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    Ford Service Manual 1993 2

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    Ford Service Manual 1993 2

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    Ford Service Manual 1993 2

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    Enio Perche Cruz

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    0201-4 GROUP FRAME AND mountina Q2 SECTION TLE PAGE SECTIONTITLE ENGINE AND TRANSAXLE MOUNTING vnsnsnnnnonns0208-4 SUBFRAME. SECTION 02-01 Subframe suavecT PAGE SUBJECT PAGE REMOVAL AND INSTALLATION SPECIFICATIONS 02018 Subtrame, Frost. VEHICLE APPLICA’ SPECIAL SERVICE. VEHICLE APPLICATION ‘Taurus/ Sable. REMOVAL AND INSTALLATION Subframe, Front 8. Disconnect lower control arm at pinch bolts to To's Required: balonts. ee ee ee oo 8 Bamove wo uta attach tering gear oN Removal 10. Remove retaining nuts from RH front engine 1. Disconnect battery ground cable. ‘mount and RH rear engine mount to subframe. 2. natallengne it eyes. 11. Remove stabiizer bar ink attachment to stabilizer 3. _ install Three Bar Engine Support DSSL-6000-A or er ‘cquvalent to existing engine iting eyes. 42, Remove LH transaxle mount insulator at through 4. Raise vehicle on hoist with vehicle resting on four bolts to subframe. contact points. Refer to Section 00-02. 13. Support subframe with adjustable jacks at 5. Remove ont tres and wheels. fer to Section subframe body mount eation pots 04°04 14, Remove four body mount retaining bots ©. Support steering gear with wire from the tle rod 16. With an assistant, lower adustable acks and {end to col spring fo hold steering goa n poston allow subframe to lower. Rotate front of subframe Secure housing of gear to suitable support to hold down and pick up rear of subframe off of exhaust itinpostion. Pipe. Work subframe rearward untlit can be 7. Disconnect exhaust system at flex couping and rowered down past exhaust pipe stop down. 16, Place subframe on oor or bench an transfer ‘suspension components to the new subframe, 7905 Taurus / Sable ly, 1902 02-01-2 2 sca AR RRR ss SSO REMOVAL AND INSTALLATION (Continued) Installation 4, ©n3.0L SHO engine equipped vohicles with ‘manual transaxle, intall four body mount ‘retaining nuts to each mount. Tighten to 8-11 Nem {6-8 Ib*), On vehicles equipped with 3.0L, 3.2L ‘SHO and 3.8L engines instal front body mounts toRH and LH eubirame. instal four nuts fo each ‘mount and tighten to 8-11 N-m (6-8 fo). NOTE: DONOT TIGHTEN AT THIS TIME, 2, With an assistant, align subframe to body. Install ‘wo rear subframe-to-body rubber mounts on 3.0L, 3.21 SHO and 3.8L engine equipped Vehicles. Install four bots into mounts. REE ole RES mee -_ a 1 ; a weirs 1 gel Sern ee ca 3. Install a 19mm (3,4 inch) outside diameter pipe © similar too! into front LH subframe and body alignment holes. After aligning the holes, slightly tighten the LH front body mount bolt. 4, Repeat Step 2 on front RH alignment holes, 5. Check front LH alignment holes with tool 8. After subframe alignment is complate, tighten four gublame-to-body bots to 75-102 Nem (85-75 ib). Install LH transaxle mount insulator at through lls to eubframe, Thten to 81-116 Nm (0085 bf. 8. Install stabiizer bar link attachment to stabilizer bar. Tighten to 47-65 Nom (35-47 Ib). 9. _Installtwo retaining nuts that secure the steering ‘gear to the No. 2 crossmember. Tighten to 115-135 Nem (86-99 Ib-). 10. Remove wire supporting steering gear from tle rod end to coil spring. 