Werkstatthandbuch Book 1 · Seiten 801–900

21-01-18 General Gasoline Engine Service 21-01-18 diameters of 0.003, 0.015 and 0.030 inch are available refinishing operation allow the cylinder bore for service for all engines except 2.3L 1-4 and 2.8L V.6. to cool, and make sure the piston and bore are For these engines, oversize valve stems are available clean and dry before the piston fit is checked. in diameters of 0.008, 0.016, and 0.032 inch oversize. Fitting Piston RingsAlways reface the valve seat after the valve guide has been reamed. Refer to Reaming Valve 1. Select the proper ring set for the size cylinder bore. Guides. 2. Position the ring in t

21-01-19 General Gasoline Engine Service 2 1-01-19 CRANKSHAFT 8. Repeat procedure for remaining bearings that require replacement. Dress minor scores with an oil stone. If the lournals are severely marred or exceed the wear limit, they PLACI PLASTIOAGF FULL CHECK 010TH OF should be refinished to size for the next undersize 010TH OF JOURNAL PLASTI CAGE bearing. ABOUT C INCH OFF

21-01-20 General Gasoline Engine Service 21-07-20 motor oil. Operate the hone in such a way to produce 4. Cylinder front cover on engines using cast iron a cross-hatch finish on the cylinder bore. The cross-hatch material. pattern should be at an angle of approximately 30 5. Cylinder head, along the rocker arm cover gasket degrees to the cylinder bore. After the final surface. operation in either of the two refinishing methods described and prior to checking the piston fit, The following procedure should be used to repair porous areas or sand boles in cast iron.thoroughly clean with a detergent and water solution and oil the cylinder walls. Mark the pistons 1. Clean t

21-01-2 1 General Gasoline Engine Service 21-01-2 1 Inspection If the push rod is bent beyond specifications, it Inspect the cylinder head joining flanges of the should be replaced. Do not attempt to straighten pushrods.exhaust manifolds for evidence of exhaust gas leaks. CYLINDER HEADS Inspect the manifolds for cracks, damaged gasket surfaces, or other damage that would make them unfit Cleaning for further service. Warped or cracked exhuast With the valves installed to protect the valvemanifolds must be replaced.

2101..22 General Gasoline Engine Service 21-01-22 Install the tool on the valve stem until it is fully seated, and tighten the knurled set screw firmly. Permit the valve to drop away from its seat until the too! contacts the upper surface of the valve guide. Position the dial indicator with its flat tip against the center portion of the tool’s spherical section at

21-01-23 General Gasoline Engine Service 2 1-01-23 Replace all the components of the timing chain and sprocket assembly, if any one item needs replacement. FUEL PUMP ECCENTRLC CHECK SPECIPICATION Cleaning Clean the fuel pump eccentric in solvent and dry with CLOSED COIL END DOWNWARD compressed air. Inspection Inspect the fuel pump drive eccentric for scores, ni

21-01-24 General Gasoline Engine Service 21-01-24 mating surface is worn, scared or grooved, replace the CONNECTING RODS pump. Inspect the rotor for nicks, burrs or score marks. CleaningRemove all high points by stoning. Remove the bearings from the rod and cap. Identify Measure the outer race to housing clearance Fig. 47. the bearings if they are to be used again. Clean the connecting rod in solvent, including the rod bore and With the rotor assembly installed in the housing, t

21-01-25 General Gasoline Engine Service 21-01-25 piston, offset from the centerline between the piston pin holes, can be caused by a bent connecting rod. Replace pistons that show signs of excessive wear, wavy ring lands or fractures or damage from detonation or pre OR ignition. *FATIGuE FAILUReP01 IMPROPER SEATING RATCIILS DIRT IMBEDDED OVERLA INTO REARING MATERIAL OIPPD OuT scRATcHED BY DIRT LACK OF OIL RING CLEANER

21-0-26 General Gasoline Engine Service 21-01-26 CRANKSHAFT VIBRATION DAMPER AND SLEEVE grooves in the crankshaft bearings and bearing retainers.Cleaning Inspection Clean the oil seal contact surface on the crankshaft damper or sleeve with solvent to remove any corrosion, After the block has been thoroughly cleaned, check sludge or varnish deposits. Excess deposits that are not it for cracks. Tiny cracks not visible to the naked eye readily removed with solvent may be removed with may be detected by coating the suspected area with crocus cloth. Use crocus cloth to remove any sharp a mixture of 25 percent kerosene a

_______________________________________________________________________________________________________ ___________________ 21-01-27 General Gasoline Engine Service 21-01-27 SPECIAL SERVICE TOOLS Description Hyd ía uIrc Tappet H ernDver Crankshaft Front Sea! Installing Tool Crankshaft FrgIRemovin Tool Impact Hammer Puller Attachment Use with T5OT-100-A or TSQL-100-B Handle Adapter Differential Backlash arid Runout Gauge, with UnIversal Bracket and Dial Indicator 1-1/4 inch range. Includes lndicatDr TOOL-6565 Engine Lifting Hook - Engine Lifting Hook Engine LifEing Biackets Cm B ewin Ba re P lpglnstalliii Too I Core Plug Replacer CylInder Front Covec Pilot Front Covet Alignm

__________________________________ __________________________________ __ _________ ___ ________ 21-01-28 General Gasoline Engine Service 2T-OT-28 SPECIAL SERVICE TOOLS Continued Application Engine Size 5.Q/5.81. £BL sM’/ 1.51 3.31/4.1 302/351 6.61 4611 Fo

21-05-1 2.3L 1-4 Engine 21-05-1 PAHT 2.3L 1-4 Engine 21-05 Pinto/Bobcat/Mustang Il/Fairmont/Zephyr SUBJECT PAGE SUBJECT PAGE DESCRIPTION Main Bearings. - . . 05-17 Crankcase Venti Ia ti on System 05-3 OH Filter 05-17 Exhaust Emission Control System 05-1 Oil Pan 05-13 Oil Pump

4Engine :j Left View..23L 1-4 Engine "This publication contains material that is reproduced and distributed under a license to Detroit Iron from Ford Motor Company. No further reproduction or distribution of the Ford Motor Company material is allowed without the express written permission of Ford Motor Company."

