Engine Diagnosis and Repair 32 - Engine Repair Student Guide FCS14627REF FCS-14627-REF Course Code: 32S09T0 April, 2007 Ford Customer Service Division Technical Training IMPORTANT SAFETY NOTICE Appropriate service methods and proper repair procedures are essential for the safe, reliable operation of all motor vehicles, as well as the personal safety of the individual doing the work This manual provides general directions for accomplishing service and repair work with tested, effective techniques Following them will help assure reliability There are numerous variations in procedures, techniques, tools and parts for servicing vehicles, as well as in the skill of the individual doing the work This manual cannot possibly anticipate all such variations and provide advice or cautions as to each Accordingly, anyone who departs from instructions provided in this manual must first establish that he compromises neither his personal safety nor the vehicle integrity by his choice of methods, tools or parts As you read through the procedures, you will come across NOTES, CAUTIONS, and WARNINGS Each one is there for a specific purpose NOTES give you added information that will help you to complete a particular procedure CAUTIONS are given to prevent you from making an error that could damage the vehicle WARNINGS remind you to be especially careful in those areas where carelessness can cause personal injury The following list contains some general WARNINGS that you should follow when you work on a vehicle • • Always wear safety glasses for eye protection • • • To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler Be sure that the ignition switch is always in the OFF position, unless otherwise required by the procedure • • Do not smoke while working on the vehicle Set the parking brake when working on the vehicle If you have an automatic transmission, set it in PARK unless instructed otherwise for a specific service operation If you have a manual transmission it should be in REVERSE (engine OFF) or NEUTRAL (engine ON) unless instructed otherwise for a specific service operation • Keep hands and other objects clear of the radiator fan blades Electric cooling fans can start to operate at any time by an increase in underhood temperatures, even though the ignition is in the OFF position Therefore, care should be taken to ensure that the electric cooling fan is completely disconnected when working under the hood Use safety stands whenever a procedure requires you to be under the vehicle • Operate the engine only in a well-ventilated area to avoid the danger of carbon monoxide • Keep yourself and your clothing away from moving parts when the engine is running, especially the fan and belts To avoid injury, always remove rings, watches, loose hanging jewelry, and loose clothing before beginning to work on a vehicle Tie long hair securely behind your head The recommendations and suggestions contained in this manual are made to assist the dealer in improving his dealership parts and/or service department operations These recommendations and suggestions not supersede or override the provisions of the Warranty and Policy Manual, and in any cases where there may be a conflict, the provisions of the Warranty and Policy Manual shall govern The descriptions, testing procedures, and specifications in this handbook were in effect at the time the handbook was approved for printing Ford Motor Company reserves the right to discontinue models at any time, or change specifications, design, or testing procedures without notice and without incurring obligation Any reference to brand names in this manual is intended merely as an example of the types of tools, lubricants, materials, etc recommended for use Equivalents, if available, may be used The right is reserved to make changes at any time without notice WARNING: Many brake linings contain asbestos fibers When working on brake components, avoid breathing the dust Breathing the asbestos dust can cause asbestosis and cancer Breathing asbestos dust is harmful to