32S05T1 engine repair 2006

Engine Repair

Engine
Repair
Student Book
COURSE CODE: 32S05T1
ORDER NUMBER: FCS-14567-REF
Updated January, 2006

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 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 © 2002 Ford Motor Company

Produced and Coordinated by
Technical Support Operations
Ford Customer Service Division
September, 2002


CUSTOMER EXPECTATIONS
Customer Expectations: Service

1. Make it convenient to have my
vehicle serviced at your dealership.

2. The Service Advisor should

5. Provide me with a clear and thorough

explanation of the service performed.

6. Call me within a reasonable amount of

demonstrate a genuine concern for
my service needs.

time after my service visit to ensure that
I'm completely satisfied.

3. Fix it right the first time.
4. Complete servicing my vehicle in a

7. Be responsive to questions or concerns
I bring to your attention.

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
#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
– Self Study
– Self Study
– 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”


TABLE OF CONTENTS
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
Student’s Answer Sheet ................................................................................................. Day One-29
WORKSTATION 2 ..................................................................................................DAY ONE-41
Workstation 2 – Run Stand B
Student’s Answer Sheet ................................................................................................. Day One-47
WORKSTATION 3 ................................................................................................. DAY ONE-63
Workstation 3 – On-Vehicle
Student’s Answer Sheet ................................................................................................. Day One-69
WORKSTATION 4 ................................................................................................. DAY ONE-79
Workstation 4 – Bench
Student’s Answer Sheet ................................................................................................. Day One-85
DAY TWO
Day Two Agenda – Morning .............................................................................................. Day Two-2
Day Two Agenda – Afternoon ............................................................................................ Day Two-2
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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i


TABLE OF CONTENTS
WORKSTATION 6A ............................................................................................... DAY TWO-31
Workstation 6A – Cylinder Head Disassembly and Measurement
Student’s Answer Sheet ................................................................................................. Day Two-37
WORKSTATION 6B ............................................................................................... DAY TWO-51
Workstation 6B – Engine Block Disassembly and Measurement
Student’s Answer Sheet ................................................................................................. Day Two-57
WORKSTATION 7 ................................................................................................. DAY TWO-65
Workstation 7 – Cylinder Heads to Block
Student’s Answer Sheet ................................................................................................. Day Two-73
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

ii

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Engine Repair


INTRODUCTION

DAY ONE

Engine Repair

September, 2002

Intro-1


INTRODUCTION
ENGINE REPAIR CURRICULUM PATH

ENGINE REPAIR
CURRICULUM PATH

Automotive
Measuring Tools
T
–
FMT

Prerequisites

q

Leg
gend
= Self Study
d (SS)

– NVH –
–

= Ford
r Multimedia Training
r
(FMT)

–

oom

–

= FORDSTAR
T

–

= Instructor Led – Classroom
r

–

– Electronic System Diagnosis (Classroom) -

Intro-2

September, 2002

34S19T0

Engine Repair


INTRODUCTION
Curriculum Goals
The goals of this curriculum are:
– To provide the necessary training to enhance the technician’s ability to identify, diagnose, and perform
timely “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 do
not 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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Intro-3


INTRODUCTION
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 the
material on his or her own. The training material consists of a reference book and an accompanying
videotape. The videotape is designed to support the material in the reference book and should not be
used
on its own.
– Ford Multimedia Training (FMT) – This type of course is also self-paced. The multimedia course allows
the technician to interact with the training materials. The multimedia course allows the technician to
utilize the knowledge attained in the self-study course. The FMT concentrates on relationships, such as
the causeand-effect relationships between symptoms and components.
– FORDSTAR – This type of course is instructor led, distance learning. The technicians interact with the
instructor through an interactive satellite communications system.
– Classroom – The classroom course allows for practical, real-world application of skills and knowledge
learned 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

Intro-4

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Engine Repair


INTRODUCTION
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 Specialty
Training (STST) Engine Repair Specialists and have completed the prerequisites.

