| The following technical bulletins were published by AERA. |
| | PISTON BORE CLEARANCE | Piston To Bore Clearance Changed On
Ford Products 2.3L Engines
Ford Motor Company updated Piston to Bore clearance limits to .0032 maximum for the 2.3L engines listed below:
Ford 1982-83 Mustang, Fairmont, Granada & LTD
Lincoln-Mercury 1982-83 Capri, Zephyr, Cougar & Marquis
Light Trucks 1983 Ranger
Note additional engine specifications below:
ENGINE SPECIFICATIONS
Ford Products 2.3L Engine
PISTONS AND RINGS
PISTON
Diameter
Coded Red 3.7780-3.7786
Coded Blue 3.7792-3.7796
0.003 Oversize 3.7804-3.7810
Piston-to-Bore Clearance (Select Fit) 0.0014-0.0022
Service Limit .0032 Max.
Pin Bore Diameter 0.9123-0.9126
Ring Groove Width
Compression (Top) 0.080-0.081
Compression (Bottom) 0.080-0.081 oil 0.188-0.19
PISTON PIN
Length 3.010-3.040
Diameter
Standard 0.9118-0.9124
0.001 Oversize 0.9130-0.9133
Piston-to-Pin Clearance 0.0002-0.0004
Pin-to-Rod Clearance Interference Fit
PISTON RINGS
Ring Width
Compression (Top) 0.077-0.078
Compression (Bottom) 0.077-0.078
Side Clearance
Compression (Top) 0.002-0.004
Compression (Bottom) 0.002-0.004
Oil Ring Snug Fit
Service Limit 0.006 Max.
Ring Gap
Compression (Top) 0.010-0.020
Compression (Bottom) 0.010-0.020
Oil (Steel Rail) 0.015-0.055
LUBRICATION SYSTEM
OIL PUMP
Relief Valve Spring Tension
(Lbs. Spec. Length) 15.2-17.2 @ 1.20
Drive Shaft-to-Housing
Bearing Clearance 0.0015-0.0030
Relief Valve-to-Bore Clearance 0.0015-0.0030
Rotor Asmbly End Clear.(Assembled) 0.004 Max.
Outer Race-to-Housing Clearance 0.001-0.013 l Capacity (Quarts U.S.) 4 (7)
FUEL PUMP
STATIC PRESSURE (PSI) (8) 5.0-7.0
MINIMUM VOLUME FLOW (9) (10) 1 Pint in 25 Seconds
ECCENTRIC TOTAL LIFT (Inches) 0.304-0.326
TORQUE SPECIFICATIONS-SPECIAL APPLICATIONS
ITEM SIZE Nm LB-FT
Auxiliary Shaft Gear Bolt M-10 38-54 28-40
Auxiliary Shaft Thrust Plate Bolt M-68-126-9
Belt Tensioner (Timing Pivot Bolt) M-1038-54 28-40
Belt Tensioner (Timing Adjusted Bolt) M-819-2814-21
Camshaft Gear Bolt M-128-96 50-71
Camshaft Thrust Plate Bolt M-6 8-12 6-9
Carburetor To Spacer Stud M-8 10-20 7.5-15
Carburetor To Spacer Nut M-8 14-19 10-14
Carburetor Spacer-To Manifold Bolt M-819-2814-21
Connecting Rod Nut (11) M-941-49 30-36
Crankshaft Damper Bolt M-14136-162100-120
Cylinder Head Bolt (12) M-12 108-122 80-90
Distributor Clamp Bolt M-1019-2814-21
Distributor Vacuum Tube To
Manifold Adapter 7-115-8
Exhaust Manifold To Cylinder Head
Bolt Stud Or Nut (13) M-1022-3116-23
Flywheel To Crankshaft Bolt M-1073-8756-64
Fuel Pump To Cylinder Block M-819-2814-21
Intake Manifold To Cylinder Head
Bolt Nut M-819-2814-21
Main Bearing Cap Bolt (15)M-12108-122 80-90
Oil Pressure Sending Wire To Block 11-248-18
Oil Pump Pickup Tube To Pump M-18 19-28 14-21
Oil Pump To Block M-819-28 14-21
Oil Pump Cover 10-15 90-130
Oil Pan Drain Plug To Pan M-14 21-33 15-25
Oil Pan To Block M-67-116-8
M-811-138-10
Oil Filter Insert To Cylinder Block 28-33 20-25
Oil Filter To Engine (16)
Rocker Arm Cover To Cylinder Head M-67-115-8
Spark Plug To Cylinder Head M-14 7-13 5-10
Temperature Sending Unit To Block 11-24 8-18
Water Jacket Drain Plug To Block 32-37 23-28
Water Pump To Block Bolt M-8 19-2814-21
EGR Valve To Spacer Bolt M-8 19-28 14-21
EGR Tube To Exhaust Manifold Conn. 13-149-11
