| 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 | | ENGINE SPECIFICATIONS | Piston-To-Bore Clearance Specifications On
1983 Ford Products With 2.3L (OHC) Engines
Ford Motor Company has provided AERA with specifications for
servicing pistons on 1983 model vehicles equipped with the 2.3L
(OHC) engine.
The specifications listed on the reverse side of this bulletin,
only apply to the following vehicles:
Ford - Mustang and Thunderbird
Lincoln-Mercury - Capri and Cougar
Additional engine service information is also listed for your
use.
ENGINE SPECIFICATIONS
2.3L 1-4 (OHC)
Piston
Piston
Diameter
Coded Red 3.7764-3.7770
Coded Blue 3.7776-3.7782
0.003 Oversize 3.7788-3.7794
Piston-to-Bore Clearance
(select fit) .0030-.0038
Pin Bore Diameter 0.9123-0.9126
Pin Groove Width
Compression (top) 0.080-0.081
Compression (bottom) 0.080-0.081
Oil .188-.189
Piston Pin
Length 3.010-3.040
Diameter
Standard 0.9118-0.9124
0.001 Oversize 0.9130-0.9133
0.002 Oversize 0.9140-0.9143
Piston-to-Pin Clearance .0003-.0005
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 Clrnce 0.0015-0.0030
Rotor Assembly End Clearance
(assembled) 0.004 Max
Outer Race-to-Housing Clrnce 0.001-0.013
Oil Capacity 5.0
Torque Specifications - Special Applications
Item Size N·m Lb.Ft
Auxiliary Shaft Gear Bolt M10 38-54 28-40
Auxiliary Shaft Thrust Plate Bolt M6 8-12 6-9
Belt Tensioner (Timing Pivot) M10 38-54 28-40
Belt Tensioner (Timing Adjustg) M8 19-28 14-21
Camshaft Gear Bolt M12 68-96 50-71
Camshaft Thrust Plate Bolt M6 8-12 6-9
Carburetor to Spacer Stud M8 10-20 7.5-15
Carburetor to Spacer Nut M8 14-19 10-14
Carburetor Spacer To Manifold
Bolt M8 19-28 14-21
Connecting Rod Nut M9 41-49 30-36
Crankshaft Damper Bolt M14 136-192 100-120
Cylinder Head Bolt M12 108-122 80-90
Distributor Clamp Bolt M10 19-28 14-21
Distributor Vacuum Tube to
Manifold Adaptor 7-11 5-8
Exhaust Manifold to Cylinder Head
Bolt Stud or Nut M10 22-31 16-23
Flywheel to Crankshaft Bolt M10 73-87 56-64
Fuel Pump to Cylinder Block M8 19-28 14-21
Intake Manifold to Cylinder
Head Bolt Nut M8 19-28 14-21
Main Bearing Cap Bolt M12 108-122 80-90
Oil Pressure Sending Wire
To Block 11-24 8-18
Oil Pump Pickup Tube to Pump M18 19-28 14-21
Nut-Turbo to Manifold 38-54 28-40
Nut-Oil Supply Line 27-40 20-30
Nut-Oil Supply Line Fitting 12-16 9-12
Nut-Oil Return Fitting to Block 8-12 6-9
Bolt-Intake Manifold-Upper to Lower 19-29 14-21
Nut-Throttle Body to Upper Intake 19-29 14-21
Oil Pump to Block M8 19-28 14-21
Oil Pump Cover 10-15 90-130
Oil Pan Drain Plug to Pan M14 21-33 15-25
Oil Pan to Block M6 7-11 6-8
M8 11-13 8-10
Oil Filter Insert to
Cylinder Block 28-33 20-25
Oil Filter to Engine
Rocker Arm Cover to Cyl Head M6 7-11 5-8
Spark Plug to Cyl Head M14 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 M8 19-28 14-21
EGR Valve to Spacer Bolt M8 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 M6 8-12 6-9
Water Outlet Connection Bolt M8 19-28 14-21
Cylinder Front Cover Bolt M6 8-12 6-9
Inner Timing Belt Cover Stud M8 19-28 14-21
Outer Timing Belt Cover Bolt M6 8-12 6-9
Rocker Arm Cover Shield Bolt M10 38-54 28-40
Thermactor Check Valve
to Manifold 17 24-27 17-20
Fuel Filter to Carburetor
Assembly-Bolt 9-11 80-100
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 Type Belt Condition and Tension in Lbs
Installed Reset Limits
1 4V 50-80 40-60
All other V 120-160 90-120
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 enginehas 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 18 of travel with 50
lb load leakdown fluidin 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. Measure at the position 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 ID
11. Torque in 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 tow 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 23-31 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. 12 turn after gasket contacts surface - oil gasket.
17. Then rotate to position.
The AERA Technical Committee
October 1983 - TB 294
##END## |
|
|
