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Main Bearing HousingBore Caution For 1993-2002 Ford/Mazda
2.5LVIN B & KL EnginesThe AERA Technical Committee saysthere
may be some confusion abouthow to properly determine the
mainbearing bore diameter on 1993-2002Ford 2.5L VIN B and KL
engines.This engine is made by Mazda andused in the Probe and 626
car models.
It appears some previously pub-lished information may have
beeninaccurate. Many service specifica-tions have listed a housing
bore diam-eter .002 smaller than it should be.
While the amount of inaccuracymay seem minimal, if the diameter
isused, it will provide insufficient mainbearing oil clearance.
The correct main bearing housingbore size for the 2.5L engines
listedabove should actually be 2.6378-2.6384 (67.000-67.016 mm).
Desiredmain bearing oil clearance is listed as.0015-.0022
(.038-.056 mm).
Engine Ticking NoiseOn 2001-2006 Ford3.0L VIN S EnginesIf you
have received questions or com-plaints about a ticking noise in
certainFord 3.0L engines, youre not alone.
Some 2001-2005 Taurus/Sable,2001-2006 Escape and
2005-2006Mariner vehicles built prior to 1-17-2006 and equipped
with the 3.0L 4VDuratec engine may exhibit a tickingnoise from the
left bank cylinder
head, only when the engine is at nor-mal operating
temperature.
The ticking noise may be comingfrom the left hand intake
camshaft atcylinder No. 6. Your installer cus-tomers can easily
diagnose this con-dition, with the engine running atnormal
operating temperature, using amechanics stethoscope (Figure 1left).
If the ticking noise can be veri-
fied at those locations, refer to thisservice procedure.
1) Remove the left bank valvecover.
2) Rotate the engine clockwiseuntil the cylinder number 6
intake
cam lobes are pointing up and thevalves are fully closed.
3) Remove all left hand intake camcaps individually and
reinstall themfinger tight. Note: the camshaft capsmust be
completely lifted off and thenset back into position. Loosening
and
re-torqueing cap bolts is not sufficient.4) Torque bolts in
sequence shown
in Figure 2 (below) to 72 in.lbs. (8Nm) excluding No. 8L
camshaft cap.
5) Using a screwdriver positionedon each side of the top of cam
capNo. 8L (Figure 3, below) apply handpressure and shift cam cap
No. 8Ltoward the exhaust side of the cylin-der head.
6) While holding cam cap No. 8Lin the shifted position, torque
the fas-teners, No. 9 (inboard) first, to 72in.lbs. (8 Nm) then
torque fastenerNo. 10 to 72 in.lbs. (8 Nm) (Figure 3).
7) Install the left hand camshaftcover.
8) Fully warm the engine to nor-mal operating temperature to
verifythe repair.
Balance Shaft TimingProcedures For 2000-2006 Ford 4.0L VIN
E& K EnginesThe AERA Technical Committeeoffers the following
informationregarding the proper balance shafttiming for certain
2000-2006 Ford4.0L VIN E and K engines.The infor-mation in this
bulletin applies only tothose all-wheel- or
four-wheel-drivevehicles that use a balance shaftengine.
To correctly time the balance shaftfor this engine, first locate
the numberone cylinder piston at top dead cen-ter.The number one
cylinder on thisengine is located at the farthest front,right
bank.
1) Install the balance shaft assembly
2 AERA TECH SOLUTIONS GUIDE | February 2007
Figure 1 Cam cap listening points for2001-06 3.0L Ford
engine.
Figure 2 Torque sequence for 2001-063.0L Ford engine.
Figure 3 Apply pressure and shift cap No.8L toward exhaust side
on 3.0L engines.
Figure 4 Balance shaft assembly torquespecs (20 ft.lbs) for 4.0L
Ford engine.
1 2
3
4
5
6
78
9
10
12
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(Figure 4, page 2).2) Tighten the bolts to 20 ft.lbs. (27
Nm).3) Align the timing marks. NOTE:
due to the gear ratio between thereversal shaft and the balance
shaft, upto seven complete turns of the bal-ance shaft may be
required to find thecorrect position.
4) Install a 4 mm (0.16) pin tohold the shaft in place
5) Install the balance shaft chainand crankshaft sprocket.