21-05-3 2.3L 1-4 Engine 21-05-3 CRANKCASE VENTILATION SYSTEM This engine is equipped with a positive, closed-type crankcase ventilation system re-cyctng crankcase vapors to the intake manifold. FIG. 2 Valve Train Lubrication System ADJUSTMENTS CAUTION: Do not operate engine with hood . a. lb open until the fan has been first examined for possible cracks and separation.

21-05-4 2.3L 1-4 Engine 21-05-4 CAMSHAFT TIMING Remove the access plug Fig. 4 from the cam drive belt cover.Checking Timing 2. Set the crankshaft to TOC by aligning the timing An access plug is provided in the cam drive belt cover painter on the belt cover with the 0 mark on the so that comshaft timing can be checked without removal crankshaft damper. Always turn the engine inof the cover or any other parts. t

21-05-5 2.3L 1-4 Engine 21-05-5 cap and set the distributor rotor to No. 1 firing position by turning the auxiliary shaft. 6. Install the timing belt over the crankshaft sprocket BELTRELEASINGTENSION TOOL - TI4P.6254-A and then counterclockwise over the auxiliary and camshaft sprockets. Align the belt fore and aft on the sprockets. 7. Loosen the tensioner adjustment bolt to allow the tensioner to move against the belt. To be sure that the belt does not jump time during rotation in Step 8, remove the spark plugs. 8. Rotate the crankshaft two complete turns in normal rotation to remove the slack from th

____ 21-05-6 2.3L 1-4 Engine 2 1-05-6 5. Install the flywheel or converter housing lower mounting bracket, and adust the belt tension to attaching bolts. specification. Install the tan and the radiator. Connect the radiator upper and lower hoses. Fill On a vehicle with automatic transmission, attach and bleed the cooling system. Fill the crankcase the converter to the flywheel and torque the with the proper grade and quantity of engine oil. attaching nuts to specifications. 6. Install the flywheel or converter housing d

21-05-7 2.3L 1-4 Engine 21-05-7 NBO01 79 3 REQO. 36-60 FT-LB 383421- 52 74-S2 -‘-B ASS?. P14 34978-52 40-60 FT-LB NO. 2 382802-52

21-05-8 2.3L 1-4 Engine 2 1-05-8 FILTER PACIC ELBOW - 382956-S FILTER RETAINER AIR CLEANER SMELL IREF.I HOT IDLE COMPENSATOR UI’PER CRANKCASE OIL FILLER CAP -6766

21-05-9 2.3L 1-4 Engine 21-05-9 5. Clean the gasket surfaces of the valve cover and 4. If air pressure has forced the piston to the bottom cylinder head. of the cylinder, any remaval of air pressure will 6. Coat the gasket contact surfaces of the valve cover allow the valves to fall into the cylinder. A rubber and "UP" side of the valve cover gasket with oil band, tape or string wrapped around the end of resistant sealer. Allow to dry and then install gasket the valve stem will prevent this condition and will in valve cover, making sure locating tabs are still allow enough travel to check the valve for properly positioned in slo

21-05-10 2.3L 1-4 Engine 21-05-10 Fl ASTIC INSTALLATION CAP TOOL T73P-557 1-A lOlL SURF ALL UP LAP UiIOLC TU FALILI IA/C LUN I AG I SEAL INSTALLATION SHOULDER VALVE GUIDE 4 -_i I - LISP/li STEP±12 STEP #3 SIEPR1 DITH VALVES IN HEAO PLACE PLASTIC INSTALLATION CAP OVER END OF VAL VE STEM STEP 2 START VALVE STEM- SEAL CAREFULLY OVER CAP 0USII SEAL OUA1N UNTL -ACKET TOUCHES TOP QF GLIDE STEP 3 REMOVE PLASTIC iNSTAi LATION CAP US

21-05-11 2.3L 1-4 Engine 21-05-11 TO 300V THE Lv ND0 P I/VGA BOLTS TO SPPL 1 ICATICINS IN TAO VII *:*:lRVVlV**V V 5V5. IN THE SEOLIFFVCV 5130333 GASKET 9447 :-ALOCV *c:V VFILVOT** SI OAN ON I UP OF TABI -- >-m A-HEN !NVA LLINGC YLI0. O

21-05-12 2.3L 1-4 Engine 21-05-12 TOOL TI4P-62B5-A LE! P3748-lA FIG. 24 Removing Crankshaft Sprocket P3748-ic FIG. 22 Removing Cam or Auxiliary Shaft Sprocket NOTE: CENTER Apoon nEMOVEa

21-05- 13 2.3L 1-4 Engine 21-05-13 AUXILIARY SHAFT AND BEARINGS Inspection procedures are outlined under Flywheel Cleaning and Inspection in Part 21-01. Refer to Fig. 3 1 for installation information on the Removalauxiliary shaft. 1. Remove the transmission, clutch pressure plate, and If necessary, the auxiliary shaft bearings can be disc following the procedures in Volume One,removed using the slide-hammer Tool T58L.101.A. Gr

21-05-14 2.3L 1-4 Engine 21-05-14 PILOT BEARING TOO L-T1 IP-7 131-C A3430-IB FIG. 29 Installing Clutch Pilot Bearing-Typical "This publication contains material that is reproduced and distributed under a license to Detroit Iron from Ford Motor Company. No further reproduction or distribution of the Ford Motor Company material is allowed without the express written permission of Ford Motor Company."