EGR Tube Nut 13-149-11
Auxiliary Shaft Cover BoltM-68-12 6-9
Water Outlet Connection Bolt M-8 19-28 14-21
Cylinder Front Cover Bolt M-6 8-12 6-9
Inner Timing Belt Cover Stud M-819-28 14-21
Outer Timing Belt Cover Bolt M-68-12 6-9
Rocker Arm Cover Shield Bolt M-10 38-54 28-40
Thermactor Check Valve To Manifold 17 24-27 17-20
Fuel Filter To Carburetor
Assembly-Bolt 9-11 80-100 Lb-In
NEW AND USED DRIVE BELT TENSION SPECIFICATIONS
Belts have differing tension specifications depending on whether they are Newly Installed (1) or Used (more than ten minutes of engine operation). When belts are found to be below the allowable minimum they must be RESET (adjusted). Specifications for these situations are shown below:
Belt Condition and Tension in Lbs.
Belt Type Installed Reset Limits
14V 50-80 40-60
All other V 120-160 90-120
V-Ribbed
4 Rib (Air pump only) 90-130 90-120
4 Rib 110-150 100-130
5 Rib 130-170 120-150
6 Rib (Fixed)140-180 130-160
6 Rib (With Tensioner) 85-14080-140
NOTE: FIXED refers to systems with manually adjusted centers which are bolted in place and considered fixed.
(1) Newly Installed - Refers to the condition of the NEW drive belt before the engine has made no more than one rotation and before the belt has had a chance to stretch or seat into the pulley grooves.
(2) Time required for plunger to leak down 1/8 or travel with 50 lb. load leakdown fluid in lash adjuster.
(3) Distance in inches that front bearing is installed below front face of bearing tower.
(4) 0.002 undersize = Add 0.001 to Standard Thickness
(5) Pin bore and crank bearing bore must be parallel and in the same vertical plane, within the specified total difference when measured at the ends of an 8 bar - 4 on each side of rod centerline.
(6) Measured at the piston pin bore, centerline - 90 to the pin.
(7) Add one pint with filter change.
(8) On Engine, temperature normal, curb idle, in neutral, brakes set.
(9) Pump to tank return line pinched off, new fuel filter in line.
(10) Smallest Orifice = Not less than 0.220 I.D.
(11) Torque sequence in two steps:
Step 1 - 34-41 Nm (25-30 lb-ft)
Step 2 - 41-49 Nm (30-36 lb-ft)
(12) Torque cylinder head bolts in sequence in two steps:
Step 1 - 68-81 Nm (50-60 lb-ft)
Step 2 - 108-122 Nm (80-90 lb-ft)
(13) Torque in sequence in two steps:
Step 1 - 7-9 Nm (5-7 lb-ft)
Step 2 - 22-31 Nm (16-23 lb-ft)
(14) Torque in sequence in two steps:
Step 1 - 7-9 Nm (5-7 lb-ft)
Step 2 - 19-28 Nm (14-21 lb-ft)
(15) Torque in sequence in two steps:
Step 1 - 68-81 Nm (50-60 lb-ft)
Step 2 - 108-122 Nm (80-90 lb-ft)
(16) 1/2 turn after gasket contacts surface - oil gasket.
(17) Then rotate to position.
The AERA Technical Committee | | PISTON TO BORE | Piston To Bore Clearance Changed On
Ford Products 2.3L Engines
Ford Motor Company updated Piston to Bore clearance limits to .0032 maximum for the 2.3L engines listed below:
Ford
1982-83 Mustang, Fairmont, Granada & LTD
Lincoln-Mercury
1982-83 Capri, Zephyr, Cougar & Marquis
Light Trucks
1983 Ranger
Note additional engine specifications below:
ENGINE SPECIFICATIONS
Ford Products 2.3L Engine
PISTONS AND RINGS
PISTON
Diameter
Coded Red 3.7780-3.7786
Coded Blue 3.7792-3.7796
0.003 Oversize 3.7804-3.7810
Piston-to-Bore Clearance (Select Fit) 0.0014-0.0022
Service Limit .0032 Max.
