, staner solenoid. Ignition SWitch and neutral stan SWitch (automatic transm iSSion) or clutch Interlock SWi tch (1984 and later manual transmission models). 5 Starter motor pinion lammed In flywheel ring gear II eqUipped With a manual transmission, place the transmission in gear and rock the vehicle 10 manually turn the engine Remove the staner and Inspect the pinion and lIywheel at earliest convenience. 6 Staner solenOid faulty (see Chapter 5). 7 Staner motor faulty (see Chapter 5). 8 Ignition SWitch faulty (see Chapter 12). 9 Neutraj start SWitch (au tomatic transmission) faully (see Chapter 7B) 10 Clutch Interlock SWitch laully (see Chapter 8)
2
Engine rolates but will nol start
1 Fuel tank empty 2 Battery discharged (engine rotates slowly). Check the operation 01 electrical components as deSCribed in prevIous Section. 3 Battery lerminal connections loose or corroded. See previous Sec\Jon 4 Carburetor flooded and/or fuel level in ca rburetor Incorrect. ThiS Will usually be accompanied by a strong luel odor from underthe engine cover. Wall a few minutes. depress the accelerator pedal all the way 10 the tloor and hold the pedal down while attempting to stan the engine 5 Choke control inoperative (see Chapter 4). 6 Fuel not reaching carburetor or luel Injector{s). On carbureted ve' hicles. With the Ignition switch in the 011 position, remove the top plate of the air cleaner assembly and observe the top of the carburetor (manually move the choke plate oack If necessary). Depress the accelerator pedal
and check that fuel spurts Into the carburetor 11 no\. check. the fuelliller (see Chapter 1). fuel lines and fuel pump (see Chapter 4), 7 Fuel inJecl or(s) or luel pump faulty (luellnJected vehicles) (see Chapter 4). 8 No power to fuel pump (see Chapter 4). 9 Worn, fau lty or Incorrectly gapped spark plugs (see Chapter 1) 10 Broken, loose or disconnected wifing In the starting CirCUli (see preVIOUS Section). 11 DISlnbutorloose. causing Ignition liming \0 Change. Turn the distributor as necessary to start the engine, then set the ignition liming as soon as possible (see Chapter I). 12 Broken, loose or disconnected wires at the Ignillon COil or faulty coil (see Chapter 5). 13 Fuel pump shut-off switch triggered (models With electriC fuel pump) . Locate the SWitch In the trunk and push the reset button (see Chapter 4).
3
Starter motor operates without totatlng engine
1 Staner pinion sticking. Remove the staner (see Chapter 5) and Inspect. 2 Starter pinion or flywheel teeth worn or brOken. Remove the cover al the rear 01 the engine and InSpect
4
Engine hard 10 slart when cold
1 Battery discharged or low. Check as described in Section I 2 Choke contro l Inoperative or ou t of adjustment (see Chapter 4 ) 3 Carburetor flooded (see SectIOn 2). 4 Fuel supply not reaching the carburetor or fuel Injection system (see Section 2). 5 Carburetorlfuell njeCIiOn system In need 01 o~erhaul (see Chapter 4). 6 Olstflbutor rotor carbon tracked and'or damaged (see Chapter t). 7 Fuel InjeCHon malfunction (see Chapter 4).
5
Engine hard 10 start when hot
1
Choke sticking In the closed pOSition (see Chapter 4). Carburetor flooded (see Secllon 2). An filter clogged (see Chapter t). Fuel not reaching the carburetor or fuellnjector(s) (see Section 2). Corroded electrical leads at the battery (see Chapter 1) 6 Bad engine ground (see Chapter 12) 7 Staner worn (see Chapter 5). B Corroded electrical leads at the fuellOjector (see Chapter 4). 2 3 4 5
6
Starter mo to r noisy o r excessivel y rough in engagement
Pinion or flywheel gear teeth worn or broken. Remo~e the cover at the rear of the en{]lne (i f so eqUipped) and Inspect. Staner motor mounting bolls loose or missing 2
7
Engine starts but stops immediately
1 Loose or faulty electrical connections at distributor. COil or alternator. 2 InsuffiCient fuel reaching the carburetor or luel in)ector(s). Caution : On fuel·mJ6cted models. relieve fuel system pressure (see Chapter 4) before performmg thiS test Disconnect the fuel line. Place a contamer under /hedisconnectedfue/lmeandobserve the flowolluel from the line. If little or none a/ all, cheCK for blockage m the Imes and'or replace the fuel pump (see Chap1er 4).
Troubleshooting 3 Vacuum leak althe gasket sulfaces 01 the carburetor or tuellnJeCtlon Unit (eFt models) Make sure that all mounting bolts/nul s are l ightened se-
curely and thai all V3CtJum hoses connected to the carburetor or luellnJeclIOn unit and manifold are poSitioned properly and In good condition
8
0-23
4
Distributor components damp or damaged (see Chapter 5) . Faulty emissiOns system componeOls (see Chapter 6) . 6 Faulty or incorrectly gapped sparl\ plugs (see Chapter 1). Also check spark plug wires (see Chapter 1). 7 Vacuum leak at Ihe carburetorl1uelmjection 1,1011 or vacuum hoses. Check as described In Secllon 8.
5
Engine lopes while idling or Idles erratically
Vacuum leakage ChecK mounting bolts/nuts al the carburetor or fuel InJ9C110n unit (CFI models) and Intake manifold lor tightness. Make sure Ihat all vacuum hoses are connected and In good condition. Check under·
12
sides 01 vacuum hoses: an apparently good hose may have a concealed hole or crack. Use a stethoscope 01 a length 01 fuel hose held against your
2
ear to listen lor vacuum leaks while the engine IS funning A hiSSing sourld WIll be heard Check the carburetor fuellnJectof and Intake manifold gasket surtace 2 Leaking EGR valve or plugged PCV valve (see Chapters 1 and 6) 3 Air hlter clogged (see Chapl er I). 4 Fuel pump not delivering sufficient luel lo the carburetor/luel injector (see Section 7). S Carburetor out 01 adjustment (see Chapters 1 and 4). 6 Leaking head gasket II thiS IS suspected, take the vehicle to a repair shop or dealer where the engine can be pressure checked 7 Timing chain and or gears worn (see Chapter 2 ). 8 CamshaUlobes worn (see Chapter 2)
9
Engine lacks power
Incorrect IQnltlon liming (see Chapter 5 ) ExceSSive play in distnbiJtor shalt At tne same lime. check lor worn rotor. laulty dlstnbutor cap. Wires. etc. (see Chapter t and 5). 3 Faulty or Incorrectly gapped spark plugs (see Chapter I) . 4 Fuel .njElctJOfl untt not adjusted properly or excessIVely worn (see Chapler 4). 5 Faulty coil (see Chapter 5). 6 Brakes binding (see Chapter 1) 7 Automatic transmission lIU1d level incorrect (see Chapter 1). 8 Clu tch slipptng (see Chapter 8). 9 Fuel lilter clogged or Impurities in Ihe fuel syslem (see Chapter t). 10 EmiSSions control system not functioning property (see Chapter 6). 11 Use of substandard luel. Fill tank With proper octane fuel 12 Low or uneven cylinder compresSIOn pressures Tesl Wl\h compresSIOn lesler. whICh Will detectleaklng valves andfor blown head gaskel{see Chapter 2). 1
Engine m i ss es at Idle speed
13 Spark plugs worn or nol gapped properly (see Chapter 1). 2 Faulty spark plug wi res (see Chapter t) . 3 Choke not operating properly (see Chapter 1). 4 Slicking or l aulty emission system components (see Chapter 6). S Clogged luel tilter andi or foreign maner In luel, Remove the fuel filter (see Chapter 1) and Inspect 6 Vacuum leaks at the Intake manifold or al hose connectlOOs. Check as described In SectIOn 8 7 Incorrect Idle speed or Idle mixture (see Chapter 1). S Incorrect Igntl!On timing (see Chapter 5). 9 Uneven or low cylinder compression Check compression as deSCflbed In Chapter 2.
Engine backlires
1
1
Emissions sys tem not functioning properly (see Chapter 6). Igf'lltlon timing incorrect (see Chapter 1). 3 Faulty secondary ignilion system (cracked spark plug insulator. faulty plug Wires, distribu tor cap andlor rotor (see Chapters 1 and 5). 4 Carburetorlfuel injectIOn untl If'l need 0 1 adjustment or worn excesSIVely (see Chapter 4). 5 Vacuum leak altha carburetorlfuellntecllOfl unit or vacuum hoses Check as described 10 SectIOfl 8 6 Valves stICking (see Chapter 2). 7 F.flng order incorrect (see Chapter 1).
2
14 10
Engine misses throughout driving speed range
Fuel filter clogged and 'or Impuntles in the luel system (see Chapter 1). Also check fuel output at the carburetor1uellnlector (see Section 7) . 2 Faulty or Incorrectly gapped spark plugs (see Chapter 1). 3 Incorrect IgOillon liming (see Chapter 5). 4 Check for cradl.ed distributor cap. disconnected dlstflootor wires and damaged distfibuior components (see Chapter 1). S leaking spark plug wires (see Chapler 1). 6 Faulty emiSSions system components (see Chapler 6). 7 Low or uneven cylinder compression pressures. Remove the spark plugs and test the comp ression With gauge (see Chapler 2) . S Weak or faulty ignt\lon s~stem (see Chapler 5) 9 Vacuum leaks at Ihe carburetorlluellnJectlon untl or vacuum hoses (see SectIOn 8)
11
Pinging or knocking engine sounds during acceleration or uphill
Engine slalls
1 Idle speed Incorrect (see Chapter 1). 2 Fuel hlter clogged andloTwater and Impuntles in the fuel system (see Chapler 1). 3 Choke improperly adjusted or sllckmg (see Chapler 4).
t Incorrect grade of fuel. Fill tank With fuel of the proper octane rat.ng . 2 tgnlliOfl hm.ng Iflcorrect (see Chapter 5) . 3 Carburetorl1uel injectJOfl unit in need of adjustment (see Chapt8f 4). 4 Improper spark plugs. Check plug type against EfTlIsslOn Control InformatIOn label located under hood Also check plugs and Wires for damage (see Chapter 1)_ S Worn or damaged distnbutor components (see Chapler 5) . 6 Faulty emiSSions system (see Chapter 6). 7 Vacuum leak. Check as descnbed in Section 8.
15
Engine diesels (continues 10 run) after sw itching 0"
1 Idle speed too htgh (see Chapter 1). 2 Electncal solenoid at side 01 carburetor nollunctlOnlng properl)' (not all models. see Chapter 4). 3 Ignillon liming Incorrectly adjusted (see Chapler 5) . 4 Thermo-controlled air clean8f heat valve not operating property (see Chapter I) . S Excesslveenglne operaling l emperature Probable causes of this are malfunctioning Ihermoslat. clogged radiator. faulty water pump (see Chapler 3)
0-24
Troubleshooting
Engine electrical system 16 1 ter 2 3 4 5 6 7
Baltery will not hold a charge
4 Thermostat faulty (see Chapter 3). 5 Fan blades broken or cracked (see Chapter 3). 6 Radiator cap no! maintalnmg proper pressure Have cap pressure lested by gas stallan or repair shop 7 Ignition IImmg incorrect (see Chapter 5)
Alternator dnvebell defecHve or not adjusted properly (see ChapI).
Electrolyte level low or battery discharged (see Chapter 1). Battery termmals loose or corroded (see Chapter 1), Alternator nOI charging properly (see Chapter 5) Loose. brOken or faulty Wiring In Ihe charging Circui t (see Chapter 5) Short In vehiCle wiring causing a continual drain on battery. Battery defective internally.
22 1
2
23
,7
Faull in alternator or charging circuit (see Chapter 5). Alternator driyebelt defective or not properly adjusted (see Chap· ter 1). 1
External coolant leakage
Detenorated or damaged hoses or loose clamps Replace hoses and! or tighten clamps at hose conneclions (see Chapter t). 2 Water pump seals defectlye. If thiS IS the case. water Will drip from the weep hole In the waler pump body (see Chapter 3) . 3 Leakage from radiator core or header tank. ThiS Wil l require the radla· tor to be prolesslonally repaired (see Chapter 310r remoyal procedures).
Alternator light lalls 10 come on when key Is turned on
Warning light bulb defective (see Chapter 12). Alternator laulty (see Chapter 5). 3 Faull in Ihe printed Circuit, dash wifing or bulb holder (see Chap· ter 12)
1
2
Fuel system 19
Thermostat faulty (see Chapter 3) Inaccurate tempe rature gauge or sender (see Chapter 3).
Alternator light stays on
2
18
Qyercoofing
EKCesslye luel c onsumption
Dirty or clogged air filler element (see Chapler 1). Incorrectly set ignition timing (see Chapter 5). 3 Choke sticking or improperly adjusted (see Chapler 1). 4 Emission system not functioning properly (not all vehicles. see Chapter 6) 5 Carburetor Idle speed andlor mixture not adjusted properly (see Chapter 1) 6 Carburetorlfuel injection parts excessively worn or damaged (see Chapter 4) 7 Low tire pressure or Incorrect tire size (see Chapter 1).
24
Internal coolant leakage
Note: Internal coolant leaks can usually be delected by examinmg the oil. Check the dipstick and mSlde of the rocker arm cover(s) for waterdeposlls and an all COnslslency like thaI 01 a mllkshake. 1 Leaking cyl inder head gasket. Haye the cool ing system pressure tested 2 Cracked cylinder bore or cy linder head. Dismantle engine and inspect (see Chapter 2).
1
2
25 1 2 3 4
26 20
Fuel leakag e and/or fuel odor
Leak In a fuelleed or vent hne (see Chapter 4). Tank oyerfilled. Fill only to automatic shu t·off. Emissions system clogged or damaged (see Chapter 6). Vapor leaks from system lines (see Chapter 4). 5 Carburetorlfuel injection internal parts excessiyely worn or ou t of adjustment (see Chapter 4). 1 2 3 4
Cootant loss Too much coolan t In system (see Chapter 1). Coolan t bOIling away due to overheating (see Section 21). Internal or ex ternal leakage (see Sections 23 and 24). Faulty radiator cap. Have the cap pressure tested.
Poor coolant circulation
Inopera\lye water pump. A qUick test IS to pinch the top radiator hose Closed wi th your hand while the engine IS Idling. then let It loose. You should feel the surge 01 coolant if the pump IS working properly (see Chapler 3). 2 Restriction in cooling system. Dram, flush and refill the system (see Chapter 1). If necessary. remove the radiator (see Chapter 3) and have it reverse flushed. 3 Water pump driyebelt detective or not adjusted properly (see Chap· ter I). 4 Thermostat sticking (see Chapter 3).
Cooling system 21
Ove rheating
1 InsuffiCient coolant In system (see Chapter 1). 2 Waler pump driyebel1 defectlye or nol adjusted properly (see Chapter 1). 3 Radiator core blocked or radiator gnlle dirty and restricted (see Chapter 3).
Clutch 27
Fails to release (pedal pressed to the floor - shift leyer does not move freely In and out of Reyerse )
Clutch lark 011 ball stud. Look under the vehicle. on the lett Side 01 transmiSSion.
Troubleshooting 2 Clutch cable OUI 01 adjustment or broken (mechanical release sys tem) (see Chapter 5) 3 Master or slave cy lmder faulty. faulty hydraulic line, low flu id level or air In system (hydraulic release system). 4 Clutch self-adjus ter quadranl laulty (1981 alld laler models) (see
Chapter 8). S 6
Clutch plale warped or damaged (see Chapter 8) IIlhe pedal makes a ralchetmg nOise while travelling to the lloor. the seH-ad)uster quadrant IS probably faulty (see Chapler 8).
28
33
0-25
Noisy in Neutral wllh engine running
Worn clutch release bearmg (see Chapter 8) (release bearing IS con· stantly engaged). To determme whether noise is from release beaflng or transmiSSiOn. disconnect clutch cable Irom release lever and puN release lever away Irom cable. It the noise Slops, It IS the release beanng. llit conhnues. It IS from the transmlssioo. 2 Damaged maIO drive gear bearing. 3 Worn counlershaft beaflngs. 4 Worn or damaged counters halt end play shims
Clutch slips (engine speed increases wllh no Increase in vehicle speed)
34
Noisy in all gears
Clutch plate 011 soaked or Ilntngworn. Removeclutch (see ChaplerS)
and Inspect 2
Clutch plale not sealed II may lake 30 or 40 normal starts lor a new
1 2
Any oltha above causes. and/or: InsulfiCientlubflcant (see checking procedures In Chapter I).
one 10 seal 3
Pressure plale worn {see Chapter B}. 35
29
Grabbing (chattering) as clutch Is engaged
I
2
01 on clutch plate IInll'lg Remove (see Chapter 8) arid Inspect Cor· recl any leakage source 2 Worn or loose engine or IransmlSSlon mounts These umts move slightly when clu tch IS released Inspect mounts and bolts 3 Worn splines on clutch plate hub. Remove clulCh componenls (see Chapter 8) arid Inspect 4 Warped Pfessure plate or lIywheel, Remove clu tch componenl s and Inspect
30
36
Worn, damaged or chipped gear teeth lor that particular gear Worn or damaged synchronizer 101 thaI parllCUlar gear
Slips out of high gear
t
TransmisSion mounting bolts loose Shltt rods not working freely. 3 Damaged mamshall pilol beanng 4 Olrt t:..etween transmiSSion case and engine or mlsaltgnmentot trans· miSSion
2
Squeal or rumble with clutch lully engaged (pedal relea sed) 37
1 Worn. delecllve or brOken release beanng (release beaflng IS con · stantly engaged on all models) (see Chapter 8) 2 Release beanng blrldlng on transmiSSion beaflng relalner, Remove clutch components (see Chapter 8 ) and check bearing Remove any burrs or nicks. clean and relubrlcate before relnslallahon
Squeal or rumble with clulch lully disengaged (pedal depressed)
Worn. defectIVe or broll.en release beamlg (see Chapter 8), Worn or broken pressure plate spnngs (or diaphragm Ilngers) (see Chapter 8) 3 All In hydraulic line (see Chapter 8). I
2
Dilliculty In engaging gears
Loose. damaged or out·ol-adJustment shlltllnkage Make a thOrough Inspection, replaCIng parts as necessary 2 Clutch cable oul of adlustment (1979-1980) Of self-adjusting mecha msm worn or damaged (1981 and later) (see Chapter 8).
38 31
Noisy in one par1icular gear
Lubricanlleakage
1 ExceSSive amount ollubncant In transmiSSIOn (see Chapter t 10fCOf reet checking Pfocedures) , Dram lubflcant as required. 2 Side cover loose Of gasket damaged. 3 Rear 011 seal or speedometer oil seal In need of replacement
Automatic transmission 32
Clutch pedal slays on lloor when disengaged
1
Bind In clulch cabfe Inspecl cable as necessary Blndmg release beanng Removeclu tch housll'lg (see Chapler 8) and Inspect 3 Faulty self·adJustlng system (t98t and lalermodels) (see Chapter 8).
Note: Due /0 the complex/IYof the automa/lc tfansmlSSI(}I'I, It IS diffICult for /he home mechaniC /0 ptoperly diagnose and servICe thIS component For probJemso/her !han !he folloWIng, the vehICle should be /aken /0 a dealer or reputable repa/( shop
2
Manual transmission Nole: All the folloWing references are fa Chapter 7. unless otherwise
ooled
39
General shill mechanism problems
1 Chapter 7 deals With checkIng and adjusting the shift linkage 00 aulo· matlc transrruSSlons. Common Pfoblems whICh may be annbuted to poorly adjusted linkage are; Engme slartlng In gears other than Park or Neutral Indica for on shllter pomtmg to a gear a/her than the one actually bemgused
0-26 2
40
Troubleshooting
Vehicle moves when in Park Refer to Chapter 7 to adjust the linkage.
Transmission will not downshift with accelerator pedal pressed to Ifoor
45
Pronounced wear In the universal joint beanngs Check as described in Chapte r 8.
46 Chapter 7 deals with adjusting th e downshift cable, downshift SWitch or TV cable to enable the transmission to downshift properly.
Metallic grinding sound consistent with vehicle speed
Vibration
Note: Before assummg that/he dnveshaf/ls allault, make sure the tires
are perfectly balanced and perform Ihe lollowing lest
41
Transmission slips, shifts rough , is noisy or has no drive In forward or reverse gears
There are many probable causes for the above problems. but the home mechanic should be concerned with only one poSSibility - !IUld level. Before taking the vehicle to a repai r shop, check the level and condl ' 2 tlon of Ihe tluid as described in Chapler 1. Correct flUid level as necessary o r change Ihe fluid and liller i! needed. II Ihe problem persists. have a professional diagnose the probable cause
42
Fluid leakage
Automat!c transmiss!on IIUld IS a deep red color. Fluid leaks should not be con fused With engine oil, which can eas ily be blown by air Ilow to the transmiSSion. 2 To pinpoint a leak. IIrst remove all bUl lt·up dirt and grime lrom around the transmission . Degreasmg agents and/or steam cleanmg wi ll achieve this. With the underSide clean . drive the vehicle at low speeds so ai r flow will not blow the leak far Irom its source. Raise the vehicle and determine where the leak is coming Irom. Common areas 01 leakage are: a) Pan : Tighten mountll)9 bolts and lor replace pan gasket as neces· sary (see Chapters ,' and 7) . b) Filler pipe: Replace the rubber seal where pipe enlers the transmiSSion case . c) Transmission all lines: Tighten connectors where lines enter transmission case and/o r replace lines. d) Vent pipe : Transmission overfilled andl or water In lIuld (see check · Ing procedures. Chapter'). e) Speedometer connector : Replace the O'flng where speedome ter cable enters transmiSSion case (see Chapter 7).
t Install a tachometer Inside the vehicle to moOitorengine speed as the vehic le is driven. Drive the vehicle and note the engine speed at wh ich the Vibration (roughness) IS most pronounced. Now shi ft the transmiSSion to a different gear and bnng the engine speed to the same point 2 If the Vi bration occurs at the same eng ine speed (rpm) regardless 01 which gear the transmiSSion IS In , the dflveshalt is NOT at fault since the dflveshaft speed varies . 3 II the vlbrallon decreases or 15 e liminated when the transmiSSion IS In a dltferent gear at the same engine speed, refer to the lollowlng probable causes . 4 Bent or dented dflveshaft Inspect and replace as necessary (see Chapter 8). 5 Undercoating or built-up dirt. etc on the dflveshalt. Clean the sha lt thoroughly and recheck 6 Worn universal JOin t bearings. Remove and Inspect (see Chapter B). 7 Dnveshaft and/or companion f lange out-aI-balance. Check lor miss Ing weights on the shaft. Remove the driveshatt (see Chapter B) and rein stall t BO-degrees from Original posItion . then retest Have the driveshalt profeSSionally balanced II the problem perSists
Axles 47 1
2
3
48
Noise Road nOise. No corrective procedures availab le Tire noise Inspect the tires and check lire pressures (see Chapter 1). Rear wheel bearings loose. worn or damaged (see Chapter 8).
Vibration
See probable causes under DriveshaTt Proceed under the gUidelines listed lor thedr iveshalt . 11 the prob lem perSists. check the rear wheel bearIngs by raising the rear 01 the vehicle and spinn ing the rear whee ls by hand. Li sten lor eVidence 01 rough (no isy) bea rings Remove and Inspect (see Chapter B) .
Driveshaft 43
Oil leak allront 01 driveshaff
Oelectlve transmission rear all seal. See Chapter 7 for replacement procedures. While thiS is done, check the splined yoke l or burrs or a rough cond llJon which may be damaging the seal. Burrs can be removed Wi th crocus cloth or a fine whetstone .
49
Oil leakage
Pinion seat damaged (see Chapte r 8) Axleshaft oil seals damaged (see Chapter 8) . 3 Dllferenlla l lnspectlon cover leaking Tighten the bol ts or replace the gasket as reqUired (see Chapters 1 and 8 ). t 2
Brakes 44
Knock or clunk when Ihe transmission is under initial load (lust atter transmission is pul inlo gear)
Loose or disconnected rear suspenSion components . Check all mounting bolts, nuts and bushings (see Chapter 10). 2 loose driveshaft bolts. Inspect all bo lt s and nuts and tighten them to the specilled torque , Worn or damaged universal JOint bearings. Check for wear (see 3 Chapter 8).
Note: Before assummg that a brake problem eXISIS. make sure that the tires are m good condition and Inflated properly (see Chapter t), that the front end alignment IS correct and thai the vehicle rs not loaded wrth Weight
m an unequal manner 50
Vehicle pulls to one side during braking
Defective, damaged . or 0 11 contaminated brake pads or shoes on one Side. Inspect as described In Chapter 9
Troubleshooting 2 E~cessl ... e we ar 01 brake shoe or pad material or drum'dlsc on one side. Inspect and correct as necessary 3 loose or disconnected Irani suspension componen ts. Inspect and lighten ail bolts 10 the specified lorque (see Chapter 10), 4 Defective drum brake or caliper assembly Remove the drum or cal!per and Inspect lor a stuck piston Df other damage (see Chapter 9).
51
Noise (high-pi tched squeal with the brakes applied)
56
0-27
Brake pedal pulsates during brake application
\ Wheel bearings not adjusted propeny or in need of replacement (see Chapler I) . 2 Catlper nOI sliding properly due 10 improper Installation or obstrtJC· hons Remove and Inspect (see Chapter 9). 3 Rotor 01 drum defective Remove the rolor or drum (see Chapter 9) and check for excessive lateral !Unout. out-ot·round and parallelism Have the drum or rotor resurtaced or replace It With a new one
Note : OccaslOna/squealJsnormal Severecondilionssuchassno w, ram,
sail. mud. extreme cold or extreme heat may make the condition worse An occaSIOnal squeal does no/ necessarily mdlCale loss of braking ef/ec-
Suspension an d steering systems
IHleness or a need for correc/lve actlOlJ DISC brake pads worn out The noIse comes flom the wear senSOf rubbing ag3ms! the diSC. Replace lhe pads With new ones Immediately (see Chapter 9). 2 MISSing or damaged brake pad Insulators (diSC brakes). reptace pad insulators (see Chapter 9), 3 Linings contaminated With dirt or grease. Replace pads or shoes. 4 Incorreclllnings Replace With correct linings
S2
57
Vehicle pull s to one side
Tire pressures uneven (see Chapter 1). Delecti ve Ille (see Chapter I). 3 ExceSSive wear in suspension or steenng components (see Chapter \0). 4 Front end out 01 alignment. 5 Front bfakes draggIOg Inspect the brakes as deSCIlbe
2
Excessive brake pedallravel
58 Partial brake system fai lure Inspect the entire system (see Chap ter 9) and correct as required 2 InsuffiCient flUid In the maSTer cylinder, Check (see Chapter 1), add nul(! alld bleed the sySTem II necessary (see Chapter 9) 3 Rear brakes not adtustlng properly (drum bfakes). On models wllh rear drum brakes (an except Muslang SVO), make a senes 01 starts and stops WIth the vehicle 10 Reverse II thiS does not correct the SituatIOn, re move the drums and Inspect the self-adlusters (see Chapter 9).
Shimmy. shake or vibration
1
Tire or wheel ou t-ot -balance or ou t-ot -round. Have protesslonally bal anced 2 loose_worn or oul -ot -adjustment wheet beamlgs (see Chapters 1 and 8). 3 Shock absorbers and 'or suspenSion components worn or damage::! (see Ch apter 10).
S9 S3
Brake pedal leels spongy when depressed
\
Au In Ihe hydrauliC lines Bleed lhe brake syslem (see Chapter 9). Faulty fleXible hoses Inspect an system hoses and lines Replace parts as necessary 3 Master cylinder mounting bolts'nu ts loose 4 Master cy linder defective (see Chapter 9).
2
\
Detective shock absorbers Replace as a set (see Chapter 10). Broken or weak spnngs and or suspension components Inspect as descflbed In Chapler 10
2
60 54
Excessive effort requ ired to slop vehic le
\
Power brake booster not operating properly (see Chapter 9). Excessively worn linings or pads Inspect and replace If necessary (see ChapTers 1 and 9) 3 One or more caliper pistons or wheel cylinders seized or Slicking,lnspect and relxlIld as required (see Chapter 9) 4 Brake linings or pads contaminated wllh 011 or grease, Inspect and replace as reqUired (see Chapters 1 and 9 ) 5 New pads or shoes Inslaned and nol yet seated It will lake a while lor the new matenaj to seat against the drum (or lotor)
2
S5
Excessi ve pitching andlor rol1ing around corners or during braking
1
2 3 4
5
61
Excessively stilt steering Lack ot flUid In power steenng reservolf (see Chapter 1). Incorrect tile pressures (see Chapter I ). Lack ot lubncatlon at steeling 101niS (see C hapter I ). Front end oul ot alignment See Section 62
Excessi ve play in sleerlng
Loose Iront wheel beanngs (see Chapter 1). ExceSSive wear In suspenSion or steeflf'IQ components (see C hapter (0 ). 3 Steering gearbox out of adjustment (see Chapter 10). I
2
Pedallr8vels 10 the lIoor with tittle reslslance
Lmle or no lIuid In the master cylinder reservotl caused by leaking wheel cyllnder(s)_ leakmg caliper piston{s). loose, damaged Of disconnected brake lines Inspect the entire system and correct as necessary 2 Worn master cylinder flUid seals (Ihe problem can occur even when the master cylinder IS tull of flUid) (see Chapter 9)
62
Lack 01 power assistance
Sleefing pump dllvebeltlaulty or nol adjusted properly (see Chapter I). 2 FlUid level low (see ChapTer 1).
0 - 28
Troubleshooting
3 4
Hoses or lines restricted. Inspect and replace parts as necessary. Air In power steering system. Bleed the system (see Chapter 10).
63
Excessive tire wear (not specific to one area)
3 Front end alignment Incorrect (excessive toe-in). Have pfOl esSionally aligned. 4 Suspension arm bent or twisted (see Chapter 10) .
65 1 2 3 4
Incorrect tire pressures (see Chapter 1). Tires out-ai-balance. Have professionally balanced. Wheels damaged. Inspect and replace as necessary. Suspension or steering components excessively worn (see Chap or 10).
64
Excessive Ure wear on Inside edge
1 2 3
Inllalion pressures incorrect (see Chapter 1) Front end alignment incorrect (toe·out). Have professionally aligned. Loose or damaged steering components (see Chapter to).
66
TIre tread worn in one place
1 2 3
Tires out·of-balance. Damaged or buckled wheel. Inspect and replace if necessary. Defective tire (see Chapter 1).
Excessive tire wear on outside edge
1
Inflation pressures incorrect (see Chapter 1).
2
Excessive speed in turns.
Chapter 1
Tune-up and routine maintenance
Conlents
Air lilter replacement. Automatic transmission lIuld and litter cha!'lge Automatic transmiSSIon lIuld level check AlJtomatlc \ransmlSSJOfl shift linkage lubrication
Battery check and maintenance Brake system check Carburetor choke check . ChasSIS lubncalJon Clutch linkage lubncahon and adjustment
CompresSion check . .
16 12
, "
26
25 32
"
27 See Chapter 2
Cooling system servicmg (draining. flushing and relilhng)
22
Cooling system check Crankcase vent filter replacement DIfferential (rear axle) lubrlCanllevel check and change Orivebelt check, adjustment and replacement Engine 011 and hlter change E~hausl system Check Fluid leyel checks . . From wheel beanng check, repack and adjustment
"" "" 7
23 3 28
Fuel liner replacement Fuel system check
Idle speed check and adjustment (carbureted models) IntroductJOnJmalnlenance schedule Manual transmiSSion lubrlcanllevel check and change Owner salety checks PCV valve Check and replacement Power steeflng lIuld level check Spar1l plug Wire, distributor cap and rotor check and replacement Spark plug replacement
Steering and suspenSIOn check Tire rotallon Tire and tile pressure checks Tune-up general in/ormation _. UnderhQOd hose check and replacement Valye clearance check and adjustment (2.8l V6 engines only) Windshield WIper blade check and replacement
20
'9 33
,•
,.•
3'
31
30 2' 9 8 2 13 29 3<
1-2
Chapter 1 Tune-up and routine maintenance
Engine oil vi scosity chart For best fue l economy and co ld starti ng. select the lowes t SAE viscosity grade oil lor th e expected tempe rature range
• Specifications
Recommended lubricants and fluids Engine oil Type Viscosity ........ . Power steering lIuld type . . . ........ . Brake fluid type Clutch fluid type Automatic transmission lIuid type C5 transmission Through 1982 1983 on ........ . C3. C4. AOD and A4LO transmissions Through 1987 ......... . ......... . 1988 on Manual transmission lubricant type T50-0 All others ................. . Coolanttype ....... . ..... .. . Front whee l bearing grease Chassis grease ............. _. Oilferentiallubricanl"
API grade SG See accompanying chart MOlorcraft Type F aulomatic transmission fluid DOT 3 heavy duty brake fluid DOT 3 heavy duty brake fluid
OEXAON II automatic tra!'ismission lIuid Motorcraft Type H automatic transmission !tuid OEXRON II automatic transmission fluid MERCON automatic transmission tlUld MERCON automatic transmission fluid 80W gear oil (Ford spec. no. M2C83C/part no. 080Z-19C547-A) Ethylene glycol-based antifreeze and water NLGI No.2 grease (part No. C1AZ-19590-BA) Motorcraft multi-purpose grease (part No. Cl AZ -19590-B) Hypoid lubricant (part No. 080Z-19C547-A)
• For Trak -Lok axles add 4 oz. of fnction modiller (part C8AZ-198546-A) when the lubricant is changed.
Capacities Engine oil" All except four-cylinder turbo Without filter change _. .... .. .... _ With filter change Four-cylinder Turbo Without IiIter change With liller change . Cooling system" 1979 Four-cylinder SIC . . ......... _...... _. Four-cylinder non-turbo AlC . ........... . Four-cylinderturbo AlC .. ...... _. . . . . .. . . _. 2.8L V6 MIT SIC ......... . ............ _ 2.8L V6 (all others) ...... _. . . . . .... .. .. . . _. 5.0L VB SIC. _..... . .. . .. . .......... . 5.0L V8 AlC . _.. _. . ..... _.
4qls 5 qts 4.5 qts 5.5qts
8.6 10.0
8.6 9.2 9.4 14.0 14.6
Chapter 1 Tune-up and routine maintenance
1-3
1980 8.6 9.0 9.2 81
Four-cylinder non turbo SIC Four-cylinder non-turbo Ale Four-cylinder turbo (all)
3.3L 42LV8SC 42LV8NC 1981 and 1982
'"
13,5 8.6 90
Four-cylinder non-turbo SIC Four-cylinder non-turbo Ale Four-cyhnderlurbo 3.3L 4 2L VB SIC
4.2L
5.0L
va Ale
""
'47 '50
.
va SIC
13.1
5.0l va Ale 1983 and 1984
'" 86 9.0 10.5 '07 108
Four-cylinder non-turbo SC
Four-cylinder non-turbo Ale Four-cylinder turbo
3.BL V6 SIC
3.el V6 Ale
5.0L va SIC 5.0L va Ale 1985 Four-cylinder non.turbo SIC
'"
'" "
8.7
Four-cylinder non ·turbo Ale Four-cylinder turbo
10.2
3.eL V6 S,OL VB HO (carbureted) 5.0L VB HO (eFt) 1986 and 1987 Four-cylinder non -turbo MfT, SIC
Four-cylinder non-turbo MfT, Four-cylll'lder non· turbo AfT Four-cylmder turbo SiC
Ale
Four-cylinder MOO A,C
J.8l V6 SOL va
'" 13.5 '"
"
92 9.98 96 10.9 13.3
1986 Four-cylinder
SOL va 1989 on Four-cylinder M'T. S,C Four-cylmder MfT AlC Four-cylmder AlT . 5,OL VB • USe dipstiCk 10 determme exactflli leval
99
'"
10,0
9.7 10,0
'"
-- Capaclly may vary . - 15"'0 due 10 eqUIpment vanatlOns Mosl servICe reMs lake only 80% of listed capacity because some coolant remams m the engme, All capac/lies expressed m quarts SIC mdlcales slandard coalmg (no air condillonmg) AlC md,ca/es air condlllomng. MIT mdlCates manual transmission AIT mdlcates automatic transmission.
Drlvebelt tension (with specia l tOOl) 1979 and 1980 114-lnch V-belt New belt Used belt All other V -belts (Including cogged l New belt Used bell V-ribbed belt New belt Used belt
50-80 40-60 120-160 75· 120 140-170 110-130
1981 114-lnch V-bell New bell Used belt
so-eo 40-60
1- 4
Chapter 1 Tune-up and routine maintenance
Drivebeillension (with special tool) - continued All other V-belts New belt Used belt 4K V-ribbed belt New belt Used belt. SK V-fibbed belt
120·160 90120 90120 90110
Fi~ed
New belt Used bell With tenSloner New belt Used belt 6K V-ribbed belt
110-140 110-130 75·140 75·130
Fi~ed
New belt Used belt With tenSloner (new or used belt) 1982" 114 Inch V bell New bett Used belt All pump V-bell New belt Used belt All other V belts New bell Used bell 5K V-ribbed bell New belt Used belt 6K Vnbbed belt
140-170 140-160 85-140
50·80 40·60 90-130 90120 120-160 90120 130170 120150
Fi~ed
New belt Used bell With lenSloner New bell Used betl 1983 through 1987 I 4-lnch V-belt NewbeU Used belt 318-lnch V-bel t New belt Used belt 5K V-nbbed belt New belt Used bel! 6K V-fibbed bell New belt Usedbel\ 1988 on (all)
140-180 130-160 85 140 80140
50-90 40-60 90-130 80· 100 120160 ttO 130 150-190 140-160 Reter 10 lhe wear mdlCal0r {see S9i;\Jon 141
Radiator cap pressure (psi) 1979 through 1984 All e~cept lour-cylinder without air condltionmg Standard Lower limit (must hold pressure) Upper limit (must relieve pressure) Four-cylinder without air conditioning Standard Lower hmlt (must hold pressure) Upper limit (must relieve pressure) 1985 on Standard Lower limit (must hold pressure) Upper IUTllt (must relieve pressure)
""
" "
"
" " " "
Chapter 1 Tune-up and routine maintenance
1-5
Brakes OISC brake pad thickness (minimum) Orum brake shoe lining th ickness (minimum)
11811'1 1 16 In
Ignition system Spark plug type and gap Idle speed
Reter to the VehICle EmrSSlOn Contro/lnformatlon label Reter to the VehICle EmissIOn Controllnforma/lon label
Valve clearances (2.BL V6 engine only) - engine cold Inlake
OOl6m
Exhaust
00181n
Torque specifications
Ft·lbs (unless otherwise noted ) 8010 105
Wheel lug nuts Front hub adJusllrlg nul Slep 1 Step 2
Slep 3
1
171025 Back oM 1 2 turn
tOtolSmlbs
Spark plugs Four cylmder
2.8L V6 In-line Six -cylinder
3.8L V6 va engines 1979 through 1987
1988-on 0,1 pan drain plug 2 3L lour-cylinder 2 8L V6 In line Six-cylinder 3.8L V6 Engine block coolanl drain plug(s) 2 3l louf·cyllndef 2 8L V6 In·llne slxcyllndef All olhefs Automallc IfansmlSSIOn pan bolts
C3 C, C5 A4LD
AOD
5·10 10· 15 10· 15 5· 11 10· 15 5-10
15·25 21 ·38 15·25 15-25 23·38 14· 18 nol speclhed
58 12 17 1216 1216 8· 10 6· 10
Intfoducllon This Chapter IS designed to help the home mechanIC malnlaln the Ford Muslang'Mercury Capri With the goals of maximum performance. econo my_ safety and relIability In mind Included IS a master maintenance schedule (page 1·6) , followed by procedures dealing speclflcaJly Wllh each Item on the schedule. Visual checks. adjustments. componenl replacemenl and Olher helpful items are included Refer to the accompanying Illustrations Of the engine compart· ment and the underSide of the vehicle for Ihe ~lIOns of various components ServlClllg the vehICle In acCOfdance With the mlleage 'Ilme maintenance schedule and the step-by -step pfOcedures Will fesutt In a planned mamtenance program that should produce a long and relIable servICe lIfe Keep tn mind that IllS a comprehenSive plan. so maintaining some Items but not others at speCIfied intervals Will not produce the same results.
As you service the vehicle. you Will discover thai many ot the proce dures can ~ and should - be grouped together because of the nature of the partlcutar pJocedure you re performlllg or because 01 the dose proxlm · I'y 01 two otherwise umelated components 10 one another For example If the vehICle IS raIsed lor chaSSIS tubocattOfl. you should Inspect the exhaust. suspenstOfl . steenng and luel systems while youre under Ihe vehICle. When you 're rotallng the tlfes, 1\ makes good sense 10 check Ihe brakes since the wheels are already removed. Finally. let's sup· pose you have to borrow or renl a torque wrench. Even!f you only need 11 10 ligh ten the spark plugs. you might as well check the lorque of as many Cfll+cal fasteners as lime allows The first step In thIS maintenance progfam IS to prepare YOUfselt belore Ihe actual work begins Read through all Ihe procedufes youre planmng 10 do. then gather up aillhe pans and lools needed If 1\ looks like you might run Into problems dunng a partlculaf JOb, seek advICe from a mechanIC Of an experienced dO·lt·yourselfer
Ford Mustang and Mercury Capri
Maintenance schedule The foUowing maintenance intervals are based on the assumption that the vehicle owner will be doing the maintenance or service work, as opposed to having a dealer service department do the work. Although the time/mileage intervals are loosely based on factory recommendations. most have been shortened to ensure. for example, that such items as lubricants and fluids are checked/changed at Intervals that promote maximum engine/ driveline service hfe. Also, subject to the preference of the individual owner interested in keeping his or her vehicle in peak
Every 250 miles or weekly, whichever comes first Check the engine oil level (Section 3) Check the engine coolant level (Section 3) Check the brake fluid level (Section 3) Check the windshield washer fluid level (Section 3) Check the tires and tire pressures (Section 8) Perform owner safety checks (Section 35)
Every 3,000 miles or 3 months, whichever comes first All items listed above, plus . .. Check the power steering fluid level (Section 4) Check the automatic transmission fluid level (Section 6) Change the engine oil and oil filter (Section 10) Check/adjust the clutch pedal freeplay and lubricate the linkage (Section 27)
Every 6,000 miles or 6 months, whichever comes first All the items listed above, plus . .. InspecVreplace the underhood hoses (Section 13) Check/adjust the drivebelts (Section 14) Check/service the battery (Section 15) Check/regap the spark plugs (Section 30)
Every 12,000 miles or 12 months, whichever comes first
condition at all times, and with the vehicle's ultimate resale In mind, many of the maintenance procedures may be performed more otten than recommended In the following schedule. We encourage such owner Initiative. When the vehicle IS new it should be serviced initially by a factory authOrized dealer service department to protect the factory warranty. In many cases the initial maintenance check IS done at no cost to the owner (check With your dealer service department for more Informallon)
Inspect the exhaust system (Section 23) Inspect the steering and suspenSion components (Section 24) Inspect the brakes (Section 25) Lubricate the automatic transmission control linkage (Section 26) Check the front wheel bearings (SecllOn 28) Adjust valve clearances (2.8L V6 engine only) (Section 29) Replace the spark plugs (Section 30) InspecVreplace the windshield wiper blades (Section 34) Check the exhaust heat control valve (3.8L V6 and VB) (Chapter 4)
Every 24,000 miles or 24 months, whichever comes first All items listed above plus . .. Change the automatic transmission fluid and filter (Section 12)' Adjust automatic transmission bands (Chapter 7)" Service the cooling system (drain, flush and refill) (Section 22) Check/replace the spark plug wires, distributor cap and rotor (Section 31) Check the choke and lubricate the linkage (Section 32) Check the idle speed (carbureted models) (Section 33)
All items listed above, plus . ..
Every 30,000 miles or 30 months, whichever comes f irst
Check/replenish the manual transmission lubricant (Section 5) Check the rear axle (differential) lubricant level (Section 7) Rolate the tires (Section 9) Lubricate the parking brake cable (Section 11) Replace the air filter (Section 16) Check/replace Ihe crankcase venl filter (Section 17) Check/replace the PCV valve (Section 18) Check the fuel system (Section 19) Replace the fuel filter (Section 20) Inspect the cooling system (Section 21)
Change the rear axle (differential) lubricant (Section 7) Lubricate the chassis components (Section 11) Replace the EGR vacuum solenoid filter (3.8L V6 engine only) (Chapter 6) • If operated under one or more of the following conditions, change the automatic transmission fluid and adjust the bands every 12. 000 miles: In heavy city traffic where the outside temperature regularly reaches 90-degrees F or higher In hilly or mountainous terrain Frequent trailer pulling
1-7
Chapter 1 Tune·up and routine maintenance
pcy VAlVE
"""'"
RECOMMENDED INfEflY .. L
~ BELT TENSION
GAUGE - '63l-I6:1'O·A CHEel( SEll TENSION
AT RECOMMHIO£O flOWER STURING
INTERVALS
~MPD,mICI(
FLUID SHOULD 8( BET'o'jEEN FULL COLO AND
""'01.11 TOA COOLAN T
FUll HOT ", ,,,"I(S.
LEVEL
DEPENDING ON TEMPERATURE
REFER TO SECTIC'" !to-1J FOR CHECKING PROCE~URE
AND SECTION!tO-:HI FOR OAAIN AND fill PROCEOUIU
1 000l..AN1 IUCOVERV
,
AIR"LTEA REnACE ELEMENT
AT RECOMMENDEO
ENGINE Oil lEVEL 01'5TICO:
AUTOMA TIC TRANSMISSION FLUID LEVEL OI,-nICK CHEel( Wiliol ENGINE R U NNING AND TRANSMISSION IN PARI( REFER TO SECTION 50·17
5£C110 ... 1201
COAT GASKET WITH ENG''''E Oil
.----"./
-
Il00o~ooilOOl
Fuel.. FILTER
"(PLACE AT "(COMMENDED INTEI'IVAL
~ , ~:.,.
Oil FlUE" REPLACE AT
CRANKCASE VE'HILAnON fiLTER REPLACE AT
\VJu:.:"
IUCOMMENOED "HERVAl
RECO"''''ENOEO , .. TERV"'l
Four-cylinder engine companment service points (carbureted, non-turbo)
ORAIN ~lUG CHANGE OIL AT IUCOlo
1-8
Chapter 1 Tune-up and routine maintenance
PC ... VA,lI/E REPLACE AT RECOMMENDEO INTERVAL
ENGINE OIL
L(VEl DIPSTICK
COAT GASKET I'/ITH ENGIt.lE OIL
OIL FILTER
FL·300 REPLACE AT RECOMMENCED HHEAVAL
SHfTENSIOH GAUGE _ rUl ·8620 A
WINDSHIELD
CH~CI';
BELT TENSION AT RECOMMENDEO 'NTERVALS
POWER STHRING AIIil FIL TE;!
",.,,,,, ,~
PUMP DIPSTICK FLUID SHOULD BE BETWEEN FULL COLO AlIIo FULL HOT MA.RI(S, DEPENDING ON TEMPERATURE
REPLACE AT RECOMMENOED INTERVALS
RADIATOR COOLMH LEVEL ENGI"IE OIL
DRA'N PLUG CHANGE OIL AT RECOMMENDEO INTERVAL
IWITH A ICI REFER TO SECTION 5G-27 FOR CHECKING PRoceOURE AND SECTION 50 ·29 FOR DRAIN AND FilL PROCEDURE
RADIATOR COOlAro.rt LEVEl [WITHOUT A CI
REFER TO SECTION W 21 fOR CHEC
AIliO seCTION 50 29 FOR DRA"iII AND FILL PROCEDuRE
Four-cylinder engine compartment service points (Iurbocharged ; fuel InJected non-turbo models similar)
1-9
Chapter 1 Tune-up and routine maintenance RAOIATO~
"""'"
QllllYH DII'STICK
CII ... iidE ELEMENT AT RICOM"'ENDIQ INTER VAL
t C"A"'ICC"SI VOlntATID N
'Ult.,lTIII
,ye v.t.LVE
CIIO(ij(jE ...T RlCOMMENDED II(TUIVAl
"Ill_til_""
CHANGE AT RECOMMENDE D INTERVAL
CR~KCUE
VENTILATION FIt lER IN Cll.o.NEII_ AT "'ECONM(NDED IIH£IIV 4l
CH~GE
.0.'"
." I~CIOI
MOTDIIC"A" OIL FlUUI
C.U,,,,GE ...,
RfCO"''''INO(O INTERv"l
In·line six-cylinder (3.3l) engine compartment service points
CHANGE Oil AT fUCOUlollNDIO 'I
Chapter 1
1 - 10
Tune-up and routine maintenance
fR ONT
RADIATOR
~ ENGINE O IL OIliAIN
~LUG
CHECI( AT "'fCOMMENOEO INTERVAL
!'OWEIII STUR ING ~OII'STICI(
FLUtO SHOULD BE BETWEE N ADO A"IO f U LL M"'''I':$
EN G INE OIL DIPSTI CK
f UlL fiLTER CHANGE AT RECOMMENOED'NTERVAL
C RAN I':CAS E V ENTI LAT IO N PCVVAlVE
A IIil CLEANEIII CHANGE ELEMENT AT RECOMMENDED 'NHRVAL OI L F ILTER COAT GASKET WITH U
A UTOMA TIC TR AN SMI SSIO N OIPST leK ICHECK WITH ENGINE RUNNI .. G TRA"SMISSION IN 'PARK"I
2.8L V6 engine co mpar1 menl service points
Chapter 1
Tune-up and routine maintenance
POWER STEERING PWP DIPSTICK THE FLUID MUST 8E IN THE FULL HOT OR FULL COlD AANGE DEPENDING ON THE FLUID TE MPERATURE
1 -11
RAO'ATOR COOLANT lEVEl REFER TO SECTION 2J-.1l1
u
u
BELT TEHSIOH GAUGE TI3I.-I&2O-... CHECK 8€lT 1EN5IOO "T RECOMMENDeD
COOLANT
INTERVAL
,., PCV V.t.L.VE WINDSHIELD WASHER
REPLACE AT
RECOMMENOEO INTERVAL
..
PCV VALVE
......
10000000001
\)j:----r------
~ ..."
.J
AIR AlTER REPLACE ELEMENT AT RECOMMENDED INTERVAL
O IL FILTER
co",r
GASKET WITI'1
ENGINE Oil REPLACE AT RECOMMENDED INTERVAL
8RAKE
AUTOMATIC TRANSMISSION flUID. LEvtL OIP$TICI( CHECK WITH ENGINE RUNNING AND TRANSMISSION IN PARK REfER TO SECTION 17-01
CVLINDER
REFER TO BOOY , CHASSIS, ELECTRICAL MANUAL SECTION '2-{)1
.....
eRA"'''''
VENTILATION fILTER REPLACE AT RECOMMENDED INTERVAL
ENGINE OIL ORAIN PLUGS CHANGE OIL AT RECOMMENDED INTERVAL ALL V-8 EQlJIPPED VEHICLES HAVE A DOUBLE PLUG
OIL PAN WITH PlUGS "'OONfEO FRONT AND REAR (LEFT SIDE) V-t\ ENGINE HAS ONI. Y ONE PLUG
,....
atGIHE OiL LEVEL DlPSTICI(
CRANKCASE
MAINTAIN OIL
VENT1U. T10N
IN SAFE RANGE 00 NOT AOO OIL ~ ............... BEYOND "MAX"
FILTtR REPLACE AT RECXlMMENDEO INTERVAL.
~ MAll
SIt>
UU.c1'SO' ......
3.8L V6 and carbureted V8 engine compartment service points
1 -12
Chapter 1 Tune-up and routine maintenance
POWER STEERING PUMP DIPSTICK FLUID SHOULO BE BETWEEN FULL COLD AND FULL HOT MARKS. DEPENDING ON TEMPERATURE
RADIATOR COOLANT LEVER
00 ~~, ~."~;'~~,~\~~~~U"
BELT TENSION GAUGE T63L8620· A CHECK BELT TENSION AT RECOMMENDED IN1ERVAL
ENGINE OIL FILLER CAP
COOLANT
WINDSHIELD WASHER RESERVOIR OIL FILTER
_."
~
, .,'
COAT GASKET WITH ENGINE OIL
AUTOMATIC TRANSMISSION FLUID LEVEL DIPSTICK CHECK WITH ENGINE RUNN ING AND TRANSMISSION IN PARK REFER TO PRE· DELIVERY MANUAL SECTION
5O.n
BRAKE CYLINDER REFER TO BODY . CHASSIS . AND ELECTRICAL IoMNUAL. SECTION 12-{)1 MAINTAIN OIL IN SAFE RANGE DRAIN PLUGS
ENGINE OIL DRAIN PLUGS CHANGE OIL AT RECOMMENDED INTERVAL
Fuel injected va engine compartment service points
Chapter 1 Tune-up and routine maintenance 2
Tune -up general information
The term tune -up IS used In Ihls manual to represent a combmallon 01 individual operations rather than one specific procedure. If, from the lime the vehicle IS new. the roullne maintenance schedule is followed closely and frequent checks are made 01 fluid levels and high wear items. as suggested throughout this manual, the engine W ill be kepi In relatively good running condition and the need for additIOnal work w ill be minimized. More likely than not. however, there will be limes when the engine is running poorly due to a lack 01 regular maintenance. Th is is even more likely if a used vehicle , which has not received regular and frequen t maintenance checks , IS purchased. In SUCh cases, an engine tune-up will be needed outside of the regutar maintenance Intervals. The lirst step in any tune -up or diagnostic procedure to help correct a poor running engine is a cylinder compression check. A compression check (see Chapter 2 ) Wil l help determine the condition 01 Internal engine components and should be used as a gUide lor tune -up and repair proce dures. If. lor Instance. a compression check indicates serious internal engine wear. a conventional tune-up Will not Improve the perlormance of the engine and wou ld be a waste of time and money. Because of ItS importance . lhe compression check should be done by someone With Ihe flghl eqUipment and the knowledge to use It properly. The follOWing procedures are those most often needed to bnng as gen erally poor running engine back Into a proper state of tune.
1 -13
Engine oil 2 Engine oil IS checked With a dipstick. which IS located on the side 01 the engme (refer to the underhood Illustrations at the front of thiS Chapter for dipstick locations). The dipstick extends through a melal tube down InIO the oil pan. 3 The engme 011 should bechecked before the vehicle has been dnven. or about IS mmutes after the engine has been shutoff. II the oil is cheeked Immediately alter drivmg the vehicle . some of the oil will remain In the upper part of the engine. resulting in an inaccurate reading on the dipstick. 4 Pull the dipstick out 01 the tube and wipe all 01 the 011 away Irom the end With a clean rag or paper towel. Insert the clean dipstick all the way back into the tube and pull It out agam. Note the oil at the end 01 the dipstick. At its highest pomt. the all should be above the ADD mark. m the SAFE range (see illustration).
1 MAINTAIN OIL IN
-SAFE-
@laUARTd
DO NOT ADD OIL
RANGE~ ~F':L~~D
~ll
3.4
Minor tune-up Clean. Inspect and test the ballery (see Section 15) Check all engine related flUids (see SecMn 3). Check and adjust the dflvebelts (see Section 14) Replace the spark plugs (see SectIOn 30) Inspect the distnbutor cap and rotor (see Section 31 ) Inspect the spark plug and coi l wires (see Section 31) Check and adlust the idle speed (see Section 33) Check the PCV valve (see Seclion 18) Check the air tilter (see Seclion 16) Check the cooling system (see SecMn 21 ) Check all underhood hoses (see Section t 3)
Major tune-up All items listed under mmor tune-up. plus _ Check the EGR system (see Chapter 6) Check the Ignition system (see Chapter 5) Check the charging system (see Chapter 5) Check the fuel system (see Chapter 4 ) Rep lace the distributor cap and rotor (see Section 31) Replace the spark plug w ires (see Seelion 31 )
The engine oilleyel should be in the SAFE range - 11 It's below the ADD line, add enough 011 to bring the level Into the SAFE range (DO NOT add more all if the level is at the FULL line)
5
II lakes one quart 01 01110 raise Ihe level from Ihe ADD marX to the FULLor MAX markon the dipstick. Do nOI allowlhe level to drop below the ADD mark oroil starvation may cause engine damage. Conversely. overfilling the engme (adding oil above the FULL or MAX marX) may cause oil fouled spark plugs. oil leaks or 011 seal failures . 6 To add oil, remove the filler cap located on the valve cover (see the illustrations at the front 01thiS Chapter) . After adding oil. wait a lew minutes to allow the level to stabilize. then pull the dipstick out and check the level agam . Add more oil II required . Install the filler cap and lighten il by hand only. 7 Checking the 011 level IS an Important preventive maintenance step. A consistently low oil level indicates oil leakage through damaged seals. defective gaskets or past worn rings orvalve guides. The condit ion of the 011 should also be noted. If the oil looks milky in color or has water droplets in it .the cylinder head gasket(s) may be blown or the head(s) or block may be cracked . The engine should be repaired immediately. Whenever you check theoillevel, slide yourlhumband index finger up Ihe dipstick before wlpmg off the all. If you see small dirt or melal particles clinging to the dipstick. the oil should be changed (see Section 10) .
Engine coo/ant 3
Fluid level checks
Refer to Illustrations 3.4. 3.9. 3. 16a, 3 16b, 3.17. 3.23a and 3.23b.
Nole: The followmg are lIU1d level checks to be done on a 250 mile or weekly basis. Addi/ionailluid level checks can be found in specific maintenance procedures which follow Regardless of mtervals . he alert to flUid leaks under the vehicle which would Indicate a taullto be corrected Immediately
I FlUids arean essen\lal part 01 the lubrication. cooling. brake and wmd shield washer systems. Because the lIuids gradually become depleted al"ldJorcontammaled dUring normal operation of the vehicle . they must be periodically replenished . See Recommended lubricants and flUids at the beginning of th is ChapTer before adding flUid ~o any of the following components. Nole: The vehicle must be on level ground when fluid levels are checked.
Warning: Do nol allow antifreeze to come in contacl wllh your skin or painted surfaces 01 the vehicle _ Flush contammated areas immediately With plenty of water. Do not store new coolant or leave old coolant Iymg around where it's accessible 10 children or pelS - they are anracted by ilS sweet taste IngestIOn of even a small amount of COOlant can be fatall Wipe up garage floor and drip pan coolant spi/ls. Keep antifreeze containers covered and repair leaks in your coolmg system Immediately.
e
All vehicles covered by Ihis manual are equipped wilh a pressurized coolant recovery syslem. A white plastic coolant reservoir located at the front of the engine compartment IS connected by a hose to the radlatorfiller neck. If the engine overheats, coolant escapes through a valve in the radiator cap and travels through the hose into the reservoir. As the engine cools . the coolant is automalically drawn back into the cooling system to maintain the correct level. 9 The coolant level in the reservolfshould be checked regularly. WarnIng: Do not remove the radiator cap to check the coolant level when the
1 -14
Chapter 1 Tune·up and routine maintenance COVEPPETAIN EFl
T YPIC AL CO OLANT RE COVER Y RESERVOIR
C OVER
3.9
Coolant reservoir marks
N
M'"''''''"'''
3.16a Prying loose the reta iner on 1he masler cylinder cover (early models) Checking the brake fluid level (earl y models)
engme IS warm' The level In the reservol' vanes with the rempera/ure of the engme . When the engme IS cold, the coo/am level should be at or slightly above the COLO FULL mark on the reservoir. Once the engme has warmed up, the level should be al or near the FULL HOT mark (see illustration). If 1/ Isn"l. a/low the engme to cool. then remove the cap from the reservoir and add a 50/50 mo(/ure of ethylene glycol-based anllfreeze and waler 10 Drive the vehicle and recheck the coolant level. Don'\ use rust mhlbltors or additives. II only a small amount 01 coolant is required to bring the system up 10 the proper level , water can be used, However, repeated addi tions of water Will dilute Ihe antllreeze and water solul ion. I n order to main tam the proper rallO 01 antifreeze and water, always top up the coo lant level with the correct mixture. An empty plasllc milk jug or bleach bottle makes an excellent container lor miXing coolant. II li the coolant level drops consistently, there may be a leak m Ihe system. Inspect the radiator. hoses, filler cap, drain plugs and water pump (see Section 21 ). II no leaks are noted. have the radia tor cap pressure lested by a service staMn. t2 II you have to remove the radiator cap, walt unlll the engme has cooled completely, then wrapa thick ctoth around the cap and turn lito the first stop. If coolant or steam escapes. let the engine cool down longer, then remove the cap 13 Checkthecondltionolthecoolantas well . It should be relallvelyclear 1111's brown or rust colored. the system should be drained, flushed and refilled. Even ilthe coolant appears to be normal, the corrosion inhibitors wear out. so It must be replaced at the specified in tervals.
check the level in both reservoir compartments . It should be 1141nch below the top edgeof the reservOir. Top up the level. II necessary, With the recommended brake IIUld. but do not overfill 17 On t 987 and later models. the brake lIuld level IS checked by looking through the translucent plastic reservOir mounted on the master cylinder. The lIuld level should be between the MAX and MIN lines on the reservolf (see illu stration ). If the HUld level IS low, wipe the top of the reservolf and Ihe cap with aclean rag 10 prevenl contamination of the system as the cap IS unscrewed. Top up the level With the recommended brake fluid , but do not overfill. 18 Wh ile the reservoir cap IS off, check the clutch or brake IIUld for conlamlnallon . If rust depo.slts, dirt particles orwater droplets are present. the system should be drained and ref illed by a dealer service department or repair shop 19 Afte r filling (he reservOir to the proper level, make sure the cap IS seated to preven t fluid leakage andlor contamination. On 1979 through 1986 models, make sure the rubber diaphragm inSide the brake lIuld reservOir cover IS seated properly 20 The flUid level In the brake master cylinder Will dropsllghtly as the diSC brake pads wear. A very low level may indicate worn brake pads_Check for wear (see Section 25). 21 If the brake fluid level drops cons istently, check the en\lre system for leaks Immediately. Examme brake hnes, hoses and conneClions, along w ith the calipers , wheel cylinders and master c~hnder (see Section 25).
Brake and clutch fluid Warnin g: Brake flwd can harm your eyes and damage paimed surfaces. so use extreme caution when handling or pounng I/. Do nOI use brake flUid thaI has been standing open or is more than one year old. Brake flwd absorbs mOisture from the alT, whICh can cause a dangerous loss of brake effectIVeness. Use only the SpeCified type of brake flU/d. Mmng different types (such as DOT 3 or4 and DOT S) can cause brake failure. 14 The brake master cylrnder IS mounted at the left (driver's Side) rear corner of the engine compartment. The clutch fluid reservoir (used on some later models With manuallransmlSSlonsj is mounted adjacent to It. 15 To check the clutch fluid level. observe the level through the translu cent reservOir. The level should be at or near the step molded into the reservOir. II !he level IS low. remove the reservoir cap to add the specified flUid . 16 On 19791hrough 1986 models, the brake lIuid level is checked by removmg the master cylinder cover. Clean the area around the master cylindersodlrl doesn't fall inlothe brake lIuid. Pry back the cover relainerw ith a screwdriver (see illustration ). lilt off the cover (see illustration) and
3.17
Brake fluid reservoi r (Ialer models)
Chapter 1 Tune-up and routine maintenance
_____
1 -15
RESERVO I R~
Cb
-_ ~~
BATTERY
"-
FRONT OF VE HICLE
\ 3.238
3.23b
Typical windshield washer reservoirs (early models)
Windshield washer reservoi r (later models)
22 When checking the flUid level, I!YOU discover cnecr both reservoirs to be empty or nearly empty, the brake or clutch release system should be checked for leaks (see Section 25) and bled (see Chapters 8 and 9)
Windshield washer fluid 23 FlUid for the Windshield washer system IS stored In a plastiC reservoir in Ihe engine compartment. On early models, the windshield washer reservoir IS combined With Ihe coolant reservOir (there are separa te compart · ments lor Ihe two different flUids ), On later models, the wmdshleld washer reservoir IS mounted inSide tile lender. and ItShfter neck protrudes ttlrough a hole in the lendellnto the engine compartment (see illustrations) 24 In milder climates, plain wate r can be used In the reservolf, bu t It should be kept no more than 213 fuft to aftow lor e~panslon II the water freezes . In colder climates. use Windshield washer system antifreeze , a~allable at any auto parts store. to lower the freezing point of the IIUld This comes in concentrated or pre · ml~ed torm. It you purchase concentrated antifreeze, ml~ Ihe antifreeze With water In accordance With the mallufacturer's directions on the container. Caution: Do not use cootmg system antifreeze -It will damage the vehicle 's paml
4
Power steering Uuid level c heck
4.5
Once the engine is properly warmed up and the wheel has been turned back-and-forth a lew times to rid the system 01 bubbles, pull the dipstick out and wipe It ott, reinsert it and verily the power sleerlng fluid level is in Ihe FULL HOT range (be sure to use Ihe proper range ; o ne side is for checking Ihe fluid cold) - if it Isn' t, add enough fluid to bring Ihe level between the two lines
Refer to illustration 4.5 Check the power steell ng lIU1d level penodlcaily to aVOid steeling sys· tern problems , such as damage to the pump Caution : DO NOT hold the steermg wheel agamSI el/her slop (ex/reme left or fight turn) for more than (Ive seconds. If you do. the power sleermg pump could be damaged. 2 The power steering pump. located at the left fronlcornerof the engine on all models. IS equipped With a twist·off cap With an integral flU id level dipstick 3 Park the vehicle on level ground and apply the parking brake. 4 Run the engine unti l It has reached normal operating temperature With Ihe engine al Idle , turn the steenng wheel back-and-forth several times to get any air out of the steering system. Shutthe engine 011, remove thecapby tUfnlng Itcounterclockwlse. wipe the dipstick clean and reinstall the cap (make sure It IS seated). 5 Removethe cap again and notethellUld level . It must be between the two lines deSignating the FULL HOT range (see illustration) (be sure to use the proper temperature range on the dipstick when checking the fluid level-Ihe FULL COLD lines on the reverse side of the dipstick are only usable when the engine IS cold ).
6
If necessary. add small amounts of fluid until the level is correct Caulion : Do nol overfill the pump. If/oo mucfll/Uldis added. remove the ex· cess With a clean syringe or suction pump. 7 Check the power steering hoses and connections fOf leaks and wear (see Section 13) . 8 Check the condition and tenSion olthe powersteering pumpdrivebelt (see Section 14) .
5
Manual transmission lubricant level check and change
Refer /0 Illustralion 5. / Note: The transmission lubrlcant/evel and quality should not deteriorate under normal dnvlng condi//Ons. Howel/er. Irs recommended thaI you check the level occasionally. The mosl convementtlme would be when the vehicle IS raised for another reason, such as an engme 011 change.
1
Chapter 1
1 -16
Tune-up and routine maintenance FILL PLUG
CHIECKtFlU PLUG
5.1 The manual transmission lubricant
checklflll plug is localed on the right side ollhe
..... ,,""
100 NOT 1lEMQV!; TO CHEat
transm ission case (wh ich Is the p8!1Senger's side ollhe vehicle) - a 3lS-inch drive ratchet or breaker bar will fit Inlo the square hole to unscrew Ihe plug
7. 2
Remove Ihe lin plug
lUIIIIOCAHT LEVEll)
1 The transmiSSion has a check/hI! plug which mus! be removed to checklhelubncanllevel (see illustration) Warning: Thecheck. fl/lpJugls the upper one - 00 NOT remove the drain plug by mistake' Also. some early models have a reverS6 for#( pivot boll moun/ad on the side of Ihe IransmlSSIOfl near tile checkAil1 plug DO NOT remove Ihe pivot bolt' If the vehICle IS falsed /0 gam access /0 Ihe plug, be sure /0 support 1/ safely on ,acks/ands - DO NOT crawl under a vehicle which IS supported only by a iaCkI 2 Remove the plug Irom the transmission and use your 1,"le fi nger to reach inSide the hoUSing and feel the lubricant level. It should be at or very near the botlom 01 the plug hole 3 tlltlSll't. acid the recommended (ubncantthrough the plug hole With a syringe ()( squeeze bollie 4 tnslatl and tighten Ihe plug securely and check lor leaks alter the lusl tew miles 01 dnving. 5 ManualtransmiSSlon lubricant does nol normally need changing during Ihe life 01 the vehicle. bul il you Wish 10 do so. place a drain pan benealh the drain plug. Remove thechecktlill plug. then remove Ihe drain plug and letlne lubricant drain Into a pan. Let it drain lor to minutes or more. Ihen reinslallthe dl"atn plug and lighten 11 securely 6 Fililhe transmiSSIOn 10 the botlom 01 the hiler plug hole wllh recom · mended h..Ibncanl 7 Install and lighten the check/fill plug securely and check for leaks aller the hrSllew miles 01 driVing
6
Automatic tran sm Ission lIuid level check
The automatic transmiSSion fluid level should be carefully main· talned Low lIU1d level can lead to slipping or loss 01 drive. while overfilling can cause foaming and loss 01 flUid Either condition can cause transmlS' Slon d amage. 2 Since transmiSSion iluf(! expands as II healS up, the flUid level should only be checked when the tranSmiSSiOn IS warm (at normal operating tem · perature). If the vehICle has iust been dnven over 20 miles (32 km) . Ihe IransmlsslOf'l can be considered warm Caution : II/he vehICle has JUs/ been dnven for a long lime al htgh speed Of In CI/y /rafflC. 10 hoI weather. Of If It has been put/lOg a trailer, an accurate liVId level readIng cannot be ob tamed A/low the transmiSSIOn tocoo/down for about 30 mmutes YOt: ~an also check IhetransmlSSlonlluid level when the transmiSSion IS cold lithe vehicle has nOI been driven for over five hours and the flUid IS about room temperature (70 10 95·degrees F). the transmission is cold However. the fluid level IS normally checJ<.ed With Ihe transmiSSion warm to ensu re accu· rate results . 3 Immedlatelyafterdnvlflg Ihe vehICle . park Il ona level surface. set the parking brake and starllhe engine. While the engine IS Idling. depress the brake pedal and move the selector lever through all the gear ranges. begmning and ending in Park 4 l ocal e the automatic transmission dipstick tube 10 the engine com-
parlment (see Ihe Illustrations al Ihe Ironl of thiS Chapter for dipstick loea· lion). S With the engine slll1ldhng pull the dlps\ock away Irom the lube. Wipe It 011 with a clean rag push It all the way back InlO Ihe lube and Withdraw II again. Ihen nole the !Iuld level 6 If the transmiSSion Iscold.the level should be In the room temperature range on the dlps\lck (between the two cucles); If 11 swarm. Ihe Iluid level should be In the operaling temperalure range (between the twO lines) If the level IS low, add Ihe specified automatic transmiSSion IIUld through Ihe dipstick tube - use a clean funnel to prevent Spills 7 Add Just enough at the recommended lIuld 10 hllthe transm,sSlon to the proper level "takes about one pIOtto raise the level from the lower 11(18 to the upper I.ne when Ihe flUid IS hoI. so add the lIuld a little at a time and keep checking the level unlJllt s correct 8 The condit ion olthe flUid should also be checked along With the level. If the flUid IS a dark reddlsh·brown color. or If II smells burned. 1\ should be changed (see Sectlon't 2). If you are," doubt aboui li sconditlon , purchase some new Iluid and compare the two lor color and smell
7
Oillerenli at (tear axle) lubricant level c heck and change
Refer 10 II/us/rallons 72 7.9 and 712 t The dllferen\lal has a fill plug which mUSI be lemoved to check the lu· bflcanllevel It the vehicle IS raised to gam access 10 the plug be sure 10 support It safely on Jackstands - DO NOT crawl under the vehICle when liS supported only by the lack l 2 Remove the hll plug Irom the dli1erenl!8l (see illu stration ) 3 Use your little "ngel as a dlpshck 10 make sUle Ihe lubncanl levelrs even With Ihe bottom 01 the plug hole 11 not. use a syflnge to add the rec· ommended lubllcanl unllill Just starts 10 run out of the opening On some models a tag Is loca ted In the area of the plug which gives Inlormatlon reo gardlng lubricant type . pa rt icu larly on models eqUipped With a limi ted slip differential 4 InSlalilhe plug and tighten It securely 5 11 It IS necessary to change the dilleren\lallubrlcan\. remove the fill plug (see illustration 7.2) Ihen drain the dlfferen\laJ Some dJilerenhals can be drained by removing the dram plug while on others II s necessary 10 remove Ihe cover plate on the dli1eren\la1 hoUSing As an alterna\lve. a hand suction pump can be used to remove the dlfferenllal lubncant through the /111 plug hole. It there IS no drain plug and a suction pump Isn't aVailable , obtain a lube 01Silicone sealant to be used when reinstalling me dlferentlal cover 6 Raise the vehICle and support It securely on Jackstands Move a drain pan. rags . newspapers and Ihe tools you Will need under the vehIcle "eqUIPped With a dram plug, remove the plug and allow the dlffelen7 tlallubncanllo drain completely. Alter II has dramed. Install the plug and tighten II securely 8 It a sUC\lon pumplS being used. Insert thefle~lble hose Work the hose
1-17
Chapter 1 Tune-up and routine maintenance
1v ,,~~, " ' 0 ,~ " A, L.'.M •• ~ " "uS' ••
.e.
......" .~ .0, .",~ .~S., ,~, . ~ • • , ". A'" " aT''''' T SU" , Of ~o us' ~ G . ~ O '"" Q' 0"
Q' "
"
C. "~" ~,,, u$T"
7.9
With the differential cover retained by two loosened bolls althe top, carefully pry it loose and allow the lubricanllo drain
7.12 Apply a bead 01 RTV sealant 10 the differential housing just before inslallation
available at auto parts stores and
service stations and cost very little
down to the bonom of the dlNerenlial housing and pump the oiToul. 9 If the ditlerenlialls being drained by removing the cover plale. remove all of the bolts e~cept the two near the lop. Loosen the remaining two bo lt s and use them to keep the cover loosely attached (see illustration). Allow the lubricant to drain Into the pan . then completely remove the cover. 10 Using a lin1-iree rag . clean the Inside of the cover and the accessible areas of the differential housing. As this IS done. check for chipped gears and metal particles In the iutlrlcanl, Indicating that-the differential should be more Ihoroughly Inspected andlor repaired . 11 Clean all old gasket malerial trom the cover and differential housing. t 2 Apply a bead of sealant to the hOUSing mating surlace. Run Ihe bead inside the housing bolt holes (see illustration). 13 Place the cover on the differential hOUSing and install the bolls. Tight· en the bolts securely In a criss-cross pattern. Don·1 overtighten them or the cover may be distorted and leaks may develop. 14 On all models, use a hand pump, syringe. squeeze bottle or funnel to lillthe dlfferen\lal hOUSing with the speCified lubricant until it's level with the bottom of the plug hole . 15 Install the fill plug and tighten It securely
Condition
8.2 A tire tread depth Indicator should be used 10 monitor tire wear -they're
8
nre and lire pressure checkS
Refer to ,"us/rations B.2. B.3. B.4a. B.4o and B.B 1 Penodic inspection of the tires may save you the inconvenience of beIng stranded with a flat tire. It can also provide you with vital inlormallon regarding possible problems in the steering and suspenSion systems be· lore major damage occurs. 2 Tires are eqUipped wilh 112-inch wide bands that Will appear when tread depth reaches illS-Inch. bulthey don', appear untillhe lires are worn oul. Tread wear can be mOOilored with a simple. Ine~pensivedevice known as a tread depth indicator (see lIIuslration). 3 Note any abnormal lire wear (see lIIustratlon). Tread panern Irregularities such as cupping, lIat spots and more wear on one Side than the other are Indications of Iront end alignment andlor balance problems. II any 01 these conditions are noted, take the vehicle to a tire shop or service statfon to correct the problem. 4 Look closely for cuts, punctures and embedded nails or lacks. Sometimes a tire will hold air pressure lor a short lime or leak down very slowly
, .--.. --, .-.--
_-
p",to.bM
~u_
eorr.ctln .etlon
Condition
. (I>0
• H_d_"II
• I.aCI< 01 I0Il.11001
od!UOII_..
P",babIe
cau_
. -~
C-.cth • .etlon
• AdjuoI-."
• RopoI,,,, L
~IICO
. ~-
-.-
Too .. _
. -... II
.-
--D"._ -----. -
."""'.-
ptONU ..
. " 1i'I<:OrIOoeIea..,_
. L
• ~-io:Jno
• R.pooI, '" ~
• u_ _ _
' 101..-",
~
• 0"...,1·,0I>'Id
• T_",
Ol..act"'""...,.,
0_,,_
u"..,.,,_
8.3
This chart wilt help you determine the condition of your tires, the probable cause(s) of abnormal wear and the correcllve action necessary
1-18
Chapter 1 Tune-up and routine maintenance
8.4a If a tire loses air on a steady basis, check the valve core Ilrst to make sure it's snug (special Inexpensive wrenche s are commonly available at auto parts stores) alter a nail has embedded Itself In the tfead 11 a slow leak pe rsists, check the valve slemcore to make sure 11 is ttght (see Illustration). Exsmlnelhe tread lor an object that may have embeddeclltsell in the tlfe or for a "plug" that may have begun 10 leak (radial tire punClures ate repaired wllh a plug thai IS Installed In Ihepuncl ure). 11 a punc1ure ISSUspecled, llean be easdy
verilled by sp!'aylng a solution of soapy water onto the puncture (see IIlustt8110n) The soapy solution WIll bubble ilthers 15 a leak. Unless the punctUfe IS unusually large, a lire shop or service sl atlon can usually repair the tire 5 Carelully inspect Ihe Inner sidewall 01 each lire lor evi dence 01 brake Iluid leakage. II you see any, inspectl he brakes Immediately. 6 Correct air pressure adds miles to the hfespan 01 the tires. Improves mileage and enhances overall nde quahty, Tire pressure cannot be accu rately estimated by looking at a tire, especially II it's a radial. A lire pressure gauge IS essenllal. Keep an accurale gauge In the glove compartment The pressure gauges attached 10 the nozzles 01 air hoses algas Sl allons are olten Inaccurate 7 Atwayscheck tire pressure when the Ilres are cold. Cold. In Ihls case, means Ina vehicle has not been dnven over a mile In the th ree hours preceding a tire pressure check, A pressure flse 01 Ioor 10 eighl pounds is not uncommon once the tires are warm. S Unscrew Ihe valve ca p protruding from the wheel or hubcap and push the gauge hrmly onto the valve stem (see illustration), Note the reading on the gauge and compa re the figure to th e recommended tire pressure shown In your owner's manual Of on the lire placard on Ihe passengefs side door or door pillar Be sure 10 reinslallthe valve cap 10 keep din and
8.4b
IIlhe valve core Is l ight, raise the corner of the vehic le with
Ihe low lire and spray a soapy water solution onlo the tread as the Ure is rotaled - slow leaks will cause small bubbles to appear mOIStureoul 01 the valve stem mechanism. Check all lour tires and, If nec· essary, add enough air to bring Ihem to the recommended pressure 9 Don l lorgel to keep the spare lire Inllated \0 the specllled pressure (reler 10 yoor owne(s manual Of the placard attached to the door pillar). Nole thai the pressure recommended tor temporary (mini) spare Ilr95 IS hlOher Ihan lor the 'Ires on the vehICle
9
TIre r otation
Refer to If/ustra tion 9.2 , The !Ires should be rolaled at Ihe specilled intervals and whenever uneven wear IS noticed Smce the vehICle ... 111 be raised and the tires checked anyway. che<;k the brakes also (see Section 25). 2 Radial IIres must be rOlated In a specific pattern (see illustration)
fRONT
fRONT
I
I
I
I
IXI
• WHEEL ROTATION
I
Vel 5 WHEEL
ROTATION
IIAS·PL V Tilles
fRONT
I
I
IJl
• WHEEL ROTATION
5 WHEEL
ROTATION
"ADIAL TillES
8,8 To extend the life 01 the tires, check the air pressure at least once a week with an accurate gauge (don 't lorgel the sparel)
9,2
TIre rotation diagram
1 -19
Chapter 1 Tune-up and routine maintenance
IN-UNE SIX CYUNDER ENGINE
-\<:,,:::"-((~J _
FRONT
~Z:.
CYUNDER EN GINE
ORAl"
PlUGS
10.2 The se too ls are required when chi'lnging the engine oil and filter Drain p an - II should be fairly shallow in depth. but wide /0 prevent Spills 2 Rubber gloves - When removing the drain plug and filler. you Will get all an your hands (rhe gloves will prevent bums) 3 B reaker bar - Sometimes the oil drain plug is /lgh/ and a /ong breaker bar IS needed to loosen it 4 Socket - To be used with the breaker bar or a ratchet (mus t be the correct Size to fit the drain plug - six-point preferred) 5 Filter wrench - This is a metal band-type wrench. which requires clearance around the filler to be effectIVe 6 Filter wrench - ThiS type fits on the bottom of the filter and can be turned With a ratchet or breaker bar (different size wrenches are available for dIfferent types of fillers)
3
Aeferto the Inlormallon In jacking and towing a t the front of this manu· al for the proper procedure to follow when raising the vehicle and changing a tire . II the brakes must be checked . don't apply the parking brake as stated. 4 The vehicle must be raised on a hOist or supported on jackstands to get all four !Ires off the ground. Make sure the vehicle is safely supported! S A!terthe rotallon procedure IS limshed. check and adjusl the lire pres sures as necessary and be sure to check the lug nut lightness.
10
Engine oil and IiIter ch ange
Refer 10 If/uslrallons to.2. 10.7. 10. 12 and to. 16 Frequent all c hanges are the most important preventive maintenance procedures that can be done by the home mechanic. As engine oil ages, it becomes diluted and cof1lamlnated. which leads to premature engine wear. 2 Make sure that you have all the necessary tools before you begin this
NOTE - ALL V-B EOUIP1"EO VEHICLES HAVE A DOUBLE PlUG OIL PAN WITH PLUGS MOUNTED FRONT AND REAR ILEFT SIDE) V·6 ENGINE HAS ONLY ONE PlUG.
10.7
ENGINE OIL LEVEL OlpsnCK
Engine 011 pan drain pfug locations
procedure (see illustration). You shoukf also have plenty of rags or news· papers handy for mopPing up oil spills. 3 Access to the oil drain plug and tilter will be improved it the vehicle can be li fted on a hoist, driven on to ramps or supported by jackstands. WarnIng: Do nol work under a vehicle supported only by a bumper. hydraulic or sClssors·type jack - always use jackstandsl 4 If you haven't changed the oil on this vehicle before, gel under it and locate the drain plug (both drain plugs on engines) and the oil filler. The exhaust components will be warm as you work , so note how they are routed to avoid touching them when you are under the vehicle . S Start the engine and allow it to reach normal operating temperature oil and sludge w ill flow more easily when warm . If new oil, a tilter or lools are needed, use the vehicle to go getlhem and warm up the engine oil at the same time. Park on a level surface and shut off the engine when it's warmed up. Remove the oil filler cap Irom the rocker arm cover. S Raise the vehicle and support it on jackSlands. Make sure it is safely suppo rt edl 7 Being careful nOI to touch the hot exhaust components , poshion a drain pan under the plug in the bottom of the engine (see illustration). Clean the area around the plug (both plugs on VB engines), then remove the plug{s). II's a good idea to wear a rubber glove while unscrewing the plug the final few turns to avoid being scalded by hot oil. It will also help to hold the drain plug against the threads as you unscrew it. then put! it away from the drain hole sud denly, This wit! place your arm OUI of the way of the hot oil. as w ell as reducing the chances at dropping the drain plug inlO the drain pan. It may be necessary to move the drain pan slighlly as oil flow slows to a a trickle. Inspec! the old oil lor the presence of metal particles. 9 After all the all has drained, wipe off the drain plug(s) with aclean rag . Any small metal particles clinging to the plug would immediately contaminate the new 011.
va
1
Chapter 1 Tune-up and routine maintenance
1 - 20
10.12
Removing the olllllier
10 RelnSlail1tle plug(s) and tighten securely. but don't strip the threads " Move the drain pan in to poSition under the 011 hiler. 12 loosen the oil lilter by lurnu'9 It counterclockwise with a filter wren.ch (see Illustration ). Any standard litter wrench Will wor!<.. 13 Sometimes the oil filter is screwed on so tightly that 11 can', be loosened If It is. punch a metal bar or long screwdriver directly through It. as close to the engine as possible. and use II as a T-bar to turn the filler Be prepared lor 01110 spurt out althe canister as irs punctured. 14 Once the Mer IS loose, use your hands to unscrew IIlrom the block Just as the filter IS detached from the block. Immediately till the open end up to prevent Otllnslde the litter Irom spilling out 15 USing a dean rag . Wipe 0" the mounting surface on the block. Also . make sure Ihal none of the old gaskel remains Sluck 10 Ihe mounting sur lace It can be removed with a scraper II necessary 16 Compare Ihe old liller with Ihe new one to make sure they are Ihe same Iype. Smear some engine 011 on the rubber gasket of the new filter and screw It Into place (see Illustration), OvMlghtening the IIlter Will damage the gasket. so don't use a IIlter wrench. Most IIlter manufacturers recommend tightening the filter by hand only Normally. they should be tightened 314-lUrn after the gasket contacts the block. bul be sure to follow the directions on the filter or container 17 Remove all tools and matenals Irom under the vehICle. being careful nollo Spitlthe oit In the drain pan. then lower the vehicle 18 Add new 01110 the engine through the all htter cap In the rocker arm cover Use a lunnetto prevent 011 from Spilling onto the top 01 the engine Pour four quarts ollresh all IntO the engine Walt a few minutes to allow the all to drain into the pan. then check the level on the dipstICk (see Section 311 necessary), II the oil level IS In the SAFE range. install the filler cap 19 Start the engine and run it lor abOut a minute. Check the 011 pressure gauge or Indicator light to make sure the engine develops normal oil pressure. While the engine is running. look under the vehicle and check for leaks at the oil pan drain plug and around the oililiter. It either one IS leak· Ing. stop the engine and tighten the plug or IiIter sllghlly 20 Walt a lew minutes. then recheck the level on the dipstick. Add 011 as necessary to bWlQ the level into the SAFE range 21 Dunng the lirsl few tnps after an oil change. make II a potnt 10 c~ Irequenlly lor leaks and proper 011 level 22 The old 011 drained Irom the engine cannOt be reused In lis present slate and should be discarded Od rectama\lon centers. auto repair shops and gas stations Will normally accept Ihe 011. which can be recycled Alter Ihe oil has COOled. il can be drained inlo a conlalner (plastiC lugs . benles, milk cartons. elc.) for transport to a disposal sile.
10. 16
11
Lubricate the all IIlter gasket with clean engine all belore Installing the IlIIet on the engi ne
Chassis lubrication
Refer to ,lIustrat,ons II. I. 112a. 112b. 11.9 and II 14 Reter to Recommended tubllcan ts and IIUlds at the front of thiS chap· lerto obtalO the necessary grease. etc You'll also need agreasegun (see illustratIon). OccaSionally plugs Will be installed rather than grease iiilings If so. grease filllOgs Will have 10 be purchased and installed 2 Look under the vetucle and see II grease Iltllngs or plugs are IOslatted 10 the tie-rod ends and batljolOts (see l1Iustration s) II there are plugs. remove them and buy grease IIl1lOgS. whICh wllllhread Into the component A dealer or aula parts slore WIll be able 10 supply the correct hllings SlralQhl. as well as angled. fittings are avallabte 3 For easier access under Ihe vehicle. false It With a lack and place jackstands under the frame Make sure the vehicle IS salely supported - DO NOT crawl under the vehicle when It IS supponed only by Ihe jackl II the wheels afe to be removed at thiS IO teNal lor tire rolallon or brake IOSpeC' lion, loosen the lug nuts slightly wh ile the vehicle IS stili on the ground
Chapter 1 Tune-up and routine maintenance TtE ROD ENOS
1 - 21 TIE ROO ENDS
.... LUBRICATION POINT 1'.2a
11 .1
The lie-rod ends should be lubricated unlit the rubber seal Is firm
Materials required for chassis and &ody lubrication
Engine oil- Light engme all In a can like this can be used for door and hood hinges 2 Graph ite spray - Used /0 lubn'cale lock cylinders 3 Grease - Grease. In a vanery of types and weights, is available for use in a grease gun Check the Specifications for your reqUirements 4 Grease gun - A common grease gun. shown here with a detachable hose and nozzle. IS needed for chassIs Ivbriea/lon. After use, clean 1/ thoroughly!
1l.2b
12
II ptugs are Installed (arrow), they must be removed and grease littlngs musl be threaded into the holes
Automatic transmission fluid and litter change
In proper working order.
12 The key lock cylinders can be lubricated with spray graphite or Silicone lubricant. which IS available at auto parls stores. 13 Lubricate the door weatherstrippmg with SIlicone spray, This Will reduce chafing and relard wear 14 lubrrcate the parking brake linkage (see illustration) Note that two different types of lubricant are required . Use multipurpose grease on the linkage. adjuster assembly and connectors: use speedometer cable lubricant on parts of the cable that touch other parts of the vehicle. lubricate Ihe cable twice: once With the parking brake set and once With it released .
Refer to ilfus/rations 12.9and 12. 12 Caution : The use of transmission fluid other than the type listed in the Specifications could result in transmission malfunctions or failure. 1 At the speci fied Intervals, the transmission fluid shoukl be drained and replaced . Since the fluid will remain hot long after driving , perform thiS procedure only after the engine has cooled down completely. 2 Before beginning work, purchase the specified transmiSSion flUid (see Recommended lubricants and fluids al the front of this Chapter). a new filler and gasket. Never reuse the old filter or gasket l
8ALL JOINT COVER
~~~)f~\ ~NEW OK
.
. . . LUBRICATION POINT
PAAKING BRAKE CABLE
WORN IF FLUSH OR 8ELOW SURFACE OF COVER
CHECKING SURFACE
11 .9
Replace the balliaints ilthe grease fitUng hex is lIush with or below the cover surface
11 .14
Lubricate the parking brake linkage at the indicated points
1 - 22
Chapter 1 Tune-up and routine maintenance
12.9 With Ihe rear bolts loosened and holding It In place, lower Ihe Iront at Ihe transmission pan and allow the fluid to drain
3
Other lools necessary lor this job Include jackstands to support Ihe
vehicle in a falsed position, a large. shallow drain pan capable 01holding al least eight pints, newspapers and clean rags.
4
Raise the vehicle and support il securely on jackstands. DO NOT
crawl under Ihe vehicle when it is supported only by a jack! 5 Place Ihe drain pan beneath Ihe transmission. S On pan-tilled C4 and C5 transmissions, disconnect the lIuid filler tube from Ihe pan to drain the transmission lIuid. 7 On all other models, with the drain pan in place, remove the mounting bolts from the front and sides of Ihe transmission pan. S Loosen the rear pan bolts approximately four turns, Let the pan ha[lg down so the fluid can drain, 9 Carefully pry the transmission pan loose with a screwdriver, allowing the fluid todrain (see Illustration), Oon't damage the pan or transmission gasket sul1aces or leaks could develop, 10 Remove the remaining bolls, pan and gasket. Carefully clean Ihe gasket surlace of the IransmiSSlon to remove alilraces of the old gasket and sealant. 11 Drarnthe lIuld from the transmiSSion pan, clean It with solven t and dry it With compressed air (if available), 12 Remove the filter from the mount inside the transmission (see iIIustra\lon), 13 Install a new filler and gasket. Tighten the mounting OO1t(s) securely, 14 Make sure Ihe gasket sul1ace on the transmission pan is clean, then Install a new gasket. Put Ihe pan in place against the transmission and instailthe bolts, Working around the pan, tighten each bolt a little at a time until a final torque is reached, Don't overtighten the bolts! On pan -hlled models, re-connect the filler tube to the pan, t5 Lower the vehkle and add automatic transmission flUid through the filler tube (see Section 7), Caution: Refer to Specifications at the front of this Chapter for the COffect amount and type of transmission flUid. Use of the wrong type or the wrong amount can cause transmission damage. 16 With the transmission in Paril. and the paril.rng brake set, run the en gme at a last idle. but don't race It. 17 Move the gear selector through each range and back to Park. Check the fluid level. Add fluid if needed to reach the correct level. 18 Check under the vehicle for leaks during the lirst few trips.
12.12
The automatic transmission filter is held In place with small boll(s)
General High temperatures under the hood can cause detenorallon of the rubber and plastiC hoses used l or engme, accessory and emission systems operation. Perrodic Inspection should be made for cracks, loose clamps, matenal hardening and leaks. 2 Inlormallon speCific 10 the cooling system can be found In Section 21 . 3 Most (but not all) hoses are secured to the finrng With clamps Where clamps are used, check to be sure they haven't lOS! thelrtension. allOWing the hose to leak If clamps aren 't used. make sure Ihe hose has not expanded and lor hardened where il slips over the fitting , allowrng 11\0 leak.
PCV system hose 4 To reduce hydrocarbon emiSSions. crankcase blow-by gas IS vented Ihrough the PCV valve to the Intake manifold via a rubber hose on most models. The blow-by gases miX With Incoming air In the intake manifold before being burned in the combustion chambers. 5 Check the PCV hose for cracks. leaks and olherdamage. Disconnect It from the rocker arm cover and the intake manrfold and check the Inside for obstructions. If it's clogged, clean It out With solvent
Vacuum hoses 6
II's quite common for vacuum hoses. espeCially those In Ihe emis Sions system, to be color coded or Identified by colored stnpes molded IOta them. Vanous systems require hoses With dlfferenl wall thicknesses. collapse resistance and temperature resistance When replaCing hoses, be sure the new ones are made 01 the same matenaL 7 Often the only effective way to check a hose IS 10 remove Itcompletely from the vehicle. If more than one hose IS removed . be sure to label the hoses and fillings to ensure correcllnstallation. 8 When checking vacuum hoses, be sure to Include any plastiC T-fltlings in the check. Inspect the fittings for cracks and the hose where It fits over each fitt ing lor distortion, which could cause leakage 9 A small piece of vacuum hose (1 14-inch inSide diameter) can be used as a stethoscope to detect vacuum leaks. Hold one endof the hose to your ear and probe around vacuum hoses and linings, listening for the "hiss mgsound characteristic of a vacuum leak. Warning: When probmg wl/h the vacuum hose stelhoscope, be careful nOlto come into contact With mov109 engme components such as drlVebells. the coolmg fan, etc.
Fuel hoses 13
Underhood hose check and replacement
Caution: Replacement of alf conditionmg hoses must be teft to a dealer service deparrment or air conditioning shop thaI has the equipment to depressurize the system safely. Never remove air conditiomng hoses or components until the system has been depressurized.
Warning: Gasolme is extremely flammable. so take extra precautions when you work on any parrof the fuel system Oon't smoke or al!owopen flames or bare light bulbs near the work area, and don 't work in a garage where a nalUral gas-type appliance (such as a warer heater or clothes dryer) With a pilot light is present. If you spill any fuel on your skin, rmse il off immediately with soap and water When you perform any kind of work on
Chapter 1 Tune-up and routine maintenance OUAL RESERVOIR BRAKE MASTER CYLINDER
1 - 23
HYDRAULIC PRESSURE CONTROL VALVE POWER BRAKE
BOOSTER
13.16 Brake lines should be checked for cracks, loose
REAR DRUM BRAKE LINING AND SHOE ASSEMBLY
linings and leaks
BRAKE
1
LINES
FRONT OISC BRAKE CALIPER DISC BRAKE SHOE AND LINING ASSEMBLY
the fuel tank. wear safety glasses and have a Class B type firee X/ingUlsh-
14
Drlvebelt check, adjustment and replacement
eran hand. 10 The fuel lines are usually under pressure, so il any fue l lines are \0 be disconnecl edoe prepared to catch spilled fuel. Warning: If your vehicle is
Refer to Illus/rations 14.2a. 14.20, 14.2c, 14.2d. 14.20, 14.3, 14.4, 14.5. 14.6, 14.7a, 14.70. 14.7c. 14.11 and 14.17
eqUipped with fuel inJection. you must relieve Ihe fuel system pressure be· lore serviCing Ihe luellines. Refena Chapter 4/0( the fuel system pressure
The accessory drivebelts are located at the front of the engine. The belt s drive the water pump. alternator. powersteering pump, aircondilloning compressor and Thermactor air pump. The condition and tens ion 01 the drivebelts are critical to the operation of the engine and accessories. Excessive tension causes bearing wear. while insulficient tension produces slippage. noise. component vibration and belt failure. Because 01 !heir composition and the high stress to which they are subjected. drive· belts stretch and continue to deteriorate as they get older. As a result. they must be penodically checked. Some belt s reqUire periodiC tension adjustmen t: others have au tomatic tensloners and require no adjustment lor the lil e of the bell.
relief procedure. • 11 Check all rubber fuel lines for deterioration and chafing. Check espe· cially for cracks in areas where the hose bends and just before 1illlngs, such as where a hose attaches to the fuel pump, fuel filter and carburetor or fuellnjecllon unit. 12 High quality fuel line, usually identified by the word Fluoroelastomer printed on the hose. should be used for fuel line replacement. Never. under any circumstances. use unrelnforced vacuum line. clear plastic tubing or water hose for fuel hnes t3 Spnng·type clamps are commonty used on fuel lines. These clamps often lose their lens Ion over a period of time, and can be "sprung " dUring removal Replace all sprlng·lype clamps With screw clamps whenever a hose IS replaced.
Check 2 The number and type olbelts used on a panicularvehicle depends on the engine, model year and accessories ins talled (see illustrations).
Meta/lines Refer fa Illustration 13.16
14 Sections of metal line are often used lor luelline belween the fuel pump and carbure tor or luel Injecllon system. Check carefully to make sure the line Isn't bent. Crimped or cracked. 15 If a section of metal l uel line must be replaced, use seamless steel tubing only, Since copper and aluminum tubing do not have the strength necessary to Withstand the vibration caused by the engine. 16 Check the metal brake lines where they enter the master cylinder and pressure control valve (i l used) lor cracks In the lines and loose fill ings (see illustration). Any sign 01 brake fluid leakage calls for an immediate tMrough Inspection of the brake system.
Nylon fue/lines 17 Nylon fuel lines are used at several POin ts in luellnjeclion systems. These lines require speCial materials and methods for repair. ReIer to Chapter 4 lor de tails.
Power steering hoses 18 Check the power steering hoses lor leaks, loose connections and worn clamps. Tighten loose conneClions Worn clamps or leaky hoses should be rep laced.
14.2a
Drlvebelts (later va engines)
Chapter 1 Tune-up and routine maintenance
1 - 24
"'vC T
.ow ... UR ..... OR MOUN' (WITHOUT O'OWtR 'HH ,NO " ' - I
.. " "•• LHR .... OA MOUN, .... 0 O'OW~A
---
PEe'A • • "nRUCTlONS
40 ..... " .,M CO .. O'TlOIo' .... . . IT.A'OATO.,R ........
LOW MOUN' .. ,M . , , -
.ELT
(WITHOUT " 'R CONOI,'OOI,NC I
14.2b
Dri ve belts (early four-cylinder engines)
14.2c
Orlvebelts (later lour-cylinder engines)
Chapter 1 Tune-up and routine maintenance
. , Ll ROV" .... _. ,. '''lOR
1 - 25
".,cy
l
I
1 14.2d
Drivebells (3.el V6 engines)
~I
'"
n.
''I """,0,, •• ,
,"
""A~'£1
NOTE SPR ING TANG MUST DE '10
BRACHT HOLE 'R.oR TO 8. DUR'NG ,.1.01 TlGHTEN'NG ASSEMO l v O F H"SooN E R TO ..au .. T I"G 8R .. C~ET
8 . l1 ROUT'"G IIS DNlV
14.2e
Drivebelts (early VB engines)
a
SMALL CRACKS
~~.
i~', 14.3
3
DIHerent types 01 drillebells are used to power the various accessories mounled on the engine
Various types of drivebelts are used on these models (see illustra-
tion ). Some components are driven by V -belts. of either smooth or cogged deSign. Others are driven by V'flbbed belts. 3.al V6 and va engmes. as well as later/our·cyllnder engines. use a single V-fibbed belt todnve most or all of the accessones. ThiS IS known as a ' serpentlne" bell because of thewinding path it l ollows between vanous dnve. accessory and idler pulleys
GLAZED
GREASE
I~
"wm ' "''' 1i00i unden,dIt 0 1 !M bt>i! .
14 .4 Here are some 01 the more common problems associated with drivebelts (check the belts very caretully to prevent an untimely breakdown) 4 With the engine oN, open the hood and local e the dnvebalt(s) al the front 01 the engme. With a flashlight. ched<. each bait lor separation of the rubber plies from each side of the core, a severed core. separation of the nbs Irom the rubber, cracks , lorn or worn nbs and cracks in the inner ridges of the nbs. Alsocheck for fraymg and glazing. which gives the bel! a Shiny appearance (see Illustration). Cracks m the fib side of V-ribbed baits are acceptable. as are small chunks missing from the ribs. II a V-ribbed bait
1 - 26
Chapter 1 Tune·up and routine maintenance BELT TENSION GAUGE
-'I \
RULER _ _
STRAIGHT EDGE
MAKE SURE RULER IS PERPENDICULAR TO STRAIG HT EDGE
14.5 A drivebeU :enslon gauge is recommended for checking Ihe belts (the unit iUuslrated Is a Burroughs model -follow the manufacturer's Instructions
has losl chunks bigger Ihan 112-i nch (13 mm) from two adjacent ribs. or it the miSSing chunks cause belt noise. the bell should be replaced. Both SKies of each bell should be Inspected, which means you'll have to twist them \0 check the underSides. Use your fingers to feel a belt where you can ', see It . If any ollhe above condit ions are evident. replace the belt as descnbed below 5 To check the tension of V-belts and fixed (manually adjusted - used on earlier models) serpentine belts In accordance With factory recommendations. install a dflvebelt tension gauge (special tool No. T63L-8620-A) (see illustration). Measure the tension In accordance with the tenSion gauge instructions and compare your measurement to the speci fied drivebeltlension for either a used or a new belt. Note: A "new" beltrsdefmedas any belt which has nOI been run: a "used" bell is one that has been run for more than ten mmutes 6 The special gauge is the most accurate way to check the tension of V-belts and manually adjusted serpentine belts. However. if 'Iou don't have a gauge, and cannot borrow one. the following "rule of thumb" method IS recommended as an alternative (lor smooth and cogged V-belts only .do not use thiS method on V- ribbed beits). Lay a straigh tedge across the longest free span (the distance between two pulleys) of the belt Push down firm ly on th e belt at a POint half way be tween the pulleys and see how mUCh the belt moves {deflects}. Measure the dellectlon with a ruler (see illustration) The belt should deflect 118 to t l 4-lnch If the distance from pulley center-to-pulley center IS less than 12lnches: it should deflect from 118 to 318-lnch If the distance from pulley center -la-pulley center is over 12 inches 7 Later models With V-fibbed belts use au tomatic tensioners and wear Indicators (see illustrations). lithe Indicators show that the serpen\lne bell IS worn beyond the maximum. the bell should be replaced .
14.6
Measuring drivebell deflection with a straightedge and ruler
lug which IS designed to accept an open end wrench . which can be used to pry the accessory. Caution : If If'S necessary to pry against an accessory 10 lighten a drlvebell. be very carefuf nOlto damage the accessory or the pomt the prybar resls agamst 12 Hold the accessory in poSition and check the belt tenSion. If It'S COtrec\, tighten the two bolts until snug, then recheck the lenSlon. I! It'S alright. tighten the two bolts completely 13 ToadjuSllhe serpenttne belton 3.8L V6eng lnes, loosen the Idlerlock109 bolts and tighten the adjustment bolt (see illustration 14_2c) 14 Wh en lenSlon is cor rect. tighten the Idler locking bolts
Replacement 15 To rep lace a V-be lt or the serpenllne bell on 3.8L engines. tollow the above procedures for dnvebelt adjustment but loosen the belt untit it Will slip 011 the pulleys, then remove lIOn some models. it may be necessary 10 remove lorward belts 10 replace a rear belt_ Stnce belts tend to wear out althe same time. It'S a good Idea to replace ail of them at the same time. Mark each bell and the corresponding pulley grooves so the belt can be reinstalled properly. 16 To replace a serpentine belt on later four-cylinder engines 1979 through 1984 V8 engines. pry the tensloner away from the belt (see illustration 14.2b or 14.2d) Hold the lensionerin place and slip the belt all the pulleys. I! the tens loner IS removed and disassembled. be sure the spnng tang engages the hole in the tens ioner bracket dunng reassembly. 17 Hold Ihe tenSloner away trom the belt. Install a new belt and make sure It is routed co rrectly (see Illustration 14.2b or 14.2d). Be sure the
Adjustment 8 AdJustment Is necessary on smooth and cogged V-belts. as well as the serpentine belt on 1983\hrough 1986 3.8L V6 engines. All other engines, including V8 and later model four-cylinder engines. use V-nbbed belts which are adjusted by automatic tensloners. Manual adJustment IS not required for these models 9 To adjust V-belts. move the belt·driven accessory on the bracket. 10 For each accessory. there will be a locking bolt and a pivot bolt or nut. Both must be loosened slightly to enable you to move Ihe component II After the two bolts have been loosened, move the component away from the engine (to tighten the belt) or toward the engine (to loosen the belt). Many accessories are eqUipped With a square hole deSigned to ac· cepta 112-lnch square dnve breakerbar( see illustration). The bar can be used to leverthe componen t and tension the drivebelt . Others have acast
I
WEAR -INDICATOR
11 II
[
14_7a
'---=
Drive belt wear Indicators (earlv four"cyllnder engines with V-ribbed belts)
Chapter 1
Tune-up and routine maintenance
1 - 27
MINIMUM BELT
"'''" """'".",.
BELT LENGTH INDICATOR
'-...t
I
~ ~
MINUI..IU BELT I.E N'H..
1 PERCENT BELT STRETCH ItoIDICATOAREPLACe BELT
use SOU TO LIfT TEMSIONER TO RElEASE BELT TENSION
~~~~~~~ I~TOA
USE BOLT TO LIFT TE. . . , . . "
~
TO REL£ASE BELT TENSION AUTOMA
14.7b
V
nc 8ti.T TENIK:ItoIEfI ALTVlNATOf'IIClCI!
Drlvebell wear Indicators (Ialer lour-cyllnder englnes with V-ribbed belts)
BELT LfHGTH INDICATOR
......
1 PERCENT BELT STR£TCH
INOICATOR-
""'-"'" em
use BOlT TO LIFT TENSIONEJ'I TO RELEASE BELT TENSION
14.11 On some models . 'I2-lnch drive breaker bar can be used to tension the Ale compressor drtvebell as the bolla
a re lightened
14.7c
Orlvebelt wear indicator (later
va engines)
em
}:";h'~ """" """"'"'
'''.17 V-ribbed drivebelts should be centered on the pulleys, noloffset
ribs of the new belt engage the pulley ribs correctly (see illustration). Release the lensioner once the bell is installed. 1B To replace a serpenboe belt on 1985 and later va engines, rolale the lenslonerwlth a breaker bar and socket (see iIlustralion 14.2e). Hold the lensioner away from the belt and slip the bell off the pulleys. II the tension· er Is removed and disassembled, be sure the locating pin engages The hole in The bracket during reassembly. 19 Hold the tensioner away from the belt. inSlal1 a new bell and release the tensloner 15
Battery cheek and maintenance
Refer to illustrations 15. 1, IS.8a, IS.8b, IS.Be and 15.8<1
Warning : Certain precautions must be followed when cheddng and servo ICing the battery Hydrogen gas, whICh IS highly llammable, is always pres. enlln the battery cells. so keep hghted tobacco and all other flames and sparli.s away from ft. The electrolyte Inside the battery is actuallyd,iu/e sui· furic aCid. which will cause injury If splashed on your skin orin your eyes. II will also rum clothes and painted surfaces. When removing the battery cables. always detach the negative cable first and hook it up last! Note: On models equipped Wllh the Dlslributorless (DIS) Ignition System, some precaullOns must be taken afterdisconnectmg and reconnecting the battery cable(s) . See Battery - removal and Installa rion in ChapterS, Sec· /Ion 2.
1- 28
Chapter 1 Tune-up and routine maintenance
IS.8a
Battery term lnat corro si on usually appe ars as light . lIuffy powder
15.1 Tools aod malerials required lor battery maintenance
Face shleldlufety goggles - When removmg corrosion With a brush. the acidic partICles can easily fly up Into your eyes
2
J 4
5
Baking soda - A solullon of bakmg soda and waler can be used /0 neutralize corrOSion Petroleum jelly - A layer of thIs on Ihe ballery posts WIll help prevent corroSion Battery post/cable cleaner - ThiS wife brush cleamng tool WIll remove all traces of corroSion from the battery posts and cable clamps
Treated felt washers - Placmg one of Ihese on each post.
directly under the cable clamps. wI/I help prevent corrOSion 6 Puller - Sometimes the cable clamps are very ddl/cul/lo pull off the posts. even after the nul bolt has been complelely loosened. ThiS 1001 pulls Ihe clamp stral{}h/ up and off the post WIthout damage 7 Battery posVcable c leaner - Here IS another cleamng tool which IS a slightly different verSIOn 01 number 4 800ve. but 1/ does the same thing 8 RubbM g loves - Ano/her safely Ilem 10 consider when servICIng lhe ballery: remember Ihals aCId mslde the barteryl
Battery maintenance IS an Imponanl procedure whoeh Will help ensure Ihal you are nOI Slranded because 0 1 a dead baHery Severallools ale re· qUlred lor Ihls procedure (see Illustration ) 2 BefOle servICing Ihe battery. always lurn Ihe engine and all accesso· nes all and dlsconlleC1 the cable from the negative terminal ollhe battery 3 A sealed (sometimes called maintenance lree) battery is Slandard eqUipment on t980 and laler models. The cell caps cannot be (emoved no electrolyte checks are /eqUifed and waler cannol be added to the cells However. II an ahermarKel battery has been Installed and It IS a Iype Ihal requires regular maintenance, the follOWing procedures can be used. 4 Check Ihe electrolyte level In each of the battery cells. It must be abOve the plates. There's usually a spllt-nng indICator In each cell 10 Indlcatethecorr9Ct level. II the level IS low. add distilled waleronly. Ihen Install the cell caps. Caullon : Overflllmg the cells may cause electrolyte to Spill over dunng penods of heavy charging. caUSing corroSIOfI and damage to nearby components.
1S.8b Rem oving the cable h o m a bal1 ery pos t wi th a wrenc h some1 1mes a special bal1 ery plier s is req uired lor this procedure il corrosion has caused deterioralion 01 the nut hex (alw ays remove the ground cable fit st and hook II up last!) 5 If the poSitive termmal and cable clamp on your vehic le's battery IS equipped Wi th a rubber protector make sure that 115 not tOln Of damaged It should completely cover the terminal 6 The external COnditiOn 01 the battery should be checked penodlcally Look fOI damage such as a cracked case 7 Check the tightness of the battery cable clamps 10 ensure good elec, trlcal connecllons and Inspect the enlile length at each cabte . looking lor Clacked 01 abraded IOsulatlon and tlayed conductors 8 II corroSion (vIsible as whlte_ lIuHy deposits I IS eVident remove the cables Irom Ihe terminals, clean Ihem wllh a battery brush and relnStaU them (see illustrations) Corrosion can be kept to a minimum by InslalllOg specialty trealed washelS available at aulo parts stores 01 by applying a layer 01 petroleum Jelly or grease to the termmals and cable clamps alter they are assembled 9 Make sure Ihat the battery carner IS In good condl tJon and that the hold-down clamp bolt is lighl It Ihe batt ery is removed tsee Chaptel 5 lor the removal and IOstallalion procedurel. make sure that no pans remamln the bottom of the carner when liS relnsmlled When reinstalling the hold· down clamp. don t ovenlgh ten Ihe bolt 10 CorrOSion on the camer. battery case and surrounding areas can be removed With a solutIOn at waler and baking soda Apply Ihe ml.ture With a small brush, let It work, then "nse It ott With plenty 01 clean water 1t Any metal pans 01 the vehicle damaged by corrOSion should be coated With a zinc-based pI/mer, Ihen painted 12 Additional m'ormallon on the battery. chalglng and Jump slanmg can be lound In Chapter 5 and the Iront ollhls manual
Chapter 1 Tune·up and routine maintenance
1 - 29
1 IS.8e
Regardless of Ihe type: of loot used on the ballery posts, a clean, shiny surface should be Ihe result
lS.8d When cleaning the cable clamps, all corrosion must be removed (the Inside 01 the clamp Is tapered to match the taper on the post, so don't remove 100 much material)
16.2 On carbureted and eFt models, remo ve Ihe air cleaner w ing nul ...
16
16.3
Air liIter replacement
.. , and lift out the lifter
EN GINE AIR INTAl(E RESONATOR "'SSEMBLY
Reier to Illustrations 16.2. 763 16.7, 16.13 and 16.19 Purchase a new flUer for your speclllC englll8 type 11 the vehICle IS eqUipped wllh Sequen\lal ElectrOniC Fuel In~llOn (later va engines), the fiHer IS Impregnated wl,h charcoal Be sure the replacement filter IS the
OOSCONHECT V"'CUUM HOst
same type
Carbureted and Central Fuel Injection (eFI) 2 Remove Ihe wing nul from Ihe top ollhe hOUSing and hit Ihe lop plate 011 (see illustrati on) :3 Remove the ,iller (see illustration) 4 Wipe Ihe inside 01100 alf cleaner hoUSing wl,h a clean cloth. S Place lhe new all hlter In the hOUSing lithe hlter IS marked TOP be sure the marked side faces up 6 Inslall the cover and wing nut Don'\ overtigh ten the nut I
un- .... R CLE... NER IolR CLEANER OUTLET TUBE
--"-'io/"lt?,>,
IlNGINE ... IR CU: ... NER INLET TU8E ... mMIllY
Four·cyfinder EFI non-turbo 7 Qlsconnecllhe vacuum hose and outlellube from the air cleaner cov er(see illustration) Remove the cover retaining screws and 11ft thecover oil 8 Remove the filter 9 Wipe the InSide 01 the air cleaner hOUSing with a clean cloth. to Ptace the new air htter In the hoUSing If the hlter IS marked TOP, be sure the marked Side laces up
~\"-.
'iROKTOF ~NGINE
" 16.7
Air cleaner assembly (four-cyllnder non-turbo models)
1-30
Chapter 1 Tune-up and routine maintenance fliES'" AlII
INLET TUBE
AIR CU A NEII TUBE ADAPTER
Hose CLAMP
...
VIEW l
HOSE C L AMP
fR ONT OF (NGINE
#>
AIR CLEANER
AlA CLE A NER OUTLET tu e E
A IR CLEANER BRACKET
16.13
Air cleaner assembly (lour-cylinder turbo models)
""'"""~ ~~
f'LHRRH" 'NE" ... .. C L£ .. NE .. SHEU I"H .I
(
Ut
IFT ., .';:'~';~,;;';O;L
-
, ~.
17.3 Crankcase ventlitler - 1979 through 1987 models, except four-cylinder non· turbo and 3.8L V6
16.19
11
Air cleaner assembly (Va models with SEFI)
Reinstall the cover and retaming screws. Dan" overtighten the
screws! 12 Raconnectlhe vacuum hose and outiet lube.
Four·cylinder EFI turbo 13 Detach the air cleaner lube adapter (see illustration ) 14 Remove the cover wing nul and grommet. lilt the cover oH . 15 Remove the IiIler. 16 Wipe the Inside of the air cleaner housing With a clean cloth. 17 Place the new air filter in the hOUSing. If the filter is marked TOP. be sure the marked side faces up 18 Reinstall the cover and wing nut Don't overtigh ten the wing nut I
VB engines with Sequential Electronic Fuel Injection (SEFI) 19 loosen the air cleaner outlet tube clamp (see Illustration). 20 Unfasten the cover clips and lift the cover at!. 21 lift out the fi lter. 22 Wipe the Inside of the air cleaner housing with a clean cloth . 23 Place the new air filter in the housing. If the filter IS marked TOP be sure the top Side faces up. 24 Reinstal l the cover and secure tlie clips. 25 Reconneclthe outlet hose to the air cleaner.
17
Crankcase venliliter replacement
Refer to Illustrations 17.3. 17. 9a. 17.9b and 17. 10 1 Obtain a new crankcase venlfilter for your specific engine
Chapter 1
Tune-up and routine maintenance
1 - 31
• ,eO "
PC V filTER --1"'-~
~ RONl
OF VEHICLE
1 LOWE ll CA."'~ C "Sl
v ENt HOSt
PCV VALVE
",u. ..
17.98
17.9b
Positive crankcase ventilation system (Iour-cyltnder non-turbo through 1987)
Positive crankcase ventllallon system (3.BL V6 engine)
Through 1987, four-cyllnder non-turbo snd 3.SL V6 engines Through 1987, a/l except four-cylinder non-turbo snd 3.8L V6 engines 2 Remove the alf cleaner top plate (see Section 16) 10 expose the crankcase venllilter. 3 Remove the IiIterfrom its pocIIelln the side of the air cleaner housing (see illustration). 4 Clean the filtElf pocket with a cloth or paper lowel moistened with solvent 5 Install the new filler 6 Install the air cleaner top plate (see Section 16) .
7
The 011 filler cap. filter and rube are replaced as an assembly
8 Disconnect the tube. 9 Unscrewlheoilliller cap from the valve cover (_Illustration s) and Install a new one.
1988 on (VB only) to Remove the PCV valve and grommet from the lower Intake manifold (see illustration). 11 Remove and discard the litter 12 Instan a new fitter. 13 Install the grommet and PCV valve.
1-32
Chapter 1
Tune-up and routine maintenance TO EVAI'ORATOR
VALVE
OIL FILLER
--
C'" AIR CL EANER CAR e. INT. MAN. ROCKER COVE R ENGINE CRANKCASE
• 18.1.
HOSES
/ -----'~~ "'v
PCV system (typical)
18.1b
AIfI THAOlTU
18.1c
18
~ VALVE PCV valve in rocker arm cover (typical)
KNOCK
SENSOR
PCV valva and hose. (Iour-c:yllnder engina) (1990 and 8arller m~.)
PCV valve check and replacement
Refer to Illus/rations IS. la, IS. lb, 18. 1cand IB. ld Nola: To maintain the efficiencyof lhe PCV system, clean the hoses and check the PCV valve al the intervals ffK:OrTlmended in the mamtenance schedule. For additional informatJOfl on the PeV system, fefor to Chap-
ler6. t Locale the PCV valve (see the accompanying illustrations and illustration 17.10). On lour-cylinder EFI engm8S, the air deaner assembly must be removed (see Chapter 4) 10 gain access to the PCV valve. 2 To check the valve, first pull it out 01 the grommet in the rocker arm cover or manilold, or out 01 the lower hose, Shake the valve. It should ranle, indicating that it is not clogged with deposils. II the valve does nOI rattle, replace it with a new one. If it does rattle , reinstall it. 3 Start the engine and allow it to idle, then disconnect the PCV hose (Iromtheaircleaneron most models). lIvactJum is felt, the PCVlvalvesyslem is working property (see Chapter 6 tor additional PCV syslem information). 4 II no vacuum IS telt, the oil tiller cap, hoses or rocker arm cover gasket may be leaking or the PCV valve may be bad. Check for vacuum leaks at the valve, filler cap and all hoses. 5 Pult straight up on the valve to remove it. Check the rubber grommet for cracks and distortion (on four-cylinder models, check the hose where the PCV valve seats). II it's damaged, replace it.
18.1d
PCV valve and hoses (four-cyllnder engine) (1991 and later models)
6 lithe valve is dogged, the hose ISalSO probably plugged. Removethe hose and clean tI with solvent. 7 After cleaning the hose. Inspect it for damage. wear and deterioration. Make sure (t lits snugly on the littlngs 8 If necessary, install a new PCV valve. Nole: The elbow (models so equipped) is not part of the PCV valve A new valve will not include the elbow. The original musl be transferredlo the new valve. /I a newellJowis purchased, it may be necessary fO soak if in warm waler forup 10 an hourto slip II onlo Ihe new valve . Do nol atrempllo force the elbo w onto the valve or il will break. 9 Inslall Ihe clean PCV system hose. Make sure the PCV valve and hose are secure.
19
Fuel syslem check
Warning: Gasoline is eXlremely flammable. so take eXfra pl9Cautiofls when you war/{ on any part of the fuel system. Don't smoke or a/lowopen flames or bare light bulbs near the WOr/{ area. and don', work in a QIJ(8f16 where ana/ural gas-type appliance (such as a waler healer or clothes dryer) with a pilo/light is pl8senl. If you spill any fuel on your skm, nnse It all
Chapter 1 FUEL
Tune-up and routine maintenance
FI~TER
1-33
FLEXIBLE
$IDEMEMIER
~ 8RAKfREL 20.28
Fuel pump snd IIUer
assemblv (earlier luel-lnJected models)
fLEX llILE HOSE
2O.2b
Details ollhe !uallUlar used on later luel.lnJected models - be sur. the arrow on the new IUter points In Ihe proper direction after the fllter Is Installed
20.98
Mounting details of. typical Inline fuel tllter
Imm9diarelywilh soap and wa/ef. When you perform any kind a/work on the fuel tank, wear safety glasses and have a Class B type fire8xUnguish-
, ••, " ... , ''''f ',a.,...,h Sla' >C.''''~
Bran hand. I If you smell gasoline while dnvlng or after the vehicle has been sinmg in the sun, mspec1 the !uel system immediately. 2 Remove the gas hiler cap and inspect it tor damage and corrosion. Thegaskel should have an unbroken sealing impnnl.ltthegaskel is dam-
aged or corroded, install a new cap. 3 Inspect the fuel feed and return lines lor cracks. Make sure that the connections between the luellines and the carburetOl' or fuel injection sys· tern and between the lueilines and the In· line fuel tiller are tight. Warning : vehicle isluel Injected. you must relieve the fuel system pressure ba· fore serviCing fuel system components. 11Ie fuel system pressure relref procedure is in Chapter 4. 4 Since some components 01 the luel system -the fuel tank and partol the luelleed and return lines, lor example - are underneath the vehicle, they can be inspected more easily with the vehicle raised on a hoiSt. " that's not possible, raise the vehicle and support it on jaCkstands. S With the vehicle raised and safely supported, inspect the gas tank and liller neck lor punctures, cracks or other damage. The connection between the filler neck and the tank is particularly critical. Sometimes a rubber filler neck will leak because 01 loose clamps or deteriorated rubber. Inspect all fuel tank mounting brackets and straps to be sure the tank is securely at· tached 10 the vehicle Warning : Do not, under any CIrcumstances, try 10 repair a fuel tank (except rubber components). A welding torch or any open flame can easily cause fuel vapors mslde the tank to explode. 6 Carefully check all rubber hoses and metal or nylon lines leading away trom the lueltank. Check tor loose connections. deteriorated hoses, aimped ~nes and other damage. Repair or replace damaged sections as I'IEICEIssary (see Chapt8f4).
'~vt.flD
' ~ .fT
,~c~ .." r,'."u'
"the
20
Fuel filter replacement
Wlrnlng : Gasoline IS extremely lIammable, so take extra precautIOns when you work on any part of the fuel system. Don~ smoke or allowopen flames or bare light bulbs near the work area, and don't work m a garage where a nalUral gas·type appliance (such as a water heater or clothes dry· er) with a pilot light IS present. ,( you spll any fuel on your skin, rinse It off immediately With soap and water When yoo perform any kInd of work on /he luellank. wear safety glasses and have a Class B type fire extingUish· erDn hand.
Fuel-Injected models Reier to illustrations 20.2a and 2O.2b 1 Obtainanewluel tiller before star1l11g. Warning : Besuretflenewlilter isS{J9CIficallydeslgned for theenglfle. FuellflfectlOfl system lilters are built /0 withs tand high pressure, and as a result. often cost more than lilters meant for use m carburered systems, Filters mean! for carbureted sys'
a .....
(S(
"Ie.t). "0'010
01\. '0 ''''- '~.(aO
a",
yO ~ . 0100<' O. ~'DOIaV'" HalaN'.,g ..,
'OC''''
'0'''' .... UD.
2O.9b On screw·ln fuel fittlH'. with an Inverted Hare Inlet fI"lng, apply a drop of thread sealant to the filter·to.carburetor thread.; apply motor 011 to the fueiline-to-Illler threads
stems may burst due to the htgh pressure. Also, be sure the new filter m· eludes replacement hairp;n clIps. Ford recommends against reusing the clIps. Warning: Before removing the fue/lilter, the fuel system pressure must be relieved (see Chapter 4). 2 Locale the tuellilter on the frame rail, near the fuel tank (see 11Iustr.tlons). Inspect the hose IlIlJOgs at both ends oltha filter to see Jlthey're clean. If more than a light coating 01 dust is present, clean the fittings be· lore proceeding. 3 Remove the hairpin clip from each fining. To do this. first spread the two clip legs apart about1 18·lllCh and detach the clip from the lining. 4 Once both hairpin clips are released, grasp the tuel hoses, one at a time, and pull them straight 011 the filter. S Note which way the arrow on the tilter is poinllng -the new lilter must be installed the same way. Loosen the damp 01' two bolts and detach the filter from the bracket. 6 Instaft the new filter in the bracket with the arrow pointing in the right dIrection. Tighten the clamp or bolts securely. 7 Carefufty push each hose onto the tilter until it's seated against the collar on Ihe titting, Ihen install the hairpin clips. The lriangular side 01 each cijp must point away from the filter. Make sure the clips ate securely al· tached to the hose fittings - if they come oll,the hoses could back 011 the lilter and a lire could resultl 8 Start the engine and check tor fuel leaks.
Carbureted models Refer to Illustrations 2O.9a, 2O.9b, 2O.9c and 2O,9d 9 Remove the air cJeanerhOUSlllg from the topolthecarburetorto gain access to the filler (see illustratIons).
Chapter 1 Tune-up and routine maintenance
1 - 34
2O.9c
Use new hose clamps when Installing a screw-In lilter will'! hose conneclion
20.9d
Replaceable element lueliliter (2700VV or 1200VV carburetor)
10 Place a rag under the filter, Ihen remove Ihe luel hne(s) from Ihe filter
On hose connections, squeeze Ihe clamps with phers and slide them up the hose On Inverted flare connections, unscrew Ihe luelline from Ihe filter while holding the hlter hex With a back-up wrench . A Ilare-nul wrench should be used it available -It Will prevent rounding olf the fuel line lining
he.
AL W AYS CHECI!; _
......... , ...
00 bu".«1 .......... ....... .... .. ....
..eI.
~ft."
_
. ... 11 , , .......
liOn models with an mline lilter, dISCard Ihe old lilter. Install a new filter Ihe line and secure it with clamps Spring-type clamps should be re-
In
placed with new ones 12 Illhevehlcle hasacarburelor-mounlad hiler, unscrew Ihe filte r orluel Inlet lining from Ihe carburelor. On models with a separate hlter element, remove the element and spring Irom the hOUSing in the carburetor body 13 If the vehicle has a screw-in lilterwlth an inverted flare-nut seat (illus, tratlon 20.90), apply a drop of Locllte hydraulic sealant No. 069 to the hltel threads 14 Screw the IIlter InlO the carburetor and 1\ lighten securely. On Holley 1946 carburetors, hold the luellnlet titling with a back-up wrench so the carburetor body Isn', damaged. 15 On models With a flare-nut luel hne connection, apply motor oil to the lIare·nut litllng threads. Thread the tlare nut Into the hlter. hold the hlter With a back-up wrench and tighten the lIare-nut securely. 16 On models With a fuel hose, slide new hose clamps down the metal iuelline. Install the tuel hose on the hlter and metal line, then position the hose clamps on the hose. 17 Reinstall the air cleaner hOUSing
$O f 1 ...... ,"" " •• u
OtIc! . ..... .... ,,, ... '"
SWO lLE~ "".. '" 0,1 ..... '" ..",.
.,...,. " " , "' _ ~_
'ft
..."....... ' ..I.... h _
con ......... " on '0 10<• •• <1 1<" _
0,1 ... ... _ ....
21
,ft.,,," IHI . " ...."OII
,. .,' "W'_.'"", C ... c.......'"ft.,. ,... cooh"" .,,,_
~
..
1><0 ... .
Cooling sy stem c heck
Refer /0 IIlus/raltOfl 2 1.4 Many major engine failures can be anflbuted to a faulty cooling system. If the vehicle IS eqUipped With an automatic transmiSSlon,the cooling system also plays an Important role in prolonging transmiSSion life because It cools the !luid. 2 The engine should be cold for the cooling system check, so pen orm the follOWing procedure before the vehicle is dnven for the day or alter It has been shut off for at leasl three hours 3 Remove the radialorcap and clean It thoroughly, InSide and out, With clean water Alsocleanthe liller necJ(, on the radiator. The presence of rust or corrOSion In the hiler neck means the COOlant should be changed (see SectIOf122). The coolant inSide the radiator shoold be relatIVely clean and transparent lilt's rust colored, drain the system and relitl With new coolant . CarelullychecklheradlatorhosesandsmaJlerdiameterheaterhoses 4 (see illu stra tion ). Inspec! each coolant hose along its entire length, re o placing any hose which IS cracked , swollen or deteriorated. Cracks Will show up better il the hose is squeezed. Pay close att ention 10 hose clamps
21 .4 Hoses, like drive bells, have a habit of falling at Ihe worst possible time - to prevenllhe Inconvenience of a blown radiator or heater hose, Inspect them carefullv as shown here
that secure the hoses to cooling system components, Hose ctamps can pmch and puncture hoses. resultmg)n coolant leaks. Make sUl e all hose connections are light. A leak In the cooling system 5 WIll usually shew up as white or rust-cololed depoSits on the alea adlOmlng the leak. If wife-type clamps are used on the hoses, it may be a good idea to replace them wrth screw·type clamps 6 Clean the Iront of tile radiator and air conditioning condenser WIth compressed air, If available. or a soft brush . Remove all bugs, leaves, etc. embedded In the radiator Iins. Be e:tlreme!y careful not to damage the cooling fins or cut your lingers on them
Chapter 1
Tune-up and routine maintenance
1 - 35
remove rust and scale from the engme and cooling tube surfaces. 9 These depoSits can be removed by the chemical actlOfl 01 a cleaner such as Ford Premium COOling System FlUSh. Follow the procedure outlined m the manufacturer's Instructions II the radiator IS severely COr' roded, damaged or leaking, II should be removed (see Chapter 3) and taken 10 a radiator repair shop. laThe healer core should be backflushed whenever the cooling system IS flushed , To do this, disconnect the heater return hose from the thermo· stat hOUSing or engine. Slide a female garden hose fitting IntO the heater hose and secure it with a clamp. ThiS Will allow you 10 attach a garden hose securely II Attach the end of a garden hose to the fttting you Installed m the healer
ho",
22.5
Four-cylinder engine block drain plug - V6 and VB
engines have a drain plug on each side ollhe block
12 Disconnect the heater inlet hose and po$l\lOtlll to act as a drain, 13 Turn the water on and 011 several times to creale a surgmg actIOn through the heater core. Then tum the water on luillorce and allow It to run for approximately five minutes 14 Turn 011 the water and disconnect the garden hose from the lemale f,"ing. Remove the fitting Irom the healer return hose, then reconnect the hoses 10 the engine. 15 Remove the overflow hose from the coolant recovery reservoIr. Dram Ihe reservolf and flush It With clean water, then reconnect the hose.
Refilling 16 Claseand Ughten the radiator drain. Install andtightentheblockdram
7 If 'he coolanllevel has been dropping conSlslenlly and no leaks are detectable, have Ihe radlalor cap and cooling system pressure checked al a servICe statIOn
22
Cooling system servicing (draining, flushing and relililng )
Refer /0 r/lus/ral/on 22 5 Warning : Do no/ allow anllfreeze /0 come In contact wIth your skm Of pillnted surlaces 01 the vehICle. Rmse Spills Immediately wllh plenty of
0"
waler An/!freeze IS hlf/hly 10xIC If Ingested Never leave anllfreeze Iymg around m an open contamer Of to puddles on the floo,_ chIldren and pelS
are attracted by 1/ S sweet smell and may drink 1/ Check WIth local au/hanlies about dlsposmg of used antIfreeze. Many commUni/les have co/Iee/1011 centers whICh WIll see thaI antifreeze IS disposed 0/ sa/ely I PenodlCally. the cooling system should be dramed. flushed and refilled to replenish the antifreeze mixture and prevent formallon of rust and corrOSion. which can Impair the performance 01 the cooling system and cause engme damage When the cooling system IS serviced, all hoses and the radialor cap should be checked and replaced If necessary.
