Cylinder Head Removal And Installation
                          Information For 1991 Ford 1.8L Engines

Ford Motor Company recommends the following procedure when removing and reinstalling the cylinder head on 1991 Ford Escort automobiles equipped with the 1.8L DOHC (double overhead camshaft) engine.

On this engine the cylinder head, exhaust and intake manifold may be removed as a single unit.  Loosen and remove the cylinder head bolts in the order shown in Figure 1.

Install the cylinder head and torque the cylinder head bolts in the sequence shown in Figure 2 to 30-40 lbs.ft.  Then tighten the bolts in sequence until a final torque of 56-60 lbs.ft. is reached.  Be sure to lubricate the cylinder head bolts with engine oil before installation.

The camshaft bearing caps should be installed according to the numbers and arrows stamped on them.  Torque the bolts in the sequence shown in Figure 3 to a final torque of 100-126 lbs.in.

                                                                                  The AERA Technical Committee

               Cylinder Head Removal Procedure for
             Ford 1.6L & 1.9L (98 & 116 CID) Engines


The AERA Technical Committee has been informed of a revised
procedure developed by AERA member service station customers to
reduce cracks in the cylinder heads of Ford 1.6L & 1.9L (98 & 116
CID) engines.

It has been discovered that a removal procedure which starts by
loosening each of the four outside corner bolts of the cylinder
head assembly by a quarter (90o) turn, before loosening any other
bolts, reduces the chance of inducing cracks in the cylinder head
(see illustration below).  Following this procedure is especially
important when the engine has been overheated and the cylinder
head needs to be removed to replace a damaged cylinder head
gasket.

Abused Escort cylinder heads are known to bow away (upward) from
the cylinder block in the center of the head.  Loosening the
center bolts first will contribute to the warp, therefore
increasing the chance of stress cracks near the center of the
cylinder head.


                                     The AERA Technical Committee


February 1989 - SB 165


Ford 1.6L & 1.9L (98 & 116 CID) Engines, Cylinder Head

##END##

                   Setting Timing Belt Tension
                Ford Escort 1.6L (98 CID) Engines


AERA members have reported that improper tension of the camshaft
timing belt can result in camshaft failure.  Camshafts have
sheered between the camshaft sprocket and the first main journal. 
Improper tensioning of the timing belt has been attributed to
this failure.

Ford Motor Company's procedure for setting the proper tension
after replacing the timing belt requires the following steps to
be taken:

     1.  Install the timing belt over the sprockets in a
     counterclockwise direction starting at the crankshaft and
     aligning the proper timing marks.  Allow the loose belt
     tensioner to rest against the belt before snugging up one of
     its attachment bolts.

     2.  After confirming that all timing marks are in the proper
     position and that the crankshaft pulley is secured, crank
     the engine for 30 seconds with the starter.  Double check
     your timing mark alignments making adjustments as necessary. 
     Repeat the cranking procedure if adjustments have been made.

     3.  Loosen the belt tensioner bolt tightened in step 1. 
     Holding the crankshaft pulley stationary, turn  the cam
     sprocket counterclockwise using Ford tool 
     D81P-6256-A or equivalent and a torque wrench.  Tighten the
     belt tensioner attaching bolts when the following torque
     reading is observed:

          New Belt: 27 to 32 foot pounds
          Used Belt: 10 foot pounds

According to Ford, a timing belt is considered to be used after
30 days or more of service.

NOTE:  Never set timing belt tension on an engine which is not at
ambient (room) temperature.  Failures occur when tension is set
on hot engines.

Refer to your Service Manual for a more detailed timing belt
replacement procedure.


                                     The AERA Technical Committee


March 1987 - SB 142 

##END##

             Burned Pistons Or Broken Ring Lands On
                 Ford 1.6L (Except H.O.) Engines


Burned pistons or broken ring lands in 1981-82 Ford Escort and
1981-82 Lincoln-Mercury Lynx 1.6L (except H.O.) engines can be
the result of detonation caused by operating the engine with
insufficient coolant.

In these cases it is important to inspect the entire cooling
system before releasing the vehicle for operation.

While the engine is disassembled, check the cylinder head for
cracks and the head gasket surface of the cylinder block for
metal damage caused by engine overheating.

Inspect the gasket surface of the head for warpage, using a
straightedge.  If the head is warped, do not machine more than
.010 (.254mm) from the surface.

After reassembly, pressurize the cooling system and check for
leaks at all hose connections, the radiator and heater cores,
heater cross-over tube, water pump, and thermostat housing.

In addition check that the electric cooling fan is operating
properly and that the timing is set at specifications.