14. Install retaining nuts that secure the RH front ‘engine mount and the RH rear engine mount to ‘subframe. Tighten to 75-102 Nem (86-75 lb-f). 12. Connect lower control arm at pinch bolts to ball joints. 48, Connect exhaust system at flex coupling and position in place. 14, Install tires and wheels, Refer to Section 04-04, 16, Lower hoist 16. Remove Three Bar Engine Support DEBL-6000-A ‘or equivalent and engine iting eyes. 17. Check frontend alignment. Adjust if necessary. Refer to Section 04-00. sae 1903 Tauren Sabla Jay 7002 02-01-3 Subtrame 02-01-3 CO ee RN SPECIFICATIONS SPECIAL SERVICE TOOLS SS Tool Number Desention Description eaates LE Deat-<000-4 Gar Enine Support Body own Relaing Boe 75-102 | 5576 Body Mount to Sb Boe en [oe TransasieMoutio-Subrane | oxrse | cos Bote Fron engine MomtioSoprane | revor | 6575 Bot rH Rear Engine MowrioSibrame | 76102 | #570 Bot ae) Siabie: lncioStabiaeraar [ares | 3547 nae Gearto Grosamember Nate Tees | ess0 1969 Taurus/Sabe July, 1992 02-03-1 Engine and Transaxle Mounting 02-03-1 SECTION 02-03 Engine and Transaxle Mounting ‘SUBJECT PAGE SUBJECT PAGE REMOVAL AND INSTALLATION SPECIAL SERVICE TOOLS. 02-09-9 Engine Mounts, 3.0L EFI Engine. 1208-4 SPECIFICATIONS... Engine Mounts, 3.0L SHO Ent 203-1 VEHICLE APPLICATION. 2056 VEHICLE APPLICATION Taurus /Sable. REMOVAL AND INSTALLATION Engine Mounts, 3.0L SHO Engine 2. Raise vehicle on hoist. Refer to Section 00-02. 8. Place jack and wood block in suitable place under engine. 4. Remove roll damper to engine mount retaining bolts and remove roll damper. 5. Raise engine with jack (enough to unload insulator). Insulator, RH Front, No. 2 and/or RH Rk Removal 1. Remove lower damper retaining bolt from RH side of engine, f, No. 3 7008 Taurue/ Sable July, 1902 02-03-2 Engine REMOVAL AND INSTALLATION (Continued) 6. Remove two through bolts and remove inaulator from engine bracket. Installation 4. Installingulator-to-engine support bracket with ‘wo through bolts. Tighten through bolts to 54-75 ‘Nem (40-86 lb-ft). Refer to ilustration under Removal, Step 6. 2. Lower engine down onto frame. 3. Inetall nuts retaining RH front and RH rear ingulators to frame. Tighten nuts to 75-102 Nem (65-75 lb-ft). Install rol damper. Tighten bolts 10 54-76 Nem (40-55 Ib. 4, Remove jack and lower vehicle. 6. Install bolt retaining RH engine damper to engine. Tighten bolt to 54-76 Nem (40-55 Ib). Ineulator, LH and Support Assembly No. 1A Removal 4, Remove bolt retaining roll damper to lower ‘damper bracket and place damper shaft out of the way. 2. Remove backup lamp switch. Remove energy management bracket. 4, Raise vehicle on hoist. Refer to Section 00-02. Position jackstands under vehicle body allowing subframe to hang. 6. Remove LH tie and wheel. 6. Place jack and wood biock in suitable place under transaxle and support transaxle. 7990 Tawra Sable ly, 1902 Engine and REMOVAL AND INSTALLATION (Continued) ‘Mounting 7. Remove bots retaining lower damper bracket to ‘engine mount. 8. Remove bolts retaining insulator to transaxle and subframe. 9. Raise transaxle with jack (enough to unload insulator) 410. Remove insulator and lower damper bracket. LH, No. 14, Part Item | Number _| Description ‘3A [N6O5G14-S107 | Bolt (2 Req'a) 4B |'N804749-8100 | Bolt (2 Req'd) Part Item | _Number___| Description 1 |= Transaxle 2 [eros Bracket Assy ‘Continued 5 |— Subframe A Tighten to 95-190 Nem (71-95 LFD, 8 Tighten to 81-116 Nm (60-85, Lo-Fi) Installation 4. Loosely install insulator and damper bracket to transaxle and subframe, 2. Install damper bracket to insulator. Tighten bots 1054-75 Nem (40-55 Ibs). 