32S09T0 engine diagnosis and repair 2007

Course AgendaLESSON ONE: Prerequisite Review, Demonstrations-Bore Gauge Calibration and Use/Measuring Tools, Lesson 1 Workstations On-vehicle Noise/Oil Leak Diagnosis, Cam Phaser Replace

Engine Diagnosis

and Repair

Student Guide

FCS-14627-REF Course Code: 32S09T0

April, 2007

32 - Engine Repair

FCS14627REF

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.

Copyright © 2007 Ford Motor Company Produced and Coordinated by

Customer Expectations: Service

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, on time.

4. Complete servicing my vehicle in a

timely and professional manner.

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 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.”

— Repeat vehicle sales

— Repeat service sales

INTRODUCTION INTRO - 1

Course Description Intro - 2Course Requirements Intro - 3Course Objectives Intro - 3Course Agenda Intro - 4

PREREQUISITE REVIEW 1 - 1 LESSON ONE WORKSTATIONS 1 - 9

Lesson One – Bore Gauge and Measuring Tools Demonstrations 1-10Lesson One – Workstation 1 Part 1: Oil Leak Diagnosis 1 -14Lesson One – Workstation 1 Part 2: Noise Diagnosis 1 - 16Lesson One – Workstation 2: Cam Phaser Replacement With Timing Cover Installed 1 - 19Lesson One – Workstation 3: Scan Tool/Smoke Machine 1 - 21Lesson One – Workstation 4: Precision Measurements 1 - 23Lesson One – Written Activity 1 - 30

LESSON TWO WORKSTATIONS 2 - 1

Lesson Two – Workstation 1: On-Vehicle Runs Rough/Lack of Power Diagnosis 2 - 3Lesson Two – Workstation 2 Part 1: Engine Misfire CMT 2 - 6Lesson Two – Workstation 2 Part 2: Engine Overheat 2 - 8Lesson Two – Workstation 3: On-Vehicle Runs Rough/Engine Noise Concern 2 - 10Lesson Two – Workstation 4 Part 1: Lower Engine Noise CMT 2 - 13Lesson Two – Workstation 4 Part 2: Lower Engine Noise CMT 2 - 17Lesson Two – Written Activity 2 - 20

LESSON THREE WORKSTATIONS 3 - 1

Lesson Three – Manual Compression and Cylinder Leakage Tests Demonstration 3 - 2Lesson Three – Workstation 1: Misfire and Low Compression Concern 2.3L Engine 3 - 5Lesson Three – Workstation 2: Engine Teardown 4.0L SOHC 3 - 8Lesson Three – Workstation 3: Engine Teardown 5.4L 2V 3 - 12Lesson Three – Workstation 4: Engine Teardown 4.6L 3V 3 - 16Lesson Three – Written Activity 3-19

LESSON FOUR WORKSTATIONS 4 - 1

Lesson Four – Workstation 1: Camshaft Timing 2.3L 4 - 3Lesson Four – Workstation 2: Camshaft Timing 4.0L SOHC 4 - 5Lesson Four – Workstation 3: Camshaft Timing 5.4L 2V 4 - 6Lesson Four – Workstation 4: Camshaft Timing 4.6L 3V 4 - 8

APPENDIX APPENDIX - 1

Write-Up Job Aid Appendix - 2

INTRODUCTION

This is a 4-day course facilitated by an instructor This course is designed to provide hands-on opportunities fortechnicians to learn and improve their skills using tools and equipment, and to apply knowledge learned inprevious curriculum courses Each day you will have multiple opportunities to practice selected skills Theresults of your work are recorded on worksheets.

ENGINE DIAGNOSIS AND REPAIR

4.6L 3V Engine

Course Description

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-onexercise 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

Course Agenda

LESSON ONE:

Prerequisite Review, Demonstrations-Bore Gauge Calibration and Use/Measuring Tools, Lesson 1

Workstations (On-vehicle Noise/Oil Leak Diagnosis, Cam Phaser Replacement, On-vehicle Scan Tool/Smoke Machine Diagnosis, Precision Measurements)

LESSON FOUR:

Lesson 3 Workstation Review, Lesson 4 Workstations (Cam Timing 1, Cam Timing 2, Cam Timing 3, CamTiming 4) Final Review, Post-Test

