32S05T1 engine repair 2006

Engine RepairEngine Repair Student Book COURSE CODE: 32S05T1 ORDER NUMBER: FCS-14567-REF Ford Customer Service Division Technical Training Updated January, 2006... Intro-2 September, 20

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Engine Repair

Engine Repair Student Book

COURSE CODE: 32S05T1 ORDER NUMBER: FCS-14567-REF

Ford Customer Service Division Technical Training

Updated January, 2006

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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.

• Use safety stands whenever a procedure requires you to

be under the vehicle.

• Be sure that the ignition switch is always in the OFF

position, unless otherwise required by the procedure.

• 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

RE-VERSE (engine OFF) or NEUTRAL (engine ON) unless

instructed otherwise for a specific service operation.

• 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 prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler.

• Do not smoke while working on the vehicle.

• 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.

• 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.

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 do 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.

Technical Support Operations Ford Customer Service Division September, 2002

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5. Provide me with a clear and thorough explanation of the service performed.

6. Call me within a reasonable amount of time after my service visit to ensure that I'm completely satisfied.

7. Be responsive to questions or concerns

I bring to your attention.

1. Make it convenient to have my

vehicle serviced at your dealership.

2. The Service Advisor should

demonstrate a genuine concern for

my service needs.

3. Fix it right the first time.

4. Complete servicing my vehicle in a

timely and professional manner.

Expectation 3

“Fix It Right The First Time, on Time.”

Both service advisors and technicians are important players when it comes to Expectation

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:

– FordStar Broadcasts – FordStar Broadcasts

– Ford Multimedia Training (FMT) – 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”

Customer Expectations: Service

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Engine Repair September, 2002 i

DAY ONE

INTRODUCTION INTRO-1

Engine Repair Curriculum Path Intro-2 Curriculum Prerequisites Intro-2 Curriculum Goals Intro-3 Engine Repair Curriculum Intro-4 Course Objectives Intro-5 Day One Agenda – Morning Intro-6 Day One Agenda – Afternoon Intro-6 Day Two Agenda – Morning Intro-7 Day Two Agenda – Afternoon Intro-7 Day Three Agenda – Morning Intro-8 Day Three Agenda – Afternoon Intro-8 Day Four Agenda – Morning Intro-9 Day Four Agenda – Afternoon Intro-9

PREREQUISITE KNOWLEDGE REVIEW DAY ONE-1

Student’s Answer Sheet Day One-2

DAY ONE INTRODUCTION TO WORKSTATIONS DAY ONE-19

Introduction Day One-20

WORKSTATION 1 DAY ONE-23

Workstation 2 – Run Stand B

Workstation 3 – On-Vehicle

INTRODUCTION TO DAY TWO WORKSTATIONS DAY TWO-9

Workstation Introduction Day Two-10

WORKSTATION 5 DAY TWO-13

Workstation 5 – Engine On Stand

Student’s Answer Sheet Day Two-21

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ii September, 2002 Engine Repair

WORKSTATION 6A DAY TWO-31

Workstation 6A – Cylinder Head Disassembly and Measurement

WORKSTATION 6B DAY TWO-51

Workstation 6B – Engine Block Disassembly and Measurement

WORKSTATION 7 DAY TWO-65

Workstation 7 – Cylinder Heads to Block

DAY THREE

Day Three Agenda – Morning Day Three-2 Day Three Agenda – Afternoon Day Three-2 Introduction Day Three-4

WORKSTATION 8 AND 9 DAY THREE-11

Workstation 8 – Timing Chain Installation

Student’s Information Sheet Day Three-19

DAY FOUR

Day Four Agenda – Morning Day Four-2 Day Four Agenda – Afternoon Day Four-2 Introduction Day Four-4

WORKSTATION 8 AND 9 DAY FOUR-11

Student’s Information Sheet Day Three-19

GLOSSARY GLOSSARY-1

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Engine Repair September, 2002 Intro-1

DAY ONE

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Intro-2 September, 2002 Engine Repair

ENGINE REPAIR CURRICULUM PATH

Automotive Measuring Tools T –

FMT

ENGINE REPAIR CURRICULUM PATH

Prerequisites q – NVH – oom Leg gend

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Curriculum Goals

The goals of this curriculum are:

– To provide the necessary training to enhance the technician’s ability to identify, diagnose, and performtimely “Fix It Right The First Time-On Time” repairs