3. Install insulator to transaxle. Tighten bolts to 95-190 Nem (71-95 ibs). 4. Install insulator to frame. Tighten botts to 81-116 Nem (60-85 lb-t). 5. Remove jack and jackstands. 6. Install tre and wheel. Tighten whee! ug nuts to 115-142 Nem (65-105 Io-f). 7. Lower vehi 8. Install darnper to damper bracket. Tighten bott to ‘54-75 Non (40-55 Ib. 9. Install backup lamp switch. 10. Install eneray management bracket. 7908 Tauraa/ Sable Jy, 1902 02-03-4 Engine and Transaxle Mounting REMOVAL AND INSTALLATION (Continued) Engine Mounts, 3.01 EFI Engine Part tom Number __| Description 1/— ‘Side Member 2 | eroes Inaulator No. 1A 3 [eros ‘Support Assy 4 | e038 s|— 6 _|s065 No. 3 nsulator Insulator, RH Front, No. 2 and/or RH Rear, No. 3 Removal 1, Raige vehicle on hoist. Refer to Section 00-02. ‘engine block. 3. Remove nuts retaining RH front and RH rear insulators to frame. 2. Place jack and wood block in suitable place under Raise engine with jack (enough to unload insulator) Remove two bolts from No. 3 insulator and one bolt from No. 2 ineulator and remove insulator from engine bracket. 7606 Faure Sable Jay 1092 02-03-5 REMOVAL AND INSTALLATION (Continued) Engine and Transaxle Mounting 02-03-5 4 4, 1 2. 3 insulator, LH and Support As Removal Attach insulator-to-engine support bracket with ‘wo bolts on No. 3 insulator. Tighten bolts to 54-75 Nim (40-55 lb-ft). Attach bolt to No. 2 insulator. Tighten bolt to 164-173 Nam (120-127 bt). Refer to ilustration under Removal, Step 6. Lower engine down onto frame. Install nuts retaining RH front and RH rear insulators to frame. Tighten nuts to 75-102 Nem (66-75 ib), Remove jack and lower vehicle. smbly No. 18 Raise vehicle on hoist. Refer to Section 00-02. Remove LH tire and wheel. acs jack and wood block in suitable place under transaxle and support transaxle, Remove two nut retaining insulator to support assembly. Remove two through boli retining insulator to ‘ame. r Part Pant tom | Number | Description ttem| number | Description Ta” Woosess-S107” [eat 7 [bos inser 2 | cose peur A Tone 164-173 l= — Beare fafliaeerreore, |e 8 Stanton 76-1020 (66-75 5 1— Engine sid ec |naosrrasi00 [bon Rea) e Ratantose 76m oes Tones Installation 7903 Teura/Seble Joy, 1082 02-03-68 REMOVAL AND INSTALLATION (Continued) Engine and Traneaxle Mounting 02-03-6 Part ltom | Number _| Description va | Na00es7-102 | Nut 2 eros) | Engine Mount Assy 98 |Na04749.8100 | Bolt(2 Req’e) af Frame 5 | eross ‘Support Assy A Tighten o.74-102 Nem (55-75 Lord, a Tighten to 81-118 Nom (60-85 LF), 6. Raise transaxle with jack (enough to unload insulator). 7. Remove bolts retaining support aseembly to transaxle, 8. Remove trangaxle support assembly by rotating ‘support assembly counterclockwise to ‘disengage upper stud on mount. 9. Remove mount. 4, Lower transaxle (enough to load insulator). 5. Attach inoulator to eupport assembly with two huts. Tighten nuts to 74-102 Nem (58-75 Ib. Refer to illustration under Removal, Step 5. 6. Attach damper shaft to support assembly using & ‘new flag nut, Tighten boit to 28-41 Nem (21-30 et. 7. Remove jack, Install LH tire and wheel. Tighten whee! ug nuts to 115-142 Nom (85-105 ib-). 9. Lower vehicie. Part ltem | Number _| Description vi Traneax 2 | erocs Support Assy 3a | Ne0s922-S102 | Bolt (2Req'd) 4 | 07002 Transaxle a Tighten 10 54-75 Nim (40-65, Lord, lation 1. Loosely install mount. 2. Attach eupport assembly to transaxle. Tighten bolts to 54-75 Nem (40-55 lb-ft), Refer to ilustration under Removal, Step 8. 