REVIEW

1 Explain the difference between a free-wheeling and non-free-wheeling engine.

_

2 Write the name of each type of camshaft timing method used under the following engines

3 What symptoms can be caused by a mis-timed engine?

_

4 What are the four types of Variable Cam Timing Systems?

5 Label the VCT components in the graphic below

6 Explain the operation of a Vane Type Phaser VCT system.

_

7 Which timing components on a VCT engine could produce an abnormal engine noise?

_

8 List the diagnostic procedures that are similar and those that are different between gas and diesel

engines

9 If low compression is suspected on a diesel engine, which least invasive test should you perform?

A ICP pressure test

B Crankcase pressure test

C Cylinder leakage test

D Compression test

10 In a hybrid vehicle, how is the engine cranked during a manual compression test (after entering thecranking mode)?

_

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

12 What does SSCC stand for and why do we use it?

_

13 List all the tests that could be performed for an engine misfire concern

_

14 When a dry compression test indicates low compression in one cylinder, what test should you performnext?

15 Interpret and record the readings of the micrometers shown

mm

Example 23.25

10 5

0

45

5 0

16 What is the proper procedure for checking flatness with a straight edge and feeler gauges?

_

17 What three things are you trying to determine when measuring a cylinder bore?

_

18 Why does Ford Motor Company use metric measurements?

_

NOTES:

LESSON ONE

LESSON ONE DEMONSTRATION

Summary:

Demonstration on bore gauge calibration and use

Demonstration on measuring tools use

BORE GAUGE DEMONSTRATION

Notes on bore gauge demonstration:

_

MEASURING TOOLS DEMONSTRATION

Notes on measuring tools demonstration:

_

LESSON ONE WORKSTATIONS

Workstation: Summary:

1 Hands-on activity at vehicle in which the students will diagnose an oil leak The

stu-dents will also diagnose a noise concern using the noise diagnostic process

2 Hands-on activity at engine stand where the students will replace a cam phaser

3 Hands-on activity at vehicle to diagnose a rough idle concern Students will use the

scan tool to monitor PID data and use the smoke machine to diagnose the concern

4 Hands on activity at bench Students will use various measuring tools to take and record

measurements of engine block and head components

WORKSTATION 1 PART 1 OIL LEAK DIAGNOSIS

DIRECTIONS: Complete Workstation 1 at the VEHICLE workstation, following the steps in this

work-sheet

SUMMARY: In this activity, you are diagnosing an engine oil leak and engine noise concern Use the

Ultraviolet Lamp to diagnose the oil leak concern Diagnose the noise concern using the EngineEAR orstethoscope Answer the following questions as you complete your diagnosis

1 Check the oil level, record the results

_

z Visually inspect the engine and find the oil leak Use the Ultraviolet Lamp to locate the oil path and itssource

2 Which component is the cause of this oil leak?

_

3 What is the difference between an oil leak and oil seepage?

_

4 Can this oil leak be responsible for an oil consumption concern? Yes No

5 What is the specification for oil consumption?

_

6 What would be the proper repair for this oil leak concern?

_

7 Do you expect to find oil dye from the factory on a new vehicle? Yes No

8 Start the engine and verify the noise concern How would you describe this noise?

9 Use the EngineEAR and listen for the noise Where is the noise located?

Upper Engine Lower Engine

Right Bank Left Bank

10 Can you identify which cylinder is the cause, if so which one?

_

11 What component(s) do you suspect is causing this noise?

_

12 In the following table write the type of noise the component would cause if worn or severely damaged.Circle the correct yes or no answer for the remaining questions

PART 2 NOISE DIAGNOSIS

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13 In the following table write the type of noise each component would cause if worn or severely aged Circle the correct yes or no answer for the remaining questions.

dam-14 List the components that are affected by temperature Explain why they would be affected with perature change

tem-

15 List the components that are affected by canceling cylinders Explain why they would be affected bycanceling cylinders

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e h t r a e h

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16 List the components that are affected by changes in engine load Explain why they would be affected

by engine load

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

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WORKSTATION 2 CAM PHASER REPLACEMENT WITH TIMING COVER INSTALLED

DIRECTIONS: Complete Workstation 2 at the ENGINE workstation, using the tools and information

available at the workstation

SUMMARY: In this activity, answer questions 1 through 7, then remove and install the right bank camshaft

phaser

1 What might happen if the cam phaser was replaced without removing the camshaft?

2 What is the global tool number for this special tool? Write the number next to the tool

3 Circle the three roller followers that must be removed before removing the camshaft

4 What type of engine is this? Freewheeling Non-Freewheeling

5 Can this procedure be done without the timing chain wedge with the front cover on? Yes NoWhat is the purpose of the timing chain wedge?