Draining Apply the parkmg brake and block the wheels II the vehICle has just been drrven, walt several hours to allow the engme to cool down before beginning this procedure 3 Once the engille IS completely cool, remove the radiator cap. 4 Move a large Container under the radlalor to catch the coolant. Anach a JlB'lnch diameter hose to the dram fitting to direct the coolant mto the contamer, then open the dram IIttmg (a pair of phers may be reqUired to turn it). The drain littlng IS normally at the lower nght (passenger's Side) corner of the radiator 5 Alterthe coolant stops 1I0wmg out of the radiator, move the container under the engme block dram plug (see illustralfon) Remove the plug and allow t"e coolant m the block to dram 6 While the coolant IS draining, check Ihe condition 01 the radiator hoses, heater hoses and clamps (see SectIOn 2t If necessary). 7 Replace any damaged clamps or hoses (see Chapter 3 tor detailed replacement procedures). 2
Flushing 8 Once the system IS completely drained, ftush the radiator wllh fresh water from a garden hose until the water runs clear at the dram. The lIushiog action 01 the water Will remove sediments Irom the radiator bul will not
plug{s). 17 Place the heater temperature control in the maJClmum heat poSitIOn, 18 Slowly add new coolant (a 50150 mixture of water and anllfreeze) to the radiator until It IS futl. Add coolant to the reservoir upto the lower mark. 19 Leave the radiator cap 011 and run the engine in a well-ventilated area until the thermostat opens (coolant Will begin flowing through the radiator and the upper radiator hose Will become hot). 20 Turn the engme all and let it cool. Add more coolant mixture to bring the coolant level back up to the lip on the radiator filler neck. 21 Squeeze the upper radiator hose to expel air, then add more coolant mixture if necessary. Replace the radialor cap. 22 Start the englOe, allow ilto reach normal operating temperalure and check for leaks.
23
Exhaus t system check
With the engine cold (at least three hours after the vehicle has been driven). check the complete exhaust system from the engine to the end of the tailpipe, Ideally, Ihe inspection should be done With the vehicle on a holst to permit unrestricted access. If a hoist isn't available, raise the ve' hicle and support It securely on Jackstands. 2 Check the exhaust pipes and connections lor evidence of leaks, se. verecorroSlon and damage. Make sure that all braCkets and hangers are In good condllton and are tight. 3 At the same time, Inspect the underside of the body for holes, COHOStOn, open seams, etc. whICh may allow exhaust gases to enter the passenger compartment. Seal all body opentngs With SilICOne or body puny. 4 RaWes and other noises can ohen be traced 10 the exhaust system, especially the mounts and hangers. Try to move the PIpes, muffler and cat' alytlC converter. If the components can come in contact with the body or suspension parts, secure the exhaust system With new mounts. 5 Check the runningcondilion olthe engine by inspecting inside the end 01 the tailpipe The exhaust deposits here are an Indication of engme state. oHune. If the pipe is black and sooty or coated With white deposits, the engine may need a tUlle' up, Including a thorough luel system inspection and adjustment.
24
Steering and suspension check
ReIer to iIIus/ratlOns 24. 10 and 24. " Nota: The sleering linkage and suspension componenfs should be checked peflodically. Worn or damaged suspension and sleering linkage
1
1 - 36
Chapter 1 Tune-up and routine maintenance
24.11 To check the steering gear mounts and lie-rod connections for play, gras p each Itont tire like this and Iry to mo ve it back-sod -forth - if pl ay Is noted , check the steering gear mounts and make s ure Ihallhey're Ughl; II either tie-rod is worn or bent , repla ce it
24.10 To chec k Ihe sus pen si on ball jo in!s, try to mo ve the lower edge of each fronllire in-and-o ut whil e wat c hing/feeling for m ovement allhe lo p of the Ure and baliJoints
components can result In excessive and abnormal tire wear. poor fide quality and vehicle handlmg and reduced fuel economy For detailed illus trations of the steermg and suspension componenls. refer /0 Chapler 10.
Strut and shock absorber check Park the car on level ground. turn the engme off and set the parking brake. Check the tire pressures. 2 Push down at one corner 01 the vehicle. then release It while notlrlg the movement olthe body. It should stopmovlrlg and come to rest In a level poSition With one or two bounces. 3 II the vehicle continues to move up-and·down or illt falls to return to Its onglflal position. a worn or weak strut or shock absorber IS probably the reason . 4 Repeat the above check at each of the three remain ing corners of the vehicle. 5 Raise the vehicle and support It on Jackstands. 6 Check the shock absorber and struts for evidence of fluid leakage. A light him of flUid is no cause for concern. Make sure that any flUid noted IS from the shocks and not from any other source . lIleakage is noted. rep lace the struts or shocks as a set 7 Check the struts and shock absorbers to be sure that they are secure ly mounted and undamaged. Check the upper mounts for damage and wear. It damage or wear IS noted, replace the stru ts or shock absorbers as a set. II the struts or shock absorbers must be replaced , refer to Chapter 10 lor the procedure.
a
Steering and suspension check g Visually inspect the steering system components lor damage and distortion . Look for leaks and damaged seals. boots and httlflgs 10 Clean the lower end of the steering knuckle . Have an assistant grasp the lower edge of the \Ire and move the wheel in·and-out (see illustration) while you look for movement at the steering knuckle-to·control arm ballJOIrl!. II there is any movement or the wear Irld,cators are worn below the surtace( see Illustration 11 .9), the suspenSion balljolrlt must be replaced. 11 Grasp each front lire allhe fronl and rear edges. push In at the fronl. pull out at the rear and feef for play In Ihe steenng system componen ts (see illustration ). If any freeplay is noted, check the steering gear mounts and the \Ie-rod bal1lolflts lor looseness. If the steering gear mounts are loose, tighten them. It the tie·rods are loose, the balljoints may be worn (check to make sure the nuts are tight). Make sure the steenng gear rack and pinion boots are kept clean. Additional steering and suspension system illustrations can be found in Chapter to.
Front wheel bearing check 12 Reter to 5ec1ion 28 for the wheel beaflng check, repack and adjust· ment procedure.
25
Brake system ch eck
Refer to Illustrations 25. 7. 25 II . 25.15 and 25. 17 Note: In addition to the specified mteNa/s. the brake syslem should m· spected each time the wheels are removed or a malfunctlon;s Indicated. Because of the obVIOUS safety conSldera/ions . the followmg brake system checks are some of the most Important marntet1ance procedures you can perform on the vehicle.
Symptoms of brake system problems The diSC brakes have bUilt-In wear Indicators which should make a high-pitched squealing or scraping nOise when they·re worn to the reo placement point. Whim you hear thiS nOise. rep lace the pads immediately or expenSive damage to the rotors could resul t. 2 Any of the following symptoms cou ld indicate a potential brake sys· tem detect. The vehicle pulls to one Side when the brake pedal IS depressed. the brakes make squealing or dragging noises when appjled, brake travel IS excessive. the pedal pulsates and brake flUid leaks arB noted (usually on the inner side of the tire or wheel) . If any of these condi· lions are noted, Inspect the brake system Immediately.
Brake lines and hoses Note: Steeltubmg IS used throughout the brake system. With the exception of fleXible. remforced hoses althe front wheels and at connectors at the fear axle. Peflodlc mspectlon of these Imes IS very Important. 3 Park the vehicle on level ground and turn the engine off. 4 Removethe wheel covers. Loosen. but do not remove , the lug nuts on all four wheels. 5 Raise the vehicle and support It securely on jackstands. 6 Remove the wheels (see Jackmg and towmgatthe tront of thiS book, or refer to your owner·s manual. il necessary) . 7 Check all brake lines and hoses for cracks, challflg of the ou ter cover. leaks. blisters and distortion. Check the brake hoses at front and rear ot the vehicle lor softening, cracks. bulging. or wear Irom rubblflg on other components (see illustrati on). Check all threaded fittings lor leaks and make sure the brake hose mountlflg bolls and clips are secure. 8 If leaks or damage are discovered, they must be fixed Immediately. Reter to Chapter 9 for detailed brake system repair procedures.
Disc brakes 9 If It hasn· t already been done. raise the veh icle and support it securely on jackstands. Remove the front wheels (also remove the rear wheels on Mustang SVO). 10 Thediscbrakecalipers. which contain the pads. are now vIsible. Each cahper has an outer and an Inner pad - all pads should be checked.
Chapter 1 Tune·up and routine maintenance fLEXIBLE BRAKE _ _ _ _-,~;;::::
FLEXIB'. E BRAKE HOSE CHECK FOR SIGNS OF SOFTEN ING, CRACKING RUPTURE OR OTHER DAMAGE
HOSE
I
1 - 37
NON ·FLEXIBlE BRAK E LINE
Y CHECK FOR LEAKS
NON· FlUI8 LE BRAKE UNE FRONT WHEEL
REAR WHEEl
1 25 .7 The brake hoses at th e Iront and rear of the vehicle should be inspected and replaced 11 they show any defects
25.11 The lining thicknes s of the Iront disc brake pad (arrow) can be checked through the caliper Inspection hole
A
o
25.15 The rear brake shoe lining thickness (A) Is measured Irom the outer surface of the lining to Ihe metal shoe
11 NOle Ihe pad thickness by looking through the inspection hole In Ihe caliper (see IIlu51r8110n) It necessary. measure the thickness by placing a small ruler over the Inspection hole Compare your measurement with Ihls Chapter's SpeclllcallOns Keep In mmd Ihal the lining ma tenalls flV eted or bonded to a metal plate or shoe - the metal por1lOn IS not Included In thiS measurement t2 Check the cond illon of the brake diSC, Look for score marks. deep scratches and overheated areas (they Will appear blue or discolored). II damage or wear is noted. the diSC can be removed and resurfaced buy an automollve machine shop or replaced With a new one. ReIer to Chapter 9 lor more delalled Inspection and repair procedures
Drum brakes 13 Refer to Chaple, 9 and remove the rear bfake drums t4 Warn ing : Dustproducedbybmng wear anddeposi/edonbrakecom· ponents may contain asbestos. wllich IS hazardous to your health. DO NOT blow II out With compressed air and DO NOT mllale 1/ 1 DO NOT use gasolme or solvents to remove the dust Srake system cleaner should be used /0 /lusllthe dUSI 1010 a drain pan. After the brake components are Wiped wllh a damp rag. dispose of Ihe contaminated rag(s} and brake cleaner In a covered and labeled contamer Try to use non·asbes tos replacement parts whenever poSSible 15 NOle the thlcknessol l he linmg material on the rear brake shoes (see lIIuslralion) and look for signs of contamination by bf ake lIuld or grease II the ~nlng matenal ls wlthm I 16-mch 01the recessed nvelS or metal shoes. replace the brake shoes With new ones. The shoes should also be replaced II they are cracked. glazed (shiny lining surfaces), or contaminated With bfake lIuid or grease See Chapter 9 lor the replacement procedure t6 Check the Shoe return and hold-down spnngs and the adJusling mechanism to make sure they are Installed correclly and In good condl·
25.17 Carefully peel back the rubber bool on each end of the wheel cylinder - if the exposed area Is covered with brake fl uid, or II fluid runs out. the wheel cylinder must be overhauled or replaced
lion De teriorated or distorted spnngs, it rIOt replaced . could allow the linIngs to drag and wear prematurely. 17 Check the wheet cyHnders lor leakage by carelurty peering back the rubber boors (see illustration) Shghl moisture behind the bools IS ac· ceptable II brake lIuld IS noted behind Ihe boots or il lt runs 0i.J1 olrhe wheel cylinder. the wheel cyhnders musI be overhauled or replaced (see Chapter9) 18 Check the drums for cracks. score marks. deep scratches and hard spots. whK:h Will appear as small discolored areas . lfimperiectlonscannot be removed With emery cloth , the drums must be resurfaced by an auto· motive machine shop (see Chapter 9 tor more detailed mlormalion) . t9 Refer to Chapter 9 and install the brake drums. 20 InSl ali the wheels, but don·1 lower the vehicle yel
Parking brake Note : The parkmg brake cable and linkage should be penodlcally IUbrrcated (see Section I f). ThiS maintenance procedure helps prevent tile parinng brake cable adjUsler or the linkage Irom bmdlng and adversely a'fectmg Ihe operatloo or adjustment oflhe parking tKake. 21 The easiest, and perhaps most obvIOUS. method of checlung the parkIng brake IS to park the vehK:le on a steep hilt With the parking brake set and the transmiSSion in Neutral. If the par1\ing brake doesn·t prevent the vehicle from roiling. refe r to Chapter 9 and adlUStl\'
Chapter 1 Tune-up and routine maintenance
1-38
_ loIl lW .
' AI'I! KCVfIUV TO TOf' Of' TIJHN fL. " lACU
>+OUSI:";,":... - • "'(0'0 '8-12 I... Ln 'SHIIl ... "" - PRfIID21 - LIGH'
CIRCUIT
~ HOUSI'IG .. NO LEVER ASSE"'llV
10-2OfT· US 11'·11 N-", '
(NCAGE
'L""~'
.ru<
IN &L0Ta Of' ROD U FOfIIl ""'I.YI NG TOI'IOUE
r.:::::1
~
26.38
Shiflle.... er and linkage (lyplcal rod type)
• FAONT __
26
Automallc transmission shUt linkage lubrication
Refer to "'ustra/lOfIs 26.3a and 26.3b Raise the vehICle and support it securely on jackstands. locate the shift cable or rod contact points. 2 Clean the linkage and pivot points 3 lubncate the shift linkage and pivot points with multi-purpose grease
(see illustrations).
27
Clutch linkage lubrication and adjustmen t
ReIer to tI/us lratlOfls 27.3. 27.9 and 27. 11
Lubrication 00 vehICles WIth a cable-actuated clutch, the clutch linkage should be lubricated with the specilied grease whenever clutch movement becomes sluggish. DO NOT lubrICate the clutch cable lining! 2 Raise the vehicle and support It securely on jackstands. 3 Lubricate the linkage lrictlon points under the vehicle. on the trans miSSion bellhousing (see illustration). 4 Lower the vehicle and lubricate tha IrlCllon points at the top 01 the clutch pedal.
Manual adjustment 5 Clutch pedal hetght on 1979 and 1980 models requires manual ad· fUstment 6 Measure and make a note ollha lollowlng distances: 7 Steenngwheel nm-to-clutch pedal. measuring tothe flat 01 the pedal. oft to the side 01 the ribbed contact palch 8 Depress the clutch pedal to the floor and measure the distance between the steernlQ wheel rim and the clutch pedal
OF VEHI CLE
---
TRANSMISSION
-..--l ........~~ ~
L
CABLE
. . . LUBRICATION POINT
26.3b
Shift lever and linkage (typical cab le type )
9 SUbtract the two measurements (dimenSion X) (see illustrati on). The difference In measurementS Should be 6·112 In. If Irs not. adlust the clutch cable to Remove the dust shield covering the clutch cable-Io-transmlsslon belihouslllQ Junction. I I Loosen the cable locknut (see illu stration) 12 Adjust lhe cable by USing Ihe adjUSbng nullO lengthen or shorten lhe cable as required . I 3 Tighten the locknut. 14 Depress the clutch pedal to the lloor several IJmes and then recheck the pedallravel. Readjust as necessary t5 Reinstall the dust shield.
Chapter 1 Tune-up and routine maintenance
1 - 39
.
,", ~"_'."e'~'_..~~' :,~"
QUADRANT
CABLE
PIVOT BUSHING
IIIA.u:E PEDAl. SUPPORT
SCREW CLUTCH PEDAL
VIEWl
HAlA PIN CUP
VIEW)(
5.DL ENGINE ONLY
CABLE ASSEMBLY
/, ~~.../.n'.<\I .~> , ,
~ ClEVlS
RETAINER RING
CLEVIS PIN
S.CII.. AND L3t. HI E!+GINES
VIEW Z
VIEW'
l.ll. HI ENGINE ONLY
VIEWY
27.3
7,eu.
Lubricate the clulch linkage at the friction points on the transmission bellhouslng and above the pedal, in Ihe vehicle
"II.'~C_"L ,~o
CLU'C~
'N " . I f
.. OO!H'
.. O~,
_"'01'<
,,' c·
'" !TORQUE TO J · IO N '"
("
27.9 To measure clutch pedal height on 1979 and 1980 models, measure from lhe steering wheel rim to lhe clutch pedal (dimension A), Ihen depress Ihe pedal and measure again -the dillerence between Ihe two measurements (dimension X) 15 Ihe pedal height
Automatic adjustment 16 An automatlcadjus!Jng mechanism .sused 0/'11981 and later models
AI the Intervals spe'Clhed In the maintenance schedule the mechanism shoukl be operaled by fOOl
l '·H l AHER HOAl HEI GHT AOJUSTMENT
27.11 The clutch adjusting nut and locknut are located at the end 01 the cable, where II attaches to the transmissIon bellhousing (1979 and 1980 models)
17 Lift the clulCh pedal to the top 01 ItS tfallel wllh your loot. This shoukl take only about 10 Ib 01 effort. 18 Push the pedal all the way to the lloor, II a click IS heard. adjustment was necessary and has taken place
1
1 - 40
Chapter 1
Tune-up and routine maintenance 28
Front wheel bearing check, repack and adjustment
Refer /0 Iflus/rallons 2B.l. 283. 28. 7, 28.9, 28 15,28.16 and 28.23 In moslcases the Iront wheel bearings Wi ll not need servicing until the brake pads are changed. However. the bearings should be checked when· ever the Iront of Ihe veh icle IS raised lor any reason. Severaillems, Including a torque wrench and speCial grease, are required lor thiS procedure
(see illustration) 2 With the vehicle securely supported on jackstands, spin each wheel and check lor nOise, rolling resistance and Ireeplay. 3 Movethewheel in·and-Qul on the spindle (see Illustration) If there's any noticeable movement. Ihe bearings should be checked and then reo packed with grease or replaced If necessary Remove Ihe wheel. 5 Remove the brake caliper (see Chapler 9) and hang iI oul 01 the way on a piece 01 wire. Warning : DO NOT allow the brake caliper to hang by
4
the rubber hose l
6
28.1
I 2
3 4
S
6 7 8
Tools and materiats needed lor Iront wheel bearing maintenance
Hammer - A CCJmmon hammer Will do just fine Grease - High-temperature grease that IS formulated specially for front wheef bearmgs should be used Wood block - ff you have a scrap piece o( 2x4. It can be used 10 drive the new seal IOta the hub Needle-nose pf/ers - I)sed to straighten and remove the coller pm in the spmdle Torque wrench - Th,s IS very Important In this procedure; if the beaflng is to(} tight. the wheel won"t turn freely - II It S to(} loose. the wheel will "Wobble" on Ihe spmdle_ £lIher way. It could mean extensive damage Screwdrlver - Used 10 remove Ihe seal from the hub (a long screwdrIVer would be preferred) Socket/breaker bar - Needed to loosen the nut on the spmdle if !t's extremely tight Brush - Together With some clean solvent. thiS Will be used to remove old grease from the hub and spmdle
28.3 To check the wheel bearings, try to move the tire In-and-out - if any play is noted, or if the bearings feet rough or sound noIsy when the tire Is rotated , maintenance is required
Pry the grease cap out of the huh with a screwdflver or hammer and chisel 7 Straighten the bent ends of the cotler pin. then pull the cotler Pin outot the retaining nu t and spindle (s ee illustration) Discard the cotler pin and use a new one during reassembly 8 Remove the retaining nut. adJusling nut and Iial washer Irom Ihe end 01 Ihe spind le. 9 Puilthe hub assembly out slight ly. then push It back InIO ItS Original posi tion. ThiS should force the outer bearing off the spindle enough so 1\ can be removed (see Illustration) 10 Pull the hub off the spind le. 11 Use a screwdnver to pry the grease seal out of the rear ollhe hub As th is IS done, nole how the seal IS Installed 12 Remove the inner wheel bearing from the hub 13 Use solvent to remove ali traces 01 o ld grease from the bearings. hub and spindle. A sma ll brush may prove helplul: however make sure no bristles Irom the brush embed themselves InSide the bearing rollers A llow the parts to a ir dry_ 14 Care fully inspect the bearings lor cracks. heat discolora\lOn, worn rollers. etc. Check the bearing races inside the hub tor wear and damage If the bear ing races are defective. the hubs should be laken to a machine shop with the facilities to remove the old races and press new ones In Note thaI the bearings and races come as matched sels and o ld bearings should never be Installed on new races 15 Use h igh-temperature front wheel bearing grease 10 pack the bearIngs. Work the grease completely IOta the beanngs. 10rCIng It between the ro llers. cone and cage tram the back Side (see iIIustrallon) 16 Apply a thin coat of grease to the sp indle al the outer beanng seat. lOner beanng seat. shoulder and seal seal (see illustration)
28.7 Front hub and wheet bearing components - exploded view
28.9
Pull out on the hub 10 dislodge Ihe outer bearing
Chapter 1 Tune·up and routine maintenance
1 - 41
......
WIT)oI HUll ROTAnNG TORQUE AO.IUSTlNO HUT
1lAa( ADJUSTING HUT Off" ONE+IALF
"""
28.15 Pack each wheel bearing by working the grease Into the rollers hom the back side
29.7
nGKTEH AOJUsnNG HUT
28.16 Apply a thin coal 01 grease to the spindle. particularly where the seal rides
IHST.u.J.. THt: RflAlHlNG HUT AHO A NEW COlTER~
...
conER
WlIh the engine in the correct
position (see lellt), insert a feeler gauge between the valve slem and rocker arm -lIlhe clearance is Incorrect turn the adjuster screw
wilh
a bo)(-end wrench, as shown
28.23
(2.8L V6 engine)
17 Put a small quantoty of grease Inboard 01 each beamlg racelOslde the hub USing your linger, lorm a dam al these points 10 ptovlde exira gfease aVilJlablhly alld 10 keep thinned grease from lIowlng out ollhe beanng 18 Place the grease-packed mnerbesnng Inlo the rear 01 the hub and put
a hnte more grease outboard of the beanng 19 Place a new seal oller the mner bearing and tap the seal evenly Into place With a hammer and block of wood unllll!'S flush Wit h the hub 20 Carefully place the hub assembly onto the spindle and push the grease·packed outer bearing Into poSItion 21 Install the flat washer and adjusting nut nghten the nut only slightly 22 Spm the hub In a forward direction to seat the bearings and remove any grease or burrs which could cause excessive beartng play later 23 While spmnlng the whee t. lighten the adjuSllng nut to the specified torque (Step t In thiS Chapter's Specihcatlons) (see Illustration). 24 loosen1he nut I 2 turn . no more 25 nghten Ihe nut to the specified to/que (Step 3 m the SpeCIfications), Install the retamlng nut and a new cotter pm through the hole m the spindle and retalnu'lQ nut If the nut slots don't line up. remove the retammg nut. turn it slightly and reinstall I\. Repeat until the slots hne up 26 Bend the ends at the cotter pm unlll theyre Itat agamst the nul Cut off any extra length which could interfere With the grease cap, 27 Instatt the grease cap . tapping Into place With a hammer. 28 Instatt the ca liper (see Chapter 9) 29 Instatt the tlrelwheel assembly on the hub and lighten the lug nuts. 30 Check the bearings m the manner described earher In thiS SectiOn. 31 lower the vehicle
29
Ihe 2 .8l V6englne. On all other models. II IS adjusted automatically by hydraulIC lifters. 2 The valve clearances are checked and ad,usted With the engme cold 3 Remove the rocker arm covers (see Chapter 2) 4 Oisconnectthe coil (high tenSion) wIre from the dlstnbutor and ground 1\ on the engine block. 5 Place your finger on the adjustment screw lor the No.5 cylinder intake valve (see tltuslration 31.3 it you 're not sure about cylinder locations). Havean assistant operate the starter. a lillie ata time . unlll you can feel the rocker arm just start to move to open the valve 6 With the engme In thiS poSition, you can adjus t the valves forthe num· ber one cylinder 7 Sl art With the Intake valve clearance . Insert a feeter gauge 01 the thICkness listed In thiS Chapter's Specifications between the intake valve stem and Ihe rocker arm (see illustration) Withdraw II; you should feet a slIght drag. 11 Ihere·s no drag Of a heavy drag. loosen or Il9hten the adjuster screw until the correct clearance is obtained 8 Adlust the number 01lE! exhaust valve USIng the same procedure you used lor the mtake valve(s). Be sure to use a feeler gauge olthethickness specified lor exhaust valves . 9 Adjust the remaining valves by repeating the above procedure lor the remaining cylinders . The following lable shows which valves can be ad· justed when a par\lcular Intake valve is just slarting to open. Intake valve opening on cylinder no.
S 3 6
Valve clearance check and adjuslment (2.8l V6 engines only)
Refer to Illustralron 29 7 I The valve stem·to -rocker arm clearance IS adjusted mechanically on
Wheel bearing adjustment procedure
to
Adjustlhe valves for cylinder no.
,
,
4 2 S
4 2
6
3
Aeconnectthe COil wire to the dlstnoutor and Instatt the valve covers
1
Chapter 1 Tune-up and routine maintenance
1 -42
30.2
Tools required for changing spark plugs
Spark plug socket - This will have special padding inside to protect the spark plug's porcelam msulator 2 Torque wrench - Although nor mandatory, using this 1001 is the besl way to ensure the plugs arB /I{}h/ened properly 3 Ratchet - Standard hand /00 / /0 III/he spark plug socket 4 Extens/on - Dependmg on mod9I and accessones, you may netJd special extensions and umversal pnlS to reach one or more of the plugs 5 Spark plug gap gauge - ThIS gauge for checkmg the gap comes in a variety of styles. Make sure the gap for your engine 15 Included.
30
Spartc plug replacement
Refer /0 illustratiOns 30.2. 3O.5a, 3050, 30.6 ancl30. 10
1
The spark plugs are located on the slde(s) 01 the angUlB.
2 In most cases. the lools necessary lor spar\( plug replacemenlloclude a spark plug socket whICh lits Into a ratchet (spark plug sockets are padded Inside to prevent damage to Ihe porcelain Insulators on Ihe new plugs and 10 hold the plugs In the socket dunng removal and Installahon), vaflous extenSIOns and a gap gauge to check and adjust the gaps on the new plugs (see illustration). A special plug wire removal tool Is available for separating the wire boots Irom the spark. plugs, but it isn't absolutely necessary. A torque wrench should be used 10 tighten the new plugs 3 The best approach when replaCing Ihe spark. plugs is to purchase the
3O.5a Spartc plug manufactUrers recommend using a wire type gauge when checking the gap - lithe wire does not slide between the electrodes with a slight drag, adjustment is required
new ones In advance. adjust them to lhe proper gap and replace the plugs one at a Ilme. When buying the new Spark. plugs. be sure to obtain Ihecorrect type fOf your particular engine . This informatIOn can be found on the EmiSSion Control Information label located under the hood and in the factory owner's manual. 1\ differences eXist between the plug specilied on the emissions label and in the owner 's manual. assume the emissions label is correct. 4 Allow Ihe engine to cool completely before anempting to remove any of the plugs_Some models have aluminum cylinder heads, which can be damaged ilthe spark plugs are removed when the engine is hot. While you are waiting for the engine to cool, check the new plugs Iordelects and ad· just the gaps. 5 The gap is checll.ed by inserting the proper thICkness gauge between the electrodes attha tIP of the plug (see illustration). The gap between the plugs should be the same as the one specilied on the EmiSSIOns Con· Irol Informallon label. The gauge Wife should Just slide between Ihe elec' trodes With a slight amount of drag. II the gapls Incorrect, use the adjuSler on the gauge body to bend the curved Side electrode slightly until the speCi fied gap IS obtained (see Illustration). "the side electrode is nOI exactly over the cenler electrode. bend it with the adjuster until it is. Check for cracks in the porcelam Insulator (II an~ are found , the plug should not be used). 6 With the engine cool. remove the spark. plug wife from one spark.plug. Pull only on the boot at the end 01 the wire - do not pull on the wire. A plug wire removal 1001 should be used II available (see illustration) 7 II compressed air is available, use 1110 blow any dirt or foreign matenal away from the spark plug hole. A common bicycle pump Will also wof1l.. The Idea here is to eliminate the poSSIbility of debns falling Into the cylinder as the spark. plug IS removed . 8 Place the spark. plug socket over the plug and remove II Irom the en· glne by turning it counterclockwise. 9 Compare the spark plug to those sho.....-nln the accompanying pho10510 get an Indication of the genetlIl running condition 01 the engine. ,0 Threadoneof the new plugs into the hole until ~ou can I"\() longer turn it With your lingers. then lighten it Wi th a torque wrench (if available) or the ratchet . It might be a good idea 10 slip a short length of rubber hose over tOe end of lhe plug to US8"9S a fool to Ihread II Into place. particularly illhe cylinder head is made oj aluminum (see Illustration). The hose Will gflp Ihe plug weH enough to tum It. but Will start to slip if lhe plug begins to crossthread In the hole -thiS Wilt prevenl damaged threads and the accompany· ing repair costs. 11 Before pushing the spark plug wire onto the end ot the plug, mSpec!it follOWing the procedures oullined In Section 31 . t2 Anach the plug wire to Ihe new spark. plug. agam usmg a twlS!lng molion on the boot until it is sea ted on the spark plug. t3 Repeal the procedure tor the remaining spark plugs, replacing them one at a time to prevent mixing up the spark plug wires.
3O.5b To change the gap, bend the side electrode only, as Indicated by the arrows, and be very careful not to crack or chip the porcelain insulator surrounding Ihe center electrode
30.6 When removing the spartc plug wires, pull only on the boot and twist It back-and-forth
For a COLOR version of this spark plug diagnosis page, please see the Inside rear cover of this manual
""-
CARBON DEPOSITS Symptoms: Dry sooty depclSlts 1rw:!lcate a rich m'llture or weak ignlbon. Gauses mistinng, hard starting and heSitation . Recommendation: Check lor a clogged air cleaner, high IIoal level, sticky choke and worn 9nillon P<>Ints. Use a sp3r11: plug with a longer core nose for greater anli-fouling protection.
OIL DEPOSITS Symploms; Oily coating caused by poor oil control. 011 is leaking past worn valve guides or piston rings inlo Ihe combustion chamber. Causes hard starting, misfiring and hesition. Rec ommendation: Correct the mechanical condi tion with necessary repairs and install new plugs. TOO HOT
NORMAL
S ymptom s: Brown to grayishtan color and slight electrode wear. Correct heat range 101 engine and operating cond ltlonS Recommendation; When new 5p8r11: plugs are Installed. re~ace with plugs of the same at range. ASH DEPOSITS Symptoms: Loght brown deposits 60CNsted on the side or center electrodes or both. Derived from oil arw:!/or fuel add ItlVes. Excessive amounts may mask lhe 5p8r11:, causing misfir· Ing and hesitation during acceIeratlon. Recommendation: If excessive deposits accumulate over a short lime or low mileage, inslall new valve guide seals to prevent seepage of oil into the combustion chambers. Also Iry changing gaSOline brands.
Symptom&: Blistered. white insulator, eroded eleclrode and abSence of deposits_Results In shortened plug tile. Recommendallon: Check for the correct ptug heat range. over-advanced ignition timing, tean fuel mIXture, intake manifold vacuum leaks and sticking valves. Check the coolant level and make sure the radiator IS not clogged.
WORN
S ymptoms: Roonded elec· trodes Wi th a small amount of deposits on the firing end. Normal color. Causes hard startong in damp or cold weather and poor luel ecooomy. Recommendetlon: Replace With new plugs of the same heat range_
PREIGNITION Symraloms: Melted electrodes. Insu ators are white. bul may be dirty due to misfiring or fly· ing debris in the combustIOn chamber. Can lead to engine damage. Recommendellon: Check for tha correct plug heat range, over-advanced IgfliUon timing, lean luet mixture. cl&ged cooIing system and lac 01 lubrication.
DETONATION S ym~'om s: Insulators may be crac ed or chipped. Improper gap settlnp lechniques can also rasult In a lractured insulator lip. Can lead 10 piston damage. Recommend"/on: Make sure the fuel anti-knock values meet engina requirements. Use care when selling the gaps Of) new plugs. Avoid lugging the angill8.
HIGH SPEED GLAZING
SPLASHED DEPOSITS srmplom.: After long periods o misfiring, deposits can loosen when normal combus· tion lemperature is restored ~ an overdue tull8-Up. At hlg speeds, deposits flake off the piston and are thrown against the hot inSUlator, causlng misfiring . Recommendation: Replace tile plugs with new ones or clean and reinstall lhe OOg· inals.
S ymptom.: Insulator has ~ellowish, glazed appearance.
ndicates that com bustion chamber temperatures have risen sudden~ during hard accelera tlon. ormal deposits melt to form a conductive coat· Ing. Causes mistinng at hogh speeds. Recommendation: Install new plugs. Consider USing a colder plug il driving habits warrant GAP BRIDGING
Symplom .: CombuslJon dePOSits lodge belWeen the alectrodes. Heavy deposits accumulate and bridge the electrode gap. The plug ceases to lire, resulting in a dead cylInder. Recommendation: Locate the faulty plug and remove tha deposits from between the electrodes.
MECHANICAL DAMAGE Symptom.: MaTt be caused by a Io~ object n the combuslion amber or the piston striking an iflCOrrect reach (too 10ng)~ . Causes a dead cyIif1der could result In piston damage. Recommendation: Ramove the lo re~n Object lrom the engine an lor Install Ihe corree! reach plug.
1
1-46
Chapter 1 Tune·up and routine ma intenance
f tVID<""'. ~O'OOI
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31 .12 The Ignition rotor should be checked lor wear and corrosion as indicated here (II in doubt aboullts condition, buy II new one) C ..... ~"lD OA II'IODEO Tf" ... ,N ..... S
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31 .11b Shown hera are some 01 the common defects to look for when Inspecting the distributor cap (If in doubt about its condition, install II new one)
arid worn . burned or loose terminals (see IIlustraUon). 12 Check the rotor lor cracks and carbon tracks. Make sure the center terminal Spring tension is adequate and lOOK for corrosion and wear on the rotor tiP (see illustration) Note : The silICOne dieleclflc compound used
on slngle·pom/ rOIOIS darkens WI/h age and may look like dlft orCOffOSIOfl. Do not replace a rotor Just because of the d,electnc compound·s appear-
,,""
31 .13
.
.......'_._00100'"'"
.,.....-~
A ppl y silicone dielectrIc compound to single-point distributor rotors
pivot shaft) In the carburetor throat (see Illustration) 4 Operate the th ronle linKage and maKe sure the plate closes completely. Start the engine and watch the plate - when the engine starts. the choKe plate should open slightly 5 Allow the engine to conltnue running at Idle speed. As the engine warms up to operating temperature. the plate should slowly open
ance 13 Replace the cap and rotor II damage or defects are found. Note that the rotor is held on the shaft by two screws (some models) and on some models IS Indexed so It can only be Installed one way. Before installing the cap, apply silicone dielectriC compound to the rOlor tip of single-point rotors (see IItustratlon) t4 When Installing a new cap. remove the wires trom the old capone at a time and anach them to the new cap In the exact same locatIOn - do not Simultaneously remove all the wires from the old cap or tiring order mixups may occur
32
CHOU Pl "n
Carburetor chOKe check
ReIer to IlIus/raI1Ofl32.3 1 The chol<.e only operates when the engu\8 IS cold. so thiS check should be performed before the engine has been started lor the day. 2 Open the hood and remove the air cleaner cover and filter from the top 01 the carburetor. 3 Locate the choKe pla te (the lIat plate attached by small screw s to a
32.3
Wi th the air cleaner housing cOver removed , the choke plate can be checked for proper operation
Chapter 1 Tune-up and routine maintenance
.""",,,.,, .eo."
1-47
"'''OL'
". "0..
\
33.10
ICUR.,DlE 'P"OJ-_ _:":'--~lll>'~ ~ OJU'TlNO
33.15
Adjusting the last Idle on a model 5200 carburetor
5C"'W
Locations of the TSP-on and TSP-ott adjusting screws on a model 6500 carburetor
6
Alter a few minutes, the choke plate should be fully open to the verti -
cal poSition. 7 Note that the engme speed corresponds to the plale opening angle.
With the plate closed, the engine should run at a last Idle speed. As the plate opens, the engine speed Will decrease. The last idle speed IS controlled by the fast Idle cam, and even though the choke plale IS open completely, the Idle speed w ill remam h igh unliithe thr2tt1e p late IS opened, releaSing the faslldle cam. Check the drop In Idle speed as the choke pla l e opens by occasiona lly -blipping" Ihe Ihroltle 8 II the choke doesn't work as deSCribed, shut off the engine and check the shaft and linkage lor deposits which could cause binding, Use a sprayon choke cleaning solvent to remove the depoSits as you operate the linkage. T his should loosen up the linkage and the shaft and al low the choke to work properly. If the choke stili falls to function correctly, the chok-e bimetal assembly IS malfunctioning and the carburetor may have to be overhauled. Re fer to Chapter 410r carburetor overhaul In forma \lon , 9 AI regular In terva ls, clean and lubricate the choke sha ft. the fast Idle cam and linkage and the vacuum d iaphragm pulldown rod to ensure good choke performance.
33
Idle speed check and adjustment (carbureted models)
Note: The followmg adjustments are for carbureted models only. Idle speed does nOl reqUire penodlc adjustment on fueHn/ected models If the procedure below conflicts With the procedure listed on the Vehicle EmiSSion ControUnforma/lon label m the engme compartment, the procedure on the label IS correct 1 Connect an accurate tune -up tachometer to the engine, fo llOWing lhe manufacturer's Instructlons_ On models so equipped. conneCI the ta chometer pickup to the TACH TEST terminal on the Ignition COil Block the vehiC le's wheels so It cannot move while adjustments a re being made
Model 5200/6500 carburetor Refer /0 II/ustratlons 33. 10 and 33./5 2 The Holley /W eber Model 5200 carburetor IS used on early (through 1982) four·cyl lnder models firsl sold oUls ide California The Model 6500, a feedback verSion of the same carburetor deSign , is used on Ca llforma four-cylinder models through 1982 3 Remove the air cleaner and plug all vacuum lines that were al\ached to the air cleaner at the vacuum source end 4 Apply Ihe park ing brake and block the wheels so the vehicle Will nol ro ll 5 Check and adjust, II necessary, the choke and throttle hnkageforfreedam of movement
6
Start the engine and run it up to normal operating temperature, Disconnect the EGA vacuum line at the valve , and plug the line Where applicable, set the air conditioning to OFF. 9 Where applicable, remove the spark delay valve and route the primary advance vacuum signal line directly to Ihe distributor vacuum diaphragm UI1l\ (advance Side). 10 Place the transmission In Park (automatiC) or Neutral {manual) , then run the engine at normal operating temperature, Check that the choke plates are closed, then set the throttle so thai the fast idle adJusung screw contacts the kick-down step of the choke cam ; adjust the fast idle adjusting screw to obtam the specified fasl idle rpm (see illustration) t 1 Set the throttle to the high step of the choke cam and allow the engme to run for apprOXimately hve seconds t 2 Rotate the choke cam un\ll the fast Idle adjusting screw contacts the choke cam kick -down step _Al low the engine speed to stabi lize, then re check the fast Idle rpm, as deSCribed in Steps 10 and 11 . readjust il neces sary, then repeal the procedure given In the first sentence of thiS paragraph to ensure the same, conSlslenl result 13 A llowthe engme to return to the normal Idle, then , for automatlctransmiSSion models , select Dflve Warning: Be sure the parl<mg brake IS sel secure/yand the wheels are blocked before selec/lng Dnve. Do not accelerate the engme while It'S in DrIVe. and stand to the Side of the vehicle, not in front of II. wh/le makmg Ihe follOWing adjustments 14 Where no TSP assemblyis filted, adlust the curb idle screw in or out to obtam the speCified curb Idle speed, then proceed to Step 18 15 Where a TSP assembly is tilled , adlust the curb Idle screw which contacts Ihe solenOid plunger to obta in the speCified curb Idle speed (the solenOid is energized and the plunger ex tended when the igl1ltlon IS On) (see illustration) 16 Now collapse the solenOid plunger by forCing the thrott le linkage against the p lunger, grasping the throttle lever and solenOid housmg between the thumb and index finger to alleviate movement of the solenoid assembly poSition. 17 AdJust the TSP-ofi adJusling screwto obtam the speCihedTSP-olf idle speed 18 Open the throtlle slighlly to allow Ihe solenoid plunger 10 extend, 19 PrOVided that all adjustments are now satisfactory, stop the eng me, then Install the air cleaner and ItS associated vacuum Imes 20 Restart the engme and. II necessary. run It up to normal operallng tempera ture. With the engme running at 2000 rpm (apprOX imately). select Park (automatic transmiSSion) or Neutral (manual transmission) . AllOW hve seconds (apprOXimately) for the speed to stabHlze, then let the engine relurn to Idle; sel aulomatic transmiSSion models 10 Olive. Recheck Ihe curb idle speed, and. If necessary readjust as deSCribed begmnmg at Step 12. 21 Reconnect all vacuum lines as they were Originally
7 8
1
Chapter 1 Tune-up and routine maintenance
1 - 48
33.35
33.28
Fast idle adjustment (YFA carburetor)
YFA 1 V carburetor ReIer fa !/Iusrrallons 33.28 and 33.35 22 Thiscarburetor,lnfeedbackand non-feedback verSions. was usedon 1983 through 1986 non-turbocharged verSions of the four-cylinder englOe. The adjustments thallallow apply to both versIOns. 23 Warm the engine to normal operating temperature. 24 Place the lranSmiSSlOn In Pa~ (automallc) or Neutral (manualJ,lhen shut the engine of! 25 Leave the key in the on poslhon arid make sure the air condilloner (If so eqUlpPe
",.w 30 Blip" the Ihronle and let the engine speed drop to normal Idle 31 Turn the engine off. 32 Unplug and reconnect the EGR hose Reconnect the electrIC PVS wue (II so eqUipped). 33 Check that the transmiSSion is stili In Park or Neutral. the e ngine IS 51111 at normal operating tempera1Ure and the air condilioner IS off 34 Start the engine and let It Idle Place the 1fansmlSSlon In the speCI fied gear lor idle adjustment (reler to Vehicle EmiSSion Controlln l ormal lon la· bel) . 35 Check curb Idle speed. Adjust il necessary by turnlr19 the hex -head adJustnlg screw (see Illustration) 36 Place the transmiSSIOn In Park or Neu1fal "BI!p" the throttle. then let the engine Idle 37 Place the transmission In the gear sp8Clhed lor Cl'lecklng Idle speed . then recheck Idlespeed ReadJuslasneeded.thenturn the engine olf, Ae connect all vacuum hoses and the PvS wile. II eqUipped.
Location 01 the curb idle s peed adjustment screw on a typi cal YFA ca rburet o r
40 Warm the engine to normal operating temperature . 41 Remove the air cleaner top plate and make sure the choke is o lf (see Section 32). Reinstall the air cleaner top plate 4 2 With the engine at normalopera\lng temperature. raise engine speed to 2500 rpm lor IS seconds. 43 Aefer to the Vehicle EmiSSIOn Informahon label lor the correct fast Idle cam seiling Place the fast Idle screw on the specilled cam step 44 let the engine speed stabilize . then measure Ihe engine speed (rpm). DependIng on the engine and the stale 01 tune . II may reqUire anywhere trom 15 seconds to two minutes for the engine speed to stabilize ThiS Wlil be indicated by a steady reading on the tachometer 45 Aepeat Step 44 three times to ensure accuracy 46 If necessary. adJust the lasl ldle speed adJus\lng screw (see Il1uslralion 33.38) 47 Aepeat the rpm check If an adjustmen t has been made 48 Turn the engine olf. Unplug and reconnect the EGR hose 49 Make sure the engine IS al normal operaTing lemperature and the air contlilioner is olf. 50 let the engine Idle and check lis speed on the tachometer Compare to the VehICle EmiSSion Conlrollnlormatlon label II Ihe speed l1uctuates. use the average speed 51 Recheck each rpm range by raiSing the rpm to 2500 10115 seconds, then lelling the engine speed drop back to Idle Measure the engine speed between 15 seconds and two minute s of returning to Idle Readlust Idle speed II necessary
"
1946/ 7946C carburetor 36 The model 1946C c a rburetor (see lIIustraUon) was used on Cahlor ma models eqUipped Wit h the 3.3L inllne Six -cylinder engine. The M odel 1946 carburetor was used on 49-stale 3 3L models.
1980 models Refer /0 illustratIOn 33.38 39 Dlsconnec1 the vacuum hose Irom the EGA valve and plug the diS· connected end of Ihe hose DIsconnect and plug the luel evaporative purge hose, To 00 this . trace the hoSe from the purgevaJve (on or nearthe evapora\1ve emiSSIOns "charcoal" canister) to the flrsl place where It can be d isconnected from the underhood roullng; e,g. , a vacuum tee connec lion Disconnect the hose and plug both the hose and the open connec · \1on
CI,' ·
·.Lf SPHD' I SP 0 <1 1
All' .11 " (.scnc w
33.38
Detail s 01 a modet1946C carburetor
Chapter 1 Tune-up and routine maintenance
... FAST IDLE RPM ADJ USTME NT
SCRe w
33.61
CURB IDLE RPM
1 - 49
I
~1'r=;; AOJUSTMENT
SCREW
A-JiJ"="'7.l ('''' )
Lb:.bi::L---<~_;;<'J~ Location s 01 the adjustment screws on a model 1946 c arburetor
52 On models without a solenO id pOSitioner, turn the curb Idle speed ad· justlng screw 10 obtain the specIfied speed 53 On models equipped with a solenoid poSitioner. turn the engine oN. Collapse the solenoid plunger. then check the clearance between the plunger and the throttle lever. Compare the clearance to the VECI Iabel and adjust il necessary 54 On models With an aoh-dlesellng solenoid ppSltioner (blue plastic connector), set curb Idle (TSP-on) speed by turning the TSP -on adjusting screw Then push the throttle lever against the TSP plunger to col lapse the plunger. Adjust the TSP -oH speed by turning the curb idle speed adjusting screw 55 On models With an air conditioning solenOid positioner (black rubber connector). set curb Idle speed by turning the curb Idle speed adjusting screw. 56 On models With an air conditioning solenoid poSitioner (black rubber connector). se t the AIC -on rpm. Turn on the air conditioner. Move the throttle linkage so the TSP plunger can extend. then release the throttle linkage. Disconnect the AIC compressor wire at the compresso r. then adJUSt AlC-on speed by turn ing the TSP-on adjus\lng screw 57 Turn 011 the air conditioner and reconnect the comp ressor wife. 58 Unplug and reconnect the luel evaporallve purge hose.
1 33.68a Adjustment screws on a model 1946 carburetor (the model shown is equipped with an automatic transmission and air conditioning)
1981 and 1982 models Refer /0 lilus/ratlons 33.61 . 33.68a. 33.68b and 33.68c 59 Warm the engine to normal opera\lng temperature. then place the transm iSSion In Neutral or Park 60 Disconnect the vacuum hoses from the EGA valve and canister purge valve Plug the disconnected ends of the hoses. 61 Place the fast Idle rpm adjustment screw on the second step of the fast Idle cam (see illustration). 62 Check the engine speed on the tachometer. If necessary. use the l ast idle adjustment screw to adjust the speed \0 the fast Idle speed specified on the Vehicle Emission Con trolln lormalion label in the engine compartment 63 Unplug and reconnect the EGA and canister hoses. 64 Make sure the engine IS stili at normal operating temperature and the transmission is stili in Neutral or Pane 65 On 1981 models. turn the air condilioner and heater 011 _ 66 On 1982 models. set the heater to Heat, set the blower on High and turn on the high beam headlights 67 Place the transmission in the gear specihed on the Vehicle Emission Control Information label. Set the parking brake. 68 Check the curb Idle speed and adjust if necessary (see illustrations).
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33.68b Adjustment screw s on a model 1946 carburetor (the model shown is equipped with an automatic tran smission , but no air c onditioning)
33.66c Adjustment screw s on a model 1946 carburetor (the model shown is a Canadian model equipped with a manuallransmission j
1 - 50
Chapter 1 Tune-up and routine maintenance 81 Reconnect the compressor wire and turn olt the air conditioner Connect the hoses to the canister purge valve and EGR valve
2150-2V carburetor Refer /0 l/lus/fa/lOns 33.9'.33 92a and 33 92b 82 Warm the englne!o normal opera1lng tempera ture Shu t the engine 011 and remove the air cleaner. The air cleaner assembly must be In poSI. tlon when engme speeds are measured 83 Apply the parking brake and block the rear wheels. 84 Check and adJust. If necessary. the choke and throttle Imkage for freedam of movement 85 Where applicable. turn the air cond'lIoner to Off 86 Dlsconnectthe evaporatIVe purge lone Irom the carburetor and plug It 87 Disconnect the EGR vacuum hose and plug II II the vehICle IS eQUipped With a ported vacuum SWitCh (PVS). do nol disconnect the EGR
ho,. 33.91
A typical fast Idle adjusling screw used on a model 2150-2V carburetor
69 On' 982 models, measure the dashpol clearance (see illustralion 33.68d) II should be 0 lOQ-lnch Adjust II necessary 70 Turn all the headlights, blower and heater 71 On 1982 models. place the transmiSSion In Park or Neutral 72 Make sure the engme IS Shll al normal operallng temperature 73 Unplug the TSP electrICal connector 74 Place the transmiSSion In the gear specified on the VehK:le Emlss~n Conlrollabei 75 Check the TSP-o!t Idle speed and compare II to the Vehic le Emission Conlrollabel. Adjust as needed with th e TSP·off adjustment screw 76 Place the transmission in Parit or Neutral and "blip" the thrott le. Lei the engine Idle, place the transmiSSion In the speci fied gear and recheck the curb Idle speed Readlust II necessary Connect the electrical connector to the TSP 78 On all air conditioned 1981 models and 1982 air conditioned Canadian models. set the air conditioner for maXimum cooling 79 Disconnect the air condllJonlng compressor clutch wire 80 Place the transmiSSIOn In the specified poSItion and check AiC -on speed Adfust as needed.
n
68 Disconnect the dlStnbulor vacuum hose from the advance Side of the distributor and plug the hose 89 Follow Ihevacuum hose tromthe Thermactor (air pump) dump valve to the ca rburetor and disconnect the dump va lve vacuum hose nea rest the carburetor Plug the onglnal vacuum source and connect the dump valve directly to manifold vacuum 90 With the transmiSSion In Park {automatlc) or Neulral {manual) and the choke plate lully open, run the engine at 2500 rpm for 15 secoflds Place the fast IdJe lever on the last Idle cam Step specified on the Vehicle EmiSSion Information label. Allow the engme speed 10 stabilize ( I 0 to 15 seconds) and measure the last Idle rpm 91 Repeat the pfOcedure three times and adlust the fast Idle rpm II not as specllled (see illustration) 92 Belore adjusting the curb Idle, It IS necessary to determine whiCh 01 the vanous th rottle poSltloners and engme speed contro l deVices the carburetor IS eQUiPped With (see illustrations) 93 Make all adjustments alter adjus1lng the last Idle speed by following the procedure deSCribed In steps 82 through 91 94 On vehicles Without air cond,loonor1g or other solenOid devices. the curb Idle IS adjusted by turning the curb Idle speed adjusting screw 95 II the carburetor is-equlpped With a dashpot 10 controllhe throttle clos· Ing thedashpol plunger must be collapsed With the engine olt Check the clearance belween Ihe plunger and the throtUe lever pad and adJUSt. It necessary, to the specificatIons on the Vehicle EmiSSIon ContrOl label Each time the curb Idle IS adjusted, the dashpot clearance must also be adjusted
33.92a A sotenoid·dashpotthrotlle positioner used on model 2150·2V carbu retors
Chapter 1 Tune-up and routine maintenance
1 - 51
1 33.92b A solenoid throttl e positioner used on model
33.102
21SO-2V ca rburetor s
Fast idle speed adjustment on a model 4180C-4V carburetor
96 On anti -d ieseling solenoid (TSP) equipped vehicles, the curb idle speed IS adjusted by collapsmg the TSP plunger by forcmg the throttle Jever pad against the plunger. The curb idle speed is then adjusted by turnIng the curb Idle speed adjusting screw. 97 If equipped with air conditioning. dashpot and TSP, turn the air conditIOning off and measure the curb idle speed. AdjUst 10 the curb idle speed listed on the Emissions Control Information label by turning the curb Idle
speed ad)us1lng screw. Turn the engine off, collapse the TSP plunger and Check Iheclearance between the plunger and thethrotlle lever pad. To adjust. turn Ihe long screw which is part of the assembly mounting bracket 98 Reconnect all vacuum lines and Thermaclor hoses to their proper 10callons and reinslalilhe air cleaner.
4180C-4V carburetor Refer
to rllustratron 33. 102
99 Place Ihe transmiSSion In Neutral or Park. 100 Warm the engine to normal operating lemperature 101 Disconnect the vacuum hose from the EGR valve. Plug the disconnected end of the hose 102 Place the fast Idle adjusting screw on the specified step of the fast idle cam (see illustrati on ). Refer to Ihe Vehicle EmiSSion Controllnlormatlon label for Ihe speclhed slep and fast Idle speed. Using the screw. adjust the last Idle speed II necessary 103 Rev the engine momentarily. place the last idle adjusting screw back on the specilled slep of Ihe last idle cam and recheck lasl Idle speed. ReadJust If necessary 104 Unplug and reconnect the EGR vacuum hose. 105 Make sure the transmission is sllilin Neutral or Park and Ihat Ihe en· gme IS still at normal opera\lOg temperature. t06 Place the air conditioning/heat selector in the Off poSition. 107 Disconnecl1he vacuu m hose from the throWe kicker on Ihe carburetor and plug the disconnected end of the hose. 108 Place the transmission in the specified gear (see the Vehicle Emis· Slon Control Information label). 109 Check curb Idle speed on Ihe tachometer. Adjust If necessary to Ihe speed listed on the Vehicle Emission Control label by lurnmg the curb idle speed adjusting screw 110 Place the transmission In Neutral or Park and "blip" the throttle mo" mentarlly 1I 1 Place the transmisSion back in Ihe specified gear and recheck curb Idle speed Readjust II necessary. 112 Unplug and reconnect the throttle kicker vacuum hose. 113 Whenever engine Idle speed must be changed by more than SO rpm. readlust the AOD lever at the carburetor (see Chapter 7).
33.115
Fast idle speed adjustment on carburetor models 2700VV and 7200VV
2700vvn200VV carburetor Refer to illustrations 33. 1/5 and 33. 123 11 4 Disconnecl l he vacuum hose trom the EGR valve and plug Ihe diS' connected end ot the hose. 115 W ith the choke off and the engine at normal operating temperature, raise engine speed to 2500 rpm for 15 seconds. Place the fast idle adjusting screw on the specified step of the fast idle lever (see Illustration). Re" fer to Ihe Vehicle EmiSSion Control Information label lor the specified step and fast idle speed. 116 let engme speed stabilize. then measure the engine speed (rpm). Depending upon Ihe engme and the state 01 tune , it may require anywhere from 15 seconds to 2 minutes l or the eflQine speed (number of rpm) to sta" bilize. 117 Repeal the above step three times to ensure accuracy. 118 Adjust last idle speed, if necessary, by turniflQ the fast idle screw. t19 Repeat the rpm check if an adjustment has been made. 120 Turn Ihe engine off. 121 Disconnect and plug the fuel evaporative purge hose. Todothis, trace the hose from the purge valve (located on or near the evaporative emisSions ·charcoal" camster) to the first place where it can be disconnected from the underhood routing. eg: vacuum tee connection. Disconnect the hose and plug both the hose and the open connection.
Chapter 1 Tune-up and routine maintenance
1 - 52
,(I(I(UI
O ... SHI'OT
V,",CUUM KICIt(R
SOL" 0 ... 5" THRU ADJUST
PlUNGEIl
DHf'lESSEO
THROTT LE
POSITION ER
SOLENOID n'RU ADJUST
33.123
The va r ious types of throttle po siUoners used on carburetor models 27001111 and 72001lV
122 Chedl Ihe engine last Idle speed as descnbed In Steps 115 through 117 123 The method at curb Idle adjustment IS determmed by the type 01 Ihfonte POSitioning devICe .nstalled on Ihe carburetor (see iIIustrallon) The adlustmenl procedures are as follows a) 2700VV carburetors with solenOid poSltioners must be In Dnve when Ihecurbldle rpm IS checked. The curb Idle IS adjusted by turn ing the adjustment screw In Ihe bracket b) On vehicles with no solenOids or poSltloners. turn Ihe thrott le stop adjustment screw to obtain Ihe specified curb Idle rpm c) On dashpol eqUipped carburetors. adjust the cu rb Idle speed Wi th the thronle stop adjustment screw Turn the engine of!. collapse the dashpol plunger and measure the distance between the thronle lever pad Adjust totl1especlhcatlons Ofllhe EmlSSlonsControllnlor· maTlon label I! necessary Start the engine and check the curb Idle speed. repealing the procedure untltthe proper curb Idle speed IS obtained d) On 7200VV carburetors equipped With vacuum-operated thronle modulator (VOTM). turn the thrOl\le stop screw coun terclockwise and recheck If the curb Idle rpm IS below speclflcallons. shut oil the engine and turn the throttle stop screw a ful l turn clockW ise Start the engine and recheck the curb Idle. repeating the procedure unliithe idle IS Within specifica tions. t 24 Reconnect all vacuum hoses
34
Wind sh ield wiper blade check and replacement
Refer 10 II/us/ra/lons 34 5 and 34 /6
Road film can build up on the Wlpel blades and ef!ect thelr elliciency. so they should be washed regularly Wi th a mild detergent solullOn.
..
~
34.5
Windshield wiper blade asse,mbly replacement (Tridon type )
Check 2 The windshield Wiper and blade assembly should be Inspected petlodlcally Even II you don t use your wipers. the sun and elements Will dry oullhe rubber por1lOns. causing them to crack and break apart II Inspec\Ion revea ls hardened or cracked rubber. replace the wiper blades It In·
Chapter 1
$ '
\
Tune~up
and routine maintenance
1 - 53
t ORIElUSE PVSHOOWH All .. .us.EM81Y Ul
.....
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1
SHMT UHMetY
VIEW 0 HOTE: INSEAT SCREWOfIIVf:R 111 IN,(12 _ J 0fI tESS ,"",ST ntiS fOGE
'flEWS
~
SLIDE EU!M(HT STAIniNG
ElEIIIENT
AT THIS POINT
VIEW E
stop
(80TH ENOl)
'o"IEWC
34 .16
"'I£WD REMOVAL BLADE ELE .. £,," IIEPlACfMEHT
INSERTION
WIndsh ield wiper blade element replacement (TrieD type )
spectlOf'l reveals nolhlng unusual, wet Ihe windshield, turn Ihe Wipers on , a)low them to cycle several times, then shut them oM An uneven WIper pattern across the glass or streaks over clean glass Indicate Ihat Ihe blades should be replaced 3 The operallon of the wiper mechanism can loosen the tastene rs. so !hey should be checked and lightened, as necessary. al lhe same ti me the wiper blades are checked (see Chapter 12 for further information regard· Ing the w iper mechanism).
II lill the blade 011 the surlace and lei II hang Slack. 12 Slide lhe plasl lc backing stnp dow n the blade untilihe removal notch aligns With the nex t relalOlng lab TWist the element sltghtly to pop II out 01 the blade 13 Repeat Step 12 wll h the rema ining tabs 10 remove the blade. I
Blade assembly replacement (Tridon blades)
t5 Remove the Wiper blade from Ihe arm (see Step 20 below) . t6 Insert a lIal·bladed screwdflver 1 8-lnch Of less Inlo the space be· tween the elemen! and rubber backlng stnp (see lIIuslrallon) While ptesSlng the screwdnver down and Inward. twlSll1 clockWise to separate Ihe element trom the retaining tab 17 Slide Ihe element oul 01 the other relalOlOg tabs 18 Slide the new elemenllnlO lour 01 the five retaimng tabs TWISI the element Into the fifth retaining tab to secure It 19 Make Sure the new elemenllS secured by all five tabs, then IOs1ali the Wiper blade on Ihe arm.
4 Pari<. the wiper blades In a convenient poSlhon to be wori<.ed on lodo thiS, run the wipers. then turn the tgnltlOn key to Of! when the wiper blades reach the deSired poSl\lon 5 Lift the blade slightly from Ihewlndshleld Pull up 0f1 the spring lock 10 release the blade (see iIIuslralion) and take the blade 011 Caution: Do nol pull /00 hard on Ihe spong lock or II will be dls/orted 6 PUSh the new blade assembly onto the arm Pivot pm Make sure the spring lock secures the blade to the pin.
Blade element replacement (Trlco blades)
Blade element replacement (Tridon blades)
Blade assembly replacement (Trico blades)
7 Remove the wiper blade from the arm 8 Locate one of the 7/ 16'lOch removal notches In the blade assembly There IS a notch at each end of the blade, approximately one Inch from the end (see Illustration 34.5) 9 Sland the blade on a non-slippery surlace. then press down on the upper end 01 the blade enough to bow II sltghtly Caution : Do not press do wn hard enough 10 break Ihe blade 10 Take firm hold of the blade element 5 plas tIC backing sl np. Pull up on the element and tWi st It counterclockwise allhe same time. 50 Ihe plastiC backlOg stnp snaps oul 01 the relalOlng tab on the end of the blade
20 Trice metal blades have a rectangular release hole above the Wiper arm mountlOg plO. 2t Pari<. the wiper blades In a convenient poSltlon!o bewori<.edon. To do thiS, run the wipers. then lurn the Ignition key 10011 when !he wIper blades reach the deslfed poSition 22 LeI the blade assembly rest 0f1 the Windshield and Insert a smaU lIat· bladed screwdriver in!o the release hote (SH Illustration 33.16) Push down on the COil Spring InSide the hole and pull the wiper blade Irom the
"m 23 Push the ne w blade onto the piVOt pm unlll it locks.
1-54 3S
Chapter 1 Tune-up and routine maintenance
Owner sa fely checks
Most 01 these checks can be easily done while the vehicle IS being dllven, Simply by paylllO atlentlon to the specified lIems The checks are Intended 10 make the vehicle owner aware 01potential safety problems ba· fore they occur. 2 Check the seatbelts forwear, fraYing and cuts. Make sure the buckles latch securely and that the automatic retractors function correctly Do no! try to repair seatbelts; always replace them II any problems are lounel 3 Make sure thelgntllon key cannot be removed when the transmiSSIOn IS III any gear other than Par!< (automatIC) or Reverse (manuat). Make sure !he steering column locks whe n the key IS removed from the ignition. II may be necessary to rotate the sleering wheel slightly to Iod<.the steenng column 4 Check the paJ1dng brake The easiest way to do thiS IS to park on a steep hili, set the parking brake and note whether it keeps the vehicle trom lolling. II eqUipped With automatic transmi SSion, also check the Par!<. mecha5 nism, Place the transmission in Park, release the parking brake and note whether the transmission holds the vehicle Irom roiling. II the vehicle rolls while in Park, the transmiSSion should be taken to a qualilled shop lor re pairs 11 eqUipped With an automatIC transmiSSIOn. note whether the shill In· 6 dicator shows the proper gear lilt doesn't, reler to Chapter 7 lor ~nkage adjustmenl procedures. II &quIpped With automatIC transmiSSion, make sure the vehicle starts 7 only in Park or Neutral. lilt starts In any other gear, refer to Chapter 7for SWitch adjustment procedures 6 On 1985 and later models eqUipped with a manual transmiSSion. the
siMer should operale only when Ihe clutch pedal IS pressed to the !lOOt II Ihe starter operales when 1\ shouldn1. reler 10 Chapter 8 for clutCh salety SWitch service 9 Make sure the Orak.es do nol pull to one side while slOPPIng The brake pedal should feel firm , but excessive effort should not be required 10 stop the vehicle If Ihe ~al sinks 100 low. It you have 10 pump 1\ more Ihan once to gel a hrm pedal. or If pedal aHort IS too high. refer to Chapter 9101 repair procedures. A squealing sound trom the front brakes may be caused by the pad wear IndiCators Reier 10 Chapter 9101 pad replacement procedures 10 Rearvlew mirrors should beclean and undamaged. They should hold thelf poSItion when adjusted 11 Sun Visors should hold thelf poSition when adjusted They should reo main securely out 01 the way when lilted 011 the Windshield 12 Make sure the deiroster blows heated an onto the wmdshleld. lilt doesnt, refer to Chapter 3 lor heating system service. 13 The horn should sound With a clearly audlbte tone every time It is operated II not, refer to Chapter 12_ t 4 Make sure WindOWS are ctean and undamaged t 5 Turn on the hghts, then walk around the vehicle and make sure they wor!< Check headlights in both the high beam and low beam poSitions Check the lurn indICators lor one Side 01 the vehicle, the n lor the other Side II poSSible, have an assistant watch the brake ligh ts while you push the pedal. I! no aSSISlant IS available, the brake!lghts can becheclled by backIng up to a wall or garage door. then presSing the pedal. There should be two diSTInct patches 01 red IlQht (three lor modets eqUipped With a htgh mount brake tight ) when the brake pedal is pressed. 16 Make sure locks operate smoothly when the key IS turned Lubricate locks II necessary With Ford Lock LubrICant or an eqUivalent product Make sure all latches hold securely
Chapter 2 Part A
Four-cylinder engine
Contents Auxiliary shalt - removal, Inspection and installation 8 Camshalt and lollowers - removal, inspeclion and installatIOn 7 Camshait cover - removal and 1051all3110n ,......... 4 Cylinder compression check. .. ..... ......... See Chapter 2E Cylinder head - removal and installation ,........... 12 Orivebel\ check, adjustment and replacement .,..... See Chapter 1 Engine mounts - check and replacement ....• , . . . • . . . 17 Engine 011 and hiler change. . . . . . . . . See Chapter 1 Engine overhaul - general information . . See Chapter 2E Engine - removal and installation. .. .. See Chapter 2E Exhaust manifold - removal and installation. II Flywheel- removal and installatIOn .... .......... 15
Front 011 seals - replacement . ••..• . ........ _. . . . . . 9 Generallnlormation . . . . . . . . . . . . . . . . . . .. ............... 1 Intake manifold - removal and installalion .. ........... 10 Oil pan -removal andinslallation . . . . . . . . . . . 13 OJ( pump - removal and installation ........................ 14 Rear crankshaft oil seal- replacement . . . . . . . . . . . . . . . . . . . . .. 16 2 Repair operations possible with the engine In the vehicle. . . Spark plug replacement ............. See Chapter 1 6 Timing belt - removal. installation and adjustment .... Top Dead Center (TDC) lor number one piston -locating 3 Valve seals and springs - replacement . . . . . . . . . . . . . . . . . . . . 5 Water pump - removal and Installation. . . . See Chapter 3
Specifications
General Cylinder numbers (front·to·rear) ................... . Firing order ................ .
Camshaft Lobe hft (In take and exhaust) 1979 through 1982 1983.1984 and 1991 on 1985 through 1990 Allowable lobe 11ft loss .. Endplay Standard . . . Service limit .. . Journal diameter . Runoullimil . Out·ol·round limil JournaHo·beafing (011) clearance Siandard . .. . ...... . Service limit . .. .. Front bearing Iocauon .. ..
Torque specifications Camshaft sprocket bolt ... Crankshaft pulley/sprocket bolt 1979 through 1986 . . . . . . . . . . . . . . .. .. 1987othrough 1990 .. ..... ... . 1~lon .... . ............ . Camshaft retaining plate bolt AUXiliary shall sprocket bolt AU~lljary shaft retaining plate screws Timing belt outer cover bolts ..... Timing belt tensloner adiustment boll .. Timing bell lenslOf'l8r PIvot bolt .... Camshall cover bolts . . .. .. Camshaft cover shield bolt (il eQUipped) . Cylinder head bolts Step 1 . . . . . . . . . . Step 2 Flywheel bolls .....
0.2437 in 0.2381 In a 400 in 0.005 in max 0.001 to 0007 in 0.009 in 1.7713 to 1.7720 in 0.005 In (total indicalor reading) 0.0005 in 0.001 10 0.003 in 0.006 in 0.000 to 0.01 0 in below Iront lace 01 bearing lower Ft·lbs (unless otherwise indicated) SO to 71 100-120 103-133 114-151 6to 9 28 to 40 6109 6109 14 to 21 281040 6108 28 to 40 so 10 60 801090 56 to 64
2A
2A-2
Chapter 2 Part A
Torque specifications (continued) tntake manifold bolls 1979 through 1986 Step 1 Step 2 1987 through 1988 1989 on Exhaust manifold bolts 19791hrough 1986 Step t Step 2 1987 on (except 1991 on 2.3L four-cylulder engines) ....... . Step 1 Step 2 1991 and later 2.3L four-cyllrlder engines Regular bolts Step 1 ............ . SIep2 . . . ....... . Stud Iype bolts . . . .. ................. . ... . Heal shield nuts (1991 on 2.3L four-cyl inder engines) 011 pan-to-engine block bolls 1979 through 1986 Small bolts Large bolls ....... _.. 1987 on (eltcepl 1991 on 2.3L four-cybnder engines) ... . 1991 on 23L four-cylinder engines 011 pan-Io-transmlssion bolls (1991 on 2.3L four-cyllnder engines) Slep I Slep 2 .... Od pump bolls Oil pump pick-up lube nUl .. Engine mount-to-block boils 19791hrough 1981 1982 1983 through 1987 19880n Eltcepl convertible ... Convertible Engine mount-Io-frame nulS and bolts 19791hrough 1981 1982 1983 1984 1985 Non-turbo . Turbo Boll
N"
1986 1987 on Boll N",
Engine mount-Io-brackel boll
Four-cylinder engine Ft·lbs (unless olherwlse indicated)
5107 14 to 21 151022 20 to 29
60 to 84 in-Ibs 16 t023 17810204 in-Ibs 20 to 30
151017 20 1030 20 1033 20 to 29
72 to 96 in-Ibs 96 to 120 in-Ibs I 20 10 162 In-tbs 12010 144in-lbs 30 10 36 301039 14 1021 14 to 21 35 to 60 401055 331045 331045 25 to 35 40 to 60 70 to 90 57 to 65 50 to 65 80 10 106 3310 45 50 to 65 451055 451063
80 to 106 65 to 85
General information This Part of Chapter 2 is devoled 10 In-vehICle repair procedures for Ihe 2.3L Over Head Camshaft (OHC) four-cylinder engine. Information concerning engine removal and installation. as well as engine block and cylinder head overhaul, is in Part E 01 this Chapter. The following repair procedures are based on the assumption Ihat the engine is Inslalled In the vehICle. Illhe engine has been removed from the vehICle and mounted on a stand. many ollhe steps Included In thiS Part of Chapter 2 wll1llOl apply. The specifications included in Ihis Part of Chapler 2 apply only 10 the engine and procedures in this Part. The specifications necessary lor rebUilding the block and cylinder head are found in Part E.
2
Repair operations possible with th e engine in the vehicle
Many malor repair operations can be accomplished without removing the engine from the vehicle Clean the engine compartment and the eltterlor 01 the engine With some type 01pressure washer before any work IS done_A ctean engine will make the;ob easier and Will help keep dirt ou1 of the internal areas of the engine_ Depending on the components Involved, II may be a good Idea to remove the hood to Improve access to Ihe engine as repairs are performed (relet 10 Chapter 11 if necessary). If vacuum. elthaust. Oil or coolant leaks develop, indicating a need lor gasket or seal replacement. the repairs can generally be made WITh the
Chapter 2 Part A
I
Four-cylinder engine
2A-3
TIMING
POINTER
FROHT
I
ATOC
TOC
I
lJ
I II~' ~Ic I~ ROTATION
IlOl.. T 5 PEQ'O
BT,
,~
,;
""'"
~
CRANKSHAFT TIMING MARKS 3.6 Turn the crankshaft untilihe TC marie on the pulley is aligned wIth the pointer on the timing belt cover - nole that In this lliustralion the crankshaft must be turned Just a IIftle more to align the mark wilh the pointer
4.7
Exploded view 01 camshaft cover and related
components (typical)
engine in the vehicle. The intake and exhaust manifold gaskets. od pan gasket. camshaft cover gasket and cylinder head gasket are all accessible WI!h the engine 10 place The crankshaft 011 seals can also be replaced without removlOg the engine. Englnecompooenls such as the intake and exhaust manifolds. the oil pan, the 0.1 pump, the 8ultiliary shaft. the waler pomp, the starter molor, the al'ernator, the distributor and the fuel system components can be re" moved lor repair with the engine in place, Since the cylinder head can be removed without pulling the engine, camshalt and valve component servicing can also be accomplished with the engine in the vehicle, In extreme cases caused by a lack 01 necessary equipment, repair or replacement of piston rings, pistons, connecting rods and rod bearings is possible with the engine in the vehicle. However, this practICe is not recommended because 01 the cleanmg and preparation work that must be done to the components involved
Aemove the distributor cap as described in Chapter I. Tum Ihe crankshalt (see Paragraph 3 above) until the ignition timing mark fOt TDC on the crankshaft pulley is aligned With the timlflg pomter on the belt cover (see iIlustrallon). 7 The rotOt should now be pointlflg directly at the mark you made earlier on the distnbutOt. If 11 Isn't, the piston is at TC on the exhaust stroke. B To gel the piston to TOC on the compression stroke, turn the crankshaft one complete turn (360-degrees) clockwise. The rotor should now be pointing at the mark. When the rotor is pointing at the number one spark plug wire terminal in the distributor cap (which Is Indicated by the mark on the distnhutor) and the ignition timing marks are aligned, the number one piston is at TDC on the compression stroke. 9 Merthe number one piston has been positioned at TOC on thecompression stroke, TOC lor any 01 the remaining cylinders can be located by turning the crankshaft and follOWing the liring order (refer to the SpecIIica· tions).
3
4
Top Dead Center (TOe) lor number one piston - locating
5
6
CamshaH cover - removal and Inllallation
Refer /0 lIIus/ration 3.6
Refer to iIIus/ration 4. 7
t Top Dead Center (TOC) is the highest point in the cylinder that each pston reaches as it travels up-and-down when the crankshalt turns. Each pston reaches TOC on the compression stroke and again on the exhaust stroke, but TDC generally relers to pston position on the compression stroke. The timing marks are referenced to the number one piston at TDC on the compressIOn stroke . 2 POSitioning the piston(s) al TOC IS an essential part 01 many procedures such as in-vehicle valve tram service, timing belt replacement and dlStnbu tor removat . 3 tn ordertobnng any piston to TOC, the crankshaft must be turned us· ing one at the methods outlined below, When Iookmg at the Iront of the engine, normal crankshaft rotation is clockwise, Caullon: Turning the crank.shah backwards may cause the tlmmg belt 10 jump lee/h, a) The preferred method is to turn the crankshaft with a large socket and breaker bar attached to the large bolt thaI's threaded inlo the Irant at the crankshaft. b) A remote starter switch, which may save some time, can also be used. Attach the switch leads to the SWitch and battery terminals on the solenoid. Once the piston is close to TOC, use a socket and breaker bar as described m the prevIous paragraph. c) If an aSSIstant IS available to turn the ignition switch to the Start poSition in short bursts, you can get the piston close 10 TOC Without a lemote starter SWllch. Use a socket and bfeakerbar as described in Paragraph a) to complete the procedure, 4 locate the number one spark plug wife terminal in the distributor cap, then mark the distributor base direclly under the terminal.
I Disconnect the negative cable Irom the battery. 2 Non·Turbo - remove the air cleaner (see Chapter 4). 3 Turbo -detach the air duct Irom the turbocharger and throttle body (Chapter 4). 4 Aemove the PCV tube from the camshah cover (Chapter 6). 5 On EFt-equipped models, remove the throttle body (Chapter 4), 6 Remove the plug wires from the plugs and detach the wire holder from the camshaft cover. 7 Remove the bolls and studs and separate the cover from the engme (see illustration). 1\ may be necessary 10 break the gasket seat by tapping the cover wllh a soft·face hammer. lilt's really stuck, use a knile, gasket scraper or chisel to remove it, but be very careful not to damage the gasket sealing surfaces at the cover or head. Don't lose the sealing grommets. B Place clean rags in the camshaft gallery to keep foreign material out at the englOe. 9 Aemave all traces of gasket material Irom the cover and head, Be carelul not to nick or gouge the surfaces. Clean the mating surfaces With lacquer thinner or acetone. to Aeinstallthe cover With a new gasket - apply FOI'd adhesIVe no, 7AZ-I QS50B·A (or an eqUivalent Oil-resistant sealant) to the mating surlaceso! the cover and head. The tabs on the gaSket must lit into the slots in the cover. Install the bolts and tighten them to the specified torque in a cnss·cross panern. , 1 AelOslall the throttle body (Chapter 4) and the remaining components previously removed or disconnected. 12 Aun the engine and check lor vacuum and oil leaks.
Chapter 2 Part A
2A-4
Four-cylinder engine
5.8 Valve components - note thai In this view the camshaft lobe Is contacting the cam follower (arrow), which compresses the valve spring and opens the valve -lor work described in Section 5 the valve
5.17
Ford valve stem seal tool
should be closed, with the cam lobe 5.7
While compressed air holds the
valve closed, a special tool is used 10 c ollapse the spring so the cam follower and lash adjuster can be removed
5
pointing up, away from the follower
A B C
Cam follower
Lash adjuster
o E
Valve spring Valve keepers
Valve
Valve seals and springs ~ replacement
Refer to Illustrations 5.7,5.8 and 5.17 Note: Broken valve springs and defective valve stem seals can be reo placed without remoVing the cylinder head. Two special tools and a com· pressed air source are normally required to perform this operation. so read through this Section carefully and rent or buy the tools before beginning the job. If compressed air isn't available, a length of nylon rope can be used/a keep the valves from falling into lhe cylinder during this procedure.
I Refer to Section 4 and remove the camshaft cover. 2 Remove the spark plug from the cylinder which has the defective component. II all of the valve stem seals are being replaced. all 01 the spark plugs should be removed (Chapter I). 3 Turn the crankshaft until the piston in the affected cylinder is at top dead center on the compresSion stroke (refer to Section 3 for instructions).
If you're replacing all of the valve slem seals, begin With cylinder number one and work on the valves for one cylinder at a time. Move from cylinderto-cylinder following the l iring order sequence (1-3-4-2).
4 Thread an adapter into the spark plug hole and connect an air hose from a compressed air source to it. Most auto parts stores can supply the air hose adapter. Note: Many cylinder compression gauges utilize a screw-in fitting that may work with your air hose quick-cisconnect fitting.
S Apply compress~ air to the cylinder. The valves for that cylinder should be held in place by the air pressure. II the valve faces or seats are in poor condition. leaks may prevent the air pressure from retaining the valves ~ refer to the alternative procedure below. 6 If you don't have access to compressed air. an alternative method can be used. Position the piston at a point just before TDe on the compression stroke, then feed a long piece of nylon rope through the spark plug hole unlil it filis the combustion chamber. Be su re to leave the end of the rope
BELT COVER OUTER
SCREW AND W",."" --6'I~'
CRANKSHAFT PULlEV
6.10a
Timing bell cover Installation details (1979 through 1990)
6.10b
Timing bell cover Inslallatlon details (1991 and later models)
Chapter 2 Part A
2A-5
Four-cylinder engine .LT GUIOl .o.$$(MIU
IIHT GUlOE ASSEMBLY
".
,
WA,SHER
lONG BOLT SEALING TYP'E
DIfIECTJOfrI
'"
ROTATlON CAMSIiAFT
2A 6. 11a Timing bell and related components - ell:ploded view
IECTJOfoI • QlANK~ II'fIOCI(fT • INSTAU. WID!
IIfCtSS TOWARD Sloat
hanging out 01 the engine so it can be removed easily. Use a large breaker bar and socket to rolate the crankshaft In the normal directIOn 01 rotatIOn unll' sl,gh! resistance IS lelt. 7 Siulf shop rags Into the cybnder head holes near the valves to prevent pans and tools !tom laUing Inlo the engine. then use a valve spring compressor to compress the spring (see illustration) 8 With the spring compressed, slide the cam tollower over the lash adiuster 10 remove It (see illustration). Also remove the lash adjuster.
9 Stili compressing the spring. remove the keepers. Release the valve spring tool and remove the spring retainer, damper assembly and valve spring. 10 Remove and discard the vaJve stem seal. Note : /I air pressure fails to hold the valve in the closed position during this operation, lhe valve face or seat IS probably damaged. If so. lhe cylinder head Will have 10 be removed !of ad(Jr/lonal repair operations 11 Wrap a rubber band or tape around Ihe lap 01 the valve stem so the valve WI" notlall inlo Ihe cy~nd9f". then release the air pressure. 12 Inspeclthe valve slem lor damage. Rotate the valve in the guide and check the end lor eccentnc movement. which would indicate lhatlhe valve is benl. 13 Move the valve up-and-down In Ihe gUide and make sure it doesn't bind. lithe valve stem binds, eilher the valve Is bent or Ihe guide is damaged, In ellher case, the head Will have to be removed lor repair. 14 Reapply all pressure to the cylinder to retain the valve in the closed poSition, then remove the tape or rubber band from the valve stem. Lubricate the valve stem With engine oil and Install a new umbrella type guide seal. il used 15 Place the plastic inslallalion cap over the end ollhe valve slem. 16 Start Ihe valve Slem seal carefully over the cap and push the seal clown untIl the jacketlouches the top of the guide \ 7 Remove the plastIC cap and use the inslalialJon 1001 (see illustration) or two screwdrivers to bollom Ihe seal on the valve gUide. \ 8 Install the valve spring, damper and relalner, compress the sprmg and install the keepers. t9 Install the lash adjuster and cam follower.
20 Disconnect the air hose and remove lhe adapter from the spark plug hole. 1/ a rope was used In place 01 air pressure, puN il out of the cylinder. Caullon : Do not tum thecrankshaft backwards to r9leasethe rope. Turning the crankshaft backwards wiN cause the tlfning belt to jump teeth 21 Reinstall the various components removed. 22 Sta11 and run the engine, then check lor 011 leaks and unusual sounds coming from the camshaft cover area.
6
TIming belt - removal, Installallon and adjustment
Refer to Illustrations 6. 10a, 6. 1Ob, 6. 1 ta, 6. 1 tb, 6,24 and 6.27 1 Disconnect the negative cable from the ballery. 2 Remove the fan shroud (Chapter 3). 3 Remove the Ian and the water pump putley (Chapter 3). 4 Remove the drivebelts (Chapter 1). 5 Drain Ihe cooling system (Chapter 1) and remove the upper radiator hose (Chapler 3). 6 Remove the thermostat houslI'IQ and gasket (Chapter 3). 7 Position the number one piston at top dead center on the compression stroke (Section 3). Caullon : Always tum the crankshaft;n Ihedirec· lion of normal rotation (clockw;se, viewed from the front), Backward rotation may cause the liming bell to jump leeth. DO NOT tum the crankshaft during this procedure, after the number one piston is at TOC, until after Ihe timmg bell is reinstalled/ a Make sure the distributor rotor is pointing altha number one plug wire terminal 9 Remove the crankshaft drivebelt pulley and bell guide. 10 ()r11979 through 1990 models, remove !he lour bolts and one SCf8W anddEtlachtheoutertiming belt cover( seelllustrallon). On 1991 andlater models, remove the one bolt, then carelully release the elghl cover interlocking tabs and detach the outer timing belt cover (see lIIustraUon). 11 Loosen the belltensioneradjustmentboll,then position spreader tool no. TI4p·6254·A on the tensioner pin and retract the belt tens loner (see illustrations), II the special tool is not available, a prybar wedged be-
2A-6
6.11b
Chapter 2 Part A
A special Ford 1001, or a prybar, can be used to release the tension on the timing belt
Four-cylinder engine
6_24
Before starting the engine, remove the plug from the belt cOver and recheck the timing marks
!Ween the roll Pin and tenslOner may work. Ttghten the adjustment boll 10 hold ltIe tensionar In the retracted POSition. 12 Remove the liming belt and inspect it lor wear and damage. II It'S worn or damaged, replace the belt. Caution : Ifmdoub/ abourlhebencondltlOil. install a new one. If /h6 belt bteaks during engm9 operation, extenSJVe
damage may occur/ 13 Check the sprockets lor wear, cracks and burrs on the leeth. If the
sproclc.els are worn or damaged, they can be detached alter removing the mounting bolts. Make sure the new sproclc.ets are installed correctly (see Illustralion 6.11 a). r",hlen the mounting 0011$10 the torque listed In this Chapter's Specificallons. Note: Install a new camshaft sprocket bolt or use Teflon saaJing tape on the old bol/. 14 Make sure the valve timing mark on the camshaft sprocket is aligned with the poimer on the engine case. Install the liming bel t over the crank shaft sprocket, then over the auxiliary shaft sprocket. 15 Pull the belt up (pulling slack from between the aUKlliary and camshaft 5pfock.els) and install it on the camshaft sprocket in a counterclockwise direction so flO slack will be between the two sprockets. Align the bett fore and aft on the sprockets. 16 loosen the tensioner adjustment bolt to allow the tenSloner to move against the bett. If the spnng does not have enough tension to move the roller against the belt (the belt hangs loose) . it may be necessary to insert tool no. T74P-6254-Aor a prybarbetween thetensloner and pin and push the roller against the belt. Tighten the bolt to the torque listed m this Chapler's Specificatlons_Note: The spring cannot be used to set ben tenSion . A wrench must be used on the tensioner assembly 17 Remove the spark plugs. Slowly rotate the crankshaft two complete turns in the directIOn of normal rotation to make sure the belt IS seated and 10 remove any slack While turning the crankshaft, feel and listen forvatveto-piston contact Oon·t force the crankshaft - if binding IS lell. recheck all work or seek professional advicel 18 Tighten the tensioner adjustment and pivot bolls 10 the specified torque. Recheck the alignment of the valve timing marks. 19 On 1979throogh 1990 models_install thellmlngbettoutercoverand tighten the bolts to the torque listed m this Chapl efs Specifications. On 1991 and tater models_snap the cover Into place, making sure all interlocking tabs are engaged properly, then install the one bolt and ligh ten to the torque listed in this Chapter's SpecillcatJons. 20 The remaining installation steps are the reverse of removal. Be sure to tighten the crankshaft pulley/sprocket bolt to the speci fied torque. 21 Bring the number one piston 10 top dead center on the compreSSion stroke (Section 3). 22 Remove the diSlnbulOf cap and make stJre !he distributor rotor IS IX)lnllng at the number one spark plug wire terminal. 23 Remove the access plug from the timing beh cover 24 look through the access hole In the belt cover to be sure that the timing mark on the camshaft sprocket is Imed up With the pointer (see illustration),
, , !'O$ITlON
6_27
II the mari<s are aligned as s hown here, the valve timing Is co rrect (which mean s the timing belt has been installed co rrectly )
25 Make sure the timing mark on the crankshah pulley align s With the TOC mark on the belt cover. 26 Reinstall the belt cover access plug. 27 II the marks don't align as descflbed (see Illustration), recheck the liming belt installa\lOn
7
Camshaft and tollower s - remova l, inspection and Installation
Refer to Illustra tions 7.9 and 7. 12
Removal Disconnect the negative cable Irom the battery. 2 Remove the camshaft cover, the tImIng belt cover and the timing belt (SectIOns 4 and 6), Unbolt the alternator bracket trom the cylu\der head and push It aSide. 3 Remove the spring clip trom the hydraulic valve lash adjuster end ot each cam lollowar
1
Chapter 2 Part A
Four-cylinder engine
2A-7
RETAINING PLATE Ill' IN OIl "III()!I TO INST ...U .... T1()fI
PLUG
SCREW AND WA SHER
7.9
The camshaH retaining plate Is held in place with two screws
4 Usmg a valve spring compressor, compress the valve spnng and slide out the cam follower (see Section 5 If necessary). Keep the cam followers in order $0 they can be reinstalled In their originallocalions.
2A
5
Liftoullhe hydraulic lash adjusters, keeping each one with its respective cam lollower. 6 Remove the camshaft sprocket mountIng bolt and washer. A long sCfewdnver placed through one ollhe holes In the sprocket will prevenllhe camshaft from turning. 7 Draw olf the sprocket with a puller. then remove the bell guide. S Remove the sprocket locating pin from the end of the camshaft. 9 Remove the camshaft retaining plale from the rear bearing pedestal
(see illustration). 10 Raise the vehICle and support it securely on Jackstands. 11 Position a floor Jack under the engine. Place a"block of wood on the jack pad. Remove the left and right engine mount bolts and nuts. Raise the engine as high as it Will go. Place blocks 01 wood between the engine mounts and frame brackets and lemove the jack. Warning; 00 NOT place your hands under the engine where they would be crushed if the Jack fai/edl 12 Using a hammer and a brass or aluminum drift, drive the camshaft out toward the front of the engine, taking the front seal with It (see illustration). Be very careful not to damage the camshaft bearings and tournals as Its pushed out.
Inspection Camshaft and bearings 13 After the camshaft has been removed from the engine, cleaned with solvent and dried, inspect the bearing loumals fOf uneven wear, pits and galling If the Journals are damaged, the bearing inserts In the head are probably damaged as well . Both the camshaft and bearings Will have to be replaced with new ones. Measure the Inside diameter of each camshaft beanng and record the resufts (take two measurements, 9O-degrees apart. at each beanng). 14 Measure the camshaft bearing journals with a micrometer to determine if they're excessively worn or out-ol·round. If they 're more than 0.OO5·inch out-of-round, the camshaft shouk! be replaced with a new one. Subtract the bearing journal diameters from the corresponding bearing Inside diameter measurements to obtain the oil clearance. If iI's excessive. newbeanngs must be Installed. Note: Camshahbearingrepiacemen/ reqUIres sp8C18/looIs and eJCpertise that place II outside the scope of the doI!·yourseffer. Take the head 10 an automotIVe machine shop 10 ensure Ihat the JOb is done correctly 15 Check the camshaft lobes for heat discoloration, score marks. chipped areas, pitting and uneven wear. If the lobes are in good condition the camshaft can be reused. 16 Make sure the camshaft Otl passages are clear and clean. 17 To check the thrust plale for wear, install the camshaft in the cylinder head and poSition the thrust plate at the rear. using a dial indicator, check the lotal end play by lapping the camshaft carefully back·and-forth. II the end play is outSide the speclhed limit. replace the thrust plate with a new one.
7.12
camshaft and related components - exploded yiew
Cam followers 18 Check the faces 01 the cam followers (whiCh bear on Ihe cam lobes) tor signs of pitting, score marks and other forms of wear. They should fit snugly on the pivol bolt. 19 Inspect the face which bears on the valve stem. If it's pitted, the cam follower must be replaCed With a new one. 20 II excessiye cam follower wear IS evident (and possibly excessive cam lobe wear), it may be due to a malfunction of the valve drive lubrica· lion tube. If this has occurred, replace the tube and the cam follower. If more than one cam follower IS excessively worn, replace the camshaft, all the cam fol lowers and the lubrication tube. This also applies where excessive cam lobe wear Is found. 21 During any operation which requires removal of the camshaft cover, make sure that oil is being discharged from the lubrication tube nozzles by cranking lhe engine With the starter motOf
Installation 22 Uberallycoatthecamshaftroumalsandbearingswithengineassembly lube or moly·base grease, then carefully Install the camshaft in the cylInder head. 23 Install the retaming plate and screws. 24 Lubncate the new camshaft oil seal with engine 011 and carefully tap il Into place atlhe front of the cylinder head with a large sodIet and a hammer. Make sure it enterSlhe bore squarely and seats completely. 25 Install the belt guide and pm at the Iront end of the camshaft. then carefully tap on the sprocKet. 26 Install a new sprocket bolt or use Teflon sealing tape on the threads of the old one. 27 Coat the hydraulic lash adjusters with engine assembly lube or molybase grease. then install them in Iheir original locatIOns. 28 Coal Ihe camshaft lobes and cam follOwers WIth engine assembly lube or moly·base grease. 29 Install the timing belt (Section 6). 30 Compress each valve spnng and POSitlOfl each cam followeron Its respective valve end and adjuster. Install the retaining spring clips. 31 Install the remaining components preyiously removed.
8
Auxiliary shaft - removal, inspection and installation
Refer to illustration 8.4 1 Detach the negallVe batlerycable from the battery. Removethe large bolt from the front oltha crankshaft and pull the drtvebelt pulley oft Re-
Chapter 2 Part A
2A-8
Four-cylinder engine
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Au xiliary shaft and related
components - exploded view
move the bolts/screws and detach the outer timing belt cover (see illus-
tration 6.1 0). 2
Loosenlhe auxiliary shalt sprocket bolt (see illustration 6.11 a), 11 the
shaft turns, immobilize the sprocket by inserting a large screwdriver or 318·inch drive extension through one of the sprocket holes. Detach the timing belt (Section 6). 3 Pull off the sprocket (a puller may be required) and remove the pin
trom the shalt. 4
Remove the three bolts and detach the auxiliary shaft cover (see II·
lustration). 5 Remove the screws and detach the retaining plale. 6 Withdrawlheshafl. lf it's light. reinstalilhe boll and w asher. Use a prybar and spacer block 10 pry out the shaft. Be exl remelycareful nol to damage the bearings as you pull the shaft out of the block. 7 Examine the auxiliary shaft bearing for pits and score marKs. Replacemenl must be done by a dealer service department or a repair shop (although it's easy to remove the old bearing, correct installation 01 the new one requires special tools). The auxiliary shaft may show signs of wear on the bearing journal or the eccentric. Score marks and damage to the beamlg journals cannot be removed by grinding. If in doubt. ask a dealer service department to check the auxiliary shaft and offer advice on replacement. Examine the gear teeth for wear and damage. If ei ther is evident. a replacement shaft must be obtained. 8 Dip the auxiliary shaft in engine all before installing it in the block. Tap it in gently with a soft-face hammer to ensure thai it's seated. Install the retaining plate and the auxiliary shaft cover. 9 The remainder of the procedure is the reverse of removal. Make sure that the auxiliary shaft pijn is in place before installing the sprocket. Tighten the sprocket mounting bolt to the torque listed in this Chapter's Speci fications.
9
Front all seals - replacement
Note: The camshah. crankshah and auxiliary shah oil seals are all replaced the same way, using the same tools. ahertheappropriatesprocket has been removed. When replacing the sprockel(sJ, always use a new Ford boll or clean out the oit hole and use Teflon tape on the old bolt. t Disconnect the negalive battery cable from the battery. 2 To remove the camshaft or auxiliary shaft sprockets, referring to Seclion 7 or 8. Ford manufactures a special puller designed for Ihis purpose. 3 To removelhecrankshaftsprockel. use Fordtool no. T74P-6306-Aor
10.8
Intake manifold and related components - e xploded view
a gear puller. 4 Ford tool no. T74P-6700-B or equivalent may be used 10 remove all the seals. When uSing the 1001. be sure the jaws are gripping the thin edge of Ihe seal very tightly before operating the screw portion of the tool . If the tool isn't available. a hammer and chisel may be used to remove the seal(s) if care is exercised. 5 Clean the seal bore and shalt surface prior to installation of the new seal. Apply a thin layer of grease to the outer edge 01 the new seal(s). 6 Install the seal(s) with Ford tool no. T74P-6t50A. II the special tool isn·1 available, you may be able to use a large deep socket and a hammer or a short piece of pipe, the sprocket bolt and a large lIat washer. 7 Install the components removed to gam access \0 Ihe seals. 8 II the Iront cover (see illustration 8 .4) is removed for any reason, reinstall il without the seal. Before lighlening the bolts. center the cover with Ford 1001 T7 4P-60 19-B Of equivalent.lhen install the seal as described previously.
10
Intake manifold - removal and In slallation
Refer to illustrations 10.B. 10.13a and 10.13b 1 Relieve the fuel system pressure (Chapter 4). 2 Disconnect the negative battery cable from the battery. 3 Drain the cooling system (Chapter 1J.
Chapter 2 Part A
3
Four-cylinder engine
2 d
o
o OO? 14---1----"0";
0000 0 Intake manifold boll TIGHTENING sequence-1979 through 1985 models
10.13b
Disconnect the negative banery cable from the banery. 2 On 1991 and later models, remOllethealrcleanerandthealr ductassembly (Chapter 4), 3 Remove the tu rbocharger (vehicles so equipped) (Chapter 4). 4 Disconnect the EGR tube at the exhaust manifold and loosen the EGA valve. 5 On vehicles so eQuipped, disconnect the EGO sensor Irom the e ~ hausl manifold (see Chapter 6). 6 Remove the exhaust pipe-to-manllold bolts and carefully move the exhaust pipe out of the way. 7 Remove the mounting bolts and detach the e~haust manifold and lifting "eye" from the engine, On vehicles so eqUipped, remove the heal shield. Note: Some vehicles are eqUipped with a combmatlon of belt types (regular and stud· type). Note the location of these different bens 8S they
perfectly clean when the manifold IS installed. Gaskel remollal soli/ems in aerosal cans are allailable al most au/o parts stores and may be helpful when remOlllng oldgasker material/hat's s/uck /0 the head and manifold. Be careful not /0 scrape or gouge the sealing surfaces. 11 Clean and 011 the manifold mounting bolts. 12 Position the new intake manifoid gasket on t~ manifold. 13 Position the Intake manifold and gasket, along With the lilting "eye", on the head, Instalt the fasteners and tighten them in sequence, in two steps, to the torque tlsted in this Chapter 's Specifications (see illustrations). 14 The remainder of installation Is the rellerse of removal. 15 Aeconnectthe banery and refill the cooling system. 16 Start the engine and let it run while checking torcoolant, luel and vacuum leaks.
must be reins/ailed in the COffect location dunng ms/allatlon. 8 Clean the manilold and cylinder head mallng surlaces With a gasket scraper, them wipe them off With a cloth saturated With lacquer thinner Of acetOfl9. Clean the bolt threads with a Wire brush.
Installation 9 Using a new gasket, install the manifold and the bolts anaching 1\ to the cylinder head. Make sure the lifting "eye" is attached to the rear of the manifold. On vehicles WIth different types 01 bolts. make sure there installed In the correct location. 10 On 1979 through t990 models, in the sequence shown, tighten the bolts (in two or three steps) to the torque listed in this Chapter's Specifica· tlons (see illustrations). tl On 1991 and later models, tighten the regular botts and then the stud
Exhaust manilold - removal and instaUation
Refer 10 II/ustratlons II . IDa, " . lOb and II. "
: ~T~
Intake manifold TIGHTENING sequence - 1986 and later models
Removal
4 Remove the air cleaner and ducts (Chapler 4). 5 Label and disconnect Ihe vacuum hoses Irom the thronle body and emiSSions devices attached 10 the intake manifold. 6 Remove the throttle body, tuel injection wiring harness, luel rail and upper Intake manilold (Chapler 4) . 7 Remove the four bottom mounting bolts from the in take manifold. S Remove Ihe four upper mounting bolls from the manifold. Note that the Iront two bolts also secure the engine lifting "eye" (see illustration). 9 Detach Ihe manifold Irom the ellQlne. 10 Clean Ihe manifold and head mating surfaces and check the manifold lor cracks. Note : The mating surfaces of lhe head and manlfoki musl be
11
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1'.'0a Exhaustmanllold mounting details aod bott TIGHTENtNG sequence - 1979 through 1988 models (Turbo shown; noo-Turbo similar)
2A
Chapter 2 Part A
2A-10
Four-cylinder engine
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1' .10b Exhaust manifold mounting details and bolt TIGHTENING sequence-1989 and 1990 models
bolts to the torque listed in this Chapter's Specitications (see illustration). 12 Attach the exhaust pipe and lighten the bolts securely. 13 On vehicles so equipped, install the heal shield and lighten the nuts to the torque listed in this Chapter's Specilicalions.
14 The remainder of installation is the reverse 01 removal. Run the en· gine and check for exhauslleaks.
12
Cylinder head - removal and installatIon
Refer to il/ustrations 12.31 and 12.33
Removal Begin the procedure by positioning the number one piston allop dead
center (TOC) on the compression stroke (see Section 3) . 2 Drain Ihecooling system (Chapler 1). Removethe air cleaner assembly and the air duct, 3 Remove the boll relaining the heater hose to the camshaft cover. 4 Detach the distributor cap from the distributor. 5 Label and detach the spark plug wires from the spark plugs and remove the distributor cap and wires as an assembly. Remove the spark plugs. 6 Label and disconnect all vacuum hoses attached 10 the components on the head, 7 Remove the engine 011 dipstick tube by pulling it straight out. 8 Remove the camshaft cover (Section 4). 9 Remove the intake manifold bolls (Section 10). 10 Loosen the alternator mounting bolts, remove the belt Irom the pulley and remove the bracket bolts. 11 Remove the upper radiator hose. 12 Remove the timing belt front cover. 13 Make sure the valve timing is correct (Section 6, Steps 21 through 25). then loosen the timing belttensioner (Section 6). 14 Remove the timing belt from the camshaft and auxiliary shaft sprockets. 15 Removethe exhaust manifold mounting bolts (Section 11) . The manifold itse~ can remain in place. 16 Remove the timing belt tensioner bolts. 17 Remove the timing belt tensioner spring stop from the cylinder head. 18 Disconnect the oil pressure sending unit lead wire at Ihe left rear corner 01 the head. 19 Reier to Section 10 and remove the intake manifold. 20 Using a new head gasket, outline the cylinders and bolt pattern on a piece of cardboard, Be sure to indicate the front of the engine for reference. Punch holes at the bolt locations.
11.11
Exhaust manifold mounting details - 1991 and later modelS
lA 2 .3
Spark plug Exhaust manifold Lifting "eye "
It
48 5 7
CAMSHAFT 90° TO PAN RAil
CAMSHAFT~ 6250 30.9"
/38.9" VIEW A
Regular boll EGO sensor Guide pin
14.0-1 4.5 mm (0.55-0_57 !NCH'l
~l SECTION B
12.31 Be sure to turn the camshaft until the pin Is in the five o 'clock position as shown here before Installing the head 21 Loosen the cylinder head mountmg bolts In 1/4-turn increments until they can be removed by hand. 22 Store the bolts in the cardboard holder as they're removed - this will ensure that they're reinstalled in their original locations.
Chapter 2 Part A fRONT OF £NGINI
2A-ll
Four-cylinder engine M6. IO . 230 HEX FLANGE HEAD SCREW
# Oil PAN AS$V
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ESE .M'GI9$-C SEALER
Cylinder head bolt TIGHTENING sequence
A~FlOX
GUIDE
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30 mm i l/8-INCI-I1
2 PLACES
13.16
23 lilt the head ott the engine. If It'S stuck, don', pry between the head and block. Instead. rap Ihe head with a solt-Iace hammer or a block 01 wood and a hammer to break Ihe gasket seal. 24 Place the head on a block 01 wOOd to prevent damage to the gasket surface. Reier to Part E for cylinder head disassembly and valve sefVlCEI procedures.
Instsllation 25 If a new cylmder head is bemg Installed , transfer all external parts Irom Ihe old cylmder head to the new one. 2S The mating suffaces of the cylinder head and block must be perfectly clean when the head is installed. 27 Use a gasket scraper 10 remove all traces of carbon and old gasket material, then clean the mating surfaces with lacquerlhlnneror acetone. It there's oil on the mating surfaces when the head is Installed, the gasket may not seal correctly and leaks may develop. Use a vacuum cleaner to remove any debns that lalls into the cylinders. 28 Check the block and head malHlQ surfaces for nicks, deep scratches and other damage. If damage is slight, It can be removed With a lile: if iI's exceSSive, machining may be the only al ternative. 29 Use a tap of the correet size \0 chase the threadS In the head boll holes. Mount each bolt In a vise and run a die down the threads to remove COfrOSlon and restore the threads Dirt, corrosion, sealant and damaged threads Will aHeet cfllical head bolt torque readings 30 POSition the new gasket over the dowel pins in the block. 31 Make a maJ1l. on the cylinder head indicating the poSition of the pin in the er.d of the camshah. Turn the camshah until the pin is In the five o'clock poSition - this must be done to avoid damage to the valves when the head is installed (see Illustration). 32 Carefully position the head on the block Without disturbing the gasket. 33 Install the cylinder head bolts ar.d lighten them in sequence (see 11· lustrailon) to the torque listed In thiS Chapter's Specllications. 34 Return the camshaft to its onglOal position (with the pin aligned with the mark you made on the head) , 35 The remalnderol installation is the reverse of the removal procedure. 36 Change the engine oil and liller (Chapter 1).
One-piece 011 pan gasket installailon details - models through 1990
Removal 1 POSition number one piston at Top Dead Center (see SectIOn 3). This Will also position the number lour piston at the top of Its travel, so the oil pan will clear the reaf part of the crankshaft during removal. 2 Disconnect the negative battery cable from the battery. 3 Raise the vehicle and supper! it securely on jackstands. 4 Drain the cooling system (Chapter 1). Remove the fan and shroud and disconnec1 both hoses from the radiatOf (Chapter 3). 5 Drain the oil and remove the oil filter (Chapter 1). 6 Disconnect the oll pan· mounted low oil level sensor, if eqUipped. 7 Refer to Section 17 and detach the engine mounts so the engine can be raised. B USing a block 01 wood to protect the oil pan. carefully raise the engine as lar as It Wlfl safely go with a jack. Then place blocks 01 wood between the mounts and the sublrame btackets. Warning: Don't place any pan of your body under the engineltransmission when 'I's supported only by a jack,' 9 Remove the bolt retaining the flex coupling to the steering gear. Un· bolt the steetlng gear from the chaSSIS and position itlorward and down. 10 Remove the chassis stlHenlng brace (vehictes so eqUIpped), 11 Unbolt the sway bar (see Chapter 10) and lower 1\ out 01 the way. 12 Remove the starter motor (Chapter 5). 13 Remove the oil pan bolls and reinforcements. 14 Break the gasket seal by striking the pan with a rubber hammer, then detach the pan from the block. If the pan hangs up on the oil pump or pick· uptubeandcan'tberemoved,unboltthepumpandplCk·uptubeassembly from the engIne and drop it into lhe pan (see Section 14). 15 Remove alllraces 01 old gasket material and sealant with a gasket scraper,then clean the pan and block mating surfaces with lacquer thinner or acetone. They must be perfectly clean to prevent oil leaks after the pan is Installed Remove and clean the oil pump pick·up screen.
Installation
1978 through 1990 models
Models with. one-piece gasket Refer 10 iIIuslraoon 13. 16 16 Attach the oil pan gasket to the pan with Ford adhesive D7AZ·19B508· A or equivalent. Use a dab of RTV sealant at the corners (see illustration)
Note: Some /986 through 1990 models have a one-pI8C(I oit pan gaskel O/hers have a four·piece gasker Be sure 10 obtain the correc/ type for your anglne.
Models with a four.plece gasket Refer 10 II/us/ralron /3. 17 17 Apply Ford sealer (D7AZ· 19B508·A or equivalent) to the block·to·
13
011 pan - removal and installation
2A
2A - 12
Chapter 2 Part A
Four-cylinder engine
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front cover and rear bearing cap-!o-blockjoinls. Position the end seals in place and press the tabs into the block (see illustration).
All models 18 II the oil pump and pick·up tube were removed, instal! them. il lhey had to be removed for clearance to remove the pan, wait until the pan is lihed into place (Slep 21 J. 19 Install two guide pins (supplied with the gasket sel), as shown in the illustrations. 20 Install the oil pan and bolts (and reinforcement strips. if equipped).
Aemove the guide pins. Inslalithe remaining boilSand tighten them to the torque listed In this Chapter's Specifications (follow a clockwise pattern). 21 The remaining Steps are the reverse of removal. 22 Replace the oil filter, oil and coolant. 23 Run the engine and check for leaks. 24 Remove the jackstands and lower the vehicle.
1991 snd Ister models Removal 25 Disconnect the negative battery cable from the battery. 26 Remove the air cleaner outiet tube at the throttle body (Chapter 4). 27 Drain the engine oil and remove the oil filter (Chapter 1). 28 Raise the vehicle and suppon it securely on jackstands. 29 Remove the engine oil dipstick. 30 Remove the staner (Chapter 5). 31 Disconnect the exhaust manifold tube to the inlet pipe bracket Disconnect the catalytic converler at the Inlet pipe (Chapter 4). 32 Relerto Section 17 and detach the engine mounts so the engine can be raised. 33 Using a block of wood to protect the oil pan carelully raise the engine as far as it will go with a jack. Then place blocks of wood between the mounts and the sub·frame brackets. Warning : Don~ place any parr of
your body under the engineltransmission when it's supported only by a jack! 34 Removethe two oil pan-to-transmission bolts, then removethetransmission (Chapter 7).
35 Remove the flywheel (Section 15). 36 Removethe oit cooter lines from the retainer on the engine block (au· tomatic transmission vehicles) . 37 Remove the oil pan bolts. 38 Break the gasket seal by striking the pan with a rubber hammer, then detach it from the block and iower the pan in the chassis 39 Remove the oil pump drive and pickup lube assembly from the engine and drop it into the pan (Section 14). Remove the oil pan. 40 Remove all traces of old gasket material and silicone sealant with a gasket scraper, then clean the pan and block mating surface with lacquer thinner or acetone. They must be perfectly clean to prevent oil leaks atter the pan is installed. Remove the oil pump pick-up screen. Installation Refer to il/ustration 13.4 1 41 Apply silicone gasket and sealant, Ford E3AZ-19562-A to the six places on the engine block as shown (see illustration). 42 Install the oil pan gasket onto the oil pan and press it into the groove. Thegasket should be retained in the oil pan by press-fit only - not with the aid of an adhesive. 43 Place the 011 pump drive and pickup tube assembly IOta the oil pan in its correct orientation to the engine. 44 Move the oil pan into position In the chassis. Install the oil pump drive and pickup tube assembly onto the engine (Section 14) . 45 Install the oil pan and boilS. Tighten the oil pan bolts tight enough to compress the corXIrubberoil pan gasket to the block. 001 loose enough to allow movement of the oil pan relative to the cylinder block. 46 Install the flywheel (Section 15). 47 Install the transmission (Chapter 7). 48 Using a block of wood to protect the oil pan carefully raise the engine sufficiently until the wood blocks between the moun ts and the sub-frame brackets can be removed , then remove them. 49 Lower the engine, refer to Section 17 and attach the engine mounts. 50 Install the two oil pan'lo-transmlssion bolts and tighten to the Slep 1 torque listed in this Chapter's Specifications. Loosen these two bolts one· half turn.
Chapter 2 Part A
Four-cylinder engine IOOfI..
:u "'='IIO~ ~ _T.......... -
2A-13 ~
13.41 One-pIece oil pan gasket Installation details 1991 and later models
14.2 Tighten all other oil pan flange bolts 10 the torque ~Sled
Oil pump mounting details
2A
57 Remove the jacks lands and lower the vehicle.'
5 Install the pump Intermediate shaft with the collar end in the engine block. Be sure the shaft seats in !he distributor. Hold the shaft in place and Install the pumpand oitpan (see Section 12). Be sure totighten thebottsto the torque ~sted in this Chapler's Specifications. 6 Add oil to the engine (Chapter 1), then start it and besure the oil pres· sure comes up. If it doesn't come up within 10 or 15 seconds. shul off the engine immediately and lind the cause of the problem. caution: Continued running of the engine without oil pressure will severely dam8f)e the mOVIng partsl 7 Check lor oit teaks.
14
15
51
In this
Chap--
tet's Specifications. 52 TlQhten the two 011 pan-Io-transmission bolts to the Step 2 torque ~sled in this Chapler"s Specllications. 53 Inslall the 011 cooler Jines onto the talamer on the engine block (aulomaliC transmission vehicles) .
54 The remaining Steps are the reverse of removal. 55 Replace the oilliller and add oil (Chapter 1). 56 Aun the engine and check for leaks.
all pump - removal and Installation
Refer /0 lIIusrra/ion 14.2 t Remove the oil pan as described in Section 13. Removethe nut securing the pick-up lube to the engine, then remove the bolts secunng the pump to the engine. Remove the pump and pick-up tube as an assembly. then separate them when they're 011 the engine (see illustration). The pump Intermediate shalt should drop out of the bonom of the distnbutor shalt as the pump IS removed. 3 II there is any possibility that the pump is laulty or il an engine overhaul IS being performed. replace the pump. Caution : A faultypumpcanruinan olh6rwise good engine. 4 Pnme the pump before installation. Hold it with the pick-up tube up and pour a few ounces 01 clean oil into the inlet screen. Turn the pump driveshall by hand until oil comes out the outlet. 2
Refer /0 il/us/ralron 15.4 t Raise the vehicle and support it securely on jackstands, then refer to Chapter 7 and remove the transmission. If ~'s leaking, nowwould be a very good time to replace the Iront pump seaVO·ring (automatic transmission only). 2 Remove the pressure plate and clutch disc (see Chapter 8) (manual transmission equipped vehicles). Now is a good time to chec:kfreplace the clutch components and pilot beanng. 3 Use a center-punch to make alignment marks on the flywheel and crankshaft to ensure correct alignment during reinstallation. 4 Remove the bolts that secure the lIywheel to the crankshaft (see Illuslratlon). lIthe crankshalltums, wedge a screwdriver through the starter openmg to jam the flywheel . Jl..YWHEn At«) I'IIfUUfll!'\ATt I'NC11OH SVllFAClI IIlUIT N 111f.E Of DIfIT, GllUSl AND 011.. "'I0Il TO IN STAU.~
"PP'l.V fORO POI.VETi'!VL[NE GIIE"SE OOOU 1_ _ " 011 EOUIV"LENT
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Flywheel- removal and Installallon
"'LOT HOLE RYWHUL " ND ",Essu"[!'\An 1111CTIOtI S-UAfACU ,""UST N fIIU Of DIIIT. CIlEASf: At«) 011.. ~ TO INST"lll1Of
INSTALL WITM lEAl TOWAMl
~-~ RYWHEEl a.UTCH DISC
15.4 fLVWf4EEl
."m
AUlOrol"nc TAANSMISSIQN
Flywheels snd
relsted componentsexploded view
Chapter 2 Part A Four-cylindtr engine
2A-14
4' FRONT O F ENGlNf LUBRICATE SEAL AND CVLINDEA BLOCK SEAL MATING SURFACE WIT~ OIL
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A specIal Ford tool Is recommended to ins tall the rea r main oil seal
17.8
5 Removethe Ilywheellrom the crankshaft. Since the flywheel is fairly heavy, be sure to support it while removing the last boll. 6 Clean the flywheel 10 remove grease and oil. Inspect the surface for
cracks. rivel grooves. burned areas and score marks. Ugh! scoring can be removed with emery cloth. Check larcracted and broken ring gear teeth. Lay the flywheel on a flat surface and use a straightedge to check lor warpage. 7 Clean and inspect the mating surfaces of the flywheel and the crankshaft. lfthecrankshaft rear seal is leaking, replaceilbefore reinstalling the flywheel. 8 Position the flywheel against Ihe crankshaft. Be sure to align the marks made during removal. Note that some engines have an alignment dowel or staggered bolt holes to ensure correct installalion. Before installing the bolts. apply thread locking compound 10 the threads. 9 Wedge a screwdriver through the starter motor opening to keep the flywheel from turning as you tighten the bolts to the torque listed in this Chapter's Specifications. to The remainder of installation is the reverse olthe removal procedure.
16
Rear cranks haft 011 5&al - repla ce ment
Refer /0 illustration 16.5 1 Removethe transmission and all othercomponenls necessary, such as the clutch and pres sura plate, to get at the 011 seal in the back of the engine (Chapters 7 and B). 2 Remove the flywheel (Section 15). 3 Use a small punch to make two holes on opposite sides of the seal and install small sheet metal screws in the holes. Pry on the screws with two large screwdrivers until the seal is removed from the engine. It may be nectlssary to place small blocks of wood against the block to provide a fulcrum point for prying. Cauti on: 8ecareful not to scratch orotherwise damage Ihe crankshaft oil seal surface. 4 Apply a thin film 01 engine oil to the outer edge of the new seal and the seal bore in the block, as well as the seal lips. 5 Position the seal on Ford special tool no. TB2L-6701-A or its equivalen\, then position the tool and seal at the rear of engine (see illustration). Install the seal with the spring side toward the engine. Alternate tightening of the bolts to seat the seal in the block. 6 lithe special seal installer is not available, wor!<. the seal into place and tap it gently into the bore with a soft-lace hammer. Use the drive end 01 a
Engine mount details - typical
socket extension, or other blunt, smooth object. to ease the lip of the seal over the end of the crankshaft. 7 The remainderol installation Is the reverse 01 the removal procedure.
17
Engine mounts - check and replacemen t
Engine mounts seldom require attention, bu t broken or deteriorated mounts should be replaced immediately orthe added strain placed on the driveline components may cause damage or wear.
Check 2 During the check, the engine must be raised slightly to remove the weight from the mounts. 3 Raise the vehicle and support it securely on jackstands.then position a jack under the engine oil pan. Place a large block of wood between the jack head and the oil pan. then carefully raise the engine just enough to take the weight off the mounts. Warning : DO NOT place any part of your body under the engine when it's supported only by a jackl 4 Chad the mounts to see if the rubber is cracked. hardened or separated from the metal plates. Sometimes the fubberwlli split right down the center. S Check tor relative movement between the mount plates and the engine or frame (use a large screwdriver or pry bar to attempt to move the mounts). If movement is noted. lower the engine and tighten the mount fasteners. 6 Rubberpreservative should be applied to the mounts to slow deterioration.
Replacement Refer to illustration 17.8 7 Disconnectthe negative battery cable from the battery, then raise the vehicle and support it securely on jackstands (if not already done). B Remove the lasteners and detach the mount from the frame bracket (see illustration). 9 Raise the engine slightly with a jack or hoist (make sure the fan doesn·t hit the radiator or shrOUd). Remove the mount-to-block nutslbolts and detach the mount. 10 Installation is the reverse of removal. Use thread locking compound on the mount bolts and be sure to tighten them securely.
I, I I
Chapter 2 Part B 3.3 liter inline six-cylinder engine Coolents Clutch pilot beating - removal and installation
Compression check Crankshaft 011 seals - replacement Cylinder Iront cover and timing chain - removal and Inslallal10n Cylinder head - removal and installation
See Chapler 7A See Chapler 2E 13
8 6 Onvebel1- check and ad,ustment See Chapter 1 Engine - removal and installation See Chapter 2E Engine mounts - check and replacement 12 Engme 011 and hiler change See Chapter 1 Engine overhaul - general IntormallOn See Chapler 2E Engine removal - methods and precautions See Chapler 2E Flywheel dllveplate - removal. Inspe1::llon and installation 11
Generallnlormation . . 1 lifters and camshatl - remOllal, Inspection and InSlallalion 9 7 Manifolds - removal and installation Oil pan and oil pump - removal and InslaliallOn 10 Radla tQr - removat and Inslallallon See Chapler 3 Repair operations poSSible With Ihe engine In the vehICle 2 Rocker arm cover and rocker arms - removal 4 and Installation Spark plug replacemenl See Chapler 1 Thermostat - removal and InslallallOn See Chapler 3 Top Dead Cenler (TOC) for number one PlSlon - Iocallllg 3 Valve spnng . relalner and seal - replacemenl 5 Waler pump - removal and Inslallalion See Chapler 3
Specifications
Camshaft end play
o 009 In max
Torque specifications
FI-tbs
Cams hall sprockel boll CamshalllhruSI plate-Io-block bolts Cylinder tronl cover boilS Cylinder head bolts Step I Step 2 Step 3 Vibrallon dampeHo-crankshall bolt PulleY' lo,vlbration damper boll Fuel pump-la-block or Iront cover bolls Flywheel-Io-crankshaft bolls Exhausl manllold-Io-cyllnder head 011IllIer Insert 10 block 0.1 pan-Io-block bolts OIl pump 1n1ellube-lo-oll pump bolts 0.1 pump-la-block bolts Rocker arm shalt -la-cylinder head bolts Rocker arm cover bolts
3510 45 121018 6109 501055 60 to 65 70 to 75 8510 100 3510 50 121018 751085 18t024 1010 IS 7109 1010 IS 1010 15 301035 3105
2B
28 -2
Chapter 2 Part 8 CV~IND E R
3.3 liter inline SI - ylinder engine fiRIN G O RDE R AND AOT Al lOIII
NUMBE RING AND
DISTRI BUTOR LOCATION CLOCKWISE
DISTRI BUTO R
FRONT
/
CAP CLIP POSITION
FRO"lr
Cylinder numbers and firing order
General Information ThiS part of Chapter 2 IS devoted to repair procedu res lor the mime SIX'
cylinder engine. The latter Sections in this part of Chapter 2 cover the reo mOllal and Installation procedures. All mformatlon concernmg engme block and cylinder head servicing can be found in Part E of this Chapter. Many repair procedures included in thiS part are based on the assumption the engine IS stillmslalled in the vehicle. Therefore, il this information is being used dunng a complete engine overhaul. with the engine already ou t of the vehicle and on a stand. many of the sleps included here will not apply. The specifications included In thiS part of Chapter 2 apply only to the engine and procedures found here. For specifications regarding engines other than the Inllne slx·cyllnder. see Part A, Cor 0, whicheve r applies. Part E of Chapter 2 contains the specifications necessary for engine blOCK and cylinder head rebUilding procedures The 3.3 liter six-cylinder engine IS an inline design, with overhead valves operated by hydraulic lifters and pushrods. The camshaft IS located to the righ t of the cranKshaft and IS dnven by the crankshaft via a multi-link timing chain. The camshaft fides on four replaceable bearings The crankshaft IS held In place by seven main beanngs. Each main beanng consists of two replaceable sections. The engine is lubricated by a pressurized Oiling system. 011 is held In the 011 pan where irs splashed on lower engine surfaces, as well as being pumped to the top of the engine (to the valve train), then forced down through the other components of the engine until It returns to the 011 pan. Because vanous components rub against one another. a certain amount of wear Will taKe place. The rate of component wear depends on the cleanliness of the oil and filter and the replacement of all other filte rs at the specified Intervals. OverSize components are available to prolong the operallOnal life of the engine. They Include overSize pistons. pushrods. valve gUides and connecting rod and main bearings.
2
Repai r operations possible with the engine in the vehicle
Many malar repair operations can be accomplished Without removing the engine from the vehicle. Clean the engine compartment and the extenor 01 the engine With some type of degreaser before any work is done. Ifli make the job easier and help keep dirt out of the internal areas of the engine. Depending on the components involved, it may be helpfuf to remove the hood to Improve access to the engine as repairs are performed (refer to Chapter II If necessary). Cover the fenders to prevent damage to the
paint . SpeCial pads are available, bu t an old bedspread or blanket Will also work. If vacuum. exhaust. ollar coolant teaks develop. indicating a need tor gaSKet or seal replacement. the repairs can generally be made With the engine in the vehicle The intaKe and exhaust manifold gaskets. cylinder front (timing) cover gasket, oil pan gasket, crankshaft oil seals and cyhn· der head gasket are all accessible With the engine In place Exterior engine components, such as the Intake and exhaust man· Ifolds. the oil pan (and the oil pump), the water pump. the starter motor. the alternator. the distributor and the fuel system components can be re· moved for repair With the engine In place Since the cylinder head can be removed Without pulling the engine, valve componen t servicing can also be accomplished With the engine In the vehicle. Replacement of the camshaft. timing chain and sprockets is also poSSible With th~ engine in the vehicle. In exl reme cases caused by a lack of necessary equipment, repair or replacement of piston rings. pistons. connecting rods and rod beanngs IS possible w ith the engine in the vehicle However. thiS practice is not rec· ommended because 01 the cleaning and preparation work that must be done to the componen ts involved
3
Top Dead Center (TOC) lor number one pi ston - Iocaling
Note: The followlI'' I9procedure IS basedon Iheassumprlon /hespark plug wires anddlslrlbu/or are correctly ms/alled. If you are /'1mg 10 locale TOC /0 ms/all the dls/flbulor correctly. pis/on poSition muSI be delermmed by feelmg for compression al rhe number one spark plug hole. rhen aligning the Igm/lon /lmmg marks as deSCribed In Slep 8. 1 Top Dead Center (TOC) IS the highest POint in the cylinder each p'stOfl reaches as It travels up-and·down when Ihe crankshaft tums Each plslon reaches TOC on the compreSSion stroke and again on the exhaust stroke, but TDC generall~ reters to piston poSition on the compression stroke. 2 POSltlonmg the plslon(s) at TDC IS an essential part of many procedures such as rocker arm removal , camshaft and liming cham/ sprocket removal and distnbutor removal 3 Before beginning th is procedure. be sure to place the transmiSSion in Neutral and apply the parking brake or block the rear wheels. Also . disable the Ignition system by detaching the 'coil Wire from the center terminal of the dlstnbutor cap and grounding It on the block With a Jumper wire. Remove the sparK plugs (see Chapter 1)_ 4 To bring any Piston \0 TOC , the crankshaft must be turned uSing one of the methods ou tlined below. When looking at the front of The engme. normal crankshaft rotat ion is ClOCKWise a) The prelerred method IS to turn the crankshaft With a socket and ratchet attached to the bolt Ihreaded 111\0 the front of the crankshaft
i
Chapter 2 part:j 3.3 liter in line six-cylinder engine b) A remote starter sWitch. which may save some time, can also be use
4
28-3
Rocker arm cover and rocker arm s - remoYal and Installal10n
Refer /0 Illustrations 4.4, 45, 4 8a, 4 8b, 4 lOaOO4. /4
Removal t Remove the air cleaner assembly and the crankcase ventllalton system (Chapter 6) , Remove the accelerator cable bracket. 2 3 Remove the rocker arm cover bolts and separate the rocker arm cover from the ellQlne. Discard the rocker arm cover gasket. 4 Loosen the rocker arm shalt bolts t l2·lurn at a time in the recom· mended sequence (see illustration) 5 Remove the rocker arm shalt assembly (see Illustration). Make sure the pushrods are IdentJiied before removal so they can be returned to the same locallon dunng installatIOn, 6 Remove the pushrods
Installation 7 Apply moly·base grease or engine assembly lube 10 bolh ends ot Ihe pushrods and 10 the valve stem tipS
2B
4.4 When removing or installing the rocker arm shaH, loosen or lighten the bolls In the sequence Shown here
tOLl
\
----
----...
FRON T OF ENGINE
St
PLUG
suPl'OAT SOL THOLES
I~
~ PIN
$l'RI N GWASHER
4.5
Rocker arm shaH component s - exploded view
,.
2B-4
Chapter 2 Part B
4.8a Lubricate the pushrod ends with molv-base grease or engine assemblv lube belore installation
3.3 liter inline six-cylinder engine
4.8b Make sure Ihe pushrods are engaged in the rocker arms belore Installing the bolts
4.10
Tighten the rocker arm shalt bolts to the specified torque
8 Instalilhe pushrods (see illustrations) and posllion the rocker arm shaft assemblV on Ihe cV llnder head 9 Inslall and Ilghl en aU lhe rocker arm support boilS 112-turn at a time 11"1 the recommended sequence (see Illustration 4.4) unlil the supports con· lact the cylinder head. 10 Tighten the bolts to the speCIfied torque In Ihe same sequence (see Illustration) 11 Check Ihe valve clearance followll"lg the procedure in Chapter 2. Part E 12 Clean the rocker arm cover and cvlmder head gasket sunaces. 13 InSl ali a new gaskel in the cover Make sure all the gasket tangs are engaged in the notches prOVided 10 Ihe cover 14 Install the cover tsee 11Iustratlon) and tighten Ihe bolts 10 two steps First tighten the bolts to lille It-Ibs.then retighten them to hve It-Ibs agam two mlOutes later 15 Inslail lhe accelerator cable bracket 16 Install the crankcase ven\l lallOn system and air cleaner assembly 4.14 Make sure all gasket surfaces are clean belore installing the rocker arm Caller - if the COlier flange is distorted (this usually happens around the bolt holes), use a hammer and block 01 wood to lIatten and restore it
5
Valve spring , retainer and seal- replacement
Refer to il/ustratlons 5 4 and 5 10
5.4
Use an air line adapter and compressed air to hold the vallie closed while compressing Ihe vallie spring
Nole: Broken valve spnngs and defecllve lIalve stem seals can be reo placed wlthoul removmg the cylinder head Two special tools and a compressed alrsource are normally reqUired to perform thiS operation. so read through thiS Secllon carefully and renl or buy the tools before begmnmg the Job If compressed all Isn'l available. a length of nylon rope can be used to keep the valves from falling 1010 the cylmder durmg thiS procedure. I Rel erto Section 4 and remove the rocker arm cover from Ihe cy llOder head 2 Remove the spark plug from Ihe cyl inder which has the del ectlye component If all of the vallie Slem seals are bell"lg replaced. all of Ihe spark plugs should be removed. 3 Turn Ihe crankshaft untillhe piSlon 11"1 the allected cylinder IS al top dead cente r on the compreSSion stroke (refer to Section 3101 instructions). If you're replaCing all of Ihe valve stem seals. begin With cylinder number one and work on the valves lor one cY"l lnder al a lime Move from cylinder· lo·cyllnder follOWing the fir ing order sequence (see this Chapter's Speci!i· callons) 4 Thread an adapter into Ihe spark plug hole (see illustration) and connect an air hose Irom a compressed all source to It Most aula parts stores can supply the air hose adapter Note: Many cylmder compression gauges utilize a screw-m flllmg that may work With your alf hose qUick ·dlsconnect fl/fmg
Chapter 2 Part B
3.3 liter inline six-cylinder engine
2B -5
rope was used Instead of 3Jr pressure, turn the crankshatt In the nofmal dlfecllon 01 rotatlOO untlt slIght resIstance is leI\. I S Lubricate the valve stem With engine all and ,"slall a new seal 16 Install the spring and sleeve In poSition over the valve . 17 Install the valve spnng relalner. Compress the valve spring and carefully poSition the keepers," the groove. Apply a small danolgrease to Ihe ,"side 01 each keeper to hold it in place. I 8 Remove the pressure from the spring tool and make su re the keepers are seated. 19 Disconnect the al( hose and remove the adapter from the spark plug hole. II a rope was used in place 01 alt pressure. pull it oul 01 the cylinder 20 Reier to Section 4 and install the rocker arm assembly and pushrods 21 tnstallthe spark plug(s) and hook up the Wlr~s) . 22 Reter \0 Secllon 4 and Install the rocker arm cover 23 Start and run theengme , then check lor 011 leaks and unusual sounds coming from the rocker arm cover area
, 5.10 Removing Ine umbrella-type valve stem seal - when installing Ihe new seal, Ihe open end must lace the cylinder head 5 Loosen Ihe rocker arm shalt support bolts unlit valve spring tenSion IS relieved. Slide the rocker arms to the SIde and restrain them WIth pieces 01 wire . then remove both pushrods Irom Ihecyllnderto be servICed Note: If ai/ the valvesrem seals must be replacecJ. remove l/lerocker arm assembly (refer /0 Sec/Ion 41_ 6 Apply compressed air 10 Ihe cylinder Warning : The PIston may be
lorced down by compressed alf, causing the crankshaft to /Urn suddenly If Ihe wrench used when posi/lofllng the number one'piston al TOC is 5/1// attached 10 the boll in the crankshaft nose. II could cause damage or injury when the crankshaft moves
7
The valves should be held In place by the alf pressure. It the valve taces or seats are In poor condition, leaks may prevent air pressure trom retaining the valves - refer to the alternative procedure below 8 II you don·t have access to compressed air. an alternative method can be used POSlilon the piston at a pOint lust before TDC 0f1 the compression stroke. lhen teed a long piece 01 nylon rope through the spark p lug hole unlliit hils the combustion Chamber. Be sure to leave the end of the rope hanging oul ot the engine so It can be removed eaSily Use a large ratchet and socket to turn the cranksha/t In the normal direction at rOtation until shght resistance IS felt 9 Siult shop rag s Into the cyhnder head holes above and below Ihe valves to preven t parts and 100ls trom fai ling Into the engine. then use a valve spnng compresso r 10 compress Ihe spring, Remove the keepers With small needle-nose pliers or a magnet. Note: A couple of different types 01100/5 are available for compressing the valve springs wl/h the head In place One type grips Ihe /o wer spring COIls and plesses on the relalfler as the knob IS turned. while the other type (see Illustration 5.4) utlhzes rhe rocker arm shafl for leverage Both types work very well. although the lever type IS usually less expenSive to Remove thespnng retainer steeve and valve spnng. then remove the umbrella-type gUide seal (see Illu stration ) Note : If air pressure falls to hold the valve IfI lhe closed posilion durmg Ihls operallon. the valve face or
sealrs probably damaged. If sO,lhe cylinder head will have lobe removed lor addilional repalf operaflOns. II Wrap a rubber band or tape around the top o t Ihe valve stem so the valve won I lalllnlO the combustion chamber, then release Ihe air pres sure. No te: /I a rope was used Instead of alfpressure, tum the crankshaft
slightly In the alrec/lon opposite normal rotairon 12 Inspect the valve stem tor damage Rotate the valve In the guide and check the end tor eccentnc movement. which would Indicate the valve IS
be" 13 Move the valve up-and-down In the guide and make sure It doesn t bind If the valve stem binds. either the valve IS bent or the gUide IS dam aged In either case, the head Wi ll have to be removed lor repair_ 14 Reapply air pressure to the cyl inder to fetaln the valve in the closed posllion, then remove the tape or rubber band Irom the valve stem. II a
6
Cylinder head - removat and Inslal1ation
Refer /0 lIIus/ratlon 6.30
Removal Nole: If the engme has been removed 'rom the vehICle. you can slop Steps I through /4
1 Dram the cooling system (Chapter I) . 2 Remove the 3Jr cleaner and hoses/ducts leading to the alf cleaner_ 3 Detach the PCV valve trom the rocker arm cover and remove the valve 4 Remove the vent hose from the intake manllold inlet tube . S Dlsconnecl the 'uelline lead,"g tram the tuel pump \0 the carburetor_ 6 Detach all vacuum IKles tram the carburetor. 7 Disconnect the choke cable al the carburetor and poSi tion It out of the way. 8 Disconnect the accelerator cable or accelerator linkage Irom the carburetor. Remove the return spnng 9 Disconnect Ihe klCkdown link at the carburetor. 10 Remove the upper radIator hose trom the thermostat outlet 11 Remove the heater hose at the coolant outlet elbow 12 Remove the nuts sea.mng the e.haust pipe to the e.haust manifold and support the pipe out of the way t3 Mark the Wires leading to the coil and disconnect them_Remove the COil bracket bolt and secure the coli and bracket out of the way 14 Remove the rocker arm cover (Section 4 ). 15 Remove the rocker arm shalt assembly (Section 4) . 16 Remove the pushrods, Labe l them so they can be remstalled in thelf Oflglnallocatlons - a numbered box or rack Will keep Ihem organized. 17 Disconnect the spark plug wires al the spark plugs. 18 Loosen the cylinder head bolls In 1/ 4-lum Increments unliithey can be removed by hand It you have an engine hOIst or Similar deVICe handy. attach eyelet bolts at the ends 01 the head In the holes provided and lift the head olf the engine block. II equipment of thiS nature Isn't avaltable, have a helper available and carefully pry the head up. olt the block_ Caution : Do nol wedge any tools between the cylmder head and bIocIc gasket matmg surlaces 19 Turn the cyhnder head upside-down and place lion a workbench Note: New and rebUll1 cylinder heads are commonly available 'or engines al dealerships and aulo parts slores Due 10 /he lacI thaI some specialized
tools are necessary for disassembly and inspection of Ihe head, and re placement parts may nOI be readily available. 1/ may be more practICal and economIcal for the home mechanIC /0 purchase a replacement head and install II
20 Another alternatIVe at thIS POint IS to take the cylinder head 10 an automOhVe machine shop or shop Specializing in cylinder heads and e.change It or leave 11 for an overhaul. 21 11 the complete engine IS being overhauled at thiS lime, however, it may be wise to walt until the Other components have been Inspected 22 II you're attempling to repair a part of the cylinder head assembly. or It YOU're gOing 10 Inspect the components yourself. reler to Chapter 2,
Part E
2B
28-6
Chapter 2 Part 8
3.3 liter inline six-cylinder engine INSTRUCT IONS
'NSl .o.u
311- 16 STUD . . .... SH{ " ASSE " BlY _ HOLES ",UMB ERED • • ~ TOROUf TOSl'£C IF leA"ONS. l(8.18 X 2.6180LT _ HOLES l-6-1-. TORQUE TO Sl'EeiFI CATIONS. 318-1& X ' . ' 7 8 0LT - " OLES 1·'·9- ' 0. " TORQUE TO Sl'EClf IC... · TION S.