3. Attach inaulator to frame with two through bolts. ‘Tighten bolts to 81-1 16 Nem (60-85 lb‘. Engine Mounts, 3.8L EFIEngine Tools Required: © Three Bar Engine Support D&8L-6000-A Hydraulic Engine Mount, RH Front @© 814802-8 Part tem | _Number__| Description +a | Na00sa7-8102 | Nut 2|— AIC Bracket 3 |ecoss Shi 4 [60a Insulator Assy (Color Code Yeliowston-Police; Color Code Blue Police) 88 |Nao2978-sts0 | Nut 6 |— Frame A Tighten to 54-75 Nem (40-56 LF, 8 Tighten to 75-102 Nem (55-75 Lor) 7909 Taorwe/ Sable uy, 1992 02-03-7 Engine and Traneaxle Mounting 02-03. rN NT SEN i SCRE REMOVAL AND INSTALLATION (Continued) Removal ‘Transaxle Hydramount Assembly, LH 1. Remove mount upper retaining nut through engine ‘compartment between A/C compressor and ‘compressor bracket using a long extension and fan 7mm swivel socket. 2. Install Three Bar Engine Support DBBL-6000-A or ‘equivalent. 3, Raise vehicle on hoist. Refer to Section 00-02. 4. Loosen RH rear mount lower retaining nut. 5. Remove RH front mount lower retaining nut. 6. Lower vehicle. 7. Raise engine approximately 25mm (1 inch) using engine support tool. & Raise vehicle. 9. Remove engine mount Installation 1. Instatlengine mount. 2. Lower vehicle. 3. Lower engine using engine support tool 4. Raise vehicle, ‘5. Install RH front mount lower retaining nut and tighten to 75-102 Nm (55-75 lb). ' Part NOTE: During installation of mount, hold lower Hom | __tumber__|} Description. can to prevent twisting when lower nut is 1A | Na00957-8162 [Nur tightened. 2 |eroest.t) | Engine Mount Assy 6. Tighten RH rear lower mount retalning nut to 98 |Ne04749-8100 | Boit Red's) 75-102 Nem (65-75 lb) 8 cae Frame support Assy e pawerwenee. a Tightonto 74-102 Nan (66-78 8. Remove engine support tool. Loro ‘9, Install mount upper retaining nut through engine e Tighten to 81-116 Nm (60-95 ‘compartment between A/C compressor and Leo, ‘compressor bracket using along extension and ‘an 18mm swivel socket. Lene! 10. Tighten mount upper retaining nut 1 64-76 Nem 1. Raise vehicle on hoist. Refer to Section 00-02, GOS b-). 2, Remove tire and wheel. 3, Place ajack and wood block in a suitable place Under the transaxle and support the transaxle. 4. Remove the nut retaining the transaxle mount 10 the support assembly. 5. Remove two through bolts retaining the transaxle ‘mount to the frame. 6. Raise the transaxie with the jack (enough to unload mount). 7. Removes the bolts retaining the support assembly to the traneaxi 8. Remove transaxle support assembly by rotating support assembly counterciockwise to disengage upper stud on mount. 9. Remove mount Installation 1. Loosely install mount. 2. Attach support assembly to the transaxle and tighten to 54-75 Nem (40-55 lb-. 1903 Tews Sabio Jay, 002 02-03-8 REMOVAL AND INSTALLATION (Continued) Engine and Transaxle Mounting 3. Attach insulator to frame with two through bolts ‘and tighten to 81-1 16 Nem (60-85 lb-ft). 4. Lower the transaxle (enough to load the mount). 6. Install ransaxie mount retaining nut insulator to ‘ascembly and tighten to 74-102 Nem (65-75ibH). 6, Removejack. 7. Install tire and wheel. Tighten whsel lug nuts to 116-142 Ne (85-105 Ib). 8. Lower vehicle. Engine Mount, RH Rear 6. Loosen retaining nut on the LH rear (No. 3) mount and heat shield assembly. 6. Raise vehicle on hoist. 