– Increased customer satisfaction

– Increased technician productivity

– Reduce or eliminate repeat repairs

Curriculum Prerequisites

All students must have completed the prerequisite courses prior to enrolling in this course Students who donot show passing credit in their STARS planner for the previous courses should not be admitted to this class.Their presence will slow down the course flow, as well as monopolize valuable instructor time

Each technician enrolled in this course must meet the following prerequisites:

– NVH – Classroom course code: 30S03T0– Basic Electrical Theory & Operation – Web course code: 34S11W0– Electrical Diagnostic Tools and Testing – FMT course code: 34S13M0– Basic Electrical Diagnosis – Classroom course code: 34S14T0– Electronics Theory and Operation – Web course code: 34S15W0– Understanding Electronic Systems – FMT course code: 34S16M0– Electronic System Diagnosis – Classroom course code: 34S19T0

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ENGINE REPAIR CURRICULUM

The Engine Repair Curriculum Path consists of four types of courses Each course is one of the

following types:

– Self-Study – This type of course is a self-paced program The technician is responsible for learning thematerial on his or her own The training material consists of a reference book and an accompanyingvideotape The videotape is designed to support the material in the reference book and should not beused

on its own

– Ford Multimedia Training (FMT) – This type of course is also self-paced The multimedia course allowsthe technician to interact with the training materials The multimedia course allows the technician toutilize the knowledge attained in the self-study course The FMT concentrates on relationships, such asthe cause-

and-effect relationships between symptoms and components

– FORDSTAR – This type of course is instructor led, distance learning The technicians interact with theinstructor through an interactive satellite communications system

– Classroom – The classroom course allows for practical, real-world application of skills and knowledgelearned in the other courses

The courses included in the Engine Repair Curriculum are as follows:

– Engine Repair Fundamentals – Self-Study course code: 32S01S0– Automotive Measuring Tools – FMT course code: 32S02M0– Basic Engine Operation and Diagnosis – FMT course code: 32S03M0– Engine Repair – Classroom course code: 32S05T1– Servicing Overhead Cam Engines – FORDSTAR course code: 32S06F0

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Course Objectives

Upon completion of the Engine Repair Classroom Course, the technician will be able to:

Identify which diagnostic test to perform given an engine concern

Perform diagnostic test correctly and interpret results

Perform disassembly and inspection of cylinder heads

Perform disassembly and inspection of engine block

Perform measurements using the correct tools and interpret results correctly

Perform proper procedure for installing the crankshaft

Perform proper procedure for installing piston and rings

Perform proper torquing procedures

Perform proper camshaft installation and timing procedure

Audience

This course is designed for Ford service technicians who are registered as Service Technician SpecialtyTraining (STST) Engine Repair Specialists and have completed the prerequisites

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DAY ONE AGENDA – MORNING

The agenda for the day is as follows:

NOTE: Times may be adjusted to coordinate with Training Center normal hours.

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DAY TWO AGENDA – MORNING

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DAY THREE AGENDA – MORNING

(195 min)

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DAY FOUR AGENDA – MORNING

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NOTES

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Engine Repair September, 2002 Day One-1

PREREQUISITE

KNOWLEDGE

REVIEW

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Day One-2 September, 2002 Engine Repair

PREREQUISITE REVIEW QUESTIONS STUDENT’S ANSWER SHEET

1 Why does Ford Motor Company use metric measurements?

2 A What three things are you trying to determine when measuring the cylinder bore?

B How many measurements are required to accomplish this?

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3 Interpret and record the readings of the micrometers shown

IGK099-A

20

30 25 20

15 10

mm

Example 23.25

10

5 0 45

5 0

20 5

0 10 5

25

35 30

30 15

10 20 20

45 5 0

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4 If coolant were leaking into the oil, what would the oil look like and where could the coolant come from?

5 What concerns can be caused by a faulty oil pump pressure relief valve?

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6 A List concerns that can be identified by using a Borescope

B When using a Borescope inside the engine, what should you never do?

7 List some tests that can be performed with the WDS for misfire that you will use before removing any majorengine components

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8 List several tests for engine knock that you would perform before removing any major engine components

9 When dry compression test indicates low compression in one cylinder, what are the next steps?

10 What steps should be carried out when performing a compression test properly?

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11 Name two tools or procedures that can be used to identify an oil leak

12 List some tests for diagnosing a cylinder head gasket failure without removing the cylinder head

13 How many times can torque-to-yield bolts be reused in Ford Motor Company vehicles?

Why?

14 Name some different types of coolant

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15 What is the purpose of superchargers and turbochargers and how does each function?

