2.8l v6 - VIN [s] Ford Cab & Chassis Ranger

ENGINE IDENTIFICATION

Note. For engine repair procedures not covered in this article, see ENGINE OVERHAUL PROCEDURES - GENERAL INFORMATION article in the GENERAL INFORMATION section.

Engine is identified by the 8th character of Vehicle Identification Number (VIN). The VIN is stamped on a metal plate visible through windshield on left upper side of instrument panel. VIN is also located on Safety Compliance Certification Label, attached to left door lock pillar.

ENGINE IDENTIFICATION CODES

Valve Clearance Specifications Courtesy Ford Motor Co. Scheme 15

1. Engine must be cold for correct valve clearance adjustment. Remove valve covers. Turn engine until intake valve of No. 5 cylinder just starts to move into open position. Adjust both valves for No. 1 cylinder (Scheme 15)
2. Intake valve clearance is correct when.014" (.36 mm) feeler gauge is snug or drags lightly while.015" (.38 mm) gauge is very tight. Exhaust valve clearance is correct when.016" (.41 mm) feeler gauge is snug or drags lightly while.017" (.43 mm) gauge is very tight, refer to «VALVE CLEARANCE ADJUSTMENT»(/ford/cab-chassis-ranger/1985-1986/remont/mechanical/#28l-v6-vin-s) table (Scheme 15)
3. To adjust valves in cylinder firing order (1-4-2-5-3-6), rotate engine so that intake valve is just opening on cylinders in order 5-3-6-1-4-2. Adjusting screws are self-locking type. Turn screw clockwise to reduce clearance or counterclockwise to increase clearance. (Scheme 15)
4. Use (1) feeler of each size to adjust clearances rather than stepped "go/no-go" gauge. When checking clearances, feeler gauge must enter gap from leading or trailing side of rocker arm pad. Gauge must be moved to opposite side of pad in motion parallel to centerline of crankshaft. CAUTION: DO NOT use a step-type "go/no-go" feeler gauge. Measuring valve clearance in direction perpendicular to crankshaft will result in poor feel. Valves measured in this incorrect manner will be adjusted too tightly. Damage to valves or valve seats will result.
5. Install valve covers (be sure to use new valve cover gaskets and reinstall cover reinforcement plates). Start engine and check for oil and vacuum leaks.

VALVE CLEARANCE ADJUSTMENT

ENGINE REMOVAL

See ENGINE REMOVAL article in the ENGINE section.

Removal

1. Disconnect negative battery cable. Remove air cleaner assembly. Disconnect throttle cable from engine. Drain cooling system. Remove water hose from water outlet to radiator. Remove by-pass hose from intake manifold to thermostat housing rear cover.
2. Remove distributor cap and spark plug wires as an assembly. Disconnect vacuum hose and wiring harness from distributor. Observe and mark position of rotor and distributor housing for reassembly reference. Remove distributor hold-down bolt and distributor.
3. Remove valve covers. Remove fuel line and fuel filter. Remove intake manifold attaching bolts and nuts. Lightly tap intake manifold with plastic mallet to break gasket seal. Lift intake manifold from engine.

Installation

1. Remove all gasket material and sealant. Apply sealing compound to mating surfaces. Place intake manifold gasket in position. Ensure tab on right cylinder head gasket fits into cut-out on manifold gasket. Apply sealer to attaching bolt bosses on intake manifold.
2. Position manifold and install attaching bolts. Start each bolt at least 2 full turns by hand. Tighten bolts and nuts to levels stated in «TORQUE SPECIFICATIONS»(/ford/cab-chassis-ranger/1985-1986/remont/mechanical/#28l-v6-vin-s__torque-specifications) in sequence. (Scheme 16) Reverse removal procedure to complete installation. Bleed cooling system and check ignition timing.