6.30 Cylinder head bolt TIGHTENING sequence (reverse th e sequence when loosening the bolts)
,
Installation
( X..... USTM ..... ,. O LD
23 The ma\lng surfaces althe head and block must be perfeclly clean
when the head
IS
may not seal correctly and leaks may develop. When working on the block, irs a good Idea to cover the lifters With shop rags to keep debriS oul of them. Use a shop rag or vacuum cleaner to remove any debriS that falls into the cylinders. 25 Check the bfock and head mating surfaces for nicks, deep scratches and other damage. II damage is sligh1. it can be removed With a file: if irs exceSSive, machining may be the only alternative. 26 Use a tap of the correct size to chase the threads in the head bolt holes. Dirt. corrosion. sealant and damaged threads wi ll affect to rque readings. 27 POSition the new gasket over the dowel pins in the block. Some gas· kets are marked TOP or THIS SIDE UP to ensure correct Installation. 28 Carefully position the head on the block without disturbing the gasket. 29 Using the previOusly installed lilting hooks (or a helper), carefully low· er the cylinder head into place on the block. Don ·tlflove the head sideways or scrape It across the block. as It can dislodge the gasket andlordamage the mating surfaces. 30 Coat the cylinder head bolt threads with light engme oil and thread the bolls into the block. Tighten them In the recommended seQuence (see iI· lustrati on). Work up to the final torque in three steps to avoid warpmglhe head 31 Inslallthe pushrods. the rocker arm assembly and the rocker armcov er (Section 4). 32 The remaining steps are the reverse of the removal procedure. 33 Start the engme and allow il to reach operating temperature. Shut It off. allow It to cool completely. then retorque the head bolts. Note: Besure to read the Instructions wl/h Ihe new head gasket. Some gaskets do not reqUire retorqUing - the Instructions With rhe gasker should be followed If they differ from the mstructions here.
7
Man llolds - removal and installation
Refer to Illustration 7.7
Removal 1 Remove the air cleaner assembly and related parts. Tag all wires and vacuum hoses to Simplify Inslallatlon. On later mod· 2 els, a light·off catalyst IS bolted directly to the outlet 01the exhaus t manilold and must be disconnected from the manifold flange . 3 Remove or disconnect the EGR tube and all other emission compo· nents which would mterfere with the removal of the manifold. 4 Remove the manifold mounting boltsmuts. It may be necessary to apply penetrating all to the threads. 5 Detach the manifold.
Installation 6
7.7
installed.
24 Use a gasket scraper to remove all traces of carbon and old gasket matenal, Ihencleanthe matmg surfaces With lacquer thinner or acetone. II there 's oil on the mating surfaces when the head is installed, the gasket
Clean the mating surfaces 01 the mani fold and cylinder head.
Exhaust manifold bolt TIGHTENING sequence
7 Install a new gasket. il applicable. Position the manifold on the cylln· der head and install the bolts/nuts. Tighten the bolts/nuts In sequence to the specified torque (see illustration). 8 Position the light·off catalys t Unit on the exhaust manifold. 9 Install and tighten the mounting nuts . 10 Install or connect the emission component vacuum hoses and wires preVIOusly disconnected. 11 Install the air cleaner assembly and related parts. 12 Start the engine and check for leaks at the manifold{s).
8
Cylinder Iront cover and timing chain - removal and Installation
Refer to illustration 8.5
Removal Drain the cooling system and disconnect the hoses Remove the cooling fan. dTivebetts and the crankshaft and water pump dTive pulleys. 2 Remove the Iront cover-to·englne block and all pan bolts. Carefully pry the cover away from the engine block at the top. Do not nick or gouge the mating sunace of the engine block. 3 Scrape all gasket mateMI and seal anI off the engine block and cover ma\lOg sunaces. then clean them With lacquer thinner or acetone. 4 Before removing the timing chain and sprocke ts. the chain deflection must be checked as follows · a) Turn the crankshaft counterclockwise and take up the slack on the left Side of the cha in. b) Establish a reference point to the left of the tlmmg chain. Measure the distance from the reference point to the cen ter of the left run of the cha in. c) Turn the crankshaft clockWise and take up the slaCk in the right run of the timing chain. d) Press the slack cham In the left run toward the center With your thumb and measure the distance from the reference point to the cen ter of the slack chain on the left run e) Subtlact the smaller figure from the larger and the difference Wi ll be the total deflectIOn. Note: If riming cham deflection is greater than 114·inch, rhe timing chain and sprockets must be replaced. Never replace lust rhe cham or sprockels. replace rhem as a set. S Rotate the crankshaft until the two timing marks on the sprockets are aligned (see illustration) 6 Remove the camshaft sprocket bolt and pull both sprockels away from the front 01 the engine . 7 Clean the chain and sprockets In solvent If you have decided 10 reuse them. Inspect the sprocket teeth for damage and wear and the cham for a distinctive wear pattern. II a wear pattern exists on the cham or the sprock· ets, we recommend that you Install new pans
Chapter 2 Part 8
8.5 The camshaft and crankshaft sprocket timing marks (arrows) must be aligned with each other during installation
3.3 liter inline six-cylinder engine
9.4 Special tools are available for removing lifters. bullhey aren'l always necessary
9.88
28-7
II the bottom 01 any lilter Is worn
concave, scratched or galled. replace the entire set with new ones
2B
Installation 6 POSition the camshaft and crankshaft sprockets In the cham with the tlmmg marks on the sprockets aligned . 9 Slide the two sprockets. comp lete with thellmmg cha in. onto the ends of thE! crankshah and camshaf1 10 Install the camshaft sprocket bolt and lighten II to the specified torque, 11 Belore installing the front cover, check the condition of the oil seal If the seal is dned out or been leakmg, II must be replaced (see Section 13). 12 Apply ATV-sealantlo the new front cover gasket and posItion thegasket on the cover. Coat all exposed portions of the gasket with sealant 13 Install the cover To prevent damage 10 the seal as It passes over the Woodruff key on the crankshaft. place a thin-wail socket over the crank shaft end Make sure the outSide diameter of the socket IS less Ihan the mSlde diameter of the seal 14 Tighten all mounllng bolls lathe specIfied torque 10 three orfour equal sleps. Follow a Criss-cross pattern to avoid warpmg the cover
9
lifters and camshaft - removal , inspection and installation
Lihers
9.8b The foot of each lifter should be slighUy convex -Ihe side of another lifer can be used as a s traightedge 10 check il; if it appears lIal. It's worn and must nol be reused
Refer /0 !I/ustranons 9 4. 9.8a, R8b and 9.8c A nOISy va lve lifter can be isolated when the engine IS Idling Hold a mechafllc's ste thoscope or a length of hose near the loca\lon 01 eaCh valve while listening at the other end Another method IS to remove the rocker arm cover and. with the engine Idling. touch each of the valve spnng retainers. one at a time If a valve hfter IS detective. 11"11 be evident from the shock felt allhe retainer each lime the valve seats. 2 The most likely causes of nOISy valve lifters are dirt trapped InSide the hlter and lack 01 011 flow, VISCOS ity or pressure. Belore condemn ing the hfters, check the oil tor fuel contamination. correct level. cleanl iness and correCI VISCOS ity
Removal 3 Remove the cy linder head and gasket as descnbed In Section 6. 4 There are several ways 10 extracllhe lifters from Ihe bores in the block. A special tool designed to gnp and remove lifters (see iIIustralion)IS manulactured by many tool co mpanies and is Widely available. bu t it may not be reqUired In every case On newer engines without a lot Of var· nlsh bUildup. the lifters can olten be removed With a small magnet or even With your fingers . A machinist's scnbe With a bent end can be used to pull the lilters out by positioning the point under the retainer rmg In the top 01
each litter. Caution: Don '/ use plters to remove the lifters unless you Inlend to replace them With new ones (along wrlh the camShaft). The pliers may damage the preCISion machined and hardened MIers, renderrng them useless 5 Selore removing the lifters. arrange to store them rn aclearly labelled box to ensure they're reinstalled in their original locations. Remove the lifters and store lhem where Ihey won't gel dirty inspection and installation 6 Parts for va lve lifters are not available separately. The work required to remove them from the engine again II cleaning IS unsuccessful outweighs any poten\lal savtngs Irom repairing them. 7 Clean the lifters With solvent and dry them thoroughly Without mlxrng them up. S Check each lifter wall. pushrod seat and fOOl lor SCUffing , score marks and uneven wear (see illustration) Each lifter fOOl (the surface thaI Jides on the cam lobe) must be shghtly convex, although thiS can be difficult 10 delermrne by eye (see illustration). If Ihe base of lhe lifler IS concave. the Irfters and camshaft must be replaced If the lifter walls are damaged or
2B-8
9.6c
Chapter 2 Part B 3.3 liter inline six-cylinder engine
Check the pushrod seal (arrow) In the top of each litter lor wear
9.21 Apply mol y-base grease o r engine assembly lube to the lobes and journals on the camshaft prior to installation
worn (which isn't very likely) , Inspecllhe hlter bores in the engme block as well. If the pushrod seats (see illustration) are worn , check the pushrod ends 9 If new lif1ers are being Installed , a new camshaft must also be installed. If the camshaft is replaced. then install new litters as well. Never install used litters unless the original camshaft is used and the II/ters can be Installed in their onglnallocations! When installing hfters. make sure
Installation 21 Camshaft Installation IS the reverse 01 removal . Coat the cam bearIngs and Journals With a thick , even layer of moly-base grease or engine assembly lube (see illustration)
they 're coated with moly-base grease or engine assembly lube. Soak new
10
Oil pan and oil pump - removal and Installation
hiters in oil to remove trapped air.
Camshaft Refer /0 Illus/ration 9.21
Removal 10 Remove the front COlier, but leave the liming chain and sprockets in place. t t Check the camshaft endplay before removing the camshaft. Install a diaJ Indicator on the Irontolthe engine so the plunger 01 the Indicator rests on the ef'ld of the camshaft. Push the camshall as far to the rear 01the engine block as It Will go and zero the indicator. Push the cams halt to the front of the block as far as it Will go and record the movement indicated on the diaJ indicator. This is the endplay. If Ihe endplay exceeds the service limit given in Ihe specifications. the thrust plate will have to be replaced 12 Remove the timing chain and sprockets (Section S). 13 Remove the bolls and detach the camshaft thrust plate. t4 Carefully pull the camshaft out of the blOCk. Oon'l damage the bearings With the cam lobes. Inspection 15 Aller the camshaft has been removed from the engine. cleaned With solvent and dned. inspect the beanng Journals for uneven wear, pilling and evidence of seizure. If the journals are damaged, the beanng Inserts in Ihe block are probably damaged as well. Both the camshaft and bearings Will have to be replaced . t6 Measure the bearing Journals Wi th a micrometer to de termine If they 're e~cessively worn or out-of-round . 17 Check the camshaft lobes and beaflng Journals lor heat discolorallon. scoremark.s, chipped areas, pitting and uneven wear. If the lobes and journals are In good condilion , the camshaft can be reused . 18 Check the bearings In the block for wear and damage. look for gall1n9, pining and discolored areas. 19 The Inside diameter of each beaflng can be del ermined Wllh a small hole gauge and oulslde micrometer or an inSide micro meier. Subtract the camshall beaflng journal dlameter(s) trom the corresponding beaflng InSide diameter(s) to obtain the bearing 011 clearance. II irs e~cessive, new bearings will be required regardless of the condition of the onginals. 20 Camshaft bearing replacemen t requires speciallools and expertise that place It outside the scope of the home mechanic. Remove the engine and take the block to an automotive machine shop to ensure the job IS done correctly.
Refer /0 II/usrrallons 10.25 and 10.29 Note: This procedure IS for removal and ms/aliallOn of /he 011 pan With the engme 10 the vehicle only. If /he engme has been removed for an overhaul. follow Step II andS/eps 13/hrough27
Removal Dram the engine oil and disconnect the negative cable at the battery. Remove the oil dipstick. 2 Drain the cooling system. 3 Remove the radiator as descnbed In Chapter 3 RaJse the vehicle and support II securely on jackstands. Disconnect 4 the starter cab le at the starter, 5 Remove the sl arter Irom the bellhousmg 6 Remove the four nuts and bolts anaching the sway bar to the chaSSIS and allow the sway bar to hang down 7 Remove the K·brace . 8 Remove the bolt retalrllng the flex coupling to the steering gear. Unbolt the steenng gear Irom the chaSSIS and poSllion It forward and down 9 Remove the engine Iront insulator'lo-support bracket retaming nuts. loosen the two rear engme support boilS. 10 Raise the fronl of the engine With a Jack. Place a thick wooden block between the Jack and the all pan. II Place 1-1/4-inch wood blocks between the Iront support insulators and the support ing brackets 12 Place a jack beneath the tranSmiSSiOn and raise It ,ust enough to pro· Vide removal clearance for the oil pan. 13 lower lhe engme on to the spacer blocks and remove the jack. 14 Remove the all pan bolts. 15 lower lhe pan to the crossmember 16 Remove the two all pump Inlet tube·to-oll pump retainmg bolts. t7 Remove the all pump inlet assemply and allow It to rest in Ihe oil pan. IS RemovetheOl1 pan from the vehicle. 11 may be necessary to rotate the crankshafl for the coun terweights to ctear the pan. 19 Clean all old gasket materiallrom the matmg surlaces of the block and the pan. 1
Installation 20 Remove the rear main beaflng cap 011 pan seal. 21 Remove the timing cover 011 pan seal
Chapter 2 Part B
3.3 liter inline six-cylinder engine
2B-9
28
10.25
Oil pan gaskets and seals
J/8 · 1~ NUT TIG HTEN TO Sf'ECIF ICATIOfllS
OIL P UMP A,SSY.
31 Raise the engine with a jack and a block of wood underneath the 011 pan and remove the wood spacers previously Installed under the support brackels. 32 Lower the engine to the correct Installed position and mslalilhe front and rear engine mount bolts/nuts. 33 The remainder of installation is the reverse of the removal procedure. 34 Start the engine and check carefully for leaks at the oil pan gasket surfaces
11
ThiS procedure is essen tially the same for all engines Refer to Part A and fo llow the procedure ou tlined there.
FRONT OF ENGINE '--
~ 10.29
Flywheell driveplate - removal , Inspection and installation
011 pump Installation details
22 Clean all matmg sunaces and seal grooves. 23 Install a new 011pan to-front cover 011 seal 24 Install a new rear main bearmg cap seal. 25 Inslall new 011 pan Side gaskets on Ihe block (see Illustration) Apply a thin coal of RTV -sealanl to both Sides of the gaskets. 26 Make sure the labs on thelron! and rear seals ill properly into the mal ing slots in the 011 pan Side seals. A small amount of RTV-sealantat each jOint Will help prevent leaks allhese cri tical spots 27 Clean Ihe inlet tube and screen assembly and place 1\ In the oil pan . 28 Posillon Ihe oil pan undernea th Ihe engine 29 Llftlhe inlet tube and screen assembly from the oil pan and secure lIto the 011 pump With a new gaskel (see illustration). Tigh ten the two retain · 109 boilS to the specified torque 30 Attach the oil pan 10 the engine block and install the boll s TIghten the bolts to Ihe specIfied torque. slamng from the cen ler and working out In each direction.
12
Engine mounts - check and replacement
This procedure is essentially the same for all engines. Refer to Part A and fo llow the procedure outlined there
13
Crankshaft oil seals - replacement
Front seal Refer to illustrations 13.6a and 13.6b Note: The factory recommends special tools for proper seal ins/allatloo. 1 Drain the coolant and engine oil (Chapter 1). 2 Remove the radiator. 3 Remove the crankshaft pulley and the timing cover (Section 6). 4 Drive out the 011 seal With a pin punch. 5 Clean out the recess 10 the cover.
28-10
Chapter 2 Part 8
3.3 liter inline six-cylinder engine
13.6b lithe speci al tools aren't available, the seal can be Installed with a secllon of pipe o r a sockellhat has the same outside diameter .$ the seal hdes. remove the dnveplale. 11 Remove Ihe I!ywheel and engine real cover plate Note: Some mod·
13.68
The factory recommends speclallools for InslatlaUon althe Iront cr ankshaft oil seal In the liming cover
6 Coat the outer edge 01 the new seal With grease and Install I! uSing the speclallOOls des'9ned tor this operation (see lIIuslraUon). As an aJtema
live. a large PIece 01 PIpe or a socket can be used to push the new seal In (see illustration). However, use e.-\remecaullon as the seal can be dam· aged eaSily. Drive In the seal unlll It'S completely seated In the recess Make sure !he spring IS properly positioned within the seal. 7 The rest of Inslallallon IS the reverse altha removal procedure
Rear seal Nole : If rear crankshaft 011 seal repiacemen/IS rhe only opera/Ion bemg performed. 1/ can be accomphshed with Ihe engine In the vehJC/e. II, flowever Ihe oil seal IS bemg rep/aced along with the rear mam beanng. the
engme must be removed B Disconnect the negative battery cable from the battery. th en remove the starter 9 Remove the transmisSion (Chapter 7) 10 On manual transmisSion eqUipped vehicles. remove the pressure plate. diSC and clutch assembly On automatIC transmiSSIon equipped ve-
els mcorpora/e a tWO·pl8Ce. spli/·I,p seal which reqUires removal of the re8rmam beanng cap. ff thiS IS /hecase wi/h your vehicle. reler /0 /heprocedure m Chap/er 2, Part E. One,plece seals can be seNlced as follows 12 Use an awl 10 punch IwO holes In Ihe seal Punch the holes on Oppel' Slle SideS ollhe crankshaft. JUSI above Ihe beanng cap-to-engine block Junction 13 Thread a sheet melal screw Into each punched hole 14 Use Iwo large screwOlivers or small pry bars 10 pry against both screws at Ihe same time. removing Ihe seal Blocks of wood placed against the engine Will provide addilionalleverage. 15 Be very careful when periormlng thiS operation - do not damage the seal contacl suriaces 16 Clean the seal recess In Ihe rear 01 the engine block and Ihe main beallng cap t 7 Inspect and clean Ihe 011 seal contact sur1ace 01 the crankshalt t 8 Coat Ihe new 011 seal With engine 011 19 Coat the crankshalt With engine Oil 20 Start the seal Into the cavity in the back 01 the engine With the seal lip laCing lorward, uSing the speCial dflve tOol Make sure the 1001 stays In alignment With the crankshaft untillhe tool contacts tile block See Slep 6 lor seal installation alternatives 21 Inslall the engine rear cover plate 22 Attach the lIywheel (or dnveplale) to the crankshaft 23 Theremalnder a! Inslallallon IS the reverseo! the removal procedure
2C
Chapter 2 Part -C
2.8 liter V6 engine
Contents Camshaft - removal, inspection and installation . 13 15 Cranksha ft 011 seals - replacement . See Chapter 2E Cylinder compression check Cylinder heads - removal and installation ••. 9 Drivebell check. adjustment and replacement See Chapter 1 Engine front cover - removal and Installation 10 Engine 011 and Iilter change. . . . ........... . See Chapter 1 Engine mounts - check and replacement . . 17 See Chapter 2E Engine overhaui- generalmlormation Engine - removal and installa tion See Chapter 2E Exhaust manifolds - removal and installation 8 FlywheeVdnveplale - removal and installation 16 ....... . ..•... General in formation
Intake manitold - removal and installation 7 14 Oil pan and pump - removal and installaTIon Repair operations poSSible With the engine In the vehicle . Rocker arms and pushrods - removal, inspection and Installation . 5 Rocker arm cover(s) - removal and Installation See Chapter 1 Spark plug replacement 11 Timing gears - check, removal and installation 3 Top Dead Center (TDC) for number one piston - locating Valve springs. retainers and seals - replacement 6 12 Valve lifters - removal. Inspection and installation See Chapter 3 Water pump - removal and installation .
, ,
Specllicalion s
General Displacement Cylinder numbers (front· to-rear) left (driver"s) side Right side Firing order ..
2.8 111ers
4-5-6 '·3 1·4·2-5-3-6
Camshah lobe hit (intake and exhaust) Allowable lobe lilt loss . Theoretical val .... e lift@ zero lash (Intake and exhaust) Endplay Standard Service limit . Journal-lo·beanng (oil) clearance Standard Service limil .
0.255 in 0.005 in 0 .3730 In 0.0008 to 0.004 In 0.006 In 0.001 10 0 .002S In O.OOSln
!C-2
Chapter 2 Part C 2.8 liter V6 engine
Journal diameter
No.' No 2
No3 No 4 Journal runoul. maximum (totalllldlCalor reading) Journal OUI-ohoune!. maximum (totallOdlcatof reading) Beam'lg tnSlde diameter
No No No No_
1
2 3 4
Camshaft gear backlash
1.6497 to 1.6505 In 16347 to 1.635510 16197101.620510 1.6047 to 1.6055 In 000510
00003 In 16515to1652311'1 1.6365 to 1 637311'1 1.6215 to 1.6223 In 1 6065 to I 6073 In 0006 to 0010 In
Torque specifications
Fl-Ibs
Camshaft gear bolt
30 to 36 12 to 15 9210103
Camshalllhrus\ plate boilS Crankshaft damper bolt Cylinder head boil S
Slep 1 SIep2 51ep3 Exhaust manifold mounting bolts Exhaust Plpe-Io-manlfold nuls Flywhee~dnyeplale bolls FrOn! cover plate boilS FrOn! cover bol\s Intake manifold bolts/nulS
Step 1 SIep2 Step 3 5tep4 all pump Inlel lube-la-pump boll 0.1 pump Inlet lube· Ie-main bearing cap boll
011 pan bolts Rocker arm cOver boIl S
Rocker arm shalt support bolts
29 to 40 40 to 5 1 65 to 80 271049 251035 47 to 51 12 to 15 12 to 15
3 to 6 610 \I \I 10 15 15 to IS7to 9 12 to 15 710 10 3 to 5 43 to 49
'Retlghten in sequence to 7510 18 fr-Ibs after engine has been run
General inlormaUon ThiS Pan o! Chapter 2 IS devoted to In-vehlc!e repair procedures lor the 2.8 Iller V6 engine AU In!ormation concerning engine removal and in· staUalion and engine block and cylinder head overhaul can be !ound In Pan E 01 thiS Chapter. The 10Uowing repair procedures are based on the assumption that the engille IS Installed In the vehicle. If the engine has been removed Irom the vehicle and mounted on a stand. many 01 the steps ouliined In thiS Pan 01 Chapter 2 Will not apply The SpeCilicauons II'Icluded In thiS Pan 01 Chapter 2 apply only to the procedurescontalnedtn thiS Pan. Pan E 01Chapter 2 con tains the SpeCI"callons necessary lor cylinder head and engine block rebUilding
2
engine In the vehicle The Intake and exhaust manifold gaskets. liming cover gaskets. 011 pan gasket. crankshatt 011 seals and cylinder head gas· kets are aJi acceSSible With the engine In place Extenor engine components, such as the Inlake and eMhaust manIiolds, the oil pan (and the 011 pump), the waler pump, the starter malar. the alterna tor, the distributor and the luel syslem components can be removed lor repall With the engme m place Since the cylinder heads can be removed Without pulling the engine. valve component servlcmg can also be accomplished With the engine In the vehICle. Replacement ot the camshatt and liming gears IS also poSSI· ble WIth the engine In the vehicle In eMtreme cases caused by a lack 01 necessary equipmen t. repall or replacement of plSIon lings. pistons. connectm9 rods and rod beanngs IS poSSible Wit h the engine In the vehicle. However. thiS practice IS not rec· ommended because 01 the cleaning and preparation work that must be done to the components involved
Repair operaUons pos sible with Ihe engine In Ihe vehicle
Many maJOr repan operallons can be accomplished Without removtng the engine Irom the vehicle Clean the engine compartmen t and the exterior 01 the engine With some type 01 degreaserbelore any work is done. It Will make the lob easier and help keep dirt out 01 the tnternal areas 01 the engine, Depending on the components involved, It may be helplul to remove the hood to Improve access 10 the engine as repairs are perlormed (reler to Chapler tll l necessary). Cover Ihe lenders to p!'eventdamage to the pamt SpecIal pads are available. but an old bedsp!'ead or blanket will also wo~
II vacuum, exhaust, 011 or coolant leaks develop, Indicating a need lor gasket or seal replacement. the repairs can generally be made With the
3
Top Dead Center (TOG) tor number one piston - locating
Note: The follo wmg procedure IS based on /he assumptIOn that the spark plug wires and dlS/fibUlor are correct/yms/alled If you are Irymg /0 locale TDC /0 mslall the dlstflbulor correctly. pIs/on poSlflon must be delermmed by feelmg for compression at the number one spark plug hole. then align· mg the tgmtlon tlmmg marks as deSC(lbed In step 8 1 Top Dead Center (TDC) IS the highest POII'I, m the cylinder thaI each piston reaches as 1\ Iravels up-and ·down when the crankshalt turns. Each piston l eaches TOC on the compression stroke and again on the exhaust stroke. but TOC generally relers to Piston poSition on the complesslon Sl roke
Chapter 2 Part C 2 POSItiOning the piston(s) at TDe IS an essential pan of many procedures such as rocker arm removal. camshaft and liming gear removal and distributor removal 3 Before beginning thiS procedure , be sure to place the transmiSSion In Neutral and apply the parking brake orbiock the rear w heels. Also , disable the Ignition system by detaching t~e cOil wire from the center terminal of the distribu tor cap and grounding It on the block with a Jumper wire. Remove the spark plugs (see Chapter 1). In order \0 bring any p iston to TDC. the crankshaft must be turned us4 mg one of the methods outlined below. When looking at the fron t of the en gme, normal crankshaft rotation IS clockWise. a) The preferred me thod IS to lum the crankshaft with a socKet and ratchet at1ached to the bott threaded Into the front of the crankshaft b) A remote starter SWitch , which may save some time. can also be used. Follow the instructions Inctuded w ith the SWit ch. Once the piston IS c lose 10 TDC, use a socket and ratchet asdescnbed In the prevIous paragraph. c) II an assistant is available 10 turn the IgOillon SWitch to the Sl art poSition In short bursts. you can get the piston close to TDC without a remote starter SWi tch. MaKe sure your assistan t IS out 01 the vehicle, away from the ignition SWitch. then use a socket and ratchet as described In Paragraph a) to complete the procedure. 5 Note the position of the te rminal lor the number one spark plug wife on the distributor cap. II the termlnallsn 't marked. follow the plug WIre Irom the number one cyl inder spark plug to the cap. 6 Use a felt-lip pen or chalk to make a mark on the distributor body d" rectly under the term inal 7 Detach the cap from the dlstnbutor and sel lt aSide (see Chapter 1 If necessary). a Turn the crankshaft (see Paragraph 3 abovel untlt the notch in the crankshaft pulley IS aligned with the "TC" mark pointer on the engine front
2.8 liter V6 engine 7 thiS a 9
5
2C - 3
Inslallthe cover and lighten the screws evenly to the torque listed In Chapter's Specifications. The remainder of installation is the reverse of the removal steps. Run the engine and cheCK tor oil leaks.
Rocker arms and pushr ods - removal , Inspection and i n stallation
Remo va l Reier /0 Illustra/ions 5.3 and 5 4 1 Refer to Sec\lOn 4 and detach the rocKer arm cover(s ) from the cylinder head(s) . 2 Loosen the rocker arm shalt support bolls two turns at a time. working from the center out. unlll the bolts can be remolled by hand . lIfl the rocker assembly and all baHle oH of the cylinder head (see il3 lustration) The pms Will hold the components together. 4 Lift the pushrods out of the engine (see IIlustraUon). Place the pushrods In order in a holder so they can be returned to thei r ongmal poSitions.
2e
cover. 9 Look at the dlstnbutor rotor - It should be pOin ting directly at the mark you made on the dis tributor body 10 II the rotor is laO-degrees 011, the number one piston IS at TDC on the e~haust stroke 11 To gel the piston to TDC on the compreSSion stroke. turn the c rank shaft one complete turn (36D -degrees) clockw ise. The rotor should now be pointing at the mark on the distributor When the rotor IS polnllng at the number one spark plug wire terminal In the d,stllbutor cap and the Ignition timing marks are aligned. the number one piston is at TDC on the compression stroke, 12 Afterthe number one piston has been positioned at TDC on the compression stroke, TDC lor any of the remaining pistons can be located by turning the crankshaft and following the filing order, Mark the remaining spark plug Wire terminal locations on the distribu tor body just like you did lor the number one terminal , then number the marks to correspond w ith the cylinder numbers. As you turn the crankshaft. the rotor Will also turn When It'S pointing directly at one of the marks on the distributor. the piston lor that particular cylinder is at TDC on the compression stroke,
4
5.3
Lift off the rocker assembl y and pu shr od s as s hown
Rocker arm cover (s ) - remollal and installation
Remove any emiSSion control components that obstruct access to the cover (see Chapter 6), 2 Mark the spark plug w ires . then disconnect them Irom the spark plugs and lay them back out ot the way (see Chapter 1). 3 Detach the throtlle linkage Irom the carburetor. if necessary. 4 Remove the rocker arm cover screws and lilt the cover 011. II it won 't come 011 eaSily, don't pry It loose. Make sure all screws are removed . then tap lightly on the end of the cover With a rubber mallet or a block at wood and a hammer to break the gasket seal 5 Clean all traces of gasket and sealer from the cover and cylinder head. Aerosol gasket remOllers , available from auto parts stores. can be used to ease gasket removal 6 Coat the rocker cover sideol a new gasket w ith ATV sealer, then Slick the gasket to the cover
5.4
RemOlle Ihe push rods and place them in a rack so they can be returned to their or iginal po sitions
Chapter 2 Part C 2.8 liter V6 engine
2C-4
Rocker arm
flJV\J\!VI
Support
Spring Shaft
::-::- .,
Support
:
Spring wa, har
. -_ __ _ __ Pin
5.5
. oJ
Rocker assembly - exploded view
Inspection Refer /0 ,/Ius/ratIon 5.5 5 Aemove the PIns and disassemble the rocker arm assembly (see illustration ) Place the parts in order on a clean workbench 6 Check each rocker arm for weal , cracks anctotherdamage. especially where the push rods and valve siems conl ae! the locker arm l aces 7 Make Sure the hole al lhe pushrod end 01 each locker arm IS open
Plugging can be cleared with a piece of wire 8 Check each rocker arm bore , and li S correspondmg poSi tion on the rocker shatt olor wear. cracks and galling II the rocker arms or shalt are damaged. replace them wIth new ones 9 Inspeclthe pushroos IOf cracks and excessIVe wear althe ends. Roll each pushrod across a PIece 01 plale glass 10 see II Irs benl (II II wobbles. lIs benl). 10 If necessary, remove Ihe plug from each end of Ihe rOCKer shall. Dn!1 lniO one plug and Insel'1 a long sl eel rod through It to KnOCK out lhe other plug KnOCK out the lirSl plug In lhe same manner 11 II the rOCKer shaft plugs we re removed. tap in new ones With a hammer and SUitable dnll 12 Assemble Ihe rOCKer assembly (see illustration 5.5). lubricate all InctlOfl pomts With engine 011 or assembly lube 13 Installnewconer pms In the ends 01 the rockershalt. Besuretherock· er shalt notches l ace down when the shaft IS Instal!ed
used 10 keep Ihe valves from falling mto Ihe cylinder during Ihls procedure 1 Refer to Secllon 4 and remove Ihe rocker arm cover Irom Ihe affected cylinder head If all of Ihe valve slem seals are being replaced. remove both rOCKer arm covers 2 ~emove lhe spark plug from Ihe cylinder which has Ihe defective component II all 01 the valve stem seals are being replaced . all 01 the sparK plugs should be removed 3 Turn the cranksha ft until the piston In the aHected cylinder is al top dead center on the compression stroke (refer to Section 3 for inSlruC110ns). II you 're rep laCing all of the valve stem seals. begin With cylinder number one and worK on Ihe valves loronecyllnOef at a lime. Move Irom cyllnderto-cylinder lollowlllQ Ihe linng order sequeroce (see Ihls Chapter's Speafl· cabons) . 4 Thread an adapter Into the sparK plug hole (see illustration) and con· nect an air hose Irom a compressed an source to It Most auto parts stores can supply the an hose adapter Note : Many cylinder compression gauges u/l/lze a screlllf-m fl/lmg Inal may work Wllh your alf nose qUick ·dls· connect fitting
Installation 14 Coat each end of each pushrod With assembly lube, then install them In the engine (see illustralion 5.4). 1\ you are relnsta!hng the angina! push· rodS . be sure to return them to their ongmal poSitions 15 Coat the rocker arm pads With lubrrplate or eqUivalent. 16 loosen Ihe valve adjusllng screws several turns 17 Install the all bailie and rOCKer assembly on the engine The nol ch on the shalt should face down 18 PoSItion the rOCKer arm ball ends In the push rods 19 Tighten the rOCKer sha ft suppol'1 bolts two lurns at a lime, from the center oul. to the torque hs ted in 1hls Chapter 's Speclhcatlons 20 The remainder of installation IS the reverse of removal 21 Adjust the valve clearances (see Chapter I ). 22 Run,he engine and check lor leaKS
6
Valve springs, retainers and seals - replacement
Refer 10 Iflus/rallons 6.-4. 6 9and6. to Note: Broken valve spnngs and defeelwe valve slem seals can be replaced wi/hout (emoVlng the cylinder heads Two special tools and a com · pressed air source are normally reqUired to perform thiS operatron, so read Ihrough thiS Section carelully and rent or buy the lools before begmnmg the Job If compressed air isn ', available. a lenglh of ny lon rope can be
6.4
Use an air line and adapter to hold the va lve closed while com pressing Ihe valve spri ng
Chapter 2 Part C
6.9
2C-5
2.8 liter V6 engine
Val ves and rel ated components - exploded view
6.10 The valve stem seals are removed and installed
5 Removethe rocker arm assembly(ies) and pull out the pushrod(s) fOI the cylinder{s) being seNlced. II all of the valve stem seals are being re-
with this special Ford tool or equivalent
placed, all of the rocker arms and pushrods should be removed (refer 10 Seclion 5).
3
6 Apply compressed all to the cylinder. Warning : The piston may be forceddownbycampressedalf. causing Ihecrankshaft to rurnsuddenly./f the wrench used when positioning the number one piston al TDC IS 51111 attached to the bolt In the crankshaft nose. II could cause damage or mjury when the crankshaft moves 7 The valves should be held In place by the air pressure. If the valve faces or seats are in poor condition. leaks may preyen\ alf pressure from retain ing the valves - refer to the alternative procedure below. 8 If you don't have access to compressed air, an alternative method can be used. PosItIOn the piston at a point just before TDC on thecompression stroke. then feed a long piece 01 nylon rope through the spark plug hole until It fills the combustion chamber. Be sure to leave Ihe end of the rope hanging out of the engine so It can be removed eaSily. Use a large ralchet and socket to rotate the crankshaft In the normal direction of rotation until slight resistance IS fell 9 Stull shop rags inlo the ~ylinder head holes above and below the va lves to prevent pans and tools from falling into the engine. then use a valve spring compressor to compress Ihe spring. Remove Ihe locks with small needle·nose pliers or a magnet(see lllustraUon). Note: A couple of different types of 10015 are available forcompressing the valve springs with Ihe head m place One type gnps the lower spring Calls and presses on the retainer as the knob is turned. while the other type. shown in Illustra tion 64. utilizes the rocker shaft for leverage. Both types work very well. al· though Ihe lever type is usually less expensive. 10 Remove the spring reta iner and valve spring, then remove the stem seal With a seal removal tool (see illustration). Note: If air pressure fails 10 hold the valve in /heclosedpositionduring Ihisoperalloo. lhe valve face or seat IS probably damaged. If so, the cylinder head will have to be removed lor addilional repal( operations. 11 Wrap a rubber band or tape around the top of the valve stem so the valve won't fall into the combuslJon chamber. then release the air pressure. Note : If a rope was used instead of air pressure, turn the crankshaft s/lgh/ly in the dlfecllon opposite normal rotation. 12 Inspect the valve stem for damage. Rotate the valve in the guide and check the end for eccentfiC movement, which would indicate thallhe valve IS bent 13 Move the valve up·and -down In the gUide and make sure it doesn't bind . It the valve stem binds. either the valve is bent or the guide is damaged. In either case. the head will have to be removed for repair. 14 Reapply alt pressure to the cylinder to relain the valve in the closed poSition, then remove the tape or rubber band from Ihe valve stem. If a rope was used mSlead of alt pressure. rota te the crankshalt in the normal direction ot rotallon unlll slight resistance is felt. 15 Lubricate the valve stem With engine oil and install a new seal. 16 Install the spring in pesilion over the valve. 17 Install the valve spnng retamer. Compress the valve sprmg and care
,
7
2
2C
6 7.7
8
4
Intake manifold bolt locations and tightening sequence
tully position the locks in the groove. Apply a small dab 01 grease to the inside of each keeper to hold it in place. 1B Remove the pressure Irom the spring tool and make sure the locks are sea ted. 19 Disconnect the air hose and remove the adapter from the spark plug hole. If a rope was used in place of air pressure, pull il out of the cylinder 20 Re ier to Section 5 and IOstalithe rocker armIs) and pushrod(s). 21 Insl all the spark plug(s) and hook up the wire(s). 22 Refer to Section 4 and install the rocker arm cover{s). 23 Start and run the engine. then check foroilleaks and unusual sounds comi ng from the rocker arm cover area.
7
Intake manifold - removal and Instatiation
Removal 1 Disconnect the negative battery cabla from the battery. 2 Remove the air cleaner (see Chapter 4) and disconnect the accelerator cable. 3 Drain the cooling system (see Chapter 1). Disconnect the radiator hose from the thermostat housing and 1he by -pass hose from the mtake manifold (see Chapter 3). 4 Remove the distnbutor (see Chapter 5). 5 Remove the fuel filler (see Chapter 1) and luel hne. 6 Remove the rocker arm covers (see Sechon 4). 7 Aemove the intake manifold bolls and nuts (see illustration). Note: A special crows -fool wrench (Forti tool T72C·65190requivalenl) is required /0 loosen or tighten boll number six when the carburelor IS m·
2C -6
Chapter 2 Part C 2.8 liter V6 engine
RI GHT SIDE
J
CD ,-\ 1
lEFT SIDE
QUI RED
9 .10
8
3REQUIREO::::::::::.:::..----"Qk 8.6 Exhaust manifold bolt/s tud locations and tightening sequence stalled II you don ', have the special 100/, remove the carburetor (see
Chapter 4). B Remove any Wires, hoses or other components that would Interfere with removal, then 1If! the manilold off If the manifold IS slucJ<.. lap illightly wi th a plastic maliello break the gasket seal. II absolutely necessary. pry the manllold oil, but pry against a casllng protrusion. nol against any gasket mating surfaces, or vacuum and oil leaks may occur
Installation Nole: T/16 mating surfaces of the cylinder heads, block and manifold muSI be perfectly clean when the mamfold IS Installed Gasket removal so/vents
In aerosol cans are available al most auto parts stores and may be helpful when removlfIg old gasket ma/enalthat's s/vck to the heads and manifold
Be sure 10 lollow the directIOns prmled on Ihe contamer, 9
Use a gasket scraper to remove all traces at sealant and old gasket material, then clean the mallng surfaces With lacquerthlnneror acetone. II there's old sealan t or all on the mating surf aces when the mani fold is installed, oil or vacuum leaks may develop When working on the heads and block, cover the litter valley With shop rags to keep dirt out of the engine Use a vacuum cleaner to remove any gasket material that falls InIO the Inlake ports In the heads 10 Use a tap at the correct Size to chase the Ihreads In the bolt holes, then use compressed air (If ava~able) to remove the debris Irom the holes Warning: Wear safety glasses or a face shl8ldlOprotecl your eyes when usmg compressed a;rl Remove excess carbon deposlls and CQfrOSlOn from Ihe exhaust and coolant passages In the heads and manifold 1 I Coat the gasket mating surfaces With a thin layer of sealan\. 12 Install the gasket. Be sure to place the lab on the righ l head gasket InIO the cutout In the intake manifold gasket. 13 Carefully se t the manl told In place while the sealan t is stili we I. Cau· tlon : Don't disturb Ihe gaskel and don't move Ihe manifold fore-and-aft afler II contacts lhe gasket. 14 Coat the mamfold bolt bosses With sealant. InstaJlthe bolts and nuts. then ttghten them to the torque hsted In thiS Chapter's Speoflcatlons ,n four sleps, tollowlng Ihe sequeflCe In iIIustrallOn 7.7 Note : If lhecarbure10flS on the manifold. Ford 1001 T72C ·6519 will be necessary to torque bolt number SIX accurately. 15 The remainder of installation is the reverse of removal. 16 Start the engine and check carefully lor leaks at the intake manifold JOints 17 Recheck the mounting bolt and nul torque ,
1
Cylinder head bolt loosening and tighten ing sequence
Elthaust manifolds - remova l and installation
Warning : The engme must be comple/ely cool (allow 1/10 cool for several hours) before attemptmg /hIS procedure - Ihe exhausl manifolds remam very hot after Ihe engme IS shul down and can cause severe burns
Removal Refer to II/uSlratlon 8.6 Remove Ihe alt cleaner (see Chapter 4 ) 2 00 Ihe nght mamlold. remove the heal shroud 3 Raise the vehicle and support it securely on jackstands, then detach the exhaust pipe from the manltold Discard Ihe exhaust pipe gasket 4 Remove the thermactor componen ts as necessary to prOVide remov· al access (see Chapter 6). 5 Disconnect the choke heat tubes from the carburetor, 6 Removethe mamfoklfasteners (see Illustration) , then take the man· Ifold all the engme. 1
Installation 7 Check the manifold for cracks and make sure the fastener threads are clean and undamaged The mamfold and cylinder head maling surfaces must be clean belore the manifolds ale Installed - use a gasket scraper to remove all carbon depoSits amVor gasket malerlal B Place a new gasket on the manllold (usmg two bolls to hold II In POSI ' lion), then poslllOn the manilold on Ihe head and install the remainder of the fasteners. Tighl en them to the torque listed In thiS Chapter's Speclfica· tions, follOWing the sequence shown in illus tration B.6. 9 Insl all a new elthausl plpe ' lo-manlfold gasket, then tighten the pipe. to-manilold tasleners to the torque listed in Ihls Chapter 's Specihcatlons. 10 The remaining installation steps are the reverse 01 removal. II Start the engine and check for exhaust leaks
9
Cylinder heads - removal and In stallation
Refer 10 ,1/uslraI1Ofl9 'o Caution: The engme mus/ be complelely cool when the heads are re · moved, Failure 10 a/low Ihe engme 10 cool off could resull m head warpage Note: Ford recommends the use of gUide Sluds 10 mstall Ihe cylinder heads. These can be made by cutting Ihe heads off of a pair of eXIra cylm · der head bolls, gnndlng a laper and cu/lmg a screwdriver slOI m the CUI ends.
Removal Disconnect the negallve battery cable from Ihe banery Remove the air cleaner (see Chapter 4) and disconnect the acceler a· tor linkage. 3 Drain the cooling system (see Chapter 1)_ 4 Remove the distributor (see Chapter 5)_ 5 Disconnect l he radialor hose from the thermostat hOUSing and the coolan t by·pass hose from the intake manifold (see Chapter 3) 6 Remove the rocker arm covers (see Section 4). 1
2
Chapter 2 Part C
10.12
10.11 Remove the guide s leeves from the Ironl cOlier with your lingers - the sleeve chamfers face the fronl cover
7 8 9
Remove Ihe rocker arms and pushrods (see See1l0n 5). Remove Ihe Intake manifold (see Section 7). Remolle the exhaust manlfold(s) (see Section 8).
10 Loosen the cylinder head bolts in several stages, following the specified sequence (see illustration) 11 Remove the head bolts and lilt the head off. II it IS stuck, try tapping
hghtly With a plastic mallet to break the gasket seal. 111I won', come off, pry carefully at a casting protrUSion. bu t do not pry against any gasket sur· faces or leaks may develop.
Installation 12 The ma\lng surfaces of Ihe cyhnder heads and block must be perlectly clean when Ihe heads are Installed. Use a gaskel-scraper 10 remove all Iraces 01carbon and old gasket matenal. then clean Ihe mating surlaces
With lacquer Ihlnner or acelone. If there's oil on the mating surlaces when the heads are installed. the gaskets may not seal correct ly and leaks may develop. When working on Ihe block. cover the lifter va lley With shop rags 10 keep debris out of Ihe engine. Use a vacuum cleaner 10 remOlle any de· brls thai falls InIO the cylinders 13 Check the block and head mallng surlaces for OIcks. deep scralches and other damage. If damage is slight. il can be removed With a lile - II irs exceSSive , machining (must be done by an automotive machine shop) may be the only aUernahve t4 Use a lap of the correct size 10 chase Ihe threads In Ihe head boll holes. Mounl each bolt In a vise and run a die down Ihe threads to remove corrOSion and reslore the threads. Dirt. corrosion. sealant and damaged threads Will aflecltorque readings. t5 Install the new gaskets on the block. The gaskets are marked FRONT and TOP to indicate correct poSl\lon. Gaskets are not interchangeable between left and nght Sides 16 Install gUide studs In two of Ihe cylinder head bolt holes (see the Note at the beginning Oflhis Section tor instructions on fabricating these Sluds). 17 Install the head over the gUide studs. 18 Install head bolts in the unoccupied holes and tighten them. using just your fingers. Remove the gUide studs, then Install bolts In their holes and lighten them with lingers. 19 Tighten the head bolts In three stages to the correct torque (see thiS Chapter's SpecificatIOns). Tighten them in the order shown In illustration 9.10. 20 The remaining inSlalialion steps are the reverse of removal. 21 Run the engine and check for coolant and all leaks.
10
2C-7
2.8 liter V6 engine
The Irani cover plate and gasket Bre secured with
two bolls 4 Remove the air conchtioning compressor (it eqUipped) and set It aside. DO NOT disconnect any refrigerant lines! 5 Remove the alternator and thermactor pump dnvebelts (see Chap· ter 1). 6 Remove the alternator (see Chapter 5). 7 Remove the thermactor pump (see Chapter 6). 8 Remove the water pump (see Chapter 3). 9 Remove the small outer bolls at the front of the crankshaft dnvebelt pulley and disconnect the pulley from the crankshaft. 10 Remove the front cover boilSand take the front cover off the engine . II Irs stuck. tap It gently with;>. plastiC mallet to break the gasket seal. Do not pry between the gasket surlaces or you may damage them and leaks may develop. 11 Remove the front cover guide sleeves (see Illustration). 12 Remove two bolts tha t secure the Iront cover plate (see illustration) Remove the plate and gasket.
Installation 13 The ma\lng surlaces of the cylinder block, Iront cover plate and front cover must be perlectly clean when the plate and cover are Iflstalled. Use a gasket scraper to remove all traces at carbon and old gasket matenal, then clean the mating surlaces Wi th lacquer thinner or acelone. 14 Apply a thin, even layer 01 sealant to the mating surlaces on the en· gine and the rear side of the front cover plate. 15 Place the cover plate gasket on the englfle, then Install the cover plate (see illustration 10.12) Temporarily Install lour of the front cover screws to poSition the cover plate accurately. Install both cover plate bolts. tighten the bolts to the torque listed in thiS Chapter's Specifications and remove the four screws. 16 Install new seal flngs on the guide sleeves. 17 Install the gUide sleeves. without sealant. In the cylinder block The sleeve chamfers lace the Iron t cover. 18 Apply a thin, even coat 01 sealant 10 the gasket surlace on the front cover. Stick the gasket 10 the cover. 19 Place the front cover on the engine. Install all 01 the cover screws and lighten them two or three turns. 20 Place a centering tool (Ford 1001 T74P 6019-A. or equivalent) in the fron l cover all seal hole 21 Tighten the fronl cover screws to the torque listed in this Chapter's SpeCifications. 22 Remove the centering tool The remaining installation steps are the reverse of removal. 23 Run the engine and check for coolant and oil leaks.
Engine front cover - removal and Installation
Refer
ro illusrrartons
1t
Timing gears - check, removal and Installation
10.11 and 10.12
Removal
Backlash and endp/ay check
1 2 3
Refer 10 d/uSlrations Jf.S:and 11 .8 t Dram the cooling system (see Chapter 1). 2 Remove the oil pan (see Sectlon·t4).
Remove the oil pan (see Secllon 14) . Drain the cooling system (see Chapter t). Remove the fan and radiator (see Chapter 3).
2C
2C-S
11 .5
Chapter 2 Part C
TIming gear backlash Is checked with a dial Indicator po siti oned against one at the camshaH gear teelh
2.S liter V6 engine
11 .8
Camshaft endplay Is ch ecked w i th a dial Indicator placed against the gear bolt bos s
Installation Relertol/iustratlOn 11. 15 13 Install the Woodruff keys (It removed ) t4 Install the camshaft gear and make sure It seats securely against the spacer. Tighten the camshaft gear bolt to the correct torque (see the torque listed m this Chapter's Speclhcatlons), 15 InSlalithe crankshaft gear Be sure the alignment mar1<.s on crank· shalt and camshaft gears are poSi tioned dlreclly opposite each other (see illustration ). 16 The remain ing InstaliaMn steps are the reverse ot removal 17 Run the engine and check. for leaks
12 11 .11
The crankshaft liming gear Is remo ved with a gear puller
3
Remove the front cover (see SeeMn 10).
4
Remove the rocker arm covers (see Section 4). loosen Ihe va lve ad·
justlng screws to relieve the valve spring tension. Set up a dlallndlcalor with ils pointer against one ollhe camshaft gear teeth (see lltuslratlon) 6 Hold the crankshaft gear from turmng and rolate Ihe camshaflg8ar against the d13111'1(1Ica10r. 7 Note the indICator reading (gear backlash). II II IS excessive (see thiS
S
Chapters Specifications), replace Ihe camshaft and crankshaft gears as a
'"8
Set up Ihe dlallndlcalor 10 check camshall endplay (see illuslralion) Push the camsha\t gear back agamst the thrust plate and zero the dlallndl·
cator Pry the camshaft gear forward against the dial mdicator and note the reading (camshaft endplay), 11 II is excessive (see thiS Chapter's SpecllI· callons) , replace the camshalt thrust plale or spacer ring (see Sec lion t 3). These are available In two thicknesses.
9
Valve l itters - remova l. In spection and installation
Removal Refer to Illus/ratlon 122 1 Remove the cylinder head{s) (see Section 9), 2 There are several ways to extract the lifters from their bores, SpeCial tools designed to gnp and remove hfters (Ford 1001 no. T70P· '4151 or equivalent) are manulactured by many tool companies and are Widely available, bul may not be needed In every case Onengmes Without a Iotol varnish bUildup. the lifters can often be removed With a small magnet (see iltustrallon ) or even wllh your lingers A machinist's SCribe With a ben! end can be used to pull the hfters cut by poSl\lonlng Ihe POIn! unde, the ,elaine' flng In the topol each hher. Caution: Don', use pllefS 10 remove the lifters unless you Inlend to replace them WIth new ones (along WIth the cam· shaft) The pliers maydamage lhepreciSIon machined and hardened 11ft· ers. rendering them useless On engines With a lot of sludge and varnish, work the lifrers up and down. usmgcarOuretorcleaner spray to loosen the deposits. 3 Belore removing the hlters, arrange 10 store them In a clearly labeled box 10 ensure that they 're reinstalled In their oflglnallocatlons 4 Remove the lifters and store them where they won't get dirty
Inspection Removal RefertOlilustrallons II, II and II. 12 10 Removethecamsha\t timing gear boll. Tapthe \Jmlng gear lightly With a plastIC mallet to separate 1\ trom the camshalt II Remove the crankshaft timing gear w1\h a gear puller (see i llustra· tio n) 12 II necessary, remove the tlmu'\g gear Woodruff keys (see lIIustra· tlon).
Retenoi/lustrallOn 12,6 5 Clean the hfters With solvenl and dry them thoroughly wlthoul mIXIng them up 6 Check each Illler wall , pushrad seal and loot lor scuffing. score marlls and uneven wear Each litter 1001 (Che surface thaI fides on the cam lobe) must be sllghlly convex. although thiS can be difficult to determme by eye, Note : Placmg the fool 01 one lifler agamst the side 01 another may help you determme If Ihe foot IS convex II the base 01 the IIIrer is concave{ see lIIus·
Chapter 2 Part C
2C -9
2.8 liter V6 engine
BEARINGS
C.... HAFl· m"NG GEAR
KEy----
~
WASHE~JEW
....
'\
CAMSHAFT REAR BEARING BORE PLUG
THRUST PLATE
r
BOLT
SCREW 11 .12
Camshaft components - exploded view
2C
/ 11.15 TIming marks on the gears must be direcUy opposite each other alter Ihe gears are installed
Iralion). the Mers and camshaft must be replaced. If the lifler walls are damagedorwom (which isn't very likely) , Inspect/he lifrerbores In the en gme block as well 7 II new htters are being installed. a new camshaft must also be installed. If a new camshaft IS Installed. then use new lifters as well. Never install used lifters unless the original camshaft is used and the lifters can be reinstalled In thelf originallocationsl
Installation 8 The originallilters, if they 're being reinstalled, must be returned to their Orlgmalloca!tons_ Coat them With moly-base grease or engme assembly lube. 9 Install the Illters m the bores. 10 The remaining Installation steps are the reverse 01 removal. 11 Adjust the valve clearances (see Chapter 1).
13
12.2 If the lifters are not heavily coated with varnish, it may be possible to remove them with 8 magnet
A.CCEPTA.IIl-E ICONTACT FACE
,.......-.,--........ UNACCEPTA.8lf
FLAT
CONCAVE
Camshaft - removal , Inspection and installation
Camshaft lobe lift check In order to determme the ex tent 01 cam lobe wear, the lobe 11ft should be checKed prior to camshaft removal. Reier to Section 4 and remove the rOCKer arm covers. The rocKer arm assembly must also be removed (Secti on 5). but leave the pushrods in place.
12.6 Lifters In good condition should be slightly conve)( -litters worn 'Iat or concave should be replaced (the contours shown are exaggerated lor clarity)
2C -10
Chapter 2 Part C
2.8 liter V6 engine
••
• (i; , :~
• " • •
•
•
"
"
0
~
I 'N5T"l~
IH[$E BOlTS fIRS!
I
"
... ...-----0
'"\~ ).
" I!l._ _ .l---::::=-=-=~-'-...
~
F,.ONT Of ENGINE
4 •
" 13.25
2
Instalilhe camshaH thrust pl ale so it covers the all gallery
POSition the number one piston at TOe on the compression stroke
(see Section 3). 3 Beginning With Ihe number one cylinder. mount a dial mdicator on Ihe engme and poSition Ihe plunger In-line With and resting on Ihe first push·
",,,
4 Zero the dlalln(lIcator, Ihen very slowly tum Ihe crankshaft In Ihe nOfmal direction 01 rotatIOn until the indicator needle stops and begins to move In Ihe opposite directIOn. The pOint at which It stops Indicates ma)(1mum cam lobe 11ft. 5 Record thiS figure lor fulure relerence, then repoSitIOn the piston al TOC on Ihe compression slfoke 6 Movethe dial indicator to the remaining number one cylinder pushrod and repeat the check. Be sure to record the results for each valve. 7 Repeat Ihe check for the remaining valves. Since each pisl on must be at TDC on the compression stroke for this procedure, work from cylinderto·cylinder 101l0wlI"lQ the firing order sequence. 8 AUer the check IS complete. compare the results to thiS Chapter's Specifications II camshaft lobe 11ft is less Ihan specified. cam lobe wear has occurred and a new camshaft should be Installed
"
"
"
ro
•
"
l<
0
" "
14.9 Oil pan bolt local lons and Ughtenlng sequence
and be careful nol lo scrape or nick the bearings. 24 Insl allthe spacer ring wllh its chamfered Side toward the camshaft 25 Install the camshaft Woodruff key 26 Apply moly-base grease or engine assembly lube to the friction sur· faces on both Sides of the thrust plate. InSlalithe thrust ptale so It covers the oil !1allery (see illustration) then tighten the aUachlng boilS to the torque listed In thiS Chapter 's SpeclhcatlOns 27 The remaining InstallalJon steps are Ihe reverse of removal 28 Belore startJOg the engine. refill It with 011 and Install a new o.II,l1er (see Chapter 1).
14
011 pan and pump - rem oval and Installation
Refer ro Illustralion 149
Removal
Inspection
Disconnect the ~atlve battery cable frorTtthe battery 2 Remove the Ian shroud bolts and place [he shrood over the Ian (see Chapter 3) 3 II necessary for access. Jack up the vehICle and place II securely on Jackslands DO NOT get ullder a vehicle that IS supporteO only by a lack l 4 Dram the engine 011 and replace the dram plug (see Chapter 1) 5 Unbolt Ihe sleeting gear !rom the crossmember (see Chapter to). Move the steeling gear so It resls on the Irame and prOVides removal ac· cess l or the all pan. 6 Remove the engine mount nUlS (see Section 18) 7 Place a lack beneath Ihe engme all pan Use a blockol wood between Ihe jack and engine to prevent damage. Raise the engine. place 2 X 4 wOOden blocks beneath the engine moonts and lower the jack 8 Remove Ihe 10Uf bolts secuflOg the rear K·braces 9 Remove the all pan mounting bolts (see Ill ustration ) Lower the pan tothe frame lilt IS stuck. tap It lightly w!lh a rubber mallet to break the gasket seal Reach lOlO Ihe all pan and remove [he all ptJmp and pick-up screen attaching bolts. Lower Ihe all pump. IntermeOla[e shalt and p,ck·up tube lOtO the all pan. 10 Take Ihe all pan out I! necessary. rotate Ihe crankshaft so the all pan clears the crankshaft throws
20 Refer to Part A. Section 7. for the camshaft and bearing inspection procedure. Lifter Inspection procedures are covered In Section t2.
Installation
Removal Remove the rocker arm covers (see Sec1l0n 4). Remove the rocker arms and pushrods (see SectIOn 5). Remove the Intake manifold (see SecMn 7). Remove the cylinder heads (see Section 9). Remove the Iilters (see SecMn 12). Remove the 011 pan (see Sec\lOn 14). Remove the engine front cover (see Section 10). Remove the camshaft timing gear bolt (see Illustration 11 .12). 17 Remove the camshaft thrust plale screws and take olf the thrust plate 18 Carefully pull the camshaft Irom the blOCk. rotating It as you pull Thread a long bolt Into the timing gear bolt hole to act as a handle Use both hands and carefully support the camshaft near the block. Work slowly and carefully to prevent damaging the camshah beating surlaces dutlng reo moval 19 Remove the Woodrulf key and spacer flng from the camsha ft
9 to 11 t2 t3 14 15 16
Bearing replacement 21 Camshaft bearing replacement requites special tools and expertise that place It ootside the scope 01 the home mechanIC. Take the block 10 an automo\lve machine shop to ensure that the JOb IS done correctly.
Installation Refer 10 IlIusrra/lon 13.26 22 Lubflcale Ihe camshaft beating lournals and cam lobes With molybase grease or engine assembly lube 23 Slide the camshaft into the engine Support the cam near the block
I
t I Use a gasket scraper or putty knlle to remove all traces 01 gasket rna · terral and sealant tram the pan. block and ffOnt cover 12 Clean the mating surfaces With lacquer thlOneror acelone Make sure the block and front cover bolt hOles are clean. 13 Check the oil pan lIange for dlstotllon. particularly around the bolt hOles 11 necessary placethe pan on a btockot wood and use a hammerto lIanen and restore the gasket surlace 14 Remove Ihe old rubber seals tram the rear main beanng cap and en· gine front cover. then clean Ihe grooves 15 Install new seals. Use gasket contact adheSive [0 hold the seals In place.lhen apply a bead of RTV sealant to the block-la-seal Junctions
Chapter 2 Part C
15.4 Removing the Iront cover oil seal wllh a seal puller (cover Ins talled on the engine)
2.8 liter V6 engine
15.7 A Ford 1001 is available 10 Inslal1 the front cover seal with the ftont cover on the engine - a large socket or piece of pipe the same diameter as the seal
2C -11
15. 14 Drive Ihe seal in squarely and evenly - a large socket or piece of pipe can be used if a seal driver Isn't available (cover removed from engine)
can also be used 16 Stick new ga!=kets to the engine with gasket contact adheSive. 17 Posilion the 011 pump and ,nlet lube In the oil pan Caution: Be sure the m/ermed/sle shaft 15 ins/ailed In the 011 pump. or the pump won" lurn when the engme IS run 18 Instalilhe 011 pump. then the 011 pan Tighten the bolts to the torque listed In thiS Chapter sSpeclhcatlOns Follow the sEl'Quenc:e shown In dlus-
Irahon 149 19 The remammg InSlatlatlon sleps are the reverse 01 removal 20 Install a new 0,1 hllel (see Chapter I). Fllllhe engme With 011 21 Run the engme and check tor leaks
15
Cranksnaft 011 se al s - replacement
Front seal- engine front cover in place Refer 10 il/uslratlons 15 4 and 15, 7 1 Dram the coo lmg system and remove tne drivebeits (see Chapter 1), 2 Remove the radia tor (Chapter 3) 3 Remove the cranksha ft dnvebelt pulley. 4 Remove the seal with a slide hammer and seal puller (see illustra· tion ) Similar tools are available trom rental ou tlets. 5 Check the seal bore and crankshaft, as wel l as the seal contact sur· l ace on Ihe crankshatt pulley. tor nicks or burrs. POSition Ihe new seal m the bore With the open end ol\he seal facmg IN 6 A small amount 01 all applied to the outer edge ot the seal Will make installation easier - cIon 't overclo II' 7 Carefully dnve the seallnlO the bore unt,t,! seals agamst the Iron! cover Special tools are available (see Illus tration ). but If you don't have them. use a hammer and a socket the same diameter as the seal to dnve the seal In Note: A ptece of PIpe can be used" a sockel/sn 'l aVdllabie 8 Reinstall the crankshaft p!.IlIey and lighten ItS bolt (see Ihe torque Iisled In thiS Chapters Specifications). The remaining InSlallallon sleps are the reverse of removal 9 10 Run the engine alld check tor leaks
seal dnver (see illu stration) It a seal dnver isnt available, use a socket or piece 01 pipe the same diameter as the seal
Rear seal Referto Illus/ralions 15.20 and 15.24 15 Remove the transmiSSion (see Chapter 7). 16 Remove the clulch (il eqUipped) (see Chapter 8) . 17 Rerr.ove the lIywheel (see Section 16). 18 Remove the engine rear plale 19 With a sharp awl or Similar tool , punch two holes 10 the seal on opposlle Sides just above Ihe POIOI whefe the main beaflng cap meets Ihe cylinder block 20 Thread a sheet metal screw InlO each hole (see Illustration) Pry against the sheet metal screws With two large screwdnvers or small pry bars 10 remOve the seal. Note: If you need a fulcrum 10 pryagainsl, use small blocks of wood Caution : Oon '/ scra/chorgouge Ihecrankshaftseaf surface 21 Clean Ihe 011 seal bore 10 the block and main beaTing cap. CheCK the seal bore and crankshatt sealing surface for nicks or burrs 22 App ly a thin coal 01clean engme all to the outer diameter of the seal. Apply a'thln coat 01 Lubnplale or eqUivalent 10 the con tact surfaces of the seal and crankshalt 23 POSition the seal In the bore With ItS open end laCing IN 24 Drive the seal in With a seal dflver (see Illustration) until It IS securely seated Use a socket Of ~ece 01 pipe the same diameter as the seal II a sea! dflver isnl available
Front seal- fronl cover removed Refer/olf/ustrallon 1514 11 Support the Iront cover on wooden blocks. then drive out the seal With a punch and hammer 12 Check the seal bore In Ihe Iront cover for nicks or burrs 13 Apply a Ihln coal 01clean engine 011 to the ou ter Circumference 01 the seal. 14 POSlllon Ihe new seal With its lip lacmg IN Dnve In the new seal With a
15,20
Thread two sheet metal screws Into the cranKshalt rear 011 seal to pry II out
2C
2C-12
Chapter 2 Part C
2.8 liter V6 engine stalling the ilywheelfdrlyepla te. 8 Position the lIywhee1JdrlYepiale against the crankshaft. Be sure to align the mark s made during removal. NOle that some engines have an alignment dowel or staggered bolt holes \0 ensure co rrect installallon. Before installing the bolts, apply thread locking compound to the Ihreads. 9 Wedge a screwdriver through the starter motor opening to keep the flywheel/driyeplate tram turning as you tighten the bolts to Ihe to rque listed in thiS Chapter's the torque listed in this Chapter's Specilicatlons. 10 The remalnderol installation is the reverse ollhe remoyal procedure.
17
Engine mounts - check and replacement
Refer to iIIus/ratlon 17.B I Engine moun ts seldom require allen1l0n, but broken or deteriora ted mounts should be replaced immediately or the added strain placed on the dnyellne components may cause damage or wear.
15.24 los tall the cra nkshaft rear oil seal with the open end facing into the engine - use a socket o r large piece 01 pipe II a seal driver Isn' l available
16
Flvwheelldrlveplate - removal and installation
Raise the vehicle and support II securely on J8ckstands, then refer to Chapter 7 and remove the transmission. If it's leaking. now would be a very good lime 10 replace Ihe front pump seallO-ring (automatic transmission only).
2 Remove the pressure plate and clutch disc (see Chapter 8) (manual transmiSSion equipped vehicles). Now is a good time to check/replace the clutch components and pilot bearing 3 Use a cenler-punch to make alignment marks on the flywheel/drlveplate and crankshaft to ensure correct alignment during relnstaliallOn. 4 Remove the bolts that secure the flywheel/dnveplate to the crank shaft If the crankshaft turns, wedge a screwdriver through the starter opening to Jam Ihe lIywheeL 5 Remove Ihe lIywheell driveplate from the crankshaft Since the lIywheel is fairly heavy. be sure to support il while removing the last boll 6 Ctean the flywheel to remove grease and oil Inspect the surface for cracks, nyet grooves, burned areas and score marks. Light scoring can be removed wllh emery ctoth. Check for cracked and broken ring gear teeth Lay Ihe Itywheel on a Itat surface and use a straightedge to check for war· page 7 Clean and Inspect the mating surfaces of the lIywheel/driyeplate and the crankshaft If the crankshaft rear seal IS leaking, replace il before rein ·
Check 2 During the check. the engine muSI be ra ised slightly to remove the weight from the mounts 3 Raise the Yehlcle and support It securely on Jackstands, then posllIOn a jack under the engine oil pan. Place a large block of wood between Ihe Jack head and the oil pan, tnen carefully raise the engine Just enough 10 take the weight olf the mounts. Warning : DO NOT place any part of your body under the engine when Its supported only by a Jack I 4 Check the mounlS to see it the rubber IS cracked, hardened or sepa· rated tram the metal plates. Sometimes the rubber wi ll spilt right dow n the cente r 5 Check to r relat iYe movement between the mount plates and the engine or frame (use a large screwdrlyer or pry bar to attempt to move the mounts). If movement is noted. lower the engine and tlghlen the mount fasteners. 6 Rubber preservative should be applied to the mounts to slow deteriorat ion.
Replacement 7 DlsconneCtlhe negatlye ballery cable Irom the battery, then ra ise the Yehlcle and support It securely on Jackstands (il not already done). Remoye the l asteners and detach Ihe mounllrom the Irame (see il8 lustration). 9 Raise Ihe engine slightly With a Jack Of hoist (make sure the fan doesn't hi t the radiator or shroud) . Remoye the mount·to·block bolts and detach the mount. 10 Installallon IS the reverse of remoyal. Use thread locking compound on the mount bolts and be sure to tighten them securely
l~.O·O
~,
'" \ ;&-,X -=====:~I"LATQoo ,".,.~v ..
""..,FT ,...., ......, ~- ~"~
... " .. v
000-.0 'T l' I....' ' ' .. '
NOTE W.. E'<EvfR Sf~F ~OCK I '
17.8
Engine mount details
..0 ,,,,"OI$>,l!"'I,1I
""IWI
'-...
Chapter 2 Part 0 3.8L V6 and all V8 engines Contents Camshatt and beanl'"lQs - removal. inspectIOn and installatIon Crankshaft 011 seals - replacemenl
0.1 pump - removal and InstallatIOn • Repair operatIOns poSSible With the eno1ne
IJ
\6 See Chapter 2E
Cylinder compression check Cylinder heads - removal and installation
Drlvebelt check, adjustment and replacement Flywheel 'dnvaplate - removal and InstaliallOn Engine mounts - check and replacement Engine 011 and hlter change
Engine overhaul- general information Engine - removal and InSlalialion Exhaust mamlolds - removal and installatIOn General mlormallOn
Intake mamlold - removal and installation 0.1 pan - removal and InstallatIOn
9 See Chapter 1 17
18 See Chapter I See Chapter 2E See Chapter 2E
• \
7 \4
Rocker arm covers - removal and installation Rocker arms alld pushrods - removal, inspection . ...•..... and Installation, •. , , . . Spar\l. plug replacement Timing chai n and sprockets - Inspection. removat and installallon ... Timing chain cover - removal and Installation Top Dead Center (TOC) lor number one piStOfl- locating •... Valve lifters - removal, Inspection and installatIOn Valve spnngs, retamers and seals - replacement . Water pump - removal and Ins lallatIOn
Specifications
V6engine
/
General Olsplacement Cylmder numbers (Ironl· to-rear) left (dnvers) Side RlQht side Flnng order Valve slem·lo·rocker arm clearance
3.8111ers 4·5-6
H·3 1·4,2·5·3·6 0.08810 0.189 in
Camshaft Lobe hit Inlake Exhaust Theorellcal valve hlt@ zero lash Intake Exhaust Endplay Journal diameter (all) Cam bearrng Inside diameter JournaHobeanng (011) clearance Journal/unout limit Journal OUI·ol-round limit
0.240 in 0.24\ In 0. 4t5 in OA171n None (camshaft IS restramoo by SPflng) 2.0515 to 2.050510 2.0535102.0525 0.001 \0 0 .003 In 0.002 in (rul"\Oul at no. 2 or 3 relative to I and 4) 0.001 in
COUNTERCLOCKWISE
FRONT OF VEHICLE
•
CAP CLIP POSITION
Cylinder locations and tiring order - 3.8l V6 engine
" 2
10 the vehicle
4
5 See Chapter t \I
\0
3 12 6 . See Chapter 3
I 20-2
Chapter 2 Part 0
3.8l V6 and all V8 engines
Oil pump Reliel .... alve spring tension
171 to 15 2 1bs at 120 In o 0017 10 0.0029 In 0.008 to 0 .00121n 0,002 to 0.0055 In 0005 to 0.0055 in
Reliel valve-to-bore clearance
Gear backlash .. Gear radial clearance Gear height (beyond housing)
o
Torque specifications CamshaU sprocket bolts
Ft-Ibs (unless otherwise indicated) 151022 151022 151022 60 10 106 In-Ibs 18 t022
........ . .
Timing chain cover-la-block bolts Water pump-la-liming chain cover bolts 011 pan mounhng bolts
011 pump cover bolls . Cylinder head bolts
1983 Step 1
47
SIep2 SIep3 Step 4
55 63
"
Loosen all bolts 2 or
SlepS 1984 on Step 1 Step 2
3 turns . then repeat tightening sequence
37 45
52 59
Step 3 Step 4
Loosen all bolts 2 or 31Urns. then repeat lighlenlng sequence
Step 5 Rocker arm fulcrum bolts
Slep 1 Step 2
5to 11 181026
Intake manifold-1o-cylinder head bolts
1983 Slep t Step 2 Slep 3 1984 on
5 10 18
Step 1
7
Step 2
15 24
Step 3 Exhaust manifold bolts Rocker arm cover-to-cylinder head 1983 (screw) .. 1984 on (boIUstud) Crankshaft pulley-la-vlbrallOn damper bolts Vibration damper bolt •
Flywheel/dflveplate mounting bolts.
15 to 22 36 to 61 in· lbs 80 to 106 In·lbs 201028 9310121 54 to 64
va engine General Oisplacemenl 1979 and 1963 on . 1980 through 1982 Cylinder numbers (front to rear) LeU (driver"s) Side Right side Firing order Except HO .
HO
5,0 Illers (302 cubic Inches) 4 2 Illers (255 cubiC Inches)
1·5·4·2·6·3 7·8 1·3· 7·2·6·5·4·8 COUNTERCLOCKWISE
FRONT OF VEHiClE
•
CAP CLIP POSITION
Cylinder locations and firing order - va engines except HO
Chapter 2 Part 0 Vallie stem·to rocker arm clearance DeSlIed except HO
3.8l V6 and all V8 engines
0.09610 O. 14
HO
20-3
In
0.123100.14610
Allowable
except HO
0.071 to 0 171
HO
0.098100 198 In 050 in
Timing cham dellecllon
In
Camshaft Lobe hft
1979 0.2373 In
Intake
0.2474 In
Exhaust
0.2375 In
1980 through 1982 (Intake and exhaust)
1983 on (except HO) 0.237510 0.2474 In
Intake
exhaust 1983 through 1985 (HO) Intake
0.2600 In 0.2780 in
EXhaust 1986 on (HO) (Intake and exhaust) Theoretical vallie lift @ zero lash 1979
0.2780 In
0.3823 in 0.3980 In 03753 In
Intake
exhaust 1980 through 1982 (lOtake and exhaust) 1983 on (e)(cept HO) Intake
0.375310 0.390910
Exhaust 19831hrough 1985 (HO) Intake
Exhaust 1986 on (HO) (mtake and exhaus t)
.
2D
a 4130ln 0,4420 In a 4420 in
Endplay 19841hrough 1987
Standard Service IIml!
0001 to 0.007 In 0.009 In
1988 on Standard Service limit Journal diameter No 1 No 2
No3 No 4 No 5 Beanng InSide diameter No 1 No.2 No.3 NO.4 No 5 JournaHo-beanng (Olt) clearance Standard
0.0005 to 0.0055 In 0,009 In 2 080510 2.08151n 20655102.0665 In 2.0505102.0515 In 2.0355102.0365 In 2.020510202151n 2.0825 to 2.0675 to 2.0525 to 2.0375 to 2.0225 to
2 0835 In 2.0685 In 2.0535 In 2.0385 In 2.0235 In
0,001 to 0 003 In o 006 In
Runout limn Out-ol-round limit Camshaft gear baCKlash Front bearing location
0.0051n (total indicator reading) 0.0005 In (Iolallndlcalor reading) 0.006100.011 In 0.005 to 0,020 in below fronl face 01 blOCk
Torque specifications
FI -Ibs 401045 91012 121018
Camshail sprOCKet bolt Camshaft thrust plate-Io·englne block bolts Timing chain cover bolts . Cylinder head bolts Step I Step 2 Vibration damper-to-cranKshaft bolt Exhaust manifold boilS
55 to 65 65 to 72 70 to 90 181024
20-4
Chapter 2 Part 0
Torque specifications Intake manlfold-Io-cylinder head bolts Oil filter insert-la-engine block adapter bolt Oil pan mounting bolts
3.8l V6 and all V8 engines Ft-Ibs 23 to 25' 20 to 30
1979 First step Large bolts ....... , Small bolts Second step
lIto 13 7 t09
Large bolts ........... .
151017
Small bolts ........... . 1980lhrough 1987 ....... .
10 10 12
1988 on Oil pump mounting bolts Oil pick-up lube-la-oil pump bolts 19791hrough 1987 ............... • . 1988 on Oil pick-up lube-Io-main beanng cap nul Drivebelt pulley-la-vibration damper bolls . Rocker arm lulcrum bolts •..•... Flywheel/dnveplale mounting boilS.
9 10 11 6 109 2210 32 1010 12 to 22to 35to 18to
15
18 32 50 25
75to 85
• Ahar assembly, reforque with the engme hOI
General information This Part 01 Chapter 2 is devoted to In-vehicle repair procedures tor the 3.eL V6 and va engines. All information concerning engine removal and Installation and engine block and cylinder head overhaul can be found in Part E of this Chapter. The followmg repair procedures are based on the assumption that the engine is installed in the vehicle, lithe engine has been removed from the vehicle and mounted on a stand, many of the steps outlined in thiS Part of Chapter 2 wilioot apply. The Specifications included In Ihls Part of Chapter 2 apply only to the procedures contained in this Part. Part E of Chapler 2 contains the Specifications necessary lor cylinder head and engine block rebuild·
m9·
2
Repair operations possible wlIh the engine in the vehicle
Many major repair operallons can be accomplished Without removing the engine Irom the vehicle. Clean the engine compartment and the ex tenor 01 the engine with some type of pressure washer belore any work is done. It Will make the Job easier and help keep dirt out 01 the internal areas of the engine. I! may help to remove the hood to improve access to the engine as reo pairs are performed (refer to Chapter 11 II necessary) . II vacuum. exhaust. oil or coolant leaks develop. indica ting a need for gaskel or seal replacement, Ihe repairs can generally be made With the engine in the vehicle. The intake and exhaust manifold gaskets. timing cover gasket. all pan gasket. crankshaft oil seals and cylinder head gaskels are all accessible with the engine In place. Ex terior engine components. such as the intake and exhaust manifolds. the all pan (and the all pump). the water pump. the starte r motor. the alternator. Ihe distributor and the fuel system components can be removed lor repair With Ihe engine in place. Since the cylinder heads can be removed without puUingthe engine. valve component serviCing can also be accomplished with the engine In the vehicle. Replacement of the timing chain and sprockets is also POSSI' ble With the engine in the vehicle. In extreme cases caused by a lack 01 necessary equipment, repair or replacement of piston rings. pistons. connecting rods and rod bearings is poSSible with the engine in the vehicle. However. this practice is not recommended because of the cleaning and preparation work that must be done to the compone,lts Involved.
3
Top Dead Center (TOG) lor number one piston - locating
Refer /0 Illustrations 3.6a and 3.6b Top Dead Cen ter (TOC) is the highest POint In the cylinder thai each piston reaches as It travels up-and-down when the crankshaft turns Each piston reaches TOC on the compression stroke and again on Ihe exhaust stroke. bul TOC generally refers to piston position on the compreSSion stroke. The timing marks on the vlbrallon damper Installed on the lront of the crankshaft are referenced to Ihe number one piston at TOe on the compression stroke .• 2 PositiOning the plslon(s) at TOe IS an essential part of many procedures such as rocker arm removal. valve adjustment, timing chain and sprocket replacement and distribu tor removal . 3 In order to bring any piston 10 TOC. the crankshaft must be turned us· Ingone 01 the methods outlined below. When looking al the front 01 the en· glne. normal crankshall rotation is clockWise. Warning : Before beglnmng thiS procedure, be sure to pface the transmiSSion In Neutral and ground the Call wire attached to the center terminal ofthe dlstflbutor cap to disable the Igmtlon system. a) The preferred method IS 10 turn the crankshaft With a large socket and breaker bar attached to the vibration damper bolt threaded InlO the front of the crankshaft. b) A remote starter SWitch. which may save some time. can also be used. Attach the swi tch leads to the S (SWitch) and B (battery) ter· minals on the starter motor. Once the Piston IS close to TOC , use a socket and breaker bar as deSCribed In the prevIous paragraph. c) If an assistant is available 10 turn the ignlhon SWitch to the Start po. siliOn In short bursts, you can getlhe pislon close to TOC Without a remote slarterswllch , Use a socket and breaker bar asdescflbed in Paragraph a) to complete the procedure 4 Using a tell pen, make a mark on the distributor hOUSing di rectly below the number one spark plug wire term inal on the distributor cap. Note: The terminal numbers are marked on the spark plug wires near 'hedlslributor 5 Remove the distributor cap as described in Chapter t . S Turn the crankshaft (see Paragraph 3 above) until the zero or groove on thevlbrallondamperis aligned With the pointer orTOC mark (see iIIustrallons). The pointer orTOC mark and Vibration damper are located low on Ihe lront 01 th e engine. near the pulley Ihat turns the dflvebell. 7 The rotor should nOW be pomllng directly at the mark on the dlstnbutor housing. It it isn't. the piston IS at TOe on the exhaust stroke 8 To get th e piston to TOe on the compression stroke. turn the crank· shaft one complete turn (360·degrees) clockWise. The rotor should now be pointing at the mark. When the rotor is pointing at the number one spark
Chapter 2 Part 0
I
FAOHT
I
3.8l V6 and all V8 engines
20-5
,me
~~T o_ . . .
C>
'"
ROTATION - . .
3.68 Turn the cfankshal1 until Ihe zero on the vibration damper scal e Is directly
opposite Ihe pointer
3.6b Some engines may have the scale on the Umlng chain cover and Ihe timing mark on Ihe damper
4.2
The s park plug wi re ro uting cli ps (arrow) pull afflhe stud s
plug wire terminal In Ihe dlstnbutor cap (whICh IS Indicated by the mark on Ihe houSing) and the IgnltlOl'l timing marks are aligned, Ihe number one piston is a\ TOC on the compression stroke 9 After the number one piston has been posItioned at ToC on Ihe compression stroke. TDC l or any at the remaining cylinders can be located by turning the crankshaft and lollowlng the firing order (refer to the Specifications).
4
2D
Rocket arm cover s - removal and Installation
Removal ReIer ro Illus/rarions 4 2. 4
!,
and 4 12 1 Disconnect the negalive cable Irom the battery 2 Note their Iocalions. then detach the spa~ plug wire clips Irom the rocker arm cover studs (see illustration) 3 Reier to Chapter 1 and detach the spark plug Wires Irom the plugs POSlllOn the wires out 01 the way 4 II so eqUipped, detach the dlvel1er valve and hoses Irom the rocker arm cover 5 On vehicles With cruise control, disconnect the servo linkage at the carburetor or throttle body and remove the servo bracket
4.11 Remove the oil IiIler cap and, atter d isconnectin g th e exhaust heat conlrol valve vacuum hose (arro w), pu s h It asi de
Right side 116 engine 6 POSllion the all cleaner out 01 the way (Ch apter 4) and remove the PCV valve Remove the automaliC choke heat tube (carburetor eqUipped vehicles only). 118 engine 7 Remove the air cleaner assembly (Chapter 4) and disconnect the PCV tube 8 Remove any solenOids attached to the rocker arm cover 9 Remove the automatIC choke heat tube (carbureted models only). 10 Disconnect the EGR vacuum amplltier hoses (models so equipped)
left side 116 engine t t Remove the 011 filler cap and the e~haust heat control valve vacuum hose (see Illustrati on) (II equipped). 12 Remove the bolts and SWivel the exhaust heat control valve out 01 the way (see IIlustraUon) 13 On carbureted models equipped With crUise control. detach the an cleaner and move It out 01 the way Detach the cruise control servo chain irom the carburetor. detach the servo bracket and place the bracket and servo out ollhe way
4,12
Remove the bolt s and swivel Ihe exhaust hea t con trol va llie 9O-degree s count er clockwise
20-6
Chapter 2 Part 0
3.8L V6 and all V8 engines
• "TT.lC'"ING IIOLl
5.2 The rocker arm fulcrum bolls (arrow) may nol have to be completely removed - loosen them several turns and see if the
mAE.o.DEO PEDESTAL
rocker arms can be pivoted Oul ollhe way to allow
_1!i:";;:;JI/
pushrod removal 5.3
Exploded view of a rocker arm and its related components
cover(s) On engines that don't have gaskets, apply a 3i l6·mch bead of RTV sealant to the cover flange , mSlde 01 the bolt holes 19 Cdrefully poSItion the cover on the head and install the bolts/nuts, 20 Tighten the bolt,; mthree orlour steps to the torque listed In thiS Chapter's SpecificallOns_ PlastiC rocker arm covers are easily damaged, so don'l overt igh ten the boltsl 21 The remaining InstaliaMn steps are the reverse of removal 22 Stan the engme and check carefully l or all leaks as the engine warms up
5 SA A perforated cardboard bOI( can be used 10 store the pushrods to ensure Ihal they are reinstalled in their original locations - note the label Indicating the Iront of Ihe engine
Rocker arms and pushrods - removal , inspection and installation
Removal
Installation
Refer 10 Illus/rallons 5.2. 5.3 and 5 4 1 Reier to Section 4 and detach Ihe rocker arm cover(s ) from the cy lm· der head(s). 2 Begmnmg at the front of one cylinder head, remove the rocker arm fulcrum bolts (see illustration) Store them separa tely m marked containers to ensure thaI they Will be reinstalled In thelf oflglnalloca\lons. Note: If Ihe pushrods afe the only Items bemg removed, loosen each boll Just enough /0 aI/ow the rocker arms /0 be rotated to the Side so the pushrods can be Mled OUI 3 Uft of/the rocker arms, fulcrums and fulcrum gUides (If used) (see illustration). Store them In the marked containers With the bolts (they must be reinstalled In thell onglnallocallons) 4 Remove the pushrods and store them separately to make sure they dont get mixed up during installation (see illustration)
16 The mating sur/aces of each cy lmder head and rocker arm cover must be perlectly clean when the covers are mstalled Use a gasket scraper to remove all traces of sealant and old gaske t matenal , then clean the mating surlaces with lacquer thinner or acetone. II there 's sealant or oil on the mating surlaces when the cover IS Installed, all leaks may develop. 17 Clean the mounting bolt threads With a die 10 remove any corrosion and reSlore damaged threads, Make sure the threaded holes In the head are clean - run a tap Into them to remove corrOSion and restore damaged threads . Apply a small amount of light all to the bolt threads 18 The gaskets should be maled to the covers before Ihe covers are m· stalled. Make sure Ihe tabs on the gaskets(s) engage m the slots In the
5 Check each rocker arm lor wear, cracks and other damage, espeCial· Iy where the pushrods and valve stems contact the rocker arm faces 6 Make sure Ihe hole at the pushrod end of each rocker arm is open. 7 Check each rocker arm pIVot area afld fu lcrum for wear. cracks and galling 11 lhe rocker arms are worn 01 damaged, rep lace them With new ones and use new fulcrums as well 8 Inspect the pushrods for cracks and e~cesslve wear at the ends. Roll each pushrod across a piece of plate glass 10 see If It'S bent (If II wobbles. lIS benl) _
va engine 14 On 1983 through 1985 models. remove Ihe air cleaner assembly (Chapter 4) and Ihe solenoids anached to Ihe rocker arm cover
Both sides 15 Remove the rocker arm cover bolts/nuts. then detach the cover from the head Note : If the COl/ens stuck to/he head. bumponeendwllhabioci< of wood and a hammer /0 lant/cose. /I that doesn 't work, fry /0 slip a flex Ible puny knife between the head and cover to break Ihe gasket seal. Don 'l pry al the cover-Io,head jomt or damage to the sealing surfaces may occur (Ieadmg to all leaks m the future). Some rocker arm covers are made of piastre - be mara careful when lappmg or pulling on them.
Inspection
Chapter 2 Part 0
3.8l V6 and all V8 engines WITH NO I U TOC . AT ENO OF COM""(5SION STROKE, MAKE A CHALK MARl< AT I'OINTS 2 AND l APPROlClMA T ELV 110 DEGR USA'ART
5.12 A special 1001 Is required to bleed down Ihe lifters when checking the valve slem-Io·rocker arm clearance
20-7
IElCCE'l 6CVL ENVIN(5)
POSITION 1 _ NO I AT TOC , AT ENO OF CO MPR ESSION STROI<[ POSI TI ON 2 ROTAn CRAN I( SHAn liD" lONE-HALF REVOLUTION) CLOCI(WISE . FROM POSITION I lON E REVOLUTION _ 310° ON 6 c n ENGINU I 1'051TION J _ (EKCEPT 6 cn ENGINESI ROTAn CRANI<SHAn nO" ITHR EEOI.IARlER REVOlUTION i CLOCKWln , FROM POSITION 1
5,13
Installation
Crankshaft posllion lor checking and adjusting va lve clearances
Caution: Make sure thaI both IIflers for each cyllfldor are on (he base Circle o( the cam lobe (both valves closed) before /l{Jhlemng the roc*er arm
bolts 9 lubncale the lower end 01 each pushrod with clean engine 011 or molybase grease and Install them In 'heir ongmallocallons. Make sure each pushrod seals completely In the Illter 10 Apply moly-base grease 10 Ihe ends of the valve Si ems and the upper ends of the pushrods before poSltlonmg Ihe rocker arms. fulcrums and
gUides 11 Apply moly-base grease to the lulcrums 10 prevent damage to Ihe mating surfaces before engine 011 Pfessure bUilds up Sellhe rocker arms and guides In place. then mslalilhe Iulcrums and boIlS
Valve adjustment Positive stop rocker arms Refer to Illustrations 5.12 and 5 13 Caution: 5.0L HO (hl{Jh outpull V8 engmes have a different fmng order than 4 2L V8 and5.0L rwn-HO V8engmes. For thiS reason, the valves are adJustedm a different sequence Thecoffect valve adJustment sequence for the vehicle 5 engme must be used to prevent POSSible valve tram dam age 1979 through I 9B2 models are eqUipped With the non-HO 5. OL VB O( the 4 2L V8 Some later models may be eqUippedwllh the non-HO Of HO 5.0L VB /I youareuncerfam which type o/engme the vehicle has, read the fmng order cast mto the mtake mamfold Nole : Adjustment IS normally only needed after valve tram components have been replaced or the valves and or seats have been ground a con· slderaOie amount 12 USing Ford Mler bleed-down 1001 T70P-6513-A or eqUivalent (see iIlustralion) . press on the rocker arm until the litter leaks down. Check the clearance between th e valve Slem and rocker arm wllh a leeler gauge Compare the results to the SpeCifications and wnte It down for future reference Repeat the procedure for each valve In the order shown below Note: The arrangement 01 Intake and exhaust valves IS as follows V6 engine Lelt Side - E-tE ·I· E-j Rrght side - I-E-I-E-I·E V8 engine Lell Side - E-I-E-I E-I-E-I Right Side -I-E·IE·I·E-I-E
13 POSitIOn thenumber one Plstoo at TOC (Secllon 3)_ ThiS IS ~Itlon 1 In the accompanying Illustrallon_ 14 Check Ihe lollowlng valves: V6 engine Intake - no, 1,3 and 6 Exhaust - no, 1. 2 and 4 V8 engine (ekcept HO) Intake - no, I , 7 and 8 ElChausl- no 1, 4 and 5 V8 engine (HO) Intake - no. I, 4 and 8 Exhaust - no, 1, 3 and 7 15 Rotate the crankshafllO poSllion 2 and check the follOWing valves V6 engine Intake - no 2. 4 and 5 Exhaust ~ no 3. 5 and 6 (thiS completes V6) V8 engine (ekeep! HO) Inlake - no. 4 and 5 EKhaust - no. 2 and 6 V8 engine (HO) Intake - no. 3 and 7 Exhaust - no 2 and 6 16 On V8 engines only, rotale the crankshaft to poSition 3 and check Ihe folloWing valves: ElCcept HO Intake - no 2, 3 and 6 Exhaust- no 3 , 7 and 8
HO Intake - no. 2, 5 and 6 EKhaust - no. 4, 5 and 8 17 Clearance can be changed by uSing dlfferenl length pushrods. available from your dealer If there isn't enough clearance, use a shaner pushrod; too much clearance, use a longer one
Adjustable rocker arms Reier to INustratlon 5.20 18 Some very early 5_0L V8 engines are eqUipped with adjustable rocker arms.
2D
20-8
Chapter 2 Part 0
5.20 Some very early 5.0l va engines have adjustable rocker arm nuls - check the valve clearance the same way as lor positive slop rocker arms - lIthe
3.8l V6 and all V8 engines
6.4 Thi s Is whallhe air hose adapter that threads Inlo the spark plu g hole looks like - they 're commonly available from aulo parts slores
clearance Is nol correct, adjust by
6.9 Once the spring is depressed, the keepers can be remo .... ed with a small magnet or needle-nose pliers (a magnet is prelerred to pre .... ent dropping the keepers)
turning the rocker arm nul, as shown here 19 POSItion the number one piston al Top Dead Center on the compres· SlOn stroke (see SectIOfl3). Check the valve clearance with a leeler gauge
the same manner as lor poslhve stop rocker arms (see iUuSlralion 5.12)
In
20 II the valve clearance IS Incorrect. adlust It by turning the rocker arm
nul (see Illustration) 21
Thell81 ... e adjustment sequence IS the same as lhe hnngorder (I, 5, 4,
2.6,3,7,8) Place each ~ston in turn at Top Dead Centeronthecompres· sion Slroke. Check and adjusl the .... al .... es tor that cylinder, then proceed to the next cylinder
6
Val .... e springs, retainers and seals - replacement
Refer 10 !/lustralrons 6 4.6.9.6. lOa and 6. lOb Nole: Broll:en valve sprmgs and defec/!Ve valve stem seals can be reo placed w!thoul removIng the cyl!nder heads. Two spec!al/oo/s and a com· pressed alt source are normally reqUired 10 perform th!S operatIon. SO read Ihrough thiS Section carefully and rent or buy the lools before begmnmg Ihe Job If compressed air Isn't available, a length of nylon rope can be used to keep the valves from fallmg mto the cylmder during thiS procedure 1 Reier to Sect,on 4 and remove the rocker arm cover Irom the atfected cylinder head 11 all of the valve stem seals are being replaced. remo .... e both rocker arm covers 2 Remo.... e the sparlr. plug Irom ttle cyl,nder whICh has the defectl.... e component II all of the .... al .... e stem seals are being replaced. all of the spark plugs should be remo .... ed 3 Turn the crankshaft unlll the piston In the atfected cyhnder IS at Top Dead Center on the compression strol<e (reler to Section 3 for Instruc!Ions). If you're replaCing all 01 Ihe .... al .... e stem seals. begin With cylinder number one and work on the .... al .... es for one cylinder at a lime, Mo.... e Irom cylinder· to·cylinder follOWing the IIring order sequence (see thiS Chaplers Speclflcalions), 4 Thread an adapter Into the spark plug hole (see iltusltation) and con· nect an all hose from a compressed aIr source 10 It Most auto parts Slores can supply Ihe air hose adapter Nole: Many cylmder compresSIOn gauges u/l/lze a screw-m fltllng Ihat may work With your air hose qUICk drs connecl fl/lmg 5 Remo.... e the bolt, tulcrum and rocker arm lor the .... alve With thedefec· tl .... e part and pult oul the pushrod II all 01 the .... al .... e stem seals are beIng replaced, all 01 the rocker arms and pushrOCls should be remo .... ed (relerto Section 5) 6 Apply compressed air to the cylinder, Warning : The piston may be forced down bycompressedalf, causmg Ihecrankshaft 10 turn suddenly If
the wrench used when poSII!Onlng the number one PIston al TDC!s sM aI/ached to Ihe boll In the crankshaft nose, II could cause damage or mJury when Ihe crankshaft moves 7 The .... al .... es should be held In place by the air pressure 11 the .... alve laces or seals are In poor cond,llon, leaks may pre .... ent air pressure tram retaining the .... al .... es - reler to the alternatl.... e procedure below 8 II you don 'I ha.... e access to compressed alf, an alternatl .... e method can be used POSition the piston at a POint Just before TDC on the compreSSIOn stroke, then leed a long piece 01 nylon rope through the spark plug hole until I! hils the combustion chamber Be sure to leave Ihe end of the rope hanging out 01 the engine so II can be removed eaSily Use a large ralchel and sockel 10 rolate Ihe crankshalt ,n the normal dlfectlon 01 rolallon until slight resistance IS lel1 9 Stut! shop rags Into the cylonder head holes abo .... e and below the .... alves to prevent parts and tools Irom lailing ,nlO the engine, then use a .... al .... e SPflng compressor to compress the SPftng Remo.... e the keepers With small needle-nose pliers or a magnet (see Illustration) Note: A couple of different types of tools are a .... allable for compressmg me vat.... e sprmgs With the head m place. One type, shown here, gflps the lower Spflng COils and presses on the retamer as Ihe knob IS turned, while the other type utilizes the rocker arm bolt lor leverage Both types work very wel" allhough the lever type is usually less elpensrv8 10 Remo .... e Ihe spring relalner or rotator. slee .... e (used on some Intake .... al .... es) and .... al .... e sprmg assemblt then remo .... e the umbrella·type gUide seal (see Illustrations) Note: /I air pressure fa!ls 10 nold the valve m lIle closed posmon durmg thiS opera/Ion. the valve face or seat!s probably damaged If so. Ihe cylinder head Will have 10 be removed for adc1l/IOnal repalfoperallons II Wrap a rubber band or tape around the lap ollhe .... al .... e stem so the .... al .... e w on t lalllnto the combuSilon chamber, then release the alf pres sure. Note: If a rope was used msteadot alt pressure, turn IIle crankshaft slightly In Ihe dlrec/lon opposite normal rota/ion 12 Inspeclthe .... al .... e stem tor damage. Rotate the va l.... e In the gu'de and check the end lor eccentllC movement. which would indicate that the va l~ e IS bent 13 Mo.... e Ihe .... al .... e up·and·down In the gUide and make sure II doesn t bmd IIlhe .... al .... e stem binds. either tile .... al .... e IS bent or the gwde IS dam· aged In 6!lher case, the head w,1I have to be removed lor repair 14 Reapply all pressure to the cylinder 10 retain the .... alve In Ihe closed posilion. then remo .... e ttle lape or rubber band Irom the .... alve stem If a rope was used Instead of a,r pressure rotate the crankshalt In the normal dlrecllon of rotalton unlll slight resistance IS lelt 15 Lubncate the .... al .... e stem Wllh engme 011 and the .... al .... e stem lip With polyethylene grease, th en Install a new gUide seal 16 InSlal1 the spnng In poSition o.... er the .... alve
Chapter 2 Part 0
3.8L V6 and all V8 engines
6,10b
6.10a
20-9
The seal can be pulled off the guide with. pair of pliers
2D
Valves and re lated components - exploded view
,
Keepers
2 3 4
Sleeve (m/ake only) Retamer Exhaust valve fOlalor
S 6 1
Va/II" slem seal Intake valve Exhaus/valve
17 Install the valve spong relalner Of rotator. Some Inlake valves also
have a sleeve thaI f1\S inSide the retamer Compress the valve spring and carefully poSItion the keepers In the groove. Apply a small dab olgrease to the Ins!de of each keeper to hold 11m place 18 Remove the pressure trom the spring tool and make sure the keepers are sealed 19 D1sconnect the alf hose and remove the adapter from the spark plug hole II a rope was used In place of alf pressure. pull II out 01 the cylinder 20 ReIer to SeellOn 5 and Install the rocker armIs) and pushrod(s) , 21 InSlall the spark plug(s) and hook up the wlre(s) 22 ReIer to Section 4 and Install 'he rocker arm coverts). 23 Start and run the engine then check lor otlleaks and unusual sounds comu"19 Irom the rocker arm cover area
7
Intake manifold - removal and installation
Note: Ford recommends the use 01 gUIde pms when mstaliing the man· ilold, To make Ihese, buy lour eXIra mamlold bolts CuI the heads of' the boilS. then grmd a taper and cut a screwdriver slOI In the cuI ends
Removal Carbureted models Refer 10 illustrallon 7. 10 1 Drain th e coot lng system (see Chapter 1) , 2 Remove the air cteaner. Its duct and the crankcase vent llallon hose 3 Disconnect the crankcase ventilatIOn hose Irom the rocker arm cover 4 Disconnect the automatic choke heat lube. accelerator cable and speed control linkage (vehICles so eqUipped). Remove the accelerator cable bracket
7,10
Intake manifold botllocalions (arrows) -typIcal carbureted V8englne
5 Label and disconnect the Intake manifold vacuum lines. 6 Disconnect the tgnltlOn coli pnmary and high tensIOn Wiles from the COil Remove the dlstnbutor (see Chapter 5). 7 Disconnect the fuel line from the carburetor 8 Disconnect the coolant hoses lrom the thermostat hOUSing and Intake mamfold. Disconnect the coolan t temperature sending unit (see Chapter 3). Note: The healer outlel and coolanl by·pass tubes are pressed In and cannot be (emoved 9 The carburetor may be removed now (see Chapter 4) or lett on the Intake manifold) 10 Removethe Intake manifold mounting bolts (see Illustration) and hit th e mam/old oft . II necessary. carefully pry the manil old loose from .he en· glOe. but make sure all bolls and nu's have been removed firs. I Caution: Don't pry between the block and manifold or between the heads and man· Ifold Of damage to the gasket sealing surfaces may occur, resulrlng In 'lac· uum and m/leaks Pry only al manifold casting prolruSions 11 Disassemble the manifold as needed
Fuel-injected 3.8l V6 modets Refer 10 IlIuSlrarlons 7.15, 7.25 and 7.26 12 Drain tM cooling system (see Chapter 1). 13 Remove the air cieanef, Intake duct and heat.ube (see Chap.er 4) t4 Disconnect the accelerator cable, automatic transmission cable and speed control cable (vehicles so eqUipped) at the thronle body assembly
I 20-10
Chapter 2 Part 0
3.Bl V6 and all VB engines
j INTAKE MANIFOLD
7.25
Intake manlfotd bolt tightening sequence - V6 engine
7. 15 $luff a rag into Iha Inlake manllold to prevent foreign matter from entering, Ihen unbolt the throttle cable bracket
(arrows), the emission and electrical connectors (arrows), the compressor bracket (arrow) and the healer lube bracket (arrow). 22 With Ihe EGR adapter and valve altached, work the EGR tube spacer loose from the manifold Discard the old gasket 23 Remove the Wlffng bracket at the lell front corner 01 the Intake manItold Place the bracket and spark plug wires out of the way 24 Remove the exhaust heat control valve vacuum tube moun\lng bolt located at the rearolthe lelt c~hnder head Remove the nul located on the manifold and detach the tube. 25 loosen the manifold moun\lng bolts (see illustration) In 1/4-tUln In' crements unlll they can be removed by hand 26 The manifold Will prObably be stuck to Ihe cylinder heads and torce may be required to break the gasket sea] A prybar can be poSllloned under the casHn lug ne,jrthe thermostat hOUSing (see iIIu strati on) to pry up the Iront end 01the mamlold, but make sure all bolts and nulS have been removed IIrstl Caution: Don 't pry between the bJocII. and mamfold Of heads and mamfoJd or damage to the gasket sealing surlaces may occur. leadmg to vacuum and ai/leaks Fuel-Injected va models Refer to Illustration 7.36
7.26
Carelully pry up on the manilold (arrow), but don" damage
the gasket surfaces ! IS Remove the throttle cable bracket (see illustration). 16 Disconnect Ihe lhermactor alf supPly hose Irom the check valve al the rear of the mamfold 17 Disconnect the lueillnes Irom the 1hrotl1e body assembly Olsconnectlhe radiator hose Irom the thermos tat housing and the coolan t bypass hose from the manltold (see Chapler 3).
18 DetaCh the healer tube and 115 bracket from Ihe Intake manifold. DIsconnectlhe healer hose Irom the rear of Ihe tube. loosen the hose clamp allhe heater elbow, then remove the heater tube With the hose and the fuel Imes S\)II attached Place the healer lube out 01 the way. Nole: The hea ter outlet and coolant by·pass tubes are plessedm. andcanno/ be removed 19 label and dlsconnec1lhe vacuum and errusslOns hoses and electrical connectOfS attached 10 Ihe manifold and related componenls (see lIIuslral1on 7.15) 20 Air conditioned vehICles - remove the air cooditionlllQ compressor support bracket from the lell Ironl manllold bolt 00 not disconnect any reo ... fflgeranl hnes l "2t Remove the EGR tube bo~s and three spacer mounllng screws at the intake mani fold (see Chapter 4).
27 Drain the cooling system (see Chapter I .) 28 Remove the PCV and caOister purge hoses 29 Disconnect the accelerator cable, speed control linkage and aula· maliC transmission cable (II so eqUipped). Remove the acceleral or cable macke!. 30 label and disconnect the Intake manifold vacuum lines 31 Remove the dlsmbutor (see Chapter 5). 32 Relieve the tuet system pressure (see Chapter 4) and disconnect the luel supply and return hnes 33 Dlsconnecl the radiator, heater and water pump bypass hoses Irom the water outlet (see Chapter 3). D!sconnect the throWe body cooler hoses Note: The hea/afout/at and coolant bypass tubes are prassed m, and cannot be removed. 34 Disconnect the elec\flcal connectors from the coolanl temperature sending un!\. air charge temperature sensor. thrOllle posiTIoner, Idlespeed control solenOid. EGR sensors, luelln]eclors and fuel charging assembly. 35 Remove the upper Intake manifold (see Chapter 4 ). 36 Loosen the lower Intake maOifold bolls and nuts in 1/4·lum InCte· ments unlll they can be removed by hand (see illustration) 37 The mamfold Will probably be stuck 10 the cytlnder heads and force may be requlled to meak the gaskel seal. A prybar can be used to pry up the manifold. but make sure all bolts and nuts have been removed 111$11 Caution: Don '/ pry between the block. and mamfold or the heads and man· !fold or damage 10 the gasket saa/mg surlaces may occur. leading to vacuo um and all leaks . Pry only al a mamfold casling protrUSion.
Chapter 2 Part 0
20 -11
3.8L V6 and all V8 engines
7.36 Intake manifold bolt tightening sequence - fu el-injected va engine
7,39 After covering the lifter valley, use a gasket scraper to remove all traces of sealant and old gasket material from the head and manifold mating surfaces
Installation (a/l models) I
Refer /0 ,/luSlrallons 7.39 and 7 41
a
O'A IlEA O 06 Al 19".ti 1 A II ' Sf A I E~ <• .IO"H S<
'o~
Note; The ma/lng surfaces ofrtlecylmderheads. blockandmanlfoldmuSI be perfectly clean when the mamfOld IS ins/ailed. Gasket removal solvents In aerosol cans are aVi~l/able at most aulOparts Siores and may be helpful when removing old gasket malenal thals stuck /0 the heads and manifold (since Ihe manifold and some V6 engme cylinder heads are made of alummum. aggressive scraPIng can cause damage I Bf! sure /0 follow dlrec/Ions pnnted on the contamer 38 If the manifold was disassembled, reassemble II . Use electncally con -
cV( IN D ~R
2D
ductive sealant on the temperature sending unlllhreads Use a new EGA
valve gasket 39 Use a gasket scraper to remove all traces of sealant and old gasket ma terial, then clean the mating surfaces With lacquer thinner or ace tone II there s old sealant or oil on the mallng surlaces when the manifold IS in, stalled . 011or vacuum leaks may develop When working on the heads and block, cover the IiIter valley With shop rags to keep debriS out of the engine (see lIIustralion) Use a vacuum cleaner to remove any gasket material that fans Into the Intake porlS In the heads 40 Use a tap of the correct Size to chase the threads In the bolt holes, then use compressed air (II available) to remove the debriS from the holes _ Warning : Wear safely glasses or a lace shield 10 protect your eyes when usmg compressed illfl Remove excessIVe carbon dePOSitS and corroSion from Ihe exhausl and coolant passages m Ihe heads and mamfold 4\ Apply a t /8-IOCh wide bead of RTV sealant 10 the four corners where the manifold . block and heads converge (see lIfustraUon) Note : TillS sea lanl sets up m IOmmules Do not lake longer 10 ms/all and Itghten the mamlold once Ihe sealant IS applied. or leaks may occur. 42 Apply a small dabof Fordcontact adheSive (parl no 07AZ- t9B508·A) or eqUivalent to the manifold gasket mating surface on each cylinder head. POSitron the gaskets on the cylinder heads. The upper Side of each gasket Will have a TOP or THIS SIDE UP label stamped mto It to ensure correct installation 43 POSitIOn the end seals on the block. then apply a t lS' lnch WIde bead of RTV sealant to Ihe four POintS where the end seals meet the heads (see illustration 7,41 ). 44 Make sure all intake pon openings, coolant passage holes and bolt holes are aligned correctly 45 Carefully set the manifold In place while the sealan t is still wet. Caution : Don ', disturb the gaskets and don 't move the manJlo/d fore·and·aft alter 1/ contacts Ihe seals on the block. Make sure Ihe end seals haven 't been disturbed 46 Lightly 011 the manrfold bolts (V6 enylne) _Install the boilS and tighten them 10 the torque lisled In thiS Chapter's Specclccatcons. loliowlng the rec · ommended sequence (see illustrations 7.25 and 7.36) Work up to the final lorque In three steps
1 16 · DI A UA O D6Al ' 9"161 A '0" "'~tA( ER ' . S tA L f"' OS.
7.41 Apply a bead of RTV sealanllo the corners where the block, heads and manlfotd converge (left), then position the gaskels and seals and apply more RTIJ sealant (right )
47 The remamlng mstalta\lon steps are the reverse of removal Starllhe engine and check carefully for 011 and coolant leaks althe mlake mamtold IOlnts 48 Recheck the mounting bolt torque
8
Exhaust manifolds - removal and installati on
Removal Refer to iifustratlOns 8 to, 8 12a, B. t2b and 8. t2c
1 Disconnect the negative battery cable from the battery, 2 Unplug the exhaust gas oxygen sensor (EGO) wire (if eqUipped) and remove the spark ptugs (Chapter I). 3 Raise the vehicle and support it securely on jackstands 4 WOrking under the vehICle, apply penetrattng OIt to the exhaust pcpe to·manllold studs and nuts (they're usually rusty )_ 5 Remove the nuts holding the exhaust crossover pcpe to the manIfOId(s), In extreme cases you may have to heatlhem WIth a propane or acetylene torch rn order to loosen Ihem.
20-12
Chapter 2 Part 0
3.8L V6 and all V8 engines 6 Remove the alf cleaner assembly (Chapter 4) and heal stove tube (if eQuipped) (Chapter 6). 7 Remove any cruise control brackets that are In the way
Right side manifold e Remove the thermaClor lube mounted between the alf lube check valve and the crossover pipe (Chapter 6). 9 On some vehicles with an automatic transmission . the dipstick and tube must be removed. 10 Remove the ou ter heal stove cover (if equipped) (see Illustration).
Left side manifold 11 If it's In the way. remove the 011 dipstick and tube. Also , remove the heat control valve (Chapter 6).
Both manifolds 8.10 Remove the heat stove cover nuts (arrows) and nft the co ver off (V6 engine shown)
12 Bend back the locking tabs (If equipped) . Remove the mounting bolts and separate the manllotd(s) Irom the head (see illustrations) Note the locations ot the PltOt bolts,
J 8,128 Pilot bolt location - V6 engine, left e xhaust manifold
c...__---." ,
CVUNO£R 1i€AO
SCREW ANO WASHE R
...ssv 3 REO'O
~
EXHAUST MANIFOlD STUO.o.NO WASHER
...ssv 3 REO'O
../ STUD f
SCREW AND WASHER " " __
w-=
RH EXHAUST
_
_
ASSY 3 REQ'O
8. 12b Pilot boll locati on - V6 engine, right exhaust manifold
Chapter 2 Part D 3.8l V6 and all V8 engines
8.12c Some models are equipped w ith manifold bolt locking labs - bend these down before removing Ihe bolls - use new lock ing assemblie s on inslallalion , bending th e tabs up to lock Ihe bolls in pl ace
9.11 The alternator bracket bolts (arrows) must be removed to detach the V6 engine right cylinder head
Installation 13 Check Ihe mamlold for cracks and make sure Ihe bolllhreads are clean and undamaged The mamfold and cylinder head mating surfaces
mus! be clean before Ihe mamfolds are reinstalled ...!use agasket scraper to remove all carbon depoSIts and ok! gasket malerial. 14 PoslliOn the manltokl and gasket (If eqUipped) on the head and ins tall the mounting boilS. Note: Exhausf manifold warpage is common on the V6 engme Although some were built without gaskets. we recommend installing them If youre wOrking on a V6 engll76. I17stall the PIlot bolts first (see iIIu strallons 7. 12a and 7. 12b) Somellmes It'S necessary to elongate the holes m the manifolds fo stan the bolts - neVfN Me out the pilot bolt holes I 15 WhfJfIllghtenlng the mountmg bolls. work lrom Ihe center to Ihe ends and be sure to use a torQue wrench. TlQhten the bolls In three equal steps until the torQue hsted In this Chapter 'S SpeclllCc!hons is reached. 16 The remalnmg installation steps are the reverse 01 removaL 17 Start the engine and check for exhaust leaks
9
Cylinder heads - removal and Inslallatl on
Caution : The engme must be completely cool when the heads are removed. Failure to allow the engme tocoo/ off could result In head warpage
Removal Refer to Illus/rations 9. 11 and 9. 13
Both cylinder heads 1 2 3 4
Remove Remove Remove Remove
the the the the
rocker arm cover (Section 4). push rods (Section 5). intake manifold (Section 7). dnvebelt s (Chapter 1) and Idler pulley bracket.
left (drlver's side) cylinder head 5 Unbolt the power steenng pump and lie It aside In an upnght POSition. leave the hoses connected (Chapter 10). 6 Remove the AJC compressor and poSl1ion It out 01 the way (Chapter 3). DO NOT disconnect Ihe hoses l 7 8
Remove the exhaust manllold ($eetlon 8). Proceed to Step 14
Right cylinder head 9 Detach Ihe luet hne Irom Ihe clip at the front 01the head (not all models).
2D-13
va
9.13 To avoid mi x ing up the engine head bolts, use a new gasket 10 Iransler the boll hole pattern to a piece 01 c ardboard, then punch holes to accept Ihe bolts
10 Remove the thermacior dlverter valve and pump and lhe crossover tube from the rear of the head (not all models) 11 Remove the alternator bracket (see llIustrallon). 12 Remove the exhausl manifold (Section 7) .
Both cylinder heads 13 USing a new head gasket. outline the cylinders and bo" panern on a piece of cardboard (Va engine only) (see lIIuslration) Be sure to indicate the fronl 01 the engine for reference. Punch holes allhe boll locations 14 loosen the head bolts In 1I4·turn Increments unlJllhey can be removed by hand. WorX from boll-to-bolt In a panernlhal's the reverseot the tightening sequence Store the bolts In the cardboard holder as they're removed (Va engJne only): thiS Will ensure that the bo"s are remstalled In IhelfoflglnaJ holes Note: V6 engmeneadbolts should not bereused Re · move the bolts and dIscard them - NEW BOLTS MUST BE USED when mstallmg the head(s) . IS wft the head(s) off the engine It leslslance IS lelt. DO NOT pi)' be tween the head and block as damage to themallngsurfaceswlllresul\.To dislodge Ihe head. place a block of wood against the end of it and stnke the wood block Wi th a hammer. Store the heads on blocks of wood 10 prevenl damage to the gasket sealing surlaces 16 Cytlnder head disassembly and Inspection procedures are covered In detail In Chapler 2. Part E.
Installation Refer to IllustratIons 9.20. 9 23a and 9.23b 17 The mating surtaces ofthecylinderheadsandbiockmusi be perlectly clean when Ihe heads are installed Use a gasket scraper to remove all traces of carbon and old gasket mateflal. then clean the mating surlaces With lacquer thinner or acel one. It there 's oil on the mating surfaces when the heads are Installed. the gaskets may not seal correctly and leaks may develop. When workmg on Ihe block. cover Ihe hftervalley With shop rags 10 keepdebns OUI of the engine. Use a vacuum cleaner to remove anydebns that falls mto lhe cyUnders la Check lhe block and head mallng surlaces for niCks. deep watches and other damage. It damage is slight it can be removed With a lite -If II s excessive. machining may be the only alternative. 19 Use a lap 01 the correct Size to chase l he threads In the head boll holes. Mount each bolt tn a vise and run a die down the threads to remove corrosion and restore Ihe threads (Va engine only) . Dirt. corrosIOn. sealant and damaged threads Will aHect torQue readings .
2D
I 20-14
Chapter 2 Part 0
3.8L V6 and all V8 engines
J
J
9.20 Locating dowels (arrows) are used to position the gaskets on the block - make sure Ihe maril (circled) Is correctly oriented
•
CD
10
8
9.23a Cylinder head bolt tightening sequence - V6 engine
9.23b Cylinder head boll lightening sequence - va engines
20 Posll!on Ihe newgaske \(s) ovarthe dowel pins In Ihe block (see illustration ). Make sure it's lacing the fight way. 21 Carefully poSItion the head{ s) on the block without disturbing the gasket(s ). 22 Before installing the new V6 engme head bolts. coatlhe th reads 01the four short bolts with Pipe sealant (Ford part no. D8AZ· 1955 a·A or eqUilla lent) . lightly oillhe threads of the remaining V6 engine head bolts If you 're working on a va engine. lightly oillhe threads on all of the bolls. 23 InSlallthe bolts In their ongmallocallons and tighten them linger tlgh\. Follow the recommended sequence and tighten the bolts. in two or lour steps, to the torque listed in thiS Chapter 's Specillcatlons (see illustration s) Note: On V6 efl{}mes. after reaching the fmaltorque. loosen all of the head boilS two or three /Urns. then repeat/he rrghtemfl{} sequence. 24 The remaining installation steps are the reverse of removal. 25 Change the engine 011 and liller (Chapter 1 ).Ihen start the engine and ched~ carefully lor all and coolant leaks
10
Tim in g c h ain cover - remova l and Installation
Removal Refeno illuSlraflons 10.lla. 10. lib and 10. 12 1 On V6 engines. relerto Chapter3 and remove the water pump. On va engines. perform all water pump removal sleps except actual removal of the pump. The pump may be removed or left attached to the tim ing chain cover. 2 Drain the engine oil and remove the oil1l1ler (Chapter 1) . Remove Ihe crankshaft Vibration damper (Sectton 16). 3 4 Unbolt and remove all accessory brackets al1ached to the liming chain cover.
V6 engine only 5
Position the number one piston at TDG on the compression stroke
(Seclion 3). then remove the dlstnbu tor as descnbed in Chapter 5. 6 On carburetor eqUipped models. remove the fuel pump (Chapter 4)_ 7 Remove the oil pan (Secllon 14) . 8 Unbolt the ignition timing Indicator or pOinter.
va engine only 9 Remove the oil pan-to -tlming chain cover bolts. lOUse a razor knife (thin blade) or razor blade 10 cu t the all pan gasket flush with the engine block face . All engines 11 Remove the bolts and separate the timing cham cover from the block. II irs stuck. tap It gently with a solt·lace hammer (see illustration). Cau· tion : DO NOT use excessive force oryou may crack the cover IIthecover IS difficult to remove. double check to make sure all of Ihe boilS are out. On the V6 engine. the Allen head bolt under the 011 hlter housing is easy to miSS (see illustration).
V6 engine only 12 Remove the camshalt thrUSt button and spring assembly from the end of the camshaft (see Illustrati on) 13 To remove tlle mtermediate shaft from the cover. remove the clip from the sllaft and sltde the shaft OUI.
Inslallation 14 II you 're working on a va engine. remove the Circular rubber seal from the fronl of the oil pan and stuff a shop rag Into the oil pan opening 10 keep debris out of the engme. Use a gasket scraper to remove all traces 01old gasket matellal and sealan t from the cover, oil pan and engtne block, then clean them With lacquer Ihtnner or acetone.
V6 engine only Refer /0 illustrations 10. '6a and 10 16b 15 The 011 pump IS mounted In the timing chatn cover. See Section 15 lor oil pump information. 16 To tnstall the tnlermediate shaft In Ihellmtngchatn cover, make a marl<. one inch from the end (see illustration) Insen the shalt until ilseats tntM oil pump and snap the clip onto Ihe shalt With the top of the clrp just below the marl<. on the shaft (see illustration)
Chapter 2 Part 0
10.11 a
3.8l V6 and all V8 engines
Genlly tap the timing chain cover loose with a soft-face hammer (116 engine shown)
20-15
IO.llb V6 engine timing chain cover OOilloc81100l - be sure to remolle aU bolts (no. 6 is an Allen-head bolt which Is difficult to see)
2D ) )
10.12
Camshaft thrust bullon and spring (1/6 e ngine)
10.168
2Stntn INCH-MEASURE AND W.RK
Mark the intermediate shaft one inch Irom the end ...
19 Apply a thin coal of RTV sealant to the block Side of the new gasket, then poslllon it on the engine. The dowel pins will hold it in place as the cover is mstalled 20 Apply a thm coat of RTV sealant tothe gasket surface olthe cover and attach it to the engine. The dowel pms Will position It correctly. Don t damage the seal and make sure the gasket remams m place Make sure the thrust button is bottomed in the camshalt hole. 21 Install the boilS finger tight. Tighten them to the torque lisled m thiS Chapter's Speci ficallons only atter the waler pump has been inslalled (some of the water pump bolts also hold Ihe tlmmg cham cover m place). Note; When installing the waler pump, be sure to coal the threads of boll number 10 (see illustration 10.11 b) wl/h sealant (see Chapter 3) 22 Install the oil pan (Section 14).
va engine only
1D.16b ... then inSlaH the clip with the lop Just below the mark (V6 engine only) 17 Be sure the camshalt thrust button and spring assembly IS seated in the end althe camshaft (see illustration 10.12). The small end of the spring must face the button . Lubricate the bunoo end. 1 Lubncate the timing cham and front crankshaft oil seal lips With engine oil.
e
23 Cut two sections out 01 a new 011 pan gasket to mstall between the oil pan and tlmmg chain cover. 24 Attach the gasket sections to the oil pan With Ford Contact Adhes ive (part no. D7AZ- 19850B-A) or equivalent. 25 Apply a t lB-lnch bead of RTV sealanllo the Oil pan-to-block Jomls. 26 Install a new Circular rubber seal In the 011 pan cutout (use Ford Con tact AdheSive to hold it In place). 27 Lubricate the timmg chain and front crankshaft 011 seal lips Wi th engine OIL 28 Apply a thm coat of ATV sealant to the block Side of the new cover gaskel. then poSlhon iton the engme. The dowel pms will hold It m placeas the cover Is mstalled.
20-16
Chapter 2 Part 0
3.8l V6 and all V8 engines
TlIoAING CH ...IN
me
VIEW ...
11.4
A dial Indicator Installed to measure timing chain deflection (V6 engine - 8 special cup-shaped adapter may be needed to keep the Indicator plunger from sliding off the end of the push rod)
11 .5
CR ...NKSHAFT
vIEW a
Timing chain deflection check - V6 engine
VB engine 29 Apply a thm coat 01 RTV sealant to the gasket surface 01 the cover and allach., to the engine Don'I dislodge the Circular rubber seal or the gaskets 30 II may be necessary to compress the rubber seal by lorClng the cover down belors installing the bolls. Temporarily Slip the VibratIOn damper onto the crankshalt \0 align the COYer. 31 Apply pipe sealant with Tellon to the threads. then Inslalithe bolls. Tighten the 011 pan-Ie-cover bolls 10 the tOrQue listed in thiS Chapter's Speclflcahons while aligning the cover with the damper. Make sure the
gaslc.ets and seal slay in place 32 Tighten the cover-to-block bolts to the torque listed In thiS Chapter s SpeclhcallOns, then remove the vlbrallon damper
Refer 10 IlluSlralron 11 11 9 Rotate Ihe crankshaft In a counterclockwise direction 10 lalle up lhe slack In thc left Side 01 the chain 10 Remove Ihe timing chain cover (Seellon 10). 11 Establish a referellCe point on the bfock and measure Irom that POInI to the chain (see illustration) 12 Relnstallthevlbrabon damper bolt, USing this boll. turn thecrankshaft clockWise With a wrench until the slack Is taken up on the right Side of the chain 13 Force the left Side of the chain out With your fingers and measure the distance between the reference POlOt and the chain. The dlfferellCe between the two measurements Is the deftection \4 If the deflectIOn exceeds 1/2·lllCh. install a new liming chain and sprockets
All engines 33 InSlallti1e remaining parts In Ihe reverse order 01 removal 34 Add engine oil and coolant (Chapter 1). 35 Run Ihe engine and check lor leakS
11
TIming chain and sprockels - Inspection , removal and Installalion
Timing chain inspection I
Disconnect the negallve battery cable Irom the battery
V6 engine Refertoilluslra//Ons 114 and 11.5 2 Reier 10 Section 3 and poSition the number one PIston several de· grees belore TOe on Ihe compression stroke 3 Remove the fight rocker arm cover (Section 4). 4 Remove the number Ihree cylinder eKhaust rocker arm bolt, rocker arm and fulcrum, Irs the last one on the right (passenge r) Side. Attach a dial indicator 10 the head with the plunger in·hne With and resting on the pushrod (see Illustration) 5 Turn the crankshaft clockWise until the number one PIston IS al TOC (SecllOn 3). ThiS Will take up the slack on the nght side 01 the chain (see illustration _ view A ). 6 Zero the dial IndICator 7 Slowly lurn the crankShaft counterclockwise unlll the sllQhtest movemeOlIS seen OfIlhe dial indICator Stop and note how lar the number one PIston has moved away from TOe by IooklOg althe IQnlIJon timing marks (View B In Illustration II 5). 8 lithe mark has moved morethan 6degrgeS, Install anew timing chain and sprockets
Chain and sprocket removal and installation Reier 10 ,llus/ralu:ms 11,17. 11,22, 11.23 and 11 24 Removal 15 Make sure the number one piston Is at TOC (Section 3) 16 Remove Ihe liming chain cOver (Section 10). Try to avoid turnmg the crankshaft dUring Vibration damper removal. 17 Make sure the crankshaft and camshaft sprocket liming marks are ahgned (see lItustratlon). 1f they aren·!. install the vibration damper bolt and use It to turn the crankshaft clockWise until the two mar1<.s are aligned 18 Remove the camshalt sprocket mounllng bolt{s) and 'uel pump &ecantnc (carburetor eqUipped models only). 19 Pull the sprocket/cham off the camshaft and detach the chalO trom the crankshah sprocket. Oon't lose the PIn In the end 01 the camshaft (Va engu'19 only). 20 The crankshaft sprocket can be levered off Wllh two large screwdflv, ers or a pry bar. Installation 21 Align the keyway in the crankshaft sprocket With the Woodrutl key in the end of the crankshaft. Press the sprocket onto the crankshatl With the vibration damper bot!, a large socket and some washers or tap it gently into place until it's completely seated. Caution: /I resistance IS encountered. DO NOT hammer the sprocket onto the shafl. /I may eventually move into place, but It may be cracked In the process and falila/er. causing extensive engine damage 22 Turn the crankshaft unlll the key IS lacmg up (120 'clock position) (He illustration) 23 Drape the chalO over the camshaft sprocket and turn the sprocket un· IIlthe liming mark faces down (50'clock poslllon). Mesh the chalO WIth the crankshaft sprocket and poSI\ton the camsha/t sprocket on the end 01 the cam (see Illustration) II necessary. turn the camshaft so the dowel plO
I
Chapter 2 Part 0
11. 11 Checking l im ing c hain deflection - va engine
11 .17
3.8L V6 and all V8 engines
Align the timing marks on Ihe
crankshaft and cam shaft sprockets
20-17
11 .22 Position Ihe cranksh aft with th e key facing up (12 o' clock). then ...
(arrows) as shown here before removing the s prockels Irom Ihe shafts
2D
11 .23
... s lip the c hain over the crankshaft s procket and attach
the camshaft sprocket to the cam shaft
11 .24
Correctly aligned liming m ar ks
crankshaft (see illustration). DO NOT proceed unlit the valve timing IS
correct l 25 Ins/alilhe fuel pump eccentriC (carburetor equipped vehicles only). 26 App ly loc-Tite to the threads and install the camshaft sprocket boll(s). Tigh ten Ihe boll(S) to the torque listed In thiS Chapter's Speciflca·
!Ions. 27 Aelnslail lhe remaining parts m the reverse order 01 removal
12 , 2.3a
Stubborn lifters may be removed with a special slide hammer puller
fits mto Ihe sprocket hole (VB engine) or the boll holes In the sprockel are aligned With the offset threaded holes In the camshaft flange (V6 engine) . 24 When correctly installed, a straight Ime should P!lSS through the center of the camshaft. the camshaft liming marl<. (in the 6 o'clock position). the crankshaft timing mark (in the 12 o'clock posillon) and the center of the
Valve lifters - remo val, inspection and installation
Removal Refer to Illustrations 12.3a. t2.3b. 12.4a and 12.4b 1 Remove the intake manllold (Section 7) . 2 Remove the rocker arms and pushrods (Section 5) 3 There are several ways to extract the lifters from the bores Special lools designed 10 grip and remove lifters (Ford tool no. T70L·6500·A or equivalent) are manu faclured by many 1001 companies and are Widely available (see illus tration ), bu t may not be needed m every case. On
20-18
12.3b
Chapter 2 Part 0
3.8l V6 and all V8 engines
You may be able 10 remove Ihe lifters with a magnet
newer engines without a lot of varnish buildup, the litters can often be reo moved with a small magnet (see Illustration ) or even wrth your lingers. A
machlnlsl's senbe With a bent end can be used 10 pull the Ilhers out by POSI ' tlonlng the potnt under Ihe talamer f1l19 In Ihe top 01 each 'liter. Caution : DonI use pters /0 remove rhe hfters unless you ;nlend 10 replace lhem With new ones (along wlIh lhe camshaft) The pliers may damage rhe precisIOn
machlnedand hardened lifters, rendenng them useless. On engines With a /olof sludge andvamlsh. work Ihe Mars up and down, usmg carburetor cleaner spray /0 loosen the depoSIts 4 Before removing the hlters, arrange to store them In a clearly labelled box 10 ensure that they're reinstalled In thelf original locations, Note: On engmes eqUIpped WIth faller Mters. the gUide retamer and gUide plates must be removed before the idters are Withdrawn (see illustration). Remove the Iitlers and store them where they wan', get dirty (see illustrati on)
Inspection Conventional liflers 5 The procedure for mspecllng conventJonalllfters IS In Chapter 2, part B. Section 9
Roller titters Refer to Illustration 126 6 Check the rollers carefully for wear and damage and make sure they turn freety Without excessive play (see Illustration ) 7 The InspeCllOn procedure for convenllOnallJ fters also applies to roller lifters {see Chapter 2, part B. Section 9) a Unlike conventional lifters. used roller Idlers can be remstalled With a new camshaft and the ong'nal camshalt can be used If new lIfters are Installed
Installation 9 The onglnal IIlters, if they're be'ng reinstalled, must be returned to their Orlg,nallocallons. Coal them With moly-base grease or engine assembly lube 10 Install the li fters In the bores II Instalilhe gUide plates and retainer {roller lifters only). t 2 Instalilhe pushrods and rocker arms t 3 Install the Intake manll;>ld and rocker arm covers
13
Camshaft and bearing s - remo val, Inspecti on and installation
Camshaft lobe lift check In order 10 determine the e~lent of cam lobe wear. the ~be lilt should be checked proor to camshaft removal Reier to Section 4 and remove the
"-
FRONT OF ENGINE
" 12.4a
Gu ide plale and rel alner !ocalions -
va engine
rocker arm covers. The rocker arms must also be removed (Section 5), but leave the pushrods In place 2 POSition the number one piston at TOC on the compreSSiOn stroke (see Sechon 3). • 3 Beglnnlrtgwllh the number one cylinder, mount a dlallfwjlcalor on the engine and poSi tion the plunger Irt-Ilne With and resting on the first pushrod (see illustration 11 .4)_ 4 Zero thedlallndlcatof. then very slowly turn the crankshaft In the normal dlfecllon of rolallon unlil the Irtdlcator needle Slaps and beglrtS to move In the oPPOsite dlfectlon. The point at which ,t StOPS Indicates maxImum cam lobe hit. 5 Record thiS I lgure lor luture reterence.lhen repoSition the piston al TOC on the compression stroke 6 Move Ihedlal indicator to the remaining number one cylinder pushrod and repeat the check. Be sure to record the results lor each valve 7 Repeal the check forthe remalOlOgvatves Since each piston must be at TOC on the compreSSion stroke lor Ihls procedure. woo from cylinder· to-cylinder lot~wlrtg the firing order sequence a After the check IS complete. compare the results to the SpecificatIOns II camshaft lobe 11ft IS less than specilled. cam lobe wear has occurred and a new camshaft should be Irtstatled
Remova l Refer to Illus/rations 13.11 and 13.12
9 Re ier tothe appropriate Sections and removethepushrods, the valve htters and the timing cham and cams halt sprocket The radiator should be removed as well (Chapter 3). You also may have to remove the alfcondltlonlng condenser and Ihe grille. but walt and see II Ihe camshaft can be pulled out of the englrte to Check the va engine camsha/t end play wllh a dlat Indlcatol II lIs greater than specified. replace the thrUSI plate With a new one when Ihe camshaft IS reinstalled II Remove Ihe camshaft thrust plate bolts AT -30 Torx bit IS fequlf(ldfor the boilS on the V6 eng,ne (see Illustration) 12 Carefully puillhe camshaft oul Support the cam so the ~bes don't nick Or gouge the bearings as It'S Withdrawn (see illustration)
Chapter 2 Part 0
12.4b Be sure to store the lifters in an organized manner to make sure they 're reinstalled in their originallocallons
20-19
3.8l V6 and all V8 engines
13.11
Some models use T-30 Ton:
12.6 The roller on roller lifters must turn freely - check lor wear and
screws to retain the camshafllhrusl
excessive playas well
plate (arrows)
2D
13.12 Carefully remove the camshaft to av oid damaging Ihe bearings (nole thai in Ihis case the litters are not stored In a box: because they will be discarded along with the camshaft)
Inspection 13 Reier to Pan A Section 7. for the camsha ft and bearing inspection procedure Lifter Inspection procedures lor roller Ilflers are covered m Section t 2 InspecTIon procedures lor conventional lifters are covered In Part B. Section 9 01 thiS Chapter
13.15
Apply moly-base grease or engine assembly lube to the camshafllobes and Journals prior to instalialion
20 Before starting and running the engme. change the oil and Install a new all !ilter (see Chapter 1).
14
Oil pan - removal and installation
Bearing replacement 14 Camshaft bearing rep lacement reqUires speciat loots and expertise Ihat place It outside the scope 01 the home mechanic. Take the block 10 an automotive machine shop 10 ensure that the job IS done correctly.