7. Remove No. 3insulator retaining nut. Remove No. insulator and heat shield assembly. Instattation 1. Install mount and position No. 3 mount and heat shield assembly upper stud and antirotation pin to the transaxle support bracket. Hand start lower retaining nut. 2. Lower vehicle, 3. Tighten top retaining nut on the No. Sinsulator (CH rear), Tighten to 84-75 Num (40-55 lb-ft). 4. Lower engine and remove the Three Bar Engine Support. 5. Raise vehicle. 6. Tighten retaining nuts on RH front and RH rear engine mounts. Tighten to 75-102 Nem (55-75 02-03-8 (inch). Ib-ft). 7. Lower vei ‘SPECIFICATIONS TORQUE SPECIFICATIONS Tatoo ipso eave | a0 rn Raa Tera | 8 aco Pa seesa | | | Sipthewntivictanm | tare] ame ay Bolts (4 Req'd), ‘tom | neat Teserinton tiieariasorisFane tas ~[ 7e-ce | “ee76 et Engine Damper-to-Subframe 84-75, 40-55. T= Traneexle shes ee eee RHEngine Damper-to-Engine Bolts | $4-75 “40-66, 3 |scose Shoe Sse 4 [ose Into Aas (Coa Code te anton |e | Green-Non-Police; Color Pee eee se S cerns Tio ancaveaonw(@a | ar] bear ae Cote Sees 8 |soesresseo | nee sie Mamatoie@fera) | ere | wos : Tenenoseroninanss Wes ee] ose ‘ Foran Fa are aoe SB ‘Tighten to 75-102 Nem (65-75 Inaulatorto-Frame Nuts (3.0 SHO- 7 fie = i noone Spore | Tea | e678 1. alge veiceon hot. eter to Section 00.02, parorosiareArCeram | eeve | see 2. Remove th ut etaing the AH Wont nd Sacaa See Sr waa rear engine mounts tothe frame. Aisenbiyoan —_ 3. Lower vec, a 4. Use Three Bar Engine Support D88L-6000-A or Bracket Bol cident smoconte | | | umonaieveanemneur | ears] ase ffomatorsracker Razetno cngne about zomm | | LR 1969 Touroa able ly, 1092 02-09-98 Engine and Transaxle Mounting 02-03-0 rr SS SPECIAL SERVICE TOOLS: "Took ember Description (851-6000: | Tivee Bar Engine Support 1003 Taw Sable July, 1992 03-00-1 GROUP ENGINE 05, SECTION TITLE AIR INTAKE SYSTEM DRIVE BELTS, ACCESSORY... ELECTRONIC IGNITION (E1) HiGi DATA RATE ‘SYSTEM—FLEX FUEL .. ENGINE COOLING... ENGINE —SERVICi (€000 & 9000) SECTION TITLE —i IGNITION, DISTRIBUTOR 03-07A-4 IGNITION, ELECTRONIC. 108-078-4 EVAPORATIVE EMISSIONS. 03-13-1 FUEL CHARGING AND CONTROLS—3.01. “oso4a1 FUEL CHARGING AND CONTROLS —3.0L/3.21. SH FUEL CHARGING AND CONTROLS —S.8t. STARTING SYSTEM. SECTION 03-00 Engine—Service SUBJECT ADJUSTMENTS Valve Closranc: DESCRIPTION. Engine Identification. Exhaust Emission Conivol Syston DIAGNOSIS AND TESTING 8.0L and 3.8L. Engine. Static Engine Off Vaive Yrain Analysi 8.01/3.2L SHO Engin Closed-Type Positive Crankcase Ventiation ™ (PCV) System Preseure Method PAGE ‘SUBJECT 9. SPECIAL SERVICE TOOLS. ‘VEHICLE APPLICATION VEHICLE APPLICATION ‘Taurus/Sable and Taurus 3.01./3.2L SHO. 1000 Taurve Sable Jay, 1982 03-00-2 Engine: DESCRIPTION This Section covers various engine tests, adjustments, service procedures and cleaning/inspection procedures. Engine assembly and service specifications appear at the end of the appropriate ‘engine Section For engine removal, disassembly, assembly, installation, adjustment procedures and specifications, refer to the appropriate engine Section, ‘These engines incorporate a closed-type positive crankcase ventiation (PCV) system and exhaust ‘emission control system. All engine /emission controt systems are covered in the Powertrain, Control Emissions Diagnosis Manual." To maintain the required exhaust emission levels, the {ue! system, ignition system and engine must be kept in ‘900d operaiing condition and meet recommended. adjustment specifications, ‘When performing tests, adjustments or servios to the engine, ignition system or fuel system, it is essential to follow the procedures and specifications in the ‘appropriate service section