21-05-15 2.3L 1-4 Engine 21-05-15 BELT CU IDE £R 260 USE A NEW BOLT OR NEW TEFLON TAPE AN HULl THREADS WHFN INSTALL[NA BELT 6768 CRANKSHAFT YA TO PAN RAILa VIEW FOR CRANKSRAE S ALIUNME BELT GUI OF fl[CLSS IN SFHOLKET KEY C DAN F HAlT SECTIONAL VIEW ION SPRITIK

21-05-16 2.3L 1-4 Engine 21-05-16 GEAR AND FuELPuMP ECCENTRIC MUST NOT BE ALLOWED TO TOUCH BEANING SURFACES OURING INSTALLATION AUXILIARY SHAFT- 6K230 0 RETAINING PLATE-6A222 I’ DIP SHAFT C

21-05-17 2.3L 1-4 Engine 21-05-17 FIG. 34 Gasket Installation OIL PUMP Oil pump installation information is shown in Fig. 36. Prime the oil pump with engine oil when making final installation. CRANKSHAFT REAR OIL SEAL A split lip-type crankshaft rear oil seal is used on this engine. Installation information is given in Fig. 38.

21-05-18 2.3L 1-4 Engine 21-05-18 APPLY LUBRIPLATE OR FGUIVALENT TO CRANKSHAFT PILOT HOLE AUTOMATiC TRANSMISSION REFINFORCING PLATE -6A366 REAR COVE ROCKER ARM COVER SHIELOGC509 NOTE; TRANSMISSION CLUTCH HOUSING ATTACHES TO ENGINE WITH METRIC BOF TS

21-05-19 -- 2.3L 1-4 Engine 21-05-19 DRAIN RLUG - 6730 OIL PAN -6675 M6X 16-0MM LONG SCREW PINTO/BOBCAT/MUSTANG I AND WASHER -18 PLACES OIL PAN - 6575 FAIRMONT/ZEPNYR MRX 200 MM LONG PAN GASKET IRI SCREW AND WASHER -6710 4 PLACES PAN GASKET IL 61111

2 1-05-20 2.3L 1-4 Engine 21-05-20 PINTO/BOBCAT/MUSTANG II MS 1< 25.0 LONG SCREW & WASHER OIL PUMP MUST BE TORGUETO 6600 FREE TO ROTATE OIL PUMP AFTER INSTALLATION 2 ASSY.

21-05-21 2.3L 1-4 Engine 21-05-21 OIL PRIOR TO ASSEMBLY ARROWS TO FRONT OP ENGINE AS SHOWN CAP - 6325 OIL-AFTER INSTALLATION IN BLOCK 6333 - STUD - M12-MIDY1O9 CAP

21-05-22 2.3L 1-4 Engine 21-05-22 HANDSTART UNTIL FLUSH WITH TOP GP BOLT, THEN TGRDUE IN 2 STEPS - AS DETAILED IN SPECIEICATIo ROD

21-05-23 2.3L 1-4 Engine 21-05-23 FRONTDE ENGINE 9218- OIL SENDER-SEALING TYPE lOa83 --TEMP INDICATOR OR TU6843 - TEMP SWITCH 1/2 TURN CONTA

21-05-24 2.3L -4 Engine 21-05-24 KEYS_ 6518 RETAINER - 6h14 INSTALL SEAL AFTER VALVE AND PRIOR TO SPRING INSTALLATION -SEAL MUST BE BOTTOMED ON VALVE GUIDE SPRING 6513 NOTE: LASH AOJUSTERS MUST SEAL 54513

21-05-25 2.3L 1-4 Engine 21-05-25 CAM F DIP IN ENGINE OIL PRIOR TO INSTALLATION APPLY LUBRIPLATE ON F OUI VALENT A CYLINDER FRONT OF ENGINE MAIN VIEW

21-05-26 2.3L 1-4 Engine 21-05-26 TOOL- 71P-6250A TOOL- 71P-6250A i lii ,or-TIFIcATIoN 1AR - & CAMSHAFT OIL lOLES Must BEARINO BE ALIGNED AT TIME OF INSTALLATION REMOVAL INSTALLATION A3419 IA FIG. 44 Removing or Installing Camshaft Bearings-Typicol

21-05-27 2.SL 1-4 Engine 21-05-27 RETAINING RING RETAINING RINO FOLLOWER ARM FOLLOWER ARM. FULCRUM METERING PLATE’ PLUNGERN PLUNGER. PLUNGER

21-05-28 2.3L I4 Engine 21-05-28 SPECIAL TOOLS - - -I / T74Pe1 50-A -I. T14P41 50-A TI4P 6000-LB - NOTE: CRANKSHAFT PLLLE’ REMOVER

0 33 __________________________ 21-05-29 2.3L 1-4 Engine 21-05-29 SPECIFICATIONS GENE SAL SPECIFICATIONS CYLINDER BLOCK ICnntieuS DISPLACEMENT - - - 7 3L NEAD GASKET SUN ER CE FINISH IRMS 60-ISO NUMBER OF CYLINDERS - - 4 CYLINDER BORE BOREANDSTFDKE 170n1126 Oia,oRlRn 3.7795-3,7831 1-IRINGLIRD

_____________ 21-05-30 2.3L -4 Engine 21-05-30 CONNECTING ROD PISTON AND RINGS TORQUE SPECI F I CATI ONS - Spec,aI Applicalmons Connirseed - CONNECTING ROD IT F tot - SIZE TORQUE P.ssonpinBoreOmamltHr OB100-O01t2 C,arrknhaflBeanmogBoreOma 2.1720-2.t720 PUMP TUCYLINOER0LOLK --