Installation Refer to I/Iustrallon 13.15 15 Lubrtcate the camshaft beanng Journals and cam lobes with moly· base grease or engme assembly lube (see illustration). 16 Slide the camshah Into the engine. Support the cam near the block and be careful not to scrape or nick Ihe bearings, 17 Apply moly-base grease or engine assembly lube 10 both sides of the thrust plate. then pOSllion lion the block With the oil grooves In (agamstlhe block), Install the bol ts and tighten them 10 the torque listed in thiS Chapter's Speclhcatlons 18 Refer 10 the appropriate Sections and install the lilters, pushrods. rocker arms, \lmmg chain/s procket. timing cham cover and rocker arm covers 19 The remaining mstallatlon steps are the reverse 01 removal.
Removal Refer to iIIus/ratlons 14 15and 1419 1 Disconnect the negative ballery cable from the ballery. 2 Remove the air cleaner assembly (Chapter 4). 3 Remove the tan shroud mounting bolls and posItion the shroud back over the fan 4 Remove the oil level dipstick and disconnect the 011 level sensor sWitch on the Side of the 011 pan (if equipped) If so equipped. remove Ihe screws anachmg the vacuum solenoids to 5 the firewall behind the engme. POSition the solenoids out of the way Without dlsconnecling them_ 6 If it Will obstruct oil pan removal , disconnect the exhaust crossover pipe from the mani folds (Chapter 4). 7 Drain the engme oil and remove Ihe all filter (Chapter 1). 8 On models with an automa tic transmission. disconnect the shift hnkage where It goes Irom the body to the transmiSSion (Chapter 7)_ 9 On models With an au tomatic transmission, disconnect the transmis sion coo ler lines at the radiator (Chapter 3).
20-20
14.15
Chapter 2 Part 0
Place a block of wood between I he mount and sublrame
3.8l V6 and all V8 engines
14 .19 Slip Ihe all pan out, turn ing it slightly to c lear the all pick-up (V6 engine)
10 Remove the lour torque converler CO\lef retaining boilS and detach
the cover. 11 RemOve Ihe starter molor (Chapter 5) 12 Olsconnec1 the sleenng nex coupling and remove the two bolts al lachlng !he steering gear to the sublrame (Chapter 10). lei the sleenng gear rest on the subframe away from Ihe 011 pan 13 Loosen the nulS holding the transmiSSion mount lathe cross member, but don 1 remove them completely
14 Removethe through boilSlromthe Iront engine mounts. Place a block of wood under the 011 pan and hft the engine shghlly With a fack, Caution : When ralsmg the engme on models With an automallC Iransmlsslon, walch the clearance between the transmiSSion dipstiCk" tube and the Thermactor downstream air lUbe gomg to the catalytIC converter, If the tubes contact
before adequate mount-to-subframe clearance IS achieVed, /ower the en gmeand remove thedlpstlelf tube and downstream alf tube, A clamp cut ler and cnmpmg tool (Ford tool no T78P·9481-A or eqUivalent) are recommended to disconnect the tube 'rom the convefTer 15 Pl ace wooden blocks between the mounts and sublrame (see iIIu strallo n ) 16 Remove the 011 pan mounting bolts Most models are eqUipped With a reinforcement stnp on each Side of the pan which may come loose as the bo lts are removed 17 Care fully separate the pan from the btock Don't pry be tween the block and pan or damage to the seal ing surlaces may resu lt and 011 leaks could develop Instead, dlslOCige the pan wllh a large rubber mallet or a blOck 01 wood and a hammer 18 It youre working on a V8 engine, reach In and remove the 011 pump and piCk -up tube fasteners and allow them to drop Inlo the 011 pan (the pan can I be removed With them bottedto the block there snot enough room) t9 Maneuver the pan out the rear between the sublrame and transmiSsion (see Illu s tra tion )
Installation
14.20 Scrape away all traces 0 1 gasket material and sealant, Ihen clean Ihe gasket s urfaces with lacquer thinner o r acetone
21 Clean the matlOgsurfaceswlthlacquer thmneror acetone_ Make sure the bolt holes m the block are clean 22 Check the 011 pan flange for d!ston,on, panlcularty around the boll holes II necessary, place the panon a block olwood and usea hammerto lIanen and reslore the gasket surlace 23 Remove the old rubber seals from the rear main beanng cap and lim· Ing cham cover. then clean the grooves and InSlall new seals (thiS doesn't apply to the later model V6 engme wllh a rubbergasket)_ Use RTV sealant or gasket contact adheSive \0 hold the new seals m place. then apply a bead of RTV sealant to the block-to-seal ]unCllOns It you 're working on a engme, use the contact adheSive to attach the new gaskets to the block (see Illustrations) 24 II you're workmg on an early model V6 engme, apply a bead of RTV sealant to the block l1latlng surlace as shown In Illustralion 14 23a Note:
va
Ahermarli.e/ gasket sets may mclude a gasket for use on the early model V6 engme - be sure /0 lollow the IIlstrUC/Ions mcludeci WIth/he set 25 The rubber gasket used on the later model V6engme should be POSItioned on the pan alter the pan has been maneuvered back Into place between the subtrame and transmlss!on (see i llustration ) 26 II you're WOrking on a engme, dont forget to Inslallthe Oil pump along Wi th the pan, 27 Carefully position the pan against the block and Install the bolts finger l ight (don-t forget the rein forcement strips. II usedl. Make sure the seal(s}'gasket(s) haven't shilled, then tighten the bolts In three steps to the torQue listed In this Chapters Specifications Start at the center 01 the pan and work out toward the ends In a spiral pattern 28 The remaining steps are the reverse of removal Ca ution : Don/ forgel to refllllhe engme W1lh 011 and replace the hiler before stafTIng It (see
va
Chapler 1), 29
15
SIan the engine and check carelully for 011 leaks althe 011 pan
Oil pump - remova l and in s t allatio n
Refer to Illustrations 1420, t423a, t4 23b and 14 25 No t e: Several different oil pan gasket configurations are found on engmes covered by thiS manual Mosl V6 engmes havea haff-round rubber seal m (he rear mam besrmg cap groove and no gasket RTV IS used to seal/he oil
pan la-block and /lmmg cham cover fOm/S Larer model V6S have onepiece rubber 011 pan gaskets thaI mcorpora/e the rear bearmg cap seal The VB engme IS equipped WI/h rubber seals allhe rear mam beanng cap and (,mmg cham cover_ while convenllonal gaskets are used 10 seal the sides of the pan Be sure to follow the IIlstalla/lOn ms/ructlons mcluded Wllh an OEM or ahermarker gasket set - they supersede the mlorma/lOn m· eluded here 20 Use a gasket scraper or putty klllfe to remove all traces of old gasket material and sealant from the pan and block (see iIIustraUon)
V6 engine ReIer 10 Illustrations /52,15
"a and '5"b
t The 011 pump IS mounted e~ternally on the liming chain cover 2 Detach the all filter (Chapter I) then remove the 011 pump cover bolts (see Illustration) 3 Detachthe cover and gasket, then remove Ihegears from thecavlty,n the liming chaIn cover. Discard the gasket 4 Clean and inspect the 011 pump cavity It the 011 pump gear podIel In the timing chain cover IS damaged or worn. replace the IImlllg chain cover Remove alilraces 01 gasket malerlal trom the 011 pump cover, then 5 check It for warpage wi th a straightedge and feeler gauges 11,1's warped more Ihan O.OOI6-mch, replace 1\ With a new one
Chapter 2 Part 0
14.238
3.8l V6 and all V8 engines
20-21
Many V6 engines are equipped with a hall-round rubber seal at Ihe rear main bearing cap and no all pan gasket - RTV sealant Is used at Ihe pan-Io-block and liming chain cover joint
2D
14.23b Typical va engine oil pan gaskets and rubber seals - exploded view
15.2
After the filler is removed , the all pump cover bolls are
accessible (arrows) - V6 engine only
14.25 The one-piece all pan gasket used on later model V6 engines must be slipped inlo place al1er the all pan has been maneuvered pasllhe transmission and subframe
20-22
15.118
Chapter 2 Part 0
Remove the nut (arrow) ...
3.8l V6 and all V8 engines
lS.11b ... and Ihe two bolls (arrows) 10 detach the all pick-up tube (V6 engine)
16.4 Mark the pulley and vibration damper belore removing Ihe four bolts-
the large vibration damper boll (arrow) is usually very light, so use a s ix-point so cket and a breaker bar to loosen It
16.5 Use Ihe recommended puller to remove the vlbraUon damper - II a puller thai applies force to the outer edge is used, the damper will be damaged!
16.6
A chisel and hammer must be
used to work the seal oul 01 the timing chain cover - be very careful nol to damage the cover or nick Ihe crankshaft!
6 To remove Ihe pressure rellel valve. lirSI detach Ihe timing chain cover Irorn the engine (Section 10). Drill a hole In the plug (see iIIuslralion 10.16b), then pry It out or remove II wllh a slide hammer and screw adapter Remove the spnng and valve from the bore 7 Remove all meta! chips from the bore and the valve. then check them care!ullylorwear. score marks and galling. It the bore Is wornor damaged, a new timing cham cove r Will be reqUired The valve should fi t in the bore with no noticeable side play or binding If the Spring appears to be latlgued or collapsed, replace It with a' 3W a one The tenSion can be measured and compared to the Speci fications to determine ItS condition. 9 Apply clean engine 011 to Ihe valve and mSlallltln the bore. small end first Inser1the Spring, then mstall a new plug Carefully tap It In until Irs O.OlO·mcn below the machined sur1ace of the cover 10 Intermediate shall removal and Instatlatlon IS covered In Section 10 11 The 011 pump pick-up is InSlOe the 011 pan. For access, remove the 011 pan (Section 14), Remove the prck-up tube nut and Ihe two mounting bolts (see illustrations), 12 Installation is the reverse 01 removal CauUon: Be sure topack the all
, 6,B Clean the bore, then appl y a small amoun! 01 all to !he outer edge 01 the new seal and drive i' squarely Into Ihe opening with a large socket and a hammer - don ', damage the seal In the process and m ake sure it's completely sealed
pump With petroleum Jelly (NOT multi-purpose grease} before ms/a/lmg the cover /I must fill all voids be/ween the gears, cavity and cover. If thIS Isn'l done. the pump may fall/o prrme when the engme IS started Install a new covergasket and lighten the bolts to the torque listed in Ihls Chapters Specifications m a crrss-cross patrern. Use anew plck·up tube gasket and lighten the mountmg bolls securely
VB engine 13 Unbolt and lower the 011 pan as deSCribed In Seclion 14 14 Remove the all pICk-up tube-Io-mam beating cap nul 15 Remove Ihe oil pump mounting bolts 16 Lower the 011 pump assembly Into the oil pan and 11ft them both out together. If the pump IS faulty, or you suspect that lIs faulty. rnstall a new one - do not aUempt to repair the Orlgrnal 17 Prime the oil pump prior to rnslallal~n Pour clean 011 Into the piCkup and lurn the pump shaft by hand 18 If you separate the pump from the pick-up tube, use a new gasket and tigh ten the bolts securely when reattach ing them
Chapter 2 Part 0
3.8l V6 and all V8 engines
20-23
16.10 A soft·lace hammer can be used to lap the vib ration damper onlo the crankshaft - don" use a steel hammer!
16.17 II you ' re very ca reful not to damage the crankshaft or the seal bore, the rear seal can be pried out with a screwdrivernormally a special puller is used for this procedure
19 Fit the all pump dnveshaft Into the pump. It must seat all the way. DO NOT try to force It. If 11 doesn"' al ign. turn the pumpslighUy and Iry again.
Also. the pulley must be aI/ached to Ihe damper wl/h the same onentallon to rne pms as on the ongmal. Apply moly·oase grease or clean engme ail to Ihe seal contact surface of Ihe vibration damper and coat the keyway (groove) With a thin layer of RTV sealanl. 10 Install the damper on the end 01 the crankshaft. The keyway In the damper bore must be aligned with the Woodruff key in the crankshaft nose. lithe damper can 't be seated by hand, tap 1\ into place With a softface hammer (see illustration) or slip a large washer over the bolt, Install the bol t and tighten It to push the damper mto place. Remove the large washer, then Instailthe bolt and tighten it to the torque listed in thiS Chapter"s Specifications. 11 Install the remaining parts removed 10f access to the seal. 12 Start the engine and check lor leaks at Ihe seal -to ·cover JOint
20 Instalilhe mounting bolls/nul and lighten them to the torque listed In this Chapter's SpecificatIOns.
16
•
Crankshaft oil seals - replacement
Front seal- timing chain cover in place Refer 10 iIIus/ralions 16.4. 16.5. 16.6. 16.8 and 16. 10 Remove the bolts attaching the Ian shroud to the radiator and position the shroud back over the Ian.
2 3 4
Remove the fan/clutch 8ssembly and the Shroud (Chapter 3) . Remove the dnvebells (Chapter 1) . Mar" the crankshaft pulley and Vibration damper so they can be reas-
sembled in the same relative poSition. This is Important, since the damper and pulley are Initially balanced as a unit. Unbolt and remove the pulley (see Illustration) 5 Remove the bott from the front of the crankshaft. th en use a puller to detach the Vibration damper (see illustration). Caution: Don·rusea pull· er wirn jaws thaI grip Ihe outer edge a! the damper. Thepuller must be the type shown In the illustration that utilizes bolts to apply force to the damper hub only. Glean the crankshaft nose and Ihe seal contact surface on the wbraliondamper with lacquer thinner or acetone. Leave the Woodruff key in place in the crankshaft keyway. 6 Carelully remove the seallrom thecover with asmall chisel and ham mer (see illustration). Be careful nolto damage the cover or scratch the wall of the seal bore. II the engme has accumulated a lot 01 miles. apply penetratmg all to the seal-la-cover JOint and allow it to soak in before attempting 10 remove the seal. 7 Check the seal bore and crankshaft. as well as the seal contact surface on the Vibration damper for nicks and burrs. Position the new seal in the bore With the open end 01 the seal lacing IN . A small amount o f all applied to the outer edge of the new seal Will make mstallation easlerdon't overdo It I 8 Drive the sealmto the bore with a large socket and hammer unlll it's completely seated (see illuslration). Selaet a socket that's the same out· side diameter as the seal (a section 01 pipe can be used if a socket isn't available). 9 Note; /I a new vibrallon damper is bemg mstalled. balance pins must be located In the new damper rn the same relatIVe positrons as the original.
Front seal- timing chain cover removed 13 Use a punch or screwdllver and hammer to drive the seal out of the cover from the back Side Support Ihe cover as close to the seal bore as poSSible. Be careful not to distort the cover or scratch the wall of the seal bore. tithe engine has accumulated a lot of miles, apply penetrating all to the seal-to-cover jOint on each Side and allow 1\ to soak In belore attempting 10 drive the seal out. 14 C lean the bore to remove any old seal matenal and corrosion . Sup· port the cover on b locks of wood and poSition the new seal In the bore wllh the open end of the seal facmg IN. A small amount of 011 applied to the outer edge of the new seal Will make Installation easier - don·t overdo it! 15 Dllve the seal Into the bore With a large socket and hammer until it"s completely seated. Select a socket that"s the same outSide diameter as the seal (a section of pipe can be used It a socket isn't available).
Rear seal Refer to illustratIons 16.17 and 16.19
16 Reier 10 Chapter 7 and remove the transmiSSion, then detach the flywheel ordriveplate and the rear cover plate from the engine (Section 17). 17 The old !:eal can be removed by prying It oul with a screwdriver (see i1Iustrallon). Be sure \0 note how far Irs recessed into the bore belore reo moving It: the new seal will have to be recessed an equal amount. Caulion: Be very careful not to scratch or otherwise damage thecrankshaftor the bore m Ihe housmg or oil leaks could develop' 18 Clean the cranKshaft and seal bore With lacquer thinner or acetone. Check the seal contact surface very carefully for scratches and nicks that could damage the new seal lip and cause all leaks. If the crankshaft IS damaged, the only alternative is a new or different crankshaft.
2D
20-24
Chapter 2 Part 0
3.al V6 and all va engines
/ LUBRICATE SEAl AND SEAL MATING SURFACE WITH OIL
fRONT OF ENGINE
/
=-- -, ....' .. 0'<,
~
~OR' .S$Y
(~
., H
_,,,
I
-{}/
t8.8
----
Typical engine mounts - exploded view
NOTE! f'IEAfI FAa! OF UAL MUST lIE WITHIN 0.127_ (O .OO5-IMCH) OF THE MAR FACE OF THE SLoat
16.19 Rear seallnstallallon should be done with the special Ford 1001 shown 10 en sure that the seallsn', damaged
19 Make sure the bore IS clean. then apply a thin coat 01 engme 01110 the outer edge of the new seal Apply moly-based grease to the seal lips. The seal must be pressed squarely mto the bore, so hammering II into place IS IlOI recommended II you cion! have access to Ford tool no. T82L·6701·A (see Illustration). you may be able to tap the seal In with a large sectIOn of
PIpe and a hammer II you~t use this method, be very careful not 10 damage the seal or cranksh nd work the seal lip carefully over the end 01 the crankshaft wl1h a blunt t such as the rounded end of a socket e~ tension 20 Reinstall the engine rear cover plate. the Ilywheel or dnveplate and the transmiSSion.
altgnment dowel or staggered bolt holes to ensure correct InstallatIOn. Betore InstaJllng the bolts. apply Ford sealant With Teflon (OSAZ-19554-A) 10 the threads. 9 Wedge a screwdnver through the starter motor opening 10 keep the flywheelldflveplate from turning as you tigh ten the bolts to the torque listed in thiS Chapter 's Specllications. to The remainder of IfIstaliation IS the reverse at the removal procedure
18
Eng ine mounts - check and replacement
Refer to illustration 18.8 1 Engine mounts seldom reqUire attention, but broken or deteriorated mounts should be replaced immediately or the added stram placed on the drlvellne components may cause damage or wear
Check 17
Flywheel drtve plate - remova l and i nstallation
Raise the vehicle and support It securely on jackstands, then reter to Chapter 7 and remove the transmission. II irs leaking. now would be a very good time to replace the Iront pump seal/O-n ng (automatic transmission only) 2 Remove the pressure plate and Clutch diSC (see Chapter 8) (manual transmiSSIOn eqUipped vehICles). Now IS a good Ilme to check!replace lhe clutch components and pilot bearing. 3 Look lor factory pain! marks that Indicate lIywheeHo-crankshaft alignment II they aren'lthere, use a center-punch to make alignment marks on the tlywheel/driveplate and crankshalt to ensure correct align ment dunng reinstallation . 4 Remove the bolts that secure the ltywheelldTiveplale to the crankshatt II the crankshall turns. wedge a screwdnver through the starter opemng to Jam the lIywheel 5 Remove the Itywhee~drlveplate from the crankshaft Sillce the tlywheeliS fairly heavy. be sure to support It while removing the last bolt. 6 Clean the tlywheel to remove grease and all. Inspect the surface tor cracks, flvet grooves. burned areas and score marks Light sconng can be removed With emery cloth. Check tor cracked and broken ring gear teeth. Lay the lIywheel on a lIat surface and use a straightedge to check for war·
page 7 Clean and Inspect the matlflg surfaces of the flywheeVdnveplate and the crankshaft II thecrankshalt rear seal IS leaking. replace It belore relnstallnlQ the lIywheelJdnvepiate 8 POSition the lIywheeVdnveplate agalnslthe crankshaft. Be sure 10 align the marks made dunng removal. Note thaI some engines have an
2 DUflf'19 the check. the engme must be raised slightly to remove the welghtlrom the mounts. 3 Raise the vehIcle and support it securely on jackstands. then poSl1lon a Jack under the engine oil pan. Place a large block of wood between the Jack head and the 011 pan, then carelully raise the engine Just enough to take the weight 011 the mounts. Warning: DO NOT place any part of your
body under me engme when Irs supported only by a jaek' 4 Check the mounts to see If the rubber IS cracked. hardened or separatedlrom the metal plates. Sometimes the rubber w!11 Spilt right down the center. Check lor relatlYe movement between the mount plates and the en· 5 glne or frame (use a large screwdflver or pry bar to attempt to move the mounts). If movement Is noted. lower the engine and lighten the mount lasteners 6 Rubberpreservab'i'l Should be appIted to the mounts 10 slowdeterloratIon.
Replacement 7 Dlsconnectlhe negative banery cablelrom the battery, then raise the vehicle and support it securely on jackstands (If not already done). 8 Remove the nut to disconnect the mount from the frame (see Ulustratlon ) On automatic transmiSSion models. disconnect the shift linkage (see Chapter 7). 9 Raise the engine sltghtly With a tack or holSt (make sure the Ian doesn·t hit the radiator or shroud). Remove the mount·to·block. bolts and detach the mount 10 Installa\lOn IS the reverse of removal. Use thread locking compound on the mount bolts and be sure to tighten them securely
Chapter 2 Part E General engine overhaul procedures Contents
3 18 22
Compression check Crankshaft - mspeClIOn Crankshaft - Installation and main beanng 011 clearance check
13 9 8
Crankshafl - removal Cylinder head - cleaning and inspection Cylinder head - disassembly Cylinder head - reassembly Cylinder honing Engine block - cleaning Engine block - inspection Engme overhaul - disassembly sequence Engine overhaul - general mlormallon Engine overhaul - reassembly sequence
11 16 14
15 7 2 20
•
Engine rebui lding alternatives Engine - removal and installation Engine removal - methods and precautions General information ............. . Initial sIan-up and break· m alief overhaul Main and connecting rod bearings - inspecllon Pistons/connecting rods - Inspection Pistons/connec1lng rods - installation and rod bearing oil clearance check . Pistons/connecting rods - removal Piston rings - installation Rear main 011 seal - instaliallOn Valves - servicing
6
5 1
25 19 17 24
12 21
23 10
2E Specifications
Four-cylinder engine General Displacement C~hnder compression pressure Oil pressure (engine warm )
2.3 liters 101 psi min (see accompanying chart) 40 10 60 pSI al2000 rpm
Milimum
Minimum
Milimum
Minimum
.... Imum
Minimum
Milimum
Minimum
PSI 134 136 138 140
PSI
PSI
PSI
PSI
16' 186 168 170
12' 126
22' 226 228
168 169
127
200
'30
172
129 131 132 133 135 136 138 140 141 142 14<
202
PSI 145 147 148 150 151 153 154 156 157 158 160
PSI
123
PSI 194 196 198
232
174
'34 '36 '38 240 242
175
14' 14' 146 14' 150 152 154 156 158 160 162
101 102 104 105 107 108 110 111 113 11. 115 117
"' 120 121
172
17. 176 178 180 lB' lB' 186 188 190
'"
204 206 208
210 212
".
". '" "" 222
16' 163 165 186
,.
'46
24' 250
171
177
178 180 lBl 183 lB' lB. lB7
Cylinder compression variation chart - locate your maximum compression reading on the chart and look to the right to lind the minimum acceptable compression (then compare it to your lowest reading )
2E-2
Chapter 2 Part E
General engine overhaul procedures
Four-cylinder engine (continued) Cylinder head warpage limit ................ • .. • .....
0.003 in (in any 6 Inches); 0.006 in overall
Valves and related components Minimum valve margin width ......... . .... • ...
1132 In
Intake valve
Seal angle .. Seal width Seat rvnoul liml\
Stem diameter Standard . . 0.015 oversize .... 0.030 oversize Valve stem-la-guide clearance ........ . Standard Service limit .• ............. ••. •. • •••..... Valve lace runoul limit ••.
45-degrees
0 .060 to 0.080 In 0.0016 in (total Indicator reading) 0.3416 to 0.3423 in 0.3566 to 0.3573 in 0.3716 to 0.3723 in 0.0010 100.0027 in 0.0055 in 0.002 in
Exhaust valve
Seal angle. Seat width . ....... .
Seat runout limit Stem diameter Standard ..... Q,OI5 oversize 0.030 oversize . Valve stem-to-gUide clearance Standard ... . ...•..•. .. .•.•.... SeNice limit . • . . . ...•......•......•. Valve face Nnoul limit .•..•...•. . . . Valve SPring Oul -ol'square limit Pressure Standard 1979 through 1983 .• 19840n . SeNlce I!mlt 1979 through 1982 •..• . 1983 on Installed height Hydraulic valve lash adtuster Diameter (standard) •..•.. Clearance In bofe Standard SeNiee limit . .•..••...
45-degrees 0.070 10 0.090 in 0.0016 in (Iotal indicalor reading) 0.3411 10 0.3418 in 0.3561 to 0 .3568 In 0.3711 to 0.3718 In 0.0015 10 0.0032 0.0055 In 0.002 in
In
5/64 in
71 to 791bs at 1.56 in 71 to 791bs at 1.52 in 10-percent pressure loss 8t specilied length 5-percent pressure loss at specilied length 1-17/32 to 1-19/32 in 0.8422 to 0.8427 in 0.0007 to 0.0027 in 0.005 in
Crankshaft and connecting rods Connecting rod journal Diameter 1979 .. _ .. _ .. 1980 through 1982 19830n . __ Out-ol-round limit Taper limit Bearing oil clearance Desired . .. .. . .•..•.... . ..... Allowable Cormectmg rod side clearance (endplay) Standard _ __
Service limit . Mam bearing JOurnal Diameter 19791hrough 1990 1991 on Taper limit Runout limit 1979 through I 990 1991 on .. _. Bearing oil clearance Desired . _. Allowable .
2.0464 10 2.0472 in 2.0462 to 2_0472 in 2.0465 to 2 .0472 in 0.0006 in 0.0006 in per In 0.0008 to 0.0015 in 0.0008 10 0.0026 in 0.0035 to 0.01 05 In 0.014 In
2.399 to 2.3982 in 2.205910 2.2051 in 0.0006 In per in 0.005 In 0.002 in 0.0008 to 0.0015 in 0.0008 to 0.0026 in
Chapter 2 Part E Crankshaft endplay Standard
ServICe limit .
Cylinder bore Diameter OUI-ol·round limit Taper limit
General engine overhaul procedures
2E-3
0.004 10 0.008 in 0.012in
3.7795103.7825 In 0.005m 0.0101n
Pistons and rings Piston diameter 1979 Coded red Coded blue t 980 through 1982
3.7780 to 3.7786 m 3.7792 to 3.7798 in
TwOO Coded red Coded blue Non-turbo Coded red Coded blue
3.7760 10 3.7766 In 3,7772103.7778 In 3.7780103.7786 In 3,7792 10 3.7798 In
1983 on Coded red Coded blue Piston-Ie-bore clearance limit (select fit) 19791hrough 1982
Turbo . Non-turbo
....
1983lhrough 1990 1992 on . .
Piston ring end gap Compression flngs 1979 through 1991 lOp and bonom
37764 103.7770 in 3.7776 to 3.7782 In
0.0034100.0042 in 0.0014100.0022 in 0.0030 10 0.0038 in 0024 100.00338 In 0_0018100.0029 in
o
0.010 10 0.020 in
1992
Top nng
Bonomnng 011
nng (Sleel fall)
0.010100.020 In 0.015 to 0.025 in 0.015 10 0.055 In
Piston ring stele clearar'ICe Compression flngs Standard 1979 through 1990 19910f1 . Service limit 011 flng (stee l rail)
0.002 to 0.004 in 0,016 to 0.0033 In 0.006 In snug fit
Auxiliary shaft Endplay . .. Bearing Oil clearance
0.001 to 0.007 In 0.0006 to 0.0026 in
Torque specifications·
Ft·lbs
Mam beanrIQ cap bolts 1979 through 1986
Step 1 Step 2
50 to 60 80 to 90
1987 on
Slept
50 to 60
Slep 2
751085
Conneclmg rod cap nuts Step 1 .. SIep2 ..
25 to 30 301036
• Note : Refer 10 Part A for addltlonallorque specificatIons
3.3l inline six-cylinder engine General Displacemenl Cylinder compreSSion pressure Oil pressure (engine warm at 2000 rpm)
3.3 hters (200 cu in) 101 psi min (see accompanying chart) 30 to 50 psi
Cylinder head warpage limit
0.003 In per 6 In; 0.006 In overall
2E
2E-4
Chapter 2 Part E
General engine overhaul procedures
3.3L Inline six-cylinder engine (continued) Valves and related components Minimum valve margin width Intake valve Seal angle. Seat width Seat runOUI limit Slem diameter
Stem·to-guide clearance Valve face runout limn Valve face angle Exhaust valve Seat angle
Seat width Seal runoulilmil Stem diameter Stem-to-guide clearance Valve face runout limll .•
Valve face angle Valve spring Pressure Intake ..•
Exhaust ServICe limit (both valves) Free length (appro~imate) .
Installed height Valve lifter Diameter (standard) Lifter-la-bore clearance Standard Service limit
1/32 In 45-degrees 0.060 to 0.080 In
0.002 In (Iotallodtealor reading) 0.3100 to 0 .3107 In 0.0008100.0025 In 0.002 in 44·degrees 45-degrees 0.070 to 0.090 In 0,002 In (total indicator reading) 0.3098 toO.3105 in 0.0010 to 0.0027 In 0.002 in 44-degrees
51 at 57 Ibs at 1.59 10 142 to 158100 al 1.222 In 10-percent pressure loss at specified lenglh 1,79 In
1-911610 1-19132 In 0.8740 to 0,8745 In 0.0007 to 0.0027 in 0,005 in
Crankshaft and connecting rods Connectlf1g rod ,ournal Diameter (standard) .
Out-ol-round limit Taper limit Bearing oil clearance Desired . Allowable Connecting rod side clearance (endplay) Standard ..... . ServiCe limit Main beanng JOurnal Diameter .. Out·ol-round limit Taper limit .... . .•. Beanng oil clearance Desired Allowable Crankshaft endplay Standard .. Service limit
21232102.12401n 0.000610 0.0006 In per Inch 0.0008100.0015 in 0.0008 to 0.0024 in 0.0035 to 0.0105 In 0.014 In 2.2482 to 2.2490 In 0.0006 in 0.0006 10 per inch 0.0008 to 0.0015 In 0,0008 to 0.0024 In 0,004100,008 In 0,012 In
Cylinder bore Diameter .. Out-ol-round service limit Taper service limit ...
3.6800 to 3.6848 In 0.005 in 0.Q10 in
Pistons and rings Piston diameter' Coded red Coded blue Piston-la-bore clearance ...•. Piston ring end gap Compression nngs Oil ring rails PISlon ring side clearance Compl"esslOn nngs Siandard ServICe limit 011 ring.
3.6784 to 3,6790 In 3.6796\0 3.6802 In 0.0013100.0021 In 0,008100.016 In 0,01510 0.055 In
0.00210 0.004 in 0.006 10 Snug til
Chapter 2 Part E
General engine overhaul procedures
Torque specifications·· Main bearing cap bolts . ... . . .. .. . Connecting rod cap nuts .
2E-5
Ft·lbs 60 to 70
211026
• Measured at the pin bore center/ine, al 90-degrees to the pin . •• Refer to Part B for additional torque specifications.
2.SL V6 engine General Displacement . .. . ....... . Cylinder compression pressure ..... . Oil pressure (engine warm at 2000 rpm)
2.8 lilers (2800 ee) 101 psi min (see accompanying chart) 40 to 60 psi
Cylinder head warpage limit
0.003 in per 6 in; 0.006 in overall
Valves and related components Minimum valve margin width . Intake valve
Seat angle .
Seatwidlh .. Seal runoullimil Slem diameter . . .. .. . .. . ....•... Stem-la-guide clearance .... . . .. ... . .. . . • Valve face runout limit . . ... . . . Valve face angle ..... . ... . .. .. . .. .. . . . • . Exhausl valve Seat angle .... . Seatwidth ..... . Seat runout limit ...... . Stem diameter . . . ......... . Stem-to-guide clearance . Valve lace runout limit . .......... . . ..... _ . Valve lace angle .. . .. . .. .. .... .. .. •. Valve spring Pressure Standard Service limit .. . . Free length (approximate) Installed height _. Valve lifter Diameter (standard ) Lifter-Io-bore clearance Siandard . ...... . .. . . Service limil .. . . . .. . . . . . .
1/32 in
45-degrees 0.060 to 0.079 in 0.0015 in (total indicator reading) 0.3159toO.3167 0.0008100.0025 in 0.002 in 44-degrees 45-degrees 0.060 to 0.079 in 0.002 in (total indicalor reading) 0.3149to 0.3156 in 0.0018100.0035 in 0.002 In 44 -degrees
60.0 to 68.0 Ibs at 1.585 in 1O-percent pressure loss at specified length 1.91 in 1-37/64 to 1-39164 in 0.8736 to 0.8741 in 0.0009 to 0 _0024 in 0.005 in
Crankshaft and connecting rod s Connecting rod journal Diameter (standard) Out-ai-round limit Taper limit Bearing oil clearance Desired .. .. . ... . ... . Allowable. _ .. . ...... _ Connecling rod side clearance (endplay) Standard . . . . . . .. . .. . .. .. _ Service limit .... Main bearing journal Diameter . _ . Out-ol-round limit Taper limit Bearing oil clearance Desired . ................ . .. . . ... . ... . .. . . . ..... . .. .. . .. . _ .. .. . . _. Allowable ....... Crankshaft end play Standard Service limil
2.1252102.1260 0.0006 in 0.0006 in per inch 0.0006 to 0 .0016 in 0 .0005100.0022 in 0.004 to 0.011 in 0.Q14 in 2.2433 to 2.2441 in 0.0006 in 0.0006 in per inch 0.0008100.0015 in 0.0005100.0019 in 0.004 to 0.008 in 0.012 in
Cylinder bore Diameler _ . Oul-ol-round service limit Taper service limit .... .
3.6614 to 3.6630 in 0.005 in 0_010 in
2E
2E-6
Chapter 2 Part E
General engine overhaul procedures
2.BL V6 engine (continued) Pistons and rings Piston diameter-
Coded red 0.020 In oversize. PiSlon-lo-boreclearance.
3.6605\03.6615 in 3.6802 to 3.6812 in 0.001 to 0.0019 In
Piston ring end gap CompreSSion flngS Oil ring ralls
0.015100.023In 0.015100.055 in
Piston flng side clearance CompressIOn Imgs Standard ServiCe limit Ollnng
0.0020 to 0.0033 in 0.006 In Snug IiI
Torque specifications"
FI-Ibs
Mam bearing cap bolls Connectmg rocl cap nuts
651075 21 1025
• Measured at the pin bore centerline. at go-degrees 10 the pin. ,. Refer /0 Part C for additional torque specifications.
3.8L V6 engine General DIsplacement CylJndef compression pressure
3.8 liters (231 cu In) 101 psi min (see accompanying chart)
Oil preSSlJre (engine warm at 2500 rpm)
1963 and 1984 1985 on
Cylinder head warpage limit
54 to 59 psi 40 to 60 psi 0.007 In
Valves and related components Minimum valve margin width. Intake valve Seat angle Seat width Seat runout limit Stam diameter Valve slem-Io·gulde clearance Valve face runoul limit Valve face angle ElIhausl valve Seat angle Seat width Seal runoullimit Stem diameter Valve stem to-guide clearance Valve lace runout limit ... Valve face angle Valve SPl"IIlg Pressure (nollfICluding dampener) 1983lhroogh 1985 Valve open Valve closed 1986 Valve open Valve closed . Servtce Itmll Installed height Valve htter Diameter (standard) Lltter-to·bore clearance Standard Service limit
1132 in 45-degrees 0.060 10 0.080 in 0.003 In (total indicator reading) 0.3423 to 0.3716m 0.001 to 0.0027 in 0.002 in 44-degrees 45-degrees 0.060 to 0.080 In 0.003 in (total indicator reading) 0.3418toO.3411 in 0.0015 to 0.0032 in 0.002 in 44-degrees
2151bs all .29ln 75lbsall.70in 190 Ibs 1.28 In 731bs at 1.70 in 10 Ibs pressure loss at specified length 1.70 \0 1.78 In 0.874 tn 0.0007 to 0.0027 In 0.005 in
Crankshaft and connecting rods Connecting rod journal Diameter Out-ot-round limit Taper limit
2.3103102.3111 in 0.0003 in 0.0003 in per in
Chapter 2 Part E
General engine overhaul procedures
Bearing oil clearance Desired ......... . Allowable .................... . Connecting roo side clearance (endplay)
0.001 to 0.0014 in 0.00086 to 0.0027 in
Standard ...... ......•......•..•...•..•.. Service limit ............ .. ..... . Main bearing journal
0.0047\00.0114 in O.014in
2.5190 to 2.5198 in 0.0003 in 0.0003 in per in
Diameter . Out-oj· round limit Taper limit .. Bearing oil clearance
Desired Allowable ..... Crankshalt endplay
0,001 100.001 4 in 0.0005100.0023 in 0.004100,008 in
Cylinder bore 3.810 in 0.002 in 0.002 in
Diameter . . ........ .. .. . ........... . Out-ol-round limit
Taper limit ...
. ........•
Pistons and rings Piston diameter
3.8095103.8101 in 3.8107 to 3.8113 in 3.8119 to 3.8125 in
Coded red ........ .. Coded blue .... . .................... • . Coded yellow . Piston -Io-bore clearance limit
0 .0014100.0022 in 0.0014100.0032 in
1983 1984on . Piston ring end gap Compression rings ......... .. . Dildng .. .............. ...... . . .. , Piston ring side clearance .
... ... .
Torque specifications' Main bearing cap bolts ........ .. . ....... . Connecting rod cap nuts ..
0.010100.020 in 0.015100.0583 in 0.0016 to 0.0037 in Ft-Ibs 651081 311036
- Note: Refer to Pan D for adcfitional torque specifications.
VB engines General Displacement 1979 and 19830n ......... . ..... . . 1980 through 1982 Cylinder compression pressure Oil pressure (engine warm) .
5.0 liters (302 cu in) 4.2 lilers (255 cu in) 101 psi min (see accompanying chart) 40 to 65 psi at 2000 rpm
Cylinder head warpage limit
0.003 in (in any 6 inches)/O.006 in overall
Valves and related components Minimum valve margin width ........... .. . Intake valve Seat angle ........................ . Seat width ... . Seat runout limit Slem diameler Standard 0.015 oversize 0.030 oversize . Valve slem-to·guide clearance Standard Service limil .. . Valve face angle ......... ..... .. . .. . ...... . ....... . Valve face runoullimit . Exhaust valve Seat angle . . Seat width ... Seal runoullimil Slem diameter Standard .. ..... . .. . 0.015 oversize 0.030 oversize
1132 in 45-degrees 0.060 to 0.080 in 0.002 in (total indicator reading) 0.3416 to 0.3423 in 0.3566100.3573 in 0.3716 to 0.3723 in 0.0010 to 0.0027 in 0.005 in 44-degrees 0.002 in 45-clegrees 0.060 to 0.080 in 0.002 in (total indicator reading) 0.3411 10 0.3418 in 0.3561 to 0.3568 in 0.3711 to 0.3718 in
2E-7
2E-8
Chapter 2 Part E
General engine overhaul procedures
va engines (continued) Valve stem·tOilu!de clearance 0.0015 10 0.0032 In
Standard
ServlCEllimlt Valve face angle Valve face (unout limit Valva spring
0,0055 In
44-degrees 0.002 in
Pressure (not including dampener) Intake
1979 and 1980 Valve open Valve closed . 1981 and 1982 Valve open ... Valve closed . 1983
190 to 212 Ibs at 1.36 In 74 1082 Ibsal 1.78 in
196 to 2141bs at 1.36 in 74 to 821bs al1.78 in
Valve open Except HO
HO Valve closed 1984 through 1987 Valve open Except HO
HO
196 to 2141bs all.36 in 1941021 4 Ibs a\I.33 in 7410 82 1bs at 1.78 in
19610 2141bs all.36 in 215\0 2351bs at 1.33 in
Valve closed
EJecept HO . . ...
74 to 82 Ibsal 1.78 in
76 1084 lbsal1 .79in
HC 1968 on Valve open
Valve closed ....
211 to 230 Ibs at 1.36 In 74 to 621bs at 1.76 in
Exhaust 19791hrough 1981
Valve open .. . Valve closed
. ....... .... .
190 to 210 Ibs at 1.20 in 76 to 84 Ibs at 1.60 in
1982 and 1983 Valve open Valve closed . 1984 through 1987 Valve open Excepl HO
HO Valve closed Except HO .......•...
HO
....... .
1966 on Valve open. Valve closed . Valve spnng pressure service limit Out·of-square limll . Installed height Intake 1979 through 1987 .. . .... . Except HO
HO 1988 on Exhaust 19791hrough 1987 Except HO
HO 1988 on Free length (approximate) Inlake 1979throughl982 ... 1983 through 1987 .. 1988 on • Exhausl 19791hrough 1982 19831hrough 1987 1988 on
195to 215 lbs at 1.05 in 71 10 791bs al 1.60 in
195t02151bsat 1.05 in 210 to 230 Ibs at 1.15 in 71 10 79 Ibs at 1.60 in 79 \0 67 Ibs al 1.60 in 200 to 226 Ibs al 1.15 in 77 10 85 Ibs al 1.60 in 10-percent pressure loss at specified length 5164 In
1-43164 to 1-45/64 in Not available 1-3/410 1-13116 in 1-37/64 to 1139/64 in Not available 1-37/6410 1·41f64 in
2.04 in
2.05 In 2.02 In 1.85 in 1.87 in 1.79 in
Chapter 2 Part E
General engine overhaul procedures
2E - 9
Valve lifter Diameter (standard) Llfter-Io-bore clearance Standard Service limit , .
0.8740 to 0.8745 in 0.0007 to 0.0027 in 0.005 in
Crankshaft and connecting rods Connecting rod journal
Diameter . Ou!-of -roundltaper limit . Bearing all clearance Desired Allowable
2.1228 to 2. 1236 in 0.0006 in per in
0.0008 to 0.0015 in 0.000810 0.0024 in
Connecting rod side clearance (end play) Standard Service limit . Main bearing journal
0.010 to 0.020 in
0.023 in
Diameter Out-ol -round limit Taper limit .•..• ,
2.2490 to 2.2482 in 0.0006 in 0.000 4 in per in
Runout Standard . .
. ........ .
Service limit Beanng oit clearance 19791hrough 1981 (desired) NO. 1 Journal . All others 1979 through 1981 (allowable)
No.1 journal .... All others 1982 through 1984 (desired) No . 1 journal . . . . ............ . ..................... . All olhers 19821hrough 1984 (allowable) NO . 1 journal. All others 1985 on Desired. Allowable Crankshaft endplay Standard .. Service limil . ..... . ...•..............•..... . .. • • _ .
0.002 in
0.005 in
0.0001 to 0.00 15 in 0.0004 100.00 15 in 0.0001 100.0017 in 0.0004 100.002 1 in 0.0004 to 0.0025 in 0.0004 to 0.0015 in 0.0001 to 0.0030 in 0.0004 to 0.002 1 in 0.0004100.0015 in 0.0004 to 0.0021 in 0.004 to 0.008 in 0.012 in
Cylinder bore Diameter 4.2L (255 cu in) 5.0L (302 cu In) 1979 through 1986 1987 on Out-of -round limit Taper limit
3.6800 to 3.6845 in 4.0004 to 4.0052 in 4.0004 to 4.0048 in 0.005 in 0.010in
Pistons and rings Piston diameter Coded red 1979 through 1987 1986 on Coded blue 1979 through 1987 1988 on Coded yellow 1979 through 1987 .... . ........ _ 1988 on ..... _ .................. .. .. . _ 0.003 in oversize (Ihrough 1987) Piston -Io-bore clearance limit 1979 1hrough 1987 19880n . Piston ring end gap Compression rings Oil ling .
3 _9984 to 3.9990 in 3.99 7210 3.9980 in 3.9996 10 4.0002 In 3.9984 to 3.9992 in 4.0020 to 4.0026 in 3.9996 to 4.0004 in 4.0008 10 4/1014 in 0.0018 to 0.0026 in 0.0030 to 0 .0038 in 0.010 100.020 in 0 .015 to 0.055 in
2E
2E-10
Chapter 2 Part E
General engine overhaul procedures
va engines (continued) Piston ring side clearance Compression rings Standard .. Service limit Oil ring ...................... .
Torque specifications' Main bearing cap bolts Connecting rod cap nuts
0.002 to 0.004 in 0.006 in Snug tit Ft-Ibs 60 to 70 19to 24
• Note: Refer to Part D for additional torque specifications.
General lnlormation Included in this portion of Chapter 2 are the general overhaul proce-
dures for the cylinder head(s) and internal engine components. The infonnation ranges from advice concerning preparation lor an overhaul and the purchase of replacement parts to detailed, step·by-step procedures covering removal and instalfation of Internal engine components and the inspection of par1s.
The following Sections have been written based on the assumption
thaI the engine has been removed from the vehicle. For information concerning in-vehicle engine repair, as well as removal and installation of the external components necessary for the overhaul, see Parts A through D of this Chapter and Section 7 of this Part. The Specifications included in this Part are only those necessary tor the inspection and overhaul procedures which follow. Refer to Parts A through D for additional Specifications.
2
Engine overhaul - general information
Refer to illustration 2.4 It's nOI always easy to determine when. or If, an engine should be completely overhauled, as a number of factors must be considered. High mileage is not necessarily an indication that an overhaul is need· ed, while low mileage doesn·t preclude the need foran overhaul. Frequency of servicing is probably the most Important consideration. An engine that's had regular and frequent oil and filter changes. as we ll as other required maintenance, will most likely give many thousands of miles of reliable service. Conversely, a neglected engine may require an overhaul very early in its life. Excessive oil consumption is an indication that piston rings, valve sealsand/orvaive guides are in need of anention. Make sure that oil leaks aren·t responsible before deciding that the rings andior guides are bad. Per10rm a cylinder compression check to determine the extent of the work required (see Section 3). Check the oil pressure with a gauge installed In place of the oil pressure sending unit. If irs extremely low. the bearings and/or oil pump are probably worn out. The accompanying illustration shows the sending unit location on 3.8L V6 engines. On four-cylinder engines, the sending unit is on the left rear side of the cylinder head. On 2.8L V6 engines. irs at the lower lett lront corner of the engine. On inline six-cylinder and V8 engines, it's near the oil filter. Loss of power. rough running , knocking or metallic engine noises, excessive valve train noise and high fuel consumption rates may also point to the need for an overhaul. eSpecially if they·re all present at the same time. II a complete tune-up doesn't remedy the situat!on, major mechanical work is the only solution. An engine overhaul involves restoring the internal parts to the specificationsol a new engine. During an overhaul. the piston rings are replaced and the cylinder walls are reconditioned (rebored andlor honed). II a rebore is done by an au tomotive machine shop, new oversize pistons Will also be installed. The main bearings, connecting rod bearings and camshaft bearings are generally replaced with new ones and, if necessary, the crankshaft may be reground to restore the journals. Generally. the valves
2.4
On the 3.Bl V6 engine, the 011 pressure sending unit (arrow) Is below the power steering pump and air conditioning compressor, which have been removed for this photo - see the texllor the location on other engines
are serviced as well , ,ince they 're usually in less-than·per1ectcondition at this point. While the engine is being overhauled. other components, such as the distributor. starter and alternator. can be rebUilt as well. The end result should be a like-new engine that will give many trouble -free miles. Note: Critical cooling system components such as the hoses. drivebells. thermostat and water pump MUST be replaced With new parts when an engine is overhauled. The radiator should be checked carefully to ensure that it isn·tclegged or leaking (see Chapter 3). Also, we don·( recommend overhaulmg the oil pump - always mstall a new one when an engine is rebuilt. Before beginning the engine overhaul, read through the entire proce· dure to familiarize yourself with the scope and requirements of the Job. Overhauling an engine isn't difficult if you follow all of the instructions carefully. have the necessary tools and equipment and pay close anentlon to all specifications: however, it can be time consuming. Plan on the vehicle being tied up for a minimum of two weeks , especially if parts must be taken to an automotive machine shop for repair or reconditioning . Check on availability of parts and make sure that any necessary special tools and equipment are obtained 10 advance. Most work can be done With typical hand tools, although a number of preciSion measuring tools are reqUired for inspecting parts to determine if they must be replaced. Often an automotive machine shop will handle the inspection 01 parts and offer advice concerning reconditioning and replacement. Note: Always wal/ until the engine has been completely disassembled and aI/ components. especially the engme block, have been inspected beforedeCldmg what service and repair operations must be performed by an automotIVe machine shop. Since the block's condition Will be the major factor to consider when deter· mining whether to overhaul the origmal engine or buy a rebu/ltone, never purchase parts or have machme work done on other components until the block has been thoroughly inspected. As a general rule, lime IS the primary cosl of an overhaul. so II doesn·t pay to mstall worn or substandard parts As a final note, to ensure maximum Itle and minimum trouble from a rebUilt engine, everything must be assembled With care in a spotlessly clean environment.
Chapter 2 Part E
General engine overhaul procedures
2E-ll
a slightly rough idle, a wom exhaustloOe on the camshah could be the cause. 13 I! the compressiOn is unusually high, the combustion chambers are probably coated With carbon dePOSits. If that's the case, the cylinder head(s) should be removed and decafbonized. t 4 If compression is way down or varies greatly between cylinders, it would be a good idea to have a leak·down test performed by an automo· tive repair shop. This test will pinpoint e_actty where the leakage is occur· ring and how severe it is.
4
3.6 A gauge with a threaded fitting for the spark plug hole Is preferred over the type that requires hand pressure to maintain the seal during the compression check
3
Compression check
Refer /0 ,llus /ra/1OfI 3 .6
1 A compt9SSl0n check will tell you what mechanical condition the upper end (PIstons, rings, valves, head gaskets)ot your engine is in. SpecificaUy, II can tell you II the compression IS down due \0 leakage caused by worn piston flngs , defective valves and seals or Ii blown head gasket. Note: The engme must be at normal operatmg temperature and the baltery must be fully charged for thiS check. Also. ilthe engine is equipped with acarburetor. the choke valve must be all the way open to get an accurate compression reading (if the engine's warm, the choke sl)ould be open), 2 Begin by cleaning the area around the spark plugs before you remove them (compressed air should be used, jf avallable, otherwise a small brush or even a bicycle tJre pump will work), The idea is to prevent dirt from genlng Into the cylinders as the compression check IS being done, 3 Remove all of the spark plugs from the engine (see Chapter t), 4 BlOck the thronle Wide open, S Detach the coil wife from the center of the dlstnb\Jtor cap and ground il on the engine block, Use a jumper wire with alligator clips on each end 10 ensure a good ground. S Instalilhe compression gauge inthenumberone spark plug hole(see illustration) 7 Crank the engine over at least seven compression strokes and watch the gauge, The compression should bUild up quickly In a healthy engine. Low compresSion on the first stroke. followed by gradually increasing pressure on successIVe strokes, Indteates worn piston rings. A low com· presslOf'l reading on the first stroke, which doesn't build up dunng succes· slve strokes, IndICates leaking valves or a blown head gasket (a cracked head could also be Ihe cause). DePOSits on the underSides of the valve heads can also cause low compression. Record the highest gauge read· ing obtained, B Repeat the procedure for the remaining cylinders ar.d compare the results to this Chapter's Specifications. 9 Add some engine 011 (aboul three squirts from a plunger·type 011 can) to each cylinder, through the spark plug hole, and repeat the test. 10 lithe compression Increasesaherthe 011 is added, the piston rings are definitely worn. II the compression doesn't Increase significantly, the leak· age IS occurnng at the valves or head gasket Leakage past the valves may be caused by burned valve seals andior laces or warped, cracked or bent valves. 11 I! two adjacent cylinders have equally low compression, there's a strong posslblhty that the head gasket between them is blown. The ap· pearance 01 coolant in the combustion chambers or the crankcase would venfy thiS condition t 2 II one cylinder IS 20 percent lower than the others, and th e engine has
Engloe rebuilding alternativaS!
Thedo·it·yourselfer is faced with a number of options when performing an engine overhaul. The doosion to replace the engme ~, PIston/con· nectlng rod assemblies and crankshalt depends on a number of factors, with the number one consideration being the condition of the block. Other considerations are cost, access to machine shop facilities, parts availabil· ily, time required to complete the project and the e~tent ot prior mechaOical experience on the part of the do·it·yourselfer, Some 01 the rebuilding alternatives Include: Individual parts -I! the inspection procedures reveal thai the engine block and most engine components are in reusable condition, purchasing individual parts may be the most economical alternative. The blOck, crank· shah and pistorv'connectll)Q rod assemblies should all be Inspected care· fully, Even if the block shows 1,"1e wear, the cylInder bores should be surface honed. Crank Shaft kit - This rebuild package consists of a reground crankshalt and a matched set of pistons and connecting rods. The pistons Will already be instal!ed on the connectmg rods. Piston rings and the I'\9C&Ssary bearings will be included in the kit, These kils are commonly available lor standard cylinder bores, as well as for engine blocks which have been bored to a regular oversize. Short block - A short block conSists 01 an engine block With a crank· shah and piston/connecting rod assemblies already Installed, All new beaTings are Incorporated and all clearallC8s Will be correct. The eXisting camshalt, valve tram components,cylinder head(s) and extemal parts can be bolted to the short blOck With ~tlle or no machme shop work necessary. Long block - A long block consiStS of a short block plus an oil pump, 011 pan, cylinder head(s), rocker arm cover(s), camshatt and valve train components, timing sprockets and chain or gears and timing cover All components are installed with new bearings, seals and gaskets incorpo· rated throughout. The installation of manilolds and external parts IS all that's necessary. Give carefullhought 10 which alternative is best lor you and discuss the situation with local automotive machine shops, auto parts dealers and expeflenced rebuilders before ordering or purchasing replacement parts
5
Engloe removal- methods and precautions
II you've deaded that the engine must be removed fOf overhaul or mao jor repair woril, several preliminary steps should be taken. Locating a place to work is e_lremely important. Adequate work space, along with slorage space for the vehICle, Will be needed. If a shop or gao rage isn't available, at the very least a flat, level, clean work surface made 01 concrete or asphalt is required. Cleaning the engine compartment and engine before beginning the removal procedure will help keep tools clean and organized. An engine hoist or A-frame will also be necessary. Make sure the eqUipment is rated in e_cess 01 the combined weight of the engine and ac· cessories. Salety is of primary importallC8, considenng the potential haz· ards Involved in lifting the engme out 01 the vehICle. lithe englt'le is being removed by a novice, a helper should be avail· able, Advice and aid from someone more experienced would also be helpful There are many installC8S when one person cannot simultaneously perform all of the operations required when lifting the engine out of the ve' hicle, Plan the operation ahead of time. Arrange for or obtain all of the lools and equipment you'll need prior to beginnll)Q the job, Some 01 the equip·
2E
2E-12
6.5
Chapter 2 Part E
General engine overhaul procedures
Label each wire before unplugging t he connector
6.26 Support the transmission atter engi ne removal by slipping a pipe through the frame holes and threading two bolts Into the transmission (arrows)
men! necessary to perform engine removal and installation safely and with relative ease are (io addition to an engine hoist) a heavy duty floor jack,
complete sets 01 wrenches and sockets as described at the Iront of this manual, wooden blocks and plenty 01 rags and cleaning solvent for mopping up spilled oil. coolant and gasoline. II the hoist must be rented. make sure you arrange lor it in advance and perform all of the operations possible without it ahead 01 time. This will save you money and time. Plan for the vehicle to be oul of use lor quite a while. A machine shop
will be required to perlOnTI some althe work the do-it-yourselfer can't accomplish without special equipment. Theyoften have a busy schedule. so it would be a good idea to consult them before removing the engine in order to accurately estimate the amount of time required to rebu ild or repair components that may need work. Always be e)(tremely careful when removing and installing the engine. Serious injury can result from careless actions. Plan ahead, take your time and a job of this nature, although major, can be accomplished successfully.
6
Engine - removal and InsIBtlation
Refer to illustration 6.5 and 6.26 Warning: The air conditioning system is under high pressure! Have a
dealer seNice department or seNice station discharge the system before disconnecting any air conditioning system hoses or fittings.
connect the fuel lines running from the engine to the chaSSIS (see Chapter 4). Plug or cap all open finlngs/lines . 10 Disconnect the throttle linkage (and TV linkage/speed contrOl cable. if equipped) from the engine (see Chapter 4). lIOn power steering equipped vehicles. unbolt the power steering pump (see Chapter 10). Leave the linesthoses attached and make sure the pump is kept in an upright position in the engine compartment (use wire or rope to restrain it out of the way) . 12 On air conditioned models. unbolt the compressor (see Chapter 3) and set it aside. Do not disconnect the hoses. 13 Drain the engine oil (Chapter 1) and remove the filter. 14 Remove th e starter motor (see Chapter 5). 15 Remove the alternator (see Chapter 5). 16 Unbollthe e~haust system from the engine (see Chapter 4) t 7 lIyou're working on a vehicle with an automatic transmission. refer to Chapter 7 and removethe torque converter-to·driveplale fasteners . 18 Support the transmission with a jack. Position a block of wood between them to prevent damage to the transmission. Special transmission jacks with safety chains are available - use one if possible. 19 At1ach an engine sling or a length of chain to the lifting brackets on the engine. 20 Rollthe hoist into position and connect the sling to it. Take uptheslack in the sling or chain. but don't hftthe engine. Warning: 00 NOTpiace any part of your body under Ihe engine when irs supported only by a hoist or
other lifting device.
21
Removal Refer to Chapter 4 and relieve the fuel system pressure (EFI equipped vehicles only), then disconnect the negative cable from the battery. 2 Cover the fenders and cowl and remove the hood (see Chapter 11). Special pads are available 10 proteCI the fenders, but an old bedspread or blanket will also work. J Remove the air cleaner assembly. 4 Drain the coolillQ system (see Chapter 1). 5 label the vacuum lines, emissions system hoses, wiring connectors. ground straps and fuel lines, to ensure correct reinstallation, then detach them. Pieces 01 masking tape with numbers or let1ers writ1en on them work welt (see illustratIon). If there's any possibility of contusion. make a sketch of the engine compartment and clearly label the lines, hoses and wires. 6 Label and detach aU coolant hoses from the engine. 7 Remove the cooling fan, shroud and radiator (see Chapter J). 8 Remove the drivebelts (see Chapter 1). 9 Warning: GasoJine is eXlremely flammable. so extra precaulions must be taken when working on any part o( Ihe fuel system. DO NOT smoke or allow open flames or bare lighl bulbs near the vehicle. Also, don 'I work in a garage if a nalural gas appliance with a pilot light is present. Dis·
Remove the transmission -to ·engine block bolts. Remove the engine mount-to· frame bolts. 23 Recheck to be sure nothing is stili connecting the engine to the transmission or vehicle. Disconnect anything slill remaining . 24 Raise the engine slightly. Carefully work it forward to separate it from the transmission. If you're working on a vehicle With an automatic transmission, be sure the torque converter stays in the transmission (clamp a pair of vise-grips to the housing to keep the converter from sliding out). If you're working on a vehicle with a manual transmission. the input shaft must be completely disengaged from the clutch. Slowly raise the engine out of the engine compartment. Check carefully to make sure nothing is hanging up. 25 Remove the lIywheelldriveplate and mount the engine on an engine stand. 26 Following engine removal . place a pipe across the frame and support the transmission with bolts (see iIIustrallon).
22
Installation 27 Check the engine and transmission mounts. tf they're worn or damaged, replace them . 28 If you're working on a manual transmiSSion equipped vehicle. install the clutch and pressure plate (see Chapter 7). Now is a good time to install a new clutch.
Chapter 2 Part E
General engine overhaul procedures
29 Carefully lower the engine into the engine compartment- make sure the engine mounts line up. 30 11 you're working on an automatic transmission equipped vehicle,
Inllne slx-cylinder engine Clutch and flywheel or drivSfRate Intake and exhaust manifolds RocKer arm cover RocKer assembly and pushrods TIming chain cover TIming chain and sprocKets Lifters Camshaft OIlpan ai/pump PlstonlCOnnecting rod assembfies Crankshaft and mam beanngs
guide !he torque converter into the crankshaft following the procedure outlined in Chapler 7. 31 If you're working on a manual transmission equipped vehicle, apply a dab of high-temperature grease to the input shaft and guide it into the crankshaft pilot bearino untillhe bellhouslng is lIush with the engine block. 32 Install the transmission-Ie-engine bolts and tighten them securely.
Caution: DO NOT use the bolts to fOfC6 the transmission and engine together/ 33 Aeinslalllhe remaining components in the reverse order of removal. 34 Add coolant, oil, power steering and transmission fluid as needed.
35 Aun the engine and check tor leaks and proper operation 01 all acces· sories, then inslailihe hood and lest drive the vehicle. 36 Have the air conditioning system recharoed and leak tested.
7
2.Sl V6 engine Clutch and flywheel ordnveplat6 RocKer arm covers Rocker assemblies and pushrods Intake and exhaust mamfolds Cylinder heads Oi/pan Oil;Nmp Engine front cover and front plate TIminggesfs Lifters Camshaft Pistons and connecting rods Crankshaft and main beanngs
Engine overhaul - dlsaSMmbly sequence
It's much easier to disassemble and work on the engine if It'S mounted on a ponable engine stand. A stand can often be rented quite cheaply from an equipment rental yard. Before the engine is mounted on a stand. the flywheelldnvepiate should be removed from the engine. 2 If a stand isn't available. it's possible to disassemble the engine with it blocked up on the floor. Be extra careful not to lip or drop the engine when ~ing Without a stand. 3 If YOU're going 10 obtain a rebuilt engine. all elClernaJ components must come all first. to be transferred to the repiacement engine. jusl as they will if YOU're doing a complete engine overhat,ll yourself. These include: Alternator and bracKets Emissions control components Distributor. spark plug wires and spar#{ plugs Th6rmostat and hOUSing cover Water pump
3.Sl V6 and all VS engines Clutch and flywhee/ or dnveplate Rocker arm covers Intake and exhaust manifolds Rocker arms and pushrods Valve lihers Cylinder heads Timing chain cover TIming chain and sprockets Camshaft Oil pan Orl pump (V8 engine only) Piston/connecting rod assemblies Crankshaft and main bearings
Turbocharger (som6 lour-cyNnder 6nglnes)
EFI componerrts or carburetor Intake/exhaus t manilokis Orl filter Engine mounts Clutch and flywheeVdrivepiate Engine rear plate
Note: When removing the external components from the engine. pay close attention to details that may be helpful or important during installa· /ion. Note the ins talledposilionofgaskels. seals, spacers. pins. brackets. washers. bolts and other small ilems. 4 If you're obtaining a shon block. which consists 01 the engine block, crankshaft, pistons and connecting rods all assembled. then the cylinder head(s). oil pan and oil pumpwiU have to be relTIOI/ed as well. See Engine rebuilding alt&matives for additional information regarding the dillerent poSSibilities to be considered. 5 If yoU're planning a complete overhaul. the engine must be disassembled and the Internal components removed in the following order:
6 Before beginning the disassembly and overhaul procedures. make sure the following items are available. Also. refer to Engine overhaul reassembly sequence for a list of tools and materials needed for engine reassembly. Common hand tools Small cardboard boxes or plastic bags lor stonng parts Gasket scraper Ridge reamer Vibration damper puller Micrometers Telescoping gauges Dial indica tor set Valve spring compressor Cylinder surfacing hone Piston ring groove cleaning tool Electric drill motor Tap and die sel Wire brushes Oil gallery brushes Cleaning solvent
Four-cylinder engine Clutch and flywheel ordriveplate Camshaft cover Intake and exhaust manifolds TIming belt/sprockets and covers Cylinder head Camshaft and related components Auxiliary shaft Oi/pan Cylinder front cover (front crankshaft ail seal housing) Oilpump PistonlCOnnecting rod assemblies Crankshaft and main bearings
2E -13
8
Cylinder head - disassembly
Refer /0 illustrations 8.3, 8,4 and 8.5 Note: New and rebuilt cylinder heads are commonly available formest engines a/ dealerships and auto parts stores. Due to fhe faCl that somespe-
2E
2E-14
Chapter 2 Part E
8.3 Use. valve spring compressor to compress the spring, then remove the keepers from the valve stem
General engine overhaul procedures
8.4 If the valve won't pull through the guide, deburr the edge of the stem end and the area around the top of the keeper groove with a file or whetstone
cialized /ools are necessary for the disassembly and inspection procedures, and replacement parts may not be readily available, il may be more
practical and economical for/he home mechanic ropurchase replacement head(s) rather than taking the time to disassemble. inspect and f8COndirion the original(s). 1 Cylinder head disassembly involves removal of the intake and exhaust valves and related components, If they're still in place, remove the rocker arm nuts, pivot balls and rocker arms Irom the cylinder head studs (3.Bl V6and VB engines only). Label the parts or store them separately so they can be reinstalled in their original locations. 2 Before the valves are removed, arrange to label and store them, along with their related components, sothey can be kept separate and r&installed in the same valve guides they are removed from. 3 Compress the springs on the first valve with a spring compressor and remove the keepers (see Illustration). Carefully release the valve spring compressor and remove the retainer. sleeve (if used), the spring and the spring seat (il used). 4 Pull the valve out oflhe head, then remove the oil seal from the guide. If the valve binds in the guide (won't pull through), push it back into the head and deburr the area around the keeper groove with a fine file or whetstone (see lIIultratlon). 5 Repealtheprocedureforthe remaining valves. Rememberto keep all the parts for each valve together so they can be reinstalled in the same locations (see Illustration). 6 Once the valves and related components have been removed and stored In an organized manner, the head should be thoroughly cleaned and inspected. If a complete engine overhaul is being done, finish the engine disassembly procedures before beginning the cylinder head cleaning and inspection process.
9
Cylinder head - cleaning and Inspection
Refetro illustrations 9. 12a, 9. 12b, 9. 14,9.15,9.16,9.17,9.18 and 9. 19 I Thorough cleaning 01 the cylinder head{s) and related valve train components, followed by a detailed inspection, will enable you to decide how much valve service woOl. must be done during the engine overhaul. Note: If the efl{Jine was severe/yovemeated, thecylinder head is probably warped (see Slep 12).
Cleaning 2 Scrapealltraces of old gasket material and sealing compound off the head gasket, intake manifold and exhaust manifold sealing surfaces. Be very careful nolto gouge Ihe cylinder head. Special gasket removal sol· vents that soften gaskets and make removal much easier are available at auto parts stores.
8.5
A small plastic bag. with an
appropriate label, can be used to store the valve Iraln components so they can be kept together and rein stalled in the original location
3 Remove all built up scale from the coolant passages. 4 Run a stiff wire brush through the various holes to remove deposits that may have formed In them. S Run an appropriate size tap into each of the threaded holes to remove corrosion and thread sealant that may be present. II compressed air is available, use it to clear the holes of debris produced by this operation. Warning : Wear eye protection when using compressed alrl 6 Clean the exhaust manifold stud threads (VB engine). Clean the rocker arm pivot stud threads (if applicable) with a wire brush. 7 Clean the cylinder head with solvent and dry it thoroughly. Compressed air will speed the drying process and ensure that all holes and recessed areas are clean. Note: Decarbonizing chemica/sare available and may prove very useful when cleaning cylinder heads and valve train components. They are veqcaustic and should be used with caution. Be sure to follow the instructions on the container. engines B Clean the rocker arms, fulcrums and bolts (3.Bl V6 and only) and push rods with solvent and dry them thoroughly (don't mix them up during the cleaning process). Note: Some very early VB engines may use nuts rather Ihan bolts. Compressed air will speed Ihe drying process and can be used 10 clean oUllhe oil passages. 9 Clean aUthevalve springs, spring seats, keepers and retainers (or ro o tators) with solvent and dry them thoroughly. Do the components from one valve at a time to avoid mixing up the parts. 10 Scrape off any heavy deposits that may have formed on the valves, then use a motorized wire brush to remove deposits from the valve heads and stems. Again. make sure the valves don't get mixed up.
va
Inspection Note: Be sure 10 perform aI/of the following Inspection procedures before concluding that machine shop work is required. Make a lisl of the ilems that need anention.
Cylinder head II Inspect the head very carefully for cracks, evidence of coolant leakage and other damage. If cracks are found , check with an automotive machine shop concerning repair. If repair isn't possible, a new cylinder head should be obtained. 12 Using a straightedge and feeler gauge, check the head gasket mating surface for warpage (see illustrations). If the warpage exceeds the limit listed in this Chapter's Specifications, it can be resurfaced at an automotive machine shop. Note: Iflhe V60r V8engineheadsare resurfaced, the intake manifold flanges will also require machining. 13 Examine the valve seats in each of the combustion chambers. If they're pitted, cracked Of burned, the head will reqUIte valve service thaI's beyond the scope of the home mechanic. 14 Check the valve stem-to-guide clearance by measUring the lateral movement of the valve stem With a dial Indica lor attached securely to the
Chapter 2 Part E
9.128 Check tha cylinder head gasket surface for warpage by trying 10 slip. feeler gauge under the straightedge (see thi s Chapter's Speclficallons for the
2E-15
General engine overhaul procedures
Check tor both " twist" and warpage by positioning the straightedge diagonally as well as straight across the gasket surface 9.12b
" bulge ~
9.14 A dial Indicator can be used to determine the valve stem·to-gulde clearance (m ove the valve stem as Indicated by the arrows)
maximum warpage allowed and use . feelet' gauge 01 that thickness)
VALVE
~ARGIN
WIDTH
I
0--
- ( 2)----1.=1 NO MARG'"
9.16
WOllIN VAlVE
N£'NVAlvt:
9.15
The margin width on each valve must be 8S specified
Check tor valve wear at the points fl hown here
I
Valve lip
2 3
Keopergnaove Stem (!east wom area)
4 5 6
Stem (most worn area) Valve face Margin
head (see illustration). The valve must be in the guide and approximately t/t6-lnch 011 the seal. The total val1l8 stem movement indicated by the
gaUQe needle must be divided by two to obtain the actual clearance. Alter this is done, ifther.'s sllli some daub! regarding the condition of the valve guides they should be checked by an automotive machine shop (the cost should be minimal).
Valves 15 Carefully inspect each valve face for uneven wear, deformation, crackS, pits and burned areas (. . illustration). Check the valve stem lor sculling and galling and lhe neck lor cracks. Rotate the valve and check fOf any obvious indication that It's bent. Look lor pits and excessive wear on the end 01 the stem. The presence 01 any of these conditions Indicates the need fO( valve servtee by an automotive machine shop. 16 Measure the margin Width on each valve (lee Illustration). Any valve with a margin narrower \han specjfied Will have to be replaced with a new
""..
9.17
Measure the tree length of each vatve spring with a dial or vernier caliper
Valve components 17 Checkeach valvespring for wear (on the ends) and pits. Measurethe free length and compare it to the Specifications (see illustration) Any springs that are shorter than specified have sagged and shoold not be reused. The tensIOn of all springs should be checked With a spedallixture before deciding that they're sUitable fOf use In a rebuilt engine (take the springs to an automotive machine shop for this check).
2E
2E-16
Chapter 2 Part E General engine overhaul procedures
9.18 Cheek each valve spring lor squareness
18 Stand each Spring on a flat sunace and check it for squareness (see illustration ) If any althe springs are dislorted or sagged. replace all of them with new parts. 19 Check the spring retainers (or rotalors) and keepers lor obvious wear and cracks. Any questionable parts should be replaced with new ones, as e:ttensive damage will occur illhey fall during engme operation. Make sure the rotators operate smoothly with no binding or excessive play (see ill us-
Iralio n)
Rocker arm components 20 Check the rocker arm faces {the areas that contacllhe pushrod ends and valve sIems } lor pits. wear, galling, score marks and rough spots. Check the rocker arm pivot contact areas and fulcrums (3.BL V6 and VB engines) or shafts (3.3L and 2.8L) as well. Look for cracks in each rocker arm and bott (or nut on some very early VB engines) . 21 Inspect the pushrod ends for scuffing and excessive wear. Aoll each pushrod on a Itat surface. tike a piece of plate glass. to determine if II'S ben\. 22 Check the rocker arm studs In the cylinder heads (If applicable) for damaged threads and secure installalion. 23 Any damaged or excessively worn parts must be replaced With new ones. 24 11 the Inspection process indicates that the valve components are in\ general1y poor condition and worn beyond the limits specitied. which is usual1y the case !n an engine thaI's being overhauled, reassemble the valves in the cylinder head and reterto Section 10 for valve serviCing recommendations.
Cam followers (four-cylinder engine) 25 Clean al1 the parts thoroughly. Make sure all oil passages are open. 26 Inspect the pad al the valve end 01 the tollower and the camshatt end pad for indiCations of scuffing or abnormal wear. II the pad is grooved, replace the 10110wer. Do not attempt to true the surface by grinding.
10
Va lves - servicing
Because of the complex nature of the job and the speci al toolS and equipment needed, servicing of the valves, the valve seats and the valve gUides. commonly known as a valve job, should be done by a professional. 2 The home mechaniC can remove and disassemble the head. do the initial cleaning and Inspection, then reassemble and deliver it to a dealer service department or an automotive machine shop for the actual service work , Doing the Inspection will enable you:o see wha t cond ition the head and valvetraln components are in and will ensure thai you know what work and new parts are reqUired when dealing with an automotive machine shop. 3 The dealer service department, or automotive machine shop. wil1 remove the valves and Springs, recondition or replace the valves and valve
9,19 The exhaust valve rotators can be chec ked by turn ing the inner and outer sections in opposite directions - feel for s mooth mo vement and excessi ve play
seals, recondilion the valve gUides. check and replace Ihe valve springs , spring rel ainers or rotators and keepers (as necessary), replace the valve seals with new ones. reassemb le the valve components and make sure the Installed spring height is correc\. The cyl inder head gasket surface wil1 also be resurfaced it Irs warped. 4 Afterthe valve Job has been performed by aprofessional. the head will be In like-new condition. When the head IS returned . be sure to clean II again before Inslal1a110n on the engine to remOve any melal particles and abraSive gnt that may STIli be present from the va lve service or head resurfaCing operations Use compressed air, if available, to blowout all the 011 holes and passages.
11
Cylinder head - reas sembly
Refer to Illustrations i, 4 and 11 .9 1 Regardless of whether or not the head was sent to an automotive repair shop for valve servlclOg. make sure It'S clean before beginning reassembly, If the head was sent out lor valve servicing , the valve s and related 2 components Will already be In place. Begin the reassembly procedure With Step 9. 3 On all except four'cyhnder englOes. lubricate and IOstalithe va lves. then Install new seals on each of the valve gUides. USing a hammer and deep socket, gently tap each seallOto place until II'S sea ted on the gUide, Don 't tW iSt or cock the seals dUring Installation or they Will not seat properly on the valve SIems. Onlour -cyhnderenglnes, Install the va lves , then install the valve stem 4 seals. Slip Ihe plastic Installallon cap (see illustration ) over the end 01 the valve slem to allow the seal to pass over the grooves In the valve stem. After Installation, remove the plastic cap and push the seal down unlil iI's fully seated . 5 Beginning at one end ol the head . lubricate and Install the first valve Apply moly-base grease or clean engine oil 10 the valve sl em. S Drop the spring seat or shim(s) overthe valve guide and set the valve spring, retainer (or rotator) and sleeve (If used) in place. 7 Compress the springs With a valve spring compressor and carefully inslallthe keepers in the upper groove, then slowly release the compres sor and make sure the keepers seat properly. Apply a small dab of grease to each keeper to hold It in place If necessary. 8 Repeat the procedure for the remaining valves. Be sure to return the corl'lponents to their oflglnallocallons - don't mix them up! 9 Check the Installed valve spnng heigh t With a ruler graduated in 1132·inch Increments or a dial cal iper. II the head was sent out for service work. the installed helghl should be correct (but don't automatically assume that It IS). The measuremen t IS taken from the top of each spnng seat or shlm(s) to the bottom 01 the relalner (see illustration). If the height IS greaterlhan the figure listed in this Chapter's Specifications. shims can be
Chapter 2 Part E General engine overhaul procedures ,v.sftC '"" AU.... TlON CA' tOI I. IW""'CI 0' CA# TO • •,,", . . . ''' ••' IHST Alt.A TIOIoII
2E-17
Tool._n»." ·,, JI'OIJ LO COt.ITACT ~lOlll
•
n" lifO, 1_ "'TN ..... LV" IN MIAO
P\.AC:I 'LAllie IfrtlTAll .. 'ION CIo# 0'0'1" '10100' VAlV. aTIM . n., 110. 1_ nAIIY VAI.VI.,.IM .,.; ... \. CA"I'V\,.LV OYU C,.,. I'VI>I .....L _ UNTI\. JACKIT Tour-Nil Tor 0' 00101 . I'll' NO . .... 11 • ..,...1 I'I.UTte I/rtITALlATlON c.v. VllII.'AllATION TOOL _ H • 011 ICIIIIWOIUVIII, TO IOfTOM "Al ON VAL"" 01,11011 .
11 .9
Be sure to check the valve spring Installed height lor each valve (the distance tram the top 01 the seatfshlms to the underside 01 the relainer)
.-Jl..,.
11.4 The plaslic Installation cap must be used 10 cOlier the valve siems on the four-cvllnder engine when Installing the new vatve seals added under the springs \0 correclll Caution: Don't. under any circum stances. shim the Springs /0 lhe pom' where the Installed hetght;s less
man specIfied. lOOn 3.Bl V6 and va engines. apply moly-base grease \0 the rocker arm faces and the fulcrums, then InSlalilhe rocker afms and fulcrums on the cylinder head s1uds
12
Pis10n slconnec1ing rods - removal
Refertollll.JSlralions 12 I. 12.3 and 126 Note: Poor /0 removmg Ihej)lslOfliconnecflng rod assemblies. ,emove lhe cyllnderhead{s}. Ihe all pan andlhe oil pump (excep/3 8L V6 models} by ,etefflng 10 the appropflale Sec/IOnS In Chaple' 2 1 Use yourllngernal110feellf a ndge has tormed allhe upperlimllot flng navel (aboull 4 Inch down tram Ihe top 01 each cylinder). If carbon depos liS or cylinder wear have produced ridges . they mUSI be completely re o movedw'lh a special 1001 (see iIIuslralion) FOllow Iha manufacturer'S In' S1ruCIIons provldad With the 1001 Failure 10 remova the ridges belore auemp\lng to remove Ihe pisloni connecMg rod assemblies may result In
12.1 A ridge reamer is required to remove the ridge from the top 01 each cylinder - do this belore removing the pistons!
plslonbreakage. Note: Donotlet the /oolculmto Ihe rmg travel area more than 1132-mch_ 2 Alter Ihe cylinder ridges have been removed . turn the engine upsidedown so 1he crankshaft IS law19 up 3 Belore the COfInec1lng rods are removed. check the endplay WIth reel~ gauges_ Slide them between the hrst connecllng rod and the crankshalt Ittl-ow until Ihe play IS removed (see Illustration) The endplay IS equal 10 the thickness at the feeler gauge(s). If the endplay eKceeds the seNiee limll. new connecting rods Will be reqUlfed. II new rods (or a new crank· shalt) are Installed. the endplay may fall under the specilied mlOimum (if it does. the rods Will have to be machined to restore II-consult an aul omolive machine shop lor adVice II necessary). Aepeatthe procedure for the remaining connecting rods. 4 Check the connecting rods and caps tor IdentJhcallon marKs. If they arent plainly marKed, use a small center·punch to make the appropriate number of indentalions on each rod and cap (I • 2, 3, etc .• depending on the aflgrne type and cylinder they're aSSOClaled With). 5 loosen each of the connectmg rod cap nulS 1/2-lurn at a time untrl they can be removed by hand. Remove the number one connecting rod cap and bearing insert. Don"! drop the beanng IOsert out 01 the cap. 6 Slip a shor1lenglh 01 plastIC or rubber hOse over each connecting rod cap bolt 10 protecllhe crankshaft JOUrnal and cyhnder wall as Ihe PIston IS removed (see illustration) 7 Remove the bearing Insert and push Ihe connecllng rodlplslon as· sembly oul through the top of Ihe engine. Use a wooden hammer handle to push on Ihe upper bearing surlace In Ihe connectmg rod II resistance is fal\. double check 10 make sure that all of 1he ndge was removed from the cyhnder
12.3 Check the connecting rod side clearance with a leeler gauge as shown
12.6 To prevent damage to the crankshaft journals and cylinder walls, slip sactlons of rubber or plastic hose over the rod bolts belore removing the pistons
2E
2E-18
Chapter 2 Part E General engine overhaul procedures
I
I-
13.1
Checking crankshaft endplay with a dial indicator
13.4b The arrow on Ihe main bearing cap Indicates Ihe Iront ollhe engine
13.3
Checking crankshaft endplay with a feeler gauge
14.1 The core plugs should be removed with a puller - ilthey're driven inlo the block, they may be impossible to retrieve
-rn----
13.48 Use a Ct:nler punch or number stamping dies to mark Ihe main bearing caps to ensure installation in Iheir original localions on Ihe block (make Ihe punch marks near one 01 the bolt heads)
14.8 All boll holes in Ihe block particularly Ihe main bearing cap and head boll holes - should be cleaned and restored wilh a tap (be sure 10 remove debris from Ihe holes after Ihis is done)
A
.----\.-1
14.10 A large socket on an extension can be used to drive the new core plugs Into the bores
15.4a Measure the diameter of each cylinder just under the wear ridge (A), at the center (9) and at the bottom (e)
, 5.4b The ability to '·feel "" when the telescoping gauge is at the correct point will be developed over lime, so work slowly and repeat the check until you 're satisfied the bore measurement is accurate
Chapter 2 Part E General engine overhaul procedures 8 Repeat Ihe pnx:edure lor [he remaining cylinders 9 Alter removal. reassemble the connecting rod caps anel beaflng In· serts In the,f respective connecting rods and Install the cap nuts linger lIghl Leaving the old beanng Inserts In place until reassembly will help prevent the connecting rocl beanng surlaces from bemg accidentally
nicked or gouged 10 Don t separate the pistons from the connecting rods (see Section 17 lor addlt'onalmformationl.
13
Crankshaft - removal
Refefloli/us/ra/JOns 131,13.3. 134aand 134b Nole : The crankshaft can be removed only aher /fie engme has been removed/rom Ihe vehicle. IlsassumedlhallheflywheelorcfrlVep/ate, vlbra/Iondamper, IImmgchamorgears. ol/pan. ol/pumpandPlstOf1:connectrng rod assemblies have already been removed. The cylmder front cover (oil seal housmg) on four-cylinder engmes must also be removed 1 Before the crankshaft IS removed. check the endplay Mount a dial 10dlca tor with the stem 10 line with the crankshaft am:! JUSllouchmg one of lhe crank throws (see illustration) 2 Push the crankshalt all the way 10 the rear and zero the dial indicator Ne.t. pry thecrankshailio Ihe Ironl as lar as poSSible and check the readlog on the diallndicalor. The distance Ihat 'I moves IS the endplay. If It S greater Ihan I,mlilisted In thiS Chapler s SpeclJicahOns. check the crankshal11hrust surfaces for wear. If no wear IS evident. new main beanngs should correct Ihe endplay 3 If adlallm:!lcator Isn lavallable. feeler gauges canbe used. Genlly pry or push the crankshall all the way to the 'ront 0' the engme. Silp feeler gauges between the crankshaft and the fron t face orthe Ihrust main bear· ing 10 del ermine the clea rance (see illustraUon). 4 Check the main bearing caps to see If Ihey're marked 10 indicate their locations They should be numbered consecutively from the front of the eng me to the rear It they aren·!. mark them with number stampmg diesor a center 'punch (see Illustration ) MalO beaflng caps generally have a cast· In arrow. which pomts 10 the front of the engine (see Illustration) Loosen Ihe main beanng cap bolts 1 4·Ium al a time each. until they can be reo moved by ham:!. Nole II any stud bolts are used am:! make sure Iheyre returned to Ihelf onglnallocallons when the crankshaft IS relnstaJled 5 Gentlytaplhe caps wltha soit·face hammer.lhenseparale lhemfrom the engine block If necessary. use the bolts as levers to remove the caps. Try not to drop the beaflng Inserts If they come out With Ihe caps. 6 Carefully hi t Ihe crankshaft out of Ihe engme It may be a good Idea 10 have an aSSISlant available. since Ihe crankshaltls qUite heavy. W ilh the beaflng Insel1s 10 place In Ihe engme block and maIO beaflng caps. return the caps 10 thelf respective locallons on the engine block and lighten the bolts finger tight
14
2E-19
Engine block - clean ing
Refer rOIJ/usrrarlOfts 14.1. 14.8 and 14 10 Caution : The core plugs (a/so Imown as freeze plugs or sohplugs) may be dd(lcultor ImpoSSible /0 relneve If they're dnv6(I into Ihe block coolant pas· sages Note : If you 're workmg on a four-cylinder engme, remove the auxil· lary shaft before cleanmg the block (see Chapter 2A). 1 Onll a small hole In Ihe center of each core plug and puillhem ou t with an aula body type dent puller (see lIIullrallon). 2 USing a gasket SJ:raper. remove all traces of gasket material from the engme block Be very careful not 10 nICk or gouge the gasket sealing surlaces 3 Remove the malO beating caps and separate the beanng mserlS from the caps am:! Ihe eogme block. Taglhe beanngs. indicalJogwhlCh cyflnder they were removed from and whether they were In the cap 01' the block. Ihen set them aSide. 4 Remove all ol the threaded 011 gallery plugs from the block. The plugs are usually very tlghl- they may have to be dnlled out and the holes reo tapped. Use new plugs when the engme IS reassembled 5 li the engine IS exlremelydll1y It shouk! be taken toan automotive mao chine shop to be steam cleaned or hot tanked. 6 After the block is returned. clean all oil holes am:! 011 galleries one more lime Brushes speCifically deSigned lor thiS purpose are available at most auto parts stores Flush the passages With warm water until the waler runs clear. dry the block lhoroughly and Wipe aU machmed surfaces With a l'Ohl. rust preventive all. If you have access 10 compressed alf. use It to speed Ihe drymg process and to blowout alilhe oil holes and gallenes. WarnIng : Wear eye protectIon when uSlfIg compressed alfl 7 If the block isn't extremely dll1y or sludged up. you can do an adequate cleaning job wllh hOi soapy water and a silt! brush. Take plenty of lime and do a Ihorough JOb. Regardless of Ihe cleaning method used. be sure 10 clean all all holes and gallenes very thoroughly. dry the block completely am:! coat all machined surfaces with light oil. 8 The Ihreaded holes In the block mus t be clean to ensure accurate torque readings dutlng reassembly. Run the proper size l ap mto each of the holes to remove rus!. corrosion. thread Sealant or sludge and restore damaged threads (see illustration) If poSSible. use compressed air to clear Ihe holes of debns produced by Ihis operation. Now is a good tIme to clean the Ihreads on the head bolls and the main beaflng cap bolts as welf 9 Remslall the mam beaTing caps and tlQhlen the bolts !tnger hgh\ 10 After coating the sealing surlaces of the new core plugs WIth Perma· tex no. 2 sealan!. IIlstall them lIl\he engme block (see Illustration) Make sure they're dnven III straight and seated properly or leakage could result Speclallools are available tor thiS purpose. bu t a large socket. With an out· side diameter thaI Will Just slip 11110 the core plug. a 112'lIlch dnve extension and a hammer will wo rk Just as well 11 Apply non-hardenlllg sealant (such as Permate. no. 2 or Teflon pipe sealant) to the new oil gallery plugs am:! thread them inlO the holes In the block. Make sure thet're tightened securely 12 If the engille Isn't omg to be reassembled fight away. cover II with a large plastIC Irash ba to keep It clean.
tS
Engine block - inspection
Refer 10 IlIuslrarlOns 15.4a. 15.40 and 15.4c
lS.4c
The gauge is then measured with a micrometer to determine the bore size
Before Ihe block is IIlspected. it should be cleaned as descnbed In Section t 4. 2 Visually check the block for cracks. rust and corrosion. Look for Slripped threads in Ihe threaded holes It's also a good idea to have Ihe block checked for hidden cracks by an automotIVe machille shop that has the special equipment 10 do thIS type of work If detects are found. have Ihe block repaHed. If possible. 01' replaced Check the cylinder bores for sculting and sconng. 3 4 Measure the dl8meter of each cylinder althe lop (just under the nctge area). center and bonom of the cylinder bore. parallel to the crankshah a:us (see Illu strations). 5 Next. measure each cylinder's diameter at the same three loca\looS across the crankshaft aXIs Compare the results 10 thiS Chapter's Specifications
2E
2E-20
Chapter 2 Part E General engine overhaul procedures CROSSHATCH PATTEAN
16.38 A " bollle brush" hone ill produce belter results il you 've never honed cylinders before
17.4b
... or a secllon of a broken ring
, 6.3b The cylinder hone should leave a smooth, crosshatch pallern with the lines Intersecting at approximately a 60-degree angle
17.10 Check the ring side clearance with a feeler gauge al several points around the groove
6 111he required preCISion measuring tools aren' t available, Ihe pistonto-cyhnder clearances can be obtained. though not qUite as accurately. usmg feeler gauge stock. Feeler gauge stock comes In 12-mch lengths and vanous thicknesses and IS generally available at auto parts Siores.
7
To check the clearance. select a feeler gauge and slip 1110\0 the cylin·
der along with the matching piston. The piston must be positioned exactly as it normally would be. The feeler gauge must be between the piston and cylinder on one of the thruSI faces (90·degrees to the piston pin bore). S The piston should slip through the cylinder (with the feeler gauge in place) with moderate pressure. If It lalls through or slides through easily. the clearance is excessive g and a new p4ston Will be required. If the piston binds at the lower end 01 the cylinder and is loose toward the top, the cylinder IS tattered. If tigh t spots are encountered as the plston/leeler gauge Is rotated In the cyhnder. the cylinder IS out-ol·round. 10 Repeatlhe procedure for the remaining pistons and cylinders. 11 If the cylinder waifs are badly scuffed or scored, or If Ihey're ou t-ofround or tapered beyond the limit s given in this Chapter's SpeCifica tions. have the engine block rebared and honed at an au tomotive machine shop If a rebore is done. oversize pistons and rings Will be reqUired. 12 If the cylinders are m reasonably good condition and not worn to the outSide of the limits, and If the piston-to-cyhnderclearances can be malntamed properly. then they don', have to be rebared . HOl1ing is all 'hat's necessary (see Section 16).
16
17.4a The pi ston ring g roo ves can be cleaned with a special tool , as s hown here, .
17.11 Meas ure th e pis ton diameter at a gO-degree angle to Ihe pi st on pin and in line w ith it
Cylinder honing
Refer /0 ilius/ra/IOns 16.3a and 16.3b Prior to engine reassembly. the cylinder bores must be honed so the new piston rings will seat correctly and prOVide the best pOSSible combus· hon chamber seal. Note : If you don't have Ihe lools ardon I want to tackle Ihe honing operalIOn. most au/omotlve machme shops Will do II for a rea· sonable fee. 2 Before hOning the cy linders. Install the main bearing caps and tighten the bolts to the torque listed In this Chapter's Specifications . Twotypesof cylinder hones are common ly available - the !lex honeor 3 "bottle brush" type and the more traditional surfacing hone with spflng· loaded stones Both Will do the Job. but lor the less experienced mechaniC the "bollie brush- hone Will probably be easier to use You'lI also need some kerosene Of honmg all, rags and an eleclne dnll motor. Proceed as follows: a) Mount the hone In Ihe dflll motor. compress the stones and slip It mto the Ilrst cy lmder (see illustrat ion) Be sure to wear safety goggles or a lace shleldl b) lubflcale the cylinder with plenty of hUning 011. turn on the dnll and move the hone up·and-down In the cylinder at a pace that Will produce a line crosshatch pallern on the cylinder walls. Ideally. the
Chapter 2 Part E
General engine overhaul procedures
crosshatch lines should intersect at apP(Qximaiely a SO-degree angle (see Illustration). Be sure to use plenty 01 lubricant and don', take off any more malerlal than is absolutely necessary to produce the desired finish . Note: Piston nng manufacturers may specsfy a smaller crosshatch angle than the traditional 6O-degrees - read and follow any mstructlOflS meluded with the new nngs.
c) Don', withdraw the hone trom the cylinder while it's running In· stead. shut off the drill and continue moving the hone up·and-down In the cylinder unlll it comes to a complete stop. then compress the stooes and Wlthdraw!he hone II yoo',e USing a "bottle brush" type hone, stop the dflll motor, then turn the chuck in the normal directJon of rotatIOn while wlthdrawmg!he hone trom the cylmder. d) Wipe the 011 oul altha cylinder and repeat the procedure for the re maining cylinders, 4 Alter the honing job is complete, chamfer the top edges of the cylinder bores with a smaflllie so the rings won 't catch when the pistons are installed. Be very careful not to nick the cylinder walls with the end 01 the hIe 5 The entire engine block must be washed again very thoroughly With warm , soapy water to remove all traces of the abraSive grit produced durIng the honing operation. Note: Tllebores canbeconSlderedclean when a lint-free white cloth - dampened With clean engme 0;1 - used /0 Wipe them out doesn ', pIck up any more honrng residue, whiCh Will showup as gray areas on the cloth Be sure to run a brush through all od holes and gallenes and flush them WIth runrong waler 6 After rinSing. dry the block and apply a coat of light rust preventive oil to all machined surfaces Wrap the block In a plastic trash bag to keep it clean and set It aSide until reassembly.
17
Plstonsl connectlng rods - Inspection
Refer to illustrations 17.4a, 17.40. 17,10 and 17, 11 I Betore the Inspection process can becarned out, the Piston/connecting rod assemblies must be cleaned andtheonglnalplston tlngs removed from the pistons Note: Always use new PIston nngs when the engme IS reassembled. 2 USing a piston flrtg installation 1001, ca retully remove the rings from the pistons. Be carelul not to nick or gouge the pistons in the process 3 Scrape aUtfaces 01 carbon trom the topot theplSlon A handheld wile brush or a piece 01 line emery cloth can be used once the maJoflty of the depoSits have been scraped away. 00 nol. under any Clfcumstances, use a Wire brush mounted In a drill motor to remove deposits tram the pistons The piston matenalls soft and may be eroded away by the wire brush. 4 Use a piston flng groove cleaning tool to remove carbon depoSits Irom the rmg grooves. 1/ a tool Isn't available, a piece broken 011 the old nng Will do the jOb. Be very careful to remove Oflly the carbon depoSits - don·t remove any metal and do not nICk or scratch the SideS 01 the flng grooves (see illustrations), 5 Once the depoSits have been removed, clean the piston/rod assemblies With solvent and dry them With compressed air (il available) . Make sure the 011 return holes In the back sides of the rmg grooves are clear 6 lithe piStOflS and cyllnder walls aren 't damaged or worn e~cesslVely. and II the engine block IS not rebored , new piStOflS won't be necessary Normal piston wear appears as even vertICal wear on the piston thrust surfaces and slight looseness ol the top ring In ItS groove, New piston nngs. however. should always be used when an engine IS rebUilt 7 Carefully IflSpecl each piston for cracks around the Skirt. at the pin bosses aM at the nng lands. 8 Look lor sconng and sculhng on the thrust faces 01 the Skirt, holes In the piston crown and burned areas at the edge of the crown. If the sk1rt IS scored or sculled, the englfle may have been sullering Irom ove rheallng andior abnormal combustion, which caused e~cessively high ope rating temperatures. The coollflg and lubrication systems should be checked thoroughly A hole in the piston crown IS an IndlCa1l0n that abnormal com bustion (prelQmtlOn) was OCCUrfing Burned areas at the edge 01 the piston crown are usually eVidence of spark knock (detonatIOn), If any 01 the above problems e~lst , the causes must be corrected or the damage Will
2E - 21
occur again, The causes may Include intake air leaks, incorrect luellair mi~lure, incorrect ignition timing and EGR system malfunctions. 9 CorrOSion of the piston, In the lorm 01 small pits, indicates that coolant IS leaking into the combustion chamber andlor the crankcase. Again , the cause must be corrected or the problem may persiS' In the rebuilt engine, 10 Measure the piston ring side clearance by laylflg a new PIston ring In each flng groove and slipping a leeler gauge in beside it (see iI1u stration ). Check the clearance at three or lour locations around each groove. Be sure to use the correct ring for each groove- they afe different. If the side clearance IS greater than the ligure ~sted In this Chapter's SpeclhcatlOflS, new pistons WIll have to be used, 11 Check the piston-to-bore clearance by measunng the bore (see Section 15) and the piston diameter. Make sure the pistonsand bores are correctly matched , Measure the piston across the skirt, at a 9O-degree angle to and m line With the piston pin (see illustration), Subtract the piston diameter from the bore diameter to obtain the clearance. II It'S greater than specilled,the bIoclt Will have to be rebored and new pistons and tlngs in· stalled. 12 Check the piston -to-rod clearance by twiSting the piston and rod Ifl opposite directions. A ny noticeable play indicates e~cesslve wear, which must be corrected . The Piston/connecljng rod assemblies shouk:f be taken to an automotive machine shop 10 hal/e the pistons and rods resized and new pins Installed 13 lithe PIstons must be removed Irom the connectmg rods for any reason,they should be taken to an automo\lve machme shop. While they are there have the connecting rods checked lor bend and twist. smce aulomo· tlve machine shops have special equipment lor Ihls purpose, Note: Un· less new PIstons andlor connectmg rods must be msta/Ied. do not disassemble Ihe ptstons and connectmg rods 14 Check Iheconnectlng rods lor cracks and other damage_ Temporanly remove the rod caps, 11ft out the old beating Inserts, Wipe the roct and cap beamlg surfaces clean and mspect them lor nicks, gouges and scratches_ Alter checking the rods, replace the ok! bearings, slip the caps Ifllo place and tighten the nul S linger tight. Note: If Ihe engIne is being rebul/t because of a connectIng rod knock, be sure to Install new rods.
18
Crank sh aft -Inspecti on
Refer to Illustrations 18.1. 18.3, 18.6 and 18.8 t Clean the crankshaft With solvent and dry It With compressed aIr (il available) Be sure to clean the 011 holes with a stili brush (see illustration) and lIush them With solvent. 2 Check the main and connecting rocl beanng lournals for uneven wear, seetlng, pi tS and cracks,
18_1
Use a w ire or stitt plastic bristle brush to c lean 'he 011 pas sage s In the cranks haft
2E - 22
18.3
Chapter 2 Part E General engine overhaul procedures
RubDing a penny lengthwise on
18.6 Measure the diameter 01 each c rankshaft journal at several point s to detect taper and out· ol -round conditions
each journal will relleal its condition - if copper rubs off and Is embedded in the crankshaft, the journals should be reground
~-
..
FATIGUE fA ILURE
SCRATCHED
EXCESSl~E
19.1
ev DIRT
WEA R
a.a
1 If the seats ha ve w orn grooves in the c rank shaft leumals, or if the seat contac t surlaces are nicked or scratched , the new seal s will leak
reassemb led. In some cases, an automotive machine shop may be able 10 repair the Journal by pressing on a Ihln sleeve If repalflsnt feaSible, a new or different cranksha ft should be installed g Refer 10 Section 19 and examine the main and rod beanng mserts .
~""".
IMPR OPER SEATING
lACK OF OIL
TAP ERE D .IOURNAL
Typical bearing failures
3 Ruba penny across each journal several times (see Illustration). If a Journal picks up copper from the penny, Irs too rough and must be reo ground. 4 Remove all burrs from the crankshaft oil holes Wi th a slone, hie or
scraper. 5 Check 1he rest 01 1he crankshaft for cracks and other damage. 1\ shouk! be magnalluxed to reveal hidden cracks - an au tomotive machine shop Will handle the procedure, 6 Usmg a micrometer. measure the diameter of the main and connect· Ing rod journals and compare the results to Ihis Chapter's Specifications (see illustration). By measuflng the diameter at a number of pomts around each Journal's ci rcumference, you'lI be able to determine whether or nOllhe Journal is out-of-round. Take the measurement at each end of the journal. near the crank throws. to determine If the journal is tapered. 7 If the crankshaft Journals are damaged. tapered, out-ol·round or worn beyond the limits given in the Specifications, have the crankshaft reground by an automotive machine shop. Be sure to use the correct size bearing Inserts if the crankshaft is reconditioned. B Check the oil seal Journals at each end of the crankshatt for wear and damage. If the seal has worn a groove in the journal. or If Irs nicked 01 scratched (see illustration). the new seal may leak when the engine IS
19
Main and connecting rod bearin gs - inspection
Refer to illustration 19, 1 1 Even though the main and connecting rod beanngs should be replaced With new ones dUring the engine overhaul. the old beanngs should be retained lor close examination, as they may reveal valuable mformatlon about the cond ition of the engme (see Illustration) 2 Bearing failure occurs because of lack ol lubncallon. the presence of dirt Of other foreign particles, overloading the engme and corrosion Re· gardless of the cause of bearing fa ilure. It must be corrected before the engine IS reassemb led 10 preven t It from happenmg agam. 3 When examlnmg the bearings, remove them from the engine block. the main bearing caps. the connecting rods and the rod caps and lay them out on a clean surface In the same general poSition as thelf locallon in the engine. ThiS Wi ll enable you to ma tch any beanng problems With the corre· spondlng crankshaft )ournal 4 Dirt and other foreign particles get into the engine m a vanetyof ways It may be lell ln the engine dUring assembly. or 11 may pass through IIl1 ersor the PCV system, It may get mto lhe all. and from there Into the beanngs Metal chips Irom machining operations and normal engme wear are often present. AbraSives are somellmes left In engine components after recondition ing. espeCially when parts are notthoroug hly cleaned usmg the proper cleaning methods. Whatever the source. lhese foreign objects often end up embedded m the soft beanng malerial and are eaSily recognized Large particles Will not embed In the bearing and will score or gouge Ihe bearmg and lournal. The best prevention tor this cause of bearing failure IS to clean all part s thoroughly and keep everything spollessly clean dUring engine assembly Frequent and regular engine oil and filter changes are also recommended. 5 Lack of lubrication (orlubncallon breakdown) hasa numberol lnterrelated causes. ExceSSive heat (which thinS the 011), overloading (which squeezes Ihe oil from the bearing face) and Oil leakage or throw off (from excessive bearing clearances, worn 011 pump or high engine speeds) all contribute to lubrication breakdown. Blocked all passages. which usually are the result of mlsahgned 0,1holes In a beanng shell, Wil l also 011 starve a beanngand destroy 11. When lack of lubllcatlon IS thecause 01 beanng fallure.the beanng malerial ls Wiped or extruded from the sleel backing of the bearing. Temperatures may Increase 10 Ihe point where the steel backing turns blue from overheallng. 6 DriVing habits can have a dellnlte effect on bearing hfe Full throttle, low speed operation (lugging the engine) pu ts very high loads on bearings,
Chapter 2 Part E General engine overhaul procedures which tends to squeeze out the 011 him. These loads cause the bearings 10 flex . which produces fine cracks in the bearing face (Iatigue failure) . Eventually the bearing malenal Will loosen In pieces and tear away from the
Piston rmgs Crankshaft and mam beanngs Pistons and connecting rods Camshaft Lillers Timmg gears Engine front plate and front cover Oil pump Oil pan Cylinder heads Intake and exhaust manifolds Rocker assemblies and pushrods Rocker arm covers Clutch and flywheel or dflveplate
steel backing . Shan trip driVing leads tocorrosion 01 bearings because insuffiCient engine heat IS produced to drive off the condensed water and corrosive gases . These products collect In the engine 011. forming aCid and sludge. As the oil is carried to the engine bearings, the acid attacks and
corrodes the bearing matenal. 7 Incorrect bearing installallon during engine assembly will lead 10 beanng failure as well. Tight fitt ing bearings leave insufficient beanng 011 clearance and will result In oil starvallon. Dirt or foreign particles trappe(! behind a bearing insert resuilin high spols on the bearing which lead to lallure.
20
Engine overhaul - reassembly sequence
3.BL V6 and all VB engines New camshaftbeanngs (must be done by an automotIVe machine shop) Piston rings Crankshaft and mam bearings Piston/connecting rod assemblies a,l pump (VB engme only) Oilpan Camshaft Timmg chain and sprockets Timmg cham cover Cylinder heads Valve lifters Rocker arms and pushrods In/ake and exhaust manifolds Rocker arm covers Clutch and flywheel or dnveplate
1 Belore beginning engine reassembly. make sure you have all the nec· essary new parts. gaskets and seals as well as the lollowlng Items on hand:
Common hand tools A t/2·mch drive torque wrench Pis/on ring mstallatlon /001 PlSlon nng compressor Vibration damper ms/allation /001 Short lengths of rubber or plas/lc hose to Iii over connecting rod bolls Plastlgage Fee/er gauges A fine·toolh file New engme oil Engine assembly lube or moly-base grease Gasket sealan/ Thread locking compound 2 In order to save lime and avoid problems, engine reassembly must be done In the follOWing general order:
2E-23
( 21
Piston ring s -installation
Four-cylinder engine Piston rings Crankshaft and maIO beanngs Pls/on/connectrng rod assemblies Oil pump Cylmder front cover (front crankshaft 011 seal housmg) 011 pan Auxiliary shaft Camshaft and related components Cylmder head Timmg bell/sprockets and covers Intake and exhaust manrfolds Camshaft cover Clutch and flywheel or dnveplate
Refer to Illus/rations 21.3.21.4.21.5, 21 .9a , 21 .9b and 21 . 12 Before installing the new piston rings. the ring end gaps must be checked. Irs assumed that the piston ring side clearance has been checked and verified correct (see Section 17). Layout the piston/connecting rod assemblies and the new ring sets 2 so the ring sels Will be matched with the same piston and cylinder dunng Ihe end gap measurement and engine assembly. 3 Insert the top (number one) ring into the first cylinder and square It up With the cylinder walls by pushlflg it in With the top 01 the piston (see mustraUon). The ring should be near the bottom 01 the cylinder. althe lower limit 01 ring travel.
Inllne six-cylinder engine New camshaftbeanngs (must be done by an automollve machme shop) PiSlonrmgs Crankshaft and main bearings Plston/connectmg rod assemblies 011 pump Oil pan Camshaft Llflers Timing cham and sprockets Timmg cham cover Rocker assembly and push rods Rocker arm cover Intake and exhaust mafllfolds Clutch and flywheel or drlveplate
2.8L V6 engine New camshaft bearmgs (must be done by an automotive machme shop)
21.3 When checking piston ring end gap, the ring must be square in the cylinder bore (this Is done by pushing the ring down with the top 01 a piston as shown)
2E
2E-24
Chapter 2 Part E General engine overhaul procedures
21.4 With the ring square In the cylinder, measure the end gap with a feeler gauge
21 .9b
21.S If the end gap Is too small, clamp a lIIe In 8 vise and file the ring ends (Irom Ihe outside In only) to enlarge the gap slightly
DO NOT use 8 piston ring Installation 1001 when Installing the all ring side ralls
To measure the end gap. slip feeler gauges between Ihe ends of Ihe flng unlll a gauge equal to the gap width IS tound (see illustration) The leeler gauge should slide between Ihe ring ends with a slight amount of drag. Compare the measuremenllo thiS Chaple(s Specifications. II the gap IS larger or smaller Ihan specified. double·check to make sure you haye the correct nngs belore proceedmg 5 If l/'Ie gap IS too small, It must be enlarged orthe nng ends may come In contact with each other dunng engine operation, which can cause senous damage 10 the engine. The end gap can be increased by filing the nng ends very ca1etully with a fine hie Mount the file in a Vise eqUipped With solt laws, slip the ring over the file With the ends contacting the hie face and slowly move the ring to remove material trom the ends. When pertormlng this operation, lile only Irom Ihe outside In (see illustration). 6 Excess end gap Isn't critical unless It'S greater than 0.040-lnch. Again. dOuble·check to make sure you have the correct nngs for your en· glne 7 Repea[the procedure lor each ring thai Will be Installed in the first cyl· Inder and tor each ring in the remaining cylinders. Remember to keep rings, pistons and cylinders matched up. S Once the flng end gaps have been checkedfcorrected, the nngs can be Installed on the pislons 9 The oil control nng (lowest one on the piston) IS usually Installed first. It s composed of Ihree separate components Slip Ihe spacerle~pander Into the groove (see illustration) I! an anlHotatlon tang is used, make
21 .12
21 .98 InstalUng the spacerleKpander in the all control ring groove
Inslalling the compression rings with a ring e~pander the mark (arrow) musllace up
sure It'S insened Inlo the dfilled hole In the ring groove. Next. install the lower Side rail. Oon'l use a pislon ring Ins[aliatlOn loot on the oil flng side ralls. as Ihey may be damaged. Instead place one end 01 the side rail Into the groove between Ihe spacer e~pander and lhe flng land. hold It hrmly In place and slide a linger around the pislon while pushing the rail Into the groove(see illustration) Next . install the upper siderailinihe same man-
"" 10 Alter the three
011 nng components have been Installed. Check to make sure that both the upper and lower side ralls can be turned smoothly In the flng groove. 11 The number two (middle) flng IS Installed next Irs usually stamped With a mark which must face up. toward the topol Ihe piston, Note : Always follow the instructions prinled on the rmg package or box - different manufacturers may reqUire dlfferenlapproaches. Do nol mix up Ihe lap and middle rings. as they have different cross sections. 12 Use a piston flng IfIstaliatlon tool and make sure the Identlhcatlon mark IS faclflQ the topol the piston, then slip the ring IfIto the middle groove on the piSlon (see illustration) Don I e~pand the rlflQ any more than necessary to shde II over the piston 13 Install the number one (top) nng In the same manner Make sure the mark.s faCing up. Be caretul not to contuse the number one and number IwO rings 14 Repeat Ihe procedure tor the remaining pistons and flngs
Chapter 2 Part E General engine overhaul procedures
22.5
Upper main beating In posilion
(flanged thrust bearing shown) - the oil hole In the bearing must align with the oil hcle(s) In Ihe block
22.11 Lav Ihe Plas1igage strips (arrow) on Ihe main bearing journals,
22.128
2E-25
Installing th e center main bearing cap
parallel 10 the crankshaft centerline
2E
22.12b Bearing cap numbers indicate cap position (counting Irom the front 01 the engine) - the arrow points to Ihe front 01 the engine
22
Crankshaft - installation and main bearing oil clearance check
Refer to Illustrations 22.5,22. t 122. 12a. 22. 12band 2215 1 Crank-shal! Installation is the first slep In engine reassembly. Irs assumed al lhlS POint that the engme block and crankshaft have been cleaned. Inspected and repaired or recondit ioned 2 PosItion the engine with the bouom faCing up. 3 Remove the main bearing cap bolts and hit out Ihecaps. Lay them out In the proper order to ensure correct installation. 4 If theyre stili In place. remove Ihe anginal beaflng Inserts from the block and the main bearing caps. Wipe the bearing surfaces of the block and caps With a clean, hnt-free cloth. They must be kepI spotlessly clean
Main bearing oil clearance check 5 Clean Ihe back Sides of the new main bearing Inserts and lay one In each main bearing saddle In the block If one of the bearing Inserts from each set has a large groove In It. make sure the grooved Insert IS Installed in the block Lay the other bearing from each set In the cor responding main bearing cap Make sure the tab on the bearing insert lits into the recess In the block or cap Caution : The 011 holes In the block musl line up With the 011 holes in the bearmg msert (see illustration ) Do not hammer the bearing Into place and don 'I mck or gouge Ihe beating faces. No Iubrica/lon should be used at thiS time 6 The flanged thrust beating (see Illustration 22.5) must be Installed In the third cap and saddle (all e~cept3.3L si~·cyl l nder engine) or fifth cap and saddle (3 .3L six' cyllnder engme).
22.15 Compare the width 01 the crushed Plastlgage to the scale on the envelope to determine the main bearing 011 clearance (always take the measurement at the widest point of the Plasligage); be sure 10 use the correct scale - standard and metric ones are included 7 Clean the faces of the bearings in the block and the crankshalt main beaflng Journals With a clean, lint-free cloth. S Check or clean the oil holes in the crankshaft, as any dirt here can go only one way - Slralght through the new bearings 9 Once you 're certam the crankshaft IS clean. carefully lay It m poSition In the mam beaflngs_ 10 Belorethe crankshaft can be permanently Installed. the main bearing all clearance musl be checked. 11 Cut several pieces of the appropflate size Plastlgage (they must be slightly shorter than the Width of the main beatings) and place one piece on each cran kshaft mam bearing Journal. parallel with the Journal a~is (see Illustration). 12 Clean the faces of the bearings in the caps and Install the caps In thell respective poSitIOns (don't mix them up) With the arrows pom!lng toward the lront of the engme (see illustrations). Don'l disturb the PlastJgage. 13 Start ing with the center mam andworl
2E-26
Chapter 2 Part E General engine overhaul procedures / FACHT OF ENGINE
LU8RICATE SEAt..t.HO SEAl MATING SURfACE WITH 0It. .
/
.on: ,.,.,. ,ACt. 0# SUl. MUST _ 0.127_ (O.GOIANCH)
OfF
wtT_ THE,.,.,. 'ACIl OF THlllt.oat
23.38 Re ar seal Installation should be done wUh the special Ford tool to ensure thallhe seal lsn ', damaged
23.3b
On 2.8L V6 engines, drive Ihe rear bearing wedge seal s into place as shown
!",$'''LL n Ol L wiTH LIP rOW .. ROS fAO NT OF {",GON E
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"
RE",R O'l S£"'l
st ........,,[5 lO"ROTRUOf BEVOND 'ARTING r 4CH THIS DIST ANC( TO AlLOW'OfI CAP TO eLOCK "LlG><"'ENI
I
... PPl v SE ... UR ... 5 SHQ.,•.,.
SEE NOH IflOW fRO'''' OF ENG''''E
J-"
'nA"rACf 0,
"E"'''
MAl'" SfARIN{' CAP
ANDCVUNO[A 8LOCK
~RO"TO ~
(...o, .. t
Vi' W L OO':' N(, A , PAIniNG
fACE Of SPLIT LIP TYPE CRANKS."" , SlAL
23.58 Rear 011 seal lnslaliation - earl y VB engines - appl y sealant to Ihe areas ollhe seal indicated by Ihe hatch marks
16 If Ihe clearance IS nol as spec.hed Ihe bearing Inserts may be the wrong Size (which means different ones Will be reqUired). Before deciding thai different Inserts are needed. make sure that nodln oroil was between the bearing Inserts and the caps or btock when the clearance was measured. If the Plasllgage was Wider at one end than the other. the journal may be tapered (re fer to Section 18). 17 Carefully scrape all traces of the Plastlgage matenal off the main beanng journals andlor the bearing laces . Use your IIngernall or the edge 01 a credit card - don', nick or scratch the bearing laces
se "' l[ll NOTE t u .....
T"~
..... E... I'O.. £A£ SEAlER
'S TO BE "'PPl,eo BHORE , .. ST"'ll'''G THE SE"'U
USE >ORO SPOT REMO ... ER 81'" 11571 ... DR £OU' ...... '-UH .o.FH R T"E SE"lS ""H '01 Pl ... n .... ""''-V ... 1 16 'NC" U"'O 0 > OS"'Z '_2'" OR • U"'lfR AS SHOION n"'UR MUST ",aT CaNT ... cr SE"'lS
23.5b
Rear oil seallnstallallon - earl y lour-cylinder and 3.8l V6 engines
Final crankshaft installation 18 Carelully blithe crankshatt out 01 the engille 19 Cleanthebeanngfacesln the block. IhE:napply a thin. unliorm layelol moly-base grease or engine assembly lube to each 01 the beanng sur· faces. Be sure to coat the thrusl laces as well as the )Dumal face of the thrust beaflng On engines eqUipped With sphHype (two-piece ) rear main oil seals. install the seal together With the rear main beanng cap (see Section 23).
20 Make sure the crankshaftlournals are clean. then lay the crankshall back In place In the block 21 Clean the faces of the beanngs In the caps. [hen apply lubncantto [hem 22 Install the caps In thelT respectl ...e poSlllons With the arrows pointing toward the Iront 01 the engine 23 Install the bolts.
Chapter 2 Part E Generat engine overhaul procedures
fAOM FORWARD FACE
APPLY I / IS" OlIO.. 8EAO OF CJ AZ·I9562 ·A lOR D) SEAUR AS INQICATEC ON BE.o.RING CAP _ 180TH SIOHI
OF SLINGE R GROOVE TO R EA R FAce OF
BLOC':
2E-27
lEAVE I IS"O.o,P FOR SEA,LER
EXPA,.SION
SEAUR APPLICATION s o: eTCH
SPLIT LIP TYPE SE"'L S)
"'PPL V 1/16" 01.0.. 8 E"0 OF C3AZ· I9562-A, lOR -81 SE AUR .IN SHA,OEO "REA OF CYLINDER B LOCK PRIOR TO ASSe MS LY OF BEA RING
CAP _ ,BOlM SloeSI 00 NOT PERMIT se"LE R TO GET ON LD OF SPLIT LIP SEAL
23.78 Rear all seal and bearing cap sealant application - early va engines
23
, II
APPLY SEALE R TO THESE SURFACES
23.7b
Rear all seal and bearing cap sealant application - 2.8L V6 engines
24 Tighten all except the thrust beanng cap boilS to the speci fied torque (work trom the center ou t and approach the tinal torque in three steps). 25 Tighten the thrust bearing cap bolts to 10·to·12 tt· lbs. 26 Tap the ends at the crankshaft forward and backward with a lead or brass hammer to line up the mam bearmg and crankshattthrust surlaces. 27 Rellghten all mam bearing cap bolts to the specified torque, startmg wit h the center mam and working ou t toward the ends. 28 On manual transmiSSion equipped models. Install a new pilot bearing in the end at the crankshaft (see Chapter B). 29 Rotate the crankshaft a number of times by hand to check for any ob· VIOUS binding. 30 The final step IS to check the crankshaft end play With a feeler gauge or adial indicator as described in Section 13. Theendplayshould be correct il the crankshaft thrust faces aren't worn or damaged and new bearings have been Installed. 3t II you are working on an engine With a one·piece rear main 011 seal. refer to Seclion 23 and install the new seal.
Rear main oil seallnstallalion
Block/main bearing cap counterbore Refer /0 Illustrations 23.3a and 23.3b 1 Clean the bore m the block/cap and the seal contact surlace on the crankshalt. Check the cranksha ft surlace for scratches and nicks that cou ld damage the new seal lip and cause all leakS. I! the crankshaft IS damaged. the only alternative is a new or dlflerent crankshaft. 2 Apply a light coat of engine ollar multl· purpose grease to the outer edge of the new seal. Lubricate the seal lip With moly· base grease or en· glne assembly lube. 3 Press the new seal mto place Wi th the speCial tool (If available) (see illustration). The seal lip must face toward the front of the engme. If the special toollsn', available. carefully work the seal lip over the end of the crankshatt and tap the seal In With a hammer and punch until it's seated In the bore. On 2.8L V6 engines. drive in new wedge seals alongside the rear main beanng cap (see Illustration) .
Split-type (two-piece) seal Refer /0 illus/rations 23.5a, 23.5b, 23.7a and 23. 7b 4 Inspect the rear mam bearing cap and engine block mating surlaces. as well as the seal grooves, for nicks, burrs and scratches. Remove any defects with a hne file or debumng tool. 5 Install one seal section in the block with the lip lacing the !ront of the engine (see illustration). On VB engines, leave one end protruding from the block approximately 114 to 3J6·inch and make sure it's completely seated. On 2.3l and 3.6L engines. poSition both ends of the sealliush with the black. and the locating tabs to the rear (see Illustration) On 3.8L en· glnes. remove the locating tabs. 6 Repeat the procedure to install the remaining seal hal! in the rear main bearing cap. On V8 engines, leave the opposite end of the seal protruding from the cap the same distance the block seal is protruding from the block. On 2.3L and 3.6l engmes. position both ends liush With the bearing cap. 7 DUring !inal installation of the crankshaft (after the main bearing oil clea rances have been checked With Plastlgage as described m Section 22). apply a thin, even coat of anaero~c· type gasket sealant to the shaded areas of the cap and/or block (see Illustrations). Don't get any sealant on the beanng face , crankshaft Journal, seal ends or seal lips. Also.lubricate the seal lips With moly·base grease or engine assembly lube.
2E
2E-28
Chapter 2 Part E General engine overhaul procedures SEGME'<" CAl'S TO 8E APPII Ox,,,,,o,TEl v f llOM E~ P"'NOf " G.o.p AND NOT IN "'''EA Of SK' RT
OIL RIN G SPACER
_ .0.1'1'"' '
OIL RING SEGMENT
OIL RING SEGMENT
A 8_ "
r. , ~
~
!
\
, Ip" ,o..
(c) Piston
V (f)
COMPRESSION R I NG . COMPRESSION RING Front o f Engine 24.5b
,...sTA •• "STDN INTO 'LOCK WIYI'I"''''GGIIoI''SAS fOllOWS (x' ..... OlIl _ TO fllONT Of' PI$TON SEG"'O~T - TO R£A" OF I'ISTON
24.5a
24
Ring gap position - four-cylinder engine
Pi stons connecling rods - inslalialion and rod bearing oil clearance check
ReIer 10 rl/uslfallons 24 Sa 24 5b. 24 9. 24 11. 24 13 and 24 17 , Before installing the piston/connecting rod assembli es. the cyhnder
walls must beperfecUy clean, the top edge of each cyhnder must be chamtered, and the crankshatl mus t be In place 2 Aemovelhecaplromlheendoflhenumberoneconnecllngrod(reter to the marks made dUring removal). Aemove the onglnal bearing Insens and WIpe Ihe beanng surlaces 01the connecting rod and cap wllh a clean. hnl-free cloth_ They must be kepI spotlessly clean
Connecting rod bearing oil clearance check 3 Clean the back sideof Ihe new upperbearmg inserl , Ihen lay II In place 10 theconneclmg rod Make sure Ihe l ab on the bearing fil s 1010 the recess
24.9
The nolch or arrow in the top of each piston must fa ce the FRONT of the engine as the pistons are Installed
Ring gap position - sill-cylinder and VB engines
In Ihe rod Don I hammer Ihe beanng Insert Inlo place and be very careful not to nick Of gouge Ihe beanflg face Don t lubricate Ihe beawlg allhls ome 4 Clean Ihe back Side 01 the olher bearing Insert and Install II 10 the rod cap. Ag am, make sure the tab on Ihe bearing filS Into the recess 10 Ihe cap, and don't apply any lubricanl lrs critically Important thatlhe mating sur· faces of Ihe bearlflg and connectmg rod are perfectly clean and 011 free when they're assembled 5 POSition Ihe p'Slon flng gaps atlnlervaJs around the Plslon (see iIIustra lions) 6 Shp a seCllon 0 1plastic or rubber hOse oller each connec\ing rod cap bol! 7 Lubncate the piston and rings With clean engine all and attach a pis ton ring compressor to thd"plsl on. Leave Ihe skirt protruding about! 4-lnch 10 gUide Ihe piston InIO the cyl inder The flngs must be compressed until theyre !iush wllh Ihe p'Slon 8 Rotate the crankshaft untillhe number one connecting rod JOurnal IS at BDC (bottom dead center) and apply a coat 01 engine all to Ihe cylinder walls 9 W,lh the anow or notches on lap of the piston ( see i lIustraUon) faCing Ihe fronl of the en9,"e. gently Iflsert the piston connecllflg rod assembly InlO the number one cylinder bore and res t Ihe bottom edge of the flng compressor on Ihe engine block
24.11
Orille the piston gently inlo the cylinder bore wilh Ihe end 0 1 a wooden or plastl c hammer handle
Chapter 2 Part E General engine overhaul procedures
24.13 lay the Plasligage strips on each rod bearing Journal , parallel to the crankshaft centerline
10 Tap 1M top edge of the ring compressor to make sure Irs contac1lng the block around Its enllre Circumference. '1 Gently tap on the top o f the piston with the end 01 a wooden hammer handle (see Illustration) while gUiding the end althe connecting rod mto place on the crankshaft Journal. The piston rings may try 10 pop oul of the ring compressor just belare enleflng the cylinder "bore, so keep some downward pressure on the ring compressor. Work slowly, and if any resistance is felt as Ihe p iston enters the cy linder, SlOp immediately. Find oul whal's hanging up and fix it before proceeding. Do not. lor any reason. force the p iston Into the cylinder - you might break a ring and/or the piston, t 2 Once the piston/connecting rod assembly is Ins talled, the connec ti ng rod bearing all clearance must be checked before the rod cap is permanently bolted In place. 13 Cut a p iece olthe appropriate size Plasllgage slightly shorter than Ihe Width o f the connecting rod bearing and lay It in place on the number one connecting rod Journal. parallef With the journal aXIs (see illustration). 14 Clean the connecting rod cap bearing face. remove the protective hoses from Ihe connecting rod bolts and Install the rod cap. Make su re the mating mark on the cap IS on the same side as the mark on the connecting rod. 15 Inslallthe nuts and l ighten them to the torque listed In thiS Chapter's SpeCifications. work ing up to It In three steps Note: Usea thm-wall socket 10 avoid erroneous torque readmgs that can result il the socket is wedged between the rod cap and nut II the socket lends 10 wedge Itsell belween Ihenul andlhecap. /III uponll slightly until it no longercontacls fhecap. Do nOI rOlale Ihe crankshaft at any time dunng thiS operation. 16 Remove the nuts and detach the rod cap. being very careful not to diSturb the Plastlgage. 17 Compare the Width of the crushed Plastigage to the scale printed on the Plastigage envelope to obtain the oil clearance (see Illustration). Compare It to the Specificat ions to make sure the clearance IS correct. 18 If the clearance is not as speCIfied. the bearing inserts may be the wrong size (which means different ones Wil l be required). Before deciding that different Inserts are needed. make sure that no dirt or oil was between the beanng Inserts and the connecting rod or cap when the clearance was measured. Also, recheck the journal diameter. If the Plastigage was Wider at one end than the o ther. the Journal may be tapered (rele r to Section t 8).
Final connecting rod installation 19 Carelully scrape all traces of the Plastlgage material off the rod Jour· nal andlor bearing face. Be very carefuf not to scratch the bearing - use your finge rnail or the edge of a credit card 20 Make sure the bearing faces are perfectly clean. then apply a Uniform layerof clean moly·base grease or engine assembly lube to both of them.
2E-29
24.17 Measuring the width of the cru s hed Ptastigag e to determine the rod bearing all clearance (be s ure to u se Ihe correct scale - standard and metriC one s are Inc luded ) You'll have to pUSh the piston Inlo the cylinder to expose the face 01 the bearing insen in the connecting rod - be sure to slip the protective hoses over the rod bolt s first. 21 Slide the connecting rod back into place on the journal, remove the protective hoses from the rod cap bolts. Install the rod cap and tighten the nuts to the specified torque. Again. work up to the torque In three steps. 22 Repeat the entire procedure for the remaining pistons/connecting
'00' 23 The Important points to remember are: a) Keep the back Sides of the bearing Inserts and the InSides of the connect ing rods and caps perfectly clean when assembling them. b) Make sure you have the correct piston/rod assembly for each cylinder. c) The notches or mark on the piston must face the front 01 the engine. d) Lubricate the cylinder walls With clean OIl. e) Lubricate the bearing faces when installing the rod caps aller the oil clearance has been checked 24 Afler aillhe Piston/connecting rod assemblies have been properly installed. rotate the crankshaft a number of limes by hand to check lor any obvious binding. 25 As a final step, the connecting rod endplay must be checked. Reier to Section 12 for this procedure 26 Compare the measured endplay to the SpeCifications to make sure irs correct. If It was correct before disassembly and the anginal crankshaft and rods we re reinstalled. It should still be nght.1f new rodsor a new crankshaft we re Installed. the endplay may be Inadequate. II so. the rods Will have to be removed and taken to an automotive machine shop for resizing
2S
InlUal start·up and break·in after o verhaul
Warning : Have a fire ex/mguisher handy when starting the engme for the firSI time_
I Once the engine has been Installed in the vehicle, double-check the engine oil and coolan t levels. 2 With the spark plugs out of the engine and the Igf1l\ion system dis· abled (see Section 3), crank the engine until oil pressure registers on the gauge or the light goes out. 3 Install the spark plugs. hook up the plug wires and restore the Igmtlon system functions (see Section 3). 4 Start the engine. It may take a few moments for the fuel system to build up pressure. but the engine should stan wi thout a great deal of effon Note: If backftring occurs through the carburetor or throttle body, recheck Ihe valve limmg and Ignition IImmg.
2E
2E-30
Chapter 2 Part E General engine overhaul procedures
5 After the engine starts, iI should be allowed to warm up to normal op· eratlng temperature. While the engine is warming up. make a thorough check lor fuel , oil and coolant leaks. 6
Shu! the engine all and recheck the engine 011 and coolant levels 7 Dnve the vehicle \0 an area with minimum Irallle, accelerate at full throttle from 30 to.50 mph. then allow the vehicle to slow to 30 mph with the thronleclosed. Aepeallhe procedure 10 or 1211mes. This will load the piSton rings and cause them to seal properly against the cylinder walls Check agam lor oil and coolanlleaks.
8 Drive the vehicle gently lor the first 500 miles (no sustained high speeds) and keep a constant Check on the 011 level. It IS not unusual tor an engine to use oil during the break·in period 9 AI approximately 500 to 600 miles. change the 011 and hiler 10 For lhe nexl few hundred miles, drive Ihe vehicle normally, Do nol pamper il or abuse II. 11 Alter 2000 miles, change Ihe OIl and hUer again and consider Ihe en· glne broken tn.