Pin Bore Diameter 0.9123-0.9126
Ring Groove Width
Compression (Top) 0.080-0.081
Compression (Bottom) 0.080-0.081
Oil 0.188-0.19
PISTON PIN
Length 3.010-3.040
Diameter
Standard 0.9118-0.9124
0.001 Oversize 0.9130-0.9133
Piston-to-Pin Clearance 0.0002-0.0004
Pin-to-Rod Clearance Interference Fit
PISTON RINGS
Ring Width
Compression (Top) 0.077-0.078
Compression (Bottom) 0.077-0.078
Side Clearance
Compression (Top) 0.002-0.004
Compression (Bottom) 0.002-0.004
Oil Ring Snug Fit
Service Limit 0.006 Max.
Ring Gap
Compression (Top) 0.010-0.020
Compression (Bottom) 0.010-0.020
Oil (Steel Rail) 0.015-0.055
LUBRICATION SYSTEM
OIL PUMP
Relief Valve Spring Tension
(Lbs. Spec. Length) 15.2-17.2 @ 1.20
Drive Shaft-to-Housing
Bearing Clearance 0.0015-0.0030
Relief Valve-to-Bore Clearance 0.0015-0.0030
Rotor Asmbly End Clear.(Assembled) 0.004 Max.
Outer Race-to-Housing Clearance 0.001-0.013
Oil Capacity (Quarts U.S.) 4 (7)
FUEL PUMP
STATIC PRESSURE (PSI) (8) 5.0-7.0
MINIMUM VOLUME FLOW (9) (10) 1 Pint in 25 Seconds
ECCENTRIC TOTAL LIFT (Inches) 0.304-0.326
TORQUE SPECIFICATIONS-SPECIAL APPLICATIONS
ITEM SIZE N?m LB-FT
Auxiliary Shaft Gear Bolt M-10 38-54 28-40
Auxiliary Shaft Thrust Plate Bolt M-6 8-12 6-9
Belt Tensioner (Timing Pivot Bolt) M-10 38-54 28-40
Belt Tensioner (Timing Adjusted Bolt) M-8 19-28 14-21
Camshaft Gear Bolt M-12 68-96 50-71
Camshaft Thrust Plate Bolt M-6 8-12 6-9
Carburetor To Spacer Stud M-8 10-20 7.5-15
Carburetor To Spacer Nut M-8 14-19 10-14
Carburetor Spacer-To Manifold Bolt M-8 19-28 14-21
Connecting Rod Nut (11) M-9 41-49 30-36
Crankshaft Damper Bolt M-14 136-162 100-120
Cylinder Head Bolt (12) M-12 108-122 80-90
Distributor Clamp Bolt M-10 19-28 14-21
Distributor Vacuum Tube To
Manifold Adapter 7-11 5-8
Exhaust Manifold To Cylinder Head
Bolt Stud Or Nut (13) M-10 22-31 16-23
Flywheel To Crankshaft Bolt M-10 73-87 56-64
Fuel Pump To Cylinder Block M-8 19-28 14-21
Intake Manifold To Cylinder Head
Bolt Nut M-8 19-28 14-21
Main Bearing Cap Bolt (15) M-12 108-122 80-90
Oil Pressure Sending Wire To Block 11-24 8-18
Oil Pump Pickup Tube To Pump M-18 19-28 14-21
Oil Pump To Block M-8 19-28 14-21
Oil Pump Cover 10-15 90-130
Oil Pan Drain Plug To Pan M-14 21-33 15-25
Oil Pan To Block M-6 7-11 6-8
M-8 11-13 8-10
Oil Filter Insert To Cylinder Block 28-33 20-25
Oil Filter To Engine (16)
Rocker Arm Cover To Cylinder Head M-6 7-11 5-8
Spark Plug To Cylinder Head M-14 7-13 5-10
Temperature Sending Unit To Block 11-24 8-18
Water Jacket Drain Plug To Block 32-37 23-28
Water Pump To Block Bolt M-8 19-28 14-21
EGR Valve To Spacer Bolt M-8 19-28 14-21
EGR Tube To Exhaust Manifold Conn. 13-14 9-11
EGR Tube Nut 13-14 9-11
Auxiliary Shaft Cover Bolt M-6 8-12 6-9
Water Outlet Connection Bolt M-8 19-28 14-21
Cylinder Front Cover Bolt M-6 8-12 6-9
Inner Timing Belt Cover Stud M-8 19-28 14-21
Outer Timing Belt Cover Bolt M-6 8-12 6-9
Rocker Arm Cover Shield Bolt M-10 38-54 28-40
Thermactor Check Valve To Manifold 17 24-27 17-20
Fuel Filter To Carburetor
Assembly-Bolt 9-11 80-100 Lb-In
NEW AND USED DRIVE BELT TENSION SPECIFICATIONS
Belts have differing tension specifications depending on whether they are Newly Installed (1) or Used (more than ten minutes of engine operation). When belts are found to be below the allowable minimum they must be RESET (adjusted). Specifications for these situations are shown below:
Belt Condition and Tension in Lbs.