in this manual, and inthe Powertrain Control/ Emissions Diagnosis Manual. Before replacing damaged or worn engine ‘components such as the crankshaft, cylinder heads, valve guides, valves, camshafts or cylinder block, censure the part(s) are not serviceable. WARNING: TO AVOID THE POSSIBILITY OF PERSONAL INJURY OR DAMAGE TO THE VEHICLE, DO NOT OPERATE THE ENGINE WITH ‘THE HOOD OPEN UNTIL THE FAN HAS FIRST BEEN EXAMINED FOR POSSIBLE CRACKS AND SEPARATION. Exhaust Emission Control System Operation, removal, installation and required maintenance of the exhaust emission control devices used on these engines are covered in the Powertrain ‘Control/ Emissions Diagnosis Manual. Engine Identification For quick engine identification, refer to the Safety ertilication Decal. The decal is mounted on the LH front door lock face panel, Find the engine code (letter ‘or number) on the decal, then refer to the engine Identification chart to determine the engine type and size. An engine identification labels also attached to the engine. The symbol code on the identification tag Identifies each engine for determining parts usage; for instance, engine cubic inch displacement and model year. Engine decal information is located in Section G2-91A (G01), 09018 (8.0L/9.21 SHO} 0rG8.01C Sal Emiesion Calibration Label ‘The emission calibration number label is located on the LH side door or LH door post pillar. Itidentifies the ‘engine calbration number, the engine code number ‘and revision level ‘These numbers are used to determine itparte are Unique to specific engines. Engine Emission Calibration Number Label CALIBRATION ETALONNAGE CALIBRACI ON 8-25F-ROO eese-ccost- AAA cautonarion REVISION NUMER aus Always refer to these labels when replacement parts ‘are required or when checking engine caliprations. Engine parts often differ within a CID family. Verification of identiication codes will ensure that the proper parts are obtained. These codes contain all pertinent information relating to dates, optional ‘equipment and revisions. The Ford Master Parts Catalog contains a complete listing of the codes and their application 1 Ganbeparchaaadaee 1999 Taurus Sabie July, 1992 03-00-3 Engine—Service 03-00-3 DIAGNOSIS AND TESTING Closed-Type Positive Crankcase Ventilation (PCV) System CAUTION: The removal ofthe crankcase Ventilation system from the engine will adv atfect the fuel economy and engine ventilation Tesuiting ina shortened engine life. ‘Amalnetioning closed crankcase ventilation system may be indicated by loping or rough engine ice, Do not attempt to compensate for his idle condition by disconnecting the postive crankcase ventiation ‘system and making ide speed adjustments. To determine whathor the loping or rough idle condition is ‘caused by a matfunctioning crankcase ventilation system, refer to the Powertrain Control/Emissions Diagnosis Manual Engine Oil Leaks Tools Required: © Rotunda Oit Leak Detector 112-0030 ‘When diagnosing engine oll leaks, its important that the source and location of the leak be positively identified before service. The folowing procedure has been found tobe very effective and requires minimum equipment. Prior to using his procedure, itis important toclean the cylinder block, cylinder head(s), rocker Cover(s), oll pan and flvwheel housing areas with a suitable Solvent to remove all races of ol. To perform oil leak diagnosis use Rotunda Oil Leak Detector 112-00030 or equivalent, perform the following procedure. ROTUNDA OIL LEAK DeTecron 412-00000, A15068-8 2. Drain engine oll erenkcase and refi with ecommended ol, premixed with Fluorescent Oi ‘Adaltive ESE-M99C 103-A or equivalent. Uso a minimum 14.8mi (1/2 oz) to a meximum 28,6 (G02) of fuorescent additive to all engines. if ol is not premixed, fuorescent additive must be added tocrankcase first. 