your health Dust and dirt present on car wheel brake and clutch assemblies may contain asbestos fibers that are hazardous to your health when made airborne by cleaning with compressed air or by dry brushing Wheel brake assemblies and clutch facings should be cleaned using a vacuum cleaner recommended for use with asbestos fibers Dust and dirt should be disposed of in a manner that prevents dust exposure, such as sealed bags The bag must be labeled per OSHA instructions and the trash hauler notified as to the contents of the bag If a vacuum bag suitable for asbestos is not available, cleaning should be done wet If dust generation is still possible, technicians should wear government approved toxic dust purifying respirators OSHA requires areas where asbestos dust generation is possible to be isolated and posted with warning signs Only technicians concerned with performing brake or clutch service should be present in the area Copyright © 2007 Ford Motor Company Produced and Coordinated by Technical Service Support Operations Ford Customer Service Division April, 2007 M CUSTOMER EXPECTATIONS Customer Expectations: Service Make it convenient to have my vehicle serviced at your dealership The Service Advisor should demonstrate a genuine concern for my service needs Fix it right the first time, on time Complete servicing my vehicle in a timely and professional manner Provide me with a clear and thorough explanation of the service performed Call me within a reasonable amount of time after my service visit to ensure that I'm completely satisfied Be responsive to questions or concerns that I bring to your attention Expectation #3 “Fix It Right the First Time, on Time.” Both service advisors and technicians are important players when it comes to Expectation #3 Why Customers tell us “Fixing It Right the First Time, on Time” is one of the reasons they would decide to return to a dealer to buy a vehicle and get their vehicles serviced Technician Training It is our goal to help the technician acquire all of the skills and knowledge necessary to “Fix it Right the First Time, on Time.” We refer to this as “competency.” Technician’s Role Acquire the skills and knowledge for competency in your specialty via: STST New Model — Web-Based — Web-Based — Instructor Led — Instructor Led The Benefits The successful implementation of expectations means: — Satisfied customers — Repeat vehicle sales — Repeat service sales — Recognition that Ford and Lincoln/Mercury technicians are “the Best in the Business” ENGINE DIAGNOSIS AND REPAIR TABLE OF CONTENTS INTRODUCTION INTRO - Course Description Intro - Course Requirements Intro - Course Objectives Intro - Course Agenda Intro - PREREQUISITE REVIEW - LESSON ONE WORKSTATIONS - Lesson One – Bore Gauge and Measuring Tools Demonstrations 1-10 Lesson One – Workstation Part 1: Oil Leak Diagnosis -14 Lesson One – Workstation Part 2: Noise Diagnosis - 16 Lesson One – Workstation 2: Cam Phaser Replacement With Timing Cover Installed - 19 Lesson One – Workstation 3: Scan Tool/Smoke Machine - 21 Lesson One – Workstation 4: Precision Measurements - 23 Lesson One – Written Activity - 30 LESSON TWO WORKSTATIONS - Lesson Two – Workstation 1: On-Vehicle Runs Rough/Lack of Power Diagnosis - Lesson Two – Workstation Part 1: Engine Misfire CMT - Lesson Two – Workstation Part 2: Engine Overheat - Lesson Two – Workstation 3: On-Vehicle Runs Rough/Engine Noise Concern - 10 Lesson Two – Workstation Part 1: Lower Engine Noise CMT - 13 Lesson Two – Workstation Part 2: Lower Engine Noise CMT - 17 Lesson Two – Written Activity - 20 LESSON THREE WORKSTATIONS - Lesson Three – Manual Compression and Cylinder Leakage Tests Demonstration - Lesson Three – Workstation 1: Misfire and Low Compression Concern 2.3L Engine - Lesson Three – Workstation 2: Engine Teardown 4.0L SOHC - Lesson Three – Workstation 3: Engine Teardown 5.4L 2V - 12 Lesson Three – Workstation 4: Engine Teardown 4.6L 3V - 16 Lesson Three – Written Activity 3-19 LESSON FOUR WORKSTATIONS - Lesson Four – Workstation 1: Camshaft