Belt Type Installed Reset Limits
14V 50-80 40-60
All other V 120-160 90-120
V-Ribbed
4 Rib (Air pump only) 90-130 90-120
4 Rib 110-150 100-130
5 Rib 130-170 120-150
6 Rib (Fixed) 140-180 130-160
6 Rib (With Tensioner) 85-140 80-140
NOTE: FIXED refers to systems with manually adjusted centers which are bolted in place and considered fixed.
(1) Newly Installed - Refers to the condition of the NEW drive belt before the engine has made no more than one rotation and before the belt has had a chance to stretch or seat into the pulley grooves.
(2) Time required for plunger to leak down 1/8 or travel with 50 lb. load leakdown fluid in lash adjuster.
(3) Distance in inches that front bearing is installed below front face of bearing tower.
(4) 0.002 undersize = Add 0.001 to Standard Thickness
(5) Pin bore and crank bearing bore must be parallel and in the same vertical plane, within the specified total difference when measured at the ends of an 8 bar - 4 on each side of rod centerline.
(6) Measured at the piston pin bore, centerline - 90° to the pin.
(7) Add one pint with filter change.
(8) On Engine, temperature normal, curb idle, in neutral, brakes set.
(9) Pump to tank return line pinched off, new fuel filter in line.
(10) Smallest Orifice = Not less than 0.220 I.D.
(11) Torque sequence in two steps:
Step 1 - 34-41 N?m (25-30 lb-ft)
Step 2 - 41-49 N?m (30-36 lb-ft)
(12) Torque cylinder head bolts in sequence in two steps:
Step 1 - 68-81 N?m (50-60 lb-ft)
Step 2 - 108-122 N?m (80-90 lb-ft)
(13) Torque in sequence in two steps:
Step 1 - 7-9 N?m (5-7 lb-ft)
Step 2 - 22-31 N?m (16-23 lb-ft)
(14) Torque in sequence in two steps:
Step 1 - 7-9 N?m (5-7 lb-ft)
Step 2 - 19-28 N?m (14-21 lb-ft)
(15) Torque in sequence in two steps:
Step 1 - 68-81 N?m (50-60 lb-ft)
Step 2 - 108-122 N?m (80-90 lb-ft)
(16) 1/2 turn after gasket contacts surface - oil gasket.
(17) Then rotate to position.
The AERA Technical Committee | | CRACKING FLEX COOLING FANS | Cracking Flex Cooling Fans
AERA members who are installing engines or selling remanufactured engines to installers should be aware of the following dangerous situation.
As under hood temperatures have increased and engine noise in the passenger compartment has become less acceptable, many manufacturers have resorted to installing flex cooling fan assemblies. This practice is also quite popular with RV and off road vehicles that may be pushed a little harder and can use the
extra air flow through the radiator.
On vehicles equipped with flex blade cooling fans, the National Highway Traffic Safety Administration (NHTSA) determined that: Blades may crack and may, over a period of time, loosen from the fan blade assembly. Blade pieces may damage components under the hood. If the hood is open while the engine is operating, persons standing nearby may be injured if the fan breaks. Impending
blade failure may be evidenced by rattling or vibration.
Consequently, the Ford Motor Company was asked to recall 1977 Thunderbird, Cougar, LTD II and Ranchero automobiles equipped with 5.0, 5.8 & 6.6L (302, 351M & 400 CID) engines with A/C. Also recalled were 1978-79 Granadas and Monarchs equipped with 4.1L (250 CID) engines with A/C. A revised design cooling fan was to be installed on these vehicles.
The next time you or your customer installs an engine, take a careful look at the cooling fan assembly. Maybe it too needs to be replaced. In either case, avoid leaning over or standing next to the cooling fan of an operating engine.
The AERA Technical Committee |
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