21-10-1 3.3L/4.1L 200/250 CID 1-6 Engines 21-10-1 PART 33L/4.1L 200/250 CID 1-6 Engines 21-10 Fairmont/Zephyr/G ranada/Monarch SUBJECT PAGE SUBJECT PAGE DESCRIPTION REMOVAL AND INSTALLATION Cont’d.} Crankcase Ventilation System 10-2 Flywheel 10-13 Engine 10-2 Front Oil Seal 10-12 Exhaust Emission Control System 10-2 Hydraulic Tappets 10-9

21-10-2 3.3L/4.1L 200/250 CID 1-6 Engines 21-10-2 - 44 A2748-20 FIG. 1 Typical 1-6 Engine ADJUSTMENTS CAUTION: Do not operate the engine with the care to avoid excessive pressure that might hood open until the fan has been first examined bend the push rod. Hold the tappet in this position for possible cracks and separation. HYDRAULIC VALVE CLEARANCE A shorter than standard push rod and a longer than standard push rod

21-10-3 3.31/4.1L 200/250 CID 1-6 Engines 21-10-3 and check the available clearance between the No. 2 Exhaust rocker arm and the valve stem tip with a feeler No. 3 Intake gauge. No. 4 Exhaust If the clearance is less than specified, install an under-size push rod. If the clearance is greater than No. 5 Intake specified, instolt on oversize push rod. No. 6 Sntake 3. With the No. 1 piston on TDC after the compression No. 6 Exhaust stroke, use the procedure in Step 2 and check the 5. When compressing the valve spring to remove the following valves: push rods, be s

21-10-4 3.31/4.11 200/250 CID 1-6 Engines 21-10-4 On a vehicle with automatic transmission, start 8. Install the engine left and right mount to the the converter pilot into the crankshaft. underbody bracket. On a vehicle with a manual.shift transmission, 9. Remove the plug from the fuel pump line and start the transmission main drive gear into the connect the flexible fuel line to the fuel pump line. clutch disc. It may be necessary to adjust the Using a new gasket, install the exhaust manifold position of the transmission in relation to the engine to muffler inlet pipe with lockwashers and nuts. if the input shaft will not enter the clutch disc. If Torque the nuts to specif

21-10-5 3.3L/4.1L 200/250 CID 1-6 Engines 21-10-5 Removal Removal 1. Remove the insulator to support bracket nuts and 1. On automatic transmission models, support the washers from both insulators. engine with a jack and wood block under the oil pan and remove the rear insulator to crassmember2. Raise the engine with a jack and wood block placed attaching nuts. under the oil pan. 2. Remove the rear insulator to transmission extension 3. Remove the insulator-to-engine bolts and washers housing bo

21-10-6 3.3L/4.1L 200/250 CID 1-6 Engines 21-10-6 EWO FWD RH INSTALLATION tM. INSTALLATION4- + 6038 ASSV. 387174-52 2 REOD. 4060 FT-LB 386464-57

21-10-7 3.31/4.1L 200/250 CID 1-6 Engines 21-10-7 HOSE - 3811 86-5060-A TO CANISTER PURGE HOSE GROMMET OIL FILLER CAP - 6776 VIEW ‘V FRONT OF ENGINE VIEW Z FRONT OF ENGINE A4454-2A FIG. 7 Closed Crankcase Ventilation System Compon

21-10-8 3.31i4.1L 200/250 CID 1-6 Engines 21-10-8 AIR LINE ANU ADAPTER TOOL-T8SP-8513-A Aa134-1s FIG. 9 Compressing Valve Spring-In Chassis FIG. 10 Removing Valve Stem Seal occurs, remove the cylinder head for further inspection. CYLINDER HEAD 6. Remove the valve stem seal Fig. 10. If air pressure Removal has forced the piston to the bottom of the cylinder, any removal of air pressure will allow the valves 1. Drain the cooling system. Remove the air cleaner t

21-10-9 3.3L/4.1L 200/250 CID 1-6 Engines 21-10-9 716- 14,6’ BOLT. CUTOFF HEAD. TAPER END AND SLOT FOR SCREWDRIVER * p r e S C A2224-1A A2790-lA FIG. 11 Valve Push Rod Removal FIG. 12 Cylinder Head Guide Studs head and block. Install guide studs at each end of the cylinder block Fig. 1 2, 2. Position the cylinder head gasket over the guide studs on the cylinder block. 3. Install a new gasket on the flange of the muf

21-10-10 3.31/4.11 200/250 CID 1-6 Engines 21-10-10 EXHAUST MANIFOLD 3. Place a new gasket on the muffler inlet pipe. Position the muffler inlet pipe to the manifold.Removal Install and torque the attaching nuts to 1. Remove the air cleaner assembly and related parts. specifications. Install the automatic choke hot air Disconnect the muffler inlet pipe from the exhaust tube. manifold, and remove the automatic choke hot air 4. Install or connect the emission components tube. previously disconnected, 2. Rem

21-10-11 3.31/4.1L 200/250 CID 1-6 Engines 21-10-11 7. Fill and bleed the coaling system. Operate the -- engine until normal operating temperature is ‘.2/ reached. Check for leaks and check the coolant level. CYLINDER FRONT COVER AND TIMING CHAIN Removal 1. Drain the cooling system and the crankcase. Disconnect the radiator upper hose at the coolant TIMING MARKS outlet housing and the radiator lower hose at the water pump. On a vehicle with automatic I transmission, disconnect the transmission oil cooler lines from the radiator. -.

