Engine Service - Ford LRG-423 Service Manual

01-I
Engine Service
01-I
SECTION TITLE
PAGE
SECTION TITLE
PAGE
ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..' ......................
01-I
AUXILIARY
SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 03-l
ENGINE SERVICE, 2.3L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-l
SECTION 01 - Engine Service
SUBJECT
DESCRIPTION AND OPERATION
Introduction ...............................................................................
3
Engine Identification
Nameplate .............................................
3
DIAGNOSIS AND TESTING
Inspection ..................................................................................
4
Symptom Chart .........................................................................
4
SERVICE PROCEDURES
Positive Crankcase Ventilation (PCV) System
Closed-Type ............................................................................
6
Engine Oil Leaks .......................................................................
6
Fluorescent
Oil Additive Method ..........................................
6
Pressure
Method ....................................................................
6
Testing Procedure ..................................................................
6
Leakage Points .......................................................................
7
Compression
Test .....................................................................
7
Compression
Gauge Check ..................................................
7
Test Results ............................................................................
7
Compression
Pressure Limit Chart ......................................
7
Compression Readings -
Interpreting ................................
8
Example Readings .................................................................
8
Cylinder Leakage Detector .......................................................
8
Oil Leak and Valve Guide Seal Test ........................................
8
Intake Manifold Vacuum Test ..................................................
8
Vacuum Gauge Readings - Interpretation
........................ .9
Oil Consumption
Test ..........................................................
10
Oil Pressure Test ..................................................................
11
Valve Train Analysis -Static
(Engine Off) ..........................
11
Rocker Arm/Camshaft
Follower Cover Removed ............
.l 1
Rocker/Camshaft
Follower Arm Assemblies..
.................. .I 1
Camshaft -
2.3L Engine .....................................................
11
Valve Springs .......................................................................
11
Valve Spring Retainer and Valve Spring Keys ................. .I1
Valves and Cylinder Head ...................................................
11
Intake Valve Cleaning (Valves Installed) ............................... 11
Cleaning and Inspection ......................................................
11
Camshaft Lobe Lift, 2.3L Overhead Camshaft
Engine (Camshaft
Installed) ................................................
13
Hydraulic Valve Tappet/Lash
Adjuster .................................
13
Camshaft
End Play .................................................................
13
Timing Belt (2.3L) ....................................................................
14
Camshaft Timing and Cylinder Identification (CID)
Timing Check .......................................................................
14
Crankshaft
End Play ...............................................................
15
Connecting Rod Side Clearance
...........................................
15
Cylinder Block .........................................................................
15
Cleaning and Inspection ......................................................
15
Cylinder Block Distortion ....................................................
15
Cylinder Head Deck Flatness ..............................................
15
Main Bearing Bore Alignment .............................................
15
Cylinder Walls, Refinishing ....................................................
16
Cleaning ................................................................................
16
SUBJECT
PAGE
SERVICE PROCEDURES (Cont' d.)
Inspection .............................................................................
16
Cylinder Bore .......................................................................
16
Cylinder Bore Taper ............................................................
16
Cylinder Out-of-Round ........................................................
17
Cylinder Bore Diameter .......................................................
17
Cylinder Wall Honing ..........................................................
17
Engine Block Plugs ................................................................
18
Removal and Installation ....................................................
18
Expansion-Type
...................................................................
18
Cup-Type ..............................................................................
18
Crankshaft Main and Connecting
Rod Bearings.. ............... 19
Cleaning ...............................................................................
19
Inspection .............................................................................
19
Crankshaft Main or Connecting Rod Bearings -
Fitting Plastigage@ Method ..... ........ ................ ................
19
Bore Gauge Method ............................................................
20
Crankshaft
..............................................................................
21
Cleaning ...............................................................................
21
Inspection .............................................................................
21
Crankshaft
Runout ..............................................................
21
Crankshaft
End Play ............................................................
21
Crankshaft Main Journals and Connecting Rod
Journals ................................................................................
21
Journals Refinishing ...........................................................
21
Crankshaft
Sprocket ..............................................................
21
Pistons, Piston Pins and Piston Rings ................................
22
Cleaning ...............................................................................
22
Inspection .............................................................................
22
Pistons - Fitting .................................................................
22
Piston Rings -
Fitting ........................................................
22
Piston and Piston Pin Fit ....................................................
23
Connecting
Rods ...................................................................
24
Cleaning ...............................................................................
24
Inspection .............................................................................
24
Piston Pin Clearance ...........................................................
24
Camshaft .................................................................................
24
Cleaning ...............................................................................
24
Inspection .............................................................................
24
Camshaft Bearings ................................................................
24
Camshaft Bearing Journals ..................................................
25
Camshaft Journals Oil Clearance ......................................
25
Camshaft Runout ...................................................................
25
Cam Lobe Lift (Camshaft
Removed) ....................................
25
With Calipers ........................................................................
25
On a Camshaft Grinder or Lathe ........................................
25
Camshaft Sprocket ................................................................
26
Hydraulic Roller Valve Tappets ............................................
26
Cleaning ...............................................................................
26
Inspection .............................................................................
26