Chapter 3 Cooling, heating and air conditioning systems Contents All conditioning system ~ check and maintenance Air condlt lonmg system compressor - removal and installation Air conditioning system accumulator - removal and installatIOn Air conditioning sys tem recelverdner - removal and installation Air cond itioning system condenser - removal and installation Anllireeze - general mlormallon Slower mOtor SWi tch - replacement Blower motor ClfCU lt - electrical teshng Blower motor - rep lacement (1979 through 1984 models) Blower motor - replacemenl (1985 and 1966 models) Blower motOI- replacement (1987 and later models)
Coolanl level check Coolant reservOir - removal and mstallallan
21 22 24
25 23 2 13 11 16 17 18
See Chapter 1 7
Coolant temperatu re sending unit - check and rep lacement 8 Cooling system Check See Chapter 1
Cooling system servicing (draining, flush ing and rehillng) See Chapter t Dflvebelt check, adjustment and replacement See Chapter 1 ElectriC coo ling tan and molor - check, removal and Inslallation 5 Engine-mounted coo ling fan - check and replacement 6 1 General information . Heater control assembly - removal and installation 12 Heater con trOl cables - adjustment 14 Heater contrOl cables - replacement. 15 Heater core - replacement (1979 through 1986 models) 19 Heater core - replacement (1987 and later models) 20 Heater - general Information 10 Radia to r - removal and installation Thermostat - check and replacement 3 Underhood hose check and replacement See Chapter 1 Water pump - check and replacement 9
,
Specifications
Thermostat opening temperature 3 3L sl~·cytlnder engine Stans 10 open Fully open 2.8L V6 engine Starts to open Fully open 3.8L V6 engine Starts to open Fully open 4 2L V8 engine Starts to open Fully open 5.0L V8 engine (through 19881 Starts to open Fully open
193 to 200·degrees F 212-degrees F 192 to 198-degrees F 22S-degrees F 193 to 200·degrees F 22 t -d egrees F 188 to t 95-degrees F 22 1·degrees F 193 to 200-degrees F 22t-degrees F
3-2
Chapter 3 Cooling, heating and air conditioning systems
SOL V8 engine (1989 onj Starls to open Fully open
188 to 19S·degrees F 221 -degreesF
Blower motor current draw and voltage 1979 Without air conditioning Low speed Amps Volts Medium speed
A_
Vails High speed Amps Volts With air conditiOning Low speed
Amps VeilS
4
7
5 9 7 12.8
4
39
Medium low speed
Am"
Valls
8 6.2
Medium hlQh speed
Amps VallS
13 89
High speed Amps Volts
23 12.8
1980 Without air conditioning
low speed Am" Volts Medium speed
Am", Volts High speed Amps Volts With air conditioning Low speed
Amps Valls Medium low speed Amps Volts Medium hIGh speed
36
'6 53 74 85 128
4
39 8
62
Amps Valls Htgh speed
13 89
Am"
23
Valls 1981 Without air conditiOning Low speed Amps
Volts Medium speed Amps Volts High speed
Amps Volts With air condluonmg Low speed
Amps VOlls
,,,
20 55 5.3
7. 85 12.8
•39
Chapter 3
Cooling , heating and air conditioning systems
3-3
Medium low speed
Amps Volts Medium high speed Amps Volts
8 6.2
13 8.9
High speed
Amps Vol ts 1982 through 1985 Without air cond itioning
Low speed Amps Volts Medium speed Amps Volts High speed
Amps Volts With air condit ioning Low speed Amps Volts Medium low speed Amps Volts Medium high speed Amps Vo lt s High speed Amps Volts 1986 on Withou t air conditioning Low speed Amps Vo lt s
Medium speed Amps Volts High speed Amps Volts With air condit ioning
23 12.8
36 46
53 7.4
85 12.6
3.5 to 5.0
3.5104.5 6 to 8 5.5 to 7.0 10 to 14 7.510 10.5
151022' 11 to 14
3 2.2
"
37
73 9.2 12.8
low speed Amps Volts Medium low speed Amps Volts Medium high speed Amps Volts
High speed Amps
35105.0 3.51045
6 to 8 55107.0 10 to 14 7.51010.5 16 to 22
Vo lt s '1610220n 1985 models
1110 14
Torque specifications
Ft-Ibs
Fan pulley-la-hub bol ts (through 1989) Fan clutch- to-water pump bolts (1990 5.0L V8) Thermostat hOUSing bolts 2.3l lour -cylinder engine 2.8l V6 engine 3.3L sl~ - cyhnder engine 3.8l VB engine
12 to 18 15 to 22
14 to 12 to 12 to 15 to
21 15 16 22
3-4
Chapter 3
Cooling, heating and air conditioning systems
VB engine Through 1987
1988 on Water pump-Io-block bolts 2.3L lour-cylillder er\glne 28L V6 engine
3 3L Slx-cyhnder engine 3 8L V6 engine
va engine
9to t2 t2 to 18 14 to 21 7 t09 t2 to 18 151022 12 to 18
General Inform ation
Engine cooling system All vehicles covered by this manual employ a pressurized engine cool 1n9 system with thermostatically controlled coolant Circulation An Impeller Iypewater pump mounted on the Iron\ of the block pumps coolanllhrough the engine The coolant flows around each cylinder and toward the rear of the engine CasHn coolant passages direct coolant around the Inlake and exhaust ports. near the spark plug areas and In close prO~lmlly 10 the
exhaust valve gUIdes A wall pellet type thermostat IS located In a hoUSing near the IrOOI 01 theengll"le DUring warm-up. the closed thermostat prevents coolant Irom Circulating through the radiator As the engine nears normal operating temperature, the thermostat opens and allows hot COOlant to travel through the radiator, where It'S cooled belore relurnlng 10 the engine The cooling system IS sealed by a pressure type radiator cap which raises the boiling P()lnl 01 the coolant and Increases the cooling effiCiency 01 the radiator II the system pressure e~ceeds the cap pressure rellet val ue the excess pressure In the system lorees the spnng-Ioaded valve inside the cap off Its seal and allows the coolant to escape through the overflow tube Into a coolant reservOir. When the system cools thee~cess coolant IS automatically drawn Irom the reservOir back Into the radiator The coolant reservOir does double duty' As the POint at which tresh coolant IS added to the cooling system to maintain the proper tluld level and as a holding tank for coolant when 1\ expands from the normal heat of engine operallon ThiS type of cooling system IS known as a closed deSign because coot ant Ihat escapes past the pressure cap IS saved and reused
Heating system The heating system conSists of a blower fan and heater core located heater boK. the hoses connecl lng the heater core to the engine coolIng system and the heater'alr conditioning control assembly on the dash bOard HoI engine coolant ISClrculated through the heater core_ When the heater mode IS activated, a lIap door opens to e~pose the heater box to the passenger compar1menl A fan SWitch on the control assembly actl vales the blower motor whICh torces aIr through the core healing the aIr In the
Air conditioning system The air conditioning system consists of a condenser mounted In front ot the radiator, an evaporator mounted adjacent to the healer core. a com ptessor mounted on Ihe engine. a recelver-dner (accumulator) which con· tams a high ptessure relief valve and the plumbing connec1lng an Of the above components A blower Ian lorces the warmer air 01 the passenger compartment thlOughthe evaporator core (sort oJ a radiator tn· reverse), translernng the heat from the air 10 the relrlgerant The liqUid refrigerant bolls olf Into low pressure vapor, taking the heat With It when It leMes the evaporator
warer Antifreeze IS highly rOXlc If Ingested Never leave antifreeze Iymg around m an open contamer or In puddles on the lloor. children and pers 8reallractedby It s sweel smellandmaydrmk. II Check WIth local autllon· ties abouf diSPOSing of used antifreeze Many commUni/les have coliac/Ion centers which will see that anti/reeze IS disposed 01 safely The cooling system should be filed With a water ethylene glycol based antifreeze solu\lOn. which w ill preventlreezlng down 10 at least -20-de· grees F or lower II local chmate reqUIres It It also prOVides protection against corrOSion and Increases the coolant bolhng pOint The cooling system should be dratned flushed and rehiled at least ev· eryother year !see Chapter I). The useol antllreeze solutions tor penods 01 longer then two years IS likely to cause damage and encourage the lormallon 01 rust and scale In the system II your tap water IS hard. use diStilled water With the antllreeze Belore adding antllreeze to the system, check all hose connec tions. because an tllreeze tends to searCh out and leak through very minute openings Engines do not normally consume coolant Therelore, II the tev el goes down hnd the cause and correct It The e~act ml_ture ot antllreeze-to-water whICh you should use depends on the relallve weather cond.tlOns The ml~ture should contain at least 50-percent antifreeze, but should never contain more than 70 per· cent antifreeze. Consult the mixture ratio chart on the anlilreezecontainer belore addmg coolant Hydrometers are available at most auto pans stores to test the ratlopl anlllreeze to water Use antifreeze which meets speclficallon ESE-M97B44·A (pan No E2FZ·t9S4g·A) or equivalent
3
The rmos tat - c heck and rep lacement
Warning : Do no/ remove the radlalorcap, dram the cooianlor replace the thermostat until the engme has cooled completely
Check Belore assuming the thermostat IS to blame lor a cooilng system problem, check the coolanllevet. dnvebelttenSlOn (see Chapter 1) and temperature gauge opera\Jon 2 II the engine seems to be taking a long lime to warm up (based on heater output or temperature gauge operallon), Ihe thermostat IS probably Sluck open. Replace the thermostal With a new one, 3 II the engine runs hOI , use your hand to check the temperature of the upper radiator hose (lower radiator hose on 2 8L V6 models). lithe hose Isn I hot but the engine IS. the thermostat IS probably stuck closed. pre· venung the coolant InSide the engine Irom escapmg to the radiator Replace the thermostat Cauti on : Don I drIVe the vehICle Wllflout a rhermosrar The compurer may stay m open loop and emiSSions and fuel economy will suller 4 If the upper radlalor hose IS hot_ It means thai the coolant IS flOWing and the thermostat IS open. Consult the Troubleshoo\lng Sec\lOn at l he lront of thiS manual tor cooling system diagnOSIs
Replacement 2
An tifreeze - gen eral i nlormaUon
Warni ng : Do not allow antifreeze ro come m coflfac/ wi/h your skin or painted surfaces of the vehicle Rinse off spills Immediately With plenty 01
RefertoifluslratlOns3 l1a, 3 lIb 3 flc 3 rl d 3.lle. 3 12a 3 r2b 3 14 and316 5 Disconnect the nega\lve battery cable from the battery 6 Drain the coollflg system (see Chapter I). If the coolant IS relatively
3-5
Chapter 3 Cooling, heating and air conditioning systems
WATER PU MP
3.11 a
3.11 b
Typical 2.3L thermostat installation
2.8L V6 water pump and thermostat Installation
new or in good condition (see Chapter 1). save il and reuse It . Warning: Do not leave the drained coolanl where It IS access!ble to children or pels they are attracted by I/S sweet smell. Inges/lng even a small amount of
coolant can be fata!.! 7
Follow the appropriate radiator hose to \0 the engine to locate the
thermostat hOUSing. On all excepl2.Bl V6 engines, thiS IS the upper hose On 2.BL V6 engines, follow the lower hose.
8
3.11 c
3.3l six-cylinder engine thermostat hous ing
Loosen the hose clamp, then detach the hose from the filling . II It'S
sluck, grasp it near the end With a pair 01 adjustable p llefs and twist II to break the seal. then pull It off. If Ihe hose IS old ordeteflorated. culiloff and mstall a new one. On mline engmes, detach the small hose from the fitting m the same manner. 9 On VB engines, the distributor vacuum diaphragm may block access to the thermostat. If so, remove the distributor cap and rotor, then remove the diaphragm retaining screws and take the diaphragm oul. to IIlhe outer surface of Ihe large fittmg that mates With the hose IS dete· norated (corroded , pllled, etc.) II may be damaged funherby hose ramov· al. lilt is, the thermostat housmg Wil l have to be replaced , tt Remove the bolts and detach the housing (see Illustrations). II the co~er IS stuck. tap It With a solt-faced hammer to jar II loose. Be prepared for some coolant to spill as the gaske t seal IS broken. On most models. the thermostat Will come away from the engine With the hOUSing .
,
THERMOSTAT
"-FRONT OF VEHICL.E
'" 3.11d
A lOp view 01 a V6 thermostat h ousing shows Ihe locations 01 the bolts (arrow s)
3.11e
Thermostat housing location (typical Va)
3-6
Chapter 3
Cooling. heating and air conditioning systems late the thermostat to release It Irom the hoUSing Do not pry the thermo SIal OUI or II Will be damaged 13 Slutt a fag InIO the engine openlll9 _then remove a1\ traces 01 old gas kat matenal and sealant 110m the hOUSing and engine with a gasket scrap ar Remove the rag from the opening and clean the gasket mall ng surfaces with lacquer thinner or acetone.
RECESS
/
14 On 2.3L four-cylinder engines. be sure to rotate the thermostat so the healer lube opening is unobstructed (see illuslration) 15 On models with locking flats or locking ears , Install the Ihermostalm the hOUSing then rO tate the thermostat 10 lock It In posllion (see illustra-
tions 3.128 and 3.12b)
3.128
On some models, locking 1181s secure Ihe thermoslal . ..
12 NOte how II s Installed (whICh end IS lacing away ttOm the engine) then remove the thermostat On most models. the thermostat IS secured by lockJOg flats or locating ears (see illustrations) 1/ thiS IS the case, to
16 On va modelsWllh a thermostat bleeder valve. the valve should be up (see Illustration) 17 Gaskets may beplalnor precoatedWlth adheSive Onprecoatedgas kets. peel the protective paper away from the adheSive Coat plain gas kets on both sides With a thin. even layer of gasket sealant 18 Install the thermostat gaskel on Ihe Ihermostat hOUSing (2 8L V6) or on the engine (all others) . 19 Install the thermostat hOUSing evenly and lighten the bolts to the torque listed In thiS Chapters Specihcallons 20 Reattach the hose{s) to the thermostat housmg and tighten the hose clamp(s) securely 2t On va engmes. mstallthe dlstnbutor vacuum diaphragm. cap and 10· lor (II removed ) 22 Reilllthe cooling system (see Chapler 1). 23 Slar1lhe engine and allow lIto reach normal operating temperature. then check lor leaks and proper thermostat opelatlon (as descnbed In steps 2 through 4)_
LOCATING
EA'
3.12b ... while on others, It"s secured by locating ears
3.14 On four-cylinder models . rolale the thermostat unlil the healer tube opening is unobstructed
3.16 On va models with a Ihermostat bleeder valve. the bleeder valve must be up
4.6b Use two wrenches when removing the transmis sion cooler lines to avoid damaging the lillings
4.8 Removing the upper radiator mounting bolts (intine six-cylinder model shown)
-
--~ 4.68
A Ford special tool is available 10 undo Ihe transmissIon cooler qulck-dlsconnect lillings
Chapter 3
4.9
Cooling, heating and air conditioning systems
Lilt the radiator up carefully to avoid damaging the radialor
St
OF
VEHICLE
WIRING
~~ @:,llX.rEDUNDER W"""''"
• '
~
~
COOLING FAN
~
CONTROLLER
INSTI'lUMENT
•
A
~
8
681
~ ~ ~
CIRCUIT
""RI'-IG
CONNECTOR
5.2
4
883j CIRCUIT
::~ ~::~~::
Hl:'1ilJAt·n1Cs"H.~1~tDAI
J
~ 1
,
68
CIRCUIT
45
CIRCUI T
distort the radlatorllU lngsll1 the hoses are old or deteriorated cut them off and Install new ones. 4 Disconnect the reservoir hose from the radiator l iller neck 5 On vehicles equipped With a flex·blade or c lutch·type lan, detach the shroud from the radiator and slide the shroud toward the engine S If the vehicle IS eqUipped With an au tomatic transmiSSion. disconnect the cooler lines from the radiator (see iUustralion). Use a flare ·nul wrench so the nut Isn't rounded off and hold the llIIlOg With a backup wrench so It Isn't damaged. Use a drip pan to catch spilled I luid. On vehicles With qUlckdisconnect oil cooler line hwngs. a special disconnecting tool IS available Irom Ford (see Illustration). 7 Plug the IlOes and lilllOgs A very small amount oldlrt can cause automatic transmiSSion failure 8 Remove the radiator mounting bolts (see illustration) 9 Carefully lilt the radiator out (see illustration) Don't spill coolant on the vehicle or scratch the paint 10 With the radiator remOVed. It can be Inspected lor leaks and damage lilt needs repalf. have a radlStor shop or dealer service department perlorm the work as speCial techniques are required. 11 Bugs and dirt can be removed Irom the radiator Wllh compressed air and a solt brush. Don' t bend Ihe cooling fins as this IS done 12 Check the radiator mounts lor deterioration and make sure there's nothing In them when the radiator IS Installed 13 Installation IS the reverse 01 the removal procedure 14 AflerlOstalla\lon. lill the coollOg system With the proper mlxtureol antlIreeze and water. Refer to Chapter 1 il necessary IS Start the engine and check lor leaks. Allowlhe englOe toreach normal operating temperature, indicated by Ihe upper rad iator hose becoming hOI (all excepl 2.8L V6) or by the lower radiator hose becoming hot (28L V6 ). Recheck the coolant level and add more If requlfed. 16 II you're wor!
5
Electric cooling Ian and motor - check, removal and installallon
PANEL BETWEEN
STEERING COLUMN AND .. ,..,. PILLARI
Ale CLUTCH COIL
') 6
3-7
The fan controller on most models is located under the instrument panel, near the steering column
Radiator - removal and Installation
Refer /0 !IIlJSfra/fOns 4.68. 4.6b. 4.8 and 4.9
Warning: Wait unfll/he engme IS completely cool before beginning thiS procedure. 1 Disconnect the negative battery cable from the battery. 2 Drain the cooling system (see Chapter 1) . If the coolant is relatively newor in good condilion. save It and reuse 11. Warning: Be sure los/ore coolant where children and pets can't get fo If. It"s sweet smell attracts them . Ingesting even a small amount can be fatall 3 Loosen the hose c lamps. then detach the radiator hoses from the fit· tlOgs. If they're stuck. grasp each hose near the end With a pair 01 adJustable pliers and tWist It to break the seal. then pull It off - be ca relul not to
The Electrodflve cooling fan system is Installed on 1980 and later turbocharged 2.3L engines, as well as on 1982 and later non-turbocharged 2.3L engines. It utilizes an electrically·driven Ian motor which IS triggered by a coolant tempe ralure sensor. Turbocharged. carbureted vehicles also have a temperatu re sensor m the base 01 the carburetor wh ich switches the fan on when ca rburetor temperature reaches ISS-degrees F. On air condit ioned vehicles. the Ian operates whenever the Ale compressor IS engaged. regard less of coolant temperature. Warning : On some vehicles Ihe fan may come on automatically. even wllh Ihe Ignition Off. DO NOT place your hands or tools where /tley may be struc/( by the fan If rl starts movmg suddenlyl If poSSible. disconnect /tle negatIVe cable from Ihe battery when wor/flng near /tle fan.
Check Refer 10 illustration 5.2 2 The fan controller (1 981 and later models. except Fuel Economy Leader) IS located under the mstrument panel near the steering column (see illustration). 3 To test the mol or. unplug Ihe electrical connector at the motor Connect one jumper wire from the motor positive termmal to the banery POSI tive lermmal. Connect the other jumper wife Irom the motor negative terminal to ground. lithe fan stili does not wor!< , replace the motor 4 If the motor tested OK, the fauillies Inthecoolanl lemperature SWitch. Ihelan control ler, the EEC system (see Chapte(6) or thewlflflgwhich Connects these components. Carefully check all Wifing and connections II no obVIOUS problems are found. further diagnosis should be done by a Ford dealer service department or repair shop.
Removal and installation Refer to Illustral!ons 5.7 and 5.B 5 D,sconnectlhe negative cable from the ballery. 6 Detach Ihelanwlflng harness from ItS clip. then unplug the connector
3
3-8
Chapter 3 Cooling , heating and air conditioning systems
ENGINE '-......... CO<)LI ~iG
'AN
, SU PPORT ASSEMBLY
5.7 Electrodrive cooling Ian components - exploded view
eo.OIN£ COOl'JIIG
""
F"J\I ... ssu~al"
WA.HRPUMP PUlLEY SPA.C[R
5.B The eleclrodrive cooting Ian Is secured to the motor by a retainer clip 7 Remove the Ian mounting screws (see Illustration) and take the Ian assembly oul 8 RemOve the retainer clip (see iUuslralion) and take the Ian olf the motor shalt Note: II/he molor shaft IS Ourred. remove the buff before at· /emp/lng /0 remove the fan 9 Remove the Ian motor-la-bracket nuts. then separate the motor from the bracket \ 10 Installation IS the reverse 01 the removal procedure
6
Engine-mounted cooling Ian - check and replacement
Warning : DO NOT stand In Ime with an engine-mounted cooling fan while the engine IS running'
Flex-blade fan ReIer /0 ,//u5IratIOfl6.3
t A fleK-biade Ian IS used on 1979 through 198t models. Flexible blades are nve1ed to a central stamped hub. The blades lIatten out at hlQh engine speeds. redUCing drag for lower nOise and lower fuel consumption 2 Check the fan carefully lor cracks or separation of the blades Irom the hUb. Replace the Ian II any cracks or separation are lound, no matter how
6.3
A typical lIex·blade 'an and related components
minor the problem may appear A delecTlve flex·blade Ian can break apan In operation, creating a serrous sa fety hazard. 3 To remove the Ian. detach the Ian Shroud Irom the radiator and push the shroud over the fan . Unboilihe fa n and spacer Irom the water pump pulley (see Illustration). then hIt the tan. spac er and shroud OIJt 01 the engine companment. 4 To Install the Ian. reverse the removal procedure. TlQhten the bolts to the torque listed In thiS Chapter's SpecifICaTIonS.
Clutch-type fan Reier to rllus/ra/lons 6. 'Oa. 6. lOb and 6 I' 5 The clutch·type fan employs ngld blades With an aluminum Ian clutch at the center (hub). Check the Ian carefully for cracks. especially around the base of each blade. Replace a cracked Ian Immediately.
Chapter 3
Cooling, heating and air conditioning systems
FAN ASsY
3-9
BOLT AND WASHER ASsY
TYPICAL
5116.24
-"""FFIOtfT OF
~
VEHICLE .........
FAN OFUVe CLUTCH
BOlT AND WASHER
ASSV TYPICAl
ASSV 5/16 x 18
6.10a
6.IOb
A typical clutch·type Ian - exploded view (plastic fan shown)
Remove Ihe lour bolts (arrows) to separate the Ian from the clutch (steel Ian shown)
6.11
When the fan clutch is removed , store it wllh this side down (arrow)
6 Check Ihe clutch forlluid leakage. Replace the clutch If It has been leaking 7 Try to move Ihe fan blades In a IronHo-rear directIOn, II the blades wobble , replace Ihe Ian clutch. 8 Spin Ihe fan by hand. The fan should resist spinning (more when the engine IS hot) . If II SpinS freely or won', SPin al all. replace Ihe Ian clu tch. 9 To remove Ihe fan, detach the Ian Shroudlrom the radiator and push it over the Ian. Unbolt the fan and ctutch Irom the water pump pulley, then hIt the fan, clutch and Shroud out 01 the engine compartment. 10 To separate the clutch Irom the fan , remove the attaching bolts (see illuslrallons). 11 lithe fan IS stored, be sure to place the marked side down (see illusIration) 12 To Instalithe Ian. reverse the removal procedure Tighten the bolts 10 the torque listed In thiS Chapter"s SpeCifications.
7
7.2a
Coolant recovery reservoir (early models)
C')olant reservoir - removal and Installation
Refer to illustrations 7.2a and 7.2b 1 Disconnect the overtlow hose at the radiator neci<-. 2 Detach the reservoir Irom the inner fender or braci<-et (see Illustrations).
3 -10
Chapter 3
Cooling , heating and air conditioning systems
RESERVOIR. RADIATOR
cc:xx..ANT REca.'ERY
,
SCAEW ANO.......stER ASSY MIll " 1.5 " " HEX TAP e REO'O
7.2b
Radiator and coolant rese rvoir (later models)
WIAING
"'SSEMILY
• WAlER TEMHRATURE SENDER 4SSEM8L V
8. 48
•
•
8.4b Coolanllemperalure sending unit (l .3L six.cylinder engine)
Coolanllemperalure se nding unit (2.3l l out·cylinder engine)
Check 3 4
8
Lltl1he reserVOir oul Installation IS the reverse at removal
Coolanllem peralu re sending unit - c heck and replacement
Warning : The engme must be completely cool before removing the send·
mgumt Caution: Do not ground Ihe sendmg um( ",me dlfeclly /0 Ihe engme ThiS may damage rhe gaL,Je or Instrument voltage regula/or
Refer /0 illustrations B 48, 8 4b, 8 4c and B 4d 1 II the coolant temperature gauge IS moperatlve, check the luses IIrs! (see Chapter 12). 2 II all gauges have Similar problems (high readings, low readings. errahC readings). the Instrument voltage regulator may be at laul! ThiS should be lested by a dealer service deparlmenl or quahlled etaclncal shop 3 It the lemperature Indicator shows excessive temperature alter run nmg a while. see Ihe Troubleshoollng Section 10 the Iront ollhls manual If Ihe temperature gauge indlCales -Hot" shortly aller the engine is 4 slaned co~. or If II does not Indicate any Increase In temperature, dlsconnecllhe wire at Ihe coolan l lemperalure sending unll (see illustration s)
Chapter 3
Cooling, heating and air conditioning systems
3 -11 TO FIIIIONT Of VIHICLI
....
TO fllOHT 0' VE H IClE
8.4d
Coolant temperature sending unit (V8 engine)
VIEW"
8.4c
Coolanllemperature sending unit (J.8L V6 engine)
5 Turn the Ignition key to On. but don I start the engine Connect a IO-ohm reSistor 10 the disconnected wire. then ground the reSistor to the engine The temperature gauge should Indicate In the HOI range 6 Repeat Step 4 uSing a 73-ohm reSistor The gauge should Irl(licate In the Cold' ange 7 lithe gauge Indicated properly In Sleps 5 and 6. the sending umllS
bad Replace 1\ 8 It the gauge <;lid not Indicate properly In Steps 5 and 6, the CirCUli may be open 01 the gauge maybe faulty, SeeChaplel 12101 addltlonallnforma' lion
9.9
Replacement 9
Once the Ian Is removed , the water pump pulley can
be slipped off the shall by hand (3.8l V6 engine shown, others s imilar)
With the engine complete cool. remove the cap from the radlatol 10
release any pressure. then replace the cap ThiS reduces coolant loss dur 109 sendmg Unit replacement to Disconnect the electrical connector ifom the sending unit 11 Prepare the new sending unit lor mstallatlon by applYing electncally conductive sealant (Ford D8AZ·19554-A or equIValent) to the threads 12 Unscrew the sendlllQ unit Irom the engine (see iIlustralions 8.4a, 84b, 8.4c and 8.4d) and qUICkly Install the new one 10 prevent coolant
""
13 Tighten the sending uni t securely and reconnect the electflcal connector 14 Refill the coolmg system and run the engme Check. for leaks and proper gauge operation.
3 With Ihe engme runnmg at normal operatmg lemperature, squeeze Ihe upper radlalor hose II the waler pump is WOrking properly, a pressure surge should be felt as the hose IS released Warning : Keep your hands away from the fan blades I 4 Waler pumps are eqUipped Wlthweepor vent holes. If afallure occurs In the pump seal. coolant will leak from the note In most cases you'll need a tlashbghlto hod the hole on the water pump from underneath to check lor leaks 5 lithe water pump shalt beafings lall there may be a howling sound at the fron t 01 the engine wh ile II S running Shalt wear can be leltll the water pump pulley IS rocked up and down . Don't mistake drivebell slippage, whiCh causes a squealing sound. lor water pump bearing failure,
Replacement 9
Water pump - check and replacement
A failure In the water pump can cause overhealmg and sellOUS engme damage due 10 overheatlllQ
Check 2 There are three ways to check the operation 01 the water pump while Irs Installed on the engme If Ihe pump IS delec\lve. II should be replaced With a new or rebUilt uni t
Refer 10 Illustrations 9 9.9.10.9 13a 9. f3b. 9 t3c. 9. 13d and 9 19 Warning: Walt Un/If the engine IS completely cool before begmnmg thiS procedure 6 Disconnect the negative ballery cable Irom the banery 7 Dram the cooling system (see Chapler 1'. 11 the coolant IS relallvely new or In good condition, save It aod reuse It 8 Remove the cooling Ian and shroud (see Section 5 or Section 6) 9 Removethe dfivebelts (see Chapter I ) and the pulley atthe endol the water pump shalt (see illustration)
3 -12
Chapter 3
Cooling, heating and air conditioning systems
OUTLET CONNECTION _ THERUOST AT OUTLET
"""" mo WASHER
SIOETORADlATOfI
2 REO'O
9.10
Loosen the clamps, then twisllhe hoses (arrows) to detach them from the pump fillings (3.8l V6 engine shown)
~
WATER PUNP
APPLY DtAZ·II55o'-A ./ seALlA TO I'ASTt:MEIIS FfIOt4T PfIIOfI to ASSEMII. Y OF VEttICLE
WATER PUMP
/'
- 0" RING
9.13a
9.13b 2.8L V6 engine water pump and thermostat Installation details
10 Loosen the clamps and detach the hoses from the water pump (see illustration) If they 're stuck. grasp each hose near !he end with a pair 01 adjustable phers and tW ist It to break the seal. then pull !\ off. If the hoses are deteriorated. cu l lhem off and Install new ones 11 Remove all accessory brackets trom the water pump When remov· mg the power steering pump and air condition ing compressor. doni dlsconnecllhe hoses. Tie the units aSide Wi th the hoses attached 12 2.3l four-cylinder engine - remove the outer liming belt cover lsee Chapter 2A) .
9.' 3c The water pump mounting bolls on a 3.3l six·cylinder engine (arrows) - one bolt on the bottom is obscured by the pump
Water pump and related componen ts - exptoded view (2.3l lour·c yllnder engine)
t3 Remove the bolts and detach the water pump from the engine (see illustrations). Note the locations 01 the various lengths and dllferenttypes of boits as theyre removed to ensure correct installation 14 Clean the boll threads and the threaded holes In the engine to remove corrosion and sealaTlt 15 Compare the new pumptothe old one to make sure they are Identical. 16 Remove all traces of old gasket materral from the engine With a gasket scraper 17 Clean the engine and new water pump mating surfaces With lacquer thinner or acetone 18 App ly a thin coat of RTV gasket sealant to the engine Side of the water pump gaske t POSition the new gasket on the engine t9 Prior to Installation. treat the water pump bolts as tollows: 2.3l lour·cylinder engine - coat all bolts With Teflon sealant (Ford D8AZ -19554-A or eqUivalent) 2.8l V6 and 3.3l six·c ylinder engine s - make sure the bolts are clean and free of corrosion
9.13d
Note the locations 01 aU bolts and studs during removal (3.8l V6 engine shown)
Chapter 3
Cooting , heating and air conditioning systems 10
3 -13
Heal er - general inlormation
The heater circulates engine coolant through a small radiator (heater core) in the passenger compartment Air IS drawn 10 through an openlOg In the cow l, then tlJown [by the btower motor) through the heater core to pick up heat The heated air IS blended With varylOg amounts 01unhea ted air to regulate Its temperature The heated air IS then blown IO ta the pas· senger compartment Vanous doors 10 the healer controt the !low ot air 10 Ihe !loor. IOstrument panel and defroster ou ttets
11
B lower molar ci rcuil - eleclricaltesl lng
1979 through 1981 models Reler/Ol/lus/ra/lon 11.2
9.19
On 3.8l V6 models, apply sealant to the threa ds 01 this bolt (arr ow)
3.e l V6 engine -coat only one bolt (see illustration) With Tellon sea lanl (Ford D8Al 19554 A or eqUIValent). LlghUy ollihe remaining bolts va engines -I'ghtly 0,1 all bolls 20 Apply a Ihln layel 01 RTV sealanllO Ihe gasket ma!lng surface of lhe new pump then carefully mate Ihegaskel and pump Sllpa coupleol bolts thrOugh the pump mounting holes to hold the gaskelln place 21 In51alilhe remaining bolts (1llhey also hold an accessory bracket In place. be sure to reposl!ion the bracket al thiS lime). Tighten them 10 Ihe torque listed In Ihls Chapters Specifications In 14 lurn Increments. Don't overllghlen them or the pump may be distorted 22 Reinstall all parts removed lor access to the pump 23 Refill the cooling system and check the dnvebelt tension (see Chap· ter I) . Run the engine and Check tor leaks
11.2
1 Make sure the banery IS fully charged and the fuse IS not blown (see Chapter 12). Also check the connections at the blower molar and resistor assembly to be sure theyre tigh t and not corroded. 2 Connect the poSItive fead 01 a voltmeter tothe blower motor electncal connector (orange. black wife) at the blower motor resistor assembly (see illustration) 3 Connect the negative lead 01 the voltmeter to a good ground (bale metal) on the vehICle frame. 4 Place the temperature conllollever In the middle OlliS uavel 5 Place the heater lunctlon conlrollever In the Heat poSItIon 6 Place the Ignlllon key 10 the On poSllion. 7 Move the blower SWitch through each of liS poSitions and note the volt· age read ings Compare With the Spec Iii cations at the Iront 01 this Chapter If the voltage readings are correct, but the blower motor wont work or doesnt work correctly, either the blower malar or the Wiring to Ihe blower motor IS faulty. If there are no voltage readings. and the connections and lusearegood. the problem is probably 10 the wiling II only one or !Wool the readings are too hlQh or too low, and all COnnecTiOnS In the CirCUit are light
B lower molar voltage and c urrent d raw test connections (1979 t h rough 1981 m odels)
3
3-14
Chapter 3
11 .16
Cooling, heating and air conditioning systems
Blower molor voltage and c urrent draw lest connections (1982 and laler mo dels) 't.lSTRU tOlENT ClUS HR T RI M PA t.l EL
CONT ROL ASSE MB LY
R ETA INING SCIIEWS 14 )
12.1
Healer control assembly inslallalion details (1979 through 1986 models)
and not corroded, the problem IS probably ,0 the reSistor assembly. Re move the two screws, pull,! oul althe blower case and check II visually 8 Turn off the key and disconnect the voltmeter. Leave the temperature control and function con trol levers where they are 9 Disconnect the blower motor electrical connector (orange/black wire)
draw IS too high or too low In only one or two SWitch pOSllIOns the problem IS likely In the res istor assembly
1982 and later models 16
from the resis tor assembly terminal.
Refer to Illustration "
10 Connect the positive lead of an arnmelerto the male conneclorterm i· nal on the resistor assembly. 11 ConneCllhe negative lead of the ammeter to the electrical connector If necessary. insert a male connector termlnallnlO the connector so the ammeter cl ip will have something to atla.:h t6, 12 Turn the key to the On pas-tion. 13 Move the blower switch through each of its poSI tions and note the ammeier readings. Current draw should be as shown In the SpecIfications In the front of thiS Chapter. lilt's higher In all SWi tch poSi tions. and all connections are good, the problem is probably the blower motor, 11 the current
'4 Check the fuse and all connections In the CirCUi t lor looseness and corroSion. Make sure the battery IS fully charged Move the temperature leveror knob to the Warm position Move the function control lever or knob to the Floor poSition Nole : On early produC/IOn 1985 models. the function control lever may have a Heat posilion Instead of a Floor poSition 15 With the transmission In Park. the parking brake securely set and the wheels blocked. start the engine. 16 Connect a vo ltmeter to the blower motor connector (see illustration) 17 Move the blowerswltch through each 01 ItS poSitions and note the vol\age readings. Compare With the SpeCifications al the front of thiS Chapter,
Chapter 3
3 -15
Cooling, heating and air conditioning systems
v
\;==",=__ TE MPEAATUFIE BLEND t 000I'I eIlAN'" ",AM -c';lI,,-___ SHF AOJUSTtNG >o!
CLIP
AIR OOOA CONTROl CI.8lE ASSe MBLY
_
SEV AOJUSltNG
~..
__ "_
,,~ : 6"";;;====
~(
TeMPER,\lUAE CONTROl BlENDCABU OOORASSV
""""\
SELF AOJUSTING CLIP
12.3a Healer conlrol cable aUachmenls althe healer case (1979 through 1986 models)
REMOve WITH SPECIAL 1001.
J YIEW A REMOVAL
'/
3
..... f'2'\ PUSH TOOL OVER
\:J CABLE END RETAINER
CABLE ['10 "EH INER
17\ POSITION TOOL
V
............
PULL CABLE FROM BRACKET
INSTALLATION
17\
OVER CABLE WIRE
V
PUSH CABLE END RETAINER IN TO BRACKET UNTIL LATCHED WITH BRACKET
12.3b Control cables on early models are con nected to and disconnected Irom the case with a specIal 1001
If there IS voltage. but the blower motor does not operate or II all readings are higher than specified, the blower motor IS probably laul1y I B Dlsconnecllhe vollmeter and turn olt the engine 19 leave the temperature lever or knob In the Warm poSltJon and move tile function control lever or knob to the Heal poslltOn 20 Disconnect the electrical connector tram the blower motor resistor Connect a Jumper wire between the lower terminal 01 the resistor and the black Wire's terminal in the electrical connector (see Illustration 11.16) 21 Connect an ammeter between the top terminal olthe resistor and the orange wire's terminal In the electncal connector 22 Start the engine 23 Move the blower SWitch through each of ItS poSlllons and note the am· meter reading Compare with the Speclficallons at Ihe Ironl ollhls Chapter. lithe readings are 100 high. and all connections are good. the blower motor IS probably faulty !f the readings are too high or too low In only one or two SWit ch poSItions. the resistor assembly IS probably faulty
12
Healer conlrol assembly - remov al and Installation
1979 through 1986 models Referrol/lustrallOfts 121. 123a. 12.3band 12.5 I Removethree screws from the lop edge 01 the Instrument cluster tflm panel. Lift the panel's lower locking tabs out olthel' slots. then remove the Irlm panel (see illustration) 2 Remove lour screws that secure the control assembly to the Instru' ment panel Pull the control assembly outlrom the panel 3 Delach the lunctlon and temperature cables Irom the healer case (see Illustrations) Disconnect the electflcal connectors lor the blower SWitch and control as sembly Illumination 4 Pull the control assembly out. together with the function and tempera ture cables
3 -16
Chapter 3 Cooling, heating and air conditioning systems o NOTE: PIGTAILS OF CAlLE ASSY. MUST
It:
POSITIONED AS SHOWN FOI'IINSTALLlTION CONTROL
----I TE MPeRATURE CONTROL CAIRE ASSEMBLY (SLACK)
TO RElE.,l,SE CONTROL KNOB -
J REOUIREO
BLOWER SWITCH
12.5
Heater control assembly and cables - exploded lIiew
BULB
FUNCTION CONTROL CABLE ASSEM BLY !WHITEI
".c
" , C V4C""'" HOS! ..... ~ .. ESS l 8LOC~ ASS!MBl¥
CONlROl "SSiM8l¥
\
12.10a
5 Remove the spring nut that secures the tunetion cable end loopto the funCTIon control lever Depress the white locking tang on the function cable hOUSing. then detach the lunelion cable from the control assembly (see
iUuslration) 6 Detach the temperature control cable In the same manner as the function conlrol cable 7 Install the control assembly by reverSing Steps 1 through 7. POSition the wire COils on the cable ends so they face away from the bases of the lever tangs (see lIIustralion 12.5)
1987 and later models
~
Heater control assembly mounting screws1987 through 1989 models
10 Remove the control assembly mounllng screws (see illustrations). Pull the control assembly out of the instrument panel. II Disconnect the electrical connectors. temperature control cable and vacuum harness from the control assembly (see illustrations). 12 II necessary. the control knobs can be pulled off. t 3 Installation is the reverse of Steps 8 through 12. Caution : Don·/try to thread Ihe vacuum harness relalnlng nulS ooro their posts. Push the nuts
'" 13
Blower motor switch - replacement
Refer 10 illus/rallons 12. lOa . 12. lOb. 12. 11a and 12. 11b 8 9
Disconnect the nejlatlve battery cable from the battery. Unsnap the control assembly trim panel from the Instrument panel.
I 2
Remove the control assembly (see Section 12). Disconnectlhe blower sWitch electrical connectors.
Chapter 3
3-17
Cooling, heating and air conditioning systems
, 12.10b Heater control assembly mounting details - 1990 and later
1 2 3 4 5 6 7
Ale·healer con/rol assembly Screw Blower motor speed selector knob Tempera/tJfe selector knob
Function selector knob Instrument panel
>
Nut
3
A C FUNCTION Eo TE MPUIA!l.JAE CON TROL "''''LVE "'SSEM8l~ ... C
~ACUU M
HOSE
HARNESS & BlOCI( ASSEMBLY
A C FAN CONTROL
SWI TCH ASS(M Bl v
12.1,. Heater control assembly - exploded view (1987 through 1989 models)
3 -18
Chapter 3 Cooling, heating and air conditioning systems
! : Df; ~:~"
FAN CONTROL
CONTAOL ASSV
.~
"'l(aJ.,
INSTRUMENT PANEL , _ _ _ _ _ _ _ SOCI(ET '" aULB ...sSY.
; l!"---
TEMPERATlJRE CO NTRO\. SYSTEM
•
BRACKET
, & TENPeRATURE CONTROL VALVE ASS'"
12.11 b
'''''''''~ "OSITION
fOA INST4LLAT'QN OR RE -AD.lUST ... tNT
C.... LE END RnAINU!
I
~ CONTROL ''''lIlf ASSfM8L v
L 00" "0' . , "
/
n~ _0
Heater conlrol assembly - exploded view (1990 models)
j
-
WII";( END lOOP
... ~
"""' _
SEL F AOJUSTING Cll'
14.1
~
Heeler conlrol cable
-~
-
SN"LL SCREwOAlveR
preset adjustment
3 On 1979 through 1986 models, detach the conlrolleverlang from the knob With a screwdriver and remove the knob. 4 On 1987 and laler models, pull the knob off. 5 Remove the SWItch attachmg screw(s) and take the switch out. 6 Installallon is th e reverse at removal
14
Healer conl rol cables - adjustment
Refer 10 II/us/rallon 14. 1 1 Before installing the cable: a) Slip a small screwdriver blade into the wire coil on the end of the cable (see Illustration) b) Use pliers to slide the sell -adjusting clip along the cable until It IS about one Inch Irom the wire loop. c) Install the cable (see Secllon 15).
2
It the cable IS already Installed: a) Move the control lever or knob to the Cool posillon. b) On vehicles eqUipped Wllh control levers (not rolallng knobs). move the function control lever to the all poSition. 3 If equipped With control levers. place the temperature control lever in the Warm poSition and the function con\rollever in the Del poSition 10 adJusl lhe cable. 4 If equipped with rotat ing control knobs. quickly rotate the knob to the Warm poSition to adjust the cable.
15
Heater conlrol cables - replacement
Detach Ihe cable housing from the heater case. On 1979 through 1986 models. use the special 1001 or equivalent (see Section 12). 2 Slip the self-adjusting clip off the crank arm at the healer case. 3 Remove the heater control assembly (see Seclion 12).
Chapter 3 Cooling, heating and air conditioning systems
16.1
4 5
Right venti1alor and register ducl (1979 through 1986 models)
Detach Ihe cable trom the contrOl assembly and take 1\ out. Install the cable by reverSing Steps 1 through 4 Adjust Ihe cable as
descnbed In Sec lion 13 16
Blower motor - replacement (1979 through 1984 models)
Without air conditioning Refer fa rl/()Srralions 16. I. 16.8 and 169 1
3 -19
Remove one screw 10 delach Ihe right register duel from 115 mounTIng
bracket (see Illustration) 2 Remove two screws and detach the vent!lalorcontrol assembly trom the lower edge 01 the instrument panel 3 Remove the glovebox liner 4 Remove the ventilator gnlle moun,mQ pms, lhen lake the gnlle ouI 01 Ihe vanlilator 5 Remove Ihe nghl register duct. 6 Removelhe lour venlliator assembly screws. One screw 15easB), accessible Access 10 lhe olher screws IS as tallows: a) Upper lell screw - through Ihe glOvebox opening
Chapter 3
3-20
Cooling, heating and air conditioning systems
MOTOI'! SHAFT
HUB CLA MP
16.8
16.9
Blower motor wheel installation details (1979lhrough 1986 models)
Blower motor Instatiation details (1979 thrOugh 1986 models)
SFlACKH
BOLT AND WASHER
TO fRONT
Of VEH ICLE eVAPORATOR
AND BLOWER
"sseMBl Y
OUTSIDE REelRe DOOR VACUUM
MOTOR SCREW
ANO BLOWER ASSEMBl V
'"' 16.11 Air inlel duct and blower housing assembly (1979lhrough 1984 models with air conditioning)
b) lower right screw - through Ihe vent ilator grille opening c) Upper right screw - through the register duel opening. usmg a long extension 7 Remove the venlilator assembly to the right and down and take it out from under the instrument panel a Remove the hub clamp spring (see Illustration) and pull the blower wheel off ItS shaft. 9 Remove the blower motor mounting screws (see iIIuslration) Pull the motor out. disconnect its wiring connector and remove the motor.
VIEW SHOWI"-l(i 8RACKETS AND EVAPOFIATOIII & BLOWER AS5EMBl Y VIEVI' A
10 InstallallOn IS the reverse 01 removal POSition the hub clamp spring In relat ion to the ttat on the motor shaft as shown In Illustration 16.8.
With air conditioning Refer 10 illustraMns 16 II and 16,18 11 Remove the glovebox liner. Reach through the opening and dlseon· nect the vacuum hose Irom the outslde 'reclfe door vacuum motor (see iI· lustration)
Chapter 3
Cooting, heating and air conditioning systems
3 - 21
ItOWEIII MOTOR AND 'tAn ASSE MB LY
W-.. EE t HUB
AIR INLET DUCT
"u.
e .....""
MOTQfI
$PAING
SH"' FT
"-.OWER IoIOVStN G
",SlfUl l Y
OUTSI DE- REti Re
000' C LIP
3 16.18
Air inlel duel and blower housing assembly - exploded view (1979 lhrough 1984 models with air condilioning)
12 Remove .he boll secUring the lower nght side 01 the Instrument panel
to the cowl Remove the tom panel lrom the righ t side ol \he passenger footwall 13
Remove 1he screw thai secures .he lOp 01 the support brace to the air
Inlel nul 14 Disconnect the blower molor wiring althe lohne electrical connector
way when the malar IS Installed 24 Place Ihe alr Inlel dUCI and blower hOUSing assembly In lIS Installed posi tron on the evapora tor case Slip Ihe tlange al the lop of the blower ouUet Into ItS opening in the evaporator case 25 Place Ihe blower hOUSing lower bracke t on ItS s tUd, inslallthe nul on Ihe sl ud to secure th e hOUSing 10 Ihe b racket. Note : Roule the OIower mo-
15 Remove the nut [hal secures the blower houSing lower suppon black-
lar Wiring toward the passenger's side ol/he evaporator case
ei lO the evaporalof case
26 Connect a hand vacuum pump to the Irrung on the outslde-Iecllc door vacuum motor Apply vacuum to hold Ihe outsrde·reclrc door open. then spm the blower wheel by hand There should be no rnterlerence It there IS, COffBClihe problem before continuing 27 Connectlhe blower mol ar elect neal COnl'lBClor 28 Insl alilhe screwlhal secures Ihe lop 01 the air Inlet ducllo Ihe evaporator case 29 Connect the vacuum hose to Ihe vacuum motor 30 Install the glovebox Irn e r 31 InSlal1the bolt securrng the lower right Side 01the Instrument pane l la the cowl Install the 111m panel on Ihe fight side ol lhe passenger"s Side footwelL
16 Remove ,he screw that secures !he lOp altha air mlet duclla the evap
0lal01 case 17 Pull the ai' mlet duct and blower hoUSing assembly dow n to separate It Irom the evaporator case 18 Remove Ihe lour screws that secure the blower mounting ptate to the hOUSing assembly (see ittustration) lift l he blower and wheel out o l lhe hOUSing Cau l lon : Do nol separate the moummg plate from Ihe blo wer
molar 19 II necessary, remove Ihe spring clamp Irom the blowe r shall and pull the blower wheel 011 20 lithe blower wheel was removed Irom the shall. slide II onl o Ihe shalt Pas Ilion Ihe outer edge 01 the blower wheel 3 5 8-II'lChes from the motor mounhng plate Secure the blower wheel WITh a new spong clamp, POSIIroned so lIS ends are 90 degrees trom the lIat on the motor shaft (see illustration 16. 18) 21 Place the blower molar on the hOUSing POSition the lIat Side 01 the motor lIange toward Ihe blower outlel 22 InSlalilhe blower motor attaching screws through the mol ar Ila nge Into the hOUSing 23 Tape Ihe blower molar wIfing to the air Inlet duct so It won' l be in Ihe
17
Blower motor - replacement ( 1985 and 1986 models)
Without air conditioning Refer /0 Ii/uSlra/!On 17.2 1 2
Remove the glovebox_ Re move six screws that secure the lower d uct to the upper duct and
3- 22
Chapter 3 Cooling, heating and air conditioning systems
SCREW 1'1 FlOOf'l ...oAPTtR DUCT AS5V
GASMH
BLOWER MOTOR ASSV
WHEel
""'"
GEAR SHAFT
HEATER CORE
17.2
Heater assembly (1985 and 1986 models)
heater case (see Illustration). 3 Remove the hub clamp spring (see illustration 16.8) and pull the blower wheel off liS shafl. 4 Remove the blower motor mounting screws (see Illustration 16.9) Pull the motor out. disconnect its wiring connector and remove the motor 5 Installation IS the reverse at removaL Position the hub clamp spring
ends gO -degrees from lhe lIat on the maIO! shalt (see illu stration 16.8).
With air conditioning 6 Replacement of the blower motor on 1985 and 1986 models wllh a lf condi1l0ning IS the same as for 19791hrough 1984 models wllh air candi lIaning (see Section 16)
Chapter 3 Cooling, heating and air conditioning systems ...;I""
.LOWI • .."" >UTI . SOlMI"
3-23
to detach liS retaining tabs Irom the Instrument panel Pull the glovebox out and lei II hang down 2 Disconnect the blower motor COOling hose and electrical connector 3 Remove the four blower moior mounting screws and lake the molor out (see illustration). 4 It necessary, separate the blower wheellrom the motor Remove the
_",..., "'-OWl" """OO ..... "
• " ... ., O<,ICT & ILOW," _ . , " "
spring clamp (1987 models) or push nul (198a and later models) . If the blower wheel was removed from the motor, use a new spring clampar push nut to secure il . On models With aspnng clamp, poSItion the spring clamp ends 9O-degrees from the lIal on the mOlor shalt. 6 Make sure both ends of the blower motor cooling hose are securely attached
5
7 Connect the electncal connector Reposilion the blower motor and Ill" Slall the mounting screws 8 Inslallthe glovebo~
19
Heater core - replacement (1979 through 1986 models)
Without air conditioning Refer /0 Illus/ra/ion 19.6
18.3
18
Blower molor installation delaits (1987 and later models)
Blower molor - replacement (1987 and laler models)
Refer /0 Illus/ration 18 3 1 Open the glovebox door. Squeeze the Sides 01 the glovebox together
t PaflJally drain The cooling system (see Chapter 1)_ 2 Loosen Ihe clamps on the heater hoses at the engine compartment Side 01 the hfOwall, TWist the hoses and carelully separate them Irom the heater core lUbes, 3 Plug or cap the heater core tubes so coolanT won" be Spilled In the engine compartment when the heater core IS removed, 4 Place a plastic sheet on the vehICle floor to prevent stains in case coolant spills 5 Remove the glovebo~ hner, 6 Remove the instrument panel-to-cowl brace (see IIlustraUon)
3
, 'Nst.UM'NT"~'''
T<>C"",,, •••
...
c.
__ ______\\\
"".'N'..c ______...
"'
-
co •• " .,,.'h,..c
"".'w .. ,
19,6
Heater core installation details (1979lhrough 1986 models)
3-24
Chapter 3
Cooling, heating and air conditioning systems
Access COVER
OOOR$HAn
VACUUM IIIOTOA
SUlS STUD
""'
He Al _ '"'''''''' OOOA
TEMPERATURE BLEND OOOA
--01 SEAL
CLIP
"'eAl
SLOWER RE$l$TER
SlUD
19.23
Air condilloner/healer assembly -exploded view (1979 through 1986 models)
3- 25
Chapter 3 Cooting, heating and air conditioning systems LEFT REGiSTER DUCT
DEFROSTER HOULE
EVAPORATOR ASS'"
BLOWER MOTOfI AND WHEEL ASSY
CH ...... UR ASSE"'8l y _ _ _...:~~ /l.ICPlHI U",
FLOOR AIR DIstRIBUTION
OU,"
AIR INLET DUCT AND BLOWER HOUSING ASSEMBLY RIGHT REGISTER DUCT
19.28 Air conditioner/heater assembly and related component s (1979 through 1986 models)
7 Place Iho\emperature 'ever In Ihe Warm posillon. B Remove tour healer core cover screws (see lIIustr&tlo n 19.6), Ihen remove the heater core cover through the glovebox opening. 9 Working In the engine compal'1ment, loosen the three stud nuts Ihat
23 The air Inlel duct and blower hoUSing assembly (see iIIus traUo n) has a brace whICh is secured to the cowl top panel by a screw Remove the screw 24 Disconneclthe electncal connectors Irom Ihe blower motor and reSIS-
secure the heater case Push the heater core lubes toward the passenger
'0<
compartment to detach Ihe healer core from the healer case to WoOIlng In the passengercomparlmenl. puillhe healer core through
the 9'ov8OO. opening 11 POSition the healer core with the tubes on top, then slide It through the glovebox opening Into the heater case 12 Install Ihe healer core cover and lighten its relalnlng screws, 13 Tighten the three stud nuts securely 14 tnslall Ihe Instrument panel-la -cowl brace t 5 tnSlatithe glovebox liner 16 Uncap or unplug the heater core tubes, then reconnect the hoses 17 Fill the cOOtll'IQ system (see Chapter I ). Run the engine, checll. tor leaks and test the heater
25 In the engine compartment. remove two nuts that secure the evapor a·
tor case to the dash panel 26 In the passenger compartment, remove the remaining evaporator case bracket screws. two at the cowl lap panel and one below the evaporatorcase . 27 Caretully separate the evaporator case from the dash panel and with draw It Into the passenger compartment. 28 Remove the five screws and take ot! the heater core access cover (see illustration). 29 Take the heater core out of the case "necessary, remove the seals from the heater core
With air conditioning Refer /0 l/ius/ratlOns 19.23 and /928 Warn i ng : The aIr condltlomng system IS under high pressure 00 not loos en any hose flttmgs or remove any components untIl after the system has been dIscharged by a dealer servICe department or service SlalJon. AI· ways wear eye proteellon when dlsconneclmg air conditioner system fll· tings 18 Remove the Instrument panel (see Chapter 11) , 19 Alter haVlfIg the air conditioning system discharged, disconnect the hlQh and low pressure hoses. Use backup wrenches on the hose littu19s to prevent damage 20 Cap or plug Ihe disconnected hose ends and linings 10 keep out dirt and molsl ure 21 Partially drain the cooling system (see Chapter 1), then dlsconnecl the heater hoses 110m the heater core Cap or plug the heater core tubes so coolant won', spilllnlO the passenger compartment dUring removal. 22 Disconnect the black vacuum hose at the intlnecheck valve In the en· glne compartmen t
20
Heater core - replacement (1987 and later models)
Refer /0 Illus/ra/lons 20.4 and 20. / / Warning : The air conditioning syslem IS under high pressure. Do nolloos-
en any hose '!/lings or remove any components until after the system has been discharged by a dealer serVIce department or servICe s/atron Always wear eye pro/eclion when disconnecting air condltlomng system /1/' lingS 1 Remove the center console and Instrument panel (see Chapter 11). 2 It the vehicle IS 31r condilloned , dlsconneclthe liquid line and accumu· latorfrecetver-dner inlet tube Irom the evaporator core at the dash panel DIsconnect the high and low pressure hoses (be sure to use a backup wrench so the liUll"lgs aren 't damaged dunng removal ). Cap the hoses, rllle and tube to keep out dirt and moisture 3 Drain the cooling system (see Chapter 1) and detach the heater hoses from the heater core at the firewall . Cap or plug the hoses.
Chapter 3 Cooling, heating and air conditioning systems
3-26
SEE VIEW A
20.4
Heater/evap orator case In 51al1allo n detail s (1 987 and laler models) I
Healer and blower assembly
2
Bol/ and washer
3
Nul
4 5
Screw Bracket
9
Bracket (air conditioned only) Screw and washer Nul Dash panel
7 8
A B
Hose and connector assembly
4 Remove the screw that secures the alf inlel duct/blower hOUSing as· sembly to the cDwllop panel (see Illustration). 5 Workmg in the engine compartment, disconnecllhe black healer vacuum supply hose from the inlme check valve. S Remove the two healer case stud nuts from the engine compartment side 01 the lirewall.
7 Working In the passenger compartment, disconnect the blower motor electrical connector from the motor and resistor block. Oisconnect the blower motor ground wire. 8 On vehic les without air condltiomng , remove the screw that secures the heater case sUPPOr1 bracket to the cowl lOp panel. 9 On vehicles with air conditiOning, remove the two screws that secure the evaporator case suppor1 brackets to the cowl lop panel. t 0 Remove the remaining screw that secures the lower par1 of the heater case to the dash panel. Carefully pull the heater case away trom the dash panel and withdraw it into the passenger compartment. 11 Remove the screws from the heater core cove r(see illustr ation), Uft the cover oH and remove the heater core and seal from the case. 12 If necessary. take the seal oH 01 the heater core tubes. 13 Installation IS the reverse of removal. Aun the engine, check for leaks and test the heater.
21
."i r conditioning system - check and m aintenance
Refer to II/ustratlon 21. 10 Warning : The al(cond!tioning system is under high pressure. Do not loos en any hose fillings or remove any components until after the system has
VIEW SHOWING BR.\C",n IN STA LLATIO N
been discharged by a dealer service department or service stalion. A/ways wear eye protection when disconnecting air conditioning system fittings . 1 The following main tenance checks should be performed on a regular baSIS 10 ensure Ihat lhe air conditioner continues to opera te at peak eHi clency. a) Check Ihecompressordnvebel\.lf Irs worn or deteriorated. replace it (see Chapter 1). b) Check the drive bell tension and, II necessary, adjust it (see Chapter I). c) Check the system hoses. Look l or cracks, bubbles. hard spots and deteriorallon. Inspect the hoses and all finings for oil bubbles and seepage. llthere's any evidence of wear. damage or leaks, replace the hose(s). d) Inspect the condenser fins lor leaves , bugs and other debris. Use a iin comb" or compressed air to clean the condenser. e) Make sure the system has the correct refngerant charge. 2 It's a good idea to operate the system for about ten minutes at least oncaa month , particularly during thewlnter. Long term non·usecancause hardening. and subsequent failure, of the seals. 3 Because of the complexity of the air conditioning system and the special equipment necessary to service It, In-depth troubleshoollng and repairs are not Included in this manual. However, simple checks and component replacemen t procedures are prOVided In this Chapter_ For more complete information on the air condi tioning system, refer to the Haynes au tomotive heating and air conditiomng manual. 4 The most common cause 01 poor cooling IS simply a low system refrig" erant charge . II a noticeable drop in cool air output occurs, one 01the 101" lOWing qUick checks will help you determine If the ref rigerant level is low.
Chapter 3
Cooling. heating and air conditioning systems
3-27
"£,0.1[11 COil E ,o.CC£SS COVEll
/
(DISCHARGE)
SEFIVICE
eo" EVAPORATOR
lOW AAE SSUAE (SUCTION) SERVICE PORT
ACCUMU LATOR
FIX EO TUBE
21 .10
A typical accumutator-type air conditioning system
C,o.SE ,o.SS £M8LV
Heater/evapo rator case - expl oded view (1987 and laler models)
Checking the refrigerant charge 5 6
Warm the engine up to normal operatmg tempe rature. Place the air condl\lon lng tempe rature selector at the coldest setting and pu t the blower at the highest setling. Open the doors (to maKe sure the air condit ioning system doesnt c~cle off as soon as Itcools the passenger compartment) . 7 With the compressor engaged -the clu tch Will make an audible click and the center 01 the clutch Wil l rotate 8 Feel lor a temperature differential In the s~stem . as descnbed In Slep 9 or 10 below. 9 On 1979 through 1981 models (receiver·dner sysl em), leelthe Inlet and outlet pipeS at the compressor. One side should be cold and one hot. II there 's no perceptible diff erence between the two pipeS. there's something wrong with the compressor or the system. It migh t be a low cha rge- il might be something else. Take the vehicle \0 a dealer service department or an automotive air condit ioning shop, t a On 1982 and later models {accumulator system). l eel the evaporator mlet pipe between the orilice tube and the accumulator With one hand wh ile plaCing your other hand on the surface 01 the accumulator hOUSing (see IIlustralionj , If both surfaces leel aboulthe same tem peratu re and II both l eel a hllie cool er than the surrounding air. the relrigeran t level is prob· ably okay. II the Inlet pipe has fros t accumulallOn or leels cooler than the accumulator surlace, the relngerant charge is low Add refngerant. Further Inspection 01 the system is beyond the scope of the home mechanic and should be lelt to a profeSSional.
Adding refrigerant 11 Buy an automotive charg ing KI\ at an auto parts Store. A charging ki t Includes a 14-ounce can 01 relngeran\. a tap valve and a short seclion 01
hose that can be anached between the tap valve and the system low Side service valve. Because one can 01 relrigerant may not be su fficient to bring the sys tem charge up to the proper level. irs a good Idea to buy a lew addlIIOnal cans. MaKe sure that one olthe cans contains red refngerant dye. If the system IS leaking. the red dye will leak out With the relngerant and help you pinpoint the location 01 the leak. Warning : Never addmore than Ihree cans of refngerant to the system, 12 Hook upthe charging kit to the low Side of the system by followmg the manulacturer's Instructions Warning : DO NOT hook Ihe chargmg kit hose to the system high side' 13 Warm upthe engme and turn on the alfcondltloner. Keepthechargmg kit hose away Irom the fan and other movmg parts . 14 II the system m your vehicle IS an accumulator type ' a) Add relngerant to th e low side 01 the system unlil both the accumulal or surface and the evaporator mlet ~pe feel about the same tem perature. Allow stabilization time between each addiltOn b) Once the accumulator surlace and the evaporator Inlet pipe feel about the same temperature. add the conten ts remammg m the can. 15 II the system m your vehicle is a recelver·dner type . place a thermometer in Ihe daShboard vent nearest the evaporator and add refngerant until the indicated temperature is around 40 to 4S -degrees F.
22
A ir condilioni ng system compressor - removal and Installation
Refer to Iflus trations 223. 22.5a, 22.5b and 22.Sc Warning: The air conditioning system is under high pressure. DO NOT disassemble any p artoftf1esystem (hoses. compressor.lme fittings. elc.) un til after the sys tem has been depressunzed by a dealer service depaf/ment or servICe slalion. Note: The accumulator (see Section 24) should be replaced whenever the compressor is replaced, 1 Have the air cond itiOning system discharged (see Warfllng above). 2 Disconnect the negallve battery cable from the battery
3
3-28
Chapter 3
Cooling, heating and air conditioning systems until after Ihe system has been depressurized by a dealer service depart· ment or service station. Note: The accumulator (see SecllOn 24) orrece!verldn'er (see Seclion 25) should be replaced whenever the condenser IS replaced.
1979 through 1981 models (receiver/drier system) Reier to il/ustralion 23,5 Have the air condillon lng system discharged (see Warning above). Remove the battery (see Chapter 5) 3 Remove the radiator grille (see Chapter 11). 4 Position the ambient cutoff link out of the way 5 Disconnect Ihe refngerant lines Irom the condenser (see illustration ). 6 Unbolt the condenser from the rad iator support and hft It oUl.together With the recelve r/dner. 7 Installation is the reverse 01 removal . If the new condenser does not mclude a receiver/drier. install one. Use new O'flngs, lubricated with air condi tioning refrigerant oil. at the condenser line htllngs and to mstall the new receiver/drier. 8 Take the vehicle back to the shop that discharged il. Have the air can· dltionlng system evacua ted. Charged and leak tested .
1
2
22.3
A
The air c onditioning compressor on a V6 model (other models similar) Elecmcal connecfor
B
Refngeran/ Ime connections
3 Disconnect the compressor clutch electrical connector (see illustrati on)
4
Remove the dnvebelt (see Chapter 1).
S Disconneclthe refrigerant hnes from the rear of the compressor. Plug the open fillings to prevent entry of dirt and moisture. On veh icles haVing
"spring lock." type couplings, slip the speCial tOol of the proper size oller the fitting. push the 1001 into the spring lock and pull the tubing out of the fitt ing (see illus tra tion s) 6 Unbolt Ihecompressorfrom the mounting brackets and hit II oul althe vehicle If a new compressor is being Installed, follow the directions With the 7 compressor regarding the draining of excess 011 prior 10 installation. 8 The clutch may have to be transferred from the onglnal to the new compressor. 9 Installallon is the reverse of removal. Replace all O·rings With new ones specifically made for alrcondlhOnlng system use and lubricate them With refrigerant oil. 10 Have the system evacuated, recharged and leak. tested by the shop that discharged It
23
Air conditi oning system condenser - removal and i n stallation
Warning : The air condilloning system IS under tllgh pressure. DO NOT disassemble any part or/he system (hoses. compressor, line frf/lngs, etc.)
22.5a Slip the proper size tool over the fitting with th e tang facing the spring lock, ..•
22.Sb
1982 and later models (accumulator system) Reier /0 Illus/ra/lon 23.12 Note: Whenever Ihe condenser IS replaced. Ihe accumulator/dner must be replaced also.
g
Have the air conditioning system discharged (see Warnmg above) . 10 Drain the radiator (see Chapter 1), 11 Remove the banery and its heat shield (see Chapter 5). 12 Disconnect the refrigerant lines from the condenser (see illustration ) The lines use spring -lock couplings , which reqUIre a speCial Ford tool lor conneclion an(! disconnection. 13 Detach the fan shroud and lay II back out 01 the way. 14 Disconnect the upper radiator hose. Remove the radiator retaining clamps and tilt the radiator back. 15 Remove both condenser moun ting screws and hit the conde nser out. 16 Cap or plug the condenser and line openmgs to ke ep out dirt and mOisture. 17 InstaliallOn IS the reverse at removal. Transfer the rubber isolators from the old condenser to the new one. Add one lIuld ounce 01 clean refrig· erant 01 1 to the condenser, 18 Take the vehicle back to the shoplhat discharged 11 Have the air can· dltlonlng system evacuate
. .. close the tool and push it in, _ ..
22.Sc
.•. then pull the line off
Chapter 3 Cooling, heating and air conditioning systems ~REW ~---------------------------'
BR "C ~ H
3-29
ASSV
IU ~P ["I
BRACKET .. ssv IL H. I
23.5
Air condilionlng condenser inslallatic.n details - 1979 through 1981 models
3
23.12
, 2
3 4
5
Air conditioning condenser Installation detalls-
1982 and laler models Condenser assembly U-nuts Scre ws Lower mounting bracket assembly Lower mounting
bracker assembly
6
7 8
Upper mounting bracket assemblies Aif conditiomng lag SLC clip
9
SLCcilp
B
Radiator support Refrigerant/me connec/lon Refrigerant Ime connection
C 0
o
3-30
Chapter 3
Cooling , heating and air conditioning systems 3
24
Air conditioning system accumulator - remo val a nd Installation
Reier /0 Illus/rallOn 24 3
Warning: The air conciitlOflJng system IS under hl{Jh pressure 00 NOT dlsassembleanypartofthesystem(hoses. compressor Ime flttmgs. etc} un/JI after the system has been depressurized by a dealer servICe deparr men! or servICe statIOn
1 2
Have the air condltlonmg system discharge
4 Disconnect the refrigerant hne tram the accumulator Use a back-up wrench to prevent twisting the tubing 5 Plug the open flnings to prevent entry of dirt and mOisture 6 loosen the holddown bracket pinch bolt and 11ft the accumulator oul. 7 If a new accumulator IS being Installed remove the Schrader valve and pour the all out Into a measunng cup. IlOtlng the amount Add fresh lefngelanl 01110 the new accumulator equal 10 lhe amount removed from the old Unll plus one ounce. 8 Instaitallon IS Ihe reverse of removal. 9 Take the veh icle back to the shop that discharged It. Have Ihe au con· ditloning system evacuated, charged and leak tested
25
24.3
Details 01 th e air conditioning accumulator
A
ElectrICal connector
B
Refrlfjer8nt Ime connectlOll
C
HokkJown bracket pmch bol/
Unplug the electrical connector from the pressure SWitch near the lOP
of the accumulator (see Illustration)
Air conditioning syslem receiver drier - removat and installation
Warning : The air condlliDmng system IS under high pressure DO NOT disassemble any partof lhe system (hoses. compressor. Ime fltlings. elc) un/!! after Ihe system has been depressuflzed by a dealer service depart· ment or servICe slatlOn I A receiver dner IS used on 19791hlOugh 1981 models 2 Have the an condl\lOntng system discharged (see Warning above). Remove the radlalor grille (see Chapter II). 3 4 POSition the ambient cutoff SWitch out 01 the way. 5 Disconnect the refrigeranliines Irom the rece iver/drie r (see Illustra· lion 23.5). 6 Remove the recelverldner anachlng screws and take II 011 the con· denser 7 Installallon IS Ihe reverse at removal 8 Takethevehlcteback tOlheshoplhat discharged II HavethealrcQfl' dl110nlng system evacuated. charged and leak lested
Chapter 4
Fuel and exhaust systems
Contents Air cleaner housing - removal and installation ..•. B Air tiller replacement . . . . . . . . . . . ......... See Chapter 1 Carburetor - diagnosIs, removal . overhaul and installation 10
Fuel hnes and linings - replacement . ......... . Fuel pressure rehef procedure (lueHnjected models) Fuel pump - check •.
Carburetor choke check. Central Fuellnjecllon (eFt) system -
Fuel pump - removal and mstallallon . ...••.. Fuel syslem check .,. Fuel lank - cleanmg and repair .•.. 6 Fuel tank - removal and mstallatlon 5 General Information ... Sequenllal Electronic Fuel Injection (SEFI) and Electronic Fuel Injection (EFI) systems - component replacement . 14 Throltle cable - replacement . . . . . . . . . . . . . . . . . 9 16 Turbocharger - removal and Installation Underhood hose check and replacement See Chapter 1
See Chapter'
component replacement 13 Electronic Fuel lnjeC!ion (EFI) system - component replacement (four-cyl inder engine) t5 Exhaust system check. See Chapter 1 Exhaust system servicing - general information . ........... 17 Fuel hlter replacemen t See Chapter 1 Fuel lnJec\lon systems - generalmformation 11 FuellnJ€cllon system - pressure check 12
Specifications
Fuel pressure Carbureled models Central FuellnlectlOn (CFI) . EFI and SEFI fuel-inject ion systems .
6108psl 14.5 pSI 301045 psi
Torque specifications
Ft-Ibs
Carburetor' lo-mtake manifold nulslbolls Model 5200/6500 Model YFA IV Model 2150 2V Model 7200 -VV Model 4180-C4V Mechanica l fuel pump-to -block boilS 2.3l lour-cylinder 3.3l six -cy linder 2.8l V6
VB
10 to 14 13 to 14 14 to 16 12 1015 141020 14to 12 to 12 to 19 to
21 18 15 27
Fuel chargmg assembly·to-mtake manifold nuts (CFI-eqUipped models) 1984 and 1985 10 1986 12 to 15
3 2 4 7 See Chapter t
4
4-2
Chapter 4
Fuel and exhaust systems
Torque specifications (continued)
Ft·lbs
va engines with SEFI UpPer intake manifold·le·lower intak e manifold bolts
'987 1988 on Lower Intake manlfold·to-cylinder head bolts Air Intake throttle body mounllng nuts ..
Fuel rail bolls
t5 t022 t210 18 231025 t2to 18 70 to 105 In· lbs
Four-cylinder engines with EFI Lower intake manifold mounllng bolts 1984 al'ld 1985
121015 141021 15 to 22
1986 1987 on Fuel supply manifold mounting bolts 1984 and 1985 1986aJ'ld 1987
12 to 15 151022 141021 15 t022
1988 on UpPer Intake maniloJcHo· lower imake manifold bolts
Turbocharger Carbureted engines Compressor houSing bolts Turbine houSing botts ••.
145 to 165 In· lbs 164 to 18tln·lbs 164to 1811n·lbs
Outlet elbow and waslegale assembly boilS EFI engines E~hausl ptpe-Ie-exhaust manifold bolts . Tul1Jocharger-Io·exhaust manifold nuts .. Outlet elbow-Io-turbocharger hoUSing •...
251035 28 to 40 141015
General information
Fuel system The fuel system conSists of the fuel lank. the luef pump. an air cleaner assembly. either a carburetor or a fuel injection system and Ihe vanous steel. plastic and/or nylon lines and finings connecting everything logelh·
..
"
Models covered by thiS manual are eqUipped with one of four general types olluel systems. carburelor; Central FuellnjecliOn (CF I); Bosch/Ford Eledroruc Fuel tnlectlon (EFt); and SequentlaJ ElectronIC Fuel InjeCtIOn (SEFt). To identily the system whICh applies 10 your vehICle . refer to Sec· tions 8, 10. 11 and 13 The luel pump on carburetor equipped models IS a mechanical t~pe mounted on the engine block and driven off the camshaft. Early luel' In' jected models have a Iow·pressure pump mounted Inside the fuel tank and a high pressure pump mounled on the chassIs. In tater years . fuel·lnJected models have only a Single hlgh.pressure pump Installed InSide the fuel tank The turbocharger used on some early lour ·cyllnder engines IS a draw' through type whICh pulls air and luel through a one·barrel carburetor The laler turbocharger blows air into an electronic fuel )nJectlon system. The turbocharger used With Ihe Mustang SVO Includes an Intercooler and boosl control system.
Exhaust system All models are eqUipped with one (lour and Inllne slx·cyllnder ) or two (V6 and V8) exhaust manllolds, a catalybc convener, an exhaust pipe and a mullier. Any component of the exhaust system can be replaced See Chapter 6 for further delalls regarding the catalytiC converter.
2
Fuel pressure reliel procedure (luel·lnJected models)
R.r.r /0 rlluslr3/1OfI2
,
The fuel pump SWitCh - sometimes called lhe "Inertia sWltch- - which 1 shuts 011 luet to the engine In the evenl of a ColliSion. aHords a Simple and convenient means by which fuel pressure can be relieved belore servicing
L
J
l'iI SPARE TIR E
WE l l
2.1 On most models, the luel pump switch assembly Is tocated in the luggage compartment - the reset button (arrow) must be pushed In 10 reactivate the switch /pump
luel lnJectlon components. The SWitch IS located In the luggage compart· ment. In a vallety 01locations (see lIIustration) and IS usually covered by Ihe carpet which comes up the Sides 01the trunk In some cases the wifing Irom the luel pump to the luel pump SWitch can be traced 10 M lp locate Ihe swi tch . 2 Unplug Ihe inertia switch electncal connector 3 Slartthe engine and allow II torun until It SlOpS Th lsshould take only a lew seconds 4 Thetuel system pressure IS now relieved When yourefl mshed work Ing on the luet system. Simply plug the electrICal connector back Into the SWitch and push the reset button on th e lOP 01 the SWitch (see Illustration 2.1).
4-3
Chapter 4 Fuel and exhaust systems
[}-c",, __
•
" 0" RINCiS
800Y
SPACERS
/
3.S An exploded view of the hairpin clip type push
PU SH UNTIL
CLICK IS HEARO
connect litting
,
Fuel lines and liltings - replacement
••
Refer to II/ustratlons 3.5, 3.9. 3. 10. 3. 13,3. 14 and 3.26 Warning: The fuel system pressure must be relIeved before dlsconnect-
mg fuel/ines and f!ttmgs on fuel-injected models (see Section 2). Gasolme IS extremely flammable, so exIra precautions must be taken when workmg on any part of the fuel system, DO NOT smoke or allow open flames or bare light bulbs near the worK area . Also, don "' work In a garage where a
3.9
Reassembling push connect fitUngs
natural gas appliance such as a water healer orelo/hes dryer is present
Push connect fittings - disassembly and reassembly Ford uses two differenl push connect fi tting designs. Fittings used wi,h 3/8 and 5/16-inch diameter lines have a "hairpin" type clip: finlngs used wi th 1/4-lnch diameter lines have a "duck bill" type clip. The proce· dure used for releaSing each type of fitting IsdlHerent. The clips should be replaced whenever a connector is disassembled. 2 Disconnect all push connect fittings from fuel system components such as the fuel filter, the carburetor/fuel charging assembly. the fuel tank. etc_ before removing the assembly.
3/8 and 5/16-inch fittings (hairpin Clip) 3 Inspect the Internal portion 01the fitting for accumulations 01 dirt. If more than a light coating 01 dust IS present, clean the lining before disassembly. 4 Some adheSion between the seals In the fining and the line Will occur over a peflod 01 lime. Twist the li!ting on the line, then push and pull the litllng unlilit moves freely. 5 Remove the hairpin clip Irom the fitting by bending the shipping tab down unlil it clears the body (see illustration). Then, uSing nothing but your hands, spread each leg about 1/8-lnch to disengage Ihe body and push the legs Ihrough the flltlng. Finally, pull lightly on the tflangularend of Ihe clip and work II clear of the line and fitting . Remember, don't use any tools to perform this part of the procedure. 6 Grasp the fitting and hose and pull It straight oH the line. 7 Do not reuse the original clip in the lilling. A new clip must be used.
8 Before reinstalling the fitting on the line, Wipe the line end With a clean cloth. Inspect the Inside of the filling to ensure that it's free of dirt andlor obstructions. 9 To reinstall the fitting on the line, alrgn them and push the lining IntO place. Whenthefitl ing is engaged. a definite click will be heard. Pull on the filling 10 ensure that It'S completely engaged (see illustration). To install Ihe new clip, insert It inlo any two adjacent openings in the fitting with the triangular portion of the clip poinllng away trom the fitting opening. Using your Index finger, push Ihe clip In unlillhe legs are locked on theoulsideot the filling .
1/4-inch fittings (duck bill clip) 10 The duck bill clip type fitt ing conSists 01a body, spacers, O'nrlgs and the retaining clip (see illustration). The clip holds Ihe titling securely in place on Ihe line. One ol lhe two follOWing methods must be used to disconnect this type of 111Iing. 11 Before attempting to disconnect lhe titung, check Ihe visible inlernal portion of the fi tting for accumulations 01 dirt. II more than a Irght coallng 01 dust is eVident. clean the litting belore disassembly. 12 SomeadhesionbelweenthesealSlnlhefilllngandlrnewilioccurover a penod ol time. Twislthe fitting on the line, then push and pull the fitting unllll! moves freely. t3 The preferred method used 10 disconneclthe Irtting requires a specIal tool. Todisengage the line Iromlhefitting, alrgntheslolln Ihe pushconnecl disassembly tool (Ford Part No. T82l -9500-AH or equivalent 1001) With ei ther tab on the clrp (90·degrees from the slots on the Side of the tittlng) and lrtsert the tool (see illustration). This disengages the duck bill from the
3.13 3.10
A push connect fitting with a duck bill clip
Duck bill Clip tltlfng disassembly using the specIal Ford 1001
4-4
Chapter 4
Fuel and exhaust systems 4
Fuel pump - ch eck
Mechanical fuel pump (carburetor equipped models) If a probfem occurs In the fuel pumpltsell. It will normally either delIVer no fuel at all or not enough to sustain high engine speeds or loads 2 When an engine develops a lean (tuel starved) condllion. the tuel pump IS otten to blame, bulthe same symptoms Will be eVident lIthe carburetor float bowl hiler IS clogged A lean condition Will also occur 1/ the carburetor IS malfunctlomng, the fuel lines and hoses are leaking, kinked or resTficted or the electrical SySTem IS shorting OUT or malfunctioning
3. 14
Pulling 0 11 Ine duck bill clip type pus h connec t filling
line Note: Some fuel/mes have a secondary bead which aligns with the Qu/ersurface of Ihe clip The bead can make 1001 msemon dlfflcull If nec·
.essary. use Ihe allematlve disassembly method descflbed In Slep 16 14
Holdlnglhe 1001 and Ihe line with one hand, puillhe lilling ott (see 11-
luslrat ion ). Note: Only madera/eeffort/s necessary" lhec/Jplsproper/y drsengaged The use of anything olher than your hands should not be f8
qUlred. 15 Alterdlsassembly,lnspec\ and clean the line seahng surface Also Inspectlhe inSide ollhe Iilling and Ihe hne lor any Internal pans thaI may have been dislodged from the lining Any loose internal parls should be Immediately remstalled (use Ihe line to Insertlhe parts), 16 The alternative disassembly procedure reqUires a pair of small adJustable pliers. The pliers must have a jaw WidTh of 3 16-lnch or less 17 Align Ihe Jaws 01 the pliers Wllh Ihe openings In The Side 01 Ihe liUlng and compress the portIOn of the retaining clip that engages the body ThiS disengages the retaining clip from the body (of len one side 01 the CtlP Will disengage betore the other - both sides must be disengaged) 18 Pull the fitting off the tine_ Note: Only moderate ef/or/ls required If the re/ammgcl!p has been properly disengaged Do nOI use any /ools for thiS procedure 19 Once the lining IS removed from the line end. check ThefllTlng and line for any Internal parts that may have been dislodged from the l ining. Any loOse internal pans should be Immediately reinstalled (use the line to insert the parts). 20 The relamlng clip Wilt remain on the hne. Disengage the clip from the hne bead TO remove it. Do not reuse the retaining clip - Install a new onel 21 Before reinstalling the littlng. Wipe the line end With a ctean ctoth Check the inside of the lilting to make sure that it's free of d irt and/o r obstructions 22 To reinstaillhe littlng, align II wllh the hne and push II Into place When the lilting IS engaged, a dellmte click will be heard. Pull on the fitllng 10 ensure that ItS fully engaged 23 Instalilhe new replacement clip by Insenlng one of the serrated edges on The duck bill portion Into one of the openings Push on the other side until the clip snaps Into place.
Spring lock couplings - disassembly snd reassembly 24 The fuet supply and return lines used on EFt engines utilize spring lock couplings at the engine fuet rail end Instead 01 plastiC push connect IIlImgs. The male end 01 the Spring lock COUpling. which IS girded by two O-MgS, IS Insened mto a lemale flared end engine filling The coupling IS secured by a garter spring which prevents disengagement by gripping the flared end of the female lilling On later models, a cup-tether assembly provides additional securlly 25 To disconnect the 112-lnch (12.7mm) spring lock coupling supply flltlng. you Will need to obtain a SPring lock COIJphng 1001 D871-9280·B or ItS eqUIValent, for the 318-lnch (952mm) return finmg, get Tool D87L-9280-A or ItS eqUivalent 26 Study the accompanying Illustrations caletully before detachmg either sprmg lock coupling IIl1ing (see illustration) ,
General check 3 If the fuel pump IS noisy a) Check lor loose fuel pump mounting bolTS and,ll necessary, lighTen them 10 the specified torque. Replace the gasket I! necessary b) Check for loose or mlssmgluel line mounTIng clips Loose or miSSIng clips Will sound louder when you are SlUing InSide the vehicle than when Slandlng outSide 01 it Tighten the clips on the fuel lines If necessary c) Check tor a worn, or slicking fuel pump pushrod 4 Before assuming a fuel pump IS deleetJVe a) 8e sure the Tan).. has luelln IT b) Be sure the fuel hlter IS not plugged 1111 hasn't been changed recently. mstall a new one c) Inspect all rubber hoses from the fuel pump to Ihe luel tank forklnks and cracks With the engine Idling. check all fuel lines and rubber hoses and connections from the luel pump to the fuel lank tor fuel leaks. Tighten any loose connecTions and replace kinked , cracked or leaking luellmes or hoses as reqUired Leaking or kinked lines or hoses Will severely affecl fuel pump performance d) Inspect the fuel pump mlet and outleT connechons tor fuel leaks, Tighten them It necessary e) Inspect the fuel pump diaphragm cnmp (the area where The stamped steel seeMn IS attached to Ihe cas!lng) and the breather hole{s) in the casting for eVidence 01 fuel or oil leakage Replace the pump It It'S leaking.
Output (capacity) test Warning : GasolmfJ IS extremely flammaO/e SO extra precautlOflS mus/ be taken when workmg on anyparT 01 Ihe luelsystem DO NOT smoke or allow open flames or bare light bulbs In or near the work area Also. doni work m a garage If a natural gas appliance such as a waler healer or clo/hes dryer IS present. 5 Remove the air cleaner assembly (see SecMn 8). 6 Carefully disconnecT the fuef line althe luelfiller Inlel (see Chapter I ). 7 Anach a sectIOn of rubber fuel hose 10 the end 01 the disconnected line WIth hose clamps and route the end 01 the hose Into an approved gasoline ec;ntalner(1 12-lIteror I PInt minimum) Note: Itmaybenecessaryroarrach a sectIon of hose to Ihed,sconnected fuel Ime m order 10 reach theconlamet Disconneclthe high tension wire lrom the Call and ground It on the en· glne With a jumper wire Crank the engine over about 10 revolutions The fuel pump should deliver at least 1/3-pln t of fuel 8 If the outpullS adequate, pertorm Ihe pressure lest below 9 If Ihe output IS less than speclhed repeat The leST With a remole tuel supply. Detach the hose from the fuel pump Intetllne and al1ach a separate section ol fuel hose to the tme wllh a hose clamp Route the end 01 the hose inTO The lemote fuel supply (an approved gasohne contamer alleast half lull ofluel) and repeat The procedure m Step 7 If the output Is now as specifled. the problem IS either a plugged in-tank filTer or a kinked or leaking fuel hose. Make the necessary repalrs_
Pressure test 10 Connect a fuel pressu:e gauge (0 to IS pSI) to the fuel filter end of The
"00 II Start the engine -It should be able to run lor over 30 seconds on the fuel m the carburetor bowl - and lead the pies sure aller len seconds Compare your reading \0 the specified pressure,
Chapter 4
REMCNE CUP
~
USE SPECIFIED
4-5
Fuel and exhaust systems
•
COUPUNO
use
,"EC
TOOL:
HXX. OR
f.~~
EOUIVALENT
De7L·928I:).A - 318 INCH D87L-i280-8 -
112 INCH
C'GE
CLEAN FfTTlNGS WITH SOlVENt CHECK FOR MISSM) OR D.AAtAGEO ().RINGS. RE~ MISSNl O-RINGs. F EITHER ().RN] IS DAMAGED. REPUCE 80rH Q.RINGS.
OPENING
so
FIT TOOl TO COUPliNG THAT TOOL CAN ENTER CAGE OPENING TO RELEASE THE GARTER SPRING .
•
PUSH TOOL INTO CAGe OPENING
NOTE : SPECFEO lOOt.. WIll FIT AAOUNO RU88EA COVERED FUEL LINE. PUSH THE TOOL INTO THE CAGE OPENING TO RELEASE THE FEMALE FITTING FRDM THE GARTER SPRING
GAATER SPRING
•
TO ENSURE COUPUNO ENGAGEMENt; PULL ON flT'TlNG AND VISl.IM.lY CHECK TO BE sum: GARTER $MINGo IS ewER FlAR'EO END Of
FEMAlE FITTING
UN'
PULL THE COUPLING MALE AND FEMALE FlnlNOS
APART
REMOVe THE TOOL fROM THE DISCONNECTED SPAINO lOCI( COOP\..ING
3.26
o
•
YES
Connecting and disconnecting spring lock coupling fittings -later models use a tethered clip to secure the lines
4
4-6
Chapter 4
Fuel and exhaust systems
2 AEQ' O
2 REQ'O
,,,.," 5.5 Typicalluel tank and littings
12 II pump pressure IS not as specified Install a new fuel pump irefer to Seellon 7). 13 Reconnect the luell!nes and Install the all cleaner
Electric fuel pump 14 An electric fuel pump malfunction wi ll usually result
In
a loss olluel
flow andior pressure lhat is often reilecl ed by a corresponding drop In per, formance II you suspect an electric fuel pump problem, disconnecl the Wife harness from the pump(s) (sea Section 7), attach a fused jumper be tween the battery and the pump and carefully hslen to the pump It II 5 not running replace It 1111 IS funning. then the problem lies Within Ihe tuel pumpClfcult Of elsewhere (see Troubleshootmg) DiagnoSiS 01 thiS CirCUIt IS beyond the scope at the home mechaniC. Take the vehICle to a dealer and have the fuel pump CirCUit checked by a profeSSional.
5
Fuel tank - removal and Installallon
Refer /0 Illus/ra/ion 5.5 Nole: Don't begin /hls procedure unttl/he gauge Indreates that the tank IS emptyornearlyempty If the lank must be removedwheMts full (forexampie, If the fuel pump malfunctions). Siphon any remaining fuel from Ihe lank PfJor Iv removal. Warning : Gasoline IS ex/remely flammable so extra precautions mus/be laken when working on any part of the fuel system. DO NOT smoke oral low open flames or bare light bulbs In or near the work area Also. don t work In a garage II a na/ural gas appliance such as a waler heater or clo/hes dryer is present I On luel-lnJected modets. relieve the fuel pressure (refer IOSectlOn 2) 2 Detach the cable from the negallve termmal of the battery 3 Raise the vehicle and support It securely on jacks tands.
4 Unless the vehICle has been dnven tar tlnough to completely empty the tank_ It s a good Idea to Siphon the resldu ... , tuel out belore removing the tank Irom the vehICle Siphon Of pump the fuel out through the luel hiler pipe On US mOdels a small diameter hose may be necessary because of the smalluap door Installed m the fuel hlier pipe to prevent vapors from escaping dUfing refueling luel-Injected models have reservOirs InSide the l ank to maintain luel near Ihe pump pickup dUring vehicle cornenng rna· neuvers and when the fuel level IS low The reservOirs could preven t SIphon tubes or hoses from reaching the bottom 01 the luel tank ThiS Situation can be overcome by repositioning the Siphon hose several limes, 5 Remove the hiler neck bracket bolt secunng the luel filier neck and the breather hose to the lueltank (see iIIustrallon) 6 If poSSible disconnect the luel and vapor hnes (on some models. the fittings ale on lOp of the tank and cannot be reached until the tank IS partially lowered) 7 Remove the electriC fuel pump (If equipped) and sending unu wife harness clips With a screwdflver The harness connector IS on top 01 the tank and inaccessible. Since no intermediate connection point IS provided the harness cannot be disconnected trom the luel sender until the tank IS par\lally lowered B Place a lloor lack under the tank and poSition a block 01 woOd between the lack pad and the tank Raise the jack unlilils sUPPOl1lng the tank 9 Remove the bolts or nuts tram the Iront ends 01 the fuel tank straps (see Illustration 5.5). The straps are hinged at the other end so you can sWing them out 01the way 10 lower the tank tar enough to unplug the wifing harness 11 Slowly lower the Jack while steadYing the tank Remove the lank from • the vehICle t2 II you fe replac
Chapter 4
7.1 When disconnecting a melatluel Une from Ihe pump, use a flare nul
wrench and a backup wrench 10 prevent damage
7.6 When installing Ihe fuel pump, apply white grease to the rocker arm ; use RTV sealant to hold Ihe gasket in place
14 Installation IS the reverse of removal SAE 10W-40 engme 011 can be used as an assembly aid when pushing Ihe luel filler neck back Into Ihe tank
6
Fuel tank - cleaning and repair
Repairs to Ihe lueltank ottilier neck should be performed by a profesSional with the proper training to carry oul this critical and pot entlall~ dan· gerous work. Even after cleaning and flushing, explOSive fumes can remain and could explode dUring repair of the tank, 2 11 the luel tank IS removed Irom the vehicle, it should not be placed In an area where sparks or open flames could IgOlle the fumes coming out of the tank, Warning: Be especially careful mSlde a garage where a nalural gas appliance IS located because Ihe pilot lighl could cause an explos,on'
7
4-7
Fuel and exhaust systems
Fuel pump - remova l and installation
Warni ng : Gasolme is extremely flammable so extra precautions must be taken when workmg on any part of the fuel system, DO NOT smoke or al· low open flames or bare light bulbs In or near the work area. Also. don't work m a garage If a natural gas appliance such as a water heater or clothes dryer IS present
7.12
Be sure to use a brass punch or
wood dowel when loosening the lock ring on the electric fuel pump/sending
unit (8 spark Irom a steel punch or hammer could cause an ellplosion!) 6 Insert the bolts through the pump (to use as a guides forthe new gas· ket) and place the gasket 10 poSition on the luel pump mounting flange (use RTV sealant to hold the gasket in place). Position the fuel pump on the block (make sure the pump arm engages the camshaft properly) (see illustration). Tighten the bolts a lillie at a IJme until they 're at the specified torque 7 Attach the luellines to the pump. Start the threaded filling by hand to avoldcross·threadrng It. Tighten the outlet nut securely. 11 any at the hoses are cracked, hardened or otherwise deteriorated, replace them al thiS time, S Start the engine and check for tuelleaks for two minutes 9 Stop the engrne and cheel<. the luellrne connections for leaks by run· ning a linger under each fitting . Check foroilleaks atthe luel pump mount· 109 gasket
Electric in-tank fuel pump (fuel-injected models) Refer to Illus/rations 712 and 7.15 to Relieve the luel system pressure (reler to Section 2). 11 Remove the lue! lank (reler 10 Section 5), 12 USing a brass punch or wood dowel only, tap the lock flng counter· clockW ise until It'S loose (see Illustration) . t3 Carefull~ pull the fuel pumpJsendlng unll assembly from the tank t4 Remove the old lock ring gasket and discard It. 15 If you 're planning to reinstall the original fuel pump/sending unll. reo move the strarner b~ prying It off wilh a screwdflver (see Illustration).
Mechanical fuel pump (carburetor equipped models) Refer 10 Illustralions 7. 1 and 7. 6 1 Loosen the threaded fuel hne fittings (at the pump) with the proper size wrench (a flare nut wrench is recommended), then retighten them un· tll t he~'re lust snug (see illustration) Don-t remove the lines at thiS time The outlet hne IS pressurized, so protect ~our eyes With salet ~ goggles or wrap the fitting With a shop rag . then loosen It carefull~. 2 Loosen the mounting bolts !WO turns. Use ~our hands to loosen the fuel pump if ifs stuck to the block (do not use a tool- you cou Id damage the pump). 11 you cannot loosen the pump by hand, have an assistant operate th e starter while you keep one hand on the pump As the camshal t turns, It Witt operate the pump - when the pump leels loose, stop turnrng the engrne over. 3 Disconnect the fuel hnes from the pump Be sure to use a backup wrench , 4 Remove the fuel pump bolts and detach the pump and gasket D,s, card the old gasket 5 Remove all old gasket matenal and sealant from the engrne block. If YOU're Installing the original pump, remove all the old gasket material from the pump mating surface as well. Wipe the mating surfaces altha block and pump With a clolh saturated With lacquer thinner or acetone .
7. 15 If you 're replacing lhe pump, this step isn't necessary, but if you 're going to rein stall the old pump, remove the strainer and clea n II with sorvent
4
4-8
Chapter 4
Fuel and exhaust systems
'~""'O'Yt:_
..
....*-"" ...... ......... ' .... ~LL . ..
~~:<'-"""""
...
... ,
." 8.2 An exploded view 01 a typical air cleaner assembl y l o r a VB engine equipped wi1h a carburetor or Central Fuellnjeclion (CFI)
wash I. In clean solvent. Ihen push It back onto Ihe meta) PIpe on the end 01 Ihe pump If you're 1051all1l'l9 a new pump'sencllng uM. Ihe assembly WIll Include a new strainer , 6 Clean Ihe luel pump mounting flange and the lank mounting surface and seal flng groove t 7 Installalion IS Iha reverse of removal. Apply a thin coat 01 heavy grease to Ihe new lock ring gasket to hold ,1 m place during assembly
Electric chassis-mount fuel pump (fuel·injected models) 18 Oepressunze the luel system as OUlhned In Seellon 2 and false the vehICle With a hOlsl 19 Disconnecilhe electrical connectors from Ihe body harness and re· move the Intet and ouUet lines from the fuel pump 20 The tue l pump may now be removed !rom the assembly by bending the tab out and slidmO the pump out ollhe retaining rmg. 21 Remove the electncal wifing harness from the assembly by msertmg a SClewdriver or knife between the connector and relamlng clip and sliding the connector towards tile pump Inlel 22 When Installing. make sure the finll"lgs on the pump have gaskets In place, that the gaskets are properly positioned and thallhe fi nlngs have been tightened properly. 23 Check the wIfing harness boots tomak e sure th ey are pushed Inlothe pump termlnals/ar enough to seal and check Ihallhe wire terminals are pushed onto the pump lerminals all the way 24 Wrap the fuel pump retalnll)g flng around the fuel pump locate the slot In the nng so Ihal iltaces the bracket base and push the pump and rtng assembly Into the bracket Make sure the lab on the flng contacts the tab of the bracket and that the bracket tabs do not conl acl the pump case When the pump IS Inserted into the bracket as lar as possible and the Wifing har
ness comes out the bottom of the flng. bend the rear tab to prevenllhe pump Irom shdlng out 25 Connectthelueilines tothe pump assembly. then anach the eleclrlcol harness connector to the body electncal connector 26 Start the vehiCle. check lor properopera1lOn of the pump and look for leaks.
•
Air cleaner housing - removal and Installation
Carburetor and CFt equipped models Reier /0 Il/us/rarlOn 8 2 Note: Thealfcleaner housmg assemblies used WIth carburetors and CFI are baSIcally Similar. t Detach the cable from th e negative terminal of the ballery 2 Delach the fresh air Inlet tube from the mouth of the air cleaner hous· Ing assembly snorkel (see illustration) 3 Clearly label and detach all vacuum hoses. lines and elec1f1cal connectors as necessary from the air cleaner hOUSing assembly 4 Remove the wing nut and grommet (II eqUipped) Irom the air cleaner hOUSing and remove the cover 5 Removethe alfcieanerliiter element Inspect It for Signs oldus t ordlrt leaking throug h holes in the IIl1er matenal or past the end seals (see Chap· ter 1). 6 lift the alf cleaner houslOg assembly of! 7 Instaltallon ISlhe reverse 01 removal
EFI and SEFI equipped models Nole: Because the arrc/eaner housmg assemblIes on EFI and SEF/ fuel systems are vlfTually IdentIcal, the followmg procedure applIes /0 both 01
Chapter 4
Fuel and exhaust systems
9.2 A typicallhrottJe cable/accelerator pedal installalion -10 separate the cable from the pedal, pull back on the cable while pushing forward on the upper end 01 the pedal, then Ii" the cable up and out of the slot in the pedal arm them. However, 1/ IS a general gUldelme and small bur Inslgmflcant differ· ences may be noted
VB engine 8 9 tion 10
Detach the cable from the negallve terminal at the battery. Olsconnect the air oullellube lrom the air cleaner assembly (see Sec16 In Chapter 1) Unclip\he upper half of the 81rcleaner housing assembly and remove
""
Remove the air cleaner hiler element 12 Remove the air cleaner hOUSing assembly mounting nuts and detach the assembly. 13 II you Wish to remove or replace the resonator (which IS located on the olher Side of the fender apron), Simply remove tlle mounting nuts and delach it 14 Installation IS the reverse of removal
Four-cylinder engine t S Detach the cable from the negati ve terminal of the battery 16 Remove the wing nut Irom the air cleaner hOUSing cover (see Sec · \Ion t 6 in Chapter I) 17 Remove Ihe air cleaner cover and the hlter element. 18 Remove the air cleaner housmg assembly mounting screws from the floor 01 the assembly 19 Slightty ra ise the housing assembly, loosen the hose clamp and remove the air cleaner outlet tube which connects to the vane air meter (elecllonlc air control sensor ). 20 Remove the air cleaner hOUSing assembly 21 Installation is the reverse 01 removal
9
Throttle cabte - replacement
Refer to illustrations 9.2 and 9.3 1 Remove the air intake duct and air cleaner hOUSing assembly (see Section 8). If necessary 2 Detach the cable snap-In nylon bushmg from the accelerator pedal arm (see illustration) 3 Remove the cable housmg Irom the hrewall by removmg the two bolls (see illustration) Detach the cab le from the bracket on the engine. 4 S Detach the throttle cable and, If equipped. cruise control cable assemblyirom the throttle leverby Inserting a screwdnverbetween the cable assembly and the throtl1e lever and tWIS\lng the screwdriver
9.3
4-9
To detach the throttle cable from the firewall , simply remove Ihe two bolls
6 Separate the cruise control cable (it eqUipped) trom the accelera tor cable by removing the clip attachmg them . 7 Installation IS the reverse of removal
10
Carburetor - diagnosis. removal , overhaul and installation
Warning : Gasolinels extremely flammable. so extra precaullons mustbe taken when workmg on any part Of the fuel system DO NOT smoke or allow open flames or bare light bulbs m or near the work area. Also. don't work m a garage If a natural gas appliance such as a water heater or clothes dryer IS present.
Diagnosis A thorough road test and check of carburetor adjustments should be done belore any major carburetor service work. Specilicalions for some adjustments are listed on the Vehicle Emissions Controllnlormation label lound In the engine compartment. 2 Some performance complaints directed at the carburetor are actually a resu lt of loose, out-ol-adjustment or ma)/unctlonlng engine or electrical components. Others develop when vacuum hoses leak. are disconnected or are Incorrectly routed . The proper approach to analyZing carburetor problems should include a routine check of the follOWing Items a) Inspect all vacuum hoses and actuators for leaks and correct IOstal· latlon (see Chapter 6). b) Tighten the Intake manifold nuts/boils and carburetor mounting nuts evenly and securely c ) Perform a cylinder compression test (see Chapter 2) . d) Clean or replace the spark plugs as necessary. e) Check the spark pfug Wires , t) Inspect the Ignition primary wires and check the vacuum advance operallon. Replace any defective parts. g) Check the IgOillon timing according to the instructions prrnted on the EmiSSions ContrOl InformatIOn label. h) Check the tuel pump pressure. i) Check the heat control valve 10 the air cleaner lor properoperatlon (see Chapter 6). j) Check/replace the air lilter element. k) Check the PCV system (see Chapter 6). 3 Carburetor problems usually show up as Ilooding. hard starling. stall109. severe backhring, poor acceleration and lack 01 response to Idle mi~ ture screw adjustmen ts. A carburetor that is leaking tuel andror covered With wet looking depoSits definitely needs attention. <1 Diagnosing carburetor problems may reqUire that the engine be starled and run wi th the alf cleaner ot!. While running the engme Without the alf cleaner. backfires are poSSible. This sltualion IS likely to occur II the carburetor is malfuncllonlng. but Just the removal oj the air cleaner can
4
4 - 10
Chapter 4 Fuel and exhaust systems
lean the lueValf miKture enough 10 produce an enoglne backfire. Warning : Do not poSI/lOn any part of your body. especially your face, directly over/he carburetor during inspection and servicing procedures!
Removal 5 Remove the air cleaner houSing assembly (see SecllOn 8). 6 D.seonnecllOe INotlie cable trom the thronle lever (see Section 9). 7 II your vehICle IS eqUipped with an aulomatlC transmiSSIOn. disconnect the TV rod from the throt1le lever (see Chapter 7) . 8 Nole : To slmpidy Ins/allallon. /abel all vacuum hoses and IINmgs befor8 removmg them. Disconnect all vacuum hoses and the fuellme from
the carburetor. Use a backup wrench on the fuel inlet fitting when removmg the fuellme /0 avor(} changing the floa/level. 9 Labellhe wires aootermmals, then unplug all wire harness connec· tors al the carburetor 10 Remolle the mounting nuts and detach the carburetor from the intake mamlold. Remolle the carburetor mounting gasket and, if eqUipped. spacer. Place a rag inside the Intake manllold callity to prellenl dirt and debris Irom laliing down Inlo the engine while the carburetor is remOlled
Overhaul II Once It'S determined that the carburetor needs adjuslmentor an Ollerhaut. selleral OptlOilS are allallable. II YOO 're going to attempt to OIIerhaul the carburetor yourself. first obtain a good qualify carburetor rebuild kit (which wlll lflClude all necessary gaskets. Internal parts, InstructIOns and a pans list)_ You'lI also need some speaal solllent and a means of bloWing OUt the Interflal passages of the carooretor with air 12 Becausecarburetordeslgns are constanUy modllied by the manu fac· turerln orderto meet Increasingly more stflngenl emissions regulations. it Isn't feasible lor us to do a step-by·step ollerhaul 01 each type. You'lI re ceille a detailed. well Illustrated set 01 InstruC!Jons with any carburetor ollerhaul kit: lhey Will apply In a more speohc manner to the carburetor on your lIehlCle 13 Another alternatille IS to obtain a new or rebuilt carburetor. They are readily allallable Irom dealers and auto parts stores Make absolutely sure the exchange carburetor IS Identical to the original A tag is usually at tached to the tOP of the carooretor. 11 will aid In determining the exact type olcarburetoryou halle. When obtaining a rebUilt carburetor or a rebUild kil. take time to make sure that the kit or carburetor matches your application exactly_ Seemingly InSlgnlllcant dilterences can make a large dll1erence In the performance of your engine 14 It yoo choose to ollerhaul your own carburetor. allow enough tllT'P.IO disassemble the carburetor carefully. soak the necessary parts In the cleaning soillent (usually for alleast one·hall day or according to the In' struC\lOns listed on the carburetor cleaner) and reassemble It, which Will usually take much longer than disassembly. When disassembling the car· buretor, match each part with the Illustration in the carburetor kit and lay the parlS out In order on a clean worll. surface. OIIerhauls by inexpeflenced mechanICS can result In an engine whICh runs poorly or not al all. To allold thiS, use care and pahence when dlsassembllf"lg the carburetor so you can reassemble It correctly
Installation 15 Clean the gasket mating surfaces of the Intake manifold and the car· buretor to remolle all traces 01 the old gasket Remolle the rag from the manifold Place the spacer, II eqUiPped, and a new gasket on the Intake manltold Posllton the carburetor on the gasket and spacer and install the moontlng nuls. To prellent dlstonlon or damage to the carburetor body lIange. lighten the nuts to the specified torque In selleral steps. t6 The remaining installation steps are the rellerse of remollat.
11
Fuel injection systems - generallntormatlon
Central Fuel Injection (CFI) system The Central Fuellnj8cllOn (eFt) system IS a Single point, pulse lime modulated In/ftCtlOn system Fuel IS metered Into the all Intake stream In accordance with engtne demands by two solenoid infection lIallles mounted In a throllie body on the Intake manifold Fuel IS supplied from the luel tank by a low pressure, electric fuel pump
mounted in lhe lueltank. The fuel is filtered and sent to the al! throUie body, where a regulator malntatns Ihe luel dellllery pressure at a nominal lIalue of 14.5 psi . A pair 01 Injector nozzles are mounled lIertically abolle the thro\t!e plates and connected in senes with the fuel pressure regulator Excess tuel supplied by the pump but not needed by the engine IS returned to the fuel tank by a steel fuel return tine. The luel cllargu'IQ assembly conSistS ot hlle Indillidual components whICh perform the fuel and air melenng lunctlOn . The throllie body assembly IS attached to the conllentlonal carburetor mounting pad on the tnlake manifold and houses the al! control system. luel injector nozzle, fuel pres· sure regulator,luel pressure diagnOS!lC lIallle, cold engine speed control and throUie poSition sensor. Air flow 10 the engine is controlled by a single bullerfly lIallle mounted In a two piece. dle·cast aluminum hooslng called a throttle body. The butterfly lIallle is identICal In configuration to Ihe Ihrottle plates of a conllenIlonal carburetor and IS acluated by a Similar pedal and Itnkdge arrangement The fuel tnJeclor nozzle IS mounted lIenlcally abolle the thronle plate and IS an electro· mechanical dell Ice which meters and atomizes the lue! dellllered to the engine. The Injector lIallle body conSists 01 a solenoid ac· tuated ball and seat lIallle assembly An electrical control Signal from the EEC electrOniC processor actl' lIates the solenoid. caUSing the ball to molle 011 the seat and alloWing tuel to tlow The Injector llow ofllice IS I I ~ed and the fuel supply IS constant Therefore. fuel llow to the engine IS controlled by how long lhe solenoid IS energized The pressure regulator IS Integral to the fuel chargtng maIO body near the rear olthe alf horn surface. The regulator IS located so as to nullify the ellects of the supply line pressure drops _Its deSign IS such that 1\ is not Sensltllle to back pressure In the return line to the lank A second lunc\lon 01 the pressure regulator IS to mamlaln luel supply pressure upon fuel pump Shutdown. The regutator functIOns as a down· slleam check lIallle and traps Ihe luel between lisalt and the luel pump The constantluel pressure lellet alter engine Shutdown precludes tuel line lIapor formation and allows lor rapid restarts and stable idle operation 1m· mediately thereatter It regulates the fuel pressure to the Injector nozzles al a constant nominal lIalue of 14 5 psi The throttle actuator contrOls idle speed by modulating the throttle Ie· lIer lor the reqUired air flow to maintain the deSired engine rpm tor any cp. eratJng condlllon. from an idling cold engine to a warm engine at normal operating temperature An Idte tracking SWltcn (ITS) determines when the throttle leller has contacted the actuator. Slgnalhngthe need to control en· glne rpm. The DC motor extends or rellacts a linear shaft through a gear reduction system. The mOlor direction IS determined by the polarity of the applied lIoltage A th rottle position sensor (non·adJustable) IS mounted to the throttle shalt on the choke Side 01 the luel charging assembly and IS used to supply a lIoltage OUtput proportional to the change In the thrOllle poSition The TP sensor IS used by Ihe computer (EEC) to determine the operation mode (closed thrOUie. part thronte and Wide open throttle ) for selection 01 the proper fuel mixture. spark and EGR at all engtne speeds and loads
Electronic Fuel Injection (EFI) and Sequential Electronic Fuel Injection (SEFI) Referloifluslrallon 1112 Two baSically Similar electrOniC fue l Injection systems are used on many 01 the models COllered by th iS manual The Sequen\lal ElectronIC Fuellnj8(:tlon (SEFt) system and the Elec· tronlC Fuel Inlectlon (EFI) system are known as mulh-potnt. pulse time, speed denSity control deSigns On the SEFI system (see iIIustrallon), luells metered IOta each Intake port In sequence With the engine hflng or· der In accordance With engine demand through eight injectors mounted on a tuned Intake manifold. On the EFI s~stem used ~th the 2.3L tour-cy· linder englne. luells metered Into the Intake airstream In accordance With engine demand through four Injectors mounted on a tuned Intake manIfold. A bIow·through turbocharger system IS utilized on the Mustang SVO to reduce fuel dellllery time. Increase turbine energy allallable and ellml' nate compressor throttling.
Chapter 4
Fuet and exhaust systems
4 -11
11 ,12 The main components 01 the Sequential Electronic Fuel Injection (SEFI) system
On both systems, an on -board EleclIonic Engine Control (EEe-IV) computer accepts inputs from various engine sensors 10 compu te the re o quired fuel !low rate necessary to maintain a prescribed 81rlfuel ratiO throughoullhe entire engine operational range . The compu ter then outpu ts a command to the fuel inJectors to meIer tJ1e approximate quantity of
Width and outputs a command to the Injector to meter the nght amount 01 fuel
12
Fuel Injection system - pressure check
fuel. The EEC· IV engine control system also determines and compensates lor the age althe vehicle and lIs uniqueness. The system automatically senses and compensates lor changes In altitude and, on models with a manual transmission, permits push-starting. should it become necessary. The fuel delivery systems for both designs are Similar. An electnc Intank fuel pump forces pressurized fuel through a series of metal and plas· tiC hnes and an inline fuel fliterJreservOlr to the fuel charging manlfotd assembly. The early SEFI system utilizes two pumps - a low pressure unit in the tank and a high pressure model mounted outSide the tank. The later SEFI system uses a single high-pressure pump mounted inSide the tank The fuel charging manifold assembly Incorporates electrically actuated fuel injectors directly above each intake port. When energized. the Injectors spray a metered quanll ty of fuel into the Intake air stream. A constan t fuel pressure drop is maintained across the injector nozzles by a pressure regulator. The regulator IS connected in series Wi th the fuel Injectors and IS positioned downstream from them . Excess fuel passes through Ihe regulator and returns to the fuel tank through a fuel return line. On the SEFI , each injector is energized once every other crankshaft revolUllOn In sequence with engine firing order. On the EFI. the injectors are energized every crankshaft revolution: an models through 1985. all lour Injectors are energized at once. while on 19S9 and later models. the injectors are energized In pairs (1- 4 and 2-3). The period 01 time that the Injectors are energized (known as "an tlme- or "pulse Width") IS controlled by the EEC computer. Air entering the engine IS sensed by speed, pressure and temperature sensors. The outputs 01 these sensors are processed by the EEC-!V computer. The computer determines the needed injector pulse Width and outputs a command to the Injector to meter the exact quantity of fuel . On the turbocharged four·cylinder. all injectors are energized simultaneously, once every crankshaft revolution . Air entering the engine IS mea· sured by a vane airflow meter located between the air cleaner and the turbocharger. The airflow IS then comp ressed by the turbocharger before Introduction into an Intercooler (only on SVO models) and then Into the fuel charging manifold ThiS airflow Information , combined with input from sev eral other engine sensors, enables the computer to determine the reqUi red fuel flaw rate necessary to maintain a prescribed airffuel ratiO forthe given engine opera\lon. The computer calculates the necessary inlector pulse
Refer to Illustration 12. 1 Warning : Gasolme IS extremely flammable. so extra precau/lonsmust be taken when working on any part of the fuel system. DO NOT smoke or ai-
low open flames or bare Irght bulbs in or near the work area, Also, don', work in a garage If a natural gas appliance such as a water heater or clothes dryer is present 1 With a Ford TSOL-9974-B fuel pressure gauge (or equivalent) and adapter T85L-9974·A (or eqUivalent). the fuel pressure 01 any fuel·in jected vehicle covered by th is manual can be measured easily and quickly, All fuel'lnjected versions of this vehicle are equipped with Schrader valves . On C FI-equipped models, the Schrader valve IS located on the fuel charging (throttle body) assembly (see illustration). On EFI and SEFI models, th e Schrader valve is an the fuel rail.
12.1 Th is Schrader valve littlng (arrow) on the luel charging assembly of the Central Fuel Injection (CFI) system can be used to relieve luel pressure (only if you have the special Ford pressure gauge and adapter) and to measure pressure with the Ford or any equivalent gauge (with the correct adapter)
4 -12
Chapter 4
Fuel and exhaust systems
13.6
10 I
2 3 4
5 6 7
• 9
Screw ISC mOlOr
12
Transmission lever spong Connector bracket screw
13
Throttle position sensor screw Throttle position sensor Throttle body screws Throttle body assembly Fuel charging body gasket
"
.-
15 16 17
E)(plcded view 01 a typical eFt assembly
Fuel charging mam body assembly Fuel pressure regula/or screw Fuel pressure regula/or
I.
19 20
assembly
2>
Pressure regulator D -ring Pressure regula/or gasket Fuel mjector retammg screw Fuel Injector relalner Fuel inJector assembly (throttle Side)
22 23
2 The special Ford fuel pressure gauge/adapter assembly is designed to relieve fuel pressure, as well as measure It. through the Schrader va lve If you have this gauge. you can use this melhod as an alternative 10 the procedure lor fuel pressure relief outlined In Section 2. Warning: DO NOT attempt to relieve fuel pressure through the Schrader valve Without thiS special setupl
3
To anach the gauge. Simply remove the valve cap. screw on the adapter and anach the gauge to the adapter 4 Start Ihe engine and allow II to reach a steady Idle. Note the indicated luel pressure reading and compare it 10 the pressure listed in thiS Chapter's Specifications. 5 11 the Indicated fuel pressure Is lower than specihed. the problem IS probably either a leaking fuel line, a malfunctioning luel pump or a leaking Injector. lithe pressure IS higher than speCified, the cause could be a blocked luelline or a stuck luel pressure regulator.
"
25 26
Fuel injector upper a·rmg Fuel Injector lower D-ring Fuel Injector assembly (TP sensor side) Fuel Injector upper a-ring Fuel Injector lower a·rlng Wifing assembly screw Fuel injector wmng assembly Pressure relief valve cap Schrader fuel pressure relief valve assembly
3
Remove Ihe air cleaner hOUSing assembly (see Section 8). Detach the throl!le cable and. If eqUipped. crUise control cable lilting Irom the throttle lever (see Section 9). 5 II your vehicle IS equipped with an automallc transmission, detach the downshift roo. 6 Unplug the electrical connectors to the fuel injectors, the Idle Speed Con trol (ISC) and the Throttle POSition (TP) sensor (see lIIustraUon). 7 Remove the luel hne bracket bolt. 8 Using a backup wrench. delach the fuel teed and return hnes. Note : If el/her Ime proves difficult to pull out, carefully Wiggle It up and down - do 4
not strike the Imes With a tool or attempt 10 pry them loose or you may denl them.
9 Delach the PCV hose. 10 Remove the lour mounting nuts 11 Install(llion is the reverse 01 removal
Idle Speed Control (lSC) motor 13
Central Fuel Injection (CFI) syslem - co mponenl replacement
Warning: Gasoline IS extremely flammable. so extra precautions must be taken when working on any part of/he fuel system. DO NOT smoke or allow open flames or bare light bulbs In or near the work area. Also, don 't work in a garage if a nawral gas appliance such as a water heater or clothes dryer IS presen/.
CFI assembly Refer to Illustration 13.6
1 When buying replacement parts lor the CFI assembly, always check Ihe number on Ihe Identillcatlon tag on the Side ollhe CFI assembly to make sure that you are gelling Ihe right parts 2 Relieve Ihe luel system pressure (see SecMn 2). Detach the cable lrom the negallve lermlnal of the battery.
12 Detach the cable from Ihe negative terminal of the ba!lery and unplug the electrical connector from th e ISC motor. 13 Remove the downshift lever return spring. 14 Remove the tw o mounting boilS and detach Ihe ISC motor. 15 Installation is the reverse of removal
Throttle Position (TP) sensor Note: It IS nOl necessary to remove the CFI assembly to replace the TP sensor.
Removal 16 Detach the cable from the negative terminal of the baltery 17 Unplug Ihe wire harness electrical connector from Ihe TP sen SOl con· neclor 18 Remove Ihe TP sensor electrical connector bracket retaining screw
Chapter 4
4 -13
Fuel and exhaust systems Fuel injector Refer /0 Illus/rallOn 73.27
25 Remove the CFt assembly Irom the .ntake manifold (see above). 26 Remove the air cleaner stud 27 Remove the lour throWe body-to-main body screws and separate the throttle body and main body assemblles(s" Illustration 13.6). Caution :
Do not remove the three screws which attach the pressure regula/or 10 the maIO body assembly (see illustration) 28 Clearly mark the mjectors With respect 10 their onentatlon to the throl\le lever and TP sensor. CauUon : ThemJectOfs mustnol be mll(edup
during reassembly
13.27
00 nol remove Ihese three screws (arrows) -they attach the pressure regulator to Ihe fuel charging assembly
29 Unplug the Injector electncal connectors. Pull on the connector plugs. I'IOt on the wires. 30 Remove the luelln,ector retainer screw and retainer_ 3 t Carelully pull up on the Injector while uSing a twisting mobon. 32 Discard the old a-rings and replace them wllh new ones Use a hght grade 011 to lubflcate the new O-fll"lgS before installing them. 33 Installalion is the reverse 01removal
and detach the bracket and connector Irom the thronle body 19 Remove the TP sensor retaining screws (see Illustration 13.6). 20 Slide Ihe throttle posllion sensor all Ihe throttle shaft
14
Sequential Electronic Fuetlnjectlon (SEFI) and Electronic Fuellnjeetlon (EFI) systems - component replacement
Installation
Upper intake manifold and air intake throttle body
21 Holding the lhloll1e sensor with Ihe wire harness laCIng up and to the lefl slide 11 onto the thlonle shalt 22 ROlate the thronle poSition sensor clockWIse unlllri s aligned with Ihe screw holes on Ihe throttle body. Inslalilhe retaining screws and tighten
Refer 10 Ifluslra/lOfIs 14.2a. 14 2b and 148
Removal
them securely
1 DetaCh the cable from the negative terminal 01 the battery 2 Unplug the electflcalconnectors at Ihe air bypass valve. throttle pesl\Ion sensor and EGA position sensor (see Illustrations)
23 Inslall the Ihlonle poSition sensor wiring harness bracket bolt 24 The remainder 01 installation IS the reverse of removal
14.2a An exploded view of the Sequenllal Electronic Fuel InJecUon (SEFI) assembly used on the va engine
,.
~
"'-
, 2 3 , 5 6 7
• • 10
"
12 '3 14
15 '6
\
~
17 18
"
Schrader vallie Schrader vafve cap Fuel rail assembly O-n"9 seat Fuel pressure regulator gasket Fuel pressure regula/or Upper maO/fotd cOlier Upper maO/fold cover mounting screw Upper Intake maO/fold mounting boll (long) EGR spacer gasket EGRspacer TP sensor connector TP sensor mountrng screw ThrOllle POSition (TP) sensor Throttle air bypass valve Throtlle arr bypass valve gasket ThroWe body assembly Throttle body gasket
20 21 22 23 2' 25 26 27
2. 29
30 3' 32 33 34 35 36 37 38
EGR valve gaskel EGR vallie and poslfron sensor PCV valve PCVgrommer Crankcase vent element Lower Inlake manifold Thermostat housing gasket Thermos/at Thermostat housing mounting bolt Engme coolant oullel connector assembly Healer water supply and return tube EECcoolant temperature sensor Upper to lo wer mantfold gasket Upper mtake mamfold moun/lng bon (short) DecoratIve end cover Plug-cap
Upper Intake maO/fokJ Fuel pressure regula/Of retaining saew Fue/ rail assembly mounting boll Fuel in/8Ctor
4 -14
Chapter 4
Fuel and exhaust systems
THROTTlE POSITION (TP)
SENSOR
..--
HEATER COOI..ANT SUPPLY CONNECT ION
W/
14.2b
The SEFI throttle body assembly on a va engine 14.8
An e~ploded vi ew of the upper intake manifold assembly 01 an SEF! system on a va engine
3 Detach Ihe throttle linkage (see Seellon 9) and transmission linkage (see Chapter 7) from the aIr Intake throttle body. 4 Detach 11'18 throttle cable/downshift cable bracket from lhe Intake manitold (see Section 9) and position the bracket and cables oul 01 the
w.y 5 Clearly label, then detach. the vacuum hnes 10 the upper Inl ake manIfold vacuum !ree. the EGR valve and the luel pressure regulator 6 Detach the PCV syslem by disconnecting the hose from the filling on the rear of the upper manifold 7 It equipped. detach lhe canister purge line or Imes from Ihe Ihlon)e body and detach the EGA spacer coolant hnes trom the EGR spacer 8 Remove the SIX upper Intake mamtold relamlng bolts (see ;l1uslra-
tion) 9 Remove Ihe upper Inrake manllold and rhrotlle body as an assembly from rhe lower Inrake manifold.
Installation 10 Be sure to clean and InspeClthe mounrlng faces of the lower and up· per Intake manifolds before posillOnm9 the new gasket on the lower mtake mounting face. The use of alignment studs may be helplul.lnstallthe upper Intake manifold and throttle body assembly on the lower manifold Ensure that the gasket remains In place (If alignmen t studs are not used) InStall the Sl~ upper Intake manifold retaining bolts and tighten to the specl· lied torque tns!allatJon is o!herwlse !he reverse of removal
Air Intake throttle body Removal \ \ DetaCh the cable from the negative terminal of Ihe banery. 12 Detach Ihe Ihrollie poSi tion sensor and throttle alf bypass valve con neelors. 13 II eqUipped, remove the PCV vent closure hose at the throttle body 14 Remove the four throttle body mounting nuts (see illustration 14.2b). 15 Carelully separate the alf throttle body from Ihe EGR spacer 16 Remove and discard the gaskel between the Ihrollle body afld the EGR spacer
Installation 17 Clean the gasket mallng surlaces.1! scrapmg IS necessary. becarelul not 10 damage the gasket surlaces or allow matenalto drop mto rhe man· ifold. Installation IS the reverse of removal Be sure to lighten the throttle body moun\lng nuts to the specified torque.
14.21
The ThroWe Position (TP ) sensor, mounting screws and connector
Throttle Position ( TP) sensor ReleT/o Illus/rat,on 1421 18 Detach the cable from Ihe negative termlnat of the batlery 19 Detach the throttle poSItion sensor from the WIring harness 20 Scflbe a reference mark across the edge of the sensor and the thronle body to ensure correet poSition dUling Installallon 21 Remove the two Ihrottle poSition sensor mounting screws (see illustration) 22 Remove the throttle position sensor 23 'nstal'allon IS the reverse at removal Be sure to tighten the screws securely
Air bypass valve assembly 24 Detach the cable from the negative termmal at the battery 25 Detach the alf bypass valve assembly from the Wifing harness 26 Remove !he two air bypass valve retaining bolts 27 Remove the air bypass valve and gasket 28 Clean the gasket mating surlace If scraping IS necessary. be careful nol to damage the au bypass valve or thronle body gasket surlaces or drop mal enal IOta the throttle body 29 Installation IS essentially the reverse of removal Be sure totlghlen the boilS securel y
Chapter 4
4-15
Fuel and exhaust systems
fuel fall and then seal/he entlfe asseml>ly In the lower Intake mamfold 39 Secure the fuel rail assembly with the lout retaining bolts and tighten them to the specllied torque 40 The remainder 01 Inslallal lon IS the reverse of removal
Fuel pressure regulator Removal 41 Relieve Ihe system luet pressure (see SectIOn 2). 42 Detach the cable from the negative lermlnal of the banery 43 Remove the vacuum hne at the pressure regulator. 44 Remove the three Allen retaining screws from the regulator hOUSing 45 Remove the pressure regulator assembly, gasket and O·lIng DIS· card Ihe gasket and Inspect the 0 -lIng lor Signs 01 cracks or detenoratlon 46 If scraPIng IS necessary. be carelut not to damage the luel pressure regulator or luel supply line gasket surfaces
Installation
14.34
An exploded view ollhe SEFIluel rail assembl y on a VB engine
47 Lubncate the l uel pressure regulator O-flng With engine 011 Note : Never use sllrcone grease II will clog Ihe Injectors 48 Ensure that the gasket surl acesol thefuel pressure regulator andluel ra il assembly are clean. 49 Install the O·ong and new gaske t on the regulator 50 Install the fuel pressure regulator on the fuel rail assembly Tighten the three screws securely 51 The remainder 01 installatIOn IS the reverse 01 removal
Fuel injector Fuel rail assembly
Refer /0 il/us/ra/lons 1455. 14 56 and 14.57
Refer fa illus/ratlon 1434
Removal
Removal
36 Use a rocking, side·lo-slde mOllon while IIU1nO to remove the Injectors
52 Re lieve Ihe system fuel pressure (see Section 2) 53 Remove the upper Intake mamfold assembly (see above). 54 Remove the luel rail assembly (see above), 55 CarE'fully remove the electncal harness conneclors from the IndlVlClu· a! InJectors as reqUi red (see Illustration) 56 G ra sping the Injector body. pull up while gently rocking the Injector • _ _.. from side-to·side (see lIIuslralion). 57 I nspecllhe Injector O ·flngs (two per injector) for Signs of deterioration (see illus tration ). Replace as required 58 Inspect the injector plastIC "hal" (covariflQ the !M]&Ctor PIntle) and washer for Signs 01 deterioration. Replace as required If the hailS miss· Ing. look lor 111M the !Mtake mamfold
!rom the luel lall
Installation
Installation
59 Lubflcate the newO·rlngs With IIghl grade oil ESE·M2C39-F or eqUIValent and Install two on each Inlector. Nole : Do no/ use silicone grease. II Will clog Ihe Injec/ors. 60 USing a ligh t. tWlstiflQ motion. install the injector(s). 6 1 The remainder 01 InstallatIon IS the reverse 01 removal
30 31
Relieve the fuel pressure (see Seellon 2) Detach the cable Irom the negative terminal 01 the banery
32 Remove Ihe upper manifold assembly (see above). 33 USing the special spnng lock coupler 1001D87l·9280-A or equivalent disconnect the crossover tuel hose from the fuel rail assembly. 34 Remove the IOUf fuel fall assembly retaining boits (two on each side)
(see illustration) 35 Carefully disengage the fuel lall l Tem the fuel Injectors and remove thaluel fatl Nole : /I maybeeaslfJrtoremove the Injectors with the fue/ra,1
as an assembly
37 Ensure that the Injector caps are ctean and free of contamlnallon . 38 Place the luellnlectorfuel ra il assembly over each ot the InJeclorsand seat the InJeclors 1010 the luel rail. Ensure that the Injectors are well seated 10 the fuel rail assembly Note: 1/ may be easier 10 seat Ihe InjlJClors In the
PINTlE PfIIC) IECIIOfoI CJ# cPV>S"C: ..... , I
14.55 Be ca relul when unplugging the electrical connector hom a luel injector
14.56 The proper way to remove an injector from the Intake manifold Is to grasp the body and pull up while gently rocking the injector from slde-to-slde
14.57 Note the proper location oltha two injector ().rlngs, the washer and the plastic hat that protects the pintle
4-16
Chapter 4
Fuel and exhaust systems
15.' 8 An exploded view of the EFI system used on the 2.3L four-cyllnder engine (1990 and earlier model shown, laler models similar
1 2 3 4
Throttle Throttle Throttle Throttle
body assembly body retaining nut body retaining stud body /0 intake
manifold gasket
5 6 7 8 9
15
Upper to /ower manifold screw Upper to lower manifold stud Intake upper manifold TP sensor bracket retaining screw TP sen5()( retaining screw
20
21 22
10
Throttle Position (TP) sensor
11
Throttle Position (TP) sensor
24
gasket
25
23
12
Air bypass valve retaining screw
13 14 15 16 17 18
Air bypass valve Air bypass valvegaske/ IdJescrewspring Throttle stop screw Throttle body retaining bofl Secondary throttle rod
26 27 28 29 30
'9
Throttle control lever assembly (automatics)
32
37
S8COndary throttle control lever washer Secondary throttle control lever spacer
Secondary throttle control lever spacer Carburetor thronJe return spring Accelerator pump bushing Upper-Io-/ower Intake manifold gasket Lower Intake manifold assembly
Nipple Fuel pressure regulator screw Fuel rail manifold assembly Fuel pressure relief valve assembly Valve cap Fuel inlector electrical connector wire harness
Electronic Fuel InJection (EFI) system - component replacement (four.cyllnder engine)
Refer to il/ustrations 15. 1a and 15. 1b While the appearance and deSign of the various components of this system vary somewhat from those in the previous Section, the procedures there will apply to this system as well. Exploded and assembled views of the four-cylinder engine fuel system are included here to help identify and locale the components (see illustrations),
16
Turbocharger - removal and Installation
EFlmodels Removal Refer to illustrations 16. I and 16. 10 1 The turbocharger is mounted low on the right side of the engine (see illustration). Make sure the engine has cooled overnight (or for several hours) before beginn,ng work on the turbocharger.
33 34 35 36 37
38 39 40 41
Regulator assembly Fuel regulator gasket Fuel pressure regulalor O-ring seal Fuel rail to lower manifold screw Injeclor assembly Lower in/ake mamfold-to -engine gaskt;'1 Llftmg eye Fuel pulse dampener Fuel pulse dampener screw
2 Detach the cable from the negative terminal of the battery. Drain the engine coolant (see Chapter 1). 3 lithe turbocharger is not eqUipped With an Intercooler. remove the two bolts retaining the throttle body discharge tube to the turbocharger and loosen the hose clamp on the inlet hose. 4 If th e turbocharger is equipped with an intercooler. loosen the upper and lower clamps secunng the hoses to the intercooler. Detach the aspira· tor hoses at the intercooler and loosen the bolts securing the bracket to the intercooler hOUSing. Pull the upper lront bracket pinS out 01 the lower bracket. rolale the housing clockwise to disengage the upper rear bracket, then remove the intercooler together With the upper brackets. 5 Clearly label. then disconnect. the vacuum hoses and tubes. 6 Detach the PCV tube from the turbocharger air inlel elbow. 7 li the turbocharger is not equipped With an Intercooler. remove the throttle body discharge tube and hose as an assembly. 8 II the turbocharger is equipped with an intercooler (Mustang SVO). loosen the clamp and detach the air inlet tube trom the Inlel elbow. 9 Disconnecuhe electrical ground wire and turbocharger air inlet elbow and remove the air inlet elbow. Discard the old gasket. 10 Remove the waler connections and fittings Irom the turbo center housing (see illustration). Note: Some coolant will drain from theengine block.
Chapter 4
Fuel and exhaust systems
4-17
16.1 The turbocharger used with EFI model s Is l oca ted o n th e right side of the engine - it's bol ted dlreclly 10 the exhau st manifold where it can lake full advantage 0 1 Ihe hal exhau st gases thal lI u ses 10 spIn Ihe l urbine
15.1b An assembled v iew of the EFt system used on the 2.lL four-cyUnder engine (1990 and earlier model shown, laler models similar)
11 Remove the lufbocharoer oil supply. 12 Detach the o)()'gen sensor connector althe turbocharger. 13 Raise the vehicle and place it securely on Jackslands. 14 Disconnect the e~haust Pipe by removing the two exhaust pipe-to-Iul' bocharger bolts. 15 Remove the two bolts Irom the oil return line located below the turbo· chalger. Do nOI kink or damage the line as it is removed. 16 Remove the lower turbocharger brackeHo·block stud.