21-10-12 3.3L/4,1L 200/250 CID 1-6 Engines 21-10-12 proper grade and quantity of engine oil before staffing the engine. 8. Fill and bleed the cooling system. 9. Start the engine. Operate the engine at fast idle and check all hose connections and gaskets for leaks. FRONT OIL SEAL Removal 1. Remove the cylinder front cover. 2. Drive out the oil seal with a pin punch. Clean the recess in the cover. Installation 1. Coat a new seal with grease and install the seal. A3222-1A Drive the seal in until it is fully seated in the recess Fig. 20. Check the seal after installation to be sure FIG. 18 Timing Chain Snubber Installation-4.1L the spring is properly positioned in

21-10-13 3.3L/4.1L 200/250 CID 1-6 Engines 21-10-13 BEARINGS 6261 6763 INASHFR -. 627R / - r 3/1643 S CAMSHAFT-6250 CAMSHAFT REAR RFARING BORE PLUG-6266

21-10-14 3.31/4.1L 200/250 CID 1-6 Engines 21-10-14 On a vehicle with an automatic transmission, remove the transmission and converter housing following the procedure in Volume One, Group 17-Automatic Transmission. Do not drain the transmission. 2. Refer to Part 21-01, Cleaning and Inspection, for flywheel face runout checking procedure. Remove the flywheel attaching bolts and remove the flywheel. Installation 1. Clean and inspect all parts before installation. Position the flywheel on the crankshaft flange. Apply oil-resistant sealer to the attaching bolts. Install and torque the bolts to sequence across from each other to specification. 2. On a manual-shift transmission, install the clutch pressure plate, disc, a

21-10-15 3.31/4.1L 200/250 CID 1-6 Engines 21-10-15 2. Remove radiator top support 2 bolts. GRANADA/MONARCH 3. Remove oil level dipstick. Removal 4. Raise vehicle on hoist. 1. Disonncect 2 oil cooler lines at radiator if 5. Drain crankcase. equipped. 6. Remove 4 bolts and nuts attaching sway bar to 2. Remove radiator top support 2 bolts. chassis and allow sway bar to hang down. 3. Remove oil level dipstick. 7. Remove K brace. 4. Raise vehicle on hoi

21-10-16 3.3L/4.1L 200/250 CID 1-6 Engines 21-10-16 0! L PAN GASKET 1k ‘EAR SEAL -*: r :4 A16E-2A FIG. 25 -.3.3L 200 CID 1-6 Oil Pan Gaskets and Seals 2. Position the oil pan seals in the cylinder front cover 3. Position a new gaske

21-10-17 3.3L/4.1L 200/250 CID 1-6 Engines 21-10-17 5. Rotate the crankshaft in the direction of engine rotating the pump shaft until oil emerges from the rotation to force the bearing out of the block. outlet opening. Then install the oil pump and the inlet tube, following instructions under Oil PanInstallation Installation. 1. Clean crankshaft journals. Inspect journals and 9. Clean the gasket surfaces of the block and oil pan. thrust faces thrust bearing for nicks, burrs or Be sure to clean the seal grooves of the block and b

21-10-18 3.31/4.11 200/250 CID 1-6 Engines 21-10-18 8. Install the oil pump assembly and oil pan following 8. After the piston and connecting rod assemblies the procedure under Main Bearings. have been installed, check the connecting rod side clearance on each crankshaft journal Fig. 29. PISTONS AND CONNECTING RODS 9. Prime the oil pump by filling the inlet opening with Removal the oil and rotating the pump shaft until oil emerges 1. Drain the cooling system and the crankcase. from the outlet opening. Install the oil pump and

21-10-19 3.31./4.1L 200/250 CD 1-6 Engines 21-10-19 10. Install the cylinder head by following the 1. With engine removed from vehicle and placed on instructions under Cylinder Head Installation. a work stand, remove the oil level dipstick. 11. Fill the crankcase with proper grade of oil. 2. Remove the accessory drive pulley if so equipped. 12. Start the engine and check far oil pressure. Operate Remove the crankshaft damper attaching bolt and the engine at fast idle and check for oil, coolant, washer. Remove the crankshaft vibration damper fuel and vacuum leaks. using Tool T58P-63 16-B. 13. Check and adjust the ignition timing, engine idle 3. Remove the cylinder front cov

21-10-20 3.3L/4.IL {200/250 CD 1-6 Engines 21-10-20 2. Remove the main bearing inserts from the block and 20. Turn the engine on the work stand so that the front bearing caps. end is up. Install the timing chain and sprockets, 3. Remove the connecting rod bearing inserts from the cylinder front cover and crankshaft pulley or connecting rods and caps. damper, as detailed under Cylinder Front Cover and Timing Chain Installation. -4. Clean the rear journal oil seal grooves. Install a new 21. Clean the oil pan, oil pump, and oil pump screen. rear journal oil seal in the block and rear

21-10-2 1 3.31/4.11 200/250 CID 1-6 Engines 21-10-2 1 T65L-62E3A PULLER SCREW EXTENSION A2813-2A FIG. 32 Typical Camshaft Bearing Replacement bearings with the oil hales in the cylinder block OIL FILTER when the bearings are installed. Be sure the front bearing is installed below the front face of the Removal cylinder block to specifications. The rear has 1. Place a drip pan under the filter. Unscrew the filter two oil holes and must be installed 24-3/4 from the adapter fitting. Clean the a

21-10-22 3.3L/4.1L 200/250 CID l-óEngines 21-10-22 BOLT -6A527 3 7034/S FRONT OF ENGINE SUPPOPT-6531 - ROCKER ARM-6564 "ft PIN- 372929-S SUPPORT BOLT HOLES in SPRING WASHER-EBBS

21-10-23 3.31/4.11 200/250 CID 1-6 Engines 21-10-23 before removing the valves. Be careful not to VALVE SPRING COMPRESSOR scratch the cylinder head gasket surfaces. 2. Compress the valve springs Fig. 35. Remove the valve retainer locks and release the spring. If the valve locks are stuck, place a piece of steel tubing 3/4 inch OD, 1/2 inch ID and 3 inches long over the end of the valve stem squarely against the sleeve surface. Tap the tube with a steel hammer to disengage the locks. 3. Remove the sleeve, spring retainer, stem seal, and valve. Discard the valve stem seals. Identify all valve parts. If the cylinder head is to be replaced, remove the manifold assembly. Assembly 1. Clean, inspect and repair all parts befor