3. Run engine for 18 minutes. Stop engine and inspect al sel and gasket areas for eas using Rotunda Oil Leak Detector 1 12:00080 or equivalent. A clear bright yellow or orange area willidentity leak. For extremely small leaks, Several hours may be required forthe leak fo appeer. 4. tnecessary, pressurize main oll gallery system tolocate leaks due to improperly sealed, loose or ‘cocked plugs I flywheel bots leek oil, lock for sealer on threads, 6. Service allleaks as required. Fluorescent Olt Additive Method 1. Clean engine with a suitable solvent to remove all ‘races of ol. Pressure Method Alternative Testing Procedure ‘The crankcase can be pressurized to locate oil oaks. ‘The following materials are required to fabricate the tool to be used. 1. Air supply and air hose. 2. Air pressure gauge that registers pressure in one pslincrements, 3. Airline shutoff vaive. 4. Appropriate fittings to attach the above parts to if, and PCV grommet holes and rocker arm cover tube. 5. Appropriate plugs to seal any openings leading to the crankcase. 6. Asolution of quid detergent and water to be ‘applied with a suitable applicator such as a squirt bottle or brush Fabricate the air supply hose to include the air line shutoff valve and the appropriate adapter to permit the air f0.entar the engine through the PCV Valve opening. Fabricate the air pressure gauge t0.a suitable adapter for installation on the engine at the ol fl pening, Testing Procedure 4. Open air supply valve until pressure gauge maintaine $4.5 kPa (6 psi). 2. Inspect the sealad and /or gasketed areas for leaks by applying “‘Snoop Pressure Check” or a ‘olution of quid detergent and water over the ‘areas forthe formation of bubbles, which indicates leakage. Possibie Leakage Points Examine the following areas for oil leakage FGanbe purchased ava soparaie om ee 1999 Tawus/: Engine—Service Soe eS EAN DIAGNOSIS AND TESTING (Continued) Underhood © Rocker cover gaskets © Intake manifold gaskets © Cylinder head gasket © Front cover gasket © Distributor O-ring © Oilleve indicator (dipstick) tube connection © Oil pressure sending unit ‘© Cup plugs and/or pipe plugs at the end of oil passages: Under Engine—With Vehicle on Hoist © Ollpangasket © Oilpan front and rear end seals ‘© Crankshaft front seal © Camshatt rear bore plug With Transaxle and Flywheel Removed © Crankshatt rear seal Air loakage in the area around a crankshaft rear oi seal does not necessarily indicate « rear seal leak. However, ifno other cause can be found for oil leakage, it can be assumed that the sealis the cause of the oll leakage. © Roar main bearing cap parting line. © Rear main bearing cap and seals. ‘© Rear cup plugs and or pie plugs at the end of oi passages. Cilleaks at crimped seams in sheet metal parts and Cracks in cast or stamped parts can be detected when pressurizing the crankcase, NOTE: Light foaming similar to beor foam) equally ‘around rocker arm cover bolts and crankshaft seals is. ot detrimental and no corrections are requiredin such cases. Compression Tests ‘Tools Required: © Rotunda Compression Tester 059-0008 Compression Gauge Check 1. Ensure oilin crankcase is of the correct viscosity and at proper level and battery is properly ‘charged. Operate vehicle until engine is at normal ‘operating temperature, Turn ignition switch to the OFF positon, then remove all spark plugs. 