4
17 Lowerthe vehicle. 18 Remolle the front lower turbocharger retainlOg nul. 19 Simultaneously. remove lh9threeremalnlng nuts while sliding Ihetur· bocharger all the studs. 20 Remove the turbocharger assembly from the vehicle.
Bearing clearance check 21 Manually move the turbocharger blade shaft assembly as far in one direction as possible. Spin the shaft by hancl. 22 Manually move the shaft in the opposite directIOn as far as posSIble and spin the shaft again. 23 If neither the tulbine blade nor the compressor blade contacts any portIOn of their respective hoUSings, the bearings are stitt good. 24 If either blade comes In contacl with the housing, the bearings are wom and Ihe turbocharger should be replaced.
Installation 25 Apply pipe sealant With Teflon D8AZ·19554·A or equivalent to the wa· ler inlet 9O-degree elbow fining . Install the lining in the turbocharger as· sembly center houSing. Tighten it securely and rotate it clockwise so that the fining is Within 5 degrees 01 vertical, pointing Clown. 26 Position a new turbocharger gasket on the mounting studs. Make sure that the bead laces out. 27 Install the turbocharger assembly on the mounting studs. Note: Use four new mounting studs. 28 Install the turbocharger bracket on the two lower studs, Start the two lower retaining nuts followed by the two upper retaining nuts. 29 Raise the vehicle and place 1\ seaJrely on jackstands. 30 Install the lower bracket·to·bIock bolt. Tighten it securely. 31 Install a new oil return hne gasket. Bolt the all return hne fitting to the turbocharger and tighten It securely.
16.10
The v ar ious coolant tu be assem blies connected t o the EFt turbocharger
32 Connect the water inlet tube assembly to the Inlet fining at Ifle turbo· charger assembly. Tighten the hose clamp SeaJrely.
33 Install the e)(haust pipe and ttghten the retaining nuts to the specified torque. 34 Lower the vehiCle. 35 USing four new nuts. tighten the turbocharger·to·e)(haust manifold nuts to the specified torque. 36 Apoly pipe sealant with Tellon D8AZ· 19554·A or equivalent and in· stall the water fittings In the turbocharger center hOUSing. Tighten se· curely 37 Connect Ihe water lube assemblies 10 the fining on the turbocharger and tighten It seaJfely. Be sure to use a backup wrench to hold the water outlet fitting while tightening. 38 Use a new gasket and install the compressor inlet elbow.
Chapter 4
4 -18
Fuel and exhaust systems
39 Attach the air inlel tube \0 the turbocharger mlel elbow. Tighten the hose clamp securely 40 Install the PCV lube fming alld tighten the clamp securely. 41 AUach all vacuum lines. 42 Connect the oxygen sensor 43 Connect the electrical ground wire to the air mle\ elbow, 44 Install the turbocharger oil supply line. Tighten the fiHlng securely. 45 Inslalilhe turbocharger intercooler assembly. Tighten the clamps and the nul securely. 46 Fill and bleed the cooling system (see Chapler 1). 47 Connect the cable to the negatlve terminal 01 the battery 48 Start the engine and check for leaks
Carbureted models Refer to Illustrations 1657 and 16.63
49 Disconnectlhe negallve battery cable from the baltery 50 Remove the two nuts which hold the turbocharger heat shield to the turbine housing and remove the shield 51 Raise the vehicle and position It securely on Jackstands 52 Remove the lour bolts which attach the crossover pipes to the turbo· charger. Remove the crossover pipe at that end 53 Disconnect the eKhaust Pipe from the check valve located just above the catalytic converter. 54 Remove the bolts which attach the crossover pipeS to the eKhaust mamfold. loosen and lower the crossover pipe. Remove the eKhaust pipe retaining bolts at the Inlet 01 the rear catalytic converter. 55 Remove the rear turbocharger brace bolts and the brace. 56 Remove the jackstands and lower the vehicle. Remove the air clean· er and duct assembly. Place a shop rag over the carburetor mou tn to pre· vent dirt and parts Irom failing in. 57 Disconnect the oil supply line from the turbocharger central hOUSing (see Illustration). 58 Disconnect Ihe two hoses from the wastegate actuator diaphragm 59 Remove the accelerator cable and liS two mountmg bolts from the In· take manifold. 60 Disconnect lhe turbocharger vacuum line at the Intake mamtold. 61 Remove the engine 011 dipstick bracket bolt 10 proVide removal ac· cess 62 loosen the tlange nutl1tl both ends olthe EGR tube. then remove the lube. 63 Remove three nuts and one bolt that secure the turbocharger to the Intake manifold (see Illustration). 64 Label and detach any remaining vacuum hoses 65 lift lhe turbocharger oul of the engine compartment. 66 Installation is the reverse of removal. Use new O·rlngs. lightly coated With clean engine 011. at the follOWing points
a) Compressor inleHo· manllold iOlnt b) Compressor outleHo·mamfold JOint c ) 011 drain line adapter·tO· lntake manifold JOint
17
EKhaust system servicing - general information
Warning : Inspection and repair 01 exhaust system components should be done only af/er enough time has elapsed af/erdrivmg the vehicle /0 allow the system components tocoolcomple/ely Also. when workmg under Ihe vehicle. make sure II is securely supported on jacks/ands 1 The eKhaus t system consists olthe eKhaus t mamlold{s). the catalytic conve rt er. the muffler. the tailpipe and all connecting pipes. brackels. hangers and clamps. The eKhaust system is att ached to the body Wi th mounting brackets and rubber hangers 1\ any of the parts are improperly installed. eKceSSlve nOise and vibration Will be transmitted to the body 2 Conduct regular inspections of the eKhausl system 10 keep It sale and quiet Look for any damaged or bent parts , open seams. holes. loose connecllons, excessive corrOSion or other de tects which could allow exhaustlumes to en terthe vehicle. Deteriorated exhaust sys· tern components should not be repaired : they should be replaced Wit h new parts 3 lithe exhaust system components are extremely corroded or rusted together. weld ing equipment Will probably be reqUITed to remove them The convenient way 10 accomplish this is to have a muffler repair shop reo move the corroded sections with a cutting torCh. ff . however. you want to save money by dOing It you rself (and you don't have a welding outfit With a cutting torch ). simply cut off the old components With a hacksaw. If you have compressed air. special pneumatic cutting chisels can also be used. If you do deCide to tackle the job at home. be sure to wear safety goggles to protect youreyes from metal chips and work gloves to protect your hands. 4 Here are some simple guidelines tofollow when repairing the e ~ haust system ' a) Work from the back to the fron t when removing exhaust system components. b) Apply penet ra~ng oil to the exhaust system component fastene rs \0 make them easier to remove c) Use new gaskets. hanger.. and clamps when Installing exhaust systems components. d) Apply antl·selze compound to th e threads of all exhaust system fastene rs during reassembly e) Be sure to allow suffiCient clearance between newly Installed parts and all points on the underbody to aVOid overhea\lng the floor pan and pOSSibly damaging the in terior carpet and Insulation Pay par· licularly close attention 10 Ihe cata lytiC converter and heat shield
16.63 16.57
Turbocharger connections - carbureted turbo models
Turbocharger mounting bolts and nuts - carbureted turbo models
Chapter 5
Engine electrical systems
Contents Alternator brushes - replacement (EVA type alternator)
15
Alternator - removal and installation.
14
......•.....
Ignition module - replacement ................. . 10 6 Ignition system - check. . . . . . ............ . 5 Ignition system - general information ........... . 9 Ignition timing - check and adjustment ........ . See Chapler I Spar\( plug replacement ................. . Spar\( plug wire, dislributor cap and rotor - check See Chapler I and replacement ........ . ....... Staner motor - ,emoval and installat!on ......... . . . . . . . . 20 Staner relay - removal arid installat!on .. . 21 Starting system - general information '8 Staner motor and circuit - in·vehicle check . Voltage regulator/alternator brushes - replacement (tAR·type alternator) ............. . 17
Battery cables - check and replacement ............ 4 Battery check and maintenance .................. See Chapter 1 3 Battery - emergency jump stanmg .. . . . . . . . . . . . . . . . Battery - removal and installation . .. ...................... 2 Charging system - check .. .. .......... 13 Charging system - general informaMn and precautions .. 12 Crankshaft liming sensor ............ 11 Distributor - removal and Installation ....••..•........ 8 Orivebelt check, adjustment and replacement ....... See Chapter 1 16 External Voltage Regulator (EVA) - replacement ........... General information ..... ... . . . . . .. .. I .......... 7 Ignition coil - check and replacement
"
Specifications
Orlvebelt deflection
See Chapter 1
Battery vOltage Engine off . Engme running
12·volts 14·to·15 volts
Firing order
See Chapter 2
Ignition coil-to-distributor cap wire resistance Duraspar\( II systems . TFI·IV system .
5000 ohms per inch 5000 ohms per 1001
Ignition coli resistance Duraspar\( II and lit syslems Primary resistance Secondary resistance Ba)last resistor ........ . TFI·IV system Primary resistance SecondaJy resistance
Ignition timing ...... .
0.8 to 1.6 ohms 7.71010.5 K·ohms 0.8 10 1.6 ohms 0.310 1.0 ohms 8.010 11 5 K-ohms See Ihe Vehicle Emissions Conlrollnlorma!ion label in Ihe engine compartmen t
Alternator brush length New .....
Minimum
1
Generallnlormatlon
The engine electrical systems include all ignition, charging and starting components. Because 01 their engine-related functions. these compo· nents are considered separately Irom chassis electrical devices ~ke the lights, instruments. etc. Be very carelul when working Ofl Ihe engine eleclncal components. They are easily damaged II checked, connected or handled improperly. The alternator is driven by an engine drivebelt which could cause serious
tf2 in 114 in
mjury il your hands, han or clothes become entangled in it with the engme running, Both the starter and alternator are connected directly to the bat· tery and could arc or even cause a fire if mlsharldled, overloaded or shoned oul. Never leave the Ignition Sw!lch on lor lOng periods 01 time with the en· gine off. Don't disconnect the battery cables while the engine is running. Correct polarity must be maintained when connecting battery cables trom another source, such as another vehicle, dullng jump staning. Atways diS' connect the negative cable first and hooII. it up last or the battery may be shoned by the too) being used to loosen the cable clamps.
5
5-2
Chapter 5
Engine electrical systems
2.2 To remove the battery, detach both cables (negative tlrst) and remove the battery hold-down bolt and clamp (arrow)
6.2 To use a calibrated Igniti on lester (available at most auto parts store s), simply disconnect a spark ptug wire, attach the wire to the tester, clip the tesler to a convenient ground (like a rocker arm cover boll) and operate the starter - It there 's enough power to tire the plug, s parks will be visible between the electrode tip and the tester body
Addllional safety related information on Ihe engine electrical systems can be found in Safety first near Ihe front of this manual. It should be re ferred 10 belore beginning any operation included in this Chapter.
2
Battery - removal and Installation
Refer /0 illus/rallon 2.2
Note: On models eqUipPed with the Distributor/ess (DIS) Igmlion System. some precautions must be taken after disconnecting Ihe battery cab/e(s). When the battery cable(s) has been disconnected and reconnected, some abnormal drive symptoms may occur while the EEC processor within the
ignition system relearns its adaptive strategy. The vehicle may needla be driven 10 mi/{Js or more to relearn the stra tegy. Caution should be taken dunng this penod of Ume. t Disconnect both cables from the battery terminals. CauUon : Always disconnect the negative cable first and hook it up /ast or the battery may be shorted by the tool being used to loosen the cable clamps. 2 Locate the battery hold·down clamp at the base of the battery (see illustration) Remove the bolt and the hold-down clamp 3 Lift out the battery. Special straps that attach to the battery posts are available -lifting and moving the battery is much easier if you use one. 4 Installation Is the reverse of removal
3
Battery - emergency jump start ing
Refer 10 the Booster battery (jump) starting procedure at the fron t of thiS manual.
4
Battery cables - check and replacement
Periodically inspect the entire length 01 each battery cable for damage, cracked or burned insulation and corrosion. Poor battery cable con· nections can cause starting problems and decreased engine performance. 2 Check the cable-to-terminal connections at the ends of the cables for cracks, loose wire strands and corrosion. The presence of white. fluffy deposits under the insulation at the cable terminal connection is a Sign that the cable is corroded and should be replaced. Check the terminals fordis tortion. miSSing mounting bollS and corrosion. 3 When replacing the cables, always disconnect the negative cab le fi rs! and hook it up last or the battery may be shorted by the tool used to loosen the cable clamps. Even if only the positive cable is being replaced , be sure to disconnect the negative cable from the battery first.
4 Disconnect and remove the cable. Make sure the replacement cable is the same length and diameter. 5 Clean the threads of the relay or ground connection With a wire brush to remove rust and corrosion. Apply a light coat of petroleum jelly to the threads to preven tl uture corrOSion. 6 Anach the cable to the relay or ground connection and tighten the moun\lng nuVbolt securely. 7 Before connecting the new cable to the battery, make sure that it reaches the battery post Without haVing to be stretched. Clean the battery posts thoroughly and apply a light coat 01petroleum jelly to prevent corrosion. B Connectlhe positive cab le first , followed by the negative cable. 5
Ignition system - general information
Distributor type (Duraspark II and TFI-IV) The ignition system is a solid state electronic design consisting of an ignition module, coil, distributor. the span.. plug wires and the spark plugs. Mechanically. the system Is similar to a breaker point system. except that the distributor cam and ignition points are replaced by an arma ture and magnetic pickup unit. The COil pflmary CirCUit IS cofllrolled by an amplifier module. When the ignition is SWitched on, the ignition primary circuit is energized. When the distributor armature "teeth" or "spokes' approach the magnetic coi l assembly, a voltage is induced which signals the amplifier 10 turn 011 the coi l primary current. A timing Circuit in the amphlier module turns the coil cur rent back on alter the coil held has collapsed. When irs on. current tiows from the battery through the ignition SWi tch. the coil primary Winding, the amplifier module and then to ground. When the current is interrupted, the magnetic field in the Ignition coil collapses. inducing a high voltage in the coil secondarywmdings. The voltage is con ducted to the distributor where the rotor directs it to the appropriate spark plug. This process is repeated continuously. All vehicles are equipped With a gear dflvefl distributor with a die cast base housing a "Hall Effect' vane switch stator assembly and a device lor fixed octane adjustment. However. there are a few differences between earher Canadian and US distributors. Duraspark distributors have a two piece cap. When removing the cap, the upper hall is removed. then the rotor is removed. then the lower half of the cap is removed . TFI·IV dlstflbutors have a conventional one piece cap. The distributors on earlier Canadian vehicles are equipped With centrifugal and vacuum advance mechanisms which control the actual point
Chapter 5
Engine electrical systems
01 '9nlllOn based on engine speed and load. As engine speed increases, two weights move out and alter the poSltJon of the armature In relation to the distributor shalt. advancing the tgnilion tlmmg. As engine load In-
creases (when climbing hills or accelerall/1g. 101' e~amplel. a drop in intake manllold vacuum causes the base plate to move sllghlly in the opposite directIOn (clockWise) under the actIOn 01 !he spring in the vacuum unit retarding the liming and counteracting the centnlugal advance. Under light loads (moderate steady speeds, lor example). the comparatively high in· take manifold vacuum acting on the vacuum advance diaphragm causes the base plale assembly to move In a counterclockwise directIOn to pro· vide a greater amoont of \!mlng advance Early models may be eqUIPped With OtJraspatk I (DSI) or Duraspark II (OSU) ignition modules. MOSII983 and 1984 models are eqUipped With the standard Duraspar\o; II '9M1on module. Later models use the Thick Film Integrated IV [TFI-IV) ignitIOn module. which is housed in a molded thermoplastic box mounted on the base of the distributor. The Important difference between the 0511 and TFI-IV modules is that the TFI-lV module is controlled by the Electronic Engine Control IV (EEC-IV). while the Duraspar\o; I and II modules are not. The TFI-IVIEEC·IV type distributor is similar to the Duraspark II model but has neither a centrllugal nor a vacuum advance mechanism (advance is handled by the computer instead). The TFI-IV module does, however, include a "push start" mOde that allows push starting of the vehicle il necessary.
Distributorless (DIS) type The 1992 2.3L lour ·cyllnder engines ate eqUipped With the Distributorless IgmtlOn System (DIS) that IS a solid state electronic design. It consists of a crankshaft Itmlng sensor, EDIS module, one ignitIOn coil pack, the spark angle portion of the EEC IV, the spark plug wires and the spark plugs ThIs ellglne features a twin spark plug cylinder head and IS eqUipped WIth an igmtlon coli lor each pair 01 spark plugs. This IgMlon system does not have any moving parts (no distributor) and all engme tlmlllg and spark dlstnbullon IS handled electronically. This system has fewer parts that reqUire replacement and prOVide more accurate spark timing Dunng engine operaIJon, the EOIS igmtlon module calculates spark angle and determines the turn-on and linng time 01 the ignition COil The crankshaft timing sensor Is a vanable reluctance·type sensor consisttng 01 a 36-tooth tflgger wheel With one missing tooth that is incorpo· rated Into the crankshaft front damper The signal generated by thiS sensor IS called a Variable Reluctance Sensor Signal (VRS) and it provides the base timing and engine RPM inlormallon to the EDIS ignition modules. The main functIOn of the EOIS module is to synchronize the ignition COils so they are turned on an off In the proper sequence lor accurate spark con trol.
5-3
and check them as descnbed In Chapter 1 or install new ones. 4 If flO sparll.s or inlermlttent sparks occur, remove the distributor cap and check the cap and rOlor asdescribed in Chapter \. If motsture IS present, dry out the cap and rotor, then reinstall the cap and repeal the spark test. 5 If Ihere's still no spark. detach the secondary COil wire from the distributor cap and hook It up to the lester (reattach the plug wife 10 the spark plug), then repeat the spark check 6 If no sparks OCCUr, check the pnmary (small) wire coonecbons at the coil to make sure they're clean and light. Refer to Section 7 and check the ignillon COIl supply voltage clfcui1. Make any necessary repairs, then repeat the check again. 7 II sparks now occur, the distnbutor cap. rotor. plug wlfe(s) or sparll. plug(s) (or all of them) may be defective. B II there's stili no spark. the coil·to-cap wife may be bad (check the resistance With an ohmmeter and compare it to the Specifications). If a known good wire doesn't make any difference in the test results, the ignition COil, module or other Internal components may be defective.
Alternative method Note: If you're unable /0 obtain a calibrated ignilion leSlor, Ihe following melhod will allow you /0 delermin6 if Ifw /gnilion system has spark, but il won't lell you if Ihere 's enough voltage produced /0 actually iniliale combustion in Ihe cylinders 9 Removethewire from one of the sparll.plugs. Using an insulated tool. hold the wire about 1I4-lnch from a good ground and have an assistant crank the engine. 10 If blight blue. well·deflned sparks occur, suffICient voltage is reaching the plug to fire it. However. the plug(s) may be fouled , so remove and check them as described in Chapter 1 or install new ones. 11 If there'S no spar1<, check the remaJning wtres in the same manner. A few sparks followed by no sparll. IS the same condilion as no spar1< at an. 12 II no sparks occur, remove the distributor cap and check the cap and rotor as described In Chapter 1. II moisture is present, dry out the cap and rotor, then reinstall the cap and repeat the spark test. 13 If there's still no spark, disconnect the secondary coil wire from the distribulorcap. hold It about 1/4-inch from a good engine ground and crank the englfle again. 14 If no sparks occur, check the pnmary (small) wife connectIOns at the coil to make sure they're clean and tight. 15 II sparks now occur. the dlSlnbutor cap, rotor, plug wlfe(s) or spark plug(s) (or all of them) may be defective. 16 If there's stili no Spark, the COII-\O-Cap wife may be bad (check lhe resistance with an ohmmeter and compare it \0 the Specifications), If a known good wife doesn'l make any difference in the tesl results, the ignition coil, module orotherlflternal components maybe defective. Referfurther testtng to a Ford dealer or qualified electrical specialist.
Distributorless (DIS) Ignition system 6
Ignition system - check
Refer 10 ,lluslrallOn 6.2 Warning : Becauseof Ihe very htgh secondary (spark plug) voltagegeneraled by lhe tgniflon syslem. exlreme care should be taken when Ihis check is done.
Distributor type Ignition system (Duraspark II and TFlIV) Calibrated ignition tester method 1 If the engine lurns ovel but won't start, disconnect the spark plug lead from any sparll. plug and attach /110 a calibfated Igmtlon lester (available at moSI auto parts stores). Make sure the tester is designed lor Ford Ignition systems If a unlversaltesler Isn-t available 2 Connecl the clip on the tester to a bolt or metal bracket on the engine (see Illustration), crank Ihe engine and watch the end of the tester 10 see ~ bright blue, well-defined sparks occur 3 It spar\o;s occur, suffiCient voltage is reaching the plug to fire it (repeat the check at the remaining plug wlfes to verify that the distnbulor cap and rotor are OK) However. the plugs themselves may be lou led, so remove
Calibrated ignition tester method Note : Disconnecithe spark plugs for Ihls tesl from /he exhaust side only. 17 If the engtne turns over but won't start, disconnect the spark plug lead from any spark plug and attach It to a calIbrated igrution tester (available al most auto parts stores). Make sure the tester is designed for Ford tgnitJOn systems If a universal tester isn't available. 18 Connect the clip on the tester to a bolt or metal bracket on theengtne (see Illustrallon 6.2), crank the engine and watch the end 01 the tester to see If bftght blue, well-defined sparks occur. 19 II spar1ls occur, sufficl8nt voltage is reachlf'lg the spark plug to fite It (repeat the check at the remaining plug wires to verity that alilhe IQnitlOn coils and WIres are functioning) , However, the plugs themselves may be lou led, soremove and check them asdescribed in Chapter 1 orinstall new ones 20 If no sparks orintermlnent sparks occur. there's a problem in the Ignition system. Checto; for a bad spark plug wire by swapping wires. Refer further testing to a Ford dealer or qualified electrical specialist.
Alternative method Note: If you're unable 10 obtain a calibraled ignitIOn lester. the following melhod Will allow you 10 delermine if the ignition system has sparlc, bu/;I
5
5-4
Chapter 5
Engine electrical systems
CONNECTION
7.4 To replace the Ignition coli, detach the cable from the negative terminal of the battery, unplug the coli primary connection, detach the coli secondary lead and remove
both coli bracket bolts won', /ell you if there's enough voltage produced to actually initiate comoustion in the cylinders.
Note: Disconnect the spark plugs for this lest 'rom the 81(haus/ side only. Aemovethewire Irom one of the spa~ plugs. Using an insulated tool, hold the wire about 114-il"lCh from a good ground and have an assistant
21
crank the engine. 22 II bright blue, well-defined sparks occur, sufficient voltage Is reaching the plug to fire il. However, the plug{s) may be fouled, so remove and check them as described in Chapter 1 or install new ones. 23 If there's no spark, check the remaining wires in the same manner. A lew sparl\s lollowed by no spark is the same condition as no spark at all. II there'ssparl\ at some wires but not at others. bad sparl\ plug wires may be the problem. Swap the wires and re-test to see ilthe wires are the problem. 24 IIthere's still rIO sparl\s orinterminent sparl\s. there's a problem in the ignition system. Reier further testing to a Ford dealer or qualified electrical specialist.
7
Ignillon coil - check and replac ement
Distributor type Ignition system (Duraspark II and TF/-/V) Refer to illustration 7.4
Check With the Ignition off. disconnect the wires from the coil. Connect an ohmmeter across the coil primary (small wire) terminals , The resistance should be as listed in this Chapter's Specifications. II not. replace the COIl. 2 Connect and ohmmeter between the negative primary terminal and the secondary terminal (the one that the dist ributor cap wire connects to). The resistance should be as listed in this Chapter's Specifications. If not, replace the coil.
Replacement 3 Detach the cable from the negative terminal 01 the battery. 4 Detach the wires from the primary terminals on the coil (some coils have a single electrical connector for the primary wires) (see illu stration ). 5 Unplug the coil secondary lead. 6 Remove both bracket bolts and detach the coil. 7 Installation is the reverse of removal.
Distributorless (DIS) ignition system Note : Checking the DIS coil is beyond Ihe scope of the home mechanic. Remove the coil as described below and take ilto a dealer service department for diagnosis.
8 Disconnect the negative cable from the battery. Squeeze the locking lab of the ignition coil wire retainer by hand and 9 remove the spark. plug lead from the ignition coi l assembly with a twisting and pulling motion. 00 NOT just pull on the wires to disconnect them . Disconnect all spark plug leads. 10 Disconnectthe engine wiring harness from the Ignition coil assembly. II Remove the three bolts securing the ignition coil to the mounting bracket on the engine. 12 Installation is the reverse of the removal procedure with the lollowing additions: a) Prior to installing the spark plug lead into the ignition coil. coat the entire Interiorol the rubber boot wi th Silicone Dielectric Compound (Ford part No. D7AZ·19A 133-A) or equivalent. b) Insert each sparl\ plug wire into the proper terminal 01 the ignition coil. Push the wire into the terminal and make sure the boots are fully seal ed and both locking tabs are engaged properly.
8
Distributor - removal and InstaUatlon
Removal 1 Unplug the primary lead from the COIL 2 Unplug the electrical connector lor the module. Follow the wires as they exit the distributor to find the connector. Note the ra ised -,- on the distributor cap. This marl\s the location for 3 the number one cylinder spark plug wire terminal. Remove the distribu tor cap (see Chapter 1) and turn the engine over 4 until the rotor is pointing toward the numbe!J:lne span<. plug terminal (see the locating TDC procedure in Chapter 2) . 5 Make a mark. on the edge of the distributor base directly below the ro· tor tip and in line with it (if the rotor on your engine has more than one tip. use the center one lor reference) . Also, marl\ the distributor base and the engine block to ensure that the distributor is installed correctly. 6 Remove the distributor hold·down bolt and clamp. then pull the distributor straight up to remove it. Be careful not to disturb the intermediate driveshaft. Caution : DO NOT tum the engine while the distributor is removed, or the alignment marks will be useless.
Installation 7 Insert the distributor into the engine in e~actly the same relationship to the block that it was in when removed , 8 To mesh the helical gears on the camshaft and the distributor, it may be necessary to turn the rotor slightly. If the distributor doesn't seat completely. the hex shaped recess in the lowerendol thedistributorshaft is not mating properly with the oil pumpshatt. Recheck the alignment marl\s between the distributor base and the block to verify that the distributor is in the same poSition it was in before removal. Also check the rotorto see ifir s aligned with the marl\ you made on the edge of the distributor base. Note: If the crankshaft has been moved while the distribUlor is out, locate Top Dead Center (rDC) for the number one p'ston (see Chapter 2) and posilion the distributor and rotor accordingly. 9 Place the hold-down clamp in position and loosely install the boll. 10 InstaJi the distributor cap and tighten the cap screws securely. 11 Plug in the module electrical connector. 12 Reattach the spark. plug wires to the plugs (if removed). 13 Connect the cable to the negative terminal of the battery. 14 Check the ignition timing (refer to Section 9) and tighten the distnbutor hold·down bolt securely.
9
tgnition liming - check and adjustment
Nole 1: Ignition fimingon thedistributor/ess (DIS)igmlionsystemispreset and cannot be checked or adjusted. Note 2: Always check the Vehicle EmIssion Control Information (VECI) label on your vehicle to see if a different procedure is specified, The VECI label contams detailed information which is specific fa your vehicle. 1
Applythepan<.ing brake and block thewheels. Place the transmission Pan<. (automatic) or Neutral (manual), Turn off all accessories (healer, air conditioner, elc.).
In
Chapter 5
Engine electrical systems
5-5
"
0'
0,
, , 0',
0'
, , ,
10.2 Ouraspark IIlgnilion systems will have one or the other of the above IgnItion modules - the one on the left, known as a Universal Ignilion Module (UIM), has Ihree electrical connectors; Ihe one on Ihe right Is the standard Duraspark I or II module with two connectors
10.6
To remove the TFI-IV Ignition module trom the distributor base, remove the two screws (arrows), ...
10.7 ... then pull the module straIght down to detach the spade terminals Irom the stator connector
Start the engme and warm it up. Ooce It has reached operating lemperature. turn It off. 3 It you have a vehicle with a OSI or DSII ignition system (see Section 5), disconnect the vacuum hoses trom Ihe distributor vacuum advance unit and plug Ihe hoses. 2
4 If you have a later model vehicle with an EEC-IV system, unplug the single wire connector located Immediately above the harness connector lor the module 5 Connect an InductIVe liming light and a tachometer In accordance With the manufacturer's Instructions. Caution : Make sure thaI the timing
IIghl and lach WIres don', hang anywhere near ,he electric coohng fan or lhey may become entangled In lhe fan bJades when the fan beginS to rolate. 6 locale the \lmlng marks on the crankshaft puiitty (see ChapU~1 2). 7 Start the engine again. B POint the timing light at the pulley timing marks and nOle whether Ihe speci1ied liming mark (see th e VECllabel) IS aligned with Ihe liming POinter on the fronl 01 the timing chalnJbelt cover, 9 II the proper mark Isn't ahgned With the stationary pointer, loosen the dlSlnbutor hold·down bolt. Turn the dlstnbutorclockwlse (10 retard Ilming) or counterclockwise (to advance timing) until the correct timing maf1<. on the crankshaft pulley is aligned With the stationary pClInlef. TIQhlen Ihe dlstnbutar hoId·down bolt securely when the bmlng iscoHect and recheck 1\ 10 make sure II didn't change when the bolt was tightened 10 Turn olf the engine II Plug in the Single wire connector (TFt-JV -eqUipped vehicles) or attach the vacuum I\oses (051- or OSIl-equlpped vehicles). 12 Reslart the engine and check the idle speed, The specified rpm for
10,8 Be .ur. to wipe the back side of the module clean and apply a film dielectric grease (essential for cool operation 01 the module) - DO NOT use any other type of grease!
0'
each vehicle is dillerent (see your VEC I label), On vehicles with an adjustable idle speed, see Chapter 1 lor adjustment procedure. On engines equipped With automatic idle speed control. idle rpm is not adjustable. " the idle rpm is not Within the range specified on your VECllabel, take the vehicle to a dealer service department or repair shop. Adjustment requires specialized lest eqUipment and procedures that are beyond the scope of the home mechanic. 13 Turn 011 the engine. 14 Remove the liming light and tachometer
10
Ignition module - replacement
Caution: The ignition module;s a delic:a/9 and f91atJVelyexpensive elec-
tronic compon9nt. Failure to follow the step-by-step procedures could re· suit in damage to the modul9 and/or other electronic devices, including the EEC-IV microprocessar itself. Additionally, all devices under computer control are protecled by a Federally mandated extended warranty. Check WIth your dealer before allemplmg to replace them yourself.
Duraspark I and /I ignition module Refer 10 II/USUS/Ion 10.2 1 Delach the cable from lhe negallve tem'lInal ollhe battery. 2 Vehicles eqUipped With a Duraspaf1<.1 or II system may have either Ihe standard Ouraspark I ar II module orlhe universal ignllion module (see II· lustratlon). If your vehicle is equipped wllh Ihe standard module, unplug both connectors: il your vehicle IS equipped With Ihe UIM module, unplug all three connectors,
5
5-6
Chapter 5
Engine electrical systems
oun" ....., Of a. ..... KS>W'T
I'VlUv ..... , ASS .......
c....... ~s"...-r ~ALl . . . .CT SENSQII "OSlTlONf.
......,. ..........
~""'''''
10.12
3 4
EDIS Ignition module installation details
11.6 The crankshaft timing sensor assembly and wiring harness
Remove the mounting screws and detach the module. Installation is the reverse 01 removal.
TFI-/V ignition module Refer /0 iI/us/rations 10.6, 10.7 and 10.8
5 Remove the distributor Irom the engine (reler to Section 8) if access to the module is blocked. 6 Remove the two module mounting screws with a 1/4·inch drive 7/32·inch deep socket (see Illustration). 7 Pull slraighldownon the module to disconnect Ihe spade connectors Irom the stator conneclor (see illustration). 8 Whether you are installing the old module or a new one, wipe the back side of the module clean with a soft, clean rag and apply a film of silicone dielectric grease 10 the back side of Ihe module (see Illustration). 9 Installation is the reverse of removal. When plugging in the module, make sure that the three terminals are inserted all the way into the stator connector.
EDIS ignition module Refer to illustration 10.12 10 Disconnect the negative cable from the banary. 11 Disconnect the electrical connector from the EDIS ignition module. 12 Remove the screws securing the EOIS module to the lower intake manifold (see illustration). t 3 InstallatJon is the reverse 01 the removal procedure. Prior 10 installing the EOIS module onlo the manifold, apply about a 1132·inch of Silicone Dielectric Compound (Ford part No. 07 AZ -19A 133-A) or equivalent to the mounting surlace of the module.
11
Crankshaft timing sensor (DIS ignition systems) - removal and installation
Removal Refer to illustration I 1.6 I Disconnect the negative cable from the banery. 2 Disconnect the crankshafllimlng sensor electrical connector from the engine main wiring harness. 3 Pry out the red retaining clip and remove the four wires. then remove the large electrical connectorfrom the crankshaft timing sensor assembly. 4 Remove the accessory drivebelts. Ihe crankshaft pulley assembly and the timing belt outer cover (see Chap!er 2A). 5 Rotatethecrankshaft sothe keyway is atthe ten o'clock position. ThiS will locate the vane window of both the inner and outer vane cups (part of the crankshaft pulley hub assembly) over the crankshaft timing sensor assembly. 6 Remove the two bolts securing the cranks halt timing sensor assem-
11 .13
Rolale Ihe crankshaft so Ihe
outer vane on the crankshaft pulley hub assembly engages both sides of Ihe Crankshaft Hall Effect Sensor Positioner
bly to the cylinder block (see illustration). 7 Remove the bott securing the wiring harness plastic retainer 10 Ihe mounting bracket. Carefully slide the wiring harness out from behind the timing belt inner cover and remove the crankshaft timing sensor assembly.
Installation Refer to illus/ration 11. 13 8 II a new crankshaft timing sensor assembly is being Installed, remove the large elecnicalconneclor from II. II installing the old assembly, the conneclor is already removed 9 Slide the electrical wire harness behind the timing belt inner cover. 10 InSlall the crankshaflliming sensor assembly InIO place and install the two boilS linger tight al this lime. II Install the large electrical connector onto Ihe harness. Caution: Ensure the four wires are Installed in the proper locatIOn Within the connector. /! installed Incorrectly the sensor will NOT operate correctly. 12 Connect the electrical connector to the engine main Wifing harness. 13 Rotate the crankshaft so the outer vane on the crankshaft pulley hub assembly engages both Sides of the Crankshaft Hall-Effect Sensor Positioner (Ford part No. T89P-6316-A). or eqUivalent (see illustration). Tighten the crankshalt timing sensor assembly mounting bolls. 14 Rotate the crankshaft so the outer vane on the crankshaft pulley hub assembly no longer engages the pOSitioner tool. then remove the toot. 15 Install the wire harness plastiC retainer. Install the bolt and tighten securely. If a new retainer was installed, trim off the excess. 16 Install the liming belt outer cover. the crankshaft pulley assembly and the accessory drive belts (see Chapter 2A) . 17 Anach the negative cable to the battery.
12
Charging system - general information and precautions
The charging system Includes the alternator. either an Internal or an external voltage regulator, a charge indicator or warning light. the battery, a fusible link and the wIfing between all the components. The charging system supplies electrical power forthe igOilion system. the lights. the radio. etc. The alternator is driven by a drivebelt at the front of the engine. The purpose of the voltage regulator is to limit the alternator"s voltage to a preset value. This prevents power surges, circuit overloads, etc. duro ing peak voltage output. On EVR (external voltage regulator) systems, the regulator is mounted on the right fender apron of the vehicle. On IAR (integral alternatorl regulator) systems. a solid state regulator is housed inSide a plastic module mounted on the alternator Itself. The fusible link is a short length 01 insulated wire integral With the engine compartment wiring harness . The link IS four wire gauges smaller in diameter than the circuit it protects. Production fUSible links and their identification lIags are identified by the flag color. Referto Chapter 12 for additional information on fUSible links
Chapter 5
Engine electrical systems
5-7
• ·- 1 . ~' .~
';"::':' ~r-~....·I·. .• ' I. ~ o
l.
.,
-I 13.2 To measure battery voltage, attach the voltmeter leads to the battery terminal s - to measure chargIng vollage, start the engine
14.2 To remove the alternator, unplug the electrical connectors (arrows)•...
The charging system doesn't ardmanly require periodic maintenance. However, the dflvebelt, banery and wires and connections should be inspecled at the Intervals outlined in Chapl&!" 1. Be very careful when making electrical CirCUlI connectIOns to a vehicle eqUipped WIth an alternator and note !he following : a) When reconnecting wires 10 the alternator from the banery. be sure to note the polarity. b) Before USing arc welding equipment to repair any part 01 the vehicle, disconnect the wires Irom the alternator and the battery terminalS. c) Never stan Ihe engine with a battery charger connected. d) Alwaysdlsconnectboth battery leads betoreusll1ga batterycharger.
13
Charging sys tem - Check
Refer 10 illus/fallon 13.2 II a malfunctIOn occurs In the charging CirCUit, do not immediately assume that the alternator IS causing the problem. First check the following ~ems :
a) The battery cables where they connect to the battery. Make sure the connections are clean arn;l tight. b) The battery electrolyte specific gravity. If it is low, charge the battery. c) Check the external alternator wifing and connections. d) Check the drivebelt conditIOn and tension (see Cnapter t). e) Check the alternator mounting bolts for lightness. f) Run the engine and check the altemator lor abnormal noise. 2 USlTlg a voltmeter, check the battery voltaoe with the engine 011. It should be approximately I 2-volls (see lIIustr.llon). 3 Stanthe engine and check the battery voltage again. It should now be approximately 14 to 1S-voIIS. 4 If the indicated voltage reading is less or more than the specified charging voltage, replace the voltage regulator. II replacing the regulator fails to restore the voltage to the specified range, the problem may be within the alternator. 5 Due to the speoal equipment necessary to test or service the alternator. it IS recommended that if a faun is suspected the vehicle be taken to a deaJ8f or a shop with the proper eqUipment Because ollhis, the home mechanIC should limit mamtenance to checkmg connections and the inspec· tion and replacement of the brushes. 6 The ammeter (1979 through 1986 models) on the instrument panel indicates charge or discharge - current passing into or out 01 the battery. With the electrical eqUipment sWl!ched on and the engine Idling, the gauge needle may show a discharge condition. AI last idle or at normal drivmg
fill/II
J
14.3 ... remove the dtlvebelt, remove the strut bolt (upper left arrow). swin g the strut out of the way and remo ve both alternator mounting bolls (arrowl)
speeds the needle should stay on the charge side of the gauge, With the charged state 01 the battery determining lust how far over (the lower the battery state of charge. the farther the needle should swing toward the charge side). 7 The voltmeter on the Instrument panel (1987 and later models) indicates battery voltage with the key on and engine 011 , and altemator output when the engine is running. 8 The charge light on the instrument panel illuminates with the key on and engine not running, and should go out when the engine runs. 9 II the gauge does not show a charge when it should or the alternator light (it equipped) remains on, tl"lere is a fault In the system. Before inspecting the brushes or replacing the altemator, the battery condition, altemator belt tension and electrical cable connections should be checked.
14
Alternator - ,emoval and Inl tallation
Refer 10 Illuslralions 14.2 and 14.3 I Detach the cable from II"Ie negalive terminal 01 tl"le battery. 2 Unplug the electrical connectors from the alternator and (If your charging system is equipped with an IAR type altamator) the voltage regu· lator (see illustrallon). 3 Loosen the alternator bolts (see illustration) and detach the dnvebell. 4 Remove the adjustment and piIIot bolts and separate the altemator from the engine. S Installation is the reverse of removal. 6 Alter Ihe alternator IS installed, adjust the dnvebelt tension (refer to Chapter I).
15
Alternator brushes - replacement (EVR type allamator)
Note : Internal replacement parts fOf allemators may nol be feadily avail· able In your area. Check into availability before proceeding.
Rear terminal alternator Refertoilluslratrons 15.2, 15.Sa, IS.5band 15.7 I Remove the alt8fnator as described in SectIon 14. 2 Scnbe a 608 across tile length of the anemator housing to ensure cor-
rect reassembly (see iIIustrallon). 3 Remove the housing through bolts and the nuts and insulators from the rear housing. Make a carelul note of all Insulator locations. 4 Withdraw the rear housing section from the stator. rotor and front housing assembly.
II
5-8
15.2
Chapter 5
Scribe a line across the alternator housing for alignment referen ce
IS.5a
Engine electrical systems
Remove the boils and detach Ihe
brush holder and the brush in the holder
15.5b Remove the rear field housing nut (orange) to detach the remaining brush
G"OUNO _ _~III EVElET
8"USI< I
B"USI<
'" BRUSI<
15.7
15.1 B
Insert a paper c lip through the hole In the back to reta in
the brushes 5
A piece of stiff wire Is used to hold the brushes In place on a side termin al alternator
Remove the brushes and springs from the brush holder assembly,
which is located inside Ihe rear housing (see illustrations).
16 Remove any sealing compound trom the brush holder and rear hous-
6 Check the length 01the brushes against the wear dimensions given in Ihe Specifications and replace the brushes with new ones if necessary.
ing.
7 Install the springs and brushes in the holder assembly and retain them in place by inserting a piece of sliff wire through the rear housing and brush terminal insulator (see illustration). Make sure enough wire protrudes through the rear housing so It can be wilhdrawn at a laler slage. 8 Attach the fear housing. rolor and front housing assembly to the stalor. making sure Ihe scribed marXs are aligned. 9 Install the housing through bolts and rear end Insulators and nuts but do not tighten the nuts at thiS time 10 Carefully edract Ihe piece ot wife from Ihe rear housing and make sure thaI the brushes are seated on the slip ring. Tighten the through bohs and rear housing nuts. tl Install the alternator as described in Section 14.
Side terminal alternator Refer to illustration 15.18 12 Remove the alternator as descflbed in Secllon 14 and scribe a marX on both end housings and the stator for ease of reassembly. 13 Remove the through bolts and separate the front housing and rotor from the rear housing and stator. Be careful that you do not separate the rear hOUSing and stator. 14 Use a soldering iron to unsolder and disengage the brush holder from the rear housing. Remove the brushes and spnngs from the brush holders. 15 Remove the two brush holder attaching screws and lift the brush holder trom the rear hOUSing.
17 Inspect the brushes for damage and check their dimensions against the Specifications. II they are worn. replace them with new ones. 18 To reassemble, install the springs and brushes in the brush holders. inserting a piece ot still wire 10 hold them In place (see illustration). 1g Place the brush holder in position in Ihe rear housing. using the wire to retract the brushes th rough the hole in the rear housing. 20 Install the brush holder attaching screws and push the holder toward the shaft opening as you tighten the screws. Caution; Therectifiercan be overheated and damaged if the soldering is not done quickly. Press the brush holder lead onto the rectifier Jead and solder them In place. 21 Place the rotor and Iront hOUSing In position in the stator and rear housing. Afte r aligning the scribe marXS, install the through bolts. 22 Turn the fan and p,Jlley to check for binding in the alternator. 23 Withdraw the wire which is retracting the brushes and seal the hole with waterproof cement. Caution ; Do not use RTV·type sealer on the
hole.
16 1 2
External Voltage Regulator (EVR) - replacemenl Detach the cable from the negative terminal of the battery. Locate the vollage regulator on the right side of the engine compart-
ment. 3 II necessary. remove the banery or air cleaner duct to gain access to the voltage regulator.
Chapter 5
17.3
To detach the voltage
regul ator/bru sh holder assembly, remove Ihe lour screws (arrows)
4 5 6 7
17
Engine electrical systems
17.5 To remove the brush es trom Ihe voltage regulator/brush holder assembly, detach th e rubber plugs from the two brush lead w ire sc rews and remove both screws (arrows)
Unplug the electncal connector Irom the voltage regulator. Remove lhe regulalor mounhng boilS Remove the regulator Instaltatlon IS the ,everse of removal
Voltage regulator/alternator bru shes - replacement (IAR· type alternator )
5-9
17.9 Before installing the vottage regulator/brush holder assembly, insert a paper clip as shown to hold the brushes in place during Installation - after installation, simply pull the paper clip out
lery to Ihe starter. The battery supplies the eleclricaJ energy to the starter motor. whICh does the actual work 01 cranking the engine. Vehicles equipped wilh an automabC transmission have a Neutral start SWitch In the starter control CIrCUlI. which prevents operation altha starter unless the shift lever is in Neutral or Park. The circuit on vehicles with a manuallransmission prevents operation of Ihe slarter molar unless the clutch pedal is depressed. Never operate Ihe starter motor lor more than 30 seconds at a time Without pausing to allow it to cool lor al least two minutes. Excessive cranking can cause overheating, which can seriously damage the starter.
Refer to illustratIOns 17.3, 17.5 and 17.9
1
Remove the alternator (refer to Section t3). Set the alternator on a clean workbench 3 Remove the lour voltage regulator moun\!ng screws (see illustration ) 4 Detach the voNage regulator 5 Detach the rubber plugs and remove the brush lead retaining screws and nulS 10 separale the brush leads trom the holder (see illustration). Note that the screws have Torx heads and require a special screwdriver. 6 Alter noling the relationship ot the bl1Jshes to the bl1Jsh holder assembly, remove both bl1Jshes. Don't lose the springs. 7 II you're installing a new voltage regulator, insert the old brushes into the brush holder 01 the new regulator. II YOU're installing new bl1Jshes, insert them inlO the brush holder of the old regulator. Make sure the sprmgs are properly compressed and the brushes are properly inserted into the recesses In the brush holder. 8 Inslallthe brush lead retaining screws and nuts. 9 Insert a short section of wire. like a paperClip. through Ihe hole in the voltage regulator (see Illustration) to hold the brushes In the relracted position dunng regulator Installation. 10 Carefully Instalilhe regulator. Make sure the brushes don'l hang up on Ihe rOlor. 11 Instalilhe voltage regulator screws and lighlen Ihem securely. 12 Remove Ihe wire or paper clip. 13 InSlall the alternator (reter to Section 14).
2
18
Starting system - general lnlo rmation
The lunction ollhe starting system IS 10 craM tha engine \0 slart il. The system IS composed ollhe slarter motor. starter retay, battery. sWitch and connecting wires. Turning the igOllJOn key to the Start poSition actuates the slarter relay through the slarter control CirCUit. The starter relay then connects the bat-
19
Starter motor and c ircuit -In-vehic le check
Nota: Before dlagnoslng slaffer problems, make sure lhe banery IS fully
charged
General check If the starter motor doesn't tum at all when the switch is operated, make sure the shift lever is in Neutral or Park (au tomatic transmission) or the clutch pedal is depressed (manual transmission). 2 Make sure the battery Ischarged and that all cables at the battery and starter relay terminals are secure. 3 II the starter motor $pins but the engine doesn't turn over. then the dnve assembly in the starter motor is slipping and the stalter motor must be repiaceCl (see Secbon 20)_ 4 If, when Ihe SWitch is actuated, the starter motor doesn't operate at all butthe starter relay operates (clicks), then the problem ties with either the battery, the starter relay contacts or the starter motor connections, 5 If the starter relay doesn', click when the ignition switch is aChJated, either the starter relay circuit is open orthe relay itseliis detective. Check the starter relay circuit (see the wiring diagrams at the end of this book) or replace the relay (see Section 21). 6 To check the starter relaycircuil. remove the push-on connector from the relay wire. Make sure that the connection is clean and secure and the relay bracket is grounded. If the connections are good, check the operation of the relay With a jumper wire. To do this, place the transmission in Park (automatIC) or Neutral (manual). Remove the push-on connector from Ihe relay Connect a jumper wire between the battery poSItive terminal and the exposed terminal on the relay. II the starter motor now operates,the starter relay is okay. Theproblem isin the ignition switch, Neu\fal slart SWitch, starter/clutch SWitch. or in the starting circuit wiring (look for open or loose connections). 7 It the starter motor Slill doesn't operate, replace the starter relay (see Section 21 ).
II
5 -10
Chapter 5
Engine electrical systems
·-
•:•
•• •• \
..
".
" 20.6
19.13
B
The four test lead connections for the starter cranking circuit test
If the starter molor cranks the engme al an abnormally slow speed,
first make sure the battery is tully charged and all terminal connections are clean and tight. Also check the connectioos at the starter relay and battery ground. Eyelet terminals should not be easily rotated by hand. Also check for a shorlloground.1f the engine Is partially seized, orhas the wrong viscosity 011 In it, it will crank slowly.
Starter cranking c;rcult test Retano illustration 19. 13 Note: To determine the location of excessive res/slance in the slartercir' cuit, perform the following simple series of tests. 9 Disconnect the ignition coil wire Irom the dislribulOl' cap and ground it
20
The starter molor lower mounting bolt (arrow) (upper bolt not vi s ible)
Starter molor - removal and In sl allatl on
Refer /0 "lus/rallOfl20.6 I Detach the cable Irom the negahve termmal 01 the battery. 2 Raise the vehicle and support it securely on jackstands. 3 Disconnect the large cable Irom the terminal on the starter motor 4 1979 models - remove four bolts that secure the crossmembar under the transmission bellhousing. Remove the screw that secures the fleK coupling to the steering gear. Detach the flex coupling and pull the steering gear down. S 4.2L va engines - remove the wishbone brace. 6 Remove the starter motor mounting bolts (see illustration) and detach the starter Irom the engine. II necessary. turn the wheels to one side to provide removal access. 7 8 Installation IS the reverse 01 removal
on Ihe engine. 10 Connect a remote control starter SWitch from the battery terminal 01
the starter relay to the 5 terminal 01 the relay. t! Connect a voltmeter poSitive lead to lhe starter motor terminal of the starter relay, then connect the l'Iegative lead to ground. t2 Actuate the ignition switch and take the volt meier readings as soon as a steady figure IS indicated. Do not allOw the starter motor 10 turn 10f more than 30 seconds at a time. A reading 019-volts or more. with the starter motor turning at normal cranking speed, Is normal. lithe reading is 9·volts or more but the cranking speed is slow, the molor is laulty. lithe reading is less than 9-volts and the cranking speed is slow. the relay conlacts are probably burned. t3 Make the test connections as shown (see Illustration)_Reier 10 this illustration as you perform the lollowing lour tests_ t4 Operate the ignibon switch and take the voltmeter readings as soon as a steady figure is indicated. Don't allow the starter motor to turn lor more than 30 seconds at a time. tS The voltage drop in the cirCUit Will be indicated by the voltmeter (put the vollmeter on the 0-10-2 volt range ). The maximum allowable voltage drop should be: a) O.S-voll With the voltmeter negative lead connected to the starter terminal and the positive lead connected to the battery positive terminal (Connection t In Illustration t9. t3). b) D. I -volt with the voltmeter l'Iegative lead connected to the starter relay (battery side) and the poSitive lead connected to the positive terminal 01 the battery (Connection 2). c) 0.3-vott WIth the voltmeter negatlV£ lead connected 10 the starter relay (starter side) and the positIVe lead connected to the poSitive terminal ot the battery (Connection 3). d) O.3-volt With the voltmeter negative lead connected to the negative terminal 01 the battery and the positive lead connected to the engme ground (Connection 4).
21
Starter relay - removal and installati on
Refer to iIIus/ration 21.2 I Detach the cable from the negative terminal of the battery. 2 Label the wires and the terminals then disconnect the Neutral sal ery switch wire (automatics only). the ballery cable, the lusible link and the starter cable trom the relay terminals (see illustration). 3 Remove the mounting bolls and detach the relay. 4 Installation is the reverse 01 removal
21 .2 To remove the starter relay, detach the Neulral safety switch wire (if equipped with an automatic), the fusible link, the battery positive lead and the , tarter motor leads (arrows), then remove the relay mo unting bracket bolts (arrows )
Chapter 6
Emissions control systems
Contents
Catalytic converter ElectroniC Engine Control (EEC-IV) system Exhaust Gas Recircu lallon (EGA) system Fuel evaporative emisSions control system General information
9 2
Inlet air temperalure"con trol system Managed air lhermactor system Microprocessor control unit (MCU) system PosItive Crankcase Venhlallon (peV) system
, 6
8 5 3 7
Specifications
Torque specifications
Ft-Ibs
Air pump pulley bolts Air pump moun\lng bolts
10 to 12.5 25
General information Refer /0 IIlus/rallon 1.7 To prevent po llution of the atmosphere from Incompletely burned and evaporatmg gases, and to mamtam good dnveabihty and fuel economy a number of emission control systems are Incorporated They Include Ihe' Microprocessor COn/rol Unif (MeU) system ElectrOniC Engme Control (EEC-/v) system Exhaust Gas ReCirculatIOn (EGR) system Managed Thermactor Air (MTA) system Fuel evaporatIVe emiSSion control system Positive Crankcase Ventilation (PCV) system Inlet air temperature control system CatalytiC converter
On vehicles equipped With EEC- IV, all of these systems are hnk.ed, directly or indlreclly. to the EEC-IV system The Sections In th iS Chapter Include general descnpliOns, checkmg procedures Within Ihe scope of the home mechanic and component replacement procedures (when poSSible) for each of the systems listed above Selare assuming that an emiSSions control system Is malfunCliOnlng, check the fuel and Ignilion systems carefully. The diagnOSIS of some emiSsion contro l devices reqU ires specialized lools. equipment and training If checking and serviCing become 100 dlHlcult or If a procedure IS beyond your ability. consu lt a dealer service department ThiS doesn t mean. however, that emiSSion control systems are particularly difficult to maintain and repair. You can quickly and eaSily perform many checks and do most (if not all) of Ihe regular maintenance at home With common tune-up and hand tools. Note: The most frequent cause of emiSSions problems IS Simply a loose or broken vacuum hose or Wire, SO always check the hose and wifing connections first.
Pay close attention 10 any special precautions outlined In thiS Chapter. It should be noted thai the illuSlrations of the vafiOUS systems may I'lOt e~ actly match Ihe system Installed on your vehiCle because of changes made by lhe manufacturer dunng produc\lon or from year-Io-year A Vehicle EmiSSions ContrOl Information label is located in the engine compa rt ment (see Illustration). ThiS label contains Important emiSSions spec iii cations and adjustmen t information, as well as a vacuum hose schema\lcwlth emiSSions componen ts Idenllfied. When serviCing the englne or emiSSiOnS systems, the VECIIabel in your particular vehicle should always be checked for up·to-date information.
1.7 The Vehicle Emission ControllnlormaUon (VEel) label, normally located on the top of the cooling fan shroud, contains essential and specific information (like spark plug type, the proper Ignition timing procedure for your vehicle and a vacuum hose routing schematic) that applies 10 Ihe emissions-related devices on your vehic le
8
6-2 2
Chapter 6
Emissions control systems
Electro nic Eng ine Control tEee·IV) sy stem
Refer 10 IllUSlra/lons 2 la, 2 lb. 2.IC and 21d
General description 1 All vehicles eqUipped with TFt ·IV electrOniC ignition systems (see Chapter 5) are also eqUipped with the ElectrOniC Engine Control (EEe·IV) system (lee IlIuslralions). The EEe-IV system consists of an onboard computer, known as the ElectrOniC Control Assembly (ECA). and the mtormallon sensors, which monitor vanous tunctlons 01 the englrle and send
dala to Ihe ECA Based on the dala and the .n/ormatlOn programmed Inl0 Ihecompuler's memory. the ECA generales output signals to control vaflQUS
engine lunctlOns
2 The ECA. located inside the dashboard to the lelt althe steenng column. IS the "braln"ot the EEC-IV system. II receives dala Itom a numbel of sensors and other electrOniC componenlS (swllches, relays. etc.). Based on Ihe Inlormallon It recelves.lhe ECA generales output signals 10 control vanous relays, solenOids and other actuators (see betow). The ECA Is speclhcallycahbrated to opllmize the emissions. fuel economy and drive' ability 01 your vehicle 3 Because 01 a Federally·mandated e~tended warranty (five years or 50.000 miles at Ihe time this manual was written) whICh covers the ECA. the Informallon sensors and all components under Its control. and be· cause any owner'lnduced damage to the ECA the sensors aroor the control deVICes may vOId the warranty. II ISn I a good Idea to attempt diagnoSIS or replacement of the ECA at hOme Take your vehicle to a dealer Service department II the ECA or a system component malfunctions Information Input sensors Note: Not aI/ of the fol/owlng devices will be on your vehICle Your VEel label IS the most specific and accurate source of Information for determinIng what sensors are on your vehicle 4 When battery voltage IS applied 10 the compressor clutch. a Signal IS sent to the ECA. which interprets the Signal as an added load crealed by the A.C compressor and increases engine idle speed accordingly to compensate 5 The Air Charge Temperalule sensor (ACT). threaded InIO a runner of the Intake mandold ptOVldeS the ECA With fuet.air mUlture temperalul C10fOfmalion. The ECA uses thiS Inlormatlon to correct fuel "ow and contrOl fuel flOw dUring cold ennchment (cold stans) 6 The EGR Valve POSitiOn Sensor (EVP). located on the EGA valve. lells the ECA the posilion of the EGA valve 7 The Engine Coolant Temperature (ECT) sensor, which IS threaded InIO a coolant passage in the front 01 the Intake manifold ne~tlo the ther· mostat housing. momtors engine coolanl lemperature. The ECT sends Ihe ECA a conSlantly varying voltage signal which Influences ECA control 01 the fuel mixture. I9nlllon timing and EGA operation 6 The Mamfold Absolute Pressure (MAP) sensor. mounted on the firewall. measures lhe absolute pressure 01 the mixture In the Intake manifold and sends a sl9nal to the ECA Ihatls proporllOnalto absolute pressure 9 The exhaust gas oxygen sensors (EGO), whICh are threaded Into the e~haust manifolds. constanUy monllor the oxygen content 01 the exhaust gases. A voltage Signal whICh vanes in accordance With the difference be· tween the o~ygen content of the exhaust gases and the surrounding atmo sphere is sent 10 the ECA. The ECA converts thiS e~haust gas o~ygen content signal 10 the lueUalf ralio. compares It 10 the Ideal ratio tor current engine operating condlllOns and alters the signal to the Injectors accord· ingly to The Profile IgOl\ion PlCk·up (PIP). integral With Ihedlstributor.lntorms the ECA of crankshaft poSition and speed The PIP assembly conSists of an armalure With four WindOWS and lour metal tabs that rotate past a stator assembly (the Hall Effect SWItch) , t t The Throttle POSltJon Sensor (TPS). whICh IS mounted on the side 01 the throttle body (see Chapter 4) and connected directly to the throttte shaft, senses Ihronle movement and posltJon, Ihen transmits an electrICal signal to the ECA. This Signal enables the ECA to determine when the throttle IS closed. in liS normal crwse condition or Wide open
Output devices Note Not all oHhe followmg deVices WIll beon your vehICle. Also. the Ioca· lion and appearance of the folloWIng deVICes maydlffer somewhal on your vehicle from those II/us/rared and Of descrJbed below Your VEel label IS /he most specific and accurate source of information for determining what deVices are on your vehicle t2 The AlC and cooling fan conlro ller module IS operaled by Ihe ECA, the coolant temperature SWitch and the brake light SWitCh. The con lroller module proVides an output Signal which conlrols opera\Jon of Ihe AlC comptessor clutch and the engme cooling Ian t3 The EEC power relay. which IS activated by the Ignition SWi tch. supplies battery voltage to the ECA when the SWitch IS on. t 4 Thecanlster purge solenOid (CANP).located m the lelt front cornerol the engine compartment. SWitches mamfold vacuum to operate the C<;.1IS· ter purge valve when a SlQnat IS recelYed from the ECA. Vacuum opens the purge valve when the solenOid IS energized 15 The EGR control solenoid. located m the lell Iront corner of the engine compartment, SWllches manifold vacuum 10 operate Ihe EGA valve on command from Ihe ECA Vacuum opens the EGA valve when the solenOid IS energized 16 The EGA shut·oll solenoid is an electrically operated vacuum valve located between the mamfokl vacuum source and the EGA valve A con· trolled vacuum bleed is located between the solenOid and the EGA valve ThiS vacuum bleed IS a Backpiessure Vaflable Transducer (BVT). These twO deVices operale the EGR valve lor optimum perlormance. Solenoid SWitch vacuum IS also SUpplied to the canister purge vaJve 17 The EGA vent soleflOld opens the EGA controt soleflOld vacuum tine When the vent solenoid IS energized. the control solenOid opens the EGA valve t6 The feedback control solenOid regulates the Idle, off idle and mam system fuel,'aJr rallOs In accordance With Signals Irom the ECA t 9 The solenOid opera ted luellnlectors are located 10 the throttle body on veh icles With Central Fuel Intecllon and 10 the Intake ports of vehicles eQuipped with EFI or SEFI. The ECA controls the length of lime Ihe mlector Is open The "open" time 01 the mleclor determines the amount 01 luel dehvered For Iniormation regarding Injector replacement. reler to Chapter 4. 20 The fuel pump relay (used on tuel injected vehICles) is actJvated by the ECA With the Igmtlon SWitch In the On poSition When the IQnltlon SWitch IS turned 10 Ihe On poSItion, the retay IS actlYaled to supply millailine ptes, sure to the system For InlormatlOn rega(\:'''"19 fuel pump check and re· placement, reler to Chapler 4 21 The Idle Speed Control (ISC) motor changes Idle speed 10 accor· dar.ce Wi th Signals Irom the ECA. For mlormallon regarding ISC replace· ment. refer to Chapter 4. 22 The shllt indicator light tells the dflver when to shift gears lor optimum fue l economy. The ECA Signals it to light up In accordance With the Inl or· mallon 11 receives regardmQ engine speed and manifotd vacuum levels. 23 The Thermactor Air By· Pass (TAB ) solenOid prOVides a vacuum slg· nallo the by·pass valve In response to Signals from the ECA the TAB valve then by -passes the thermactor air pump 10 the atmosphere For In· formation regarding the thermactor system. refer to SectIon 4 In thiS Chap-
'24"
The ThermactOf Air DlYerter (TAD ) sotenold prOVideS a vacuum slg' nal to lhe dlverter valve 10 response to Signals from the ECA The TAD valve Ihen dlvens thermactor pump all to either the exhaust manifold or Ihe catalytiC convener. For more mlormauon regardmg the Ihelmactor sys tem. refer to Section 5 In thiS Chapter 25 The TFI· IV ignition module (see Chapter 5). moun ted on the Side 01 the dlstflbu for base, tflggers the igOilion coil and determmes dwell. The ECA uses a Signal Irom the Profile Ignition Plck·Up to determine crank· shaft poSi tion IgOlllon tlmmg IS delermlned by the ECA. which then Signals the module to fire the COIL For lurther mforma\!on regarding the TFI -IV module, refer to the appropflate SectIOn In Chapter 5 26 The thronle kICl<er sotenold IS a two·pM valve Wi th an atmospherIC vent A vacuum diaphragm IS used 10 maIntain nom mat Idle speed on com· mand Irom the ECA. For further mforma\lOn regarding Ihe throttle kICker. reter to the appropriate Section In Chapter 4 27 The Wide Open Throttle (WOT) A,C cut·ou t CirCUit IS energized by the ECA when a WOT condition IS detected Durmg WOT. power to the AIC
Chapter 6
6-3
Emissions control systems
EGR SHUTOFF SOLENOID
EXHAUST GAS O XYGEN (EGO) SENSOR
THROTTLE POSITION (TP)
SENSOR
THROTTLE AIR BYPASS
VALVE SOLENOID
ENGINE ~-- COOLANT TEMPERATURE
(EGl) SENSOR BAROMETRIC PRESSURE (BP) SENSOR
VANE AIRFLOW (VAF ) AND VA NE AIR TE MPERATURE (VAT)
IS
SENSOR
TFI IGNITION MODULE A C COMPRESSOR CLU TCH (ACC) SIGNAL
2.1a
EEe-IV component locations - 2.3L carbureted Turbo
. en I
TMIOnu: 1'OSmON\
"""'"
FUSE IN(
EGA VAClUiI AEGll..ATOA SOUHOIO, EGA COHTROl SOLE~ . /Sl'U:O COK1lIOl. SERVO
EGA VACI.OoI REGU.ATOA , SOLENOID rCALFORNIA I ..... CANISTER
'- , """" ----"'OU,,"~ \~ ----- - -IDIP£RATlAE SWITCH
""""'"
DUAL BRAKE ---SWITCH
)\ n----~ ____ ~ /J
W~ ".". """'" SHORTING PLUG
- - - - -m
IGN1lON MOOU.E
n
.,::r
-'"
"C ~
en
m 3 en en
" ....r,
L1NKS 1 OF 3) F,G,l-t
MASS AlA FLOW SENSOR [CAlFORNIAI
/I II
iJ
~
0'
::>
en
n o ::>
-a
I.
en en
'<
iii 3 en
FORWARD CRASH SEJ
OAYTM I'tl.IN..a LAMPS [0Al ) MOOU-E
100 I«)f USE
Tin IUl1STII ... TION ... tfD GAIO FOIl ",,_flNG V(..cl(
..
FRONT (y VEttCLE
""" ..... lOC ... f1OtfS
... C a.UTCH floLO COl.'
OF _I
2. 1b
EEC·IV compo nent loc ation s - 2.3L EFI
"""'"
"",..
Chapter 6
Emissions control systems
FUEL INJECTORS
6
5
AIR CHARGE TEMPERATURE SENSOR
121
THROTILE KICKER SOLENOID
EGR VALVE POSITION SENSOR
8
ENGINE COOLANT TEMPERATURE (EeT) SENSOR THERMACTOR AIR DIVERTER (TAD) AND THERMACTOR AIR
BYPASS (TAB) SOLENOID
MAP
SENSOR
2.1c
EEe-IV component locations - 5.0L eFI
0>
I 0>
,RIGHT HEGO S£NSOA
, FUEL IOIJIECTOR COHNECTOAS
(1
OF ' 1
'" "". CONNECTOR IGHmOH SU'PRESSIOH AESISTOA 11!1Qonm 15.9 NCHES) FROM C101 ] ' ' ' ' ' Uk
CONTAOl. $OIYO
.
(") ::T
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Q
/III ,Ilr~ ~ ' Jr
l_~
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BRAKIE ______________ DUAL WARNNGSwrrCH . . . - -" " " " " <X)O.
I
MASSAIFI _ FLOW SENSOR
i> ~
0>
m 3 II> II>
I..N(S 11 OF 31 F.G.H
o
" "o "-o II>
u.lKS 11 OF 4 ) 4,8.C,D
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wor CUTOVT
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FORWARD CRASti SENSa!-..;
II>
TO HlE.,t,OlA,.., TO MARKER
~~U~ERlAM> -
- -FORWARD OlASH SENSOR
..
"""" " ""'" 2.1d
Eee-IV component locations - 5.0L SEFI
Chapter 6
Emissions control systems
compressorclulch IS disconnected until somellme after partiallhrottle operation resumes. For further Information regarding the WOT NC cuI-QuI. refer 10 Chapter 4 28 The Mass Air Flow (MAF) sensor, used on 1988 and later Callforma 5.QL engines. measures the mass at air flowing Into the engine in grams
per second. The MAF sensor uses a thermistor (an electrical resistor whose resistance changes With temperature ). The ECU maintainS a voltage signal across the thermistor, As air flows Into the engine, it cools the thermistor and causes the lIoltage lIowlng through 1\ to drop_ The ECU measures thiS voltage drop and converts It mto a measurement of air flow
Checking 29 Because of Ihe speCialized test equipment needed to check the sen sors and output deVices, diagnOSIS of these deVices is well beyond the scope of the home mechaniC. If engme performance deteriorates. take the vehicle to a dealer service department to have the EEC-IV s~stem checked.
Component replacement Note: Because 01 the Federally -mandated extended warranty which covers the ECA. the informatIOn sensors and the devices II controls, check wi/h your dealer about warranty coverage. Once the warranty has expired. you may Wish to perform some of the following component replacement procedures yourself after hallmg the problem diagnosed by a dealer service department or repair shop. Refer to IlluS trationS 2. la. 2 lb. 2 Ie and 2 Id lor component locallons
Air Charge Temperature (ACT) sensor 30 Detach the cable Irom the negative termmal o f the battery. 31 locate the ACT sensor In Ihe Intake manilold. 32 Unplug the electrical connector from the sensor 33 Remove the sensor With a wrench . 34 Wrap the threads of the new sensor wi th thread -sealing tape to prevent air leaks. 35 Installalion IS the reverse of removal
EGA Valve Position (EVP) sensor 36 37 3B 39 40
Detach the cable Irom the negative terminal 01 the battery Locate the EVP sensor on top of the EGR valve . Unplug the electrical connector from Ihe sensor. Remove the three mounting bolts and detach the sensor. Installation IS the reverse of removal
Engine Coolant Temperature (ECT) sensor 41 Detach the cable trom the negative terminal 01 the battery. 42 Locate the ECT sensor on the Intake manifold, next to the thermostat houslng_ 43 Unplug the electrical connector from Ihe sensor 44 Remove the sensor With a wrench . 45 Wrap the threadS of the new sensor Wi th thread -sealing tape to pre vent coolant leakage. 46 Instaliation IS the reverse of remova l.
Manifold Absolute Pressure (MAP) sensor 47 Detach the cable from the negative terminal of the battery. 48 locate the MAP sensor on the firewall 49 Unplug the electrical connector from Ihe sensor 50 Detach the vacuum line Irom the sensor. 51 Remove the mounting screws and detach the sensor. 52 Installation is the reverse 01 removal.
Exhaust Gas Oxygen (EGO) sensor 53 Detach the cable Irom the negative terminal of the battery_ 54 locate the EGO sensor on the exhaust mani fold 55 lilt's more convenient , raise the vehic le and support It securely on jackstands. 56 Unplug Ihe electrical connector Irom the sensor 57 Remove Ihe sensor With a wrench 58 Coat the threads of the new sensor With anti -seize compound to pre~ent the threads from welding themselves to the manifold
59
6-7
Installation is the reverse of removal
Throttle Position (TP) sensor 60 Don·1 attempt to replace Ihe TP sensorl Specialized calibration equipment IS necessary to adjust the SWitch once irs installed , making adlustment beyond the scope of the home mechaniC
Canister Purge Solenoid 61 Detach the cable from the negative termmal of the battery 62 locate the can ister purge solenOid in the engme compartment 63 Unplug the electrical connector from the solenoid, 64 Label the vacuum hoses and ports, then detach the hoses 65 Remove the solenoid _ 66 InstallallOn is Ihe reverse of removal.
Vacuum control solenoIds 67 Detach the cable from the negative termmal 01 the battery 68 II necessary, remove the coolant reservoir (see Chapter 3). 69 Locate the vacuum con trol solenOids to be replaced (reler to the VECI label) 70 Unplug Ihe electrical connector from the solenOid 71 label the vacuum hoses and ports. then detach the hoses. 72 Remove the solenoid/bracket screws and detach the solenOid 73 Installation IS the reverse 01 removal.
Mass air floVl (MAF) sensor 74 The mass air flow sensor IS mounted in the air mtake duct. 75 Disconnect the negative battery cable Irom the battery. 76 Disconnect the MAF sensor electrical connector. 77 Detach the air cleaner duct and MAF sensor from the air cleaner and from Ihe throttle bod~. Remove the mounting screws and take the MAF sensor out ollhe engme compartment. 78 Installation is the reverse of removal
3
Mic roproc essor Control Unit (MCU) system
General description Refer to Illustrations 3. ta and3.lb 1 The MCU s~stem IS used on 1980 2.3l engmes, as well as 1981 through 1983 2.3l. 4.2l and 5.0l engmes. The MCU , which controls the system , IS located In the left rear corner of the engine compartment (see illustrations) 2 Early MCU systems use lour input sources: An exhaust gas ox~gen (EGO) sensor, a Wide-open throttle (WOT) vacuum SWitch. an Idle track· ing SWitch and an engine rpm signal The earl~ system conlrols the leedback carburetor {and thus the alr-Iuel raho) and the Thermactor (air InJec\lOn) system. 3 Later MCU s~stems mclude a knock sensor, coolant temperature SWi tches and additional vacuum SWitches . The later s~stems control can Ister purge , spark retard and a tnrottle kicker solenOid. in addi\lOn to the earlier system·s functions . The MCU s~stem is similar to the EEC-IV s~stem , but doesn't control 4 igfll\lon tlmmg
Information input sensors 5 The ox~gen sel'1sor works In the same wa~ as the EEC -IV oxygen sensor It's a galvaniC generator. mounted 10 the exhaust s~stem near the engine. which produces a voltage signal In response to the ox~gen content of the exhaust gas. It transmits the signal to the MCU , which uses It to regulate the feedback solenOid in the carburetor. A signal 01 approxlmatel~ 0.4 ~olt or less mdicates an excessive amount of oxygen {lean fuel mix ture). A Signal 01 approximately 0.6 voll or more mdlcates an insuffiCient amount 01 oxygen {rich luel mixture). 6 The Wide open throttle vacuum SWitch is actuated b~ manifold vacu um. When the engine IS Idling at normal operating lemperature, the cool · ant temperature sensmg vacuum valve routes vacuum 10 the SWitch 10 keep It open. When the throttle opens past a certain pomt, the switch closes and sends an electrical Signal to the MCU.
8
6-8
Chapter 6
Emissions control systems
EGA VACUUM LOAD CONTAOL (WOT ) VALVE (USeD WITH M500 TRANSMISSION ONL VI
....._ - - ' THERMACTOR AlA BYPASS (TAB) SOLENOID (PART OF DUAL SOLENOID WITH
WIDE·OPENTHROITLE
AIR CONDITIONER
(WOT) VACUUM
SWITCH
FUEL OO'''''OL
THERMACTOR
AIR DIVERTER (TAO) SOLENOID
3.1a
Typical MCU component locations - 2.3l
Chapter 6
Emissions control systems
6-9
8
3.1b Typical MCU component locations - carbureted 5.0L
Chapter 6
6 -10
Emissions control systems
VACUUM REGULATOR SOLENOID
3.20
The vacuum regulator solenoid is normally mounted to the engine compar1menl firewall
7 The Idle tracking SWitch IS mounted on Ihe carburetor. It Indicates pro longed 1(1llI1g or deceleration to the MCU 8 The tach Input Signal IS sentlrom Ihe Ignition COIl'S primary CI(CUIIIO the MCU. IllS used by the MCU to prevent over-correction or excessively sudden cnanges when II adlusts the air-fuel rattO
9
Coolant temperature sWitches ,nd,cate engine temperature to the
MeU 10 Vacuumswltches Indicate throttle position to Ihe MCU, as we!! as preventing the Thermaclor system 110m caUSing backtlres
Output devices 11 The canister pUlge solenoid, which IS Similar to the EEC-IV solenOid. leiS manifold vacuum purge fuel vapor from Ihe evaporative emiSSion can · Ister 12 The Thermaclor air solenoids direct air flow from the Thermactor p!Jmp upslream. downstream or Into the atmosptlere 13 The vacuum regulator solenoid regulates vacuum to the air-fuel ml~ ture conllol diaphragm on the Model 6500 feedback carburetor used With early 2.3l four ·cylinder englnes_ 14 The fuel conlrol solenoid IS mounted directly on the YFA carburetor used on later 2_3L engines. It uses an eleclncal Signal, rather than vacuum, to control fuel mixture 15 The feedback carburetor actuator IS mounted on the Model7200 VV (vanable ventult ) carburetor used With ellQlnes 11 controls the air bleed let In the carburetor to regulate fuel mixture 16 The thronle kicker solenoid and actuator are used to open the throUle slightly under specified conditions
va
3.25
The luel control solenoid is mounted to Ihe carburetor
19 Disconnect the negative battery cable Irom the battery 20 Disconnect the solenOId eleclfical connector (see Illustration) 21 Label and disconnect the solenOid vacuum llfies. Check the lines to make sure they are In good condition: If nol. replace them 22 Detach the solenOid from the engifle compartment wall and take It 01,11. 23 Installation IS the reverse of removal
Fuel control solenoid Refer to Illustration 3 25 24 Disconnect the negatIVe banery cable from the banery 25 Disconnect the solenOid electrical connector (see Illustrallon) 26 Detach the solenOid from the carburetor 27 Installation is the reverse of removal
Feedback actuator (Va engines) 28 ThiS IS part 01 the complicated 7200VV carburetor. Removal and Installa\lon are beyond the scope of the home mechamc
ThroUle kicker solenoid 29 Throltle kicker solenOids are mounted on the carburetor in a poSition where they can contact the throttle linkage 30 Disconnect the negative battery cable trom the battery 31 II necessary. detach the solenOid bracket trom the carburetor 32 Loosen the solenOid locknut Unscrew the solenOid, maklllQ sure to wrlle down the number of turns reqUired 33 Install the solenOid, turnmg It the same number of turns reqUifed for removal 34 The remalrlCler of Installation IS the reverse ot remoyal
Checking 17 As With the EEC -IV system. MCU system diagnoSIs IS beyond the scope o f the home mechanic. If engme pe r1ormancedetenorates, per10rm the basic electflcal and mechanical Checks: Compression. vaculJm hne condition and connections. ignition system condition and carburetor Idte adjustment If these checks don'llind the cause. have the MCU syStem tested by a dealer service oepartment or other qualilled specialiSt
Component replacement t8 Exhaust gas oxygen sensors. coolant temperature sensors and the camster purge solenoid are replaced In the same manner as EEC-IV system components (see Secllon 2)
Vacuum regulator solenoid Refer to !lIuSfr3l1On 3.20
4
E.hausl Gas Rec lrculalion (EGR) system
General description 1 The EGR system IS deSigned to reintroduce small amounts 01 ex haust gas Into the combuSlJOn cycle, thus reducing the generation of ox· Ides 01 mtrogen (NOx) emiSSions The amount of exhaust gas rem troduced and the Ilmlllg of the cycle IS con trolled by vaflous factors such as engille speed. al\ltude. mallitoid vacuum, exhaust system backpressure, coolant temperature and throttle angle All EGA vailies are vacuum actuated (the vacuum diagram for your particular vehicle IS shown on the VehICle EmlsslonsCOntrollnformatlon [VECI]tabelIn the engillecom partment) Three types of EGR valves are used on these vehICles the ported valve. the integral backpressure valve and the electroniC type.
Chapter 6
Emissions control systems
6 -11
hand vacuum pump. Vacuum shouldn·t drop more than 1 m-Hg In 30 sec· ondS. If It does. replace Ihe valve . 11 When the valve IS suspected of leaking (indicated by a rough idle or stalling) perform the following simple Check : a) Insert a bfocking gasket (no flow holes) between the valve and base and reinstalilhe valve. b) If the engine idle Improves, replace the valve and remove the block· mg gasket. If the idle doesn·tlmprove. take the vehicle to a dealer service department
NUT AN D WASHER
Integral backpressure transducer valve
\ """m, BOOY
FRONT Of ENGINE
ASSEMBLY
4.25
An electronic EGR valve and Its related componenls - exploded view
Ported valve (four-cylinder engine) 2
The ported EGA valve is operated by a vacuum signal from the EGR
port, which actuates the valve diaphragm. As the vacuum Increases suffi ciently to overcome the spring. the valve IS opened, allowmg EGA lIow The amount 01flow is contingent upon the tapered pintle arthe poppet poSition, which IS afleeted by the vacuum signal.
Integral backpressure transducer valve (1983 US and 1983 thru 1986 Canadian V6 engines) J The Integral backpressure transducer EGR valve combines back· pressure and EGR ported vacuum Into one Unit. The valve won" operate on vacuum alone - It reqU ires both mputs to operate. There are two baSIC types ot backpressure valves: poppet and tapered pmtle.
Electronic va lve 4
The electronic EGA valve used In EEC·IV systems controls EGA flow with an EGA valve position (EVP) sensor attached to the top 01 the valve . The valve is operated by a vacuum Signal from the duat EGR sotenoid va lves or the electronic vacuum regulator which actuates the valve dia· phragm. As supply vacuum overcomes the spring load. the diaphragm is actuated, lifting the pintle oft the seat and allowing e~haust gas to recirculate. Theamount oillow IS proportlonal lothepintle position. The EVP sen· sor sends an electrical signal indicating Its position to the ECA.
Checking Ported valve 5 Make sure that all vacuum lines are properly routed (see your VECI label m the engme compartment). secure and in good condition (not cracked. kmked or broken oft). 6 When the engine is cold , there should be no vacuum to operate the EGA valve. II there is vacuum. check the ported vacuum switch (PVS) or temperature vacuum switch (TVS) and replace them as required 7 There should be no vacuum to the valve at curb idle (engine warm) . 8 There should be vacuum to the valve at 3000 rpm . II there IS no vacuum. check the TVS and PVS and replace them as reqUIred . 9 With the engine at Idle, apply 8 in·Hg vacuum 10 the valve. The valve stem should move. opening the valve. and the engine should stall or run roughly. If the valve stem moves but the engine doesn·t respond . remove and clean the inlet and outlet ports with a wife brush. Caution: Do nol sandblast or clean the valve with gasoline or damage Will resultl 10 With the engine at Idle, apply 4 m-Hg vacuum to the valve. uSing a
12 Make sure that all vacuum lines are properfy routed (see your VECI label in the engine compartment), all connections are secure and no vacu o um hoses are cracked , cnmped or broken. 13 Detach the vacuum line 10 the EGR valve and plug it. Connect a vacu o um pump to the EGA valve. Start the engine and let it idle. Apply Sl~ m-Hg vacuumto the valve. It should bleed oft and the valve should not operate. !I the vacuum holds and the valve opens and stays open. i.e. the valve does not bleed oft the vacuum . replace the valve 14 There should be no vacuum to the valve at Idle under any conditions. II there IS. check the hose routing. 15 There should be no vacuum to the valve nor should the valve operate when the engine Is cold. I! there is vacuum at the valve when the engme is cold , check the ported vacuum SWitch (PVS) or the thermal vacuum SWitch (TVS) and replace as reqUIred . (The PVS is a temperature actuated switch thai changes vacuum connections when the coolant temperature changes: Ihe TVS. which IS used With some systems Instead of Ihe PVS. conlrols vacuum to the EGR valve by responding to the temperature of the Inlet air heated by the e~haust manifold. Most PVS SWitches are mounted somewhere on the intake manifold: most TVS sWitches are located 10 the air cleaner housing. Aefer to your VECI label 10 determine which kmd of SWitch you have and whe re It is located.) 16 There should be vacuum to the valve at 3000 rpm With a normally warm engine. If there isn·t, check back through the vacuum line from the EGR to the vacuum source: lor e~ample. the TVS andl orthe PVS may not be opening. Check and replace as required . 17 If a valve IS suspected of sticking, remove ilfrom the engine and cycle the valve by pressing carefully with your fingers against the lower trans· ducer plate. If the valve sticks open when you release your fingers. re o place it.
Electronic valve Note: ASJde from the following check and maintenance steps, the electronic EGR valve cannot be diagnosed or serviced by the home mechamc. Additional checks must be done by a dealer service depanment. t6 Make sure the vacuum hoses are In good condition and hooked up correctly. t9 Clean the inlet and outlet pol1s With a wire brush or scraper. Do not sandblast the valve or clean It with gasoline or solvents as they wdl damage the valve. 20 To perform a leakage test, connect a vacuum pump 10 the EGR valve. 21 Apply 5·to-6 In-Hg of vacuum to the valve. 22 Trapthe vacuum -it should not drop morethan t in·Hg in30 seconds. 23 If the speCified conditions are not met. the EGA valve, O-ring or EVP must be replaced .
EGR valve replacement Refer to illuslration 4.25 24 Detach the cable Irom negative terminal of the battery. 25 On engines with an electronic valve, unplug the electrical connector from the EGR valve positron sensor (see illustrallon). 26 I! your vehicle is powered by a four·cylinder engme. unscrew the threaded fitting that attaches the EGR pipe to the EGA valve. 27 Remove the EGR valve mounting nuts and detach the valve. 28 Remove the old gasket. Be sure to thoroughly clean the gasket surfaces of the intake manifold (and valve. if the same valve will be remstalled). 29 If you·re replacing an electronic type EGA valve but not the poSition sensor. remove the sensor from the old valve (see Section 2) anel install It on the new valve. 30 Installation is the reverse of removal
e
6 -12
Chapter 6
Emissions control systems
5.26 To replace Ine combination air bypassfalr control valve (3.8l V6 unit shown , others similar), label , then delach , the following : Vacuum line /0 control solenoid Air pump·/o·combma/lon
2
'Ialve hose 3
4
CombinatIOn valve·to-flght
5
Combma/1OfI valve -to·left exhaust manifold hose
exhaust mamfold hose
Vacuum Ime /0
con/rol solenoid
5
Managed air Ihermeclar system
General description The thermaetor (air Inl6CtJon) exhaust emiSSion control system reo duces carbon monOKlde and hydrocarbon content In the exhaust gases by inJecling fresh air into the hot exhaust gases leaving the exhaust ports When Iresh air IS mixed with hal exhaust gases. oXidation IS Increased. reducing the concentrallOn of hydrocarbons and carbon monOXide and converting them Into harmless carbon dioxide and water 2 All 01 these models ulllize either a convenllonallhermactor system (1983 through 1986 Canadian V6 engine) or a "managed air" thermaclor system (all US models and o ther Canadian models). The two systems are baSically the same The managed air Ihermactor system diverts thermac· tor air either upstream to the exhaus t manifold check valve or downstream 10 the rear secMn check valve and dual bed catalyst. An extended Idle air bypass system In carburetor eqUipped vehicles also vents thermaclor air 10 the atmosphere dunng extended idling 3 On managed alf systems. an air conlrolvalva directs the air upstream or downstream An air bypass valve IS us~ 10 dump air to Ihe atmosphere In some applications, the two valves are com~ned Into a Single air bypass· control valve.
Checking Air supply pump Check and adjust the dnvebet\ tenSion (see Chapter 1). Disconnect the alf supply hose at the alf bypass valve Inlet 6 The pump IS opera ling satisfactOrily II air 1t0wiS feh al the pump outlet '.'11th the engine running at Idle, increasing as the engine speed IS In· creased 7 II the air pump doesn't pass the above lests, replace It With a new or rebUilt Unll 4 5
Air bypass valve 8 With the engine running at Idle. disconnect the hose from the valve outlet Remove the vacuum hose from the port and remove or bypass any restnClors or delay valves In the vacuum hose 10 Venfy that vacuum IS presl:!nlln me vacuum hose by putting your fin· ger over the end.
9
5,27 To remove the air pump (unit l or a J.Sl V6 engine shown, others similar), loo sen the ho se c lamp (arrow) and detach the hose to the com b i nation valve, then remove both mounting bolts (arrows)
11 Reconnect the vacuum hose to the port 12 With the engine running al1500 rpm. Ihe au pump supply air should be lelt or heard althe air bypass valve outlet 13 With the engine running al 1500 rpm. disconnect the vacuum hose. Air at the valve outlet should be decreased or shut off and air pumpsupply air should be fell or heard althe Silencer ports 14 Reconnect all hoses 15 II the norma:ly closed alf bypass valve doesn t successfully pass the above tests, check Ihe air pump (refello Sleps 5 through 7). 16 lithe air pump IS opera\lng satlsfaclorlly. replace the air bypass valve With a new one Check valve 17 Disconnect Ihe hoses from both ends 01 the check valve, care lully nO\lng the Installed posl\lon 01 the valve and the hoses. 18 Blow through both ends olthe chedl valve. venlymg Ihal all !lows In one directIOn only 19 If airflows m both directions or nolal all. replace the check valveW11h a new one 20 When reconnecMg the lIalve, make sure IllS Installed In the proper dlfectlon
Thermactor system noise test 21 The thermactor syslem IS not completely nOiseless Under normal condilions, noise nses In PIlCh as the en9me speed irlcreases To delermine If flOIse IS the tault 01 the air irl)ectJon system. detach the dflvebelt (after vefltymg thallhe belt tenSion IS COffect) and operate lhe engine. II Ihe noise disappears, proceed wllh the lotlowmg diagnOSIS. Caution : The
pump must accumulale 500 miles (vehicle miles) before the followmg check IS valid.
If the belt nOise IS excessive a) Check lor a loose bell and !tghten as necessary (refer to Chap. leI I). b ) Check IOf a seized pump and replace 1111 necessary c) Check for a loose putley Tighten lhe mountmg bolts as feqUifed d) CheclI. tor loose. brOken or missing moun\lng brackets or bolts Tighten or replace as necessary 23 II there IS excessive mechanical nOise a) Check lor an overtightened moun\lng bolt b) Check lor an overtightened dflvebelt (reler to Chapter 1) c) Check tor excessive flash on the alT pump ad]USling arm boss and remove as necessary d) Check lor a distorted adJUS\lng aIm and. If necessary. leplace the arm. 24 If there IS excessive thermactor system noise (whiffing or hiSSing sounds):
22
Chapter 6
Emissions control systems
6 -1 3
a) Check for a leak in the hoses (use a soap and water solution 10 hnd
the leaks) and replace the hose(s) as necessary. b) Check for a loose. pinched or kinked hose and reassemble. straighten or replace the hose andlor clamps as required. c) Check for a hose touching other engine parts and adjust or reroute the hose to prevent further contact.
d) Check for an Inoperallve bypass valve (refer to Step 8) and replace il necessary. e) Check for an lnoperallve check valve (rafarla Slep 17) and replace
if necessary. I) Check for loose pump or pulley mounting fasteners and lighten as
necessary. g) Check lor a restricted or bent pump outlet fitting. Inspecllhe tilling and remove any casting flash blocking the air passageway. Replace bent fittings . h) Check for air dumping through the bypass valve (only al idle) . On many vehicles, the thermactor system has been designed to dump air at idle to prevent overheating the catalytic converter. This condi tion IS normal. Determine that the noise persists at higher speeds before proceeding. i) Check for air dumping through the bypass valve (the decel and idle dump). On many vehic les, the thermactor air IS dumped into the air cleaner or the remote silencer. Make sure that the hoses are con nected properly and not cracked. 25 II there is excessive pump nOise. make sure the pump has had suffi cient break-in time (at least 500 miles). Check for a worn or damaged pump and replace as necessary.
Component replacement 6.2
Refer 10 iffus/ra/!ons 5.26 and 5.27 26 To replace the air bypass valve. air supply con trol valve. check valve, combination air bypass/air control valve (see illustration) or the Silencer. clearly label, then disconnect. the hoses leading to them, rep lace the faulty component and reallach the hoses to the proper ports. Make sure the hoses are in good cond ition. If not, replace them With new ones. 27 To replace the air supply pump. first loosen the engine drivebelt (see Chapter 1 ),then remove the pump mounting bolts (see Illustration) Irom the mounting bracket. Label all wi res and hoses as thei re removed to fa cilitate Installation of the new unit. 28 II you·re replacing 6IIher of the check valves on a Pulse Air System (Thermactor If). be sure to use a back·up wrench 29 After the new pump is Installed. adjust the drivebetts to the specified tension (see Chapter 1).
6
A typical evaporative emissions control system
Component replacement Charcoal canister 6 Loca te the canister In the engine compartment 7 Reach up above the canister. remove the slOgle mounting bolt and remove the canister. 8 Clearly labo:!lthe hoses and detach them from the canister 9 Installation is the reverse of removal.
All other components to Referring to the VECllabel of your vehicle. locate the component you Intend to replace . 11 Label the hoses. then detach them and remove the component 12 Installation is the reverse of removal.
Fuel evaporative emissions control system 7
Positive Crankcase Ventilation (PCV) sy stem
General description Refer 10 ilfustration 6.2 t This system is designed to prevent hydrocarbons from being released into the atmosphere by trapping and storing fuet vaporfrom the fuel tan k, the carburetor or the fuel injection system. 2 The selViceable pariS of the system include a charcoallilled canister and the connecting lines between the luel tank. fuel tank filler cap and the carburetor or fuet injection system (see illustration). 3 Vapor trapped In the gas tank is vented through a valve in the top of the tank. From the valve. the vapor is routed through a single line 10 a carbon canister located on the right lower front corne r 01the engine compartment. where irs stored until the next time the engine is started.
System checking 4 There are no moving parts and nothing to wear in the canister. Check for loose, missing. cracked or broken fittings and check for deteriorated or damaged hoses attached to the canister. tnspect the canister for cracks and other damage. If the canister is damaged. replace it (see below). 5 Check for fuel smells around the vehicle. Make sure the gas cap is In good condition and properly installed.
General description The Posi tive Crank.case Ventilation (PCV) system cycles crankcase vapors back through the engine where they are burned The valve regulates the amount ot ventilating air and blow-by gas to the Intak.e manifold and prevents backfire from traveling Into the crankcase. 2 The PCV system consists of a replaceable PCV valve. a crankcase ventilation lilter and the connecting hoses. 3 The air source l or the crankcase ventilation s~stem IS in the air clean· er. Air passes through the PCV lilter (in the rocker arm coveror the 011 hiler cap) and through a hose connected to the air cleaner hOUSing On vehicles With a PCV filter integrated into the oil filler cap, the cap IS sealed at the openlOg to prevent the en trance of outSide air. From the oillilier cap, or separate PCV lilter In the rocker arm cover, the air tlows into the rocker arm chamber and the crank.case. trom which it Circulates up Into another sec· tion of the rocker arm chamber and finally enters a spring loaded regulator valve (PCV valve) that controls the amount 01 flow as operating condll
8
6 -14
Chapter 6
Emissions control systems
COLD WEATHER MODULATOR ICWM) AlA CLEANER A SSY
8.3
A typical inlet air temperalure control system
3 When the underhood temperature IS cold. warm air radiating oN the exhaust manifold IS routed by a Shroud which fi ts over the manifold up through a hot air inlet tube and Into the air cleaner (see llIustraUon). This provides warm air lor the carburetor or CFI. resulting In better dflveablhty and laster warm·up As the underhood temperature nses. a heal duct valve IS graduaJJy closed by a vacuum motor and Ihe air cleaner draws air through a cold alt duct Instead. The result IS a conSlstenllntake air temperature. 4 A temperature vacuum sWitch (see lIIuslration) mounted on the air cleaner housing monitors the temperature of the Inlet air heated by the exhausl mani fold A bimetal diSC In the temperature vacuum SWitch orients Itself in one of two positions. depending on the temperalure One poSition allows vacuum through a hose 10 the motor ; the other poSition blocks vacuum. 5 The vacuum molor Itself IS regulated by a cold weather modulator (CWM). mounted In the Side of lhe all cleaner houSing assembly. between Ihe temperature vacuum sWitch and the motor (see Illustration), whICh provides the motor With a range of graduated positions between fully open and fully closed
Checking
Checking 4 In
Checkmg procedures lor the PCV system components afe Included
Chapter 1
Component replacement 5 Component replacement involves Simply Installing a new valve or hose In place of the one removed dUring Ihe checking procedure.
8
Inlet air temperature conlrol system
General description Reff1rlo !lIustrat!ons 8 3,8.43008.5 1 The Inlet air temperature control system (carburetor and CFI
eqUiPped vehicles) provides heated Intake a.rdurlng warm-up. then maintams the Inlel a,rtemperalure wlth,n a 70·degrees F 10 105-degrees Fop· eratmg rar"]e by mixing warm and cool alf This allows leaner lueVal1 ffill(lure senlngs lor the carburetor or CFI system. WhICh reduces emiS Sions and Improves dnveablilty 2 Twofresh air Inlets - one warm and one cold - are used. Thebalance between the two IS contrOlled by Intake manifold vacuum. a temperature vacuum SWitch and a time delay valve. A vacuum motor, which operates a heat duct valve in the air cleaner. is controlled by the vacuum sWitch
.,
-~
-
;'
Nole : Make sure that the engine IS cold before beglnmng /hls leSI 6 Always check the vacuum source and the Integrity of an vacuum hoses between the source and !he vacuum molar belore beglnmng the fol · loWing test. Do not proceed until theyre okay 7 Apply the pariling brake and block the wheels 8 Detach. but do not remove. the all cleaner hOUSing and element (see Chapter 4) . 9 Turn the air cleaner hOUSing upSide down so the vacuum motor door IS VISible. The door should be open. 1I,I,sn·\. 11 may be bmdlng or stICking. Make sure lhat Irs not rusted In an open or closed position by allemptlng to move It by hand 1I11S rusted . It can usually be Ireed by cleanmg andOllmg the hinge. 1I111alis to work properly ahet serviCIng, replace It 10 If the vacuum motor door IS okay but the motor stllllalis 10 opetate correctly. check carefully lor a leak In the hose leading to II. Check the vacuum source to and Irom Ihe bimetal sensor and the time delay valve as well. II no leak is lound. feplace the vacuum motor (see Step 26). II Startlheenglne If Iheductdoorhas movad or moves 10 the "heat on " (closed to Iresh air) position. go to Step 15 12 If the door stays In the "heat olf (closed to warm air) poSitron. place a linger over the bimetal sensor bleed The ducl door must move rapidly to the "heat on" poSition. II the door doesn t move 10 the "heat on" POSition. stop the engine and replace the vacuum motor (see Step 26). Repeat thiS Step With the new vacuum motor. 13 With the engine ott. allow the blmelai sensor and the cold weather modulator 10 cool completely.
-i.,.
8.4
..
-~
A typical lemperature vacuum switch (TVS) installation in the air cleaner housing assembly cover
8.5
A typical cotd weather modulator (C WM) installation In the alt cleaner housing assembly
Chapter 6
8.20
Emissions control systems
To remove the TVS, label and deta ch th e hoses, then pry otl Ihe retain ing c lip with a small sc rewdriver
8.24 To remove the CWM, tabel and detach the hoses, then slide ott th e retaining clip and pull th e CWM out of the mounting hole
CWM
Slep 18)
25
15 Start and run,he engine bnefly (less than 1Sseconds). TheduClooor should move to the "heal on ~ positIOn 16 ShUI off the engme and watch the duel door It should slay In the "heat on" poSition lor at least two minutes 17 If doesnl stay In Ihe "heal on " poSltton for at least two minutes. replace Ihe CWM (see Step 23).
Vacuum motor
Component replacement Refer /0 I/lustra/lons 820.824 and 8.28
24
Slide Ihe CWM retamlng clip oH (see illustration) and remove the
14 Aestartll'le engme The duel door should move to the "heat on - POSI lion IIlhe door doesn't move Of moves only parually. replace 'he TVS (see
I'
6 -15
InstaJlat,on IS the reverse at removal
26 Remove the air cleaner hOUSing assembly (see Chapter 4) and place lion a workbench. 27 Delach the vacuum hose trom the motor 28 Droll OUI the vacuum motor retainong strap fillet (see illustrallon). 29 Remove the motor. 30 Installation IS the reverse 01 removal Use a sheet metal screw 01 Ihe appropriate size to replace the flvet.
Temperature vacuum switch (TVS) 18 Clearly label. then detach bolh vacuum hoses from !he TVS (one IS coming trom the vacuum source alIne man,told and Ihe olher IS gOing 10 the vacuum motor underneath the all cleaner hoUSing) . t9 Remove the air cleaner hOUSing cover assembly (see Chapter 4) 20 Pry !he TVS retaonong clip oft With a screwOfiver (see illustration) 2t Remove the TVS 22 Installation IS the reverse 01 removal
Cold weather modulator (CWM) 23
Locate Ihe CWM. Ihen detach both vacuum hoses and remove the
CWM
9
Catalytic converter
No te: Because 01 a Federally mandated elCtended warran/)' whICh covers emrssrons·relatedcomponents such as the catalyllC converter; chedl wllh a dealer servICe department /;)efore replacmg the converter at your own elCp6nSe
General description The catalytic converter IS an emiSSion control device added to Ihe ex· haust system to reduce pollutants trom the exhaust gas stream. There are two types 01 converters. The conventional OXidation catalyst reduces the levels at hydrocarbon (HC) and carbon moncmde (CO). The three-way catalysllowers the levels of oxides of mtrogen (NOx) as well as hydrocar· bons (He) and carbon monoxide (CO).
Checking 2 The test eqUipment for a catalytIC converter IS expenSive and hoghly Sophisticated, If you suspect that the converter on your vehicle is mallunc· tlonlng, take it to a dealer or authOrized emiSSions inspecllOn facIlity for diagnOSIs and repair. 3 Whenever the vehicle IS raised tor servicing of underbody components. check the converter for leaks. corrosion. dents and o ther damage. Check the welds/flange bolts that anach the tronl and rear ends of the converter to the exhausl system. II damage IS discovered. the converter sholJld be replaced 4 Although catalytIC converters don't bteak 100 often, Ihey do become plugged The easiest way to chedl lor a restncted converter IS to use a vacuum gauge to diagnose the eHect 01 a blocked exhaust on Intake vacu·
om 8.28 To rem ov e the v acuum motor, l ab el and detach the hoses, then drill out th e r ivet (arrow) and s lide o ut the retaining strap
a) Open the throttle until the englfl6 speed IS about 2000 RPM b) Release the throttle qUickly. c) II there IS no restriction. the gauge Will qUickly dropto not morethan 2 in Hg or more above its normal readlflg.
.,
6 -16
Chapter 6 Emissions control systems
d) If the gauge does nol show 5 In Hg or ffiOfe above Its normal readIng. Of seems 10 momentanly hover around liS highest reading lor a moment before II returns. the e~hausl system, Of the converter. IS plugged (or an exhaust PIpe is benl or dented, or the core Inside the muffler has shilled).
Component replacement 5 Because the converter IS welded to the exhaust system. converter replacemenl requires removal of the exnausl pipe assembly (see Chapter 4). Take the vehicle. or the exhaust pipe system, to a dealer service depar1ment or a muffler shop.
1
Chapter 7 Part A Contents
Manual transmission ,
Gener31mtormauon Manual transmiSSIOn lubncanllevel check
ManuallranSffilSSlon overhaul- generallnlormatlcn
,
ManuallransmlSSlon - removal and Installation
3
See Chapter 1 .
Oil seal replacement Shill lever - removal and Installation Transm iSSion mount - check and replacement
See Chapler 7B 2 See Chapter 78
Specification s
lubricant type
See Chapter I
Torque specifications
Ft-Ibs
SMt lever aUachlng bolts All except T50D lransmlSSlon T500 transmiSSion TransmlsSlon·to-ciutch housing or engine bolts
17 1025
23 to 32
"
General inlormalion All vehICles covered In this manual come eqUipped with a 4-speed or 5-speed manuallransmlsslon or an automatIC transmission. Allinlarmalion on the manual transmiSSIon IS Included In thiS Parte! Chapter 7 Intor· matlon tor the automatic transmiSSion can be lound In Pan 8 01 thiS Chapter Several dlNerent manual transmissions have been used In these models Early models were equipped With SRCD. RAD or ET 4-speE.::l transmissions. The t9B l through 19B3 1lve-speed transmiSSion IS Similar to earher lour-speed deSigns. bul Incorporates an overdflve fifth gear. The T50DtransmlSSlon. used on 19B4 and later models. IS an all-new design. Due to the compleXity. unavailability ot replacement pans and the speCial tools necessary. Internal transmiSSion repai r procedures are not recommended tor the home mechaniC. The Inlormallon contained Within thiS manual Will be limited to general informatIOn and removal and installation ot the transmiSSion assembly Depending on the expense Involved In havmg a taulty transmiSSion overhauled. It may be an advantage to conSider replacrng the Unit With either a new or rebuilt one Your local dealer or transmiSSIOn shop should be able to supply you With In!ormallon concerning cost. availability and eKchange policy Regardless of how you decide to remedy a transm iSSion problem. you can Sllil save considerable eKpense by remov ing and installIng the uM yourse lt
2
3 the 4 5
Working th rough the shill lever boot hole. unbolt the shill lever trom lfansmiSSlon. lift the shift lever out 01 the transmiSSIOn (see Illustration). Installallon IS the reverse 01 the removal sleps.
Shilt lever - removal and inslallation
All models except T50D Refer /0 Iflus/fallon 2 4 t Place the transmiSSion In Neutral 2 Remove the floor 10m and carpeting as necessary to gain access to the shlltlever boot retaining screws Remove the screws and detach the shltl lever boot trom the Iloor
2.4
Manual transmission shift lever installation details - except T500
7A-2
Chapter 7 Part A
CON SOLE
BOOT
1i4,--
SHIFT
SHIFT BOOT BOLTS
~,../",.-FlOOR PAN
LEVER BOLT
TRANS ASSY
2.7 Manual transmission shift lever Installation details - T500
T50D Refer /0 illustration 2. 7 6 Remove the center console 7 Remove the tour shltt boot-\o-iloor pan bolts (see illustration) 8
Remove the two mounting bolts and detach the lever assembly from
the tranSmiSSIOn. 9 To Install, place the stufllever In poSItion and Inslaillhe bolts The bolts must be lostalled Irom the left side althe shlUer only T IQhten the boilS securely
10 Install the sMt bool and console
3
Manuallransmlsslon - removal and Inslallation
Removal Ol$connecllhe negative cable at the battery Place the cable out of the way so il cannot aCCIdentally come In contact with the negalive terminal 0' the battery. as tills would once agam allow power Into the eleclncal system at the vehICle 2 From Inside the vehicle, remove the shllt lever (Section 2). 3 Raise the vehICle and support It securely on Jackstands. 4 Disconnect the speedometer cable and electrical connections Irom the transmission 5 Removethednveshaft (Chapter8). Use a plastic bag locoverlhe end of the transmission to prevent fluid loss and contamination. 6 Remove the e~haust system components as necessary for clearance (Chapter 4) 7 Support the engine. Thlscan be done tram above by USing an engine hOist, or by placing a Jack (.....Ith a block ot ..... ood as an insulator) under the engine 011 pan. The engine should remain supported at all times while the transmisSion IS out 01 the vehicle 8 Support the transmiSSion .....Ith a lack - preferably a speclaJ tack made lor this purpose Salety chainS WIll help sleady the transmiSSion on Ihe jadl 9 Remove the rear transmisSion support·to·crossmember nuls and bolls 10 Remove the nuts from the cross member bolts, Raise the transmiS sion shghUy and remove the crossmember
Manual transmission 11 Atl e~cept ET transmiSSions - remove the bolts SecUfing the trans· miSSion to the clutch houSing 12 ET transmlSSlon- remove the bolts secuflng the clutch housing to the engine 13 Make a final check that a\l wiles and hoses have been (:IIsconnected tram the transmiSSiOn and then move the transmiSSion and Jack to ..... ard the rear 01 the vehicle until the transmiSSion Inpul shaft IS clear of the clutch hOUSing or engme Keep the transmiSSIOn level as thiS IS done 14 Once the mput shalt IS clear. lower the transmisSion and remove II Irom under the vehICle Caullon : Do nol depress Ihe clutch pedal ..... hlle Ihe transmiSSion IS removed 'rom the vehicle 15 The clutch components can be mspected while the transmiSSIOn IS removed On all e~cepl ET transmisSions. 11""'111 be necessary to remove the CIU1Ch hoUSing from the engine (Chapter 8 ) . In most cases. new cJutch components should be mstalled as a maner of course lithe lfanSmlSSIOn IS removed
Installation '6 II removed. Install the clutch components (Chapter 8). 17 If removed. attach the clu tch housmg to the engine and tighten the bolts to the specilled torque (Chapter 8) 18 With the transmission secured to the jack as on removal. raise the transmission InlO poSlhon behmd the clutch hOUSing al1cl then carefully shdeltlorward. engagmg the Input shaft ..... lth the clutch sphnes. Do 1"101 use e~cesslve force to mstall the transmiSSion -If the mput shaft does nOI slide Into place. readjust the angle 01 the transmiSSIon so It IS level and. Of turn the Input shaft so the splines engage PJoperly ..... Ith the clutch 19 Install the transmlsslon-to-clutch housmg bolts Tighten the bolts to the speCified torque 20 Install the crossmember al1cl transmiSSion support. Tighten all nuts and bolts securely 21 Remove the jacks supportmg the transmiSSIOn and the engme 22 Installthevanous Items removed preViously. relerrlng to Chapter8for the mstallallon 01 the dnveshalt and Chapter 4 lor mlormatlon regarding the e~haust system components 23 Make a final check that all .....lres. hoses and the speedometer cable have been connected and that the transmiSSion has been filled ..... Ith lubncant to the proper tevel (Chapter 1). Lo ..... er the vehicle 24 From Inside Ihe vehicle connect the shift lever (see Section 2) 25 Connect the negative battery cable Road test the vehICle tor proper operation and check lor leakage
4
Manual transmis s ion overhaul - general Information
Overhauling a manual transmiSSion Is a difficult job for the do· il·your· sell er It Involves the disassembly and reassembly 01 many small parts. Numerous clearances must be precisely measured and . 11 necessary, changed with select lit spacers al1cl snap·flngs. As a result . it!ranSmlssion problems anse. II can be removed and Installed by a competent do-It-your· seifer. but overhaul should be left to a transmiSSion repair shop Rebuilt transmiSSions may be available - check ..... lth your dealer parts department and auto parts stores. At any rate . the time and money involved In an over· haulls almost sure to e~ceed the cost 01 a rebUilt unit Nevertheless, Irs not ImpoSSible for an inexperienced mechamc to rebUild a Ifansmlssion If the special tOOls are available al1cl the lOb Is done 10 a dehberate step -by-step manner so nothing is overlOOKed. The tools necessary for an overhaul Include Internal and external snap·ring pliers. a bearmg puller, a slide hammer. a set of pm punches. a dial indicator and poSSibly a hydrauliC press In addition, a large. sturdy workbench and a vise Of transmisSion stand .....111 be reqUired . Dormg disassembly 01 the transmiSSion. make careful notes of ho..... each piece comes off ..... here It filS m relallon to olher pieces and .....hat holds It In place Before laking the transmiSSIOn apart for repair. It Will help II you nave some Idea .....hat area 01 the transmiSSIOn IS maltunctlOnlng. Certain problems can be closely lied to speCilic areas in the transmiSSIon. whICh can make component exammatlon and replacement eaSier. Refer to the Trou· bleshooting section at the tront of thiS manual lor mlormallon regarding poSSible sources 01 trouble
Chapter 7 Part B
Automatic transmission
Contents Automatic transmiSS ion lIuld and hlter change Automatic transmiSSion lIuld level check Aulomal!C transmiSSion - removal and Installatton
DiagnosIs - general Extension housing 011 seal- replacement Generallnformallon
See Chapter 1
Shih linkage - adjustment Speedometer pinion gear and seal- replacement Thronle valve (TV) linkage - deSCriptIOn. Inspec1Jon and adjustment (AOe transmiSSions only) Thlonle Valve (TV) linkage - removal and installation TransmiSSion mounts - check and replacement
See Chapter 1 7 2 6
Neutral start sWitch - removal, mSlailalion and adjustment
I 8
S 10
3
•9
Specillcatlons
Transmission types
C3. C4 C5. AOD and A4LD
Fluid type and capacity
See Chapler 1
Torque specifications
Ft-Ibs (unless olherwlse Indicated)
Oflveplate·to·torque converter nuts 01 bolls Transmission-la-engine bolts C3. C5 and A4lD
301035
C,
Four and mime slx·cylinder engines V8 engines
ADD Neulral Slart SWitch C3 t979 through t981 t982 on
C, CS A4LD
ADD 1
281038 28 to 38 401050 40 to 50
t2 to t5 7to 10 6.2108.4 5510 75 In-IOO 84 10 120 In-Ibs 810 \1
General Informatio n
All vehicles covered In thiS manual come eqUipped with either a 4·speed or 5-speed manual transmiSSion or an auiomallC transmiSSIOn All IntO/malion on the automatic transmiSSion IS mcluded 10 thiS Part ot Chapter 7. Information tor the manuallransmlSSlon can be found In Part
A ot this Chapter Due to the complexlly 01 the automatIC transmissIOns covered In this manual and to the specialized equlpmefl1 necessary 10 pertorm most ser· vICe operahons, thiS Chapler addresses only those procedures concern· 109 general diagnoSIs. loulme maintenance, adjustment and removal and IOslaliatlon
78-2
Chapter 7 Part 8
Automatic transmission
II the transmission requires major repair work. il should be lett to a dealer seNiee department or an automotive or uansmlSSlon repair shop. You
can. however. remove and install the transmission yourself and save the e~pense. even lIthe repair work IS done by a transmisSion specialist Models covered In thiS manual may be equipped wi th anyone of five automalictransmiSSlons. They are the C3, C4. C5, AOD and A4LD . which are 01 the same fundamental deSign but with varying power handling capa bilities. The A4LD and ADD use electronic controls integrated Into the onboard EEC -IV system. These controls operate a piston/plate clutch In the torque convener thaI eliminates converter slip when applied
On some models Ford speci1ies a different grade transmiSSion flUid than other vehicle manufacturers. and this must be used when refilling or adding flUid . The lIU1d speci fication for your vehicle can be found embossed on the transmission flUid dipstick.
2
Diagnosis - general
Note: Automatic transmission malfunc/ions may be caused by five general conditions: poor engme performance. Improper adjustments. hydraulic malfunctions. mechanical malfunc/ions or malfunc/ions m the computer or Its Signal network DiagnOSIs of Ihese problems should always begm wi/h a check of the easily repaired IIsms . flUid level and condition (Chapter I J. shlt/lmkage adjustment and /hrot/le Imkage adjustment. Next. perform a road test to determme If Ihe problem has been corrected or if more diagnoSIS IS necessary. If Ihe problem perslsls after the prellmmary tests and correc/lons are completed. additional diagnosis should be done by a dealer service department or transmission repalf shop.
Preliminary checks Drive the vehicle to warm the transmiSSion to normal operating tem· perature 2 Check the fluld level as described In Chapter 1· a) It the lIuid level IS unusually low. add enough lIuld to bllng the level wlthm the designa ted area 01 the dlpshck. then check lor external leaks (see below). b) If Ihe fluid level is abnormally high. dram off the excess. then check the drained lIuld lor contammatlon by coolant. The presence of en· gme coolant 10 the automatic transmiSSion fluid Indica tes that a fail ure has occurred 10 the mternal radia tor walls that separate the coolant from the transmiSSion flUid (see Chapter 3) . c) tithe lIU1d IS foaming . dram It and refill the transmiSSion. then check tor coolant in the tlUid or a high lIuid level. 3 Check the engine Idle speed. Note: Iflheengmels malfunctlomng do not proceed With Ihe prellmmary checks unMlt has been repaired and runs normally 4 Check the throule valve cable (AOD transmission) for freedom of movemen t AdJust It If necessary (Section 3). Note; The throt/lecablemay funcllon properly when the engme IS shul 011 and cold. but II may malfunc· lion once the engme IS hOI Check It cold and ar normal engme operatmg remperature 5 Inspectlhe shill COnlrollinkage (Section 5). Make sure thaI If'S proper· Iy adjusted and that the Imkage operates smoothly_
Fluid leak diagnosis 6 Most lIuld leaks are easy to locate Visual ly. Repair usual1y conSists 01 replacmg a seal or gasket It a leak IS dlHlcul t to hnd. the !ol1owlng procedure may help 7 Identity IhellUid. Make sure Irs IransmlSSlon tluld and not engmeoll or brake IIUld 8 Try to pinpom t the source ot the leak Drive the vehicle several miles. then park it over a large sheet 01 cardboard Alter a minute or two. you should be able to locate the leak by determ:nlng the source oj the lIuld dripPing onto the cardboard Make a carelul vlsuallnspeCllon 01 the suspected component and the 9 area Immediately around it Pay particular allenliOn to gasket mating sur faces . A mirror IS otten helplullor IIndlng leaks In areas thai are hard 10
".
10 II the leak stili cannot be Jound, clean the suspected area thoroughly with a degreaser or solvent. then dry It tl O"ve the vehicle Jor several miles al normal operallng temperature and varying speeds Alter dnvlng Ihe vehicle. Visually mspect lhe sus· pected component again t2 Once the leak has been located the cause must be determined betore It can be properly repalfed II a gasket IS replaced but the sealing flange IS benl. Ihe new gasket Will not stop the leak. The benll1ange must be slraightened 13 Belore attempting to repair a leak. check 10 make sure that the tollow, Ing condi\lons are corrected or they may cause another leak Note: Some of Ihe followmg conditions (a leakmg torque converTer, for mstance) can· not be fixed Without highly speCialized lools and exper1lse SUCh problems must be reterred to a transmiSSion shop or a deater service department Gasket (eaks t4 Check the pan peflodical1y Make sure the bolts are tight. no bolts are missing. the gasket ISIn good condition and the pan IS lIal (dents In Ihe pan may mdlcate damage to the val~e body InSide) t5 If the pan gasket IS leaklng.lhe IIUld level or the lIuld pressure may be too high. the ~ent may be plugged. the pan bolts may be tOO tight. the pan sealing lIange ma)' be warped. the sealing surlace 01 the transmiSS ion housing may be damaged. the gasket may be damaged or the IransmlSSlon casting may be cracked or porous If sealant Instead 01 gasket malerlal has been used \0 lorm a seal between Ihe pan and the transmission housing. It may be the wrong sealant Seal (eaks 16 It a transm iSSion seal IS leaking. the lIuld level 01 plessure may be too high. Ihe vent may be plugged. Ihe seal bore may be damaged. the seal Itself may bedamaged or Improperly Installed. the surlace 01 the shalt pro· trudlng through the seal may be damaged or a loose bearing may be caus· Ing e~cesslVe shall movement 17 Make sure the dipstick tube seal IS In good condlliOn and the tube IS properly seated. Periodically check the area around the speedometer gear or sensor lor leakage IIlransmlSSlon lIuld IS eVident. check the O· flng tor damage. Case leaks '8 II the case itself appears to be leaking Ihe cas\lng IS porous and Wilt have to be repaired or replaced , 9 Make sure the 011 cooler hose 1I1Imgs are light and In good condlliOn
Fluid comes out vent pipe or fill tube 20 If thiS COndition occurs. Ihe transmiSSion IS overlilled, Ihere IS coo lant In Ihe "Uld. the case IS porous. the dipstick IS Incorrecl. The vent IS plugged or the dlaln back holes are plugged
3
Throttle valve (TV) linkage - desc ription . inspection and adjustment (ACD transmissions onl y)
Description The throttle valve cable or rod used on AOD transmissions should nOI be thought 0 1 as merely a "downshltt device. The TV linkage controls line pressure. shill poin ts. shitt teel. part Ihrottle downshifts and detent downshills II the TV Imkage IS broken . sticky or mlsadJusted. the vehicle Will e~ 2 petlence a number 01 problems such as early and or soH upshifts and no downshift or a harsh downshllt lunctlon
Inspection Refer to Illustration
33
3 Grasp the cable or rod a few Inches behind where It attaches to the thrOllle linkage and pul1lorwald The cable should slide eaSily Through the cable terminal (see Illustrati on) 4 When re leased the cable should return to ItS Oflgmal POSIIIOn 5 lithe TV linkage does not operale as above. the cause IS mlsadlusted or damaged components
Chapter 7 Part B
Automatic transmission
7B-3 THROTTLE
""'"
PAOTECTIVE
COVEFl
VIEW Y
TAANSMISS'O"l LEVER
VIEW Z
TRANSMISSION LEVER
/ TRANSMISSION
3.3 Typical thro!1le Valve (TV) cable details
BRACKEl
VIEW 1
PI,IS" O\JT WHITE lOCKING TAB fROM THIS SlOt:
78
PR','''''''''V'C ~N
OUT Of GROMMET
'
3.9
Pry the TV cable pin out with a screwdriver
TV cable adjustment Refer 10 illustra/lons 3.9. 3.10.3. I' and 3.12 6 Cable adjustment on 1984 through 1986 models leqUlfBS special pressure lestlng eqUIpment alld should be done by a dealer servICe de· partmentorqualilied transmiSSion shop. Thecable on 1987 and later models can be adjusted Without Special equipment 7 The engine should nOI be running and the thlollie lever must be all\s minimum Idle Slop dUfII'Ig thiS adjustment 8 Remove the all cleaner cover and Inlellube Irom the thlOtUe body to prOVide
9
access.
Pry the grooved pin on the cable assembly out 01 the grommet on the
3.10
Use a s mall screwdriver to push out the whlle locking tab
throltle body lever With a Wide bladed screwdnver (see Illustration) to Push the while locking tab oul With a small screwdriver (see llIustralion)
78 -4
Chapter 7 Part 8
Automatic transmission
11 Make sure the plastic b~k with the pin and lab slides treety on the notched rod (see Illustration). It It doesn'\. Ihe while tab may nOl be
pushed outlar enough. 12 Hold the throttle lever firmly against the Idle stop and push Ihe grooved pm mto the grommet on the throttle lever as tar as 11 will go (see
IIluslralion) Make sure not to move the throttle lever away from the Idle slop dUring Ihls procedure. 13 Inslalilhe all cleaner assembly.
4
Throttle Valve (TV) linkage - removal and installation
Cable type 1
Remove the all cleaner and dlsconnectlhe cable althe thronle lever
3.11
(see Illustration 3.3).
,
Check 10 make sure the plastic block (arrow) slides healy on the notched rod
FIAMl Y AGAINST GROMMET LEvER AW,,"Y
\ .,J' .,," , v 'NS,"'.CEO WHILE HOLDING THROTILE LEVER FIRMLY AGAINST IDlE STOP GROOVED
3.1:l
2
3 4
'tV""",
Iiolding Tne !luOTlIe lever lirmly agalnsllhe Idle stop. push Ihe grooved pin inlo the IhroUle lever grommet
Under Ihe vehicle. disconnect The cable al lhe IransmlSSlon. Remove the cable from the vehicle Installation is the reverse 01 removal
Rod type Refer to Illustration 4 5 5 Disconnect the rod althe throttle lever and transmission (see illustration) Remove the rod 6 Installation IS the reverse of removal.
5
6
Extension housing oil seal - replacement
Refer /0 IIluslrallons 6.3 and 6, 7 I Raise the vehicle and support It securely on jackstands. 2 Remove the drtveshalt (Chapter 8) 3 Remove the 0 11seal from the end 01 the extenSion houstng With a seal removing too l or Ford speCial tool no. T71 P-7657-A. An alternative \0 these tools IS to use a wlde·bladed screwdriver or chisel to remove the seal (see illustration)
Shift linkage - adjustment
Refer to Illus/ratlons 5.3a and 5.3b
Place the selector lever in Drive (C3. C4 and C5 transmission<;) or Overdflve (AOD and A4LD transmiSSions). The lever must be held against the rear Drive/Overdrive stop dUring the adjustment procedure. 2 Raise the vehicle and support It securely on jaCkSlands 3 Loosen the nut attaching the rod or cable to the lever on the transmls· sion (see illustrations) 4 Move the transmission lever to the D~ve or Overdrive position. which IS the second (C3. C4 and C5) or thlfd (AOD or A4LD ) detent from the ful l counterclockwise position 5 With both the selector and transmiSSion levers now tn the same POSI' tlons. tighten the retaining nut securely. 6 Aller adjustment, check the shift selector for proper operation.
T V L~V~A ADJ <;CREW fDA 10" - _
'"
VIEW V
4.5
Typical rod -type TV cable linkage
Chapter 7 Part 8
78 -5
Automatic transmission
.. _ 1 .
~
~-
'j
" ' .. s.sEMllY
.4J
VIEW!
Y IIWl
5.38 Typical cable-type shih linkage details
5.3b Typical rod·type s hllt linkage details
...,~~
'"
IN SLOTS OF ROO BEFORE ...,..LVING TOFl-OVE
VIEW'
4 Before installing the new seal inspect the sealln9 sunace 01 the Universal JOint yoke for sconng II sconng IS found . replace the yoke. S Insped the counlerbore at the hoUSII'lQ lor burrs. Aemove any burrs With emery cloth or medium grit wet-or-dry sandpaper.
6 7
Coat the ou tside (case) diameter of the seal with RTV sealant. InSlall the new 5eallol0 the extension housing (see illustration)
8 The remainder 01 the Installation is the reverse ol lhe removal procedures
6.3 A Chisel Is used here 10 carefully lap around Ihe lIange of the all seal and separate It hom the transmission extension housing
7
Automatic transmission - removal and Installation
Removal Refer to illustratIons 75. 7.6 and 7.14 1 Disconnect the negative cable allhe banery Place lhe cable oul 0' lhe way so It cannot accidentally come In contact with the negative terml-
6.7 A large sockel or length of pipe of the proper diameter should be used to Install the new 011 s&al (a blunt punch and hammer can also be used to lap the new seat Into the bore)
78-6
Chapter 7 Part 8
7.5 Mark the torque con vener and stud with wh ite paint so they can be re installed in the same position
Automatic transmission
7.6 The torque converter plug (arrow) must be at the bottom prior to removal
nal of the ba!tery. as thiS would once agam allow power mto the electrical system of the vehicle. 2 Raise the vehicle and support it securely. 3 Drain the uansmission fluid (Chapter 1). 4 Remove the torque converter cover. S Mark one of the torque converter studs and the torque converter with wh ite pamt so they can be installed in the same position (see Illustration) 6 On models equipped with a drain plug on the torque converter, rotate the engme unlll the drain plug is al its lowest point (see ill ustration), Place a pan under the torque converter and remove the drain plug . Use a SUI!· able large socket and breaker bar on the crankshaft bolt to manually tum the engine over, 7 Remove the torque converteHo-tlywheel nuts. Turn the crankshaft bolt lor access to each nut in turn. Tum the engine only In a clockwise dl' rection (as viewed from the front) . 8 Remove the starter motor (Chapter 5). 9 Remove the dnveshalt (Chapter 8) . 10 Disconnect the speedometer cable. 11 Disconnect the electrical connectors from the transmiSSion. 12 On models so equipped, disconnect the vacuum hose from the modulator 13 Remove any exhaust components which Will interl ere With transmiS Sion removal (c hapter 4 ) 14 Disconnect the TV Of kickdown linkage rod or cable from the ballstud (see illustrat ion) 15 Disconnect the shift linkage, 16 Support the engine uSing a Jack and a block of wood under the oil pan to spread the load. 17 Remove the rear mount to crossmember attaching bolts and the two crossmember-to-frame attaching bolts. 18 Remove the two engine rear support-to· transmission ex tenSion hOUSing attaching bolts. 19 Raise the transmission su fficiently to allow removal of the crossmember. 20 Lower the transmission sllQhtly and disconnect and plug the transmis sion cooler lines. 21 Remove the transmiSSion fluid l iller tube. 22 Move the transmiSSion to the rear to disengage it from the engine block dowel pinS and make sure the torque converter is detached from the lIywheel. Lower the transmission from the vehicle.
Installation Refer to Il/us/rarlon 7.23 23 On C3 and A4LD transmiSSions. make sure prior to installation that the torque converter hub is securely engaged In the pump ThiS can be checked by measuring the distance between the outer surlace of the hub
7.14 Use a large screwdriver 10 dlsconnecllhe TV linkage
and the transmission to make sure thiS dimenSion IS as specified (see illustration) 24 Raise the transmiSSion Into posllion. making sure to keep it level so the torque converter does not slide forward Connect the transmiSSion cooler lines. 25 Tum the torque converter to line up the drive studs With the holes in the flywheel. The whi te pain t mark on the torque converter and the stud made during Step 5 muslline up. 26 Move the transmission ca relully forward until the dowel pinS are engaged and the torque converter IS engaged. 27 Install the transmission housing-to·engine bolts and nuts. Tigh lenthe bolts and nu ts to the speci fied torque. 28 Install the torque conve rt er·to-flywheel nuts. Tighten the nuts to the specified torque. On models so eqUipped, install the torque converter drain plug. 29 Install the transmis:ion moun t cmssmemoor and through-bolts, Tighten the bolts and nuts securety 30 Install the !lUld filler tube. 3 1 Install the starter. 32 Connect the hose to the vacuum modulator (it equipped) . 33 Connect the shift and TV or klckdown linkage. 34 Plug in the transmiSSion electrical connectors. 35 Install the torque converter cover. 36 Connect the dflveshah. 37 Connect the speedometer. 38 Adjust the shift linkage (Section 5) . 39 Install an y exhaust system components which were removed. 40 lower the veh icle. 41 Fill the transmission (Chapter 1). run the vehicle and check lor lIuid leaks.
8
Neutral stan switch - removal , Installation and adjustment
Refer to illustrations 8.4 and 8.6
C4 and C5 transmissions , Jack up the vehicle and support it securely on jacksl ands. 2 Disconnect the downshift linkage rod from the transmission dow nshift lever. 3 Apply penetra\lng oil to the downshift lever shalt and nut and allow it to soak for a few minutes. Remove the transmission downshlfllever retainIng nut and lilt away the lever. 4 Remove the two neutral start switch securing bolts (see III ustraUon). 5 Disconnect Ihe wire connector from the switch. Remove the switch.
Chapter 7 Part 8
Automatic transmission
78 - 7
NEUTRAL ST ART SWI TCH
•
7.23 On C3 and A4LD tran s mis sions. dimension A should be as specified lor the torque converter hub 10 be properly seated in the pump
ATTACHING BOLTS
C3-38mch ~ 7 16109 16'Inch
A4LD
8.4
Remove the C4 or C5 transmi ssion neutral start switch using a socket and ell:tenslon
NEUTRAL ST ART SWITCH
MANUAL LEVER
8.6 Use a number 43 drill bit inserled 1I2-inch Inlo the gauge hole 10 adju sllhe C4 or CSlransmi ssion neulral s larl switch
6 To Install. place Ihe SWitch on Ihe transmiSSIon and Ins\allihe boilS linger IlQht Move the selector lever 10 Neutral poSllion Rotate the sWitch and hi a No. 43 dnll bl\ln\o the gauge pin hole (see Illustration) The biT must be Inserted a tull 1 2 inch (123 mml Tighten the sWitch securing bolls tully and remove the drill 7 Check lhal the engine starts only when the selecior IS In the Neutral and Park poSlhons
e3, AOD and A4LD transmissions
8. 10 On C3, AOO and A4l0 Iransmisslons, the neutral start swil Ch can be unscrewed alter unplugging It - the switch is very Iragile so a specia t socket is recommended lor installaUon
14 Check thatlhe englfle starts only when the selector IS In the Neutral and Park poSl\lons
9
Transmission mounts - check and replacement
Refer to II/us/fallon 8. 10
8 Disconnect the ground cable at the banery 9 Dlsconnectthe etectncalconnector Irom Ihe neutrat start SWitCh . Ford 1001 T7 4P -7724 7· A IS deSigned to remove thiS SWitch Without damaglflg It 10 Carefully remove the SWitch (see illustration) Caufion: It IS easy /0 crush or punctufe Ihe walls of the swrlch 11 Insta!lthe sWitch and tigh ten to the specified torque 12 Instatt the eteclflcal connector t3 Connect the nega\lve battery cable.
Refer to ,lIustratlOn 9 2 1 Insen a large screwdflver or prybar ,nto the space between the Irans miSSIOn ell:tenSlOn and the cross member and pry up 2 The transmlSS'on should not spread ell:cesslVely away from the Insu· lalor (see illustration) To replace, support the transmiSSion With a lack and remove the two 3 nuts attaching the Insulator to the cross member and the two bolts auach· Ing the Insulator to the transmiss ion
78
Chapter 8
Clutch and driveline
Contents Axleshatt beanng - replacement Axleshafl 011 seal- replacement Axleshaft - removal and Installallon Clutch cable - removal and Installation ClutCh components - removal. inspecllon and installation
Clutch - descflptlon and check
20
Onvesha/t and universal JOints - descnptlon and check
14
19
Onvesha/t - removal and Installation Flywheel - removal and Installation
15
", 3 2
Clutch hydraulic system - bleeding 1\ Clutch hydraulic system lIuld level check See Chapler , Clutch master cylinder - removal and installation '0 Clutch pedal - removal and InstallatIOn Clutch release bearing - removal , Inspection and installation 4 9 Clutch slave cy linder - removal and installation
Generalmlorma tion
See Chapter 2
•
Pilot bearing - inspection and replacement 5 Rear axle assembly - removal alld installation 21 Rear axle - deSCriptIOn and check 17 Rear axle (differential) olllevet check SeeChaptEll't Sell-adjusting mechanism quadrant pawl- replactlment Sell-adjusting mechanism - removal and InstallatIOn _ 7 Starter/clutch Interlock switch - removal and installatIOn 13 Universal Joints - replacement
•
"
.,
SpeclllcaUons
Clutch Fluid type Slave cyJinder pushrOd travel
33/64 In (13.5 mm)
Torque specifications
Ft -Ibs
Bellhouslng-to-englne bolt s Pressure plate-to-flywhee l bolt s Oflveshaft lIange bolts Pedal support bracket bollm uts Brake booster mounting nuts Clutch self -adjuster quadrant nu t
28 to 38
See Chapter 1
12 1024 70 1095 13to 25 See Chapter 9 17to 26
General i nformation The In!ormatlOn In thiS Chapter deals With the components from the rear 01 the engine to the rear wheels , except lor the transmiSSion. whICh IS dealt With In the prevIou s Chapter. For the purposes 01 thiS Chapter,
these components are grouped into three categones ; clulch. dnveshafl and rear axle_Separate SectIOnS Within thiS Chapter oller general descriptionS and checking procedures for each 01 these three groups Since nearly all lhe procedures covered In thiS Chapter Involve workIn9 under the vehicle. make sure it's securely supported on sturdy ladl.stands or on a holst where the vehicle can be eaSily raised and lowered.