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September, 2002

Intro-5


INTRODUCTION
DAY ONE AGENDA – MORNING
The agenda for the day is as follows:
NOTE: Times may be adjusted to coordinate with Training Center normal hours.
ACTIVITY

TIME

Introduction and prerequisite review

8:30am to 10:15am
(105 min)

BREAK

10:15am to 10:30am
(15 min)

Introduction to Day One workstations (Workstations 1, 2, 3, and 4)

10:30am to 10:45am
(15 min)

Start workstation rotations

10:45am to 11:45am

(60 min)

DAY ONE AGENDA – AFTERNOON
ACTIVITY

TIME

LUNCH

11:45am to 12:45pm
(60 min)

Resume workstation rotation

12:45pm to 2:15pm
(90 min)

BREAK

2:15pm to 2:30pm
(15 min)

Resume workstation rotation

2:30pm to 4:00pm
(90 min)

Day One ends

Intro-6

4:00

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Engine Repair


INTRODUCTION
DAY TWO AGENDA – MORNING
ACTIVITY

TIME

Review Day One workstations

8:30am to 10:15am
(105 min)

BREAK

10:15am to 10:30am
(15 min)

De-torque/torque and surface preparation lecture

10:30am to 11:15am
(45 min)

Introduce and begin Workstation 5

11:15am to 11:45pm
(30 min)

DAY TWO AGENDA – AFTERNOON
ACTIVITY

TIME

LUNCH

11:45am to 12:45pm
(60 min)

Engine component comparison lecture

12:45pm to 1:15pm
(30 min)

Introduce and begin Workstations 6A and 6B

1:15pm to 3:55pm
(160 min)

Introduce and begin Workstation 7

3:55pm to 4:30pm
(35 min)

Day Two ends

Engine Repair

4:30pm

September, 2002

Intro-7


INTRODUCTION
DAY THREE AGENDA – MORNING
ACTIVITY

TIME

Review Day Two workstations

8:30am to 10:00am
(90 min)

BREAK

10:00am to 10:15am
(15 min)

Engine timing lecture/demonstration

10:15am to 11:45am
(90 min)

DAY THREE AGENDA – AFTERNOON
ACTIVITY

TIME

LUNCH

11:45am to 12:45pm
(60 min)

Introduce and begin Workstations 8 and 9

12:45pm to 4:00pm
(195 min)

Day Three ends

Intro-8

4:00pm

September, 2002

Engine Repair


INTRODUCTION
DAY FOUR AGENDA – MORNING
ACTIVITY

TIME

Engine removal and replacement lecture/demonstration

8:30am to 9:15am
(45 min)

BREAK

9:15 am to 9:30am
(15 min)

Introduce and begin Workstations 8 and 9

9:30am to 11:45am
(135 min)

DAY FOUR AGENDA – AFTERNOON
ACTIVITY

TIME

LUNCH

11:45am to 12:45pm
(60 min)

Review Workstations 8 and 9

12:45pm to 1:15pm
(30 min)

Introduce and begin Final Exam

1:15pm to 4:00pm
(135 min)

Day Four ends

Engine Repair

4:00pm

September, 2002

Intro-9


INTRODUCTION
NOTES

Intro-10

September, 2002

Engine Repair


DAY ONE

PREREQUISITE
KNOWLEDGE
REVIEW

Engine Repair

September, 2002

Day One-1


DAY ONE
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?

Day One-2

September, 2002

Engine Repair


DAY ONE
PREREQUISITE REVIEW QUESTIONS

STUDENT’S ANSWER SHEET
3. Interpret and record the readings of the micrometers shown.

30
10

15

20
25

20

Example

23.25

mm

20
0

5

10

205 35

0

5

10

15

5
15

30
10
25
mm

B

mm

A

5
0

10

5

5

10

15

20

20 20

0
15
45

mm

C

mm

D

IGK099-A

10
0

5

10

5
10

5

0

E

15

20

20
30

0
45

mm

F

mm
IGK098-B

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September, 2002

Day One-3

DAY ONE
PREREQUISITE REVIEW QUESTIONS
STUDENT’S ANSWER SHEET
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?

Day One-4

September, 2002

Engine Repair


DAY ONE
PREREQUISITE REVIEW QUESTIONS
STUDENT’S ANSWER SHEET
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 major
engine components.

Engine Repair

September, 2002

Day One-5

DAY ONE
PREREQUISITE REVIEW QUESTIONS
STUDENT’S ANSWER SHEET
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?

Day One-6

September, 2002

Engine Repair


DAY ONE
PREREQUISITE REVIEW QUESTIONS
STUDENT’S ANSWER SHEET
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.

Engine Repair

September, 2002

Day One-7


DAY ONE
PREREQUISITE REVIEW QUESTIONS
STUDENT’S ANSWER SHEET
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?

Day One-8

September, 2002

Engine Repair


DAY ONE

WORKSTATION 1

Engine Repair

September, 2002

Day One-9