6) Install the balance shaft tensioner.7) Install the tensioner
bolts (2)
and torque to 21 ft.lbs. (29 Nm)8) Position the balance shaft
chain
guide and install the two bolts (3) to89 in.lbs. (10 Nm).
Revised Valve SpringsFor 1997-2002 Ford 4.0LVIN E & K
Engines The AERA Technical Committee saysthat a revised valve
spring for 1997-2002 Ford VIN E & K engines shouldeliminate a
stored P0300 or P0301trouble code on some vehicles.
Some Ford vehicles equipped withthe 4.0L SOHC engine may exhibit
aCHECK ENGINE LIGHT ONwith Diagnostic Trouble Codes(DTC) P0300
(Random Misfire) orP0301.The DTC will be set when theengine is
operated at high rpms(4,800 rpm and higher). The misfirecode is the
result of system interactionof higher than expected transient
exhaust system backpressure (underheavy acceleration) coupled
withvalve spring resonance points experi-enced at these engine
speeds. Thisinteraction may cause the exhaustvalve to hang open at
engine speedsof 4,800 rpm and higher.
To correct, verify that the DTCsets only at 4,800 rpm or
higher.Remove current intake and exhaustvalve springs (p/n
F77Z-6513-M)and replace with new service intakeand exhaust valve
springs (p/n 2L2Z-6513-AA).
Note: All 12 valve springs (six ofeach, intake and exhaust) must
bereplaced in order to ensure propervalvetrain dynamics.
Some machine shops have elected toreplace all springs with the
updated ver-sion any time the heads are serviced.
Crankshaft Thrust FaceFailures on 1985-2003Ford 4.2L and
5.0LEnginesThe AERA Technical Committeeoffers the following
informationregarding crankshaft thrust failures on1985-2003 Ford
4.2 and 5.0Lengines. This issue seems to be morepronounced when
these engines areused in light duty trucks equippedwith an
automatic transmission.
When dealing with thrust failureon any engine, the key issues
remain,surface finish, alignment and loading.The following
information should beviewed as specific guidelines for
thesecrankshafts.
The information in this bulletinfocuses on automatic
transmissionapplications, since that seems to bewhere the majority
of the failures occur.
What to Know Was there a prior problem with thethrust bearing?
Were there any transmissions prob-lems that need to be corrected?
Has the transmission overheated?
What is the condition of the trans-mission fluid? Is the proper
flex plate being used? Are the proper flex plate bolts beingused?
Did the torque converter engageinto the pump correctly? Are the
dowel pins to align thetransmission in place? Have the external
transmission cool-ing lines and cooler been checked forproper flow
and pressure? Because these transmissions are elec-tronically
controlled you should makecertain that they have proper ground.
NoteFord service TSB 00-1-5 says anytimethe transmission is
removed for serv-ice the cooler must be tested.
If the vehicle has a stand alone oil-to-air transmission cooler
it MUSTbe replaced and the rest of the systemcleaned, flushed, and
backflushedanytime the transmission is over-hauled or replaced. On
all others(except where they have temperatureby-pass valves) you
MUST clean,flush, and backflush the completetransmission fluid
cooling system. SeeFord TSB 00-23-10.
Also, Ford is currently recom-mending the installation of an
in-linetransmission fluid filter on E4OD,4R100, 4R70W and other
Ford auto-matic transmissions with 8 mm and9.5 mm transmission
cooling lines. Itis recommended that this in-line filterbe replaced
every 30,000 miles.
Surface FinishCrankshaft thrust faces are difficult togrind
because they are done using theside of the grinding wheel.
Grindingmarks left on the crankshaft face pro-duce a visual swirl
or sunburst patternwith scratches sometimes crisscrossingone
another in a crosshatch patternsimilar to hone marks on a
cylinderwall. If these grinding marks are notcompletely removed by
polishing,
4 AERA TECH SOLUTIONS GUIDE | February 2007
Figure 5 3.0L Ford engine balanceshaft tensioner torque
specifications.
1
2
3
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they will remove the oil film from thesurface of the thrust
bearing muchlike windshield wipers remove water.
The grinding wheel side face mustbe dressed periodically to
provide aclean, sharp cutting surface. A grind-ing wheel that does
not cut cleanlymay create hot spots on the surfaceleading to a
wavy, out-of-flat surface.The side of the wheel must also bedressed
at exactly 90 to its outsidediameter to produce a thrust face
thatis square to the axis of the main bear-ings.