21-10-24 3.3L/4.1L 200/250 CID 1-6 Engines 2 1-10-24 PR ESS RAM 6148 -- DRIVER A-I OIL RING ASSEMBLY PISTON PIN PISTON 5175

21-10-25 3.3L/4.1L 200/250 CID 1-6 Engines 21-10-25 Assembly old cylinder block, following the instructions given 1. Clean the gasket and seal surf aces at aL% in the Removal and InstalLation Section of tI’sis Pan. serviceable parts and assemblies. 3. Check all assembly clearances and correct as 2. Position the new cylinder block in the work stand necessary. and transfer all serviceable parts removed from the "This publication contains material that is reproduced and distributed under a license to Detroit Iron from Ford Motor Company. No further reproduction or distri

21-10-26 3.31/4.1L 200/250 CID 1-6 Engines 21-10-26 SPECIFICATIONS GENERAL SPECIFICATIONS CAMSHAFT Conlinlaed DISPLACEMENT 3,3L/4.l L 200 CID/250 do JOuRNAL DIAMETER NUMGEROFCYLINOEBS 6 WI 1.8005.1.8105 BORE AND STROKE 3,68 K 3.! 3,31 200 LID #2 l.00J95-.8105 3.68 x 391 4.11250 LID # 3 l.8095.1

21-10-27 3.3L/4.1L 200/250 CID -6 Engines 21-10-27 CONMECTING ROD, PISTON AND RINGS TORQUE SPECIFICATIONS Eantinaad OIL FILTER INSERT TO CYLINDER BLOCK 015 ROD CONNECTING OILFILTERTOBLOCKORAOAPTER 0.9t04-0.9112 Pienu s Pna Bane Diameter OIL

21-12-1 2.8L V-6 Engine 21-12-1 PART 2.8L V-6 Engine 21-12 Pinto, Bobcat and Mustang II SUBJECT PAGE SUBJECT PAGE ADJUSTMENTS REMOVAL AND INSTALLATI ON Cont’d. Valve Clearance 12-4 Cylinder Front Cover 1212 Cylinder Head 12-10 DESCRIPTION Engine Assembly 12-5 Crankcase Ventilation System - -

21-12-2 2.81 V-6 Engine 21-12-2 A3717-2C FIG. I 2.8L V-6 Engine-With Thermactor and A/C-Left Front View "This publication contains material that is reproduced and distributed under a license to Detroit Iron from Ford Motor Company. No further reproduction or distribution of the Ford Motor Company material is allowed without the express written permission of Ford Motor Company."

A371&-20 FIG. 2 28L V-6 Engine-With Thermactor and A/C-Right Front View "This publication contains material that is reproduced and distributed under a license to Detroit Iron from Ford Motor Company. No further reproduction or distribution of the Ford Motor Company material is allowed without the express written permission of Ford Motor Company."

21-12-4 2.8L V-6 Engine 21-12-4 A3541 -28 FIG. 3 V-6 Engine Full Pressure Lubrication System ADJUSTMENTS CAUTION: Do not operate the engine with the 12. Reposition vacuum hoses as required to facilitatehood open until the fan has been first examined rocker arm cover removal.for possible cracks and separation. 13. Remove rocker arm cover attaching screws. VALVE CLEARANCE

21-12-5 2.81 V-6 Engine 21-12-5 with a rearward or forward motion that is parallel to centerline of the crankshaft. Dci not insert feeler at outboard edge and move inward toward carburetor perpendicular to the crank centerline. This will produce an erroneous "feel" that will result in excessively tight valves. d.Using the same method, adjust the No. 1 exhaust valve lash so that a 0.018" feeler has a light to moderate drag and a 0.0 19" feeler is very tight. e. Adjust the remaining valves, in firing order 1-4-2- 5-3-6 by positioning the cam according to the following chart: To adjusi both valves Ici cylinder# 4 2 5 3 6 The

21-12-6 2.8L V.6 Engine 21-12-6 19. Raise the engine slightly and carefully pull it from the drive belt and adjust the belt tension to the transmission. Carefully lift the engine out of the specifications. engine compartment so that the rear cover plate 16. Position the an shroud over the fan. Install the is not bent or components damaged. Install the radiator and connect the radiator upper and lower engine on a work stand. hoses. Install the fan shroud attaching bolts. 17. Fill and bleed the cooling system. See Part 27-01Installation for detaile

21-12-7 2.8L V-6 Engine 21-12-7 INSULATOR ASSY. - 60010 RH. 6066 ASSY FOR AUTO & -‘ 6A087 ASSY P H

21-12-8 2.81 Vó Engine 21-12-8 equipped to the transmission. Install the two attaching bolts and torque to specification. 2. If required, install the fasteners attaching the exhaust hanger to the insulator and torque to specification. 3. Install the crossmember to the frame side rails and torque the attaching nuts and bolts to specification. 4. Lower the transmission and install the insu lator to crossmember attaching nuts and torque to specification. 5. Remove the jack and wood block from under the transmission. CRANKCASE VENTILATION PCV VALVE Removal 1. Remove the inlet hose from the air cleaner. 2. Remove the air cleaner. 3. Remove the crankcase vent hose and PCV valve from the rocker cov

21-12-9 2.81 V-6 Engine 21-12-9 retainer and the valve spring. If air pressure foils Installation to hold the valve in the closed position during 1. Install a new valve stem seal Fig. 9. Position the this operation, it can be presumed that the spring over the valve. Install the spring retainer. valve is not seating or is damaged. If this Compress the valve spring and install the valve condition occurs, remove the cylinder head for spring retainer lacks. further iction. 2. Apply Lubriplate or equivalent to both ends of the push rod, the valve tips and bo

21-12-10 2.81 V-6 Engine 21-12-10 A355 liD FIG. 10 Intake Manifold Torque Sequence 5. Install fuel line. Replace rocker arm cover gaskets, and reinstall rocker arm valve covers using the procedure given under Rocker Arm Cover Installation. A483-lB6. Install distributor cap, coat the inside of each spark plug wire connector with silicone grease with a FIG. 11 Exhaust Manifold Torque Pattern- small screwdriver, and install the wires. Connect distributor wiring harness.