                                     The AERA Technical Committee


February 1984 - SB 109 


##END##

                     Minimum Cylinder Head Thickness Specification On
                                   Ford 1.6 & 1.9L (98 & 116 CID) Engines

AERA members have reported a new method for determining the minimum surfacing specification for Ford Escort Cylinder heads.

As described in AERA TB 401, the minimum thickness specification for these cylinder heads is 5.055, measured from the cylinder head deck surface to highest point of the valve cover rail. AERA members have since determined that the Escort cylinder head varies greatly in this dimension and they have developed a more accurate measurement location.

Viewing the cylinder head from the deck surface, locate two 1/2 circles just above the number 1 & 4 exhaust ports (see illustration below). These 1/2 circles are .048-.052 deep, measured from the deck of the cylinder head, when the cylinder head is new. It is safe to remove between .023-.027 from the cylinder head deck surface during surfacing operations, reducing the 1/2 circle depth dimension to .025. Do not remove additional material from the cylinder head deck surface after this minimum specification has been reached.

                  
                                                                          The AERA Technical Committee

                   Cylinder Head Thickness On
            1981-86 Ford Escort 1.6L (98 CID) Engines


Ford Motor Company recommends that a maximum of .010 be removed
from the surface of its 1.6L (98 CID) overhead camshaft cylinder
heads.  AERA members report they've successfully removed a
maximum of .015 from the cylinder head, or will remove metal
until the cylinder head reaches a minimum thickness of 5.055.

The minimum thickness dimension is measured from the deck surface
to the valve cover rail at its highest point.  Since new cylinder
heads from Ford vary in thickness, the minimum thickness is more
critical than the maximum surfacing limit.


                                     The AERA Technical Committee


September 1986 - TB 401


##END##

                                            Oil Leak At The Oil Pump On
                                             Ford 1981 Escort, 1982 EXP, 
                     Lincoln-Mercury 1981 Lynx & 1982 LN7 (1.6L) Engines

An engine oil leak at the oil pump on some 1981-82 Ford Escort & EXP and Lincoln Mercury Lynx & LN7 (1.6L engines) may be serviced by removing the external oil gallery pipe plug on the pump as shown below and applying Loctite(R)  Lock N' Seal(R) or equivalent to the plug threads.  Reinstall the plug and torque to 6-8 ft. lbs (8-12 N·m).

Ford Motor Company recommends the oil pump must be replaced if the gallery plug is found cross threaded, or if the outer surface of the gallery is cracked at the plug opening.

                                                                         The AERA Technical Committee

                                                Valve Train Clatter On 
                                     1988-91 Mazda 1.8L DOHC Engines

Numerous reports of valve train clatter on the Mazda 1.8L engine with hydraulic lash compensator (HLC) used in DOHC application have been described.  These clatter problems are most common upon cold start and/or returning to idle after extended highway use.

One possible cause has been the design of the lash compensator restricting the oil flow (Figure A).  Mazda offers a revised HLC, Part #B6Y112101, that has an enlarged oil hole to enhance oil flow and eliminate the valve train clatter.  

Engines manufactured as of the 1992 model year utilize this revised HLC.  These also include those 1.8L Mazda engines used in Ford Escort and Mercury Tracer vehicles.

Another possible cause for valve train clatter may be a damaged HLC O ring (Figure B).  Replace any O rings that are damaged. Also inspect the HLC's parent bore of the rocker arm for damage and repair as necessary.  

Exercise extreme caution when inserting the HLC into the rocker arm.  Proper assembly requires all components to be lubricated with engine oil.  Twisting the HLC during installation further eases installation and guards against rolling the O ring.

Avoiding low oil level, as well as changing the oil and filter at recommended intervals can help circumvent this problem.  

                                                                       The AERA Technical Committee

                                Torque Plate Use Recommendations


While all engines would benefit, to realize an increase in performance and a decrease in oil consumption, the following list of engines should be finish honed with a torque plate to simulate the stress of the cylinder head when the engine is
assembled.

Manufacturer  Displ. (L)    (CID)    Comments

GM        2.0L          121
              2.5L          151
              4.1L          252      V8 Aluminum Cadillac    
              4.9L          301
              5.0L          305      Late model Chevrolet
              5.7L          350      Oldsmobile
              6.6L          400      Small block Chevrolet
              6.6L          403      Oldsmobile

Ford      1.6L          98       Escort
              1.9L          116      Escort
              2.3L          140      OHC engine
              5.0L          302      Late model engines
              5.9L          360      *         
              6.4L          390      *

*  While these are not thin wall blocks, durability and oil consumption is improved when a torque plate is used during remanufacture.  It is not required to use a torque plate to prevent piston scuffing as we have noted to be necessary with the GM 2.0 and 2.5L engines.

                                                                        The AERA Technical Committee