2. Set throttle plate in wide-open position. 8. Install a compression gauge such as Rotunda (Compression Tester 059-00009 or equivalent in No. ‘cylinder. Install euxilary starter switch in starting circu With ignition switch in OFF position, and using auxiliary starter switch, crank engine at least five ‘compression strokes and record the highest reading. Note the approximate number of ‘compression strokes required to obtain the highest reading. &. Repeat test on each cylinder cranking the engine approximately the same number of compression strokes. Test Conclusion The indicated compression pressures are considered. within specification if the lowest reading cylinder is within 75 percent of the highest. Refer to the ‘Compression Pressure Limit Chart. 7993 Taurus Sable July, 1992 Engine—Service a cy 8 3 196 16 2 a 8 a @ ry a 2 mH Ey 7 26 m me 6. = | 2 iss 2 5 | Ey 7 2 1s 2 v8 20 wt 2 @ 212 @ 2 i He @ 2 = 26 @ 26 ee is @ a 28 s 2 6 @ 0 1@ 2 s 20 w @ @ i 6 coy tone or more cylinders read low, squirt approximately ‘one tablespoon of XO-20W30-QR (ESR-MZC 179-A) ‘or equivalent engine ollon top ofthe pistons inthe low reading cylinders. Repeat compression pressure check on these cylinders. 1, tfcompression improves considerably, piston rings are at fault. 2. If compression does not improve, valves are ‘ticking oF seating poorly. 8. Iftwo adiacent cylinders indicate low ‘compression prossures and squirting oilon pistons does not increase compression, the ‘cause may be a cylinder head gasket leak between cylinders. Engine oll and/or cootant in ‘oylinders could result from this problem. Itis recommended the Compression Pressure it Chart be used when checking cylinder ‘compression so that the lowest reading number is 75 percent of the highest reading. Examele Hf, after checking the compression pressures in all cylinders, it was found that the highest reading ‘obtained was 196 psi and the lowest pressure reading ‘was 155 pai the engine is within specication and the ‘compression is considered satisfactory. Excessive Engine Oil Consumption Tools Requi © Rotunda Engine Cylinder Leak Detection Kit 014-00705 “The amount of oll an engine uses will vary with the way the vehicle is driven in addition to normal ‘engine-to-engine variation. This is especially true — = When replacing a standard size valve with an oversize valve always use the reamer in sequence (smallest oversize first, and then next smallest, etc.) 80 as not to overioad the reamers. NOTE: tf oversize valve stems and oversize stem seals are not available, bore out original quide and instal service bushing. Ream ID for specified clearance for standard size valve. Reface valve seat, ‘as required, Install standard size valve stem oll seal 7905 Yaurua/ Gable duly, 1092 03-00-26 OVERHAUL (Continued) CAUTION: The interference angle of the valve _and seat should not be lapped out. Remove all grooves or score marks from the énd of the valve ‘stem, and chamfer it as necessary. Do not remove more than 0.25mm (0.010 inch) from the ‘end of the valve stem. Hf the valve face runout is excessive and/or to remove: pits and grooves, reface the valve to a true 44 degree angle. Remove only enough stock to correct the runout ‘r to clean up the pits and grooves. Ifthe edge of the, valve head is leas then 0.7@mm (1/32 inch) thick after

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