21-12-11 2.8L V-6 Engine 21-12-11 A3552-1A FIG. 12 Cylinder Head Guide Studs FIG. 14 Removing or Installing Tappets-Typical FIG. 13 Cylinder Head Bolts Torque Sequence 2. Install the cylinder head and related parts, 5. Apply Lubriplate or equivalent lubricant to both following the procedures given under Cylinder ends of the push rods. Install valve push rods, oil Head Installation. baffles and rocker arm and shaft assemblies. 6. Install distributor and connect wiring harness. WATER PUMP Install distributor hold.down bolt and cl

21-12-12 2.SL V-ó Engine 21-12-12 CYLINDER FRONT COVER Installation Clean the mating surfaces of gasket material.Removal Apply sealing compound to the gasket surfaces on 1. Remove oil pan as described under Oil Pan- the cylinder block and back side of the front cover Removal. plate. Position gasket and front cover plate on 2. Drain the coolant. Remove the radiator and any cylinder block Fig. 16. Temporarily install four other parts to provide necessary clearance. front cover screws to position gasket and cover 3. Remove A

2142-13 2.8L V-6 Engine 21-12-13 7. Install oil pan following Oil Pan Installation procedure. 8. Install water pump, water hose, A/C compressor, alternator, thermactar pump and drive belts. Adjust drive belt tension to specifications. 9. Fill the cooling system to the proper level with the TOOL-T74P6700-4 - specified coolant. See Part 27.01 for detailed instructions. 10. Operate the engine at fast idle speed and check for coolant and oil leaks. FRONT OIL SEAL In-Chassis Removal 1. Drain the coolant. Remove the radiator and crankshaft pulley and water pump drive belt. It is not necessary to remove the front cover for this operation.

21-12-14 2.81 V-6 Engine 21-12-14 Installation 1. Oil the camshaft journals with heavy SE engine oil and apply Lubriplate or equivalent lubricant to the cam lobes. 2. Install the camshaft in the block, carefully avoiding damage to the bearing surfaces. 3. Install the spacer ring with the

21-12-15 2.8L V-6 Engine 21-12-15 9. Install oil pan, as described under Oil Pan 2. Check the camshaft end play Part 21-01. If Installation. not within specifications, replace the thrust 10. Apply Lubriplate or equivalent to both ends of the plate. push rods. Install valve push rods in same location 3. Position the key in the crankshaft. Align the keyway as removed. in the crankshaft gear with the key in the 11. Install intake manifold, as described under Intake crankshaft, and align the timing marks as shown in

21-12-16 2.8L V-6 Engine 21-12-16 timing. Operate the engine at fast idle and check and rear of the oil pan. Install the remaining bolts all hose connections and gaskets for leaks. and torque to specification in the sequence shown. OIL PAN 6. Reinstall the clutch cover or converter housing. 7. Raise the engine and remove the wood blacks. Removal Lower the engine and install the engine support 1. Remove the oil level dipstick. nuts. Torque to specification. 2. Remove the radiator pressure ca

21-12-17 2.81 V.6 Engine 21-12-17 Installation 1. Using Tools T74P-7137-A and T71P-7137-H install the pilot service bearing with the seal facing the transmission Fig. 32. A13-iB FIG. 30 Oil Pump and Inlet Tube Installed position with new gasket and install attaching screws. Tighten screws securely. Clean and install the oil pump inlet tube and screen assembly with a new gasket. Torque the bolts to spe

21-12-18 2.BL V-6 Engine 21-12-18 pressure plate and disc following the procedure in in each hole Fig. 34. Use two large screwdrivers Group 16-Clutch. or small pry bars and pry against both screws at On a vehicle with automatic transmission, remove the same time to remove the crankshaft rear oil the transmission and converter housing following seal. It may be necessary to place small blocks of the procedure in Group 17-Automatic wood against the cylinder block to provide a Transmission. fulcrum point for the pry bars. Use caution throughout this procedure

21-12-19 2.8L V-6 Engine 21-12-19 2. Install rear plate, flywheel housing, and flywheel. Tighten flywheel bolts to specifications. 3. Install clutch disc and clutch pressure plate, if so equipped. Align clutch disc before tightening pressure plate attaching screws. 4. Install transmission. MAIN BEARINGS The main and connecting rod bearing inserts are selective fit. Do not file or lap bearing caps or use shims to obtain the proper bearing clearance. Selective fit main bearings are available for service in standard and undersizes. Refer to the parts catalog for the available sizes. Undersize bearings which are not selective fit, are available for use on journals that have been refinished. See specifications. If the rear main bearin

21-12-20 2.81. V-6 Engine 21-12-20 9. Fill the crankcase to the correct level with the specified oil. Start the engine and check for leaks. WEDGE SEALS PISTONS AND CONNECTING RODS Removal 1. Drain the cooling system and the crankcase. Remove the intake manifold, cylinder heads, oil pan and oil pump, following

21-12-21 2.8L V-6 Engine 21-12-21 RIGHT SACK LEFT BACK A3519-1A NuMBERED SIDE TO LEFT A3SBO-IA FIG. 39 Connecting Rod and Cap Numbering FIG. 42 Correct Piston and Rod Positions 5. Check the clearance of each bearing following the OIL RING SPACER procedure under Fitting Main and Connecting Rod Bearings in Part 21-01. OIL RING