A properly finished crankshaftthrust face should only have very
finepolish marks that go around the sur-face in a circumferential
pattern.Remember smoother and flatter arebetter. For these
applications a surfacefinish of 10 Ra or better is highly
rec-ommended.
LoadingAt the most basic level there is verylittle load placed
on the thrust bearingby the engine itself during operation.Nearly
the entire horizontal loadingon the crankshaft comes from exter-nal
sources either at the front or rearof the engine.
Thrust Bearing HelpWhen a problem application isencountered,
every effort should bemade to find the cause of distress andcorrect
it before completing repairs oryou risk a repeat failure.
A simple modification to theupper thrust bearing may help in
problem applications. Install the upperthrust bearing in the
block to deter-mine which thrust face is toward therear of the
engine.
Use a small, fine toothed, flat file toincrease the chamfer on
the ID edge ofthe bearing parting line from the oilgroove to the
rear thrust face only (seeFigure 6, below). This enlarged IDchamfer
will allow pressurized oil fromthe bearing oil groove to reach
theloaded thrust face without passingthrough the bearings clearance
spacefirst. Since there is a load against therear thrust face, the
load should restrictoil flow and there should not be anoticeable
loss in oil pressure.Although this modification is not aguaranteed
cure-all it should help if allother conditions, such as surface
finish,
alignment, cleanliness and loading arewithin reasonable
limits.
A previously published AERATechnical Bulletin (TB1465R)
hasinformation concerning crankshaftthrust bearing failures; it may
also bereferenced for additional information.
Lower Intake ManifoldInstallation For 1993-96DOHC 4.6L VIN
VEnginesThe AERA Technical Committeeoffers the following
informationregarding the installation of the lowerintake manifold
on 1993-96 Ford4.6L VIN V engines, the DOHCdesign used in Lincoln
vehicles.
This engine uses a combination oftwenty long and short studs and
nuts as
www.engine-builder.com | ENGINE BUILDER 5
Figure 6 Increase parting line inside cham-fer to approximately
.040 from groove torear only 4.2L and 5.0L engines.
Circle 205 for more information
2-7 Ford 2/12/07 8:56 AM Page 5
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well as four mounting bolts to securethe lower intake manifold
to the cylin-der heads.The correct installation pro-cedures must be
used to obtain aneffective long lasting gasket seal.Review the
steps and procedures listedhere before attempting installation.
1) Clean and verify cylinder headand intake manifold surfaces
are trueand flat within .002 (.051 mm).
2) Install new intake manifold gaskets.3) Following the sequence
shown
in Figure 7 (above), tighten fastenersnumbered 5, 7, 9, and 11
to 9-11ft.lbs.
4) In sequence, tighten the remain-ing numbered fasteners to
13-16ft.lbs.
5) In sequence, rotate all twentyfasteners an additional
85-95.
6) Tighten the 4 intake manifoldrunner control (IMRC) bolts to
71-
89 in.lbs. in sequence (A, B, C, D) asshown in Figure 8
(below).
7) In sequence, tighten them anadditional 85-95.
Timing Chain LinkIdentification For 1991-2006 Ford 4.6L &
5.4LVIN 9,W, X,Y & LEnginesOriginally, the timing chain used
in1991-2006 Ford SOHC 4.6L and5.4L VIN 9,W, X,Y and L engines
hadcopper colored links to assist inobtaining the proper cam to
cranktiming. If the coloring has beenremoved or is missing on a new
chainassembly, identifying the proper linksto mark is quite
simple.
If the copper links are not visible,lay the timing chain
entirely out.Afterdoing so, clean and mark the twoadjacent links on
one end and the sin-gle link on the other end. You havenow
positively identified the properplates to reference during
timingchain assembly.
Broken ExhaustManifold Studs On1997-2005 Ford 5.4LVIN L
EnginesThe AERA Technical Committeeoffers the following
informationregarding broken exhaust manifoldbolts on 1999-2005 Ford
5.4L VIN Lengines. This information applies tonon-supercharged
truck engines.Generally, this condition is firstnoticed because of
excessive exhaustnoise caused by manifold leakage.
This engine is used in the follow-ing vehicles:
FORD: 1997-2004 Expedition, F-150; 1999-2004 F-Super Duty;
1999-2005 E-Series.