Timing 2.3L - Lesson Four – Workstation 2: Camshaft Timing 4.0L SOHC - Lesson Four – Workstation 3: Camshaft Timing 5.4L 2V - Lesson Four – Workstation 4: Camshaft Timing 4.6L 3V - APPENDIX APPENDIX - Write-Up Job Aid Appendix - Engine Diagnosis and Repair TOC - i April, 2007 ENGINE DIAGNOSIS AND REPAIR Engine Diagnosis and Repair TABLE OF CONTENTS TOC - ii April, 2007 ENGINE DIAGNOSIS AND REPAIR INTRODUCTION INTRODUCTION Engine Diagnosis and Repair Intro - April, 2007 ENGINE DIAGNOSIS AND REPAIR INTRODUCTION ENGINE DIAGNOSIS AND REPAIR Course Description 4.6L 3V Engine This is a 4-day course facilitated by an instructor This course is designed to provide hands-on opportunities for technicians to learn and improve their skills using tools and equipment, and to apply knowledge learned in previous curriculum courses Each day you will have multiple opportunities to practice selected skills The results of your work are recorded on worksheets Engine Diagnosis and Repair Intro - April, 2007 ENGINE DIAGNOSIS AND REPAIR INTRODUCTION Course Requirements Each technician attending this course will be required to pass a combination of hands-on and written evaluations These will be administered on the afternoon of the fourth day z The hands-on evaluation is a pass/fail type It will be conducted with exercises in engine repair, measurement and diagnosis, and will cover: – engine disassembly/assembly – engine cam timing – service publication navigation – selected special tool usage In order to pass the course, you must demonstrate mastery of the skills covered at the evaluated hands-on exercise AND you must answer at least 80% of the written post-test questions correctly Course Objectives Upon successful completion of this course, you will be able to: z Identify which diagnostic test to perform given an engine concern z Perform diagnostic test correctly and interpret results z Perform disassembly and inspection of cylinder heads z Perform disassembly and inspection of engine block z Perform measurements using the correct tools and interpret results correctly z Perform proper procedure for installing the crankshaft z Perform proper procedure for installing pistons and rings z Perform proper torquing procedures z Perform proper camshaft installation and timing procedure z Perform proper diagnostic tests for engine noise concerns Engine Diagnosis and Repair Intro - April, 2007 ENGINE DIAGNOSIS AND REPAIR INTRODUCTION Course Agenda LESSON ONE: Prerequisite Review, Demonstrations-Bore Gauge Calibration and Use/Measuring Tools, Lesson Workstations (On-vehicle Noise/Oil Leak Diagnosis, Cam Phaser Replacement, On-vehicle Scan Tool/ Smoke Machine Diagnosis, Precision Measurements) LESSON TWO: Lesson Workstation Review, Lesson Workstations (Runs Rough/Lack of Power Diagnosis, Misfire CMTs, VCT Diagnosis, Noise CMTs) LESSON THREE: Lesson Workstation Review, Demonstration-Manual Compression and Cylinder Leakage Tests, Lesson Workstations (Engine Stand Disassembly 1, Engine Stand Disassembly 2, Engine Disassembly 3, Engine Disassembly 4) LESSON FOUR: Lesson Workstation Review, Lesson Workstations (Cam Timing 1, Cam Timing 2, Cam Timing 3, Cam Timing 4) Final Review, Post-Test Engine Diagnosis and Repair Intro - April, 2007 LESSON THREE WORKSTATION Perform a visual inspection Record your results below _ _ _ _ According to TSB 02-21-13, what is the specification for cylinder head warpage? _ _ _ What is the correct procedure to check cylinder head warpage using a straight edge and feeler gauges? A Place the straight edge on the cylinder head, slide feeler gauge under the straight edge B Place the feeler gauge on the cylinder head, place the straight edge on top of the feeler gauge Use the straight edge and feeler gauges to check the right hand cylinder head for warpage Use the workshop manual for procedures and specifications Is the cylinder head warpage within specification? If not, where is it warped? _ _ _ _ According to TSB 02-21-13, what should you if you find nicks or dents on the straight edge? _ _ Engine Diagnosis and Repair - 17 April, 2007 LESSON THREE WORKSTATION Use the straight edge to check the piston to deck height for cylinder number Does the piston contact the straight edge? _ _ Does the head of the piston appear to be parallel with the cylinder deck? Yes No If no, what could cause this? _ _ z Refer to the SSCC table and cross off items that are eliminated Which components may be the root cause of this concern? A Connecting rod B Cylinder head C Cooling fan D Radiator z Call the instructor to your workstation once all questions are answered z Follow the workshop manual and remove the left cylinder head Use the straight edge and feeler gauges to check the left hand cylinder head for warpage Use the workshop manual for procedures and specifications Is the cylinder head warpage within specification? If not, where is it warped? _ z Install the left cylinder using the workshop manual procedure Torque the head bolts to 20 Nm (15 lbft) and yield in two steps at 45 degrees each 10 Label the cylinder head bolt torque procedure in the graphic below z 1st, 2nd and 3rd groups in the rotation, leave the right cylinder head off the engine z 4th (last) group in the rotation, install the right cylinder head, but leave the right bank followers, timing chains and timing cover off Torque the head bolts to 20 Nm (15 lb-ft) and yield in two steps at 45 degrees each Engine Diagnosis and Repair - 18 April, 2007 LESSON THREE WRITTEN ACTIVITY LESSON WRITTEN ACTIVITY During a remanufactured long block installation, you notice metallic debris in the intake manifold What should you do? _ _ _ If oil, sludge or carbon build up is found in an intake manifold, it can be cleaned with hot soapy water True False What is the correct procedure to prime the oil system of a repaired or remanufactured engine? _ _ _ _ When installing an engine front cover with silicone sealant, how much time you have to get the cover installed and secured? A minute B minutes C 10 minutes D 15 minutes Which of the following statements concerning coolant fill and bleed is true? A The coolant can be drained into a floor drain or onto the ground B When adding coolant, fill the radiator completely, and fill the expansion tank to the COLD FILL mark C Make sure the heater is off during the bleed procedure D When adding additional coolant, make sure to add to the radiator, not the expansion tank Which tool can be used to fill and bleed the engine cooling system? A Power flush II B Pro drain C Radkitplus D None of the above Engine Diagnosis and Repair - 19 April, 2007 LESSON FOUR TOPIC LESSON FOUR Engine Diagnosis and Repair 4-1 April, 2007 LESSON FOUR WORKSTATIONS LESSON FOUR WORKSTATIONS Workstation: Summary: Hands-on activity in which the students will perform camshaft timing on a 2.3L engine Hands-on activity in which the students will perform camshaft timing on a 4.0L SOHC engine Hands-on activity in which the students will perform camshaft timing on a 5.4L 2V engine Hands-on activity in which the students will perform camshaft timing on a 4.6L 3V engine Engine Diagnosis and Repair 4-2 April, 2007 LESSON FOUR WORKSTATION WORKSTATION CAMSHAFT TIMING 2.3L 2006 RANGER DIRECTIONS: Complete Workstation at the ENGINE workstation, using the workshop manual and tools provided at the workstation SUMMARY: In this activity, you will perform the camshaft timing for the 2.3L engine z Read through the crankshaft pulley removal and installation procedure for this engine Then answer the following questions Find the special tools below in the workshop manual, and write the global tool number next to the graphic When installing the crankshaft pulley, what is aligned first, the camshaft or crankshaft, and why? _ _ Engine Diagnosis and Repair 4-3 April, 2007 LESSON FOUR WORKSTATION How should you hold the camshafts in place when tightening the camshaft sprocket bolts? _ _ _ _ z Follow the workshop manual and complete the crankshaft pulley removal and installation procedure z 1st, 2nd and 3rd group in the rotation, leave the valve cover off