21-12-22 2.81 V-6 Engine 21-12-22 12. Install the cylinder heads following procedures 8. Remove connecting rod nuts and lift off rod cap under Cylinder Head Installation. with bearing insert. Carefully push piston and rod 13. Install the intake manifold following procedures assemblies dawn in cylinders. under Intake Manifold Installation. 9. Remove main bearing bolts and lift off main 14. Fill and bleed the cooling system. Fill the crankcase bearing caps with inserts. Discard rear oil seal. with the proper grade and quantity of engine oil. 10. Carefully lift crankshaft out of cylinder block, being 15. Start the engine and check and adjust the ignition

21-12-23 2.SL V-6 Engine 21-12-23 rearward. While holding in this position, tighten the With the expanding collet collapsed, install the cap bolts to specifications Fig. 37. callet assembly in the camshaft bearing. Tighten the 7. Coat the sealing lip of a new crankshaft oil seal back-up nut on the expanding mandrel untO the with SE-type engine oil. Slide seal over end of callet fits the camshaft bearing. crankshaft and drive into position Fig. 35. Be sure 4. Assemble the puller screw and extension if the seal bottoms in groove. necessary as shown and install on the expanding 8. Using a flat tool such as a large blunt end mandrel. Wrap a cl

2 1-12-24 2.81 V-6 Engine 21-12-24 Installation repairs to correct the leakage. Check the oil level 1. Coat the gasket on the replacement filter with oil. and fill the crankcase to the recommended level if Position the filter on the adapter fitting. Hand necessary. tighten the filter until the gasket contacts the adapter face, then advance it 1/2 turn. 2. Operate the engine at fast idle, and check for oil leaks. If oil leaks are evident, perform the necessary DISASSEMBLY AND ASSEMBLY When installing nuts or bolts that must be torqued 4. Install the remaining spring washer and pin. refer to the Specification at the end of this Part for 5. Before in

21-12-25 2.81 V.ó Engine 21-12-25 Assembly 1. Clean, inspect and repair all parts before assembly. INSERT THIS ENO FOR INSTALLATION Install the manifold assembly and spark plugs. Torque the spark plugs and manifold attaching -- parts to specifications. Lubricate the valve guides and valve stems with engine oil. Apply Lubriplate DETAILDR$ V ERA-7 or equivalent to the tips of the valve stems. 2. Install each valve in the valve guide from which it was removed or to which it was fitted. Install a new stem seal on the valve.

21-12-26 2.81 V-6 Engine 21-12-26 4. Follow the manufacturer’s instructions included 2. Position the new cylinder assembly in a work stand with the piston ring package and install the piston and transfer all serviceable parts removed from the rings. old cylinder assembly, following the procedures 5. Check the ring side clearance of the compression given in the Removal and Installation Section of this rings with a feeler gouge inserted between the ring Part. and the lower land Part 21-01. The gouge should 3. Check all assembly clearances and correct as slide freely around the entire ring circumference necessary. without bindin

21-12-27 28L V.6 Engine 21-12-27 SPECWUCATIONS GENERAL SPECIFICATIONS RAPT ICoatietoedi DISPLACEMENT - -- #3 25LI2800ccI -- 1.6t97-1t215 SOMBER or CYLINDERS -

___ 21-12-28 2.81 V-6 Engine 21-12-28 CONNECTING ROD, PISTON AND RINGS TORGUE SPECIFICATIONS - SPECIAL APPLICATIONS IC unite cdl CONNECTING RGO ITEM - - - - SIZE TOROUC Pistxn Pin Rote Diameter 0.9490-0.9452 TIMING POINTFR TO FRONT COVER IRsIll MC 5-7 Crniskxliaft Beating Rorn Diemulet 2.2370-2.2378 OIL PUMP PICK-UP TUBE TO PUMP IBoIII MG 7-9 Osl-DI-tniasd 0

21-21-1 5.0L/5.8L 302/351 "W" CID V-B Engines 21-21-1 5.OL/5.8L 302/351 "W" CID 21-21 V-8 Engines Mustang II, Fairment, Zephyr, Granada, Monarch, LTD II, Cougar, Thunderbird. Ford, Mercury and Versailles SUBJECT PAGE SUBJECT PAGE DESCRIPTION REMOVAL AND INSTALLATION Cont’d Crankcase Ventilation System 21-1 Front Oil Seal 21-16 Engine 21-1 Intake Manifold 21-10 Exhaust Emission Control System 21-1 Main Bearing 21-22

21-21-2 5.OL/5.8L 302/351 "W" dID V-8 Engines 21-21-2 A3287-28 FIG. 1 3/4 Right Front View-&OL 302 CID V-8 Engine -v FIG. 2 3/4 Left Front View-5.8L 351 "W" CID V-8 Engine "This publication contains material that is reproduced and distributed under a license to Detroit Iron from Ford Motor Company. No further reproduction or distribution of the Ford Motor Company material is allowed without the express written permission of Ford Motor Company."

21-21-3 5.01/5.81 302/351 ‘lw,t CID V-8 Engines 21-21-3 REMOVAL AND INSTALLATION CAUTION: Do not operate the engine with the 10. Remove the flywheel or converter housing to engine hood open until the fan has been first examined upper bolts. for possible cracks and separation. 11. Disconnect the primary wiring connector from the When installing nuts or bolts that must be tarqued, ignition coil. Remove the wire harness from the left rocker arm cover and position the wires out of the oil the threads with light weight engine oil. Do not oil threads that require oil-resistant or water- way. Disconnect the ground strap from the block. resistant sealer.

21-21-4 5.OL/5.8L 302/351 "W" CID V.8 Engines 21-21-4 On a vehicle with a manual-shift transmission, SHIELD - install the remaining flywheel housing to engine SCOSOLit SIDE ONLY bolts. Position the clutch equalizer bar to the engine 6032 ASSV. block and install the equalizer bar bracket on the 2 REOP. frame side rail. On a vehicle with an automotic transmission,