LINCOLN: 1998-1999 NavigatorTo reduce the likelihood of
subse-
quent failure after repair, Ford nowoffers a stainless steel
stud (p/nW703902-S403) and nut (p/n
W701706-S2) for these applications.Although the supercharged
versions ofthis engine have not exhibited stud ornut failure, the
new parts could be usedfor those applications as an upgrade.
Any time these repairs are made, theexhaust manifold gasket(s)
must also bereplaced for an effective repair.To installthe
components, torque the studs in thecylinder head to 71-115 in.lbs.
(8-13Nm) and torque the nuts on studs to204-239 in.lbs. (23-27
Nm).
Revised Upper Oil PanAssembly For 2003-04Navistar/
International6.0L Diesel Engines (TB2380)The AERA
TechnicalCommittee offers the following infor-mation regarding a
revised upper oilpan assembly for 2003-2004Navistar/International
6.0L dieselengines. This information should beconsidered any time
an engine swapor components are replaced.
A new production and serviceupper oil pan assembly was
releasedfor 2003 through 2004 truck andconventional bus VT 365
dieselengine applications. See Figure 9 andChart 1 (page 7) for
details.
This new upper oil pan assemblyhas eliminated the center bosses
withmounting bolt holes found on enginesbuilt before Model Year
2004 (seeFigure 9). The new assembly is com-patible with Model Year
2003 engines.The old mounting bolts (M6 x 25) canbe reused.The old
center boss mount-ing bolts (M8 x 40) can be discarded.
A new production and serviceupper oil pan assembly has also
beenreleased for Truck, Rear Engine (RE)Bus, Semi Forward Control
(SFC)Bus, and Stripped Chassis VT 365diesel engine
applications.
This new upper oil pan assemblyhas retained the offset and
removedthe center bosses with mounting boltholes (see Figure 10)
page 7. Thenew assembly is compatible with all
6 AERA TECH SOLUTIONS GUIDE | February 2007
Figure 7 Lower intake manifold torquesequence for 93-96 4.6L
engines.
Figure 8 Torque sequence for 4.6L engineintake manifold runner
control bolts.
7
12
34
5
6
89
10
1112
1314
15
16
17
18
19
20
Front of Engine
A
BD
C
Front of Engine
Stud (Long)Stud (Short)Bolt
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engines using upper oil pan withoffset feature. The old
mountingbolts (M6 x 25) can be reused.The old center boss
mountingbolts (M8 x 40) can be discarded.
High Pressure OilPump Leakage On1998-2003 Ford 7.3LVIN F
EnginesThe AERA Technical Comm-ittee offers the following
infor-mation regarding high pressureoil pump leakage on
1998-2003Ford 7.3L VIN F diesel engines.Some 1998-2003 E-Series,
1999-2003 Super Duty, 2000-2003Excursion and 2000-2003F650/750
vehicles equippedwith a 7.3L Diesel engine mayexhibit an oil leak
at the highpressure oil pump outlet fittingsand/or end plug (see
Figure 11,above right).
This type of leak may appearto be a rear main crankshaft
seal,oil pan gasket, or other engine oilleak due to the drain
holemachined in the crankcase valleywhich allows any oil in the
valley
to run down the back of the engine.High pressure oil pump leaks
at
the outlet fittings and/or end plug canbe serviced without
removing thepump assembly. Replace the three O-rings on the
fillings and the end plugusing Kit 2C3Z-9G804-AA. Applyliquid
thread sealer (included in thekit) prior to reinstallation.
Note: do not remove the bottomplug. TSG
www.engine-builder.com | ENGINE BUILDER 7
VT 365 Application Model Year New Part No. Old Part No.Truck -
Some 2002 m/y trucks may have 2003 m/y modified upper oil pan
assembly due to midyear design change. See Figure 1 (1843537C91).
2002 1845436C91 1837341C91 RE Bus 2004 " Not applicable SFC Bus
2004 " Not applicable Stripped Chassis 2004 1845436C91 Not
applicable
Chart 1 Revised oil pan assembly identification on 6.0L diesel
applications.
Figure 9 6.0L diesel Truck andConventional Bus upper oil
panassembly.
Figure 10 6.0L diesel Truck, RE,SFC Bus, and Stripped Chassis
upperoil pan assembly.
Figure 11 7.3L engine oil pump fittings.
Circle 207 for more information
(NEW) (OLD)(NEW) (OLD)
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