z 4th group in the rotation, install the valve cover Engine Diagnosis and Repair 4-4 April, 2007 LESSON FOUR WORKSTATION WORKSTATION CAMSHAFT TIMING 4.0L SOHC 2006 RANGER DIRECTIONS: Complete Workstation at the ENGINE workstation, using the workshop manual and tools provided at the workstation SUMMARY: In this activity, you will perform the camshaft timing for the 4.0L SOHC engine z Read through the timing procedure for this engine Then answer the following questions Two special tools are used on each camshaft Write each tools purpose under its graphic below 303-577 303-564 303-576 303-578 N0010389 N0010364 _ _ _ _ What will happen if the engine is turned counterclockwise during the camshaft timing procedure? _ _ _ _ What position should the camshaft timing slots be in to correctly fit the special tool? _ _ _ _ z Follow the workshop manual and complete the camshaft timing procedure z Call the instructor to the workstation to verify the camshaft timing is correct Engine Diagnosis and Repair 4-5 April, 2007 LESSON FOUR WORKSTATION WORKSTATION CAMSHAFT TIMING 5.4L 2V 2004 EXPEDITION DIRECTIONS: Complete Workstation at the ENGINE workstation using the workshop manual and tools provided at the workstation SUMMARY: In this activity, you will perform the camshaft timing for the 5.4L 2V engine z Read through the timing procedure for this engine Then answer the following questions Find the special tools in the workshop manual, and write their names below the following graphics _ _ _ Engine Diagnosis and Repair 4-6 April, 2007 LESSON FOUR WORKSTATION What position should the crankshaft keyway be in when beginning the timing procedure? _ _ _ What direction does the crankshaft sprocket flange face? _ _ _ If the marked links are not visible on the timing chains, what should you do? _ _ _ _ z Follow the workshop manual and complete the camshaft timing procedure z Call the instructor to the workstation to verify the camshaft timing is correct Engine Diagnosis and Repair 4-7 April, 2007 LESSON FOUR WORKSTATION WORKSTATION CAMSHAFT TIMING 4.6L 3V 2007 EXPLORER DIRECTIONS: Complete Workstation at the ENGINE workstation using the workshop manual and tools provided at the workstation SUMMARY: In this activity, you will perform the camshaft timing for the 4.6L 3V engine z Read through the timing procedure for this engine Then answer the following questions Find the special tools below in the workshop manual, and write their global tool numbers below the following graphics ST2807-A ST2804-A How should the left hand and right hand cam phaser sprockets be orientated? _ _ _ _ If the chain tensioner sealing bead has separated from the tensioner body, what should you do? _ _ _ How can you tell the difference between the right hand and left hand timing chain tensioner arms? _ _ _ Why must hand tools be used to remove the VCT phaser sprocket bolts? _ _ _ Engine Diagnosis and Repair 4-8 April, 2007 LESSON FOUR WORKSTATION The VCT phaser sprocket bolt cannot be reused True False z Follow the workshop manual and complete the camshaft timing procedure z Call the instructor to the workstation to verify the camshaft timing is correct Engine Diagnosis and Repair 4-9 April, 2007 LESSON FOUR Engine Diagnosis and Repair WORKSTATION 4 - 10 April, 2007 ENGINE DIAGNOSIS AND REPAIR APPENDIX APPENDIX Engine Diagnosis and Repair Appendix- April, 2007 ENGINE DIAGNOSIS AND REPAIR Engine Diagnosis and Repair APPENDIX Appendix - April, 2007 ... Appendix - Engine Diagnosis and Repair TOC - i April, 2007 ENGINE DIAGNOSIS AND REPAIR Engine Diagnosis and Repair TABLE OF CONTENTS TOC - ii April, 2007 ENGINE DIAGNOSIS AND REPAIR INTRODUCTION... INTRODUCTION INTRODUCTION Engine Diagnosis and Repair Intro - April, 2007 ENGINE DIAGNOSIS AND REPAIR INTRODUCTION ENGINE DIAGNOSIS AND REPAIR Course Description 4.6L 3V Engine This is a 4-day course... _ Engine Diagnosis and Repair 1-7 April, 2007 LESSON ONE PREREQUISITE REVIEW NOTES: Engine Diagnosis and Repair 1-8 April, 2007 LESSON ONE TOPIC LESSON ONE Engine Diagnosis and Repair 1-9