6 If the Timing Chain Wedge was prematurely removed during assembly, what action would you need totake?

A Remove the crankshaft

B Remove the front cover and retime the engine

C Remove both cylinder heads

D Remove the crankshaft sprocket

7 Label the camshaft detorque and torque procedure, and the workshop manual torque specification

Detorque Torque

Training Torque specification: 5Nm (45 lb-in)WSM Torque specification:

WORKSTATION 3 SCAN TOOL/SMOKE MACHINE

DIRECTIONS: Complete Workstation 3 at the VEHICLE workstation, following the steps in this

work-sheet

SUMMARY: In this activity, you are diagnosing a rough idle concern Use the scan tool to retrieve codes,

and the smoke machine to diagnose the concern

z Start the engine and verify the customer’s concern of a rough idle Hook up the scan tool

1 List the DTCs and place an X in the appropriate column to indicate which type of code it is

2 Using the scan tool, run the power balance and relative compression tests What are the results of thesetwo tests?

Power Balance Relative Compression

3 Select the Fuel Trim and RPM PIDs and record their values at idle in the following table Add the longterm and short term fuel trims together to get the total

4 Select the Fuel Trim and RPM PIDs and record their values at 1500 RPM in the following table Addthe long term and short term fuel trims together to get the total

C T

D K e y O n E n g i n e

f O

e n i g n E n O y e K

g n i n n R

s u o u n i t n o C

y r o m e M

1 k n a

_

M

P

R SHRTFT1 _ _ _ _ SHRTFT2 _ _ _ _

_1TFGNO

L LONGFT2_ _ _ _ _

_LATO

T TOTAL _ _ _ _ _

1 k a

_

M

P

R SHRTFT1 _ _ _ _ SHRTFT2 _ _ _ _

_1TFGNO

L LONGFT2_ _ _ _ _

5 If at idle the long term fuel trim plus the short term fuel trim is over 20%, but decreases at higher enginespeeds, a possible vacuum leak exists Is there a vacuum leak indicated by the readings?

Yes No

z Turn the engine off

6 The smoke machine can be used to diagnose a vacuum leak What other tools may be used to diagnose

a vacuum leak?

_

z Connect the smoke machine to the engine vacuum source indicated by the instructor

z Turn the smoke machine on and inspect the intake system for leaks

7 Where is the vacuum leak?

_

8 How would you repair the concern?

9 How would you verify the repair?

z Deselect the vehicle from the scan tool

z Remove the smoke machine line, and reconnect the vacuum hose

WORKSTATION 4 PRECISION MEASUREMENTS

DIRECTIONS: Complete Workstation 4 at the BENCH workstation, using the measuring tools and parts

sup-plied at the workstation

SUMMARY: In this activity, you will use the tools provided to measure the appropriate components and record

your answers individually on your worksheets Every student should make his or her own measurements

z Questions 1 through 4 have been separated into measurements A, B and C Assign a letter to eachmember in your group, and take the corresponding measurement in these questions

1 Measure the cylinder 2 intake lobe for cam lobe lift Set the dial indicator on the base circle of the camlobe as shown Zero the dial indicator Rotate the camshaft to the highest point to measure cam lobe lift.Repeat this procedure for an exhaust cam lobe

2 Measure camshaft endplay using the cylinder head on the bench Record your reading

mm

4 Use an outside micrometer to measure the diameter of the intake valve stem at points A, B and C.

IGK002-B

A B C

mm mm mm

3 Use a small hole gauge and micrometer to measure the inner diameter of the intake valve guide in twodirections at points A, B and C

z Make sure all members of your group have made their measurements before proceeding

5 Calculate valve stem to guide clearance using measurements from questions 3 and 4

Highest valve guide reading from question 3 mm

Smallest valve stem reading from question 4 - mm

Clearance = mm

z Make sure all members of your group have made their measurements before proceeding Once allstudents have made the measurements, call the instructor to the workstation for further instructions.