16 What weight oil is required for current Ford Motor Company gasoline engines and why?

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Engine Repair September, 2002 Day One-9WORKSTATION 1

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WORKSTATION 1 RUN STAND A STUDENT’S ANSWER SHEET

NAME: DIRECTIONS: Use all tools provided at the workstation to perform diagnosis of all base engine concerns Use

the Engine System – General Information Section of the Workshop Manual for instructions onhow to perform the required tests Answer the following questions as you perform the

diagnosis

1 Use the vacuum gauge to measure engine vacuum at idle and record your results below

2 List the types of concerns the results could indicate

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3 Perform a dry compression test on all four cylinders and record the results below

DRY TEST Cylinder 1 2 3 4

Value

_ kPa/psi _ kPa/psi _ kPa/psi _ kPa/psi

4 Indicate which cylinder(s) have unacceptable/abnormal readings

DRY TEST Cylinder 1 2 3 4

5 If a fault is indicated, what are the possible causes?

Cylinder 1 2 3 4

Concern

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6 Perform a wet compression test on all four cylinders and record the results below

WET TEST Cylinder 1 2 3 4

Value

_ kPa/psi _ kPa/psi _ kPa/psi _ kPa/psi

7 Calculate the amount compression increased when the wet test was performed Use your readings fromQuestions 3 and 6

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WARNING: USE CAUTION WHEN OPENING THE COOLING SYSTEM HOT COOLANT MAY CAUSE INJURY.

9 Using the instructions provided in the workstation, calibrate the cylinder leakage detector Loosen theradiator cap Perform a cylinder leakage test on all four cylinders and record the results below For eachcylinder list the location(s) where air can be heard escaping from the engine

CYLINDER LEAK TEST Cylinder 1 2 3 4

Leak percentage

_ % _ % _ % _ %Air is leaking from:

10 List the types of concerns the results indicate for each cylinder

Concern

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CAUTION: Connect the Borescope to a steady 12 volt power source Do not use a vehicle with a running engine or a battery attached to a charger Damage to the Borescope will result.

11 Do not crank the engine while using the Borescope Use a Borescope to inspect each cylinder and recordyour results

Results

12 What can a leakage test identify that a compression test cannot?

13 What can a compression test identify that a leakage test cannot?

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Engine Repair September, 2002 Day One-15WORKSTATION 2

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WORKSTATION 2 RUN STAND B STUDENT’S ANSWER SHEET

NAME: DIRECTIONS: Following the procedures in general section of the workshop manual complete the following

questions Use an Ultraviolet Lamp to diagnose an oil leak concern Diagnose a tapping noiseusing the EngineEAR or stethoscope Answer the following questions as you perform yourdiagnosis:

1 Could an oil leak and tapping noise be related to the same root cause? If so, explain

2 Check the engine oil and level Are any concerns indicated?

3 Perform an oil pressure test List the specification and your reading below, and indicate if oil pressure iswithin specification

Actual Within Measurement Specification Specification

4 List some internal engine concerns that could be indicated by performing an oil pressure test

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5 Use the EngineEAR to isolate the location of the tapping noise Indicate which area of the engine the noise

is most prominent, the top or bottom Each person should evaluate the engine individually

6 Attempt to isolate the noise to a specific cylinder Which cylinder does the noise appear to be coming from?

7 Cancel each cylinder by disconnecting the appropriate fuel injector Does canceling a cylinder affect thenoise?

8 Based on the information obtained so far, list the conditions or components that could be causing the noiseconcern

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9 Perform a visual inspection on this engine to identify any oil leaks List the locations of the leaks found

DO NOT USE THE ULTRAVIOLET LAMP AT THIS TIME

10 Use the general engine section of the workshop manual and describe below the steps used to prepare for theleak test using the Ultraviolet Lamp

11 This engine stand has already been set-up with dye in the oil Use the ultraviolet lamp to locate the source ofany oil leaks and list the areas were leaks are indicated

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NOTES

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DIRECTIONS: For each component on the bench, answer each question as a group

1 Describe the noise each component would make if it were badly worn or damaged

Timing Chain Tensioner

2 Where on the engine would you expect to hear the noise?

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3 Will the noise change or be eliminated by canceling a cylinder?

4 Will the noise change with temperature? If so, explain

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5 Will the noise change with load? If so, explain

6 What would be a likely cause of premature wear or damage to the component?

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7 Will the component’s failure affect oil pressure? If so, why?

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NOTES

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