| 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 |
| CRANKSHAFT SPECIFICATIONS FOR DUAL PLUG ENGINES |
Crankshaft Specifications On
Ford 2.3L Dual Spark Plug Engines
The Ford Motor Company has changed the crankshaft main journal
sizes on Ford 2.3L engines used in Ranger and Bronco II trucks
that utilize dual spark plugs for each cylinder. Engines with a
single spark plug per cylinder retain the former journal sizes.
The crankshaft specifications are:
Dual Spark Plug Main Journal Size 2.2051-2.2059
Main Housing Bore 2.3971-2.3979
Single Spark Plug Main Journal Size 2.3982-2.3990
Main Housing Bore 2.5902-2.5910
All Models Rod Journal Size 2.0465-2.0472
Rod Housing Bore 2.1720-2.1728
The dual spark plug crankshaft carries the casting number E88E-AB
or E89E-AB.
The AERA Technical Committee
July 1991 - TB 786
##END## |
| FLYWHEEL SPECIFICATIONS |
Flywheel Specifications
The following flywheel specifications may be used as reference
when surfacing flywheels.
Type of
Manufacturer flywh. Specs. Comments
BMW Step .013 - .015
Datsun Step .003 - .005 No groove
Flat With groove
Datsun 240Z Step .010 With groove
Fiat Spider 1600 Step .018
Ford Falcon Cup .018 6 Cylinder engines
Ford Courier Cup .285
Cup .310
Ford Ranger Cup .003 V6 Cylinder engines
GM Cup .125
GM - Buick Cup .125 V6 Cylinder engines
GM - Spirit Cup .195
Honda Cup .030 Small cup
Cup .100 - .104
Cup .785 Long alignment pins
Cup .900 Short alignment pins
Honda Accord Cup .615
Mazda Cup .062 Rotary engines
Subaru Cup .785
Toyota Step .018 - .022 Large alignment pins
Cup .055 Small cup
Cup .965 - .970 Tercel, large cup
Step .040 Tercel, step
Step .020 Land Cruiser
VW Cup .945 Air cooled, 6 Volt
Cup .830 Scirocco
Cup .835 Rabbit/Golf
Cup .982 Air cooled bus engine
Cup .830 Air cooled engine
Cup .885 Air cooled engine
Specifications listed for Step type flywheels refer to the
height of the wear surface above the pressure plate mounting
surface. Specifications for Cup type flywheels refer to the
height of the pressure plate mounting surface above the wear
surface.
The AERA Technical Committee
February 1988 - SB 153
##END## |
| ROD KNOCK |
Rod Knock Sound On 1985-87
Ford 2.3L D (143 CID), 2.8L (171 CID) And 2.9L (177 CID) Engines
Ford Motor Company engineers advise that a rattling noise in the clutch area may be misdiagnosed as an engine rod knock. The engines listed above are found in the Ford Ranger, Bronco II and Aerostar vehicles built in 1985-87.
This noise occurs where the hydraulic clutch slave cylinder is installed in the clutch housing and can be corrected without pulling the engine or transmission. a two piece shim packet can be installed between the clutch housing and the slave cylinder as indicated in Figure 1 below. Install the shims with contact
cement by simply reaching around the clutch housing to where the slave cylinder line enters the transmission.
the shim pack is available from Ford Motor Company under part #E5TZ-7C528-A and is called Shim-Slave Cylinder.
The AERA Technical Committee |
| TEMPERATURE GAUGE FLUCTUATION ON 1995-2000 4.0L FORD ENGINES |
Temperature Gauge Fluctuation On
1995-2000 Ford 4.0L OHV Engines
AERA members have reported a temperature gauge fluctuation on 1995-2000 Ford 4.0L OHV engines. Along with this fluctuation, the customer may complain of a knocking or thumping noise as well.
This noise is most pronounced with the engine at normal operating temperatures and heard in the passenger compartment of the vehicle. The noise is caused by steam formation in the cooling system. This noise is then transmitted through the heater hoses and heater core.
Ford offers a Coolant By-Pass kit to cure this problem. This kit increases the flow, which reduces steam formation in the cooling system. Refer to the chart listed below to get the correct By-Pass kit as it depends on the type of vehicle the customer has.
Application Coolant By Pass Kit
1997-2000 Ranger with auto or manual trans and F8PZ-8522-AA
1997-2000 Explorer with auto trans
1995-2000 Explorer with manual trans and F8PZ-8522-BA
1995-1996 Explorer with auto trans
1995-1996 Ranger with auto or manual trans F8PZ-8522-CA
The AERA Technical Committee |
| CAMSHAFT SELECTION |
Camshaft Selection On
1990-96 Ford 4.0L Engines
The AERA Technical Committee offers the following information on camshaft selection for 1990-96 Ford 4.0L engines. Depending upon the transmission used, there are four different camshafts used for this engine. Using the incorrect camshaft may lead to customer complaints of lack of power or unsteady idle.
The camshaft profiles are unique to their applications, which requires the different part numbers. Identifying existing camshafts can be done by visual inspection of the area directly behind the front cam journal. Those markings include no grooves, a single or multiple cut grooves into the casting and a possible flat area behind the front cam journal as shown in Figure 1.
No grooves or a single groove on these camshafts are intended for 1990-96 Aerostar vehicles using automatic transmissions. Two grooves only, are used in vehicles with standard transmissions. Two grooves and a flat are intended for use in 1993-96 Explorer and Ranger vehicles with federal emissions. Three grooves and a flat should be used in 1993-96 Explorer and Ranger vehicles built with California emissions.
Application Lobe Dur. Lobe Ident. Part #
Lift @ .050 Sep.
Auto .276 Int. 185° Int. 108° None or F0TZ6250A
90-96 Aerostar .276 Ex. 203° Ex. 1 Groove
90-92 Explorer & Ranger
Manual .263 Int. 189° Int. 112° 2 F0TZ6250B
90-96 Aerostar .276 Ex. 207° Ex. Grooves
90-92 Explorer & Ranger
93-96 Explorer, .263 Int. 189° Int. 112° 2 F3TZ6250A
Grooves
Ranger Exc. Cal .276 Ex. 207° Ex. Flat Behind First Journal
93-96 Explorer, .273 Int. 193° Int. 115° 3 F3TZ6250B
Grooves
Ranger Calif. .277 Ex. 198° Ex. Flat Behind First Journal
AERA is aware of several aftermarket manufacturers supplying camshafts for the different applications. Some AERA shops have interchanged camshaft Part #F0TZ6250B and Part #F3TZ6250A with no apparent driveability problems.
The AERA Technical Committee |