8
8-2
Chapter 8
Clutch and driveline
21'1!O'O
' REO'O
2 REO'C,
IIUO'O 8F1EO'O
2.1
An exploded view of the clutch components
41no'o INSTALLED AFTE R CABlE ASSV
lUBRI C"TE WI THIN .1S Of R EA R SHOU lDER AFTE R INSTALLING TR""'5M I$$IO N IN H(IUSIIIIG
2
transm iSSion Into Reverse No grinding nOise should be heard A grinding noise would mosl likely indicate a problem In the pressure plale or the clutch diSC c) Tocheck for complete clutch re lease. run the engine (With Ihe parking brake applied to prevent movement) and hold the clutch pedal appro ximately 112-lnch from the floor. Shift Ihe transmiSSion be tween I slgear and Reverse several times IftheshlfllS not smooth, componen t failure IS indicated. On vehicles wllh a hydraulic release system, measurelheslave cylinderpushrod travel (With the engine slopped and the vehicle supported securely on jackstands). Wllh the clutch pedal depressed completely the slave cylinder pushrod shou ld extend t3,5 mm (33J64 Inch) minimUm, If the pushrod doesn'l meet th iS requ irement. check the flUid level In Ihe c lutch master cylinder. d) Visual ly Inspect the clutch pedal bushing at Ihe top of Ihe clutch pedal to make sure there IS no sticking or exceSSive wear. e) On veh icles wllh mechanical re lease systems, a clutch pedal that IS dlfftcul\ to operate is most likely caused by a faulty clulch cable Check the cab le where II enters the caSing for fraying , rust orother signs 01corrOSion. II It looks good . lubricate the cable With penetrating OIl. I! pedaloperallon Improves, the cable IS worn ouland should be replaced . lithe pedal makes a ratchellng noise whi le trave lling 10 the floor. the self-adJusltng mechanism (used on laler models with mechanical release syslems) is probably fau lt y. For more diagnOSIS information, see Troub leshooting al the beginning 0 1Ihls manual
Clutch - description and check
Refer to ,lIus/rallOn 2. 1
1
All vehicles with a manuallransmlssion use a single dry plale. dia-
phragm spring type clutch (see illustration). The clu tch disc has a splmed hub which allows It 10 slide along the splines 01 the transmiSSion input shafl. Theclulch and pressure plate are held In contact by spring pressure exerted by the diaphragm In the pressure plate. 2 Theclulch release system is operated by hydraulic pressureon some models, while on others a mechanical system IS used. The hydraulic release system consists ofl he clutch pedal. a master cylinder and IIUld reservOir. Ihe hydraulic line. a slave cylinder which actuates the clutch release lever and Ihe clutch release (or throwou t) bearing. The mechanical release system includes the clutch pedal with adluster mechanism. a clutch cab le which actuates the clutch release lever and the release beanng 3 When pressure Is applied to the clutch pedal 10 release the clutch. hydraulic or mechanical pressure IS exerted agains t the ouler end of the clutch release lever. As the lever pivots the shalt fingers push against the release bearing The bearing pushes against the lingers of the diaphragm spring of the pressure plale assembly. which In turn re leases the clulch plate, 4 Terminology can be a problem regarding the clutch components because common names have in some cases changed from that used by the manufacturer For example. the driven plate IS also calted the Clutch plate ordlsc. the clutch release bearing IS sometimes called a throwou t bearlng. the slave cylinder IS sometimes called the operallng cyhnder. 5 Other than to replace components With obVIOUS damage. some preliminary checks should be performed to diagnose a c lutch system failure . a) On vehicles With hydrauliC release systems. the first cheCk should be of the fluid level in the clutch master cyhnder. II the flUid level is low. add flUid as necessary and Inspect the hydraulic clutch system for leaks. II the maslercyhnder reservoir has run dry. bleed the system as descnbed In Section 7 and re- Iest the clulCh operaliOn. b) To check "clulCh spjn down time: run Ihe engine at normal idle speed With the transm iSSion In Neutral (clulch pedal up - engaged), Disengage Ihe clutch (pedal down), wa it nine seconds and shllt the
3
Clulch components - remo val , Inspection and installation
Warning : Dust produced by clutch wear and depoSited on clutch components may contam asbestos. whICh IS hazardous 10 your health DO NOT blow It oul With compressed air and DO NOT inhale II. DO NOT usegasoIme or pelroleum -based solvents 10 remove the dust Brake system cleaner should be used /0 flush the dust mto a dram pan After the clulCh components are wiped clean wJ/h a rag, dlsposeoflhecontamma/ed rags and cleaner m a covered container.
Chapter 8
After removal ollhe transmission , Ihls will be the view 01 the clulch components - be sure to mark the relationship of the
3.7
pressure plate 10 Ihe flywheel , II marks
8-3
Clutch and driveline
dan', already exist
Removal
3.12
The clutch disc
Lmmg - Ihrs will wear down in use RIVets - these secure Ihe Iming and will damage the flywhee/ or pressure plale If allo wed 10 contact the surfaces Marks - "Flywheel side - or somelhrng slm!lar
I
2 3
Refer fa ,/lus/rarlon 3. 7
1
Access to the clutch components IS I'IOrmally accomplished by re-
moving tht. transmISSion. leaving Ihe engine In the vehicle 11. 01 course . the engine IS being removed lor major overhaul. lhen the opportunity should always be taken to check the clutch lor weal aod replace worn
components as necessary The following procedures assume that the engme will Slay In place 2 Refernng 10 Chapter 7 Pan A. remove Ihe lransmlSSlon Irom the ve· hlcle. Support the engme while the transmission IS ou l Preferab ly, an en· gine hoist should be used to support 11 Irom above However. If a Jack IS used undernea th the engine. make sure a piece or wood IS used between the Jack and ofl pan to spread the load Caution : The pickup for the all pumpis verycloselolhe !>of/om oNheol/pan If the pan IS ben/ord,Slorted In any
way. engme all slarvatlon could occur
3 On models With a mechamcal release system. remove the rubber dust cover and disconnect the clutch release cable trom the bellhouslng and release lever (see SectIOn 6). On models With a hydraulIC relea se sys tem . remove the stave cylinder (see SectIOn 9). but don I disconnect the hydraulic line or the hydr aulic system Will have tobe bled (see Section 11). 4 On all models. remove the belihouslng ' lo -englne bolts and then detach the hOUSing. II may have to be gently pfled 011 the alignment d owels With a screwdriver or prybar 5 The ClulCh lork and release beaflng can remain attached to the hous ing for the lime being S To support the clu tch diSC during removal . Install a ctutch alignment tool through the clutch diSC hub (see illustrallon 3. 16). 7 Carelully Inspect the lIywheel and pressure plate for Indexing marks The markS are usually an X. an Oor a white lener If they cannot belound. SCribe marks yourself so the pressure plate and the lIywheel Will be In the same alignment dUring Installahon (see illustration) 8 Turmng each bolt only 1 2-turn a t a hme. Slowly loosen the p re ssure plate·to -flywheel bolts. Work In a diagonal pattern and loosen each bolt a htt le at a time until all spflng pressure IS reheved Then hold the pressure plate securel y and comple tel y remove the bolts, followed by the pressure plate and clu tch diSC.
Inspection Refer /0 II/us/ra/ions 3 12 and3. 14 9 Qrdlnanly, when a problem occurs In the clutch , It can be attributed to wear 01the clutch driven plate assembly (clutch diSC). However, all com ponents should be Inspected althls time 10 Inspect the lIywheel ror cracks. heat checking , groove!' or olher SlQns 01 ObviOUS delects. 11 the Imperlectlons are slight. a machine shop can rna· chine the surlace lIat and smooth, which IS hlQhly recommended regardless 01 the surlace appearance. Reier to Chapter 2 tor the flywheel remova l and installation p rocedure
UCESSIVf: flNGEA W£.f.A
3,14
Replace Ihe pressure ptale" excessive or abnormal wear 15 noled
11 Insp ect the pilot bea flng (Section 5). 12 Inspect the lining on the clutch diSC. There should be at least 1 I S-Incho! lining above t he rivet heads. Check tor loose flvets. distortion, cracks. brok en springs and other obvious damage (see Illustration) As mentioned above, ordinarily the clutch diSC is replaced as a matter 01 course. so II In doubt about the conditIOn. replace It with a new one 13 CHdlnafity. Ihe release bea flng IS also replaced along WIth the clutch diSC (see Section 4). 14 Check the machilled surlaces 01 the pressure plate (see lIIustralion) ti the surlace IS grooved Of otherwise damaged, take It to a machIne shop l or poSSible machilling or rep lacement. AJsocheck for ObviOUS damage, disto rt ion, cracking, e tc Light glaZing can be removed With medium gill emery cloth. tt a new pressure plate IS Indicated. neworlaclory -rebultt uMS are avaltable.
8
8-4
Chapter 8
Clutch and driveline 22 Install the transmiSSion. slave cy linder or release cable and all componen ts removed previously, lightening all fasteners 10 the proper torque speCifications.
4
Clutch release bearing - removal , i nspection and installation
Removal 1
Disconnect the negative cable from Ihe battery Remove the transmiSSion (Chapter 7) 3 Remove the bellhousing (Section 3). 4 Remove the clutch release lever from the ball stud. then remove the bearing from the lever 2
Inspection 5
3. 16 A clutch alignment 1001 can be purchased at most aula parts s tores and eliminates aU guesswork when centering the clutch disc in the pressure plale
Holdthe centerof the bearing and rotate the outer porllOnwhlle apply Ing pressu re. 1I1he beanng doesn· t turn smoothly or if irs noisy, replace It With a new one. Wipe the beanng With a clean rag and Inspect It iordam· age, w ear and cracks. Don·t Immerse the bearing in solvent - Irs sealed for hfe and to do so wou ld rUin It
Installation Refer to I/lustration 4.6
Installation Refer 10 illuslrallon 3.16 15 Before installation , carefully wipe the flywheel and pressure plate machined surfaces clean. It's important thai no oil or grease is on these surfaces or the limng 01 the clu tch disc. Handle Ihese parts only with clean hands. 16 POSllion the clutch disc and pressure plale With the clutch held ,n place With an alignrnenllool (see illustration) Make SUfe It'S Installed properly (mosl replacementclu lch plates Will be marked "flywheel Side" or something Similar - II nol marked, install the clutch diSC Wllh Ihe damper spnngs toward the Iransmission) . 17 Tighten the pressure plate· to-flywheel oolts only !Inger tight. work ing around the pressure plate. 18 Center the clu tch diSC by inserting the alignment tool Ihrough the sphned hub and Into Ihe pilot beanng In the crankshaft. Tighten the pres· sure plate·lo-flywheel bolls a hllle at a time. working in acrisscross pattern to prevent distorting the cover. Aller all of the bolts are snug , tigh l en them to the specified torque. Remove the alignment tool. t 9 Using high temperature grease. lubflcale the inner groove of the re o lease bearing (refer 10 Section 4). Also place grease on the release lever conlact areas. 20 Insl all the clutch release bearing as descnbed In SectIOn 4. 21 InSlalithebelihouslng and tighten the bolts tothe propsrtorque speclhcatlon.
6
Lightly lubricate With hthium base grease Ihe ctu tch tever crown and spflng retenlion crown where they contact Ihe beaflng. Fill the Inner groove oflhe bearing with the same grease (see illustration) 7 Attach the re lease bearing to the clutch lever. 8 Lubncate the clutch release lever ball socket With high temperature grease and push the lever onlo the ball stud until It'S hrmly sea ted . 9 Apply a light coal 01 hightempera ture grease 10 the/ace of the release bearing. where It contacts the pressure plate diaphragm lingers. 10 Install the bellhOUSlng and tighten the boilS to the specified torque . 11 Pnor to Installing the transmiSS ion , apply a hghl coat 01grease to the transmission fron t bearing reta iner 12 The rema inder 01 the installation IS Ihe reverse of the removal procedure , tightening all bolts to the speclhed torque.
5
Pilot bearing - Inspection and replacement
Refer to I/lustratlons 5. 1.5.5 and 5.9 1 The clu tch pilot bearing IS a needle roller type bearing wh ich IS pressed InIO the rear of the crankshaft (see illustration). filS greased al the factory and does not reqU ire addl!lonallubncatlon. Its primary purpose IS to support the fron t of the transm ission Input shaft . The pilot beanng should be IfIspected whenever the clutch co mponenlS are removed from
NEEOLE ROI.LER SEARING
SEA, LUBRICATE LEVER CROWN ANO SPRING RETENTION CROWN
4.6
lubricate the release bearing and le ver at the points shown. Al so fill the groove In the Inside diameter of the bearing
5.1 The pilot bearing incorporate s an a -ring seal wh i ch cannot be replaced separately. If there i s any ev idence that the seal has been leaking, or if the bearing is dry, replace it - the bearing must be installed with the seal toward s the transmission.
Chapter 8
8-5
Clutch and driveline
{
I 5.9 Pack Ihe recess behind Ihe pilot bearing with heavy grease and force it out hydraulically with a sleel rod slightly smaller than the bore In the bearing - when Ihe hammer strikes Ihe rOd. the bearing will pop oul 01 the cronkshalt
5.5 One method of removing Ihe pilot bearing requires an Internal puller connected 10 a slide hammer
the engine. Due to liS maccesslbliity It you are In doubt as to Its condlllon, replace 1\ with a new one. Nole: If Ihe engme has been removed from the vehicle. disregard Ihe following sleps which do nOI apply 2 Remove Ihe transmission (refer 10 Chapter 7 Pari A). 3 Remove the clutch compon ents (Sechon 3) 4 Inspect lor any excessive wear. scoring. lack of grease, dryness or obVIOUS damage II any of Ihese conditions are noted, the bearing should be replaced A flashlight will be helpful to direct light Into th e recess 5 Removal can be accomplished with a speCial puller and slide hammer (see Uluslralion), but an alternatIVe method also worl<.s very well 6 Find a solid steel bar which IS slightly smaller In diameter than Ihe beanng Alternallves 10 a solid barwouldbe a wood dowel or a socketwllh a boll he
puSh II out (see Illustration) Remove the beanng and clean all grease Irom the crankshaft recess 10 To Install the new bearing. IIghlly lubrICate Ihe outSide suriace With h· th,um ·based grease. Ihendflve II Into lhe recess With a soft·lace hammer The seal must lace out (see illustration 5.1). 11 Install theclutchcomponenls. transmiSSIOn andaliothercomponenlS removed previously. tightening alilasteners properly.
6
Clutch cable - removal and Installation
Manually adjusted cable (early models) ReIer /0 r/lus/rallo05 6,2. 6.3. and 6 5 Disconnect the negative ballery cable Irom the battery On all except 3 ,3L Inllne six-cylinder models. loosen the cable IocI<.nut and adjusting nut (see illustration) Pull the clutch cable forward out 01 Its bellhouslng boss. 3 On 3,3L models. puillhe adJustrng nut lorward out 01the rubberlnSu lator (see illustration) Turn Ihe adJustrng nut and loosen the cable until It can be removed from the bellhouslng Don'ltry to turn the adJusling nut Without pulling it clear of the rubber Insulator 4 Remove Ihe cable retaining clip at the bellhousing t
2
8 !'ULLIN THIS
OI RE CTION
INSUlATOFI
"" 6,2 On early models (except Inllne sb:-cytlnder engine), remove the clutch locknut and adjusting nut to detach the cab le from Ihe release fork
Ul !200C I,O.f 6.3 On models wilh an tnline six-cylinder engine, pull the adjusting nut clear of the rubber Insulator before Irying 10 turn II
8-6
Chapter 8
Clutch and driveline
· CLUTCH ~'~~ ~': ~.";"~
...F::::>l:::"_ . . OJU$ fM ENT REOUI I'IED
_~""' OUST SHIELD
l .ll EN GIN I C"ILI ADJUSTMENT NUT
6.5
Clutch cable and relaled components - early models with a manually adjusted cable and without a starter/clutch interlock swUch
quadrant Do not use any prying /oolto al,Jch lhe cable /0 /flequad-
5 RemOlle the retamlng clip that secures Ihe cable to the lop 01 thl" clUICh pedal ( see illustration) Detach thecablehom the peda!.\henlake II oul altha vehicle 6 Installanan IS the reverse of the removal steps Ad)uSllhe cable (see
mm b) Alter the cable IS Installed. depress the Clutch pedal several limes to adjust the cable
Chapter, ).
Self-adjusting cable (later models) Refer /0 Illustrallon 6. 7
7 lift the clutch pedal all the way up 10 disengage the pawl andquadranJ (see illustration) Push Ihe quadrant forward and unhook the cable Irom the quadrant Allow lhequadranl to SWing slowly 10 the leaf The quadran! IS under SPring pressure - don t allow It to snap back Into poSllion 8 Open the hood and remove the retaining screw that holds lhe cable to the dash panel 9 If equipped, remove the screw that secures the cable bracket to the front Sldemember 10 Raise the vehicle and support It securely on lackstands. t t Remove the dust cover from the bellhouslng. 12 Remove the retainer ring holding the cable to the belthouSlng t3 Disengage the clutch cable from the release lever a) On all e~cept 1987 and tater lour·cyl lnderenglnes. slide the ballon the endol the cabte through the hote In the clutch release lever and remove the cable b) On 1987 and laterlour..qllnderenglnes. remove the cJlpandclevls pin Irom the end 01 the cable 14 Installallon IS the reverse 01 removal With the lollowlng notes a) To Install the cable Into the adJusling assembly, hft the clutch pedal to disengage the pawl and Quadrant Caution : The clutch pedal must be lifted /0 prevent damage to the pawl and quadrant While pushmg the quadrant forward. hook the cable over the rear of the
7
Sell-adjusting mechanism - removal and Installation
1 Dlsconneclthe negallve battery cable Irom the battery 2 Remove the steeling wheel (see Chapter 10). 3 Remove the lower leh Instrument panel sectIOn (see Chapter 11 ). then remove the steenng column shrouds 4 Disconnect the hood release mechanism InSide the vehICle 5 Disconnect the master cylinder pushrod and stoplight SWitch Irom the brake pedal (see Chapter 9) 6 Carelully rOlale the QuadranllofWard unlll you can unhook the clutch cable Irom It (see iliustraUon 6.7). Hold the Quadrant and allow 1110 move slowly rearward. 7 Move the Inlerval wlpC!r governor (It equipped) out of the way and diSconnect all of the steering column electrical connectors 8 Detach the sleerlng column from the brake pedal bracket and let the column rest on the floor of the vehicle 9 Unbolt the brake pedal bracket support brace from the left·hand Side 10 Remove the brake booster mounllng nuts (see Chapter 9). II Unbolt lhe brake pedal suppor1 bfack.et from the Instrument panel and lake the bracket out t2 Remove the clutch pedaj (see SectIOn 12) Take the sell·adjushng mechamsm out of the brake pedal sUPPOr1 bracket 13 Remove the sell-adjusting mechanism shaft bushings trom the brake pedal support bracket. Inspect the bushings and reptace them If they are worn
Chapter 8
8-7
Clutch and driveline STAATERIClVTCH IHTERI..()()( SWITCH
"""
8R.AKE PEDAL
PIVOT BUSHING
CLUTCH PEDAl. 8EllHOUSII+G
twR PIN CUP
""""'"
2 3L OHC ENGINE GAEEN TAPE 5.CIl ENGINE PURPLE TI
CA8LE-.-'~1fiIrII! .....~~~ , _..., ~--Y
RETAlNEFI RING
/"
~
/ ,
HAIR PIN CLIP
. / ' /- ,
L:.~
ViEW 1
CLEVIS
CLEVIS PIN
sc,ew _ _ _.... FAOHT SlOE MEMSER
-
./
VIEW Y
6.7 Clu tch cable and related components -later models with a sell·adJusling mech anism and a star1er clutch Interlock swilen
HAIRPIN
14 Apply engme Qilialhe self-adJus1lng mechanlsmshafl .lhen Install the
CU,
mechanism In the brake pedal support bracket 15 Turn the quadran t toward the lOp of Ihe .... eh,cle Align the flats on the sel!·adJusllngshalt w ith Ihe clutch pedaillats, then install the nul and tighten It securel~ 16 Install the brake pedal support bracket and ttghten 115 nuts loosely. Inslall\he boll Tighlen 'he boll. Ihen Ihe nuts securely 17 The remainder ollns[alla[lon IS [he reverse 01 the removal step s 18 Press [he clutch pedal several times to adlustthe clutch 19 Check steering column operatIOn
8
8
Sell-adjusting mechanism quadranl pawl - repl acement
""'NO
Refer /0 I/lus/rallon 8.2 1 Remove the se ll 'adJustlng mechanism {see Section 7)_ 2 Remove both hairpin clips. then remove [he Quadrant and sp ring (see iIIuSlralion) 3 Remove the pawl Spring and pawl 4 Apply multi-purpose grease to the PIvot shatts 01 paw l and quadrant 5 Instalilhe pawl w ith ItS teeth toward the longer shal t. POSition the spring hole In the end of the arm. not beneath Ihe arm 6 Place the s[ralgh[ end of the spring In the hole {COil upwardl. [hen turn the spring t2 turn to the left and place the cod over the boss 7 Hook the spnng under the arm and Install the halrplnchpto secure the pawl
8.2
Sell-adjusting mechanism Quadrant and pawl details
8 Install the QUadrant spnng onlheshatt. Ilsbentend goes.n the hole In the arm 9 Place The Quadrant on the shah With Its bonom prOlectlon under the shalTarm. Mesh the bottom tooth of the pawl With the bonom tooth of the quadrant 10 Install the hairpin chp that retains the quadrant 11 Use pliers to hook the Quadrant spflflg behind The Quadrant ear
8-8
.....,'...,"'
Chapter 8 Clutch and driveline
u..,
.. ..
"", ,,"''''' " 9.3
Clutch slave cylinder mounUng details
12 InSlalilhe selj·adjusling mechanism (see Section 7). 13 Instalilhe clutch pedal (see SectIOn 12)
9
Clulch slave cylinder - removal and instaUation
Refer /0 Illus/rallOn 9.3
1 2
Disconnect the cable from the negative baltery terminal Raise the vehicle and support It securely on Jacksl ands
3 Remove the slave cylinder dust cover sell-tapping screw and detach the cover (see illustration) 4 Detach Ihe slave cylinder from Ihe mounllng bracket on the transmiSsion. 11 may be necessary to pry II oul with a screwdrtver. S It Ihe slave cylinder must be replaced. support thecyhnder and. USing a small punch. drive oullhe roll pm that retains the IlOe 10 the cylinder Pult the Woe 011 the cylinder. 6 To Install the slave cylinder. reverse lhe removal procedure Be sure to use a new O ' flng and roll pm when relnstallmg the Ime II a newcylmder IS being mstalled. do nOI remove lhe plastiC relamlng strap from lhe push· rod - It IS deSigned 10 break off thellrst time the clu tch pedal IS depressed
to
Clutch master cylinder - removal and Installation
Refer 10 Il/u$lrallon 10.3 I Remove the clutch slave cylinder follOWing the procedure described m the precedmg Section. 2 From InSIde Ihe vehicle. remove the tell side under dash panel and dlsconneclthe pushrod lrom lhe clutch pedal 3 Unscrew the two clutch tlUid reservoir nuts and lower U'le reservOir, taking care nOllO spill any tluid (see Illustration) 4 Grasp the clutch master cylmder and lurn It clockWise appro~lmately 45-degrees. then pull the cylinder from Ihe tlrewall 5 Remove Ihe hne Irom the master cyhnder by dnving ou t the roll pm with a small punch 6 Installallon is the reverse 01 the removal procedure. Be sure to use a new rOll pin and a new O'flng where the line enters the cylinder
10.3
Clutch master cylinder and lIuld reservoir mounting details
systemdurmg the bleedmg operation or use flUid which has been mSlde an open contamer for an extended peflod of lime 3 Raise the vehicle and place " securely on lackstands to gam access to the stave cylinder, which IS located on the lell side of the clutch hoUSing 4 Remove the dust cap which hts over Ihe bleeder valve and push a length of plasllC hoseoverthe valve Place theolherendol the hose Intoa clear conlalner With about two Inches 01 bfake tluld The hose end must be In the !Iuld al the bottom ot the comalner 5 Have an assistant depress the clutch pedal and hold II. Open the bleeder valve on th e slave cyl inder. allOWi ng lIuld to !tow th rough the hose. Close the bleeder valve when your assistant Signals that the clulCh pedal IS at the bottom of its travel. Once closed. have your assistant release the pedal 6 Con\lnue thiS process unlll all air IS evacuated Irom the s~slem . inch· cated by a lUll. sohd stream 01 !tuld being ejec ted from the bleeder valve each time and no air bubbles In the hose or container. Keep a close walch on the tlUid level inside the clu tch master cylinder reservOIr If the level drops too low, air Will be sucked back Into the system and the process Will have to be started all over again 7 Install the dust cap and lower the vehICle Check calelully lor proper operation before plaCing the vehicle In normal service
t2
Clutch pedal - removal and Inslallation
, Disconnect the cable Irom the negahve terminal ot the ba ttery 2 Remove the lett side under dash panel 3 If eqUipped. disconnect the starler 'clutch Interlock SWi tch pushrod tram the ctutch pedal (see illustration 6.7). 4 Remove Ihe nul that retains the clutch pedal to the pivot shalt and Wiggle Ihe pedal off the shalt 5 Installallon IS the reverse 01 the removal pi"ocedure
t3
Starler/clutch interlock switch - removal and Installation
Refer /0 IlIuSlra/lon 13.4
Removal 11
Clut ch hydraulic system - bleeding
t The hydraulic system shook:! be bled at all air whenever any pM 01 the system has been removed or II the lIuld level has been allowed to lall so low that air has been drawn IOta the master cylinder The procedure IS very Similar to bleedmg a brake system. 2 Fill the master cylinder with new brake flUid conforming to DOT 3 Specifications. Caution: Do no t re·use a ny o f Ihe flUid coming from lhe
t Detach the wire harness connector trom the Interlock SWitch 2 Remove the retaining clip from the SWitch rod mounting pin on the clutch pedal 3 Remove the Interlock SWitch to bracket screws and detach the SWitch
Installation 4 Position th e adjuster clip approximately ' ·mch from the endo! the rod (see lIIuslralion).
Chapter 8
TO ,,.-r A\.L, -.TIOH
Clll'lII\lV. . ON_....our
. . . _I,.ICMI'"OMIHD 01' IlOO ANO lOUun MALVII TOOITHIII TO LOCIl .... " ...
• ,,._lnCl"
13.4 The adjusting clip can be repositioned closer to the switch by compressing the barbs on the clip, separating the two halves and sliding iltoward the switch. Press the halv es together 10 lock th e clip in place.
5 Attach the eyelet end althe rod to the pin on the clu tch pedal Install the retaining clip 6 With the clutch pedal all the way up. SWing the SWitch up mto place. Install the mounting screws and I.ghten them securely. 7 Push the clu tch pedal to the 1100110 adjust the switch. Plug In Iheelec·
tllcal connector 8
Confirm that the engme starts only when the Clutch pedal is de-
pressed to the f loor. If it doesn"' . remove the adjusting clip Irom the rod and posItion It closer to the switch (see illustration 13.4). Check the SWitch operation again . lithe engine stili doesn't crank over, or cranks over when the pedal is In Ihe released poSition, replace the switch .
14
8-9
Clutch and driveline
Driveshall and universat joints - description and check
Refer to illus/ratlon 74 1 1 The dnveshafl IS a tube running between the transmiSSiOn and Ihe lear end. Unrversal jOints are located at ellher end of Ihe driveshall (see illustration) and permll power to be transmitted to Ihe rear wheels al vary-
Ing angles. 2 Thednveshaft features a splrned yoke althe Iront. which shps into the extension hOUSing ollhe transmission . This arrangement allows the drive shalt to slide back·and-for1h Within the transmiSSion as the vehicle IS In op· era tion. 3 An all seal IS used to prevent leakage 01 tluid at this point and [0 keep dlr1 and con taminants Irom en tering the transmission. II leakage IS eVident at thefrontol thedriveshaft. replace the oil seal relerring totheprocedures in Chapter 7 . 4 The driveshall assembly requires very hltle service. The universal JOints are lubrrcated lor hie and must be replaced i1problems develop. The driveshalt must be removed Irom the vehICle lor thiS procedure 5 Since the dllveshaflls a balanced unit. it's important lhal no undercoating. mUd. etc. be allowed to stay on it. When the vehicle IS raised lor service It'S a good idea to clean the dnveshaft and inspect It lor any ob· VIOUS damage. Also check that the small weights used 10 orrgrnalty bal· ance the driveshaft are in place and securely attached. Whenever the dllveshalt is removed It'S important thaI It be reinstalled In the same rela · tlve poSition to preserve Ihls balance. 6 Problems with the dnveshaftare usually indicated by a nOise orvibratlon while dovlng the vehicle A road test should veri l y il the problem is the drlveshall or another vehicle component: a) On an open road . tree oltraHic, drive the vehicle and note the en· gme speed (rpm) at which the problem IS mosl eVident. b) With this noted, drive the vehicle again. this Ilme manually keepIng the transmission In 1st.then 2nd. then 3rdgear ranges and running the engine up 10 the engine speed noted. c) II the nOise or Vibration occurs at the same engine speed regardless of which gear the transmiSSion IS in, the driveshalt IS not at fault because the speed 01 the driveshalt valles In each gear. dl If the nOise or lIibratlon decreased or was eliminated, Visually in· speclthe dllveshait fordamage . material on the shalt which would eHect balance. missing weigh ts and damaged unrllersal joints. Another poSSibility for this condi tion would be trres which are out-ofbalance. 7 To check lor worn universal jOints: a) On an open road , Iree 01 traff ic. drrve the vehicle slowly unlilihe transm iSSion is In High gear. LeloHon the accelerator, allOWing the vehicle to coasl, then accelerate. A clunking or knocking noise Will mdicate worn unlversallOlnts.
UN IV ERS4 l J OI NT KIT _
8 C"'CUI..AR FI..APoIGf
S ll ~
YO I(E
lOCKW ASKER
14.1
CIRCULAR FI..APoIGE
An exploded v iew of a typical drives halt and universal jolnls
8 -10
Chapter 8
Clutch and driveline
SEAL SPIDER
o 16.2a
CAP
SNAP
~ ~.~~
An exploded view of the universal joint components
15.3 Belore removing Ihe botls, mark the relaUonship of the drlveshaft flange and the dilferentlal companion flange. To prevent the drlveshalt from turning wh en loosening the 11ang9 bolts, Insert 8 screwdriver through the yoke.
b) Dnve Ihe vehICle at a speed 01 about 10 \0 15 mph and then place thelransmlssion In Neutral. alloWIng the vehicle locoasl.llslen lor
abnormal dnvehne nOises c) Raise the vehicle and SUpPOrll\ securely on Jackslands. With Ihe transmiSSion In Neutral, manually lurn Ihe dnll9shalt. watching Ihe universal JOIn!S lor excessive play
15
Driveshaft - removal and installation
Removal Refer 10 II/usrrallon , 5.3 1 2
curely on lackstal'lds Place the transmiSSion 10 Neulral with the parklOg brake 011 3 USing while palOl or a hammer and punch, place marks on the drIVe· shaft Uange and the differential companIOn Uange In line With each other (see illustration) ThiS IS 10 make sure Ihe dflveshaltls reinstalled ,n the same position to preserve the balance 4 Remove Ihe rear universal JOlOt lIange bolts, Turn Ihe dnveshatt (or rear wheels] as necessary 10 bong Ihe bolts IOta Ihe most accessible posi· lion 5 Lower Ihe rflar at the dnveshalt and then shde the fronl out 01 Ihe transmisSion 6 To prevenlloss 01 tluid and contamlOation while the dflveshall IS out WI ap a plastIC bag over the IransmlSSlon hoUSing and hold 1110 place wllh a lubber band
Installation 7 Remove Ihe plastiC bag on the transmiSSion and Wipe the area clean inspecllhe all seal carefully Proceclures lor replacement ollhls seal can be found In Chapter 7 8 Slide the Ilonl 01 the dliveshalllOlo the transmission, 9 Raise the rear 01 the dnveshalt Inl OpoSition. Checking to be sure that the marks are 10 alignmenl II not. tum the rear wheels 10 malch the PInion lIange and the dflveshalt flange , 0 Instalilhe flange boltS. tigh tening them 10 the speCified torque
16
16.2b
Disconnecilhe cable trom Ihe negative battery terminal Block the Iron\ wheels. Raise the rear 01 the vehicle and support It se·
Universal joints - replacement
Reier 10 IlIuslrallOns 162a. 16.2b, 164 and 169 Note: A press or large I'/se wrll be reqUIred for /hIS procedure It may be adVisable /0 lake Ihe cfflveshafllo a focal dealer or machme shop where
A pair of needle-nose pliers can be used 10 remove Ihe universal joinl snap-rings
the Universal JOmts charge I
can be
replaced for you. normally at
a reasonable
Remove the dflveshalt as oulilOed In the prevIous SectIOn USing a small pall of pliers. remove the snap-flngs from fhe SPidel (see illustrations) 3 Supporting the dnveshafl, place It 10 poSl1lon on ei ther an arbol press or on a workbench equipped wifh a vise 4 Place a piece 01 pipe or a large socket With the same IOslde diameter over one ollhe beaflng caps. POSllIOn a socket which IS 01 sllghtl~ smaller dlameler than the cap on the opposite beanng cap (see iIIuslralion) and use the vise or Pfess to force the cap out (Inside the Pipe or large socket). SlOpping Just belore II comes completety out 01 the yoke Use Ihe vise or large phers to work Ihe cap the resl 01 the way out 5 Transler th e sockels to the olher Side and press the opposite beanng cap out In Ihe same manner. 6 Pack Ihe new universal JOint beallOgs With grease Ordlnanl~, SpecifIC instructions for lubrication Will be Included with Ihe universal Joint serviCing kJl and should be followed carelully 7 POSlllon the spidel In the yoke and partially Install one beafll'lg capm the yoke 8 Start the spider Intolhe beaflng capal'ld Ihen pamall~ Instalilhe olher cap Ahgn lhe spider and press Ihe beallng caps lOla poSition. bemg carelui noll0 damage Ihe dust seals 9 Install the snap-rmgs. 1/ difficulty IS encoun tered m seating the snaprmgs, sIr ike thedllveshalt ~oke sharply wllh a hammer ThiS Will spnng the yoke ears shghll~ and allow the snap-nngs 10 sealllllhe groove (see illustration ) 10 InSlall the grease liwng and /tilihe Joml wllh grease Be carelul not to over1lll the IOlnt. as thiS could blowout the grease seals. t 1 Install t~e dnveshall. tightening Ihe Ilange bolts to the SpecrileO torque
2
Chapter 8 Clutch and driveline
16.4 To press Ihe universal joint out 01 Ihe driveshalt yoke, sel it up in a vise with Ihe small socket pushing Ihe joint
and bearing cap Into the large socket
8 -11
16.9 lithe snap·ring will not seat in the groove, 17.4 The axle Identificallon tag Is held in place wllh a d ifferentia l cove r bo ll strike Ihe yoke with a brass hammer. This will relieve the tension that has set up in the yoke, and
slightly spring the yoke ears. This should also be done it the joint feels tight when assembled.
17
Rear axle - descriplion and check
Description Refer to illus/rallon 174 1 The rear axl e assembly IS a hypold , seml-!loa1lng type (the centerline of the pinion gear is below the centerline of Ihe ring gear, and the ou ter end of the axle shalt prOVides a support surface for the rear wheel bearing) The differential carner is a cast ing With a pressed sleel or plastiCcover and the axte lubes are made 01 sleet, pressed and welded into the carner 2 The rear whee l bearings on early models (equippedwllh a 6.7S-lflch ring gear) are pressed onto Ihe a~le shafts. The rear wheel bearings on later models (eqUipped wllh a 7.S-lflch or 8.8-inch ring gear) are pressed inlo Ihe a~le hOUSing 3 An opllonallocking rear axle is also ayallable. ThiS differential allows lor normal dlfferenllal operation until one wheel loses traCllOn. The uM Uti' lizes multi-disc ctutch packs or InCIIon cones and a speed sensitive en· gagement mechafllsm which locks bolh axleshalts together. apptylng equill rotational power 10 bolh wheels. 4 In order 10 undertake certalfl operations. particularly rep lacement of the a~leshalts . Irs Important to know Ihe axle fclentlficatlon number, ThiS Ifllormation can be found on the Axle Identllication Tag. w: lIch IS located under a differential cover-to-carner bolt in the 2 o'clock position (see l1IusIration).
and run the engine 10 the same speed If the nOise IS the same. Ihe rear axle is nol al fau lt. 7 Overhaul and general repair of Ihe rear a~le IS beyond the scope 01 the home mechafllc due to the many special tools and cTI\lcal measure· ments reqUIred Thus. the procedures listed here wllllflvolve axleshait removal and Iflstallatlon. a~ leshalt oil seal replacement. axleshaft bearing replacement and removal 01 the entire Unit for repair or replacement.
18
Axleshalt - removal and installation
Early models (6. 7S-inch ring gear) Reier to illus/rations 18.5 and 18.6 1 Park Ihe vehicle on level ground 2 Securely block Ihe front wheels so the vehicle can 't roll forward or backward. 3 Jack uplhe rearofthe veh icle and place It securely on Jackslands. DO NOT get under a vehicle thaI IS support ed only by a lackl 4 Make sure Ihe par'P\lng brake is released . then remove Ihe brake drum. If the drum IS secured by speed nuts, remove Ihe nUIS and keep them for re-use S Remove the nuts securing the wheel bearlflg retalfler plate (see illustration).
Check S Many limes a fault IS suspected in the rea r a~le area when, in lact. the problem lies elsewhere. For thiS reason . a thorough check should be per formed betore assumlflg a rear a~le problem. 6 The 101i0wIflg nOises are Ihose commonly associated With rear a~ le diagnosis procedures : a) Road noise Is olten mistaken for mechanical faults . Driving the ve hicle on different surfaces Will show whether the road surface is Ihe cause ot Ihe nOise. Road nOise Will remain the same Il lhe yehicle IS under power or coastlflg. b) Tire nOise IS somellmes mistaken lor mechanical problems. Tires which are worn or Iowan pressure are particularly susceptible 10 emitting Vi brations and nOises. Tire noise will remalfl about the same during Yarylflg dnYlflg si tuations, where rear a~ le noise 1'0'111 change dUring coasting , acceleration, etc. c) Englfle and transmission nOise can be decelvlflg because II Will Iravel along Ihe dflvellne. To Isolale englfle and transmiss ion noises. make a nole ollhe engine speed at which Ihe nOise is most pronounced. Stop the vehic le and place the transm iSSion Ifl Neutral
8
18.5 The wheel bearing retainer plate nUIS are acces sible through the holes In the axle drive lIange (brake shoes shown removed for clarity - normally, Ihe shoes don', ha ve 10 be removed)
a -12
18.6 The axle shaft can be withdrawn once the retainer plate nuts are remOlled ; during InstaUation, take care not to damage the 011 seal with Ihe axle shaft
Chapter a Clutch and driveline
18.178 Position 818rge screwdriver between Ihe rear 8xle CBSe and a ring
gear bolito keep the differential case from turning when removing the pinion shaft lock bolt
Puilihe axles hall oul 01 the housmg to clear Ihe brake backlll9 plate (see Illustration) 7 Take Ihe axleshalt to a machine shop lor beanng replacement 8 Replace the 8xleshaft 011 seal whenever the axleshaft is removed (see Section 18) 9 Check lor nicks or gouges In Ihe 011 seal mounting surface 10 Usea large socket or seal dnvertolapln a new seal The hpof lhe seal laces Into Ihe axle hoUSing. Tap the new seal In squarely. making sure Ihe seal does nOl (Jilin Its bore 11 Carelully Inslallthe aJlleshah wlthoul damaging the seal. POSition the beanng retainer plale over the studs. Ihen Install the nUIS and tighten them securely 12 InSlall the brake drum and speed nuts (If used) . 13 InSlall Ihe wheel. Remove the Jackslands, lower Ihe vehic le to the ground and tigh ten the wheet nuts to specihcations (see Chapter 1)_ 6
Later models (7.S-inch or 8.8-inch ring gear) Referto illustrarrons 18 77a, 18 17b, 18. 18 and 18. 19 14 Raise lhe rear 01 the vehICle. support II securely and remove the wheel 15 Remove the brake drum or rear caliper and brake disc (rel er to Chap ler9) _ 16 Remove the cover from the differential callier and allow the 011 10 drain Into a container
18.18 Push In on the axle Ilange and remove the C-Iock (arrow) Irom the Inner end 01 the axleshafl
18.17b
Rotate the differential csse
,80-degrees and slide Ihe pinion shall out of Ihe case unlilihe stepped part of Ihe shaft conlacts the ring gear
17 Remove the lock bolt from the dilierenliat ~)lnlon shah Slide the notched end of Ihe pinion shalt out of the dilierenliaicase as far as It Will go (see illustrations) 18 Pushlhe outer (flanged) efldolthe axleshaft in and' 'move theC·lock from the Inner end of Ihe sh aft (see illustration) 19 Withdraw the axleshalt, ta king care not to damage Ine 011 seal in the efld 01 th e axle hoUSing as the spllned end ot the axleshalt passes through II (see illustration) 20 Installallon IS the reverse 01 removat Tighten the lock bolt securely 21 Refer to Chapter I lor the proper cover installatIOn procedure 22 Relitl the axle With the correct quantity and grade 01 lubncant (Chap· ter I)
19
Adeshalt 011 seal- replacement
Refer /0 I!lustra llons 19.2 and 19 J Remove the axleshalt as described In the preceding Section 2 Pry the old oil seal oul 01the end ol lhe ax le hOUSing On later models. use a large screwdflver or the Inner end 01 the axleshalt Itself as a lever (see illustration) On early models. a special slide hammer puller may be required 1
18.19 Pull the axle out 01 the housing , supporting It with one hand to prevent damage to Ihe seal
19.2 II a seal removal tool Isn't avaitable, a prybar or even the end 01 the axle can be used to pop the seal out of the housing
Chapter 8 Clutch and driveline
8 -13
,
A.XLE SHAFT
suO( HAMMER
19.3 A large socket or a piece of pipe (as s hown here) can be used 10 inslailihe seal - the diameter of Ihe tool should be slightly smaller than the outside diam eter ollhe seal.
BEARING
DRIVER
20,3 To remove the axle bearing, Insert B bearing removal tool attached to a slide hammer through the cenler, pulilhe tool up against the back s ide and use the slide hammer to yank the bearing from the axfe housing
5 Clean out the bearing recess and drive In the new beanng With a bear109 driver (see i lIu9tration) . Lubncate the new beanng With gear lubncanl. Make sure that the beanng is tapped Into the luff depth of its recess. 6 Discard the old oil seal and Install a new one (Secllon 19}, then install the axleshall
21
Rear axle assembly - removal and Installation
Removal
20.5
A correctly-sized bearing driver must be used to drive Ihe bearing into Ihe housing
3 Using a large socket as a seal driver, lap the seal Into poSition so that the lips are facing In and the metal lace IS Visib le from the end 01 the axle hOUSing (see Illustration). When correctly Installed. the taee allhe 011 seal should be flush With Ihe end of the axle hOUSing Lubricate the lips of Ihe seal With gear oil. 4 Installation of the axleshaft is covered In the preceding Section
20
AKleshaft bearing - replacement
Early models (bearing on axleshaft) Bearmg replacement on early models With Ihe beanng pressed onto Iheaxlesha!1 reqUires a hydraulic press and speclallools. Removethe ax · lesha!t (see Seclion 18) and have a dealer service deparlment or automo· live machme shop replace the beanng
Later models (bearing in axle housing) Refer to Illustrations 20.3 and 20 5 2 Remove the axlesha/t (refer to Section 18) and Ihe all seal (refer to Secti on 19) . 3 A beanng puflerwlfl be required or a tool which Will engage behind the beanng wlff have 10 be fabricated (see illustration) 4 Attach a slide hammer and puff the bearing out of the axle hOUSing .
1 Disconnect the cable from the negative battery terminal. 2 Loosen, but do not remove the rear wheel lug nuts. Block the front wheels and raise the rear of the vehicle . Supperl it securely on jackstands. Remove the rear wheels . 3 Remove Ihe brake drums or brake calipers , anchor plates and discs (see Chapter g). 4 Remove the rear axle cover and allow the lubncant to dram (Chapter I). 5 Remove both fear axleshafts following the procedure 10 Section 18 6 Unbol t the brake line junction block from the rear axle cover. 7 Detach the brake lines from the axle housmg 8 Drum brake models - remove the four bolts that attach the brake backing plates to the axle housmg. Detach lhe brake assemblies from the housing and wire them out 01 the way. g Disconnect the vent tube from the axle housmg. 10 Unbolt the driveshalt fromthedlfferenllal flange (Seclion 15) and wife It out of the way. 11 Place a floor jack under the dlfferenllal and raise the rear axle slightly. 12 Detach the tracllon bars or axle dampers (if equipped) from the axle housmg (see Chapter 10). 13 Remove the Call spnngs followmg the procedure outlined In Chapter 10. 14 Remove the shock absorber lower mounting bolts. 15 Remove the upper con l rol arm·lo -rear axle hOUSing nuts and bolts. t 6 Remove the lower control arm-to·axle housing nuts and bolts. 17 Lower the axle housing and gUide It ou t from underneath the vehicle .
Installation 18 Raise the rear axle assembly into place and mstallthe upper control arm- to-axle housing bolts and nuts Don't completely tighten Ihe nuts at thiS lime. 19 Install the COil spnngs (See Chapler 10) and connect the lowercontrol arms to the rear axle assembly 20 Connect the traction bars or axle dampers (it eqUipped) to the axle hOUSing. 21 Raise the axle housing to Simulate normal ride height and lighten the upper and lower control arm-to·axle hOUSing nuts securely.
8
8 -14
Chapter 8 Clutch and driveline
22 Connect the lower ends of the shock absorbers lathe rear axle housing and lighten the bolls securely. 23 Connect the driveshafl lo the differentiailiange, aligning the matchmarks. Tighten the bolts to the specified torque 24 Orum brake models - at!ach the brake backing plates to the axle hoUSing. hghtenll'lg the nuls securely. 2S Mach the brake ~nes to the 3J:le housing 26 Install the 3J:leshafls (see SectIOn 18). 27 Install the brake drums or rear caliper anchor plales, discs and calt·
pers.
28 Connecllhe axle vent tube, 29 Install the rear axle cover and fill the cliHerenllal with the recommended lubricant (see Chapter 1). 30 Anach the brake jUJ'lClion block to the rear axle cover (drum brake models) and tighten the bolt securely II, In the course 01 removal , the brake fluid lines were disconnected, bleed the brake system (Chapter 9). 31 InSlalllhe wheels and lug nuts Lower the vehICle and ttghten the lug nuls \0 the speclhed torque (see Chapter 1'.
Chapter 9
Brakes
Contents
,
Brake system check See Chapter 1 Brake disc - InspeCliOn. removal and mstallallon Brake flUid level check See Chapter I Brake hoses and lines - inspection and replacement 10 11 Brake hydraulic system - bleeding Brake light sWitch - replacement 16 3 Front brake cal iper - removal , overhaul and Installation Front brake pads - replacement. 2 Front wheel bearing check. repack and adjustment See Chapter 1 Generalmlormallon and precau1l0ns Master cylinder (1979 through 1986 models) - removal. installation and overhaul 8
Master cylinder (19B7 and later models) - removal. overh aul and installation ............. .
Parking brake - adjustmen t . Parking brake cables - replacement .. Parking brake - releaSing cable tenSion (1987 and later models) ... Power brake booster - removal. installallon and adJustmenl Rear brake caliper - removal. installation and pad replacemen l Rear brake shoes - replacement Wheel cylinder - removal . overhaul and In<;'allallon
9 12 14
13 15 5
6 7
Spec ificatio n s
Brake fluid type
See Chapl er 1
Disc brakes Minimum pad thickness See Chapler 1 Front brake diSC Standard thickness 0.870 in Min imum Ihlckness' 0.8101n Runouilim il 0.003 In Thickness vanal lon (parallelism ) Steel wheels 0.0005 in 0.0003 In Aluminum Wheels Rear brake disc Siandard Ihlckness 0.945 In Minimum Ihickness' 0.895 in Runouillmit 0.00310 Thickness varmllon (parallelism) 0.0005 In . Refer /0 marks s/amped on the diSC (they supersede mformatlon prmled here)
Rear brake drum diameter Standard Heavy·duty models All others
10.000 in 9.000 In
II
9-2
Chapter 9
Brakes
Maximum'
Heavy-duty models 10.060 In All others 9.060 In • Refer /0 marks cast into the drum (they supersede mforma/lon printed here)
Torque specifications
F\·lbs
Brake hose-Ie-caliper UOion boll
Front disc brakes Rear disc brakes Brake hose \0 caliper (screw -,n hose end) FlOn! disc brake caliper loca\lng pins All except SVO and 1987 and laler 5 OL va Mustang SVO and 1987 and later 5 OL V8 Rear diSC brake caliper end relalner
Rear diSC brake caliper end relalner screw Master cylinder-la-booster nuts Power brake booster nulS Wheel cylinder bolts Brake pedal Pivot shafl nul Wheel lug nul S
17to 25 20 to 30 20 to 30 30 to 40 4010 60 75to 96 16to 22 13to 25 13 to 25 9to 13 to to 20 See Chapter t
General InlormaUon and precaution s
' .. .......IIIV IIIUE"VOl " I, JIIOHT ...... 1(( SYSTEM !
SECONDMV tIIUlitllV0 11I (11( .... 11 PI .... I(( IvtTl"!
Refer to IllustratIOn' 3
Genera/Information All vehicles covered by thiS manual are eqUipped With hydraulically op
erated power assisted brake systems. All front brake systems are diSC type. while the rear brakes are BIther diSC (Mustang SVO) or drum type Alt brakes are sell ·adJusting The !ront and rear diSC makes automah cally compensate lor pad wear. while the rear drum brakes Incorporate an adjustment mechanism whICh IS activated as the makes are applied when the vehicle IS driven In reverse The hydraulic syStem IS a split deSign. meaning there are separate Clr CUltS for the front and rear brakes (see illustration) II one Circui t falls . the olher CirCUit Will remain functional and a warning indicator wi ll light up on the dashboard. shOWing that a failure has occurred
~RONT
Olle
...... I(U , ,_ _ _- ,
.
IGIUTtOH
,"
, .. n.SU .. E DIHIi .. ENTI.... l CONT"O~
1_3
v .... ~ v f
A Iypical dual master cylinder brake system
Master cylinder The master cylInder IS located under Ihe hood. mounled to the power brake booster. and IS beSt recognIzed by the large lIuld reservOir on top The flUid reservolfon pre -19S7 models IS Integral wltl1the master cylinder CaSting. while later models feature a removable plastIC reservoir In elll1er case. the reservoir IS partilioned to preventtolailiuld loss In the event 01 a front or rear brake hydraulic system failure Tl1e master cylinder IS deSIgned for the ·splll system" menlloned earli er and has separate primary and secondary piston assembhes_the piston nearest the firewall beIng the primary piston which applIes hydraulIC pressure to the tronl brakes
Brake control valve The brake control valve IS located below Ihe master cylinder and bolted to the stru t tower. IllS actually two separate valves - a pressure differential va lve and a proportioning valve (pre-19S7 models) or a proportioning valve and a shu " 'e valve (19S7 and later models). On pre-1987 models. the portion that contains the pressure dlllerential valve conSIsts of the brake light warning sWllch and a piston ThiS valve senses an unbalanced hydrauliC condition belween the fronl and fear brake systems In the event of a failure In either syslem. II there IS a sudden pressure loss In one 01the systems. the piston wllhln the valve Will move 011 center. aCTIvating the brake warning light SWitch. The warning lamp Will go 011 when the problem is co rrected. the brakes are bled and the pedal IS depressed wllh considerable torce to center Ihe pis ton In the valve On 1987 and laler models. the shuttle valve Will allow lull hydraulIC pressure to the rear brakes In the event 01 a IranI hydraulIC system failure " operates In a Similar way to the pressure control valve. except thaI there IS no brake light warning SWItch The proportlOnu'IQ valve regulates the l1ydraullC pressure to Ihe rear brakes dutlng heavy braking to eliminate rear wheel lock-up Under no
mal braking con(1I110ns It aHows lull pressure to the rear brake syslem until a predetermined pedal pressure IS reached Above that point. the pressure to the fea r brakes Wi ll be limited The brake COnlrol valve IS not serviceable - II a problem develops With the valve. It must be replaced as an assembly
Parking brake The parking brake mechanically operates the rear brakes only On drum brake models the parking brake cables pull on a lever at tached to Ihe brake shoe assembly. causing the shoes to expand against the drum. On models wllh rear diSC brakes. the cables pull on levers that are al!ached 10 screw-type acl uators In the cal iper hOUSings. w hich apply force to the caliper pistons. clamping the brake pads agamstthe brake diSC.
Precautions There are some general caUbons and warmngs involVing the bfake system on Ihls vehICle a) Use only brake tluld conforming to DOT 3 specifications b) The brake pads and linings contain asbestos libers w hich are hazardous to your health If inhaled Whenever you work on brake system components , clean all par1s With brake system cleaner or denatured alcohol. Do not allow the Ime dust 10 become airborne c) Salety should be paramount whenever any servICing 01 the brake components IS performed Do not use parts or fasteners whICh ale not In perfect condition. and be sure that all clearances and torque speclllC8 tlons are adhered to II you are at all unsure about a certain
Chapter 9 ,CALI'"
Brakes
9-3
ASSY
PISTON seAL
APPLY SILICONE GREASE TO THE LOCATING PINS AND INSIDE OF INSULA TORS
2.1
CO(" ,,.G
"N
An exploded view of the Ironl brake caliper
components - typical
procedure. seek professional advice. Upon completion 01 any brake system work. lest the brakes carefully In a control led area before putting the lIehlcle InlO normal service II a problem IS suspected ,n the brake system, dont drive the vehicle untll,!,s fixed
2
Front brake pads - replacement
Refer /0 il/usrra/Jons 2 I. 26 and 2 73 through 2 71 Warning : DISC brake pads must be replaced on both lront wheels althe same lIme - never replace the pads on only one wheel. Also, the dust crealed by Ihe brake syslem may contam asbestos. which IS harmful /0
your health. Never blow 1/ OUI WIth compressed air and don', rnhale any of II An approved fliteflng mask should be warn when workrng an Ihe brakes Do nal. under any Circumstances. useperroleum·based solvents roclean brake parts Use brake cleaner or denatured alcohol onlyl Note: When servICing /he disc brakes. useonlyhlgnquality. natlOnal/yrec· ogmzed brand name pads 1 The caliper deSigns lor all mOdels are essentially the same (see illustration)
2.6 Using a large C-clamp. push the piston back lnto the caliper bore just enough to allow the caliper to slide off the brake disc easily - note Ihat one end of the clamp is on the lIat area of the inboard side 01 the caliper and the other end (screw end) Is pressing on the outer pad ; DO NOT press directly on the piston, as some models use phenolic plstons which will be damaged by direct coniaci with the c lamp 2 Remove the covers tram the brake lIuld reservoir 3 Loosen the wheel lug nuts, raise the front of Ihe vehicle and suppon II securely on Jackslands 4 Remove the Iront wheels . Work on one bfake assembly al a lime. us· 109 the assembled brake for reference it necessary Inspectlhe brake diSC carefully as oullined 10 Section 4. II machining 5 IS necessary. fonow lhe informallon In Ihat SecMn to remove the diSC. at which I1me !tie pads can be removed from lhe cahper as well 6 Push the PIston back Inlo ils bore. If necessary. a C-clamp can be used. bot a prybar Will usually do the lOb (see lIIultration) As the PIston IS depressed to the bonom of the caliper bore. the lIuldln the master cylinder will nse. Make sure thalli doesn't overllow If necessary. Siphon all some at the lIuld 7 Follow Ihe accompanylOg photos. beginning With iIIuS1fallOn 2.7a, fOf the aClual pad replacement procedure. Be sure to Slay in order and read the captIOn under each IlIuslratlon . 8 When reinstalling the caliper. be sure 10 tighten Ihe locating pms to Ihe Specified lorque. On Mustang SVO and 5 OL V8 models from 1987 on.lhe caliper pinS may be reused On all others. the caliper pinS must be replaced wllh new ones. Afler Ihe lob has been completed. tirmly depress Ihe brake pedal a tew limes 10 bnng Ihe pads 1010 contact With the diSC
9
2.7a Remove Ihe two cal1per locating pins thai hold the cal1per to the spindle; on some models, this will require a special TORX sockel- DO NOT Iry 10 use an Allen wrench inslead of a TORX socket!
2.7b
Pull the caliper straight up and all the disc
~.7c Slide the outer brake pact out of Ihe caliper frame - note how it fits into the frame as this Is done
9-4
Chapter 9
2.7d Using a C-clamp and a block of wood, bo1tom Ihe plslon in Ihe
2.7e
Brakes
Pull the Inner brake pad straight oul 01 the caliper piston
caliper bore
2.7g To 1051811 the Inner pad, hold each end ollhe pad, align the relalnlng clips
with Ihe caliper piston, then push the
pad slraighlln until the backing plate contacts Ihe piston lace - don'llet It cock, or Ihe clips may bend
3.5 With the caliper padded wllh a wood block, use compressed air to force Ihe piston oul 01 ils bore - make sure your hands or lingers are nol caught
between the piston and caliper!
2.71 The brake pads are marked l or letl and right sides - be sure Ihey .re
installed In Ihe correcl posilions
2.7h Slide the outer pad into the caliper Irame as s hown. II the outer pad is equipped with torque bullons (early models), be sure they are seated in the holes in the caliper, or temporary brake loss may occur
3.6
Remove the dust boot Irom the ca liper bore groove
2.11
Place the caliper assembly over
the brake disc and install the locating pins, lightening them to lhe torque listed In this Chapler 's Specilicalions
3.7 The piston seal Should be removed wllh a plasUc or wooden tool 10 avoid damage to the bore and seal groove (a pencil, as shown here, will do Ihe job)
Chapter 9
9-5
Brakes
Fl.ANGES MUST BE LOCATED AS
SHOWN WHEN PRQP£RLY INSTALLED
3.12 On models with plastic sleeves Inside the insulators. remove the sleeves; grab the ends of the toealing pin insulators and, using a twisting motion, push them through the caliper ears
3
3.14 Push the new insulators through the hotes in the caliper ears, making sure they are Installed all the way; on model s wUh plastic sleeves inside the insutators, install the sleeves
Front brake caliper - removal , overhaul and inslallaUon
Warning : Dus/crea/edby the brake system maycontam asbestos. which is harmful 1<1 your health. Never blow II oul with compressed al( and don't inhale any of n. An approved fillermg mask should be worn when workmg on /fle brakes. Do nOI. under any circumstances. use petroleum-based solvents /0 clean brake parts. Use brake cleaner or denatured alcohol onlyl Note: If an overhaul is mdlcated (usually because of fluid leakage) explore aI/ op/lons before begmnmg the lob. New and fac/ory-rebUilt calipers are available on an exchange basis. which makes this job qUl/e easy. If it IS deCided 10 rebUild the caltpers. malo:e sure thaI a rebUild killS available be· fore proceedmg. Always rebuild the calipers m palfs - never rebuild lust one of them .
Removal Apply the parking brake and block the rear wheels. Loosen the wheel lug nuts. raise the front of the yehlcle and support It securely on jackstands Remoye the wheel. 2 If the cal iper brake hose screws dlreclly mto the ca liper loosen the hydraulic liltmg at the frame bracket and remove the brake hose secuflng clip (see Section 10). The brake hose can now be unscrewedtrom the call· per. II the brake hose IS secured to the caliper by a union bolt. remove the bolt and both sealing washers. Discard the washers and use new ones on installation. Wrap a plastiC bag around the end of the hose to prevent fluid loss and contamination. Note : If the caliper will not be completely removed from the vehicle-as forpadmspeC/lonordlSC removal - leave the hose connected and suspend the ca/Jper With a length of Wire. This Will save the trouble of bleedmg the brake system 3 Refer to the first lew steps in Section 2 to separate the caliper from the sptndle -It'S part of the brake pad replacement procedure.
Overhaul Refertollluslratlons3.5,3 6. 3 7, 3. 12. 3 14.3.17.3.18. 3. 19a. 3. 19b. 3.20 and3.21 4 Clean the ex tenor of the caltperwlth brake cleaneror denatured alco· hoI. Neyer use gasoline. kerosene or petroleum·based cleaning solyents. Place the caliper on a clean workbench 5 POSition a wooden blOCk tn the center 01 the caliper as a CUShion. then use compressed air to remove the piston from the caliper (see Illustration). Use only enough airto ease the piston ou t 01 the bore. II the piston IS blown out. even With the cushion in place. It may bedamaged. Warning : Never place your fingers m front of the piston In an attempt 10 catch or protect It when applying compressed air. as serious Injury could occur 6 Pull the dust boot out of the caliper bore (see Illustrat ion).
3.17
Push the new seat into the groove with your lingers, then check to see that it isn't twisted or kinked
7 UStng a wood or plastic tool. remove the piston seal from the ca liper bore (see illustration). Metal tools may cause bore damage. S Carefully examine the piston for nicks. burrs. cracks, loss of plating. corrosion or any signs oldamage. If surface defects are present. the parts must be replaced. 9 Check the caliper bore In a Similar way. Light polishing With crocus cloth is permiSSible to remove light corrosion and stains. , 0 Remoye the bleeder yalye and rubber cap , t Inspect the caliper locating pins for corrosion and damage Replace them With new ones if necessary. 12 Remove the caliper locating pin Insulators from the caliper ears (see illustration). 13 Use clean brake flUid or denatured alcohol to clean all the parts Warning : Do nor. under any Clfcumsrances. use perroleum·based sol· vents 10 clean brake parts. Allow all parts fa dry. preferably uSing com · pressed air 10 blow oul all passages . Make sure the compressed alf is IiItered. as a harmfullubncant residue or mOisture maybepresent in unfl/' tered systems. 14 Push the new locating pin Insulators Into place (see illustration) 15 Check the lit 01 the piston In the bore by sliding It into the ca liper The piston should move eaSily 16 Thread the bleederyalve Into the caliper and tighten It securely Install the rubber cap '7 Lubricate the new piston seal and ca liper bore With clean brake fluid POSition the seal In the cal iper bore groove. making sure It doesn t tWiSt (see illustration).
9
9-6
Chapter 9
Brakes 26 Install the wheel and lower Ihe vehicle Tighten the lug nuts 10 Ihe torque specified In Chapter t 27 Test the brake operation belOfe placing Ihe vehICle IntO normal ser·
"re 4
Brake disc - inspection, removal and Installation
Inspection Refer to Illus/ralions 4 .2. 4.5a , 4 5b, 4
6a and 4 6b
Note: ThiS procedure applies 10 both front and reardlSC brake assemblies
3.18
Install the dust boot In the upper groove In the caliper bore,
making sure it's completely seated 18 Fllthe new dust boot mlhecallper bore upper groove, making sure II'S seated (see illustr8lionj 19 Lubflcalethecallper piston wnhclean bfaketlutd Push the piston Into Ihe caliper. uSing a turmng motion to rotllhe I,p 01 the dust boot Ollef the piston (see illustrations) Push the piston Into the caliper by hand as far
as possible. 20 USing a C-clamp and a block 01 wood, push the PIston ali the way to the bonom of the bore Work slowly. keeping an eye on the side of the PIston , making sure II enters the bore perfeclly straight with no resistance
(see illustration) 21 Seallhe hp of the dust bool In the groove on the PIston (see lItustraUon)
Installation 22 ReIer to SectIOn 2 for the caliper inSlaliatloo procedure. as IllS part of lhe brake pad replaCement procedure 23 lithe bfake hose IS the thread " n type . lhread II InIO the caliper The hose IS not designed tothread all the way In. so don't overtighten it One or two threads should stili be exposed when the brake hose IS tightened to the correct torque 24 If Ihe brake hose IS secured lothecallper by a union boh. Instatl a new sealing washer on each Sloe or the fltlmg . then Install the union bolt and tighten 10 the correcltorque (see thiS Chapter"s SpecificatIOns), 25 B:eed the brakes as outlined In Section 11 ThiS IS not necessary II the Inlet lilting was nOlloosened or removed
3.19a lubricate Ihe plslon and bore with clean brake fluid , insert Ihe pislon Inlo the dusl boOI (NOT Ihe bore) al an angle, Ihen, using a totaling motion, work the plslon complelely Inlo the dusl boot . , ,
t loosenlhe wheel lug nuts. ralselhe vehICle and support II securelyon jackstar"lds. Remove the wheel 2 Remove Ihe brake caliper as outlined In Section 3 (IranI) or Secllon 6 (rear ) It s nOI necessary to dlsconnectlhe brake hose Alter removmg the caliper botls, suspend Ihe caliper out of the way With a piece 01 wire (see Illustration) Don 't let the caliper hang by the hose and don'l stretch or tWist the hose 3 II the rear diSC IS bemg Inspected. remstalt two lug nuts to hold the diSC agamst the axle lIange 4 Visually Check the diSC surface for score marks and other damage. light scra tches and shallow grooves are normal all er use and may not always be detnmenlal to brake operallon, but deep score marks - over 0,015-inch (0,38 mm) - reqUire diSC removal and rehntshlng by an automotive machllle shop Be sure to check both Sides 01 the diSC. II pulsallng has been nohced dUring appllCalion of the brakes, suspect diSC runcut. 5 To check diSC runout . place a dial Indicator at a POint about II2-lIlch from the ou ter edge 01 the diSC (see illustration) Set the indicator to zero and turn the diSC. The indicator reading should not e~ceed the specified allowable runout limit lilt does. Ihe diSC should be rehntshed by an aulOmO\lve machille shop. Note : ProfeSSionals recommend resurfacing 01 br'ake diSCS regardless 01 the dial indicator reading (to produce a smooth. flal surface. that Will el,mmate brake pedal pulsatIOns and other undeSirable symptoms relared /0 questionable diSCs). AI the very least. If you elect not to have the diSCS resurfaced. deglaze the brake pad surface With medlum ·gflf emery cloth (use a SWirling mouon /0 ensure a non'dlfeclional finish) (see lIIuslration) 6 Thedlsc must fIOt be machined 10 a thICkness less lhan the specified mlllimum refinish thickness. The minimum wear (or dlscafd) thickness IS cast mto the mslde 01 the diSC (see illuslrallon) II should fIOt be confused wllh Ihe minimum rellllish thickness The diSC thickness can be checked With a micrometer (see IIlusltallon).
3.19b •• , and pUSh it slralghllnlo the caliper as lar as p ossible bV hand
3,20 Use a C-clamp and a block of wood to bottom the piston in the caliper bore - make sure it goes in perfectly straight, or Ihe sides 01 the piston may be damaged, rendering it useless
Chapter 9
3.21 Inslalilhe lip of the dust bool in the groove in the caliper piston
9-7
Brakes
4.2 Suspend the caliper with a piece 01 wire after it's removed - don', let it hang by Ihe brake hose!
4.5a Use a dial indicator to check disc runoul- it the reading exceeds the maximum allowable ru nout limit, Ihe rotOf will have to be machined or replaced
MIN/MUM tHICKNESS NtA,RKIN(;
~
4.Sb
Using a swirling motion. remove Ihe glaze Irom Ihe disc surface wilh medium·grit emery cloth
4.6a
The minimum Ihickness limit is cast into lhe inside of the disc
Installation 8 Install the disc and hub assembly and adjust the wheel bearing (fronl discs only) (Chapter 1). 9 Install the caliper and brake pad assembly over the disc and position it on Ihe spindle (Iront) or anchor plate (rear) (relerto Section 3 lor the Iront caliper installation procedure, or Section 6 for the rear brake caliper installation procedure, if necessary). Tighten the caliper bolts to the specified torque. 10 Install the wheel , then lower the vehicle to the ground. Depress the brake pedal a lew times to bring the brake pads into contact with the rotor. Bleeding of the system will not be necessary unless the brake hose was disconnected Irom the caliper. Check the operation 01 the brakes carefully before placing the vehicle into normal service.
4.6b
Use a mIcrometer to measure disc thickness al several points near Ihe edge
5
Rear brake caliper - removal, Installation and pad replacement
Removal Refer 10 illustrations 5.3, 5.5, 5.8, 5.208, 5.2Ob, 5.26 and 5.30
7 Ralerla Chapter 1. Section 28. to remove the disc and hub assembly. To remove the rear disc, unscrew the two lug nuts that held the disc to the
Warning: Dustcrealedby the brake system may contain asbestos, which
axle during Ihe Inspection procedure, Ihen pull the disc off the axle flange.
is harmful to your health, Never blow itoul with compressed air and don't
9-8
Chapter 9
Brakes IfIg Ihe cost of removal and Ins/allallOn 1 Securely block the Ironl wheels. then raIse the yehlCle and suppor1l1 securely on J3ckslands DO NOT get under a vehICle thaI's supported only by a Jack'
BRACKET INSTALLED IN LOCATI ON SHOWN 5.3
Parking brake cable connection - rear disc brakes
Inhale any of II An approved hltenng mask should be worn when workmg on the bmkes Do nol. under any crrcumstar,ces. use pelroleum-based solvents to clean brake pans Use brake cleaner or denatured alcohol onlyl Note: Due /0 lhe relallVelycomplex deSIgn of Ihe rear brake caliper parkIng brake acrualor assembly_ all servICe procedures reqwnng dlsassem /)/y and reassembly should be leh loa profeSSIOnal mechaniC, The home mechanIC can, however, remove Ihecallper and lake II 10 a reparr shop or dealer servICe department or other qua/lfred shop for repair. thereby sav-
2 Remove the rear wheels 3 Detach the parking brake cable Irom the lever (see Illustration), It you use pliers, be careful not to cullhe cable or return spring. 4 II you are removing the cahper only for pad replacement. 111$1'1" neces' sary 10 dlsconnecllhe brake line, Gel a piece of Wife to \Ie the caliper up so 1\ won', hang by the brake line once II is removed 5 Removelhe caliper locating pms (see illustration ) Gil upon the lOP 01 the caliper. then rolate the bollom end out 01 the anchor plale Note: DIscard the Iocallng pin Insulators They must be replaced Wllh new ones each lime Ihe Iocatmg pms are removed 6 It the caliper IS difficult 10 remove because the pads are tight against the diSC, loosen thecahperend retainer one-hall turn (no more) sathe PiSton can retract {Steps 7 through 9)_ 7 Remove the parking brake tever (the one at the rear wheel. not the one In the passenger compartment) {see illustration 5.3). a Make alignment marks on the parking brake end retainer and caliper housing (see illustration) so you doni loosen the end retainer too tar 9 Loosen the end retainer one·hal1turn. then push the cahper Piston InlO the bore Caution : Loosenmg the end retamer more than one-hal/rum may allow brake lIuld /0 leak 10/0 Ihe parlllng brake pomon of the caliper If Ihls happens. the caliper WIll have be disassembled and overhauled 10 Remove the OUler brake pad trom Ihe anchor plate. Marl\, the pad as an outer pad If you plan to rem stall It " Remove the brake diSC retaining nuts and take the brake diSC 011
INSUI.ATOR FL .... NGES
C","LIPfll HOUSING ASSE"'8LV
VIEW"'"
INsT"'"LL.... nON Of LOC","TINGI'IN INSUL","TOR
LOC","T!NG ",N
CLI~
.NNER SHOE
INST .... LLEO
'" .,"'" "'''''0• .... Nfl.R .... TTLE
WE ","R INOIC .... TC)fI
/
-lr1~~~~~~~-.,(--~I:_
C.... LIPER HOUSING .... SSE ... 8 L V
"'STON SE .... L .... NCHOR PI.ATf ~ISTON
","NO ","OJUSTEI'I
C","LII'ER HOUSING INSULATOR BORE VI EW"'"
5.5
Rear disc brake ca liper and anchor plate assembly - ell:ploded view
IN NER
OVTEIISHOE
OUTE" SHOE
Chapter 9
Brakes
9- 9
8LHDSCIIIEWC,",P
""'" '"' "'""" j "'' ' ~"'W ~
'"'''' WOO"", C,fILIPUIL LOCATING PIN
S .. LL
" . " , . , , ' " LEVER
5.8
Rear disc brake ca liper - exploded view
MODIFY TOOL 8Y REMOVING MET AL AS INDICATED BY
DOTTED LINES
5.20a
A s pecial 1001 is recommended 10 rolale the piston on rear disc b ra kes
12 Aemovethetnner pad Irom the anchor plate label I! as an Innel pad II you plan to le,"5lallll 13 Remove the anlH3nle clip (see lIIustraUon 5.5) \4 If the caliper IS being removed lust lor pad replacemenL hang It Irom Ihevehlclewllh wire sa the brake hoselsn t stretched ItthecahperlS being removed trom the vehicle. remove the hollow bOlt to detach the brake line Irom the caliper Use new sealing washers on each Side 01 the bolton reas ·
sembly 15 Inspecllhe brake disc caretully as oul iined In Section 4 t6 Check for SlQns at brake lIuld leakage Irom the caliper al bolhthe PIS' Ion boot and the parking brake lever It any welneSSlS tound. have the cali· per overhauled by a dealer service department or quahhed brake speclatlst 17 Thoroughly clean Ihecahper. anchor plate and surrounding area Wllh spray brake cleaner Check all parts for wear and damage 18 Temporanly reinstall the caliper In the anchor pla te wllhout the pads Tighten the end retainer to the lorque listed In thiS Chapter's Specifications
5.2Ob
Bottoming the rea r disc brake piston
19 InSlall the parklng brake lever so 1\ points to the rear and down Tighten Ihe retainer screw 10 the lorque listed In thiS Chapters Specllicallons, then make sure the lever Shit moves treely 20 If new pads are being Installed. 10lale Ihe piSlon 10 bottom II In Ihe bore. Use Ford 1001 T72P·2588-B or equivalen t (see illustrati ons) Turn the pis ton until It bottoms complelely In the bore (II w ill keep lUlnlng alter II bottoms). II the specialtcolls not available. Ily rOlal lng the piston wllh a pair of needle-nose pliers, plaCing Ihe liPS of Ihe pliers Into the holes In the piston 2t Take the cahper oul 01 the anchor plate 22 Install new Iocallng pin Insulators In the caliper. 23 Apply a thin coal at Ford diSC brake caliper slide grease (07AZ -O I9590-A) or equivalent to Ihe caliper sliding surfaces on the anchor plate Be sure to use the COrrecllublicanl. the wrong type may melt and contaminate the brake pads 24 It the antHattle clip was removed. Install 11 25 InSl ali l he mner pad on the anchor plate (refer 10 Ihe Identllicallon marks made dunng removal If Ihe old pads ale bemg reIOslalled)
I
9 -10 FINS I'OINT R fA R WARD
AT TOP O' ROTOR
-
Chapter 9
Brakes
fll ONT OF VIMIC LI
C"'ll~~'" AS~~\1el~
"OTOI'I ASSfMnV
:I ~
l 5.25
The IIns cllhe rear brake d i scs should point to Ihe rear 01 th e Vehicle (a\ Ihe top 01 Ihe rOlor ) when installed
5.30
The lining cleara nce o n rea r disc brak e pad s must be sel correcll y lor pr oper brake operation
cone grease (Ford Silicone dlelectflc compound D7AZ 19A331·A or equivalent) 32 Apply a Single dropollhread locking agenllFord Ihreadlock and seal· er eOAC·19554 A or equlvalenlJ tothe threads of each Iocallng pin Install and Slart the local!ng pms by hand only Ihen hghlen Ihem 10 the lorque flsled In thiS Chaplefs Speclhcallons 33 Connect Ihe parl\.lng brake cable 34 If Ihe brake hose was disconnected bleed the brakes (see Sec· lion 11) 35 Recheck Ihe brake flUid level (see Chap!er 1) and correct I! as need· ed 36 To adJusl !he calipers, pump the brake pedal aboul 30 limes. With a1 teast one second between pumps Apply light pedal pressure labou187 Ibs), 37 Puilihe parking brake lever If travel +s excesSive or Ihe lever IS exIlemely easy to pull. repeallhe ad,uSlmenl If Ihls doesnl work check Ihe parking brake (see Sections 12 through lSI· 38 The lemalnder of InslalialJon IS the reverse of the removal sleps 39 Make sure Ihe brake pedal IS hrm, Ihen carefully road leSI Ihe 1001 brake and parking brake
6 RETURN SPAING
6.48
Drum brake componen ts (right side shown)
26 InSlalilhe bl'akedlsc and Its retaining nuts Dlscsare not Interchange-
able from Side to Side olthe vehICle The disc I.ns musl lace rearward when Ihe disc IS Installed (see lIIustraUon) 27 InSlall the ouler brake pad on the aochor plale with Ihe wear IndlCal01
'P
28 IIlhe brake hose was dlsconnect(ldlromthecallper. reconnect II Use new sealing washers and Ifghlen the boll to the torque listed In thiS Chapler's SpeclhcallOns 29 HOOk Ihe upper endo! Ihecahper InIO Ihe anchorplale.lhen 10lale Ihe caliper down over Ihe pads and disc. Take care nOllO damage Ihe piston dust boot 30 Puillhe caliper firmty out to seat Ihe Inner pad against the diSC Measure pacHo-caliper clearance (see lIIuslration) II nol as specified In Ihe Illustlalion. remove Ihe caliper and rotate the piston to adjUSI the clearance Turn lhe plSIon counterclOCkwise to reduce the gap or clockWise to enlarge 1\ One-quaner turn 01 the PIston changes lhe gap by apprOlllmale Iy t l 16·lnch Caution ; Don·' skIP Ihls adJuSlment If Ihe gap IS too small, lhe brakes may drag If II IS 100 large.thead,ustermay la/lout of tOOp/stcn when the /Nakes are applied, /I WIll/hen oe necessary to overhaul the caliper and replace Ihe ad/usler'prston assembly 31 Coat the caliper locallng pinS and Ihe inSides 01their insulalor With Sill'
Re ar brake shoes - repl acement
Refer 10 III(JslrallOns 6 4a through 6 4y Warning : Drum brake shoes must be replaced on bolh wheels at the same time - never rep/ace Ihe shoes on only one wheel Also the dust created by the brake syslem contams asbestos. which IS harmful/a your health. Never blow It outwllhcompressedalr anddon I mha/eanyof II An approved fIIterlflg mask should be worn when workmg on the brakes 00 not under any Circumstances use pelro/eum·based solvems to clean brake parts Use brake cleaner or denatured alcohoJ onlyl Caulion: Wheneverlhe/Nake shoes are replaced Ihe rellactor andhold down spnngs should also be replaced Due 10 the commuous hearmg coo/mg cycle Ihat the sprmgs are subjected to. they lose theIr lens Ion over a petlod of time and may allow the shoes to drag on the dr(Jm and wear al a much faster rale Ihan normal. When replacmg the rear brake shoes, use only high quaJrty nationally recogmzed brand·name paris , Loosen the whee ll(Jg nuts, raise Ihe rear at Ihe vehicle and suppon It sec(Jlely on jackstands. Block the tronl wheels to keep the vehICle from falling 2 Release the parking brake 3 Remove Ihe wheel. Note ; All fourrear/Nakeshoes mustoe replaced althe same lune. bulla avoidmu(mg up pariS worle onon/yone br",keas· sembly al a /lme 4 Follow the accompanymg pholOS (1lIuSlralions 6 4a through 6 4y) tor the Inspection and replacement at Ihe brake shoes Be sure 10 stay In 01' der and read the capllon under each Illustralion Note: If Ihe brake drum cannOI be easily p(Jlled off Ihe axle and shoe assembly. make sure Ihal/he
Chapter 9
6.4b Before removing anylhing, clean the brake assembly with brake cleaner and allow II to dry - position a drain pan under the brake to catch the residue00 NOT USE COMPRESSED AIR TO BLOW THE DUST FROM THE PARTS!
6.48 ... Ihen remove the spring and cable guide from the secondary shoe
6.4C Pull back on Ihe adjuster lever and lurn Ihe slar wheel 10 retract the brake s hoes
6.41
9 -11
Brakes
Unhook lhe primary shoe relurn spring from Ihe anchor pin
6.4d Using a brake spring 1001, unhook Ihe secondary shoe return spring ...
6.4g Remolle Ihe self-adjuster cable and shoe guide plale from Ihe anchor pin
• 6.41'1 Remolle Ihe brake shoe hold-down springs and pins - a special tool , shown here, will make the job easier
6.41
Remove Ihe parking brake link
6.41
Spread the brake shoes apart and
Ii" them from the backing plate and over the axle flange
9-12
6.4k Unhook the parking brake lever from the secondary brake shoe
Chapter 9
Brakes
6.41 lubricate Ihe brake shoe contact areas with high-temperature grease
S.4m
Insert the top of the parking brake
lever into Ihe notch at the lop ollha secondary brake shoe (the secondary shoe Is the one with the longer lining area). Place the shoe against the backing plate and install the hold-down pin and spring
6.4n Inslallthe parking brake strut, making sure Ihallhe slot in the strut seats In the notches In the brake shoe and the parking brake lever
6.40 Place the primary shoe against the backing plate and Install the hold· down pin and spring
6.4p Hook the automatic adju ster spring inlo the hole at the bottom of the primary brake shoe
6.4q
6.4r
6.45
Hook the other end of the spring
Inlo the adjuster lever and push the lever toward Ihe secondary shoe, hooking it Into the hole provided
Place the shoe guide plate ovef Ihe anchor pin
Inslatllhe self adjuster cable over the anchor pin
Chapter 9
6.41 Using a brake spring instaUation 1001, hook Ihe primary shoe return spring over Ihe anchor pin
6Aw
Roule Ihe cable around Ihe cable
guide, push up on the adjuster lever and hook Ihe cable inlo the hole in the lever. Check the cable again to ensure thai II rests In the cable guide groove, not behind it
6.4u Instalilhe secondary shoe return spring through the cable guide and 11'110 the hole In the shoe; hook the o ther end onlO the anchor pin
6.4x lubricate Ihe adjuster screw threads, spread Ihe shoes apart and Instalilhe screw between them
parking brake IS comple/ely released tllen squirt some pene/ra/lng 011 around lhe cenleN hub area Allow Ihe 01110 soak m and Iry /0 puillhe drum off If the drum 5/111 cannot be pulled off. lhe brake shoes WIll have 10 be retracled ThiS IS accomplished by 1/(51 remoVIng lhe plug Irom tile baclnng iNa/e W,lh the plug removed. pull the lever 011 the adlustln9 SlarwheelWllh one small screwdflver while turnmg Ihe adlus/lng wheel wuh anOfher small screwdnver. mOVing the shoes away from Ihedrum. Thedrumshouldnow come off 5 Before remstailing lhe drum It should be cheCKed for CraCKS, score mar1<.s, deep scratches and hard spots. which Will appear as sm all discolored areas If the hard spots cannot be removed With line emery cloth or il any of the other conditions listed above eXist, the drum muSI be laKen to an aUlomotlve machine shop to have II turned Note: ProfeSSionals recom · mend resurfacing the drums whenever a brake JOb IS done. ResurfaCing WIll el,mmate the poSSIbility of out·of-round drums II/he drums are worn so much that Ihey can 'I be resurfaced wi/houl exceeding the maXimum aiIowabledlameler (stamped mto Ihe drum). then Mill' ones Will be reqUired A//he lIeryleasl. If youeleel no/lohalle the drums resurfaced. remove Ihe glazmg from the surface w!lh mediUm-gol emery ClOth USing a SWlrlmg mo /Ion 6 InSlall the brake drum on the axle lIange
9 -13
Brakes
6.4'01 Bend the ends 01 the return springs around the anchor pin
6.4y
Wiggle Ihe brake shoe assembly
back and torth to make sure it's cen tered on Ihe backing plate
7
Moonl!he wheel. InslaJilhe lug nuts. then lower the vehIC le Make a number of forward and reverse stops to adJusllhe brakes until satlslactory pedal aCllOn IS obtained
8
7
Wheel cylinder - removal , overhaul and Instalialion
Nole : If an overhaul Is Indicated (usually because of flUid leakage or sticky opera/Ion) explore all optIOns before begmnmg Ihe lob New wheel cylmders are allallable. which makes Ihls JOb qUile easy If II'S deCided /0 rebuild the wheel cylmder, make sure /hal a rebuild killS allallable before proceedmg Never ollerhaul only one wheel cylmder - always rebUild both of them allhe same time
Removal Refer to Illustratron 7. 4
\ Raise Ihe feal o! Ihe vehICle and support II securely on lackslands BKlck the Ironl wheels 10 Keep Ihe vehicle ffom foiling 2 Remove the brake shoe assembly (SecllOn 6) 3 Remove all dill and !elelgn malerlal Irom around the wheel cylinder
9
9 -14
Chapter 9
Brakes from the wheel cylinder body (see illustration) 8 Clean the wheel cyl inder with brake fluid. denatured alcohol or brake system cleaner. Warning : Do not under any Circumstances. use petroleum based solvents 10 clean brake parts' 9 Use comp ressed air to remove excess lIuld from the wheel cyl inder and to blow out the passages 10 Check the cyhnder bore for corrOSion and score marks. Crocus troth can b e used to remove light corrOSion and stams. but the cylinder must be replaced With a new one If the defects cannot be removed eaSily. or If the
bore is score
face In.
Installation 7.4
Disconnect the brake line tilling (A) , then remove the two wheel cylinder boits ( e)
4 Dlsconnecl the brake line (see illustration) Don'l puilihe brake line away from the wheel cylinder 5 Remove the wheel cylinder moun\lng bolts. 6 Detach the wheel cylinder from the brake backing plate and place it on a clean workbench Immediately plug the brake line to prevent lIuld toss and contammallon.
Overhaul Refer /0 II/us lfallon 7. 7 7
Remove the bleeder screw. Cups. pistons. boots and spring assembty
13 Place the wheel cylinder in positron and mSlalllhe bolts t 4 Connect Ihe brake hne and Instail ihe brake shoe assembly 15 Bleed the brakes (Section II ),
8
Master cylinder (1979lhrough 1986 models) - removal , installation and overhaul
Removal and installation Refer to Illus/raftons 8, la. 8, Ib and 8.2 I Unscrew the brake Imes from the primary and secondary outlet ports of the master cyl inder (see illustration). Plug the ends 01 the hnes to pie· vent contam ination, Place ne wspapers or rags under the connections to catch the bl ake flUid thaI will spilt (see mustralion)
;;;~~~"~ ASSV I AND CUP E 7.7
8.1 a Disconnect the fluid lines allhe master cylinder with a flare-nut wrench, being careful nolto bend them
An exploded view of the rear wheel cylinder
8.1b Uflthe master cylinder from the engine compartment - note the newspaper to catch dripping brake fluid , which could damage paint
8.2 Remove Ihe two nuts to detach the master c ylinder from the brake booster or engine compartment fire wall
Chapter 9
Brakes
9 - 15
----
COVEF! !'lET ""N~R
PUSH ROD 1...... "'U ... l 8RAI(E ONlVI
MA.STER CYLINDER BODY
0
... SSEMllV
,,,.,"' 0"""
8."
8.14
An exploded view 01 the master cvlinder used on 1979 through 1986 models
Remove Ihe snap-ring from the master cvlinder bore
2 Remove the two nuls secunng the master cylinder to the Inewall or power boosler un!! (see illustration) :3 Puilihe master cylinder forward and hllll from the vehicle (see iUusIralion 8.1b). Brake lIuld will damage pam t. so don', spill any on the ve-
hicle. 4
InStallation 15 Ihe reverse 01 the removal procedure
5 Note: Whenever the master cylinder IS removed, rhe comple/e hydraulIC system must be bled The lime reqUired /0 bleed the system can be (educed If the master cylinder IS ,,/led wl/h Iluld and bench bled (refer 10 Steps 6lhrough 10) before the maslercyllnder IS mstalledon the vehICle 6 Insen threaded plugs 01 the correct size Into the cylinder oullet holes and lill the reservOIrs with brake lIuld The master cylinder should be sup· PC)r1ed In such a manner that brake IIUld Will not spill dunng the bench bleeding procedure 7 Loosen one plug al a lime, stanlng With the lear oullet pon first. and use a large Phillips screwdnver to push the piston assembly Into the bore
1
8
~~----::"~~::~J:~+-S(CO"OARV lUIE SEU
OUTlH
----0
to 100ce all from the master cyhnder. To prevent all from being drawn back into the cylinder, the appl'Opnate plug must be replaced before allOWing the piston to return to ItS onglnal poSitIOn 8 Stroke the piston three or lour times for each outlelto ensure that all air has been el(pelled. 9 Smce high pressure IS nollnvolved In the bench bleeding procedure_ an allernallve to the removal and renlacement of the plugs With each stroke of the ~ston assembly IS available Before pushing In on the piston assembly. remove one ot the plugs completely Before releaSing the PISton. however. instead of replaCing the plug. Simply put your tlnger tightly over the hole to keep air Irom being drawn back Into the master cylinder Wait several seconds for the brake lIuld to be drawn from the reservolf to the piston bore, then repeat the procedure. When you push down on th e ~ston 1\ Will torce your finger olt Ihe hole, allOWing the air inSide 10 be el(' pelled. When only brake fluid IS being ejected from the hole. replace the plug and go on to the other pon 10 Relill the master cylinder reservOIrs and Install the diaphragm and cap assembly
Overhaul Refer 10 illustrations 8.11 . 8.14.8 15. 8 17 and 8 19 Note : Beforedecldmg looverhaulthe maslercyimder. check on theaval/' ability and cost of a new or factory rebulit Ulllt and also !he availability of a rebuild kit 11 Clean the el(tenor 01the master cylinder and Wipe dry With a hnt free rag. Remove the cover and gasket from the top of the reservOir and pour out any remaining brake lIuid (see illustration ) 12 Use a large Phillips screwdriver to depress the PIston assembly. then remove the secondary PIston stop boll from the bottom at the master cylln· der body, If eqUipped 13 Remove the bleed screw. It eqUIpped 14 Depress the piston assembly again. then remove the snap-flng Irom the groove allhe rear of Ihe master cylinder bore as shown In the accompanYing Illustration.
9
9-16
8.15
Chapter 9
Remove the primary piston from the bore
8.17
Brakes
--
Remove the secondary piston
8.19 If the master cylinder Is made from cast iron, use a hone and drill motor to remoye minor scratches Irom the bore - 00 NOT hone the bore on aluminum cylinders
from the bore alter removing the slop screw, II equipped
15 Remove the pnmary piston assembly (see illustration) 16 00 not remove the screw an the primary piston or disassemble the
piston, The piston assembly IS replaced as a unit 17 Remove the secondary piston assembly (see illustration) 18 00 not remove the lube seals, lrom the master cylinder body 19 Examine the bore 01 the cylinder carefully lor SCOfing or fldges If the bore IS smooth. the cylinder body can be reused, If there IS any doubt 01 the condl\lon 01 the bore, Install a newor rebUilt master cylinder. Ifthecyhnder IS made 01 cast Iton. minor scratches or SCOring In the bore can be removed USing a hOfllng 1001 (see Illustration) . Caution: Do nor hone /he bore on alurrnnum maslercylmders; the haT(jened surface In the bore Will be removed. 20 If the seals are swollen or yery loose on the pistons. suspect 011 contamlnallon In the system . Oil Will swell these rubber seals and II one IS found to be swollen. others In the brake system may also be damaged
Flush the sys tem thoroughly (tollow the bleedmg procedure In section 11) With clean brake I'uid alter oyerhaul to remove the all. 2t Thoroughly clean all parts In clean brake lIuld or alcOhOl. 22 All components should be assembled weI after dipping Ihem In flesh make flUid 23 Insert the complete secondary piston and relurn spnng assembly mto Ihe master cylinder bore. easmg Ihe seals Into the bore 24 Insert Ihe pnmary PIston assembly InlO the master cylmder bore 25 Depress the pnmary piston and Install the snap-nng mto the cylinder boregrooye 26 Fit the secondary piston stop boit and O-m'IQ Into the bonom of the master cylmder body 27 Reinstall the gasket onto the coyer. malung sure f\IS correclly seated. and replace the coyer
MAS TER CVUNOE R
BOOSTER ASSY
9.2
Master cylinder and brake booster Installation on 1987 and later models - typical
'"'
SCR...
Chapter 9
9.7
Use a Phillips head screwdriver to push the primary pi ston Into the cylinder, then remove the s nap-ring
Brakes
9.8 Remo ve the primary piston assembly from the cylinder
9.10 If you must remove Ihe fluid reservoir (10 replace leaking seats or a br oken reservoir), genU'll pry il all wilh a screwdriver or prybar
9. t4
9-17
9.9 Tap the master cylinder against a block 01 wood to eject the secondary piston assembly
Coatlhe Se<:ondary pi ston with clean brake lIuid and Install i t in the master cylinder, spring end first
Overhaul 9
Master cylinder (1987 and later models) - removal, overhaul and installalion
Note: Beforedec,(jltJg looverhaul/he mas/erCy/lnder, check on /heav811· ability and cost of a new or factory rebuilt Unit and also the ava!/abll,fy of a ,ebulla 1111
Removal Refer /0 lilus /rallon 9.2
1 Place rags under the brake Ime flttmgs and prepare caps or plastiC bags 10 cover the ends ot the hnes once they are disconnected Caution : Bral<e IIwd w/II damage pam/ Co~er all body paris and be careful no/lo sf'l/lflUid dUflng thiS procedure 2 Unscrew the tube nuts at the ends althe brake hnes where they emer the maste! cylmder To p!evenl rounding afflhe lIatson Ihese nuts. a flare nut w!ench. which wraps around the fitting. should be used (see iIIustralion ) NOle : 1987 and laler models use metric tube nuts at the master cylinder connec/lons 3 Pull the brilke hnes away from the master cylinder slIghlly and plug Ihe ends to prevent contamlnat,on 4 D,sconnect the brake warOing hghl eleclrlCal connector !emove the two master cylInder mountIng nuts and detach the master cylInder from the vehICle 5 Remove Ihe reservoir cap thend,scard any lIurd remaInIng In the res· ervoll
Refer /0 illus/rations 91,98.99, 9.10, 9. 14 and g. 19 6 Mount the mastercylm-der on a vise with the vIse Jaws clamping on the moun!lngllange 7 Remove the primary plSCon snap-flng by depreSSing the piston and extrachll9 Ihe flng with a pair of SOiijHing pliers (see illustration) 8 Remove the pflmary piston assembly trom the cytlnder bore (see illustration) 9 Remove the secondary piston assembly from Ihe cylinder bore. It may be necessary to remove the maSler cylInder from the vise and Invere 'I. care fu lly lapping It against a blockof wood to expelthe piston (see illustration) I 0 II lIU1d has been leaking past the reservolf grommets, pry the reservOIr trom Ihe cylinder body Wllh a screwdriver (see illustration) Remove the grommets II Inspect the cylinder bore lor corrOSion and damage. II any corrOSion or damage is found. replace the master cylinder body WIth a new one, as abrasives cannot be used on the bore. 12 Lubricate the new reservalf grommets With SIlicone lubflcant and press Ihem InlO th e master cylinder body Make sure they're properly seated 13 lay Ihe reservOIr on a hard surface and press the master cyllndEN body omo the reservoir. uSIng a rockIng mohOn 14 Lubricate the cyhnder bore and pnmary and secondary piSton assemblies w,lh clean brake fluid Insere the secondary poston assembly IOta the cyllOder (see illustration)
8
9 -18
Chapter 9
REAR BRAl(£ OUTLET PORT
9.19
When bench bleeding the master cylinder, sta rt with the
rear brake outlet port
15 Install the primary piston assembly In the cylinder bore , depress It and Instailihe snap-nng. 16 Inspecllhe resarvOlr cap and diaphragm lor cracks and deformation. Replace any damaged parts with new ones and attach the diaphragm to
Brakes
11.8 When bleeding Ihe brakes, a hose is connec ted 10 the bleeder va lve allhe cali per or wheel cylinder and Ihen submerged in brake IIuid _Air witl be seen as bubbles in Ihe tube and conlainer. All air musl be expelled before moving to Ihe neK! wheel
lhe cap.
t? Note: Whenever the master cylinder IS removed. the complete hydraulic system must be bled. The time required 10 bleed the system can be reduced If the master cyllllder is filled With flUid and bench bled (refer /0 Steps 18/hrough 23) before the master cylmder is ins/ailed on the vehicle. t8 Insert threaded plugs of the correct size Into the cyhnder outlet holes and fill the reservoirs With brake flUid . The maSl er cylinder should be sup ported In such a manner Ihal brake IIUld wi ll not spill during the bench bleeding procedure. 19 Loosen one plug at a lime, slartlng With the rear oullet port Iirs!. and push Ihe ~slon assembly Into the bore to force air from the master cylinder (see illuslration) To prevent air from being drawn back Into the cylinder. the appropriate plug must be replaced belore allowing the piston to re turn to Its original poSItiOn 20 Stroke the piston three or four limes for each outlet to ensure tha t all air has been e~pelled 21 Since high pressure IS not Involved In the bench bleeding procedure. an allernatl ve to the remova l and replacement 01 the plugs With each stroke of Ihe piston assembly is available Before pushing in on the piston assembly. remove one of the plugs completely. Be fore releaSing the PiSton . however, Instead of replaC ing the plug . simply put your linger tightly over the hole 10 keep air from being drawn back Into the master cyl inder Walt several seconds for the brake flUid to be drawn Irom the reservOir to the plSlon bore. then repeat the procedure. When you push down on Ihe plslon il will force your finger off the hole, allowing the air inSide to be ex pelled When only brake lIuld IS being elected lrom the hole. replace the plug and go on to the other port 22 Rehilihe master cylinder reservOirs and Inslallthe diaphragm and cap assembly
Installation 23 Carefully Install the master cylinder by reversing the removal steps. then bleed the brakes (reter 10 SecllOn 1 t ).
10
Brake hoses and lines - inspection and replacement
Inspection About every SIX months. With the vehicle raised ana supported securely on Jackstands. the rubber hoses which connect the steel brake lines wllh Ihe fronl and rear brake assemblies should be inspecled for cracks. chafing ollhe ouler cover. leaks. blisters and other damage. These are 1mportanl and vulnerable parts of the brake syslem and Inspection should be
complete A ligh t and mirror will be helplullor a thorough check. II a hose exhibits any 01 the above conditions. replace It Wi th a new one.
Replacement Front brake hose 2
USing a back -up wrench. disconnect the brake hne from the hose fitling. being carelul nollo bend Ihe frame bracket or brake line . 3 Use a pair of pliers to remove the U-chp from Ihe female fltl lng at lhe brackel. then detach Ihe hose from Ihe bracket 4 Unscrew the brake hose from thecahper or remove Ihe Union bolt and sealing washers (be sure to use new sealing washers on reassembly) . 5 To Inslallthe hose. first thread It ,nto the ca liper. tightening It securely. 6 Without tW isting the hose. install the lemale fi tllng In the hose bracket 1\ Will ht the bracke t In only one posi tion . 7 Install the U-cllp retaining Ihe female fitting to the frame bracket. 8 USing a back·up wrench. attach the brake line to the hose filling. 9 When the brake hose installation is complete. there should be no kinks Inlhe hose. Make sure the hose doesn't contacI any part of the suspension Check thiS by turning the wheels to the extreme left and fight posl\lons. II the hose makes contac\. remove It and correct the Instaliatlon as necessary Bleed Ihe syslem (see Sec\lon 11)_
Rear brake hose (drum brake models) 10 USing a back-up wrench. dlsconnectlhe hose allhe frame bracket. being carelu l not to bend the brackel or steel lines 11 Remove the U-clip With a pair of pliers and separate the female filling Irom the bracket 12 Dlsconnecl1he two brake hnes at Ihe junCllon block. then unbolt and remove the hose 13 801llhe JunClion block to Ihe axle housmg and conneclthe lines , tight ening them securely_ Wlthoultwlsllng the hose, Inslall the female end of the hose In Ihe frame bracket 14 Install the U-chps retalnmg the female end to Ihe bracket 15 Usmg a back-up wrench, attach Ihe sleeiline flllmgs to the female 111lings Agam . be careful not to bend Ihe bracket or steellme _ 16 Make sure the hose Installallon did not loosen the frame bracket Tighten the bracket II necessary 17 Fill the master cylinder reservOir and bleed the system (see Seclion 11).
Rear brake hoses (disc brake models) t8 Vehicles equipped With rear diSC brakes use a brake hose at each wheel The hose IS permanently attached to a bracket bolted to the rear
Chapter 9
12,4
a~le
Park ing brak e equalizer locknut and adJusUng nut - models w ith rear d rum brakes (arrow)
The other end at the hose IS secured to the caliper by a union bolt and
sealing washers 19 USII'19 a back-up wrench. disconnect the steel hne Irom the brake hose at the rear 8Jde
20 Remove the union boll and sealing washers that secure the brake hose to the caliper
21 Remove the bracketto-a~le bott. then take the brake hOUSing and bracket off the a~le hOUSing 22 Loose ly bolt the bracket and brake hose lathe axle hOUSing. then connect the steel hne 23 USing new sealing washers. connect the brake hose 10 the caliper Tighten the union bolt to the COHeel torque (see thiS Chapter 5 SpeclflCa \Ions) 24 Tighten the brackeHo'axle hOUSing bolt and steel brake line securely Bleed the brakes as deSCribed in Section 11
Metal brake lines 25 When replacing brake hnes be sure 10 use the correct parts Don t use copper tubing lor any brake system components Purchase steel brake lines from a dealer or au to parts slore 26 Prelabncatedbfake line. with the tube ends already Itared andflttlOgs Installed. IS available at auto pans stores and dealers These hnes are also bent to the proper shapes 27 When installing the new line make sure lIs securely supported In the brackets and has plenty 01 clearance between moving or hot componen ts 26 Afler ins talla ti on, check the master cyl inderliUld level and add flUid as necessary Bteed the brake system as outlined in the next Section and test the brakes carefully before dllvlng the vehicle In traffiC
11
Brake hydraulic system - bleeding
Brakes
9 -19
4 Removeanyresidualvacuumlromthebrakepowerboosterbyapply· Ing the brake several limes With the engine off 5 Remove the master cylinder reservOir cover and hllthe reservOir With brake flU id. RelOstalithecover Note: Check theflUldleveloftendufing the bleedmg operallOn and add flUId as necessary /0 preven/ Ihe fluid level from failing low enough to allow alf bubbles In/a the master cylinder 6 Have an assistant on hand, as well as a supply 01 new I>fake lIuld. a clear contamer partially filled With clean bfake flUid. a length 013 16-lOch plastiC. rubber or Vinyl tubil'lg 10 ht over the bleeder valve and a wrench to open and close the bleeder valve 7 Beginning at the fight rear wheel. loosen the bleeder valve slightl~. then lighten It to a pomt where It IS snug but can stili be loosened qUickly and eaSily 6 Place one end of the tublOg over the bleeder valve and submerge the other end In brake lIU1d In the contamer (see Illustrati on) 9 Have the assistant pump the brakes slowty a lew times to get pres· sure In the system, then hold the pedal !lrmly depressed to While the pedal IS held depressed open the bleeder valve Just enough to allow allow 01 Ifuld to leave the valve Watch lor air bubbles to e~lt the submerged end of the tube When the lIuld 1101'1 slows atter a couple of seconds. close the valve and have your assistant release the
p.,,,,
t t Repeat Steps 9 and 10 until no more air IS seen leavmg the tube. then lighten the bleeder valve and proceed to the left rear wheel. the nght Iront wheel and the lelt front wheel. In that order. and perform the same procedure. Be sure to check the IIUld In the master cylinder reservOlrtrequenlly 12 Never use ok! brake flUid It contains mOisture whICh Will deteriorate the brake syslem components. t 3 Ref ill the master cylinder With lIuld at the end 01 the operalion 14 Check the operation ot the brakes. The pedal should feel solid when depressed. With no spongmess II necessary. repeat the enlire process Warn i ng: Do nol operate the vehICle If you a18 rn doubl about the elfec-
tlveness of the brake system
12
Parking brak e - adjustment
Models with rear drum brakes Refer /0 IllustratIon 124 Block the Iront wheels so the vehICle cant rollin either dlrecllon Jack up the rear 01 the vehicle and support the axle securely on Jack stands. DO NOT get under a vehicle that IS supported only by a Jackl 3 Release the parkmg brake and place the transmission 10 Neutral 4 On early models, loosen the equalizer locknut (see illu stration ) Slowly tighten the adjusting nut on the equalizer rod until the rear brakes Just begm to drag 5 On later models. lighten the adJusling nut against lhe cabte equalIzer unlll the rear brakes Just begin to drag 6 loosen the equalizer adjusting nut just enough so the rear wheets turn Ireely, then secure the adjuSling nul With the locknut 7 Remove the lackstands and lower the vehicle Unblock the Iront wheels and tes t parkmg brake operation t
2
Refer /0 illustration II 8 Warn ing : Wear eye pro/ec/lon when bleedmg the brake syslem If the
fluid comes m contact With your eyes. Immedlalely nnse them With water and seek medical alten/lon Nole : Bleedmg the hydraulIC system is necessary /0 remove any air thai manages 10 find liS way mto Ihe syslem when I/S been opened dUfing removal and InSlalla/lon of a hose, lme, caliper or master cylinder. II Wil l probably be necessary to bleed the systemat ali iourbrakes If an has entered the sys tem due to low lIuld level. or II the brake lines have been dIsconnected at !he master cylinder 2 II a brake hnewasdlsconnected only at a wheel. then only that caliper or wheel cylmder must be bled 3 II a bfake tlOe IS disconnected at a IIl1lng located between the master cylinder and any 01 the brakes. that part 01 the system served by the diSconnected line must be bled
Models with rear disc brakes Refer/oi/lustra/ron 12.8
8
To adjust the parking bi'ake on vehICles eqUipped With rear diSC brakes. reler to the Illustration
13
Parking brake - releasing c able tensi on ( 1987 and l ater model s)
Refer roi/lus/ratron 13 1 I ThiS procedure IS necessary to remove parKing bfake system compo· nents on 1967 and later models. which use a ratchet wheel at the parking
9
9- 20
Chapter 9
Brakes CD MAKE SURE EACH REAR OISC BRAKE
BACK OFF THE P.o.RI(IIIIG BRAKE
CABLE "'()JUSTING NUT UNTil THE CABLES ARE lOOSE.
IS PElOf'EAl Y "OJUSTEO BY MOVING THE CALIPER LEVEA IN THE APf'LIED
DIRECTION. IF THE LEVER MOVES MORE TH"'" XI OEGREES, USING HAND PRESSURE Of loU ~P. (SO PSI, MAXIMUM. "OJVST THE SERVICE BRAt::ES PER SECTION 1'·~.
~;~~::::=========l---------ill
TIGHTEN THE PARKING SR""E CA aLE ADJUSTING NUT UNTIL ONE OR 80Tft OF fH£ PAAI(HII(l BRAKES ACTUATI NG LEVERS JUST BEGIN TO MOVE.
PARI(ING BAA,KE ACTUA,TING LEVER (LH SHOWN. AH TYPICALI
---r,
CALIPEFl _ _ LEVER STOP
PARI
@A""LVANORELEASETHEPARItINGBRAKE COIHAOL. CHECK THE PARKING BRAKE LEVERS ON THE CI\LIPERS TO DETERMINE If THEY I\R E FULLY RETURNED TO TfiE $TOP POSITION BY I\TTE MPTING TO PULL TfiEM REI\RW","RO. NOTE If THE LEVER DOes NOT CONTI\CT THE P","RI<; ING BRI\I<;E CI\LIPER LEVER SToP. THE CI\BLE I\DJUSTMENT IS TOO TIGHT. REPEI\T ADJUST· MENT PROCEDURE. NOTE. IF LEVERS DO NOT RETURN TO STOP POSITION. P"'IlI<;ING ANa SERVICE BRI\I<;E FUNCTION WILL BE AFFECTED I\S MIUI\OE IS ACCUMULATED.
I
CALIPER
AIG!1T REAR CALIPER
12.8 Parking brake adjustment details - models with rear disc brakes
brake control lever (see illustration) Note: If IhlS procedure /s nol done when reqUired. Ihe ralchel wheel sprmg Will unwmd and Ihe control as· sembly Will have 10 be removed 10 resel cable lens/on. 2 Release Ihe parking brake. 3 Remove Ihe console (see Chapler 11 ). 4 Jack up the vehicle and support II securely on jackstands 00 NOT gel under a vehicle Ihat's suppor1ed only by a jack' 5 Have an asslstan! under !he vehicle pull the equalizer appro~lmately 1 to 2-1 /2 inches rearward to unwind the ralche! wheel. Allhe same time. II1ser1 a steel pin through the holes mlhe lever and conlrol assembly 10 lock the ratchet wheel in the re leased posilion Caution: Do nOl remove the sleel pm unless all paris of the parlung brake mechamsm are mstalled and connected
14
Parking brake cables - replacemen t
Refer to Illustralion /45 HOTIE: CONTROL I\SSeMIIL v REMOVED FOR CLARITV.
13.1
Have an assistant pull the equalizer cab le to the rear white you insert a steel pin Into the lever and contro t assembly to hotd the ratchet wheel in the released po sition
I Block both lronl wheels so Ihe vehicle can·t roll. Jack up Ihe rear end at the vehicle and place II securely on jacks lands DO NOT get under a vehicle that s suppor1ed only by a jack! 2 Release th e parking brake complete ly 3 On 19791hrough 1986 models. loosen Ihe cable locknut and adjust· II1g nut 10 completely release cable lenSlon (see illustration 12.4) 4 On 1987 and laler models. release thecable lenSlon (see Section 13). 5 Detach the cable(s) from the equalizer (see illustration). 6 Detach the cable snap IItllOg(S) and unbolt Ihe cable brackets from the vehicle body
Chapter 9
Brakes
9 - 21
VI EW)! T V"C .. l 2 ' lA(:($
""ONGS MUST BE SECUI1ElY lOCl(lC IN PL,",CE
VI Ew' VlfWY
...... x ,.. u .. EfFEC TI VE fOllCl USEC TO ' NSE tH END f iTTING INT O I AC '; ' NG Pl /l, TE 100 liS TO "VOID ' eA .. .. NENT O"""GE T OC~OUIT
V.lWV 2 'lAClS
V'l" V
TY'IC:"'~
TY PICAL 2 'L4CIS
14.5
Parking brake cables - typical
Models with rear drum brakes 7 B
Remove the feal brake drum (see SeellO" 6). Remove the au tomallC adjuster SPring Irom between the brake
,hoe,
9 Move the au tomatic adjuster lever and small cable as necessary to provide access to the end of the parking brake cable 10 Olsconnecl1he parki ng brake cable from the lever on the secondary
shoe 11 Squeeze the cable retamer prongs together so the reta iner will fll through the hole ,n the backing plate (thiS can usually be done by sliding an appropriately-Sized bo~ ·end wrench over the fetamer). Putl the cable out through the hole In the backing plale and take il oul from under the vehicle
Models with rear disc brakes 12 Disconnect the cablels} from Ihe caliperlS) {see SeellOn 5},
All models 13 Instatlatlon IS the reverse 01 the removal steps 14 Adl ust lhe parking brake (see Secllon 12) t 5 Remove the jackstands and lower the vehicle Unblock the Iront wheels and check parking brake operation
15
Power brake booster - removal. installalion and adjustment
2 Disassembling the blake booster requIres special tools and IS not ordlnanly done by the home mechanIC It a problem develops Install a new or tactory rebUIlt unit
Removal 3 Remove the nuts attaching the master cylinder to Ihe booster and carefutly pull the master cylinder fo rward un\ll it clea rs the moun \ln g studs Use caut ion so as nol to bend or kink the brake lines 4 D,sconnect th e vacuum hose where It attaches to the power brake boos ter 5 Working In the passenger compartment under the steering column unplug the Wifing Conneclor Irom Ihe brake lIght sWItch, then remove the pushrod retaining clIp and nylon washer from the brake pedal pm Slide the pu$hlod ott the pin, 6 Also remove the nuts anacl'1lfl9 the brake booster to tna lirewall 7 Caretully detach Ihe booster from Ihe Ilfewall and lih It oul of the engine compartment
Installation 8 Place the boos ter mto pOSItion on the firewall and \Ighten the mountIng nulS Connect the pushrod and brake light SWlich to the brake pedal Instatl the retaining clip In the brake pedal pin 9 Install the master cylinder to the booster. tIghtening the nuts to the torque hsted In Ihls Chapter s Specl/lca\lons to Carefully check the operatIon 01 the brakes beloredflvlng theyehlcle In tralhe
Adjustment Refer /0 Illus/rarions r5 11 and 15 15
The power brake booster unit requires no special main tenance apart from peri odiC InspeC\lon of the vacuum hose and the case t
tI
Some boosters feature an adjustable pushrod They are matched 10 the boos ter at the lactory and most likely Will not reqUIre adjustment. bui ll a mlsadJusted pushrod is suspected, a gauge can be fabricated oul of
sa
Chapter 9
9-22
Brakes
•
, MINIMUM
+"NCH ,. r-ttNCH ;-
I ,--.l
~1J"INCH
1
-
MAXIMUM
~INCH_I HIli! INCH-
J INCH
0.156 INCH
L
I-
I
j l l " INCH
'. __
I
POWER UNIT
250 INCH GAUGE 250 INCH OIMENSI ON
15.15 15. 11
Power brake push rod gauge template
heavy gauge sheet metal uSlI1g the accompanying template (see illustra-
tion)
-_.I.,
Checking the pushrod length (the pustuod Is lactory presel and most likely will never need adjusting)
check lor proper brake opEIrallon before dnVlng the vehICle In Iranic
.
12 Somecommon symptoms caused by a ffilSad)usled pushrod Include draggIng brakes til ihe pushrod IS 100 long) or excessive brake pedal travel accompanied by a groaning sound Irom the brake booster (il the pushred IS too short).
13 To check the pushrod length, unboillhe master cylinder from the booster and poSItion I' to one side Illsn', necessary 10 disconnecllhe hydrauhc lines, bul be carelul not 10 bend them 14 Block the front wheels , apply the parking brake and place the trans, axle In Park Of Neutral 15 Start Ihe engine and place the pushrod gauge against the end 0 1 the pushrod, exerting a force of approximately S-pouflds to seat the pushrod In the power u"it (see Illustration) The rod measurement shouldlall somewhere between the minimum and maximum cutou ts on the gauge lilt doesn' t, adlust It by holding the knurled portion olthe pushrod With a pair of pliers and turning the end With a wrench 16 When the adjustment IS complete, remstallthe master cylinder and
16
Brake light switch - replacement
Removal locate the SWi tch near the top of the brake pedal arm, under the dash, and disconnect the electrical connector 2 Remove the pushrod retaining chp and nylon washel flom Ihe brake pedal pin and slide the pushrod off far enough fOI the outer hole 01 the SWitch to clear the pln_ Now pull up on the SWitch to remove II
Installation 3 POSition the SWitch so II straddles the pushrod and the slot on the inner sldeolthe SWIlch reslson the pedal pin. Slide the pushrod and SWitch back onto the pin, then Inslalilhe nylon washer and retamlng clip 4 Reconnect the wiring harness 5 Check Ihe brake lighls l or proper opera tion
Chapter 10 Suspension and steering systems Contents Axle damper - removal and Inslallallon Bali,Olnls - check and replacement ChaSSIS lubncallon Front cod SPring - removal and Installation Front control arms - removal and InSlallallon Front end alignment - general informatIOn Fronl stabilizer bar - removal and InSlallallon Front struLshock absorber assembly - removal and installatIOn
", See Chapter 1
•
7 22 2
"
3
Front wheel beanng check. repack and adjustment General mtormatlon Intermediate shall- removal and Installallon Power steering fluid level check
Power steering pump - removal and mstaliallOn
,. ,.
Power steenng system - bleeding ... . 18 12 Rear coil spring - .removal and installation Rear shock absorbers - removal and installatIOn Rear stabilizer bar - removal and InstallatIOn ..... . 8 Rear suspension arms - removal and installation __ _ 13 Sj:>lndle - removal and Inslallation __ _ ______ _ 5 Steering gear bools - replacemenl __ ___ 20 Sleenng gear - removal and installatIOn _ Steenng wheel- removal and installation _ See Chapler 1 Steenng and suspension check __ .. __ .. , 19 Tie-rod ends - removal and installation _ Tire and tlfe pressure checks __ , .• _..•.. See Chapter I Tire rotation . •...• , . _•..•...•..• _.. See Chapler I Traction bars - removal and Inslallallon 9 Wheels and tires - generallnformatlon 21
See Chapter' 1
15 See Chapter 1 17
SpeclficaUons
Torque specifications
Ft·lbs
Front suspension Control arm-Io-crossmember p'vOI bolls/nuts 1979 through 1981 1982 19831hrough 1985 1986 on Control arm baIiJolnt-tO-Sp'ndle nut' 1979 through 1982 1983 through 1986 1987 on Struttshock absorber upper mount to -oody nuts 19791hrough 1986 (three nuts) 1987 on (two nuts) Strut/shock absorber-to-upper mount nut 19791hrough 1982 1983 through 1986 1987 on Strut/shock absorber·to ,splndle nutslbolts 19791hrough 1985 1986 on
200 to 220 215 to 260 150 10 180 11010150
8010120 100 to 120 80 to 120 621075 50 10 75
60 to 75 55 to 92
50 to 75 150 to 180 14010200
10
10 - 2
Chapter 10
Suspension and steering systems
Rear suspension Upper suspension arm-Io-frame PIvot bolVnul 1979 and 1980 1981 and 1982
1983 through 1986 1987 on Upper suspenSion arm-to-axle housing PIvot boItInul 1979 and 1980 19811hrough 1986
1987 on Lower suspenSion arm-la-frame pivot bolUnut 1979 and 19BO
1981 and 1982 1983 through 1986 1987 on lower suspenSion arm-to-ade houSIfl9 Pivot boll/nul 1979 and 1980 19S1 through 1986 1987 on
7010100 100 to 110 100 to 105 80 to 105 7010100 90 10 100 7010100 7010100 100 to 110 10010105 80 to 105 7010100 9010100 7010100
Sleeting Tie-rod end-Io-spmdle arm nuts' . Steering gear mounting botts/nuts 19791hrough 1985
\986 on Intermediate shah-la-steering gear Input shah pmch boh 19791hrough 1985
1986 on Intermediate shaft lIange -Io-steering gear clamp nuts Intermediate shatHo-Sleenng column shalt nul and bolt 1979 through 1989
1990 Sleem'IQ wheel nul or boll 19791hrOO9h 1986 1987 on Air bag module nuts Wheel lug nuts
351047
80 to 100 30 to 40 20 to 30 20 to 37 20 to 30 351045 J8 to 54
30 to 35 231033 3 to 4 See Chapter 1
- Tighten to the minimum specified torque. then align the nexl castella lion m the nut with the COlier pm hole
General information
Reter /0 ;IIUS/rations , / and 12 Warnl ng : Whenever any Of/he suspenSion or s/eenng fasteners are /oos· ened or removed they must be mspected ancJ. If necessary. replaced With newones of the same pan number or of ongmal eqUipment quality ancJ de· Sign Torque speallCa/lOfIs must be followed for proper reassembly ancJ CQmponent retenllon Never allemptto heat. straighten or weld any sus· pension or s/efJrlng component Ins/ead. replace any bent or damaged part wl/h a new one Note: These vehicles use a combmatlon of standard and me/nc fasteners on /he vanous suspension and sleermg components. so It would be a gOOd Idea /0 have both types of tools available when begmnmg work The trOnl suspenSion IS Independent alloWing each wheel to compen · sale tor road surface changes without appreciably affectlnoglhe olher (see illustration), Each wheel IS connected 10 Ihe trame by a SPlnd~ . baliJoln\. control arm and a shock absorber/strut assembly poSitioned venlcally between Ihe spindle and frame Each Side uses a Call spnng mounted be· tw een the control arm and the frame . Body side rol l IS con trolled by a stabilizer bar The rear suspension conSists of the a:>.le, two COil sprmgs. shock abo sorbers Iwo lower and twO upper control arms (see Illustration) Some models use a rear stabilizer bar.lractlon bars and hydraulIC aliledampers to conlrol axle movement The steering syslem conSists 01 Ihe steering wheel. steenng column, an anlculaled IOlermed,ate sha lt. Ihe sleeflng gear. power steering pump
{II eqUIPped) and the lie-rods. which connect th e steering gear to the spindles Frequently, when working on Ihe suspension or steering system com· ponen ts . you may come across fasteners which seem Impossible to loos· en These lasteners on the underSide of Ihe vehicle are continually subjected to waler. road grime. mud. etc.. and can become rusted Of "frozen: making them extremely dlllicult 10 remove In ofder to unscrew Ihese stubborn lasteners Without damaging lhem {o r other components), be sure to use lots o t penetrallng oil and allow It to soak In for a while . USing a wife brush to clean e~posed threads Will also ease removal of the nut or bol! and preven t damage 10 Ihe threads. Sometim es a sharp blow With a hammer and punCh is effective In breaking the bond between a nut and bolt threads, but care must be taken 10 prevent the punch from shppng 011 the fastener and rUining the threads Heating the Sluck lastener and surrounding area With a torch sometimes helps too . but isn', recom· mended because 01 the obvIOUS dangers aSSOCIated WIth lire. Long breaker bars and extensIOn, or ·cheater: pipes wtllincrease leverage, but never use an e~tenSlon pipe on a ratchel - Ihe ratche\lng mechanism could be damaged Somelimes. turning the nul or bolt 10 the tlgh l enlng {clockwise) dl rectlon first will help to break It loose Fasteners thaI require drastic mea· sures to unscrew should always be replaced With new ones Since moflollhe procedures thaI are dealt With In thiS chapler Involve Jacking up the vehICle and WOrking underneath I\. a good pall o t Jackslands Will be needett A hydraulIC floor ja(:k IS the prelerred type of ,ack to bit the vehicle, and II can also be used to support canaln components dunng van· ous operation Warning: Never, under any Circumstances, refy on a jack to support the vehicle while workmg on 1/
Chapter 10
Suspension and steering systems
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An underside view 01 a 1990 Mustang Grs rear end, showing its suspension and related components (other models similar) j
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Shock absOrbers Upper control arms Axle assembly
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Stabihzer bill Coli spnngs
6 1
Lowercontrol arms Dnveshaft
Chapter 10
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Chapter 10
Suspension and steering systems SHOCK STRUT INSULATOR
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ItflEGRAl SPlNOLE AND
8RAJ(E ANCHOR PlATE DESIGN
STANOAAO FRONT
STABILIZER
2.2b
2
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LOWER ..... .. ARlo!
Front suspension (typical) - assembled view
Front s tabilizer bar - removal and Ins lallation
Refer to II/ustratlons 2.2a and 22b
Removal Raise the vehICle and supporl It securely on lackstands Apply the parlong brake 2 Remove the stablllzer bar link nuts. notIng I'Iow the washers and bushings are poSitioned (see illustrations) On early models which use a Itnk bolt, hold the bolt head from turning With a wrench. On later models which use a link threaded on both ends. clamp a pair of locking phers to the stabilizer bar link to prevent II Irom turning 3 Remove Ihe stabilIZer bar brackel bolts and detach the bar 110m the vehicle 4 Pull the brackets off Ihe slabllizer bar and Inspect the bushings lor cracks, hardentng and other Signs 01 detefloration II the bushings are damaged. cut them off the bar
Removal Loosen Ihe Ironl wheel lug nulS, raise Ihe vehicle and SUpporll! se· on jackslands_ Remove Ihe wheel 2 Remove Ihe diSC brake caliper and hang II out ol lhe way With a piece of Wife (Chapter 9). 3 Place a floor JClCk under the control arm ar'lCl raise ItsllQhlJy The Jack must remain 10 Ihls poSition throughoulthe enure procedure 4 Unscrew the three upper mounHo-shock tower retaining outs (see iIIuslratlon 2.2b) If Ihe upper mount IS to be removed !rom the strull Shock absorber assembly, loosen (butdo nOI remove) the cen ter nul atlhis lime 5 Remove the strul lo·spindle nuts and bolts 6 Separate the slrulishock absorber assembly Irom Ihe spilldle and reo move It Irom the vehicle 7 Illhe upper mount IS 10 be replaced. remove the center retalolllg nut and slide Ihe mount ott 01 Ihe assembly curel~
Installation Instaffation 5 Lubnca te the new stablllzer bar bushings With a rubber tubrlcant (such as a Silicone spray) and slide the bushings onto Ihe bar 6 Push the brackets over the bushings and raise the bar up 10 the frame Inslallthe bracket bolts bul don't tigh ten them completely at thiS lime 7 Install the stabilizer bar link washers and rubber bushings and tighten the nuts securely 8 Ttghten the bracket bolts.
3
Front strut/shock absorber assembly - removal and installation
Note: The strut shock absorbers are not serViceable and must be rep/aced as complete assemblies
6 If the upper mounl was removed. ptace II over the top 01 the Strut! shock assembl~ and mstaltthe nut 9 GUide Ihe assembly InlOpoSition lOthe wheel well, pushing the upper mount studs Ihrough the h'Jles 10 the shock lower Install \he Ihree nuts and tighten them to the specified torque. Note: The Ford Motor Company rec· ommends thai the nuts not be fe·used - rep/ace them With new ones to Inserl the Spindle InlO the lower mounting ttange 01 the strut; shock as· sembly and mstallthe two bolts. Agam. [liS recommended Ihat new bolls and nuts be used (genuine Ford parts only). InSlali the nuts and tighten them to the torque listed in thiS Chapter's Specifications I I Tighten the upper mounH o·shock assembly relamlllg nut to the torque listed In thiS Chapters Specllicallons t 2 Remove lhe Jack from under the control arm and Install the diSC brake ca\tper as oullifled In Chapter 9 13 Inslall the wheel. tower lhe vehicle and Ilghten the lug nulS to Ihe torque speCIfied m Chapter 1
Chapter 10 4
Suspension and steering systems
10 -7
Balljoinls - check and replacement
The balljoints on this vehicle are nOI replaceable separately. The entire control arm must be replaced if the balijoints are worn out. Refer to the
Steering and suspension check in Chapter 1 lor the checking procedure. Refer to Seclion 7 In this Chapler/or control arm removal and installation.
5
Spindle - removal and installation
Removal Loosen the wheel lug nu ts, apply the parking brake and raise the vehicle. Support it securely on lackslands placed under the frame. Remove the wheel. 2 Remove the brake caliper and place lion topol the upper control arm
(see Chapter 9 II necessary) 3
Remove the brake disc and hub assembly (see Chapter 1).
4
Remove the splash shield from the spmdle.
6.3a Ford tool T82P·5310-A. or an equiva lent tool , is used on all except 1979 through 1981 models and 1988 and later 5.0L models
S 6
Separate the tie-rod end from the spmdle arm (see Section 19) Remove the cotter pin from the control arm balljoint stud and back oN the nut two turns 7 Break the balljomtloose from the spindle by rapping the spindle boss sharply With a hammer II a hammer does not work. try uSing a puller. as shown In IlIu:;tratlon 19.4. Note: A pickle fork type balljolnt separator may damage the ballJOlnt seals. 8 Posillon a floor Jack under the control arm and raise It shghlly to take the spring pressure oH the shock absorber/strut assembly. The jack must remam in thiS poSition throughout the entlle procedure. 9 Remove the two large nuts and bolts that attach th e spindle 10 the strut/shock absorber assembly (see Section 3). 10 Remove tile nut from the con trol arm baliJoin! stud. separate the spindle from the strut/shock assembly and remove the spmdle from the vehicle.
Installation 11 Place the spmdle onto the control arm balljoin!. \ 2 Insert the top of the spmdle Into the opening in the strut/shock absorb· er assembly and install the bolts. Tighten the nuts to the torque listed in thiS Chapter's Speclflca\ions. Note: The Ford Motor Company recommel,ds that these boilS (and nuts) be replaced. not re·used. 13 Tighten the cont rOl arm balljomt stud nut to the torque listed m th is Chapter's Specifications. 14 Install the splash shield. 15 Connect the lie-rod end to the spmdle arm and lighten the nuts to the torque listed In this Chapter's Specifications. Be sure to use a new colter pin 16 Install the brake diSC and adjust the wheel bearings followmg the pro· cedure outlined m Chapter 1. 17 Install the brake ca liper 18 Install the wheel and lug nuts. Lower the vehicle to the ground and tighten the nu ts to the torque listed in this Chapter's Specifications.
6
6.3b II using Ford tool T82P-S310-A, place the upper plate into the spring upper pocket in the crossmember. with the hooks facing In ..
Front call spring - removal and Installation
Warning: The follOWing procedure IS potentially dangerous If the proper safety precautions are not laken. A coil spring compressor of the type dis· cussed below must be obtained and positioned properly 10 safely perform thiS procedure.
Removal
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Refer to illustrations 6.3a. 6.30. 6.3d and 6.3e 1 loosen the wheel lug nuts on the Side to be dismantled. Raise the vehicle. support it securely on jackstands and remove the wheel. Disconnectthe stabilizer bar link from the control arm (see Sec\lon 2) . 2 3 Install the correct Ford spnng compressor or eQUivalent :
6.3c .. . then pass the compression rod up lhrough the conlrol arm and coli spring, hooking il to lhe upper plate
a) All e~cept 1979 through 1981 models and 1988 and later Mustang 5.0~ Usmg Ford spnng compressor No. T82p·531 O·A or an eQUIValent spring compressor (see illustration). Insert the upper plate 01 the tool through the spring upper pocket In the cross member With the hooks on the plate pointing towardS the center 01 the spnng. GUide the compression rod up through the hole In the contro l arm and the coil spring. !hen Insert the end 01 the compression rod into the upper plate (see Illustrations),
10
10-8
Chapter 10
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Suspension and steering systems
i I
THRUST WASHER . _
6.3e When using Ford 1001 D78P·S310· A, make sure Ihatthe spring compressor plates are lully sealed before applying pressure ; mark Ihe posilion 01 the spring plales on Ihe spring coils w ith chalk lor use during installation
---'
Installation
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-
6.3d Ford tool D78P-S31 O-A, or equivalent, Is used on 1979 through 1981 models and 1988 and later 5.0L models
6.9 The bottom 01 the spring coil must be situated so that the end of the spring coil C covers hole B,
but nol hole A b) 19791hrough 1981 models and 1988 and later Mustang 5.0- Use spru19compressorNo. 078P-5310-A(see lIIustralion).lnslalilhe compressor upper plale between two colis near the top 01 the Spring. then marlt Its locatIOn lor use during spring mslalla\Jon (see illustration). Caution: Do not nick the SPring COils WJth the upper pia/e. Guide the compresSIOn rod up through me hole in the control arm and thecoil spnng. then insert the 60001 the compression rod InIO the upper plate 4 InSlaU the lower plale. ball nul, thrust washer and beanng and the tore· ing nut on the compression roo. Tl9hten the torclng nut lust enough to leel sPOr'lg pressure. S Remove the control arm -to-crossmember nutS and Pivot bolts (see Illustrations 2.2a and 2.2b). It may be necessary 10 remove the steenng gear mountlf'lg bolts and repoSItIOn the gear to allow bolt removal. Loosen the torclng nul on lhe compressor 1001 until all 01 the spong pressure IS relieved. 6 Remove the spnng compressor compresSion rod, then maneuver the COil spring out tram between the control arm and cross member,
Refer to IllustratIOn 6 9 7 Install the coil spring Insulator on the top 01 the sprmg 8 Install the spnng In between the contrOl arm and the spflng upper pocket In the crossmember 9 POSllion the bottom ot the spnng so that the pigtail covers only one of the drain holes, bu t leaves the other one open (see Illustration) 10 Locate the spflng in the upper seat In the crossmember. install the spflng compressor tool as described In Steps 3 and 4. then lighten the 10rCIng nut unliithe control arm bushing holes hne up With the pivot boll holes 10 the crossmember. 11 InSlall!he prvot bolts and nuts In thednec\lon shown 10 Illustration 2 3, bu t don·t tigh ten them completely at thiS lime 12 Remove the spnng compressor tool. POSl\lon a floor lack under the ou tboard Side 01 the control arm and raise ilto Simulate a normal fide poSI· lion Now lighten the Pivot bolt nuts to the torque Iisted.n thiS Chapters Speclhca\lOns 13 Reconnect the stabilizer bar link to the con trol arm , 14 InSlall the wheel and lug nuts, Lower the vehicle and tighten the nuts to the torque speCified 1M Chapter 1
7
Front control arms - remova l and Installation
Note: The controt arm Oushmgs and ballJOmt are nOI servrceable It they wear ou t. the enllre con tro l arm must be replaced 1 LQOsenthewheellug nuls. raise the vehICle and support It securely on JackslanCIs Remove the wheel 2 Separate the control arm baliJotnt flam the spindle as descflbed 10 Section 5. 00 not remove the ballJOlOt stud nut at thiS time 3 Remove the coil Spflng as described in the prevIous Section, noting Ihe Warfllng in that Section . Unscrew the baJllolnt nut and remove the control arm from the vehicle. 4 S Instatlatlon IS the reverse of the removal procedure. Be sure 10 l ighten all of the fasteners to the torque listed In th,s Chapter's Specllicatlons.