6 Install the front main bearing cap with main bearing to the engine block Torque the main cap bolts to

54 Nm (40 lb-ft) Use the outside micrometer and telescoping gauge to measure the main bearingdiameter Record your measurement

Main bearing diameter mm

7 Use a micrometer and measure the corresponding main journal Record your measurement, and late the bearing clearance

calcu-Crankshaft main bearing journal mm

Main bearing clearance mm

8 Remove the main cap and install the crankshaft Lay a piece of Plastigage across the face of the shaft main bearing surface What is the correct color Plastigage for this measurement?

crank-

9 Install and torque the main bearing cap bolts to 54 Nm (40 lb-ft) Remove the main bearing cap andverify the crankshaft main journal clearance What clearance does the Plastigage indicate?

mm

AA2536-A

GA0197-A

z The bore gauge is used to measure the cylinder bore, which will be used to calculate cylinder diameter,taper and out-of-round Follow these directions to calibrate and use the bore gauge Call the instructor

to the workstation for assistance if necessary

To turn the bore gauge on: Press the Zero button

To turn the bore gauge off: Press and hold down the Zero button

z To set the bore gauge to a known size:

1 Use the workshop manual and note the cylinder bore size Round the number down to the next lowestwhole millimeter number Select the correct size insert, and install it to the bore gauge

2 Press and hold the ABS/SET button

3 Holding down the ABS/SET button will cause the numeric value to flash in sequence from left to right

4 Release the ABS/SET button on the flashing numeral Tapping lightly on ABS/SET button will changethe numeric value When the desired number is set, hold down the ABS/SET button to move to thenext digit and repeat the process Set this number to the cylinder bore size in whole millimeters

5 When the cylinder bore size is set, hold down the ABS/SET button until the “SET” icon is flashing Taplightly on the ABS/SET button to confirm The preset has now been stored

z Calibrating the bore gauge in a micrometer:

1 Carefully place the correct size micrometer in a vise Use a shop towel between the jaws of the vise andthe micrometer Use care not to overtighten the vise

2 Insert the bore gauge into the micrometer

BORE GAUGE CALIBRATION AND USE

3 Tap the MIN button to initiate the calibration Sweep the bore gauge back and forth while keeping it inthe micrometer.

4 Observe the analog scale on the indicator screen, and watch for a reversal point

5 When the reversal point is obtained, remove the bore gauge from the micrometer Press and hold theCAL button An “OK” icon will flash to confirm successful calibration while holding down the CALbutton

6 With the indicator still in MIN mode, insert the bore gauge back into the micrometer

7 Sweep the bore gauge back and forth to obtain the minimum lock The value displayed should matchthe micrometer reading (Note: The reading may shows a few thousandths off, this is acceptable) If thecorrect value is not read, repeat the calibration procedure

z To measure the cylinder bore:

1 With the bore gauge calibrated and still set in the MIN mode, insert the bore gauge into the cylinderbore and press the ZERO button This will reinitialize the MIN mode Rock the bore gauge back andforth in the bore to read the diameter

2 The reading is the bore diameter

10 Use the cylinder bore gauge to measure the cylinder bore near the top, approximately 12 mm below thedeck, in the two directions shown Then measure the cylinder bore near the bottom in the two direc-tions shown Which ever group member is done first, take measurement D.

A _ _ _ _ _mm B _ _ _ _ _mm_ _

) n i 9 2 3 ( m m 2 0 2

= e i S e r o

B

Front

13 Use an outside micrometer and measure the piston diameter.

14 Calculate the piston to cylinder bore clearance Subtract the piston diameter from the cylinder borediameter to find the piston to cylinder bore clearance

z Make sure that all team members have made every measurement up to this point

retemaiDe

mm _

LESSON 1 WRITTEN ACTIVITY

1 Which measurement would be best performed using a bore gauge?

A Crankshaft endplay

B Valve clearance

C Cylinder taper

D Piston to deck protrusion

2 If the crankshaft endplay is out of specification, what should you do?

_

3 Which tool should you use to check crankshaft endplay?

C A broken piston ring

D A piston with rings

5 Which type of engine uses a crankcase pressure test to check for blow-by past the piston rings?