8
Rear stabilizer bar - removal and Installation
ReIer /0 ,I/us/rallon 8.2 1 Raise the rear of the vehICle and support 11 securely on Jackstands 2 Support the stabilizer bar and remove the sta~llzel bar-to-Iower suspenSion arm bolts (see Illustration).
Chapter 10 Suspension and steering systems
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10-9
SUSPENSION
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Typical tear suspension with stabilizer bar and traction bars
Remove the bar from the vehicle.
4 Installation IS the reverse of the removal procedure. Be sure 10 Install the bar with the paint mark on the right hand side of the vehicle.
9
Traction bars - removal and Installation
Raise the rear of the vehicle and support it securely on jackslands. 2 Remove the two nuls thai hold the tracllon bar to the axle U-bolt and remove the traction bar. U-boll and adjusung shim(s) (see illustration B.2). 3 Installation is the reverse of the removal procedure,
10
Rear s hock absorbers - removal and Installation
Note : Some models use Torx boilS 10 secure Ihe lower ends of Ihe rear shock absorbers. If /hIS IS Ihe case and you don 'I have the proper size Torx driver, buy one before you slart the job. Do notlry to substitute an Allen wrench for a Torx dflver- it may Strip out the bolt head.
Refer to illustrations 10.5 and 10.9
Removal 1 Raise the fear 01 the vehicle and support it securely on jackstands. 2 Support the rear a)(le with a floor jack to prevent it from dropping when the shOCk absorber is disconnected. 3 On two·door models, open the trunk. On 3-door models, open the rear compartment and remove the trim panel access door. Remove the upper mounting nut from the shock absorber rod . It may 4 be necessary to prevent the rod Irom turning by holding it with a wrench or locking pliers. 5 Remove the lower mounting bolt or nut (see Illustration). separate the bottom of the shock absorber from the mounting bracket and remove It from the vehicle.
Installation 6 Before Installing a new hydraulic shock absorber, e)(pel all air. Hold the shock right side up and extend it fully. Turn the shock upside down and compress it all the way. Extend and compress the Shock absorber in thiS manner at least three times. 7 Place the inner washer and rubber insulator on the shock rod and in· sert the rod through the upper mounting hole. Note: Gas shocks wi/lex· lend by themselves unless they are equipped with a restraint strap. 8 Models with lower mounting stud - slip the end 01 the shock absorber over the stud. Inslallthe nut and lighten it securely.
10 -10
Chapter 10
Suspension and steering systems
2 R€O'O 2 REO'O
SHOCK ASSY
VIEW Y
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10.5 Typical rear suspension - exploded view
Chapter 10
Suspension and steering systems
10 -11
SHOCK ASSV
WASH ER AX LE
11.2
12
Hydraulic ade dampers are used to control 8xle motion on some models
Rear coil spring - removal and i nstallation
YIEW FROM fFlONT OF VEHICU
Nole: Rear coil spnngs should always be replaced m pairs
Removal 10.9 On models with To r x bolls at the lower ends of the shock absorber s, use only the correct size Torl! driver
9
Models with lower mounting 0011- Push up on the shock absorber to
align the lower shock eye In the mounting bracket and instali lhe bolt and nut. On models equipped w ith a self·wrenchlng nu t (see iIlusltatlon), start the boll Into Ihe nul by hand and let Ihe nut turn by il sel! until it stops. Don" try to hold It any other way. Once the nut stops. t ighten the bo lt se curely 10 In51alilhe upper mounting rubber insulator and Ihe dished washer on the shock rod Instalilhe nut and lighten II securely
11
Install the IrIm panel access door (three-door models)
Loosen the wheel lug nu ts. raise the rear of the vehicle and support It securely on jackstands placed under the frame . Remove the wheel and block the Iront wheelS. 2 Remove the re ar stabili zer bar (see Secllon 6) if the vehicle is equipped With one 3 Support the rear axle assembly wil h a jackstand placed under the axle tube on the Side being dismantled. PosiTIOn a salel y chain through one of the spring COils and around a conven ien t frame member, This Wi ll preven t the sp ring from flYing oul before irs fully extended, 4 Place a tloor jack under the lower suspension arm axle PiVOt bolt (see illustration 10.5) Remove the nut and bolt 5 Slow ly lower the Jack unlll the spring ,~ tully extended. 6 Remove the safety cha in, Call spring and insulators Irom between the suspension arm and the spong upper seat
Installation 11
Axle damper - remo val and installation
Refer to iflus/ral!on t 1,2
Removal Loosen Ihe whee l lug nulS. raise Ihe vehicle and support lion jack· slands. Remove the wheel and place a floor Jack under the rear axle to support It. Just In case II shifts when Ihe axle damper IS removed 2 Remove Ihe a~le damper front allachlng nut and bo lt from the a~le bracket (see illustrati on) 3 Remove the rear attaching nul Remove the bolts that hold the rear moun ting bracket tothelrame sldemember (see illustration 11 .2) and re o move the damper from the vehicle
Installation 4 Place the rear bracket onto the a~le damper and Install the nut Idon·t tighten It yet), S POSITIOn the rear bracket on the frame sldemember and Install the bolts. tightening them securely 6 SWing the axle damper into the moun t on the rear a~le and Install the p iVOt bolt and attaching nul. tightening them securely 7 Tighten the rear retaining nut securely Install the wheel and lug nUls and lower the vehicle Tigh ten the lug 6 nuts to the torque speCIfied In Chapter 1
7
Set the upper Insulator on top o t the Spring, uSing tape to hold It In p lace. IJ necessary. 6 Place the lower insulator on the lower suspension arm , 9 Install the Internal damper In the spnng 10 Place the spnng between the suspension arm and the frame . so that the pigtail (the end of the spring) on the lower suspension arm IS pointing toward the lel! side 01 the vehicle (see illustration 10.5) 11 Raise the lower suspenSion arm up into poSition and IOstall the piVOt bol t and nut. but don·t tully tighten the nut yet 12 Raise the axle to Simulate a normal ride height and tighten the piVOt bolt nut to the torque listed in thiS Chapter's Specijlcatlons 13 II the vehicle IS equipped With a rear sl abllizer bar, IOstalill . re ternng to Section 8 II necessary
10 13
Rear suspension arms - removal and installation
Upper arm Note : Ifone upper arm reqUires replacement. replace the olherupperarm as well. The Ford Motor Company recommends ins/ailing new fasteners when reassemblmg the rear SuspenSion components Removal 1 Raise the rear 01 the vehicle and support II securely on jackstands p laced beneath the frame ralls . B lock the front wheels
10-12
Chapter 10
Suspension and steering systems
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Suspension and steering systems
10 -13
2 POSition a Jack under the (Meren\lal and false 1\ slightly 3 Remove the upper arm -Io-rear axle Pivot bolt and nut (see illustration 10.5) 4 Remove the upper arm-Io-Irame pivot bolt and nul and remove the arm from the vehicle
Installation 5 POSition the leadmg end althe suspenSion arm in the frame bracket. Install a new pivot bolt and nut with the nut on the outboard side, but don', full~ lighten the nut at thiS time. 6 Place the ather end of the arm over the axle bushing ear. It may be necessary to Jack up the rear axle to align the holes. Install a new Pivot bolt and nut With the nut on the inboard Side. but don't tighten 11 to the speCified torque yet
7 Raise the axle to normal ride height and tighten the fas teners to the torque lisled In Ihls Ch
Lower arm
14.2b Steering wheel Installation detailS ( 1990 models equipped with air bags)
Note: Ifone lower arm reqUires replacement, replace tfleotherlower arm as well. Also. Ihe Ford Motor Company recommends mstallmg new fasteners when reassembling the rear suspension components
Removal 8 Loosen the wheel lug nuts. ra ise the rear of the vehicle and support II securely on lack.slands placed under the frame ralls. Block. the fronl wheels and remove the rear wheel. 9 Removethe COlt spring lollowlng the procedure outlined In Section 12. 10 Remove the lower arm-to-frame Pivot bolt and nut (see illustration 10.5). then remove the arm from Ihe vehicle.
lnslallalion " Posllion the lower arm m Ihe Irame mounting brack.et and mSlal1 a new pivot bolt and nut. With the nut lacing out. Do nol tighten Ihe nul completely at thiS tJme. 12 Inslallthe coil spring and connect the trailing end of Ihe lowersuspen· Slon arm to Ihe rear axle brack.et (Secllon 12). Raise Ihe axle to Simulate normal ride height, then lighten Ihe pivot bolt nuts to the lorque listed in thiS Chapter's SpecllicatlOnS 13 Inslalilhe wheel and lug nuls. lower the vehicle and tighten the lug nuts to the torque speCified in Chapter 1.
14
Steering wheel- remo va l and Installation
Reier to IllustratIOns t4.28 and 14.2b Disconnect the cable from the negative termmal of the battery. Expose the sleering wheel nut or bolt as follows (see illustrations): a) Round horn bunon - pull the bullon off. Note : On some models. it is necessary to twist the buNon counterclockwise before pulling it off. Don't pry or force the button if it won't come eaSily b) Square trim emblem -from Ihe back side of the steering wheel , insert a rod into the \WO removal holes and push the emblem out of the steering wheel Push alternately and evenly against the em blem until it can be removed. c) 1990 models (air bag equipped) - Remove the lour nuls that secure the air bag module. Separate the air bag module from Thesteering wheel and disconnect its electrical connector, Warning : Be very careful when removmg or installing the air bag module and don't allow its elecrncal connector to come into contact with any olher wires or metal oblec/s . The air bag could activate. poSSibly reSult· mg mm)ury. 3 Remove Ihe steermg wheel retaining nut or bolt (see illustration 14.2a or 14.2b).then mark the relationship ollhe steering shall to the hub (if marks don't already eXist or don't line up) to simplify Installation and ensure correct steering wheel alignment. Note : Discard the hub nut or bol/. Use a new one during mstaliatlOn 4 Use a steenng wheel puller to detach the steermg wheel tram the shafl. Don·t use an impact puller and don't pound on the steering wheel or shalt.
1
2
5 II equipped With crUise con1rol. mak.e sure the slip nng grease is not contaminated. Check. Ihe slip ring contacts lor wear or damage and mak.e sure they are properly seated. 6 To install the wheel , align Ihe mark on the sleering wheel hub with the mark on the shalt and slipthewheel onto the shaft. Install a new hub nut or bolt and tighten ilto the torque listed in Ihis Chapter's Specifications, 7 On 1990 models. connect the air bag electncai connector and install the air bag module. 8 On other models, Install the trim piece or hom button. 9 Connect the negative battery cable.
15
Intermediate shaft - removal and Installation
Note: The Ford MotorCompany recommends the rep/acement of the in· termediate shah fasteners once they have been removed. (Use genuine Ford parts or eqUivalent quality fasteners only) . 1 Turn Ihe front wheels to the straight ahead position. 2 Using white paint. place alignment marks on the intermediate shaltlo·steering shaft and the lower lIexible coupling-to·steenng gear input shalt Jom ts (see Illustration 14.2a). 3 Remove the upper clamp bolt and lower fleXible coupling pinch bolt (see Illustration 14.2a), 4 Remove the steering gear-to-frame mounting bolts (Section 16) and lower Ihe steering gear enough to allow intermediate shalt removal. 5 Pry the intermediate shaft off the steering gear input shaft with a large screwdriver. then pull the upper end 01 the shaft out of the steering column shall. 6 Installatlon is the reverse of the removal procedure. Be sure to align the marks and tighten the pinch bol ts to the torque listed in thiS Chapter's Specilica\lons.
16
Steering gear - removal and Installation
Refer /0 IllustratIOn 16.5
Removal , Raise the Iront 01 the vehicle and support It securely on jack.stands. Apply the parking brake. 2 Place a drain pan under the steering gear (power sleering only). Remove the power steering pressure and return lines and cap Ihe ends to prevent excessive l1uid loss and contamination. 3 Mark. the relalionship 01 Ihe intermediate shallllexible coupling to Ihe steering gear mput shaft. Remove Ihe pinch bolt (see illustration 14.2a).
10 -14
Chapter 10
"
Suspension and steering systems
.
, ~,~".,,"
.IUOWS
16.5
Steering gear Installation details (power steering shown; non-power similar)
4 Separate the lie-rod ends trom the spinelle arms (see Section 19). S Suppol'l the steering gear and remove the steering gear-to·frame mounlil'lg nuts and bolts (he illustration) Lower the unit, separate the intermediate shaft from the steering gear input shal' and remove the steering gear from the vehICle
Installation 6 Raise the steering gear Inl0 poSition and connect the intermediate shaft. aligning the marks. 7 Install the mounting bolts and washers and lighten the nuts to the torque listed in this Chapter's Specillcalions. 8 Connect the IJe-rod ends to the spindle arms (Section 19) 9 Install the intermediate shaft pinch bolt and lighten It to the torque hsted in thIS Chapter's SpeclticalJOns. 10 Connect the power steenng pressure and return hoses to the steering gear and fill the power steenng pump reservo.r with the recommended HUid (Chapter 1). 11 Lower the vehicle and bleed the steering system as outlined In Sec· tlon 18.
17
Power steering pump - removal and Installation
Refer /0 IIlus/ra/1Oft 17.3
Removal Disconnect the cable from the negative terminal of the battery. Place a drain pan under the power steering pump. Remove the drlvebell (Chapter 1). 3 USing a special power steemlQ pump pulley remover, remove the pulley Irom the pump (see lIIuslration). 4 Remove the pressure and return hoses from Ihe backSide 01 the pump and allow the IIUld 10 drain. Plug the hoses to prevent contaminants from entering 5 Remove the pump mounting bolts and lilt the pump Irom the vehicle. taking care not to sPllllluld on the painted sul1aces 6 POSition the pump In the mounting bracket and install the bolts. Tight· en the bolts securely 7 Connec1 the hoses 10 the pump. TlQhten the hltlngs securely
2
Installation 8
Press the pulley onto the pump shaft uSing a special pulley Installer
tool. Push the pulley onto the shalt until the Iron' 0 1the hub IS lIush with the end 0 1 the shal t. but no lunher 9 Install the dovebelt 10 Fill the power steering reservoir With the recommended lIuld (see Chapter 1) and bleed Ihe system lollowlng the proceduredeSCflbed In the nexI Seellon
18
Power steer ing system - bleeding
FollOWing any operation in which the power steetlng lIuld lines have been disconnected, the power steeni'IQ sy stem must be bled to remove all air and obtain proper steering performance 2 With the Iront wheels In the stratght ahead poSition. check the power steering tluld level and. 1\ low. add lIuld until It reaches the Cold mark on the dipstick. 3 Start the engine and allow 1"0 run at fas' Idle. Recheck the fluid level and add mOle II necessary to reach the Cold mark on the dlpsllck. 4 Bleed the system by turning the wheels from slde·to-slde. Without hitting the stops This Will work the air out of the system. Keep the reservoir lull 01 lIuld as thiS IS done. 5 When Ihe air IS worked out 01 the system. return the wheels to the s'ralght ahead poSition and leave the vehicle runmng lor several more minutes belore shutting It olt. 6 Road test the vehicle to be sure the steerlrlg system IS functioning normally and noise tree. 7 Recheck the lIuld level to be sure It is up to the Hot mark on the dipstick while the engine is al normal operating tempera1ure Add tluld II nec· essary (see Chapter I )
19
TIe-rod end s - removal and Inslallation
Removal Refer to Illustrations 19.2a. 19.2band 19.4 Loosen the wheel lug nuts. Block the rear wheels and set the parking brake. Raise the Iront 01 the vehICle and SUpporlit securely on Jackstands_ Remove the Iront wheel. 2 Hold the tle·rod end with a wrench and loosen the Jam nut enough to mark 'he posl1ion of the lie-rod end In rela1ion to 'he threadS (see illustrations). I
Chapter 10
Suspension and steering systems
10 -15 AJC RELEASE
PUU£V A$Sy
/
'AOHTOF~
PULLEY A$SY
BO"
/
S.OI..~wmtOUT
17.3 Typical power steering pump Installalions (later four-cylinder and
v_~
AJC
models shown, others similar)
10 19.23 Hold the lie-rod end with a wrench and loosen the jam nut
19.2b Use white paint to mark the position oltha lie-rod end on the tie-rod
3 Remove the cotter pin and loosen the nut on !he tle· rod end stud. 4 Disconn ect the tle·rod from the spindle arm wi th a puller (see illustration). Remove the nut and separate the lie-rod. S Unscrew the tie-rod end Irom the tie·rod.
Installation 6
Thread the tie-rod end on 10 the marked POSition and insert the lie-rod
19.4
Use a two-jaw puller to disconnec t the lie-rod end
stud into the spindle arm. Tighten the Jam nul securely
7
Install a new nul on the stud and lighten ilia the torque listed in this
Chapter's SpeCifications. Install a new cotler pin. 8 Install the wheel and lug nuts. Lower the vehicle and tighten the lug nuts to the torque specified in Chapter 1
9
Have the alignment checked by a dealer service depanment or an
alignment shop
Chapter 10
10 -16 20
Suspension and steering systems 22
Steering gear boots - replacement
Loosen the lug nuts, raise the vehICle and SUpporJlt securely on Jack· siands Remove the wheel 2 Referrrng \0 Seclron 19. loosen the tie-rod end jam nut and separate the !Ie-rod end 110m the spindle arm. 3 Remove the steering gear boot clamps and slide the boot (bellows) ott
(see illustration 16.5) 4 Before installing the new boo\. wrap the threads andserrallOnson the end of the sleerong rod with a layer 01 tape so the smal' end of the new boot
Isn I damaged 5 Slide the new boot mtopoSlllon on the steering gear until,! seats In the groovE' In the steeflng rod and Install new clamps 6 Remove the tape and mstallthe lie-rod end (SectIOn 19). 7 Instalilhe wheel and tug nuts Lower the vehICle and tighten the lug nulS to the torque speclhed In Chapter 1 8 Have the alignmenl checked by a dealer servICe departmenl or an alignment shop
21
Wheels and lires - generallnlormal ion
Reier to II/us/rarlon 27,' All vehicles covered by thiS manual are equipped with metnc,slzed II' berglass or steel belled radial IIres (see iIIuslratlon) Use 01 other size or type olilres may allectthe fide and handling 01 the vehlcte Don t mil. dlllerent types 01 tores. such as radl3l and bias belted, on the same vehicle as hancthng may be serIOUsly allected Its recommended thattores be reptaced 10 pans on the same axle. but II only one life IS being replaced. be sure It'S the same Size, structure and tread deSIgn as the other Because \ire pressure has a substantial ellecl on handling and wear. the pressure on all tlfes should be checked at least once a month or belore any extended tnps (see Chapter 11· Wheels must be replaced II they are bent. dented, leak air. have elon· gated bolt holes, are heavIly lUSted. out 01 vertICal symmetry or!1 the lug nulS won't stay light. Wheel repalls thai use welCling or peenlOg are not recommended Tire and wheel balance allecls the overall handling. braking and per lormance of the vehICle Unbalanced wheels can adversely affect handl 109 and IIde characteflsllcs as well as tire IIle Whenever a tire IS mstalled on a wheel, the lIre and wheel should be balanced by a shop With the prop. er eqUipment
METRIC TIRE SIZES
_nHTr
P 186
P T C
P"SSENGER
I
Tb\"~_~"
IlcnOH WIDTH
~~
IMILUMEUIISl 115
80
t
01 Vehicle
Vertical ... C A
1---"----1111 B
FrontV"w
13 I.
1~ CONtT llUCTIOH fYl'l
a ....s _ BELYEa D _ DllllGON .. L (III111S1
1~~
A Iront end alignment refers to the adjustments made to the Iront w heels so they are In proper angular relallonshlp to the suspenSion and the ground Front wheels that are out of proper alignment not only affect steenng contlOL but also Increase lire wear The only front end adJustments poSSIble on thIS vehicle are camber and loe-lfl (see Illustration) Gel\Jng the proper front wheel altgnment IS a very exac\lng process, one In which complicated and expensive machlOes are necessary to perform the Job property. Because 01 thiS. you should have a technICian With the proper eqUipment perform these tasks We Will, however. use thiS space to give you a basIC Idea 01 what IS IOvolved With front end altgnment so you can beuer understand the process and deallOtelitgently with the shop that cIoes the work. Toe-In IS the turning 10 of the Iront wheels. The purpose 01 a toe Speclf1 calion IS to ensure parallel rolling of the front wheels In a vehicle wIth zero toe-In. the distance between the front edges of the wheels Will be the same as the distance between the rear edges 01 the wheels. The actual amount olloe-IO IS normally only a fraction 01 an lOch Toe-In adJustment IS controlled by the lie-rod end poSlllon on the lOner lie-rod Incorrect toe-In Will cause the \Ires towear (mproperly by maklOg Ihem scrub agalnSlthe road surface Camber IS the 111\!ng 01the fron t w heels Irom the vertical when Viewed Irom the front ol thevehlcle. When the wheels ti lt oul althe top. the camber IS said to be poSitive ( ... ). When the wheels tilt in at the top the camber IS negatIVe H, The amount 01 lilt IS measured In degrees from the vertical and thiS measurement IS called the camber angle ThiS angle atfeets the amount 01 tire tread whICh contacts the road and compensa tes for changes (n the suspenSion geometry when the vehicle IS cornenng or travelling over an undulating surface.
!INCI*SI
II _ !lADlIIIL
~~~
Refer 10 IlIustraMn 22, ,
Camber Angle
80 R 13
III I " C'T !lArlO ISECTION HE!GHT! (HClION WIDTHI
UMPOII.IIIIIV COMMERCI .. L
Front end atignment - general Information
F
G
E Toe-In 1EC'T1ON ~~
---1r-------ti IlCT10N HEIGHT
~ 21.1
Metric lite size c ode
Top V"w 22_1 Front end alignment details
A mmus B. C (degrees camber) E mmus F. toe-m (measure(} m IncheS} G ~ loe-m (expressed In degrees}
Chapter 11
Body
Contents Body - maintenance . . . . . . . . . . . . . . . . . . . . Body repair - minor damage . . . . . . . . . . . . . . . . • Body repair - major damage . . . . . . . . ............ Center console - removal and installation ........ Door trim panel- removal and installation ....... . Door and lock mechanism - removal , Installation and adjustment .........••..•..••...•...••...•... General information ..•....••..•...•...•...••..••. • •....
Grille opening panel, front fender and front bumper - removal and installation ... .
1
2 5 6 15 13 14 1
7 8 17 12 11 16 10 4
.3
9
General Information
These models feature a ·unibody" layout, using a floor pan with front and maf side frame rails which support the body components, front and
rear suspension systems and other mechanical components. Certain components are particularly vulnerable to accident damage andean be unbolted and repaired or replaced. Amoog these parts are the body moldings, bumpers, the hood and trunk lid and all glass. Only general body maintenance procedures and body panel repair procedures within the scope 01 the do-It-yourselfer are included in this Chapter.
2
Hinges and locks - maintenance .......................... Hood - removal, installation and adjustment ................. Instrument panel- removal and installation .......... Rear bumper- removal and installation . . . . . .. . . . . Rear hatch - removal, installation and adjustment .. . Seats - removal and installation .. . Trunk lid - removal. installation and adjustment . . .. . Upholstery and carpets - maintenance Vinyl trim - maintenance. . . . . . . . . . . . . . . . . . . . . . . . .
Body - maintenance
The condition 01 your vehicle's body is very important, because the resale value depends a great deal on it. II's much more difficult 10 repair a damaged body than it is to repair mechanical components. The hidden areas 01 the body, such as the wheel wells, the frame and the engine compartment, are equally important, although they don't require as Irequent attention as the rest 01 the body. 2 Once a year, or9Very 12,OOOmiles, it's a good idea to have the underside of the body steam cleaned. All traces 01 dirt and oil will be removed and the area can then be inspected carefully lor rust, damaged brake liMS. frayed electrical wires, damaged cables and other problems. The front suspension components should be greased after completion 01 this job. .3 At the same time, clean the engine and the engine compartment with a steam cleaner or waler soluble degreaser. 4 The wheel wells should be given close attention, since undercoatillQ can peel away and stones and dirt thrown up by the tires can cause the paint to chip and !lake, allowillQ rust to set in. If rust is found , clean down to the bare metal and apply an anti-rust paint. 5 The body should be washed about once a week. Wet the vehicle thoroughly to soften the dirt, then wash it down with a soft sponge and plenty of
clean soapy water. If the surplus dirt is not washed ollverycarelully, itcan wear down the paint. 6 Spots of tar or asphalt thrown up from the road should be removed with a cloth soaked in solvent. 7 Once every six months, wax the body and chrome trim. If a chrome cleaner is used to remove rust from any of the vehicle's plated parts, remember that the cleaner also removes part of the chrome. so use it spar· ingly.
3
Vinyl trim - maintenance
Oon't clean vinyl trim with detergents, caustic soap or petroleumbased cleaners. Plain soap and waterworks just line, with a soft brush to clean dirt that may be ingrained. Wash the vinyl as frequenUy as the rest of the vehicle. Aftercleaning, application of a high quality rubber and vinyl protectantwill help prevent oxidation and cracks. The protectent can also be applied 10 weatherstripping, vacuum lines and rubber hoses. which 01ten tail as a result 01 chemical degradation, and to the tires.
4
Upholstery and carpets - maintenance
1 Every three months remove the carpels or mats and clean the Iolerior of the vehicle (more frequently if necessary). Vacuum the upholstery and carpets to remove loose dirt and dust. 2 Leather upholstery requires special care. Stains should be removed with warm water and a very mild soap solution. Use aclean, damp doth to remove the soap, the wipe again with a dry cloth. Never use alcohol, gasoline, nall polish remover or thinner to clean leather upholstery. .3 After cleaning, regularly treat leather upholstery with a leather wax. Never use car wax on leather upholstery. 4 In areas where the interior of the vehicle is subject to bright sunlight, COVBr leather seats with a sheet if the vehicle is to be leh out lor any length of time.
These photos illustrate a method of repairing simple dents. They are intended to supplement Body repair - minor damage in this Chapter and should not be used as the sole instructions for body repair on these vehicles.
If you can't access the backside of the body panel to hammer out the dent, pull it out with a slide-hammer-type dent puller. In the deepest portion of the dent or along the crease line, drill or punch hole(s) at least one Inch apart ...
2 ... then screw the slide-hammer Into the hole and operate It. Tap with a hammer near the edge of the dent to help 'pop' the metal back to ItI orlglnalshape. When you're finished, the dent area Ihould be close to Its original contour and about 1/8-inch below the suriace of the surrounding metal
3 Using coarse-grit sandpaper, remove the paint down to the bare metal. Hand sanding works fine, but the disc sander shown here makes the lob lOIter. Use finer (about 320-grltl sandpaper to feather-edge the paint at least one Inch around the dent araa
4 When the paint Is removed, touch will probably be more helpful than sight for telling if the metal is straight. Hammer down the high spots or raise the low spots as necessary. Ciaan the repair area with wax/silicone remover
5 Following label Instructions, mix up a batch of plastic filler and hardener. The ratio of fillar to hardener II critical, and, if you mix it incorrectly, it will either not cure properly or cure too quickly (you won't have time to file and sand It into shape)
6 Working quickly so the filler doesn't harden, use a plastic applicator to press the body filler firmly into the metal, assuring It bonds completely. Work the filler untll it matches the original contour and Is slightly above the surrounding metal
7 Let the filler harden untit you can just dent it with your fingernail. Use a body fite or Surlorm toot (shown here) to rough· shape the filler
8 Use coarse·grit sandpaper and a sanding board or bk>ck to work the filler down until it's smooth and even. Worit down to finer grits of sandpaper· always using a board or block· ending up with 360 or 400 grit
9 You shouldn't be able to feet any ridge at the transition from the filler to the bare metal or from the bare metal to the old paint. As soon as the repair is flat and unlfonn, remove the dust and mask off the adjacent panels or trim pieces
10 Apply several layers of primer to the area. Don't spray the primer on too heaV)', so it sags or runs, and make sure each coat is dry before you spray on the next one. A professional·type spray gun Is being used hent, but aerosol spray primer is available inexpensively from auto parts stores
11 The primer will help reveal imperlections or scratches. FlU these with glal:ing compound. Follow the labet Instructions and sand it with 360 or 4OO· grit sandpaper untit It's smooth. Repeat the glazing, sanding and respraying untit the primer reveals a perfectly smooth surlace
12 Finish sand the primer with very fine aandpaper (400 or 6(1).. grit) to remove the primIW overspray. Clean the area with water and allow it to dry. Use a tack rag to remove any dust, then apply the finish coat. Don't attempt to rub out or wax the repair area until the paint has dried completely (at least two weeks)
11 - 4
f
Chapter 11
Body
i
• 5
Body repaIr - minor damage
See phtXo sequence
Repair of minor scratches 1 If the scratch is superficial and does not penetrate to the metal 01 the txxIy, repair is very simple. Ugh!l)' rub the scratched area With a fine rubbing compoond to remove loose pamt and buill up W3.IC . Rmse the area with clean water. 2 Apply touch -up paint 10 the scratch, USing a small brush. Continue to appIythm layers of pamt unlillhe surface ollhe paint in the scratch is level with the surrounding paint. Allowthe new paint at teast two weeks to harden, then blend it into the surrounding paint by rubOmg With a very fine rubbing compound, Finally, apply a coat 01 Wll)l; to the scratch area. 3 II the scratch has penetrated the paint and elq)OS8d the metal ot the body, caUSing the metal to rust, a different repair technique is required. Re· move all loose rustlrom the bottom 01 the scratch with a pocket knile, then apply rust Inhibiting paint to prevent the lormation 01 rust in the luture, Us· ing a rubber or nylon applicator, coat the scratched area with glaze·type liller "required, the liller can be mixed With thinner to provide a very thin paste, which IS Ideal lor lilling narrow scratches. Before the glaze filler in the scratch hardens. wrap a piece of smooth cotton cloth around the tiP of a linger, Olp the cloth In thinner and then quickly wipe It along the surface at the scratch. This will ensure that the surlace 01 the filler is slightly hollow. The scratch can now be painted over as described earlier in this section.
Repair of dents 4 When repairing dents, the first job is to pull the dent out until the af· lected area is as close as possible to its anginal shape. There is no POint In trying to restore the original shape completely as the metal in the damaged area will have stretched on If'I'IP8d and cannot be restored to its original conlours. It is better to bring the level 01 the dent up to a point about 118-inch below tile level of the surrounding metal. In cases where the dent is very shallow, it is not worth trying to pun it back OUI al all. 5 "the back side 01 the dent IS accessible, it can be hammered out gently from behind using a sofHace hammer. While doing this, hold a block at wood firmly against the opposite side of the metal to absorb the hammer blows and prevent the metal Irom bell'lg stretched. 6 If the dent is in a section 01the body which has double layers, or some other factor makes it Inaccessible from behind, a different technique is required. Drill several small holes through the metal inside the damaged area, particularly In lhe deeper sections, Screw long, self tapping screws into the holes just enough for them to get a goodgrip in the metal , Now the dent can be pulled out by pulling on the protruding heads 01 the screws With locking pliers. 7 The next stage of repair is the removal of the paint from the damaged area and from an inch or so 01the surrounding metal. This is easily done with a wire brush or sandlllg disk in a drill motor, although it can be done just as effectively by hand with sandpaper. To complete the preparation lor filling , score the surface of the bare metal with a screwdriver or the tang 01 a lite ordrill small holes In the affected area. This will provide a good grip for the filler matena!. To complete the repair, see the Section on filling and painting.
Repair of rust holes or gashes 8 Remove aU paint from the affected area and from an inch or so of the surrounding metal USIl'lg a sanding disk or wife brush mounted in a dntl mo· tor. If these are not available. a lew sheets of sandpaper wilt do the lob Just as effectively, 9 With the paint removed, you Will be able to determine the severity of the corrosiOn and decide whether to replace the whole panel, If possible. or repair the affected area. New body panels are not as expensive as most people think and It is olten quicker to install a new panel than to repair large areas 01 rust 10 Removeall trim pieces from the aHected area except those which Will acl as a guide to the original shape 01 the damaged body, such as headlight shells. etc. Using metal SnipS or a hacksaw blade, remove all loose metal and any other metal that Is badly affected by rus\. Hammer the edges of the hole Inward to create a sligh t depreSSion for the filler malenal
11 Wire brush the aHected area to remove the powdery rust from the surface of the metal lIthe baCk ollhe rusted area IS accessible, treat it wllh rust inhibiting paint 12 Belore filling is done, block the hole In some way. This can be done with sheet metal riveted Of screwed into place, or by stutfil'lQ the hole with WIfe mesh. 13 Once the hole is blocked oft the aHected area can be filled and painted. See the fOllowing subsection on filling and painting.
Filling and painting 14 Many types at body hllers are available. but generally speaking, body repair kits which contain filler paste and a tube 01 resin hardener are best lor this type of repair work. A wide, lIexlble ptasllc or nylon applicator Will be necessary for Impal1ing a smooth and contoured lin ish to the surface of thefillermatenal Mlxupasmallamountoltilleronacleanpieceotwoodor cardboard (use the hardener sparingly). Follow the manufacturer's instructions on the package, otherwise the filler will set incorrectly. 15 Using the apphcator, apply the filler paste to the prepared area. Draw the applicator across the surface of the filler to achieve the desired contour and to level the hiler surface As soon as a contour that appro~imates Ihe original one ISachieved. stopwor!(ing the paste . It you con\lnue.the paste will begin to Slick to the applicator. Continue to add thm layers of paste at 20-mlnute mtervals until the level of the hiler is jusl above the surrounding metal 16 Once the filler has hardened, the excess can be removed With a body file . From then on. progressively finer grades of sandpaper should be used, stal1mg With a t 80ilflt paper and finishing With 6OO-grit wet-or·dry paper. Always wrap the sandpaper around a lIat rubber or wooden block, otherwise the surface 01 the filler Will not be completely flat. Dunng the sanding 01 the liller surface, the wet-or.ory paper should be penodlCally nnsed in water. This Will ensure that a very smooth finish is produced in the final stage 17 At thiS pomt, the repan area should be surrounded by a nng of bare metal, whICh In turn should be encircled by the finely leathered edge 01 good pain\. Rinse the repair area With clean water until all of the dust produced by the sanding operallon IS gone. 18 Spray the entire area With a light coat 01 pnmer. ThiS will reveal any imperfections 10 the surface 01 the filler. Repair the imperfections wrth fresh hiler paste or glaze liller and once more smooth the surface wllh sandpaper, Repeal this spray·and·repair procedure until you are satisfied that the surface of the filler and the leathered 90ge 01 the paint are perfect. Rinse the area With clean water and allow It to dry completely. 19 The repair area Is now ready for painting. Spray painting must be carried out In a warm. dry, windless and dust tree atmosphere. These conditions can be created II you have access to a large indoor war!( area, but if you are torced \0 work in the open, you will have to pick the day very carefully. 1I you are working Indoors. dousing the floor in the wor!(area With waler Will help senle the dust which would otherwise be in the alf. It the repair area IS confined to one body panel. mask off the surrounding panels. This Will help minimize the eHects of a shght mismatch In paint color. Trim pieces such as chrome strips. door handles. etc. will also need to be masked off Of removed. Use masking tape and several thicknesses 01 newspaper lor the masklng operallons. 20 Betore spraying, shake the pamt can thoroughly. then spray a tesl area until the spray painting technique IS mastered. Coverthe repair area With a thick coat of primer The thickness should be built up uSlf"lg several thin layers of primer ralher than one thick one. USlflg 6OO'9nt wet-or-dfy sandpaper, rubdown the surface 01 the pnmer unlil lt IS very smooth. While doing this, the work area should be thoroughly rinsed with waler and the wet-or-dry sandpaper penodlCally nnsed as well. Allow the primer to dry before spraYing additional coats. 21 Spray on the top coat , again building up the thickness by USing severallayers 01 pamt. Begin spraying In the center of the repair area and then, using a Circular motion, wor!( oulward unblthe whole repair area and aboul two Inches 01 the surrounding onglOal paint is covered, Remove all mask· 109 matefialtOto t 5 minutes alterspraylng on thelinal coat of paint. Allow the new paint at least two weeks to harden, then use a very fine rubblOg compound to bend the edges of the new paint 1010 the existing paint. Finally. apply a coat 01 wax
Chapter 11 6
Body repair - major damage
Malor damage must be repaired by an auto body shop speclhcally eqUipped to perform unlbody repairs These shops have the specialized equlpmenl leQUlfed to do the Job properly If the damage IS extenSive. Ihe body must be checked 101 proper 2 ahgnment or Ihe vehICles handhng charactenShCS may be adversely af· fected and other components may wear a1 an accelerated rate 3 Due to Ihe lacllha! all of the major body componen ts (hood, lenders.
etc,) are separate and replaceable units. any seriously damaged components should be replaced rather than repaired Sometimes Ihe components can be found In a wrecking yard lha\ speciali zes IS used vehICle components olten al a conSiderable savings over Ihe cost 01 new parts
7
Body
\,
11 - 5
3 Place cioths or pads al the rear corners of the hood to prevent damage during removal (see Illustration). 4 Remove the hinge assembly-to·hood mounting bolts (see llIustralion) 5 Remove the hood 6 Installation is the reverse of removal 7 The hood can be adjusted fore-and ·aft and slde-to-sldeby looSening the hood-to·hlnge bolts at each hinge Repesltoothe hood and lighten the bolts 8 To raise or lower Ihe rearol the hood, loosen the hlnge-to·body boilS. Raise or lower the hinge as necessary to make Ihe hood fl ush With the sur· rounding panels. Then tighten the hinge-to-body bolls
Hinges Bod locks - maintenance
Once every 3,000 miles. or every three months. the hinges and latch assemblies on the doors. hood and trunk should be given a lew drops 01 hght ollar lock lubricant The door latch strikers should also be lubricated With a thin coat of grease to reduce wear and ensure Iree movement Lu· bflcate the door and trunk locks With spray·on grapllite lubricant
8
Hood - removal , InSlaliation and adjustment
Refer to illustrations 8.3 and 8 4 Note : The hood IS heavy and somewhal awkward /0 remove and mSlallaf least two people should perform thiS procedure I Open the hood 2 Scnbeorpamtahgnmentma.rksaroundtheboitheadstoensureproper alignment on reinstallation
8.3
Pad the hood 10 protect the windshield when lifting the hood from the vehicle
""
11
". 8.4
Hood hinges and latch (typical)
11 - 6
Chapter 11
Body
NUT _
Rf'NfOlOCEMENT ASS" _
CIIIHIOl'I"'IOC; ~.NH "SSY -
"""
M
w .. s~["
..... V._
R I V[T
""'LaASSY 01''''''''' _ ~"' NEL
~,w
•
SCRf w _
" ' N_m
1. .. n ·LU,
!CII!w
~
, ' -_ _. . . .
9.28
9
Grille opening panel. Ironl lender and
3
front bumper - removal and Inslallation
sUpPOrt.
Refer
1 2
Grille opening panel - early models
to illustrations 9.2a, 9.2b. 9,4 and 9.5
Disconnecllhe negative cable from Ihe banery. Remove the grille opening panel (see illustrations).
Detach Ihe radiator support brace from the front lender and radiator
4 Remove the fender fasteners (nuts. boilS and splash shield push pms) (see illustration) lift the fender olf 5 If bumper removal ,s necessary, remove Ihe bumper fasteners and take It ott (see Illustration) 6 Installation IS Ihe reverse 01 removal
Body
Chapter 11
11 - 7
8OI.T AND WASHER ASS'¥' • RI:U"O
.0'-'
EACH SIDE
I REQ"O EACH SlOE
FROHT BUMPER ISOlATOR AND
8fV,CKET ASS'¥' FRONT BUMPER ISOlATOR AND BRACI(£T
".,
VIEW ..
t~j~~~:::;:,,,!;::::
FRONT BUMPER
"'"
NUT AND RETAINeR
2 REO'O EA~ SlOE
NUT AND RET "'NER 1 REQ'O EACH SlOE
V ·NUT
1 REO'O EACH SlOE SCREW AND WASHER
".,
FAONT BUMPER ISOlATOR AND 8RACKET ASSY
I
""'" ON
""'
~~
•
R,t.()IATOR G RILLE _________________ lOW£RCORNER
AEINFOACEMENT
R.t.OIATOR GRillE oPENING PANEL REINFOACEMENT ASSV
".,
lGOAI
9.2b
Grille opening panel -Ialer models (standard model shown ; GT similar)
11 -8
Chapter 11 U·NUT
Body SCREW AND
SCREW AND WASHER
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SCREW AND WASI-IER ASS'\'
RADIATOR SUPPORT
BRACE
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9.4
Front lender installation details
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9.5 Front bumper Install ation details - typical
Chapter 11 10
Trunk lid - removal , inslallalion and adjustment
ReIer to r/lus/ra/H)" 103 1 Open the trunk lid 2 Scnbe or pamt alignment marks around the trunk lid hinge boll
Body
11 - 9
7 Toadjuslthetronlot the hatch upordown , add or remove shims al the hlnge·to·rool panel 8 To adjust thsbouom 01 the hatch up ordown. screw the bumpers In Of out (see Illustration 11 ,3),
flanges 3 Remove the hinge bolts (see IIluslratlon) and hft all Ihe trunk lid 4 Installation is Ihe reverse 01 removal 5 The trunk lid can be adjusted lore-and-ah and from slde- \O-Slde The up-and·down adjustment IS made by loosenlrlg the hlnge -Io-body bolts
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2AEQ'D
and raising or Iowenng the tfunk lid
6
The tfunk lid should be adjusted lor an even and parallel IiI m Ihe
opening II should also be adjusted up-and·down and lor a !lush l it With the surrounding panels Care should be laken nOl lOdistort or mar Ihe trunk ltd Of surround'ng body panels
11
Rear hatch - removal , lnstallation and adjustment
Refer /0 Illustration 11 .3 1 Open Ihe rear hatch 2 Scnbe alignment marks around the hlnge-to-root panel auachlng bolts 3 Have an assistant support the rear hatch, then detach the tilt struts trom the lid by poppmg them olf the ballstud retainers With a screwdnver (see illustration) 4 Unbolt the hinges from the root panel and 11ft the hatch olf 5 Installation IS the reverse ot removal 6 To adjust the hatch slde·lo,slde or fore·and-alt, loosen the hinge·to· roo f boilS Make the adjustment, then lighten the bolts
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• 10.3
Trunk lid and hinges - two door models
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11 ,3
Rear hatch and related components - three-door models
LY
......
11 -10 12
Rear bumper - removal and Installalion
14
Refer /0 Illus/ralion 12.1 1 Remove the bumper cover l asleners and detach the cover from the bumper (see illustration). 2 Unbolt the bumper from the isolator and lift the bumper off. 3 To install, place the bumper m position and allach ilia the Isolator. Insialithe bumper cover
13
Body
Chapter 11
Door trim panel - removal and installation
Refer to illustration 13. / 1 On models with manual windows. remove the screw from the center of the willdow crank arm and remove the window crank (see illustration). 2 Disconnect the manual mirror knob (If equipped) by unscrewing the
Door and lock mechanism - removal , installation and adjustment
Refer /0 iIIustra/ions 14.3 and 14.4 The door hinges are welded to the door and bolted to the body. For this reason. all door adjustment IS done at the hinge·to -body bolts. 2 Open the door. Place thick padding on top of a Jack. then place the jack beneath the door to support It. 3 Remove the hinge·to·body bolts (see illustration) and take the door off. 4 To remove the lock mechanism, remove the tr im panel (see Sec· tion t 3) and reler to the accompanying illustration. S Installation is the reverse of remova l. Loosen the hlnge·to·body bolts to adjust the door, then tighten the bolts.
cone-shaped sleeve surrounding the control knob. Remove the mirrortrlm panel. :3 Removethetrim plate benea th the inSide doorlalch by lifting the latch and remOVing the screw. 4 Pry the trim plugs from the armrest. Remove the armrest reta ining screws Disconnect the armrest electrical connector (if eqUipped) and take the armrest off the door. Pull It forward until it disengages from the lock button 5 Remove the speaker grille screw (if equipped). 6 USing a special tool (available at many auto parts stores) or a putty ~nlfe. carefully pry between the trim panel and the door to separate the tr im chps tram the door. 7 Lift the trim panel to unhook ItS top edge Irom the door, then take the trim panel out. a InstallallOn IS the reverse of removal. Install the retain ing clips In the trim panel belore installing the trim panel on the door.
15
Center console - removal and installation
Early models Refer to Illustration 15. 1 1 Pry up the Iront edge of the shift lever tnm plate. then lift the plate out (see Illustration). 2 Remove the console panel trim plate and ashtray. 3 Working through the ashtray opening. remove the two screws that secure the console to the floor. 4 Open the console storage compartment and remove the lour screws secuflng the console to the floor. 5 Unplug the console el ectrical connectors and hit the console ou t. 6 Installation IS the reverse of removal.
• NUT ANa RETAINER A SSY. -
BOLT ANO
ISOLATOR
ANa IRACKIH
INSULATOR
eUMf'ER
ASSY. _
SCREW ANO _ _ _ _ _ _ _ _ _ _ WASHER _
12.1
~.
Rear bumper and cover assembly installation details
Ch apter 11 ~" NEl
Body
11 -11
.t.SSv
13.1
Door trim components - typical
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IIOll ... ' ''OOUCTION Hli'IKIl '1"" ITn,CAI,. · IJI'!'EII. LOWI!II "INOU. Dflill. T.. IIOVGH HOI.E ,II TOI' HINGE "'" ~ TO IAt .... riM IN TWO"fCn fOOl "."OVAl. 01'11111 OUT lowtll HINGE " .. AND "'TA'N 'OI'IlIf~NST"lL" T'OOI
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14.3 Door hinge components
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11 -12
Chapter 11
Body ADO .0.$$'1'
LINK IlSSV.
ReTAINER
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14.4
Door lock mech anlsm . - "p'Ical
PANEL ASSEM8L Y
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II'IACKET
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CONSOLE ASSEMSLY
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SCI'IEW
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BRACKET _
15.1 Center console
exploded view I early models)
BODY
Chapter 11
utermodels
11 -13
Remove one oltha quarler armrests (if equipped). Remove the seatback lower retaining screws, then lift the sealbadt up and out. 9 Installation is the reverse 01 removal. 7
ReftJ,toillustrstiol"ll5, 14 7 II equipped with a center BlTTlresl, pry out !he armrest bolt access covers at the rear of the console. Unbolt the armrest and lake it out. S Pry 001 the shift lever trim panel. II equipped with manuallransmission, remove the shift knob, then slide the trim panel and shift boot off the shift lever. 9 Sellhe parking brake 10 positioo the lever out of the way. Remove the lour screws thai secure the top panel, Iifllne panel and disconnect the
electrical connectors. 10 Carelully pry out the front upper trim panel by Inserting a small screwdrtver into ltIe two notches at the bottom. 11 II the vehicle doesn'1 have a radio , pry the radio opening cover panel out 01' the opening. 12 If the vehICle has a radio , remove it (see Chapter 12). t 3 Open the glove compartment door. II the vehicle has a remote fuel fill· er SWitch, detach it. Lower the glove compartment, then remove two screws thaI secure the console to the instrument panel. 14 Remove the lour screws thaI secure the console to its bracket, then remove the console from the vehicle (... lIIuatratlon). 15 Installation is the reverse of removal.
111
Body
Seata - remova' and inatallation
Front seats Refer to Hfustration 16.1 1 Remove the seat track retaining bolts and nuts, disconnect any eleclricaJ or other conneclors and lift the seat and track assembly from the vehicle (... illustration). 2 Installation is the reverse of removal. TIghten Ihe retaining nuts and bolts securely.
Conventional rear seats (early models) 3 Early models - remove the screws that secure the seat cushion to the Hoor, then 11ft the seat cushion oul. lift the seatback up and out. 4 5 Installation Is the reverse of removal.
Conventlonsl resr sests (later models) 6 Kneel on the seat cushion to push itdownward, then push it rearward to unhook it from its supports. lift the cushion out.
8
Fold~own resr sests 10 Fold the seat down. then carelully pry out fIVe push pins that secure the carpal to the seat back. 11 Remove the three screws thaI secure the folding arm to the seat back. Slide the seal outboard, off its center pivot and take it out. 12 Installation is the reverse of removal.
17
Instrument panm - removal and InawllaUon
RefIJr to iflustration 17.4 1 Disconnect the cable from \he negative terminal of the battery. 2 On early models, remove the instrument panel pad from the top of \he Instrument panel. 3 On later models. remove the lloor console (see Section 15). 4 Remove the steering column trim shroocls and covers (... lIlualralion). 5 Remove the steering column nuts and carefully lower and suppol1 the steering column. On early models, reach between the steering column and instrument panel and Iiflthe selector cable oft the shifllever. Remove the cable clamp Irom the steering column tube. 6 Remove the screws and/or nuts attaching the instrument panella the brake pedal suppol1 and to any braces below the radio orglove compart· ment. 7 On later models, r&mOVe!he defroster grille and the speaker grilles. 8 Remove the attaching screws at each end of the instrumenl panel. 9 Remove the screws along the top edoe 01 the cowl and supporl the Inslrument panel. Note: On 88rly mocIels, it will be flBCfIssary to USlJ an angle Phillips screwdriver to rBmove tfNJ top scrows. 10 Pull the instrument panel to !he rear and disconnect the speedometer cable and any electrical connectors. vacuum lines. or control cables that are attached to the instrument panet. Note: On later models it may be fI&C. 8SS8ry to disconnect ttI6 electrical conl16CtOls from ttI6 main wiring har· ness uncler the hood, thBn push ttI6 wiring harness through the grommet in
th8 firowall to create some slack. • 11 Remove the instrument panel. If you're replacing the instrument panel, tfanster all components, wiring and hardware to the new panel. 12 Installation Is the reverse of removal .
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11
15.14 Center console - exploded view (later models)
11-14 18.1
Chapter 11 Body
Front . .at and track installation - exploded vMtW CUS" 'ON itoSU WI LY
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17.4
Instrument panel· exploded view (typical)
Chapter 12
Chassis electrical system
Conlents Bulb replacement Circuil breakers - general mlo/mallon Connectors - gene /allolo/matlon Electrical troubleshooting - generalmlormallon Fuses - general mformatlon Fusible links - generalmlo/matlon General lnlo/mallcn Hazarclilurn Signaillashers - replaeemen! Headhghts - removal and Inslallallon Headlight SWitch - replacement
14
6 3 2 4
5 11
'3
Ignition key lock cylinder - replacemen t Ignition SWitch - replacement Instrument cluster - removal and installation RadiO - removal and Installation Turn Slgnallhazard flasheri dlmmer (mulu -functlon ) SWitch - replacement . Windshield wiper 'washer SWitch and motor - removal and InstallatIOn Wiring diagrams and color codes - genelallnformatlon
"
Generallolo/mation Warning : To prevent alec/fica/shorts. fifes and inJury. always disconnect Ihe cable from the negative termmal of Ihe battery before checking. repa'" Ing or replacing eloc/f/cal components The chassIs eleclflcal system ollhls vehICle IS a 12-..,01t. negatIVe ground type. Power lor Ihe lights and all electrICal accessories IS supplied by a lead/acid-type bauery whICh IS charged by the alternator. This chapter covers repair and servICe procedures lor vanous chassIs (non-engine related ) electncal components. For Inlormatlon regarding the engine electrical system components (battery. al ternator. distributor and starter motor). see Chapter 5
2
9 8 16
15
,
,. "
Electrical troubleshooUng - generallnformaUon
A typical electncal circuli consists 01 an electrical component. any sWitches. relays. motors. fuses. fUSible links or CirCUit breakers. etc _re o lated to that component and the wiring and connectors that link the compo· nents to both the battery and Ihe chaSSIS. To help you pmpomt an electncal Circuit prOOlem. Wlnng diagrams are InctUded at the end 01 thiS book Belore tackling any troublesome electrical CIrCUit. first study the appro· pilate Wifing diagrams toget a complete understanding 01 what makes up thaI IndiVidual CircUit. Trouble spots. for Instance. can often be Isolated by nollng If other components related to that CirCUli are routed through the same fuse and ground connections.
12
12 - 2
Chapter 12
Chassis electrical system
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THI! LOCItIHQ u,. ANO TWIST. GIUoP THE LOCKING AFIE ON B01H W!ftfS AND I'UlL UNn. T" LOCI(IItG TAlI SIDES OF THE CI:JoNNECTOR • ON lHl! RA ..... ~ THE CONNltlOll
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"' 3.1
Some ot the various Iypes 01lnll08 connectors used on Ihese models
Electflcal problems usually stem from Simple causes such as loose or
corrodedconneclors, a blown luse, a melted fusible link Of a bad relay VI sually inspect the condition of aliluses, wires and connectors In a problem CirCUit before troubleshooting It
The baSIC lools needed lor electrical troubleshooting Include a CirCUit lesler. a high Impedance (10K-ohm) digital voltmeter, a contlnUily lester and a JUmper W1re With an inline Circuli breaker fOf bypaSSing electrical components Belora attempting 10 locale or delfne a problem With electrical test Instruments. use the WIring diagrams to decide where to make the necessary connec1I()nS.
Voltage checks Perlorm a voltage check first when a ClrCUlt is nOI functioning properly. Connect one lead of a cirCU it tester to either the negallve battery terminal or a known good ground. Connect the other lead to a connector in the CirCUit being lested . prelerably neal est \0 the battery orluse. JI the bulbol the lesler hghtsup. voltage IS present. whICh means that the part of the CirCUit between the connector and the battery IS problem free . Continue Checking the rest 01 the CirCUit in the same lashlOn When you reach a pomt at whICh no vOltage IS present. the problem lies between thai pomt and the tastIest POint with voltage. Most of the time the problem can be traced to a loose connection. Note: Keep In mind thaI some CIfCUltS receive vol/age only when the Igmtlon key IS In the Accesso·
ry or Run POSIflOn.
Finding a short circuit One method 01 finding shorts In a ClrCUltlS 10 remove the l use and con· nect a lest ligh t or voltmeter In ItS place There should be no voltage presentln the CIfCUII. Move the wIfing harness from Side-to-side while watching the test light lIthe bulb goes on, there IS a short to ground somewhere In that area. probably where the insulatIOn has been rubbed through. The same test can be perlormed 00 each component In a Circuli. even a SWitch
Ground check Perlorm a ground test to check whether a component IS properly grounded. Disconnect the battery and connect one lead 01 a sell· powered test light. known as a conllnulty tester. 10 a known good ground. Connect Ihe other lead to the wl'e or ground connection being tested. lithe bulb goes on. the ground is good. II th e bulb does not go on. the ground is nOI
good
Continuity check A conltnulty check determines II there are any breaks
In
a clfcull- if
It IS conducllng electfiClly properly Wllh the CirCuit olf (no power In the CIf'
CUlt), a sell-powered conlinUity tester can be used to check the CIrCUit Connect the test leads 10 bolh ends 01 the CIrCUit, and If the test light C.1mes ontheclfCUlllS passing current properly 1/ the light doesn't come on, there IS a break somewhere In the CIrCUit The same procedure can be used to test a switch, by connecting the conlinUlty tester to the power In and power out sides 01 the SWItch. With the SWitch turned on, the test Itght should come on
Chapter 12
Chassis electrical system
12 -3
readily seen lor checkmg MiniatUrized fuses are used on later models These compact luses, With blade termInal desl{ln, allow fingertip removal and replacement. II an electrical component lalls, always check the luse IIrst. A blown luse is easdy identified through the clear plastIC body, With the fuse removed. Visually Inspect the element for eVidence 01 damage (see illustration), 11 a conlinUity check IS called lor, place the luse back In the fuse panel af"ld turn the IgOillon key to the ON poSition. Connect one lead of a l est ligh t to a good ground and connect the other lead to each 01 the luse's e~posed terminal ends The test light Should hght when connected 10 each end, II it doesn't light when connected to one of the terminal ends. the fuse IS open and should be replaced . Be sure to replace blown luses With the correct cype and amp rating Fuses 01 dlHerent ra\1ngs are phYSIcally interchangeable, but reptaong a fuse WIth one 01 a higher or lower value than specified IS not recom · mended EachelectncalClfCUlt needs a spectficamountolprotecllon. The amperage value 01 each luse IS usually molded Into the luse body. DIHer· ent colors are also used to denote luses 01 different amperage types . Cau tion : Always /Um off all elec/rical components and the igmllon SWitch before repfac!I1g a fuse. Never bypass a fuse wi/h pieces of metal or fori Fife anellor serious da mage 10 the electrical syslem could result. 11 the replacement fuse immediately tails, do not replace It again until the cause of the problem (a short cirCUit) IS isolated and correctftd
4.2 To tesllor a blown miniature luse, pull It out and inspect it lor an open (1), then, with the luse Installed and the ignition key turned to ON, probe each of the terminal ends (2) with a tesllighl
Finding an open circuit When diagnosing for possible open CirCUits IllS olten difhcult to locale them by sight because DxJdallon or terminal misalignment are hidden by Ihe connectors Merely wiggling a connector on a sensor or In Ihe wiring harness may correct the open circuit condition Remember this if an open circulI is Indicated when troubleshooting a CirCUli. Intermittent problems may also be caused by oxidized or loose connections. Electrical troubleshooting IS Simple If you keep In mind that all electrical CirCUits are basICally electrICity runnll'lg from the banery. through the Wires, SWitches, relays , luses and fusible hnks to each electrical component (Itght butb, motor, etc ) aOOthen to ground, Irom whICh IllS passed back 10 the battery. Any electrical problem IS an InterruptIOn In the flow 01 electriCity to and Irom Itle banery.
3
Connectors - general information
Refer /0 lIIustra/lon 3. 1 Always release Ihe lock lever(s) before attempting 10 unplug inhne type connectors, There are a vaflety o f lock lever conhguratlons (see illustration) , Although nothing more than a finger IS usually necessary to pry lock levers open. a small pockel screwdnver IS et/ectlve lor hard-to· release fevers . Once the lock levers are released , try 10 pull on the connectors themselves. nol the WIres. when unplugging two connector halves (Ihere are times , however. when thIS IS not poSSible - use QOOd judgment). It Is usually necessary 10 know which Side, male Of lema Ie, 01 the con· nector you 're checking . Male connectors are easily distinguished from fe· males by the shape 01 thelf Internal pinS When checking continuity or voltage With a ClfCUl' tester, insertion of Ihe lest probe InIOthe receptacle may open the 11111n9 to the connector and result In poor contact Instead, insert the l ast probe from the wife harness side 0 1 the connector (known as -backproblng ").
4
Fuses - general information
Refer 10 illus/rallOfl 4 2 The electrical CirCUitS are protected by a combinatIOn of fuses . fUSible ~nks and CirCUit breakers. The luse panel IS located under the left end of the dashboard. Two types 01 luses are used , depending on date 01 manufacture. Early models use a glass tube deSign where the metal elemenllnSlde can be
5
Fusible links - general inlormatlon
Some CirCUi tS are protected by fUSible links The links are used In Clf ' CUltS whICh are nol ordinanly fused . such as the Ignition CIrCUit Although the fUSible links appear to be a heaVier gauge than the wire they are protecting. the appearance IS due to the thick Insulation. All lus ible links are lour wire gauges smaller than the wife they are designed to protect. Fusible links cannot be repaired, but a new Itnk 01 the same size wife can be put In lIs place. The procedure is as follows ' a) Disconnect the negallve cable from the battery b) Disconnect the tusible link Irom the Wifing harness c) Cut the damaged fUSible link out of the Wifing Just behind the con · nectO!' dl Strip the IOsulatlOl'1 back approXimately 112-loch. e) POSition the connector on the new luslble link and cnmp It IOtO place I) Use rosIO core solder at each end 01 the new link to obtain a good solder JOint. g) Use plenty of electrical tape aroul'ld the soldered JOint. No wires should be e xposed. h) Connect the banery ground cable. Test the cirCUit lor proper opera· tlon
6
Circuit breakers - general inlormation
CIfCUII breakers prOlect accessorl8S such as power WIndows. power door locks, the WindshIeld WIpers. Windshield washer pump, interval WIPer. low washer Iluld. etc. CirCUit breakers are located In the luse bo)[, Reter to the luse panel gUide In your owner's manual lor the location of the ClfCUIt breakers used in your vehicle Because a circuit breaker resets Itself automatically. an electrical overload in a ClfCUlt breaker protected system Will cause the cirCUit to lail momentartly, then come back on. II the circuil does not come back on. check II Immediately a) Remove the CirCUIt breaker Irom the luse panel. b) USing an ohmmeler. verify that there IS continUity between bolh ter minals 01 the CirCUIt bfeaker. If there IS no continuity. replace the Clr· curt bfeak8f. c ) Install the old Of Il8W ClfCUlt breaker. lilt continues to cut out. a short CirCUit IS Indicated. Troubleshoot the appropnate CIrcuit (see the Wifing diagrams at the back of thiS book) or have the system checked by a prolessional mechanIC
12
12 - 4
Chapter 12
Chassis electrical system
8.5 An easy-out tool Is required to remove the two break-oil head bolts (arrows ) retainIng the Ignition switch to the lock cylinder housing
7
9.6 Wilh Ihe lock cylinder in Ihe Run position. pu sh in Ihe release lever wi1h a liS-Inch diameter punch 10 release the cylinder
Turn signal /hazard Ilasher/d lmmer (multl-Iunclion) switch - replacement
1 DIsconnect the negatIve cable Irom the banery 2 Remove the sleering column cover 3 Unplug the SWitch electrical connectors 4 Remove Ihe SWitch mounting screws and take the SWi tch off the sleel ing column. S Installalion IS the reverse 01 removal
8
Ign ition switch - replacement
Refer 10 illus/rallon 8.5
I
10
Disconnect the negauve cable from the banery Remove the S188f1ng column covers
2 3 Turn Ihe IQnlllOn key lock cylinder [0 the On (Run) poSItion. 4 Unplug the 'Onilion switch electocal connector 5 Use a IIS-mch drill bit to drill out the break-ort head bolls Ihal connect Ihe SWllch to Ihe lock cylinder hOUSing (see illustration) 6 Remove bolh bolts Wllh an easy -oullool 7 Disengage Ihe ignition SWitch 'rom Ihe acluator pin 8 Makesure the actuator pm 5101 In Ihe new ignitIOn SWIlch IS m Ihe Run poSition. Nole: A new replacement SWitch assembly will be sel In Ihe On (Run) poSlllon 9 Place Ihe new SWitch In position and Instalilhe break·oll head bolts Tighten Ihe boilS untillhe heads break 011 10 Pluglhe electrICal connector 1Il\0 Ihe SWitch 11 InsI3111he steerlng column cover 12 Connect the negallve battery cable
9
cylinder Depress Ihe punch while pulling out on the lock cylinder to remove II tram Ihe column housmg (see illustration) 7 Install the lock cylinder by lurnlng II to Ihe Run position and depressmg the retaining pin. Insert Ihe lock cylinder Into the lock cylinder housmg Make sure Ihe cylinder is completely sealed and aligned In Ihe Inl erlocklng washer belore turn ing Ihe key to the Of! poSition ThiS Will permit Ihe retammg pm to extend Inlo the hole S Turn the lock to ensule thai operallon IS COfrect m all poSitions 9 The remamder of installation IS the reverse 01 removal
Ignition key lock cylinder - replacement
Refer 10 lf/uslratlOn 9.6 1 Disconnect the neg. e cable from the battery II your vehicle is equl~d wilh a lilt column. remove the upper ex ten· 2 Slon shroud by snapping It loose Irom ItS retammg clip 3 Remove Ihe sleermg column cover 4 Locate the smgle key warning buzzer wire and disconnect II 5 Turn the IQflIllOn SWitch to the Run positIOn 6 Place a t ·S-Inch punch m the hole m Ihe casllng surrounding the lock
•
Windshield wiper/washer switch and motor - removat and inslallation
Wiper switch Refer 10 IIlustrallon 104 t Disconnect the negative cable tram the battery 2 Remove the steerlng column shroud 3 Unplug the SWitch electflcat conneclor Note: On some models_ It may be easier 10 remove the SWllch from the sleeting column flfSI. then unplug the elec/flcal connector. 4 Remove the SWitch mounllng screws and take th e SWltcholithesteerIng column (see Illustration) Nole: Laler models use Torx scre ws to se· cure Ihe SWitch Be sure to use the proper s,ze Torx drrver. 5 InstallaTion IS the reverSe at removal
Front wiper motor Refer 10 Illustrallon 10.7 6 Remove the cowl lop glille 7 Remove the link retamlng clip and detach the Wiper linkage from Ihe motor (see Illustrati on) 8 Remove the mOtor mounilng screws and take the molor ou t 9 Installailon IS Ihe reverse of removal Make sure the Wiper blades are In the parked position before attach ing the linkage 10 Ihe motor
Rear wiper motor Refer to ,IIUSlrallOfl 10.14 10 Raise the wiper arm 011 the rear WIndow Pull the slide latch and tift away the Wiper arm. 11 Remove Ihe pivot shalt nuts and washers
Chapter 12
•
Chassis electrical system
12 - 5
~----
ID~--- ""'. ,. NDWASHt R AS$t Me l Y
.....RNESS
.-
10.4
12 Aemove the 1,llgale trim screws and panel. 13 Disconnect the motor electrical connector. 14 Remove the screws that secure the motor and Imk.age to the litigate
Wiper switch installation - typical
(see Illustration). 15 RemOlle the motor and linkage as an assembly. 16 Installallon IS the reverse of removal.
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10.7
Wiper linkage connection details
" -....J 0· 10.14
12 J
Rear window wiper inslallation - typical
12 - 6
Chapter 12
Chassis electrical system
The lurn sign al lIasher IS loc ated in the front
a_posed side 01 the luse
CIRCUIT BREAKER
panel
HAZARD FI.ASJoIER
The hazard lIasher Is loca ted on the backSlde of the fuse panel direct ly behind the turn signal Ilasher.
11 .28
11
11.2b
Turn signal and hazard flashers on early models are boln mounted on the luse bOll
On laler models, only the lurn signallissher Is mounted on th e fuse box ...
INSTRVMENT PANEL REINFORCEMENT
Hazard/turn signal Ilashers - replacement
Referral/lus/rallons 112a. 1t.2band 1I .2c Note; No functional or operal/On check of the hazard lurn ssgnal flashers 1$ necessary. /f they slop working replace them 1 Delach the cable trom Ihe battery negallve terminal 2 The lurn Signal lias her IS located on the luse panel On some early models, Ihe hazard lIasher IS located opposite the turn signal flasher in the fuse paneL On tater models, the hazard lias her is located on the instrument panel brace above the glove comparlment (see Illustrations)
,
Turn signal flasher or fuse box-mounted hazard flasher
""",,0
It you art! replaCing a fuse box-mounted lIasher. unplug it 110m the fuse panel On some very early models. the flasher pulls straight out On
''''"''
3
later models, remove the Uasher by turning it 9O-degrees counterclock wise and pulling straight out 4 Install the new lIasher unit Be sure to hne up the metal contacts With the slots In the fuse panel and press the tlasherhrmly InlO place If you had to turn the lIasher to unlock It, lurn It 9O-degrees clockWise to lock It
Hazard flasher (mounted above glove box) 5 6
To remove the hazard lias her. pull 11 stralQht out of the Installation IS the reverse of removal
connector
l'.2c
... while the hazard flasher Is mounted on a brace above the glove comparlmenl
Pull the head lamp switch to Ihe On position Reach under the instrument panel and press the knob lelease bunon (see illustration) Remove the knob 4 Remove the SWitch retaining nut and take the sWitch out 5 Disconnect the electrical connector trom the sWitch 6 Installallon IS the reverse of removal 2
3
Later models 12
Headlight switch - replacement
Early models Refer /0 II/ustratlon 123 t
Disconnect the negailve battery cable from the battery
Refer /0 Illus/rallon 128
7 Disconnect the negatIVe battery cable flom the banery 8 Locatethe twO lock tabs that secure the SWItch. These are behind the SWitch levers. Use a small screwdriver to disengage the lock tabs (see illustration) 9 Pull the SWit ch out and disconnect the electrical connectors
Chapter 12
Chassis electrical system
12 -7
KNOB RELEASE BUTTON
PANEL
FOG lAMP
12.3
Headlight switch - early models
10 To Install , connect Ihe wiring connectors to Ihe SWitch Push It Into Ihe instrument panel untilihe lock tabs engage
13
Headlights - removal and installation Disconnecilhe negative battery cab le from the battery
Sealed beam headlights Refer /0 Illus/ralion 13.2
2 Remove the headlight bezel screws and remove the bezel (see iIIustraUon ) 3 Remove the headlight retaining screws. Pull the headlight out 01 the frame, disconnect the electrical connector and take the headlight out. Caution: Do nol disturb the (usually larger) adJustmgscrews or the headlight 81m Will be altered
4 InSlallahonlS the reverseo! removal. Havethe headlights adjusted by a properly equipped shop
Aero headfights Refer to IllustratIOn /3.7 Open the hood
5
12.8
Headlight switch -later models
6 Disconnect the electrical connector Irom the back of the bulb 7 Rotate !he retain ing ring about t /B-turn counlerclockwlse (Viewed from the rear ) and slide It 011 the base (see illustration) B Carefully pull the bulb straigh t out 01 the socket 9 Insert the bulb into the socket. Position the flat on the plastic base upward. 10 Align the socketlocatmg tabs With the grooves m the forward part of the plastic base. then push the socket firmly mto the base. Make sure the base mounting lIange contacts the socket I I Slide the retaining ring on. Turn It clockwise until It hits the stop 12 Connect the electflcalconnector. Test headlight operation . then close the hood. 13 Have headtight aim checked by a properly equipped shop
14
Bulb replacement
The lenses 01 many lights are held In place by screws. which makes It a simple procedure to gam access to the bulbs 2 On some lights the lenses are held in place by clips. The lenses can be removed either by unsnapping them or by usmg a small screwdriver to pry them off
BULB
RETAINIIIIG
"NO
12 PLASTIC
REFLECTOR 13.2
Removing the headlight bezel - early models
13.7
BASE
Aero headlight bulb components -later models
12-8
Chapter 12
Chassis electrical system
=
,,
'ANEL ,",SSEM e l'"
... ,EW,,"
1 ' -_ _ "",010 ~ECEIVEA
15.3
Radio Installation - typical
3 Severallypesol bulbs are used. Some are removed by pushing In and turning them counterclockwise . O1hers can simply be unchpped from the terminals or pulled straight oul 01 the socket. 4 To gain access to the Instrument panel lights, the Instrument cluster WIll have \0 be removed lirs!
6 Puillhe clusler the rest ot the way out and disconnect ilS wIring can· nectors 7 Apply a 3 t6-lflch diameter ball of SilICone damping grease to the dn... e hote In the speedometer head. 8 The remaJOder 01 InSlallalion IS the re ... erse 01 remo ... al
15
17
Radio - removal and installation
1979 through 1986 models Refer 10 II/ustrallon 153 1 Disconnect the negative battery cable from the battery 2 Disconnectihe power. speaker ar.d antenna wires from the radiO 3 Pull 011 the knobs and discs. then remove the radiO retaining nuts (If eqUipped) (see illustration)
4 5 6 7
Remove Itle upper support screws (If eqUipped) Remove the rear support nul or screw Take the radiO oul Installation is the reverse 01removal
1987 and later models 8 RadIO remo ... al reqUifes special tools and should be left to a properly eqUipped shop.
16 t
Instrument cluster - removal and installallon
Disconnect the negati... e ba1l6ry cable Irom the battery On 1988 and la ter models. remo ... e the SWitch assemblies tram either Side al the instrument panel (see Section 12). 3 Remo...e the screws secUring the trim panel to the cluster. Remo ...e the tnm panel Remo ... e tour clusler relaJOlflg screws 4 5 Pull the cluster out Reach behind It and disconnect the speedometer cabte .
2
Wiring diagrams and color codes - general Information
Slflce It Isn t poSSible to Include all wIOng diagrams torevery year co ...· ered by thiS manuaJ. l he lollowlng diagrams are those that are tYPIcal and most commonly needed. Prior to trouble shOaling any CirCUitS. check the fuse and Circuit break· ers (if eqUIPped) to make sure they're In good condition . Make sure Ihe banery IS properly charged and check the cable connectIOns (see Chap ler I ) When checklflg a CIrcuit. make sure thai all connectors are clean . With no broken or loose terminals. When unplugging a connector, do not pu ll on the wires Pull only on the connector houslflgs the msel... es.
Color codes Wire colors In Wifing diagrams are Idenlilied by one or two-character alphabetical codes. The follOWing list tells the color IIldlcated by each of these codes B .. Black BR .. Brown DB .. Dark blue OG .. Dark green GY .. Gray LB Light blue LG .. Lighf green N .. Natural O . Orange B
P .. Purple
PK .. Plilk A _ Red T . Tan W .. White Y .. Yellow (H) .. Hash' (D) .. Dot'
Nole: The presence 01 a Iracer on rhe WIre ISIndICated by a secondarycoJ· or foflowecl by an -H" for hash or -0 - for dot A s/rtpe IS understood If no letter follows
Chapter 12 Wi ring color key Primary colo.s Black
Brown
"" R"
Pink Orange Yellow Dark green LiJ:Ih\
green
Dark blue Light blue Purple
Diag
Component
10 07 9 C1<
Glove
R
Heater backli t!! warning
Pk
inct
6
0
Heater contrOls illuminat ion Hi beam indicator
C'
09 Lg Ob Lb
liP ash 'ray illumination
B 5 B
y
p
G,
White Hash
W
Do'
Engine compartment
T
Gray
Strope IS understood and has no color key Component Alternator 40Amp 60 Amp 70Amp Amme!er Amplifier Speed control Armature luggage camp door latch Backlite Heated BaHery 12 Vall 12 Volt Capacitor RadiO ignition interierence Choke Electric Radio receiver suppression Clock Coil Ignition Control AM Radio or speaker volume Distributor 2.3 Liter breake/less 2.8 Liter breakerless 8 Cy l 302 breakerless FlaSher Emergency warning Turn Signal Gauge Fuel Water temp Governor W / S wiper Hea!er Engine block Horn High pitch lamp AlC & Heater controls ilium Clock illumination Cluster illumination Cluster illumination Cluster illumination (51 Console ash tray illumination Dome Dome Dome/map switch Dome/map switch Dual brake warning indicator
Component
"B.
IHI IDI Dieg
2 2 2 2
A' BJ
"815
"
C5
9
E16
6
'16
,
2 2
BJ
"FJ
2 J 9
DJ CI5
2
DB
B5
7
D'
2 2 2
D5 F5 E5
5 5
C7
J J
812
B6 B2
" '" 10 Dl 5
EJ
B B B B B
"
8 9 9 9 9
B6
J
B5 B7
BB
"
D9 DIO EJ
Dll BJ
12 -9
Chassis etectrical system
bo~
5wil(;h
LH Backup LH Front side marker LH Hi beam head LH . License LH Lo beam head L.H . Front park & T/ S L,H . SlOp and park LH SlOp and park L.H Tum mdicator luggage compar tment PRNDl illuminationlfloorl RH Backup R.H Front s;de mar ker RH Hi beam head RH License RH lo beam head R.H Front park 1\0 TIS R.H . Stop and park R.H S!OP and pa rk RH Turn indicator Seat belts warning indica tor Stereo indlca!or lighter Cigal Cigar Modulator Breakerless ignition Motor Blower Blowe, Fuel pump Sta rl er W/S Washer pump W/S Washer pump W /S Wiper W /S Wiper Panel Fuse Receiver AM Radio AM Radio AM with stereo tape radio AM/FM Monaural radio AM/FM Monaural radio AM!FM/ M PX Radio AM! FM/M PX Radio Cassal1e AM/ FM!MPX Radio Stereo tapa/AM/FMf MPX Rad>o Stereo tapa/AMfFM/MPX Radio Regulator Alternator Ins!flJmen! cluster voltage Relay Back window heat cOntrol Carburetor choke control Electric fuel pump Engine cooling fan mo tor Engine electronic con t,ol Exh gas recire sol vac valve Light sensor Starter mO tor Starter mo tor Resistor Blower motor
Blower motor
Sender Fuel gauge
Wale. lemperature mdici110r 3 Servo 11 Speed cont,ol
01
Solenoid Ale CLutch Ale Clutch Ale Clutch
F4
F4
conI
B J
FJ '"
C6
Ale Cluu;h
Dl0 Dll
E2
D16 DI5 C7 Dl' D13 E6
FB F7 DI3 AB
'D D' lD D5
, 2
B B
, 2
DI5 D12 C9 811 DB B6
eo
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"
BJ
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7
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B2
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7
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2
E1
J
C5
,,6 ,, ,, ,
Cl'
2
"
B6
B
D9
C7
D12 CI5 E15 BJ
815
Wiring diagram key -1979 and 1980 models
F5
J
6
5 5 6 6 5 9 B 6 5 5 6 5 5 6 6 5
E1J D2
F1
00"'
D9 D1D
E5 F5
'" f12
EJ
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'"
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6
7
J
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3
0111 9
B
D13 Dl' D16
Carb thrOllle em'SSI(H'l
Carb th.onle emission Carburetor floa! bowl vent Edlaust gas rec"c vac valve Speaker R.H . Front radio receiver R.H Front radio receiver Radio receiver Radio receiver Radio receiver RadiO receiver Radio receiver rear seal Radio leceiver rear seat Radio receiver rear seat Radio receiver rear seat RadiO receiver rea' seal Radio receiver rear seat SWitch AlC Mode Back window heater control Backup lamp Backup lamp Carb Idllt thermactor air pump Cou!1esy lamp Couflesy lamp Dual brake warning Fan mota, Fan motor Fue l pump Gear shift neutral Gear shift neutral Headlamp l lQnition Ignition Ignition key warnmg LH . Power door lock luggage camp door lock Oil pressure Oil pressure Oil pressure Park brake signal lamp R.H Power door lOCk Rear windOW washer Rear water courtesy lamp Seat belt buckle Seat belt warning indicator Seat belt warning indica tor Speed control Stoplamp Stop lamp Turn and emergency signal W/SNo/ Washer W ! SIW Washer AlC Control Tachometer Thermostat AlC EvaporalOf Valve Dis tribu10r modula!or
,
7 7 7 7 7 7
7 7 7 7
"DB C16 E1 D1 D6 010 F2
"F6 Fe
7
E10 E16
B
81J A13
7
6
6 6
BJ
9 9 J
B5 B7
, "D2 ,, ,
EJ
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J
BB E5
6
81
9 1 J
B2
9
6 9 2 2
, J 6 11
9 J J 9
" 5" 5
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"
I
D9 A16 '16 '16 E7
DI5 DI3 C1D CIJ
DI< BI< D5 D2 B5
A5 C5
811 Bl' Dll DI2 E1J
EJ
12
12 - 10
Chapter 12
Chassis electrical system
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.
Chapter 12
r
~i[~ ~[j r"~
Chassis electrical system
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Charging, starting and Ignition systems (2) -1980 models (1979 similar)
12 -12
Chapter 12
Chassis electrical system
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" Instrument panel and gauges (3) - 1980 models (1979 similar)
"
Chassis electrical system
Ch apter 12
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12 - 27
Chassis electrical system
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12
Chapter 12
12 - 28
Chassis electrical system
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t ..... " . " . . .. . ., , ' " • '"
Chapter 12
Chassis electrical system
12 - 29
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·
12
12 - 30
Chapter 12
. ...... "''' •• ,, ........... , " '1'
Chassis electrical system
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Chapter 12
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IHOT IN ITAItT 011 MJNIIMOT AT AU fillIES
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12 - 31
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J
11
12 - 32
Chapter 12
Chassis electrical system
[ HOT AT All TIMES
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INERTIA SWITCH oPENS ON IMPACT
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81<
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ELECTRIC
57
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5127
1 51
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tAll OTHERS)
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a... TTERY TERMINAl. OF S TA.l'lTER RELAY
......:I1 ___ .L • ~
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I
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su FIELD TERW'''IAL
0AANG£iI. T BLUE
SLIP RINGS
Side-terminal alternator (ammeter system) - 1981111rougl1 1986 models
---l I I I I
I I
I I I I
Chapter 12
..
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12 - 33
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Chass,is electrical system
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Index A About this manual : 0-6 AccumlJlalor (air conditioning ). removal and installation: 3· 30 Air cleaner housing a:;sembly, remoyal and installation: 4-8 Air conditioning accumulator, removal and installation 3·30 compressor, removal and installation: 3·27 condenser, removal and Installation' 3-26 system check and maintenance. 3-26 generallnlormatlon: 3-4
Air condilioning system: 3-' through 30 Air liller hOUSing assembly. removal and Installation: 4-8 replacernal'll 1-29
Alignment, Irani end : 10· 16 Alternator brushes. removal and Installation' 5-7 removal and IOSlaliallon: 5·7 Antifreeze drammg and refi lling \-35 general mformatlon: 3·4 Automatic transmission : 78-1 through 8
diagnOSIS: 76·2 fluid, change: '-21 flUid and filter. change 1·21 fluid level. check : 1·16 gener;>1informallon: 7B-l removal and installation 7B-5 shill linkage adjustment· 78·4 lubrication 1-36 Throttle Valve (TV) linkage. inspection and adjustmen t: 78·2.4 Auxiliary shaft (lour-cylinder engine), removal , inspection and installation : 2A-7 Axle (rear), descrlplion and check : 8-11 Axle damper, removal and installation: 10-11 Axleshaft (rear) bearing replacement : 8-13 011 seal replacement. 8·12 removal and InstalialtOn: 8·11
B Back-up light bulb, replacement: 12-7 BaIlJo!nt, check and replacement : 10-7 Battery cables. check and replacement: 5-2 check and maintenance· 1-27 removal and InSlaliallon. 5·2 Battery jump starting: 0-15 Bearing, replacement , rear axle: 6-13
Bearing (clutch release), removal and Installation: 8-4 Bearing (main, engine), oil clearance check: 2E-25 Bearings, main and connecting rod , Inspection: 2E-22 Belt, timing (lour-cylinder engine), removal , Installation and adjustment: 2A-5 Belts (engine), check, adjustment and replacement : 1-23 Bleeding brake system: 9-19 clutch hydraulic system: 8·8 power steering system: 10-14 Block (engine) cleaning. 2E·19 hOning · 2E·20 Inspection: 2E·19 Blower motor (heater) circuIt. electrical testing: 3·13 replacemenl: 3·19.21.23 SWitch, re placement: 3-16 Body: 11-1 through 14 generalln formalion. 11-' maintenance: 11 -1 Body repair malor damage: 11-5 minor damage: 11·4 Booster (brake), Inspection, removal and Instatlatlon: 9-21 Booster battery (Jump) starting: 0-15 Boots, steering gear, replacement : 10-16 Brake booster. Inspection. removal and Installation: 9-21 cab les, removal and installation: 9-20 caliper. removal. overhaul and installation; 9·5 flUid bleeding : 9·19 level check: 1·13 type: 1·2 general inlormalion: 9-2 hoses and lines. inspection and replacement : 9-18 light bulb. replacement 12-7 light SWitch. removal. installation and adjustment: 9·22 lining thickness: 1·5 master cylinder. removal, overhaul and installation: 9-t4 pad thickness: 1·5 pads. replacemant: 9·3 parklr.g. adjustment: 9-19 shoes, Inspection and replacement: 9-1 0 system. check: 1-36 system bleedir.g: 9-19 wheel cylinder, removal, overhaul and instailation: 9-13 Brakes: 9-1 through 22 Break-in (engine): 2E-29 Brushes (alternator), removal and installation: 5-7 Bulb, replacement: 12-7 Bumper (front), removal and Installation : 11-6 Bumper (rear). removal and Installation: 11-10 Buying parts: 0-8
INO-2
Index
c Cable parking brake, removal and installation. 9·20 throttle, removal and Installation: 4·9 Caliper (brake). removal , overhaul and Installation : 9·5
Carnahan removal and installation (2.BL V6 engine): 2C-9 removal and instaliation (inline six-cylinder engine): 2B-7 removal and installation (Ve and J.eL V6 engines): 20- 18 Camahaft and followers (four-cyllnder engine), removal , Inspection and Installation : 2A-6 Camahaft cover (four-cyUnder engine). removal
and Inllallatlon: 2A-3 capacities: 1-2 Carburetor adjustments: '-48 choke, chectl.: '-47 diagnosis: 4·9 ollerhaul: 4·9 removal and Installation: 4-9
Carpets, maintenance: 11-' Catalytic converter: 6-15 Centra' Fuel Injection (CFI) system, component replacement: 4-12 Charging syslem alternator. removal and installation: 5·7 alternator brushes, removal and installation: 5·7 check: 5·6 generallntormation and precautions: 5·6 voltage regulator (extemal), removal and installation: 5-8 Chassla electrical system : 12-1 through 44 Ch. .slslubrlcatlon : 1·20 Chemicals and lubricants: ()"18 Choke (carburetor), check: 1-47 CIrcuit breakers, general Information : 12·3 Clutch components, removal and installatIOn: 8-2 descnphon and check: 8-2
lIuJCI level check: 1-13 type: 1-2 generallnlormation: 8-1 hydraulic system, bleeding: 8-8 linkage adjustment: 1-38 lubrication: t -38 master cylinder, removal and installation : 8-8 pedal, removal and installation: 8-8 release beating, removal and installalion: 8-4 set/-adJustlflg mechanism quadrant pawl replacement : 8·7 removal and inslallation: 8-6 slave cylinder, removal and InstallatIOn: 8-B star1erlCiutch interlock sWltch_ removal and installation: 8-8 Clutch and drlveline: 8-1 through 14 Clutch cable, removal and Installation : 8-5 Coli , Ignition, check and replacement: 5-4 Coil spring (Iront), removal and Installation : 1()"7 Coli spring (rear), removal and Installation: 10·11 Compres sion, cylinder, checking : 2E·l0 Compressor (air conditioning ), removal and Installation: 3-27 Condenser (air conditioning), removal and installation: 3-28 Connecting rods beating inspection: 2E-22 inspection: 2E-21 instatlatlOn and oil clearance check: 2E-28 removal: 2E-17 Connectors (electrical), general lnformallon : 12-3 Console, removal and Installation : 11 · 10
Control arms (front ), removal and installatio n : 10-8 Control assembly, heater, rem oval and Installation : 3-1 5 ConversIon lactors: ()"2O Converter (catalytic): 6-15 Coolant general inlormatlon: 3-4 level check: 1-13 recommended type : 1-2 reservoir. removal and installation' 3-9 temperature sending umt, check and replacement: 3-10 Cooling fan , check and replacement: 3-7, 8 Cooling system: 3-1 through 30 check: 1-34 coolant general lfllormatlon 3-4 generallnformabon: 3-4 servicing: 1·35 Core (heater), replacement : 3· 23, 25 Crankcase vent lilter, replacement : 1-30 Crankshaft Iront oil seal replacement (2.8L V6 englOe) : 2e·11 replacement (tour·cylinder engine): 2A·S leplacement (inline slx·cylinder englOe): 2B-9 replacement (V8 and 3.8L V6 englOes): 20·23 lflspection: 2E-21 InstallatIOn and main beanng Oil clearance check: 2E·25 rear all seal replacement (2 .BL V6 englOe): 2C· tl replacement (Iour·cylinder engine): 2A-14 replacement (Va and 3.8L V6 engines): 20·23 removal: 2E·19 Cylinder, front COl/er, removal and Installation (inllne slx-cyllnder engine) : 2B·6 Cylinder block cleaning: 2E-19 honing: 2E-20 Inspection: 2E-19 Cylinder compression check : 2E- tO Cylinder head cleaning and inspection: 2E·14 disassembly: 2E·13 reassembly' 2E-IS removal and installation (2.8L V6 engine): 2C-6 removal and installation (tour·cyllnder englOe): 2A·IO removal and installation (in!ine si~·cylinder engine): 2B·5 removal and installation (VS and 3.SL V6 englOes): 20·13 valves, servicing: 2E-16 Cylinder honing: 2E·20
o Dent repair maJOf damage: 11-5 minor damage: 11-4 Differential, lubricant Change: 1·16 level check: 1,16 Disc brake caliper. removal. overhaul and Installation 9-5 pads, replacement: 9-3 Distributor cap. check and replacement 1·43 removal and installatIOn: 5·4 Distributor rotor, check and repl acement : 1-43
Do.. removal and installation: 11 · 10 trim panel , removal and installation: \\·10
Index Door and lock mechanism, removal. in stail ation and adjustment: 11-1 0 Drlvebelt check, adjustment and replacement '-23
tenSion ' ·3 Orivellne: 8-1 through 14 genera1lntormatlon B 1 Drlveplsle removal and installation (28L V6 engine)' 2C·12 removal and InstallallOn (lour-cylinder engine) 2A 13 removal and InSIallal10n (mime slK·cyhnder engine)' 28·9 removal and Insta!iallon (Va and 3 8L V6 engines)' 20-24
Driveshatt, removal and inslallation: 8· ' 0 Dri vesh ah and u niver sal joints, desc riptio n and c heck : 8-9 Drum brake wheel c yl inder, rem oval, o verh aul and Inslallalion : 9-13
E EGR (Exhaust Gas Rec irculat ion) sys tem : 6-10 Electrical ClfCUl1 diagrams 12-8 connectors. general,nlormauon 12-3 system, general tnformallon 12-1 Uoubleshoollng_ general information. t2'1 Electrical system (chassi s): 12-1 thr ough 44 Electrical system s (engine): 5-11hrough 10 Efectronic Fuel Injection (EFI) sys tem, component replacem ent : 4-13, 16 Emergency battery jump starting : Emissions control systems: 6-1 Ihrough 15 generalintormation 6-1 Eng ine block cleaning 2E -19 Inspecllon 2E -19 coolant generallntOlma1lon 3-4 level check 1·13 coolanllype 1-2 cooling Ian. check and replacemenl 37.8 cylinder head removal and InstallatIOn (2,8L V6 engine): 2C·6 removal and installation (lour-cylinder engine): 2A'10 removal and InstaliallOn (inhne sl~-cylinder engine) 28·5 removal and Installation (V8 and 3 8L V6 engines). 20-13 dnvebelts, check adjustment and replacemenl. 1-23 Iront cover removal and installation (2.BL V6 engine): 2C·7 removal and InSlaUa1lon (Inllne sUf-cyllnder englne)- 28·6 removal and Installallon (VB and 3 8L V6 engines) 20·14 mount check and replacement 12.8L V6 engine) 2C·12 check and replacement (four cy linder engine): 2A-14 check and replacement (lnllne sl~·cy"nder engine): 28-9 check and replacement (VB and 3.8L V6 engines) 20·~4
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1 19 level check I 13 type 12 011 seal replacement (2 BL V6 engine): 2C·I \ replacement (tour·cyllnder engine) 2A·8 t3 replacement (Inllne Six-cylinder engine): 2B·9 replacement (Va and 3.8L V6 engines)' 20-23 overhaul: 2E·llhrough 30 disassembly sequence 2E· \ 3
INO-3
general InformatIOn 2E-l0 reassembly sequence 2E·23 overhaul alternatIves: 2E-Il overhaul general information' 2E-\0 rebUilding. alternatives 2E·ll removal. methods and precautions 2E·II removal and Installation: 2E·12 lune-up l · llhrough 55 Engine (2.8L V6) : 2e-l through 12 general Information 2C-2 repa" operatlOf1s poSSible With engine In vehicle' 2C·2 Engine (Iour-cylinder): 2A· ' through 14 general InlormahOfl 2A·2 repa" operahOfls poSSible WIth engine In vehICle 2A·2 Engine (Inline s ix-cylinder): 2B· l through 10 generallnformatlOfl- 28·2 repaH operations possible wllh engme in vehICle 2B-2 Engine (V8 and 3.SL V6): 20·1 through 24 general Information 20-4 repair opera1lons poSSible With engine In vehicle 20·4 Engine electrical systems : 5·1 through 10 general Information: 5·2 Engine emi ss ions control systems : 6-1 through 15 Engine luel and exhaust sy stem s: 4· 1 through 18 Exhaust, manllold removal and Installallon (2 ,BL V6 englOe): 2C·6 removal and IOstallatlon (Iour·cyllnder englOe): 2A·9 removal and InstallatIOn (VS and 3 BL V6 englnes)- 20·11 Exhaust Gas Rec irculation (EGR) system, general inlormation: 6· 10 Exhaust system: 4-\through 18 check ' ·35 generill information: 4·2 remova l and installation. 4-18 Exhaust, manllold, removal and Installation (Inline six·cylinder engine): 28·6 External Voltage Regulator (EVR), replacement : 5-8
F Fan, engine cooling , check and replacement : 3-7, 8 Fan belt, tension : 1·3 Fender (Iront), removal and installation : 11·6 Filter au tomatic transm iSSion. replacement 1·21 lueL replacement 1·33 Oil, change 1·19 Fluid automatIc 1fanSmlSSlon change t-21 checking l-t6 capacilles: t·2 level checks 1·13 manual transmiSSIOn, checking 1·15 power steering. checkmg 1· 15 Fluids and lubricants: t·2 Flywheel removal and Installation (2BL V6 engine): 2C-12 removal and installation (four·cyllnder engine) : 2A·13 removal and Installation (lnllne slx·cylinder englOe): 2B·9 removat and inslalla!lon (Va and 38L V6 engines): 20·24 Fronl coli spring, remov al and installalio n : 1()..7 Fron t cont rol arms, remov al and Installation : 10-8 Front cover (engine), remov al and Installation (2.8L V6 eng ine): 2C·7 Front end alignment, general inlormatlon: 10-16 Front lender, removal and installallon : 11"& Front spindle, removat and Installalion : 10·7
INO - 4 Front stabilizer bar, remol/sland In stallation : 1(H; Front wheel bear ing adjustment: '-40
check: 1-40 lubrication: 1-40 Fuel filtsr, replacement: '-33 pressure relief procedure: 4·2 pump check: 4·4 removal and installation: 4-7
system check: 1-32 genefsl lnlormatJOn: 4-2
lank cleaning and repalr: 4-7 removal and instailation: 4-8 Fuel Inlectlon system check: 4-11 component replacement: 4-16 component replacement (eFt): 4· 12 component replacement (EFf): 4- 13 component replacement (SEFI): 4· 13
general In/ormation: 4-' 0
Fuel sYltem: 4-1 through 18 lines and littings
dlscoonecting and reconoecting: 4-3 replacement: 4-3 Fu ses, general Information: 12-3
Fusible links, generallnlormation : 12·3
Index Hazard flasher switch, repl acement: 124 Head, cylinder removal and installation (2.8l V6 engine)' 2C·6 removal and InStallatIOn (foor-cylinder er'IQlne): 2A-tO removal and installation (Inhne Sll(-cyhnder engine): 26-5 removal and installation (V8 and 3.8l V6 engines): 20-13 Head (cylinder) cleaning and Inspection: 2E -14 disassembly: 2E-13 reassembly : 2E-16 Headlight removal and installation: 12-7 switch, replacement. 12-6 Heater blower motor, replacement 3-19, 21 , 23 blower molor circoil , eleclncal teslmg 3-13 blower motor sWitch replacement: 3-16 control assembly, removal and installation: 3-15 control cables adjustment: 3-16 replacement: 3-18 core, replacement: 3-23, 25 generalln!ormation: 3- 13 Heating aystem: 3-1 through 30 general mlormahon: 3-4 Hinges, maintenance: 11 -5 Honing, cylinder: 2E-20
Hood adjustment: 11-5 removal and installation; 11 -5 Ho ses brake, inspection and replacement 9· 16 check and replacement: 1-22 Hydraulic clutch system, bleeding: 8·8
G Gau ge cl u ater, removal and Inatallatlon: 12-8 Gear (atMr ing), removal and In atallatlon: 1~13 Generallnf onnatlon automatic transmission: 7B-l body ' bmkes: 9-2 chargmg system: 5-6 clutch and driveline: 6-1 coollllQ , heating and air conditioning systems: 3-4 eleclrical connectors: 12-3 eleclfical system: 12-1 emissions control systems: 6-1 engine electrical systems: 5-1 engine overhaul: 2E-1O ruelln}ection system: 4-10 ruel system: 4-2 heater: 3-13 ignition system: 5-2 manual transmlOn: 7A-l starting system: 5-8 steering and suspension systems: 10-2 tune-up: 1-13 wheels and tires: 10-16 Gen erat or (alternat o r), removal and inatallatl on: 5-7 Grille opening panel, removal and inst allation: 11-6
11 -'
H Hand brake, ad ju stment: 9-19 Hatc h (rear), remova l, installation and adjuatment: 11·9 Hazard , fla ahers, check and replacement : 12-6
ldentltlcatlon numbenl, veh ic le: ~7 Idle apeed, check and adjustme nt: 1-48 Ignition coil, check and replacement ' 5-4 distributor, removal and installation: 5-4 key lock cylinder, replacement 12-4 module, replacement: 5-5 system check: 5-3 general information: 5-2 timing , check and adjustment ' 5-4 Ignition awltch, repl acement : 12-4 Initial atart-up and break-In att er overh aul: 2E-29 Inlection (fuel) system check: 4-" component replacement: 4-16 component replacement (CFI): 4· 12 component replacement (EFI): 4· 13 component replacement (SEFI) . 4-13 general in/ormation: 4-10 Inl trument cluster, removal and In at allat lon : 12-8 Inatrument panel- removal and inat allati on: 11-13 Intake manifold removal and installatIOn (2.8l V6 engtne) 2C-5 removal and installatIOn (four-cylinder englOe): 2A-9 removal and installation (in line Sll(-cylinder engine): 28-6 removal and installation (V8 and 3 .6l V6 engines): 20-9 Intermediate shaft (atMring), removal and inatallati on: 1 ~13 Introduction to the Ford Muatang!Mercury Capri: 0-6
•
IND-5
Index
J
N
Jacking: 0-16 Jump starting : 0-15
Neutral start switch, replacement and adjustment : 78-6
o
K
011 change: 1-19 liller. change: 1-19 level check: 1- 13
Key lock cylinde r (ignillon), replacement : 12· 4
pan
L UHer s (valve) removal and installation (2. 8L V6 engine): 2C-8 removal and installation (VB and 3.8l V6 engines): 20· I 7 removal , inspection and installation {inline • six-cylinder engme)" 2B-7 Lining s (brake)
check: ' ·36 inspection and replacement 9-1a Lock (Ignil ion key). replacement : 12-4 lock mechanism (door), removal and Inslallatlon: 11-10
locks, maintenance: 11-5 Lubricants : 0-18 lubricants and fluids : 1-2
Lubrication, chassis: ' ·20
M Main and connecting rod bearings, Inspection: 2E-22 Main bearing, 011 clearance, check : 2E-25 Ma in bearing 011 seal, InSlallatlon : 2E-27 Maintenance
introduction:
'-5
schedule: 1-6 techmques: 0-8 Manifold
removal and installation (2_8L V6 engine): 2C-l0 removal and Installation (four-cy~nder engine): -0:;-1 I removal and installation (inline six-cylinder engine): 28-8 removal and installation (VB and 3_8l V6 engines): 20-19 pump removal and instaliaMn (2.BL V6 engine) : 2C-IO removal and installation (four-cylinder engine): 2A-12 removal and instaliaMn (inline slx-cylinder engine): 28-8 removal and installation (V8 and 3.8l V6 engInes): 20-20 seal replacement (2.BL V6 engine): 2C-II replacement (Iour-cylinder engme): 2A·8, 14 replacement (inline six-cytinderengine) : 28 -9 replacement (V8 and 3.8l V6 engines) : 20-23 type : 1-2 011 seal main bearing, installation: 2E-27 rear axle, replacement: B·12 replacement: 78-4,8 Overhaul engine: 2E-I through 30 general information: 2E-IO manual transmission, general information : 7A·2 Overhaul (engine) alternatives: 2E-II disassembly sequence: 2E-13 inilial stall·up and break-In: 2E-29 reassembly sequence: 2E-23 Ownermalntenance: 1·1 Owner safety checks: 1· 55
exhausl removal and Installation (2.Bl V6 engine) : 2C -6 removat and installation (four-cylinder engine): 2A-9 removal and Installation (VB and 3.Bl V6 engines): 20-11 intake removal and Installation (2.Bl V6 engine): 2C-5 removal and I05tallaoon (lour-cylinder engine): 2A-9 removal and Installation (VB and 3.BL V6 engines): 20-9 Manual transmission : 7A-l through 2 general Information: 7A-l lubricant, check: I -IS overhaul, general in for mation: 7A-2 removal and Installation: 7A-2 shlltlever, removal and Installation: 7A-I Master cyllMer, removal , overhaul and Installati on : 9-14 Master cylinder (clutch), removal and instaUatlon : 8-8 Module (I gnition), replacement: 5-5 Mount, engine check and replacement (2.Bl V6 engine): 2C -12 check and replacement (four-cylinder engine): 2A-14 check and replacement (inlme six-cylinder engine) : 28-9 check and replacement (VB and 3.8L V6 engmes): 20-24 Mounts, transmissi on, check and replacement : 78·7 Muffler check: 1-35 removal and installation 4-18 MuUl-function switch. replacement: 12-4
p Pads (brake)
checll.: 1-36 replacement: 9·3 Pan, oll removal and installation (2.8l V6 engine): 2C-l0 removal and installation (four-cylinder engine) : 2A-lt removal and installation (inline six-<:ylinder engine): 28-B removal and installation (VB and 3.Bl V6 engines): 20· 19 Parking brake adjustment: 9· 19 cables, removal and installation: 9·20 Partdng lamp bulb, replacement : 12·7 Parts buying : 0-21 , 26,30: I -I replacement: O-B
PCV filter, replacement 1·30 valve check: 1-32 replacement: 1-32 PCV (Positive CrankcaBe Ventilation) system : 6-13 Pedal (clutch), removal and installallon: 8-6
IND
INO-6 Pilo t bearing, In spection and replacement: 8-4 Piston installation: 2E-28 rings, installation : 2E-23 Pistons and co nnecting rods
inspection: 2E-21 installation: 2E-28 installation and rod bearing oil clearance check: 2E·2a remo .... al : 2E-!7 Positive Crankcase Ventllalion (PCV) system : 6-13 filter. replacement: ' -30 valve check: 1-32 replacement: \-32 Power, brake booster, inspection, removal and Installation: 9-21 Power steering bleeding : 10-14 fluid level. check: ' -15 pump. removal and installation: 10-14 Pressure (tire), checking: '·17 Propeller shaft, removal and installation : 8-10 Pump luel, removal and installation : 4-7 oil removal and inSlaUalion (2.8L V6 engine) : 2e-! 0 removal and installation (four-cylinder engine): 2A-12 removal and installation (inline six-cylinder engine): 28·8 removal and installation (V8 and 3.8l V6 engines) : 20·20 power steering, removal and installation: 10· 14
R Radiator coolant. general information : 3-4 draining, flushing and refilling: \·35 removal and installaUon: 3-7 Radiator cap, pressure: 1-4 Radio, removal and Installation: 12-8 Rear main 011 seal, installation: 2E-27 shock absorber, removal and installation: 10-9 Rear axle bearing replacement: 8·13 description and check: 8-11 lubricant change: 1· 16 level check: 1-16 oil seal. replacement: 8·12 Rear axle d amper, removal and Installation: 10-11 Rear axles haft, remov al and installation: 8-11 Rear bumper, removal and Installation: 11-10 Rear coli spring, removal and Installation: 10-11 Rear hatch, removal , Installation and adjustment: 11 -9 Rear stabilizer bar, removal and Installation: 10-8 Rear suspension arms, removal and installation : 10·11 Recommended lubricants and fluids : 1·2 Relay (starter), removal and Installation: S-10 Release bearing (clutch), removal and Installation: 8-4 Reservoir (coolant), remo val and Installation : 3-9 Rings (pislon), installation: 2E·23 Rocker arm cover removal and installation (2.8l V6 engine) : 2C-J removal and installaUon (lour-cylinder engine): 2A-3 removal and installation (inhne six -cylinder engine): 28-3 removal and Installation (V8 and 3.6L V6 engines) : 20-5 Rocker arms, removal and Installation (inllne six-cyllnder engine): 28-3
Index Rocker arms and pushrods removal and Installation (2.6L V6 engine): 2C-3 removal and installation (inhne six-cylinder engine): 28-3 removal and installation (VB and 3.8L V6 engines): 20-6 Rods (connecting ) inspection: 2E-21 installation and oil clearance check: 2E·28 removal: 2E· 17 Rotation (tire): 1·18 Rotor, check and replacement: 1·43 Routine maintenance: 1·1 through 55
5 Safe automotive repair practices : 0-19 Salety : 0· 19 checks: I-55 Seats, removal and Inslallation : 11-13 Self-adjusting mechanism (clutch) quadrant pawl replacement: 6-7 removal and installation: 6·6 Sending unit, cooling system temperature, check and replacement: 3·10 Sequential Electronic Fuel Injection (SEFI) system, component replacement: 4-13 Shift lever, removal and Installation : 7A-l Shift linkage, adju stment: 78-4 Shock absorber, lront, remov el and Installation: 10-6 Shock ab sorber (rear), removal and Installation : 10-9 Shoes (brake) check: 1·36 inspeclJon and replacement: 9- \ 0 Slave cylinder (clutch), removal and Installation : 8-8 Smog control systems: 6·1 through 15 Spark plug replacement: 1·42 wires, check and replacement: 1-43 Spindle (front), removal and installation : 10-7 Stabilizer bar fronl. removal and installation: 10-6 rear. removal and installation: 10-8 Slarter motor remova l and installation: 5· \ 0 testing in vehicle: 5-9 neutral start switch, replacement and adjustment: 78-6 Starter relay, removal and installation : 5·10 Starter/clutch Interlock switch, removal and installation: 8-8 Starting system, general information : 5-8 Steering gear, removal and installation: 10- \3 gear boots, replacement: 10· 16 intermediate shaft, removal and installation: 10·13 pump (power) , removal and installation: 10-14 system, check: 1-35 lie-rod ends. removal and installation: 10-14 wheel. removal and installation: 10-13 Steering and suspension systems, generallnformallon : 10-2 Steering system : 10-1 through 16 Stereo system, removal and installation : 12·6 Strut/s hock absorber as sembly, removal and Installation: 10-6 Suspens ion balljoint. check and replacement: 10-7 system, check: 1· 35 Suspension arms (rear) , removal and installallon : 10-11 Suspension system: 10-11hrough 16
Index Switch brake lights removal. Insralla\lOn and adjustment 9·22 headltghl. replacement 12-6 healer blowfOf molor replacement' 3-16
T Taillight bulb, replacement : 12-7 Tank (fuel) cleaning and repair. generallnlormahon 4 7 removal and Installallon: 4-6 TOe (top dead cenler) Iocatmg (28L V6 engine): 2C-2 locating (tour-cylinder engine) 2A-3 locating (Iollne slJ[-c~hnder engine I 28·2 locating (Va and 3,8l V6 engines) 20-4 Temperature sending unit, check and replacement: 3·10 Thermostat, check and replacement : 3· 4 Throttle, cable, removal and installation : 4·9 Throttle valve (TV) linkage, InspecUon and adjustment: 78·2,4 TIe-rod ends, removal and installation : 10-14 Timing, IgniUan, check and adjustment: 5-4 Timing belt (lour-cylinder engine). removal. installation and adjustment : 2A·5 TIming chain cover. removal and rnstallatJon (V8 and 3.8L V6 engines): 20·14 removal and InstaliallOn (mime six-cylinder engine) 28·6 removal and mstallatJon (V8 and 3.8L V6 engines): 20·16 TIming gears, check, removal and inslallatlon (2.8L V6 engine): 2C·7
n"
checkmg t-17 rOlallon I 18 Tires and wheels, general information : 10· 16 Tools: 0·8 Top Dead Center (TOC) Iocahng (2 8L V6 engme)- 2C·2 locating (Iour·cyllnder engine)' 2A3 Iocaling {mime sl~·cylmder engme): 28·2 Iocahng (V8 and 3,BL V6 engmes) 20-4 Towing : 0·16 Traction bars. removal and installation : 10·9 Transmission aulomatlC. shlll lmkage. lubflcalion t ,38 mounts. check and replacemen t 76 7 all seal re~acement 76 4 8 Transmission (automatic): 7B·I through 8 diagnosIS 78·2 lIuid level. check 1 16 genel almtormallon: 78·1 removal and InstaliallOn: 78-5 Transmission (manual): 7 A·I through 2 generallntormation: 7A-I overhaul, general Informa tlon_ 7A 2 removal and InstalialiOn: 7A 2 shlftlevef. removal and Installallon. 7A I Troubleshooting : 0-21 electrical. generallnl ormallon 12-1 Trunk tid, removal, installation and adjustment : 11·9 Tune· up, general inlormation: , · 13 Tune· up and rout ine maintenance : '·1 through SS Turbocharger, removal and installation : 4·16 Turn signal bulb, replacement 12·7 !lasher, check and replacement 12·6 Turn signal (multi-Iunction) switch, replacement : 12-4
IN O -7
u Underhood hose check and replacement : 1·22 Universal Joints descriptIOn and check· B-9 re placement B-' a Upholstery, maintenance: 11·1 Using this manuat : 0-6
v Valve clearance check and adjustm ent 1-4 1 speclflcallons: 1-5 litters removal and Installation (2 8L V6 engine)' 2C-8 removal and installation (Inline Six-cylinder engine): 2B- 7 removal and Installation (V8 and 3 8L V6 engines): 20·17 Valve cover removal and Installatlon (2 BL V6 englOe) 2C·3 removal and Installatlon (mline $l.·cyltnder engine): 2B-3 removal and Installation (VB and 3 BL V6 engines): 20·5 Valve cover (lour-cylinder engine), removal and installation : 2A·3 Valve job: 2E·16 Valve seals replacemenl (2.8L V6 engme): 2C·4 re placemenl (inline sl x·cylinder engine) 28·4 replacement (V8 and 3.BL V6 engines): 20·8 Valve seals and springs (four-cylinder engine), replacement : 2A--4 Valve springs, retainers and seats replacement (2 .BL V6 engine): 2C-4 replacement (Intlne Six-cylinder engine): 28·4 replacement (V8 and 3 8L V6 engines): 20 -8 Valves, servicing: 2E·16 Vehicle Identification numbers: 0·7 Vinyl trim, maintenance; 11-1 Voltage regutator (external), replacement ; S-8
w Washer switch, removal and installallon: 12--4 Waler pump
checll. 3·1' replacement 3-11 Wheel alignmenl. 10·16 cy linder. removal. overhaul and installa tion_ 9· 13 steenng. removal and installa ti on 10-13 Wheel bearing, fronl. check, repack and adjustment: 1--40 Wheels and IIres, general inlormation : 10· 16 Windshield washer lIU1d , level check 1·13 wiper blades. mspectlon and re~acement· 1·53 wiper motor. removal and installallon: 12·4 wirer SWllch, removal and InstallatIOn: 12-4 Wiper blades, check and replacement: 1-53 Wiring diagram color codes: 12-8 Wiring diagrams, general information : 12·8 Working lacilllies: 0·8
IND
HAYNES AUTOMOTIVE MANUALS NOTE: New manuals are added to this list on (J periodic basis. If you do not see (J listing for your vehicle, consult your local H(Jynes dlJaler for the /at8S/ product infOfl'TUJtJon.
,..
ACURA
m.
...
Integrl '-
L-oend '861hru '90
AMe
'" '" ""
JeepCJ - .see JEEP (4'2) MId-.1zI model., Concord, Honwt. Gremlin & :tril"10 tIIrv'83 (RltnHh) Alliance Enc~ all models '83lhru '87
AUDI 1117
.,,.
4000 .1 models 'SO Ihru '87 5000 at rnodats 77 thrv '83 5000 at models '8-t Ihrv '86 MG Midge!
Roadster (265)
' 1121
BMW 271 3201 '"::1 models 75 1hrv '83
", '"
'"
lUll " al models '7$ ltlru '80 I !lOll Ihru 2002 .. models except Turbo 'S9 1hrv 77 2500, 2tOO, 3.0 • e..".... '891twu 78
BUICK Clntu~ tront
.,'" "15$1
.n
GENE
whwI drMIj - _ MOTORS A,C." (829)
Bulck, OldlmobU.' Pontiac Ful .... 'ZII ~ronl wheel drMI).1I mode'- '85 mru '93 ulck Electra, LISlbr'lIId P.rk AYefI\.I8 ; Oldlmobl.. Delta a.~ Roy .... Ninety Eight and ~ PontIle Bonneville Buick . . . PontIK F...... (Raw wt'III 0rIvI) IkIIeII: EIeef1a 70 Ihrv '8-t , Eatt.te 70 Ihru '90. Le5abre 70 Ihru 79 0kIem00I.. Custom C/UIHI" '70 Ihru '90, Delta 86 70 \tIru '65. N~ ~mru·8-t P ville 70 \tIru '81, C.tatinf,·70 Ihru '81, Grandville 70 Ihrv 75. Perillenne '8-t Ihu '86 MIcHIa all rear-
Centu!1.
~- _GENERAL
."
TORS J.CtJrs (766) SkyIIrk at X-car modeII '80 1t1ru '85
CADILLAC CldIlIK ANr WhIII Drl.... .11 gasoline models "70 1t1ru '90 Clmerron - see GENERAL MOTORS J.CtJrs (768)
?"
...
GENERAL MOTORS
~-_GENERAL
...... .,'" '"
.,'" '"
MO S A-CIts ChrIeIIe, M8IIbu. I CImIno II V8 & V8 models '89 Ihrv '87 C............ PontIacTl000 I. model, 76 \tIru '87 CII8tIon all mode"" '80 thrv '85 Contc.l8erMtl •• models '87 thru'92 Cotvette .1 V8 model. '68lhru '82 c - n . .n mode!I '8-t 1hru '91
,Us.
...
'" '" '" ,'"
.
'"
'" '" '"
...
Atlel. Ply-mouth RII I.nt an models 61 Ihru '89 C"'VIIl • Plymouth Vo)'IgIf MInl-V,n• • 1 models '8-t 1IWu '91 C~ . Plymouth Saporro .D 7811Wu '83 Colt all models 71 Ihru 71
...". .,...=:. Cho;'l;!""'" ., ... '"
.... ·,ne ....
wMII ).N model. Ihrv '87 DSOIRem SOIPI),mouth Arrow Pick-up. " R.1der 79lhru '91 OIkota Plck .... p .It mod&Is '811t1rv'90 01'" ~h VIII",nt .U 6 crt models '6 Ihru '78 DlytONl • Cl'Irylilt la_ •• models .8-t 1IWu '89 Omnl , ~ Hortmn all models a thru '90 Plck .... p' .1 tu_,size models 7.1IWu '91 Shadow. Plymouth SuncIanee '87thru '91 SplrfI " ptymoulh Acelll." '89 \tIrv '92 Vln. - Dodge • Pllmouth va & 6 eyI model.' 1 thrv '91
FIAT OM
124 SporI Coupe • SpIder '88 thru '78
"51
J.CtJ,. (766)
F)
...",
OATSUN 2OC!SX all modeI, 'n Ihru'79 2OC!SX all mOOeII'80 Ihru '83 8-210 an mcdeII '13 \tIru 78 210 . 1 models 78 \tIru '82 2.oz. 260Z . 280Z Coupe & 2.. 2 70 mru 78 280ZX Coupe & 2.. 2 79 thru '83 300ZX - .see NISSAN ( " 37) m 310 an model. 781hrv '82 510. P1.521 P lc k-up '68 mru 73 510 a ll model. 78lhru '81 m 110.11 model. 721t1ru 76 120 s.n.. Pkk, up .11 rnod&Is 73 \tIru '79 no s.n.. Plck.... p - Mol NISSAN PidN.,,. (77') 11 OIMukM .1 gasoline models 771h1u .8-t 1200 .. models 70 Ihru 73 FlO an models 781twu '19 Putllr - _ NISSAN (876) s.nlr. - __ NISSAN {982} St.nu - .see NISSAN (98 1)
'1231
2OOO .. K I ~ .. rnoo.It '7 11hru75 2tOO , 2100 V Coupe 71 Ihru 75 2100 lilt • V6 Coupe 75 Ihru '78 Mercury CIprI -.see FORO AMWIQ (654)
c-o c:.v.I* - _
Luv Plck-up .~ 0 & . WO models "121hru '82 Monl, Clrlo .U va. V8 & Turbo models 70 Ihru '86 Nov • • 1 V8 models '&9 Ihrv 79 HoY••nd Gao PrtmI at front wh&el ~ models. '8511Wu "90 PIck ....'" '&7 thru " 7 - Chevrolet. GMC, .1 ~,size models '811t>ru '87; SlAlurban. Blazer & '871hrv '91 Plck.... p. ·" rv 'n - Chevrolet. GMC .11 full·size (C.nd K) moGeIs. '86 thru '92 Sprint" Gao '-tro '85 Ihru '91 5-10" GMC 5-1 8 Plck.... p • • n models '82lhru '92 V.ftI - C.... vrolet • GMC, V8 & in-Iine 6 eyI models '681hru '92
CHRYSLER '1 331 Ch ry'*" • ptymouUI MI6-.ta front wheel drive '82 Ihru '89 K..c. ... - _ OOOGE Atte$ (123) laler - _ DODGE Oayron/l {"40}
.'"
CHEVROLET '1471 "'Iro • GMC satlll1 Mln"vl n. a~ models '85lhrv '91 OS< c-o V8 at model", '70 thru '81 ill models '82lhru '91
....
MOTORS(~
OODGE
CAPRI
'" m
eapne.. I~.
... =
., .,,' .,..
AUSTIN HellIey Sprit' - _
'" ." ", .,'"
F~ s.de~
BIscayne. Bel Air & WIOOtlI." V6 & V8 models '59 Ihrv '90 Lumlftl -.see GENERAL MOTORS ('671) Luml~ APV - SH GENERAL
'1140
'112
',no
m '"
StrllCla .1 models 79 \tiro '82 XI /9 •• modeII7. Ihrv 'so
FORD "147& Aena.... Mlnl'V' M! aU models '86 thrv '92 Bronco.nd P lc k-upa '73lhru 79 Bronco.nd Plck· upa ·SO Ihru '91 Courlef P\ek .... p .U models 72 tNu '82 no EIeOft '- ....CUfJ L),n ••n models '81 thru'90 EKOI1 '- Mereuty TrIcer al rnod&Is '91 thru'93 ue::::'1IIuOII Nav.jo '911hru '92 Fe rmonl • IMn:U~Zeph)'l" at iIHIne & V8 rnoo.It Ihru '83 FlHtI ." mod&I, 'n Ihrv 'SO Ford .lMrcury FuI~, Ford LTO & Men:u MarquIS ~ Ihru '82); Ford llStom 500, ntry Squire, Crown V"doria & Men:u!fj COlon)' PM (751hru '81): Ford L 0 Cn:Jwn V"doria & Men:ury Gran Ma~ r 83 \tIru '87) G. . . . . Metwry Monereh .1 wHIne, & tyI & V8 models 75 \tIru '80 m Ford. lMn:ury MIcHIa, Ford ThI.IndefbIrd & Mereu~r (7511Wu '82): Ford LTD & ry MarQUis mru '88); Ford Tomo. Grarl To • Elrtl. Ral"lCt>ero PICk· UP. LTD II. Mercury Montego, Comet, XR,7 & lInc:oWI VellllUies (IS Ihrv '88) .....~. Mlr(:UfJ ~.M modeII iocIuding Turbo ' 91hru '92 MUNng VI .. models ·fi.4.1 1211Wu 73 MU'~ • at • tyI, V6 & V8 models 7. Ihru 8 Pinto. Yercury 80beM 81 models "151hru '80 ' 1170 ProW all mode'- '89 \tIru '92 Ranger' Bronco II all 9ilsoline models '831tlru '92 'IU1 T,uru.' Metc ury SllbII '861t1rv '92 ' 1.18 Tempo' Mlrcu1.Topaz at ~mcdeII ' !hru'91
....7O. '" ..... ......., ... '"
t
'"
oJ;:
.... '" '"
...
·,m
"" .,'"
.... .."
-. ~
CougarIXR1 '8311Wu . Thundlrt)lrd • Mercury ~ '89 Ind "VI) 'IIn • • 1 V8 ECOI"IOIine models 591hru"91
GENERAL MOTORS A..c.,. - Cnevrolet ~ Century. Pontilc 6000 & Ie Cutlass Cieri .11 models '82 \tIru '90 J..CfiI - Chevrolet C.vaUe< . Ponllac J ,2000, Oldsmobile Firen~ • • 6uoeIr. SIl)'hIwiI & Cedillac Cmarron II modeII'82 Ihru "92 "1. 20 H-C. ... - 6uoeIr. 5omerM! "85t1Vu '87. Ponllac Grand Am and ClIcbmobie Call.. '85 Ihru '91, BuoeIr. $kyIaIIr. '86 Ihru '91 ' 1871 GM: Bulek Regal , Chevrolet l.umIna, 0IdIm0bI1I CUt!au ~eme. Pontiac Grind Pri •. aa ront....ntel drive models '88 \tIru '90 GM : C~ Lumll\l APV, DIdamobIIe SllhoI.oIttI, PonIIK T...nI Sport '90 thru '92
..
.,
.... GEO
rt:::: ('
Metro - ... CHEVROLET 72n PrIzm - ... ~EVRCXET ( 1642) TI1Ie ..... -Mol SUZUKI s.mu..; ('626)
GMe Slf.r! -,.. CHEVROLET ASTRO (1 477) V'M! & plckm - see CHEVROI.. (42O, 831. 345. 1(64) (eontlnlAd on o ext ~ge)
shown wilt! an asterisk ( , ) indicaftl model COVfII"8f1tI tiS oIlt1is pmtinfl. Th4nuI tifJtIs wilt btl ptI(IOdicBl1y
updated to Include IBIfK model years - COfIS!JIr JIOI.N Haynes dealer for mor. lnlonnation.
Haynes North AmerIca, Inc., 861 Lawrence DrIve, Newbury Park, CA 91320 • (805) 498-6703
HAYNES AUTOMOTIVE MANUALS
(continued from J"VIouI page)
NOTE: New manuals 8(8 added to this list on 8 periodic basis. If you do not see a listing for your vehicle. consult your local Haynes dealer for the lB tssl product N1formstion.
HONDA 351 Acconl cvee aMmodftIs 761hru '83 "1221 AcconI ai ~ '8111hru '89 1&0 Civic 1200 allTIOOtIt 731hru 79 &33 Civic 1300 .. 1500 CVCC .I/TIOOeI$ 'SO Ihru '83 m C ivic 1500 cvee III models 7Stt1lu 79 ' 1m Civic all modals '$(thru '91 '601 PreI. . . CVCC tJI ~ 79 Ih..... '89
HYUNDAI "552
EIlctol"modeIa '86lhru~ 1
'1341 '771 '116
'1112 '11111
'"
'81 tlm,l '91
JAGUAR "242
X.Ie .. 8 c:yt modelI '681hru '86 XJ I2 .. xJs aM 12 cyt models '12 Ihru '85
JEEP
.,'" ." ·,m
...
163
1200, 1300. 1500 .. 1800 all modeIa ineIIdng RNa 7 4 Ihru '86
MAZDA 621 Sedan & Coupe ('N'....tINI (Iriye) all models 79 thru '82 621' MX.e (Iront wn..t cSrt .... ) aN models '631htu '91 Gl C ~tchbeck (rNr W'-I ~J .. models 771hru '83 OLe (front whMI drive) .. models '811hru '86
"" '" '" .,..,
...
.,.,
' ,4 HI
MPV '891hru '93 Nava/O - SfHJ FORD Explorer (202 1) Plc k-u~ '72lhru '92 RX-7 " models 791hn1 '85 RX·7 all models -se thru '91
MERCEDES-SENZ ' 11143 '80 5erlH allOUfqlinder ~ models, '84 Ihru '88 348 230. 250 • :zeD Sedan. Coupe & ~ aU 8 eyI tohc models 'l!.8 \t'U1J '72 983 280 123 s.n.. •• gasoline modeb
698 U7
77 1htu '81 )SO .. 450 Sedan, Coupe & RomIIef .. Ihru '80 ote.eI123 SerIH 2000, 2200, 2400 , 2.-oTO, 3000, 3OOCO, 3OOTO, s.eylInc:I, Turbo 76 thru '85
modIIII",
4- "
MERCURY FIX.n PLYiIOUTH mIN
_
"G
FORD Ua'lnf
111
IIG8 ~"GTCoupe
265
.. models '62 tI'tru '80 IIQ III.sg.t & AwtIri HNley St)ftt. RoMIster '581hru '80
MITSUBISHI ' 1&611 Corella, rr.dIJ., Galanl, Preela & '2022
Nw.ge '83lhru '90 Plc:k-. & MonI«O '83 thru '9 '
MORRIS 074 !AUllln) N.lrln. 1,1 .. models '71l1'1ru '80 024 MII'IOf 1000 ~n 8. wagono '56lhru '71 NISSAN 1137
Pul.., all models '83 ttvu '96 Senlta " models '82 Ihru '90 SlIonu ." model, '82 Ihru '90
va model. 741hru 'ell
Cut'-. . CIeB - see GENERAL MOTORS A -Cara (829) CuILa.. Sup_ - ' " GENERAL MOTORS (f6 7f) FlrefIUI - ' " GENERAL MOTORS J.CIJra (766) Nlnety.-gtol - see BUICK FuI/·. (I551) om.g. - '" PONTIAC PfIoemJf 8om.g.(55I) Silhouetta - ' " GENERAL MOTORS (203S)
PEUGEOT
LAD. "413
Plek-uptJPalhf1nct.r gllSmodeis
OLDSMOBILE CUllom Crul.... - ' " BUICK Full-sin (155 I) CIIl\aN all IIafldt,rd gasoline V6 "
ISUZU ' 1&41 Trooper. Plck-up, aR gasoIina model'
"47'
Mnlm. all models '85 ,hru '9' '80 thru '91
3OOZX aJl Turbo"non-Turbo models '''' Ihru '89
504 . 1 dlGsei models '14 Ihru '83
SUZUKI '1 1126
SamurailSldeldck and Geo Tl'Kk..- , 8 mod&I!I '86 Ihru '91
TOYOTA ' 1023
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Camry all models '83 .h,u '9' Carina Sedan aH moc:te-i, '11 1hru 74 Celica FronI WMeI 0rIve '86lhru '92 CeIIca A.., Wheel Df1Y1171 Ihru '85 c.l1ca lkIpra '191hru '92 Corolla a~ models 75 Ihru '19 Corolla all models (reef whaeI dnve) 'SO Ihru '87 Corolla all models ('ront whaeI drive ) '''' 1hru '91 Corolla Tareel ,I models '80 1hru '82 Corona. 11K" all 4 eyt tohc models '69lhru 74 Corona I" models 7 . mru '82 C,... lda all models '78lhru '82 Land Crul.... all models '68 Ihru '82 MK II all6 ev1 models 72 Ihru 76 1IR2 all mod4!s '85 \IVu '81 Plc:k-up all models 'U Ihru 78 Plc:k-up a" models 79 Ihru '92
PLYMOUTH F(H all PL YIIOI./TH m/ft, _ DOOGE 1I. 1Ing.
TRIUMPH GTI' Vl1_ aU models '62 Ihru 7. So/tfl,. , I models '62 Ihru 'II' TRl all models 751hru 'I'
PONTIAC
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CHEVROLET (449)
J.2OQO - see GENERAL MOTORS J.C.ra (768) Il00II - SIMI GENERAL MOTORS A-CatS (829/ FIotro all models '''' Ihru 88 Flr.tJIrd III V8 models a. cep! Turbo '70 thru '8' Flr.tJI,d all models '82 thru '9' Full-.u. ~ WhMI DrI.,. - _ &d.~,
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FuI'lIUa (l55f) Grand PrIx - _ GENERAL MOTORS (1671) Photonlx" Oldsmobile Omaga all X-ea, model. 'SO ll'lru '''' TranI 8J:IcK1 - _ GENERAL MOJ'ORS (203S)
PORSCHE '2$4
239 397 '1027
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1111 I HCoupe" Talgll models e. cep. Turbo & Carre.. 4 '65 th .... '89 114 III 4 eyt models '69 thru 76 124 aU models including Turbo 76 thru '82 IM4 all models indOOing TUfbo '831hru '89
RENAULT
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12 8aIoon • E,W. , I models ,289 IX enoones 70 Ihru '80
15 & 11 all models 73 \tVu '19 16 all models 89,1 ctI in 8. 95,S ct/ If1 &1101"" '65 Ihru 72 Amane." Enc:_ - ''''' AMC (934)
SU. 241 '\110
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Baetle .. It.armann Gllla III moc:te-is '5-4 Ihru '79 Da~ all gasoiina models 7 . Ihru '81 Rabbit. .latta, Sc:1toeeo. .. PIcIl-up all galOione models 7. \IVu '91 .. ConYIIrtIbIrI '80 Ihru 'II' RlbbIt, Jetta • Plck-up all diaseI models 771hru ''''
Tran, porte, 1100 all models '68 1hru '79 TrlntpCM't4or 1100, 1100 .. 2000 .. models 721t1ru 79 Type 3 1SOO .. 1 tIOO ,I models '631hru 73 Vana-gon all ail-<:OOled models '80 Ihru '83
VOLVO 203 121
' 270
400 '1550
120, 130 SerIM .. 1100 Sport4 '61 1hru '13 14Os.an-. almodels '8611m174
240 SerIH .. models 7 ' Ihru '90 260 SerIH .. models 75 Ihru ' 82 740 .. 110 SerIu '11TIOde/s '82 Ihru '88
SPECIAL MANUALS
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SUBARU 231 1100, 1300, 1400& 1600 all models 71lhru '19 '611 1600''IOO 2WD804WO , d models '80 Ihru '89
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Haynes North America, Inc., 861 Lawrence Drive, Newbury Park, CA 91320. (805) 498-6703
CARBON DEPOSITS Sympto m s: Ory sooty dePOSits Indicate a rich mixture or weak ignition. Causes misfiring, hard starting and hesitation Recommendation: Check for a ctogged air cteaner, high lIoat level, sticky choke and worn Ignition pOints. Use a spar1t plug with a longer core nose for greater anti-fouling protection.
NORMAL Symptoms: Brown to graYishtan color and shght electrode wear. Correct heat range for engine and operallng conditions. Recommendation: When new spark plugs are Installed, replace With plugs of the same heat range
ASH DEPOSITS OIL DEPOSITS Symp toms : Oily
coatln9. caused by poor oil control. 011 is leaking past worn valve guides or piston rings into the combustion chamber. Causes hard starting, misfiring and hesitlon Recommendation: Correct the mechanical condition with necessary repairs and install new plugs
TOO HOT Symptoms: Blistered, white Insulator, eroded electrode and absence of deposits. Results In Shortened plug life. Recommendation: Check for the correct plug heat range, over-advanced ignition liming, lean tuel mi xture, Intake manifold vacuum leaks and sticking valves. Check the coojantlevel and make sure the radia tor IS not clogged
PREIGNITION
Symptoms: l ight brown de· posits encrusted on the side or center elec trodes or both. Derived from all andlor fuel additives. ExceSSive amounts may mask the span<, causing misfiring and hesitation during acceleration. Recommendation: If excessive depoSits accumulate over a short time or low mileage, install new valve guide seals to prevent seepage ot 011 Into the combuStion chambers. Also try changing gasoline brands
WORN Symptoms: Rounded electrodes with a small amount of deposits on the firing end_Normal color. Causes hard starting in damp or cold weather and poor fuel economy. Reco mmendation: Replace with new plugs of the same heat range
DETONATION Symptoms: Insulators may be
Symptoms: Melted ~ec'rodes. Insulators are white, but may be dirty due to misfiring or flyIng debris In the combustion chamber Can lead to engine damage. Recommendation: Check for the correct plug heat range, over-advanced ignition timing, lean fuel mixture, clogged coolIng system and lack of lubrica tion _
cracked or chipped. Improper gap sellinS! techniques can also resul t In a fractured insulator tip. Can lead to piston damage. Recommendation: Make sure the fuel anti-knock values meet engine requirements. Use care when setting the gaps on new plugs. Avoid lugging the engine
HIGH SPEED GLAZING S ymptom s: Insulator has
SPLASHED DEPOSITS srmptoms: After long pefiods
yellowish, glazed appearance Indicates that combustion chamber temperatures have risen suddenly dUring hard acceleration . Normal deposits melt to form a conductive coating Causes misfiring at high speeds. Recommendation: Install new plugs. Consider uSing a colder plug if driving habits warrant.
o misfiring, deposits can loosen when normal combustion temperature is restored by an overdue tune-up At high speeds, deposits flake 011 the piston and are thrown against the hot insulator, causing misfiring. Recommendation: Replace the plugs wi th new ones or clean and reinstall the originals.
GAP BRIDGING
MECHANICAL DAMAGE Symptom s: May be caused by
Symptoms: Combustion dePOSitS lodge between the elec· trades. Heavy depoSits accumulate and bridge the electrode gap. The plug ceases to fire, resulting In a dead cylinder Recommendation: Locate the faulty plug and remove the depOSitS from between the elec· trodes.
a fo reign object In the combustion chamber or the piston striking an incorrect reach (too long) plug. Causes a dead cylInder and coukl result in piston damage, Recommendation: Remove the foreign object from the engine andlor install the correct reach plug _
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