Intake Manifold Bolt Tightening Sequence. Scheme 16

1. Remove air cleaner assembly. Remove nuts attaching shroud to left exhaust manifold. Remove nuts attaching exhaust pipe to exhaust manifold. Remove thermactor components as necessary to remove exhaust manifold(s).
2. Disconnect choke heat tubes at carburetor. Disconnect oxygen sensor wire at left exhaust manifold. Remove exhaust manifold attaching bolts. Remove exhaust manifold from cylinder head.

Use new exhaust pipe gasket. Reverse removal procedure to complete installation.

1. Drain cooling system. Remove intake manifold as previously described. Remove valve covers and rocker arm shaft assemblies. Remove push rods and keep in order for installation in original positions.
2. Remove exhaust manifolds. Remove cylinder head attaching bolts. Remove cylinder heads from engine and discard head gaskets.

1. Position head gasket on engine block. Install cylinder head alignment studs into upper front and rear cylinder head bolt holes in engine block. NOTE: Cylinder head gaskets are marked with words "front" and "top" for correct installation positioning. Left and right head gaskets are not interchangeable.
2. Position cylinder heads over alignment studs on engine block. Install cylinder head attaching bolts and remove alignment studs. Tighten all bolts to levels stated in «TORQUE SPECIFICATIONS»(/ford/cab-chassis-ranger/1985-1986/remont/mechanical/#28l-v6-vin-s__torque-specifications) in sequence. (Scheme 17)
3. Reverse removal procedure to complete installation of remaining components.

Cylinder Head Bolt Tightening Sequence. Scheme 17

VALVE ARRANGEMENT

Right Side - I-E-I-E-E-I (Front-to-rear).

Left Side - I-E-E-I-E-I (Front-to-rear).

1. Remove air cleaner assembly. Remove spark plug wires. Remove PCV valve and hose. Remove carburetor choke air deflector plate. Remove valve cover bolts and washer. Ensure that washers are installed in their original positions.
2. Disconnect transmission fluid dipstick tube from valve cover. Disconnect kickdown linkage from carburetor, if equipped. Position thermactor air hose and wiring harness away from right valve cover. Remove engine oil fill cap.
3. Disconnect vacuum line from canister purge solenoid and canister-to-purge solenoid hose. If equipped with power brakes, disconnect brake booster hose. Lightly tap valve cover with plastic hammer to break seal.
4. Remove valve covers. Loosen rocker arm shaft attaching bolts 2 turns each time, in sequence, until all bolts are removed. Lift rocker arm shaft assembly with oil baffle from cylinder head.

Disassembly

Remove spring washer and roll pin from each end of rocker arm shaft. Slide rocker arms, springs and rocker arm shaft supports off shaft. Mark all parts for reassembly reference.

Exploded View of Rocker Arm Shaft Assembly Notch in end face of shaft must point downward. Scheme 18

Reassembly

When rocker arm shaft is reassembled, oil holes in shaft must point downward. Notch on end face of shaft must point downward on both banks. Coat all parts with heavy engine oil and reassemble in reverse order of disassembly.

1. Loosen valve adjusting screws several turns. Apply heavy engine oil to entire rocker arm shaft assembly. Install oil baffle and rocker arm shaft assembly on cylinder head.
2. Install all rocker arm shaft attaching bolts. Tighten bolts evenly, 2 turns each time in sequence.
3. Adjust valve clearance (Scheme 15)
4. Reverse removal procedure to complete installation of remaining components. Be sure to use new valve cover gaskets and reinstall cover reinforcement plates.

1. Remove air cleaner. Remove valve cover and rocker arm shaft. Remove spark plug wire and spark plug from cylinder in which valve spring will be removed.
2. Remove both push rods from cylinder to be serviced. Install air line adapter in spark plug hole. Apply air pressure to cylinder. CAUTION: Crankshaft may rotate until air pressure forces piston to bottom of stroke. Keep hands clear of belts and pulleys.
3. Using Valve Spring Compressor (T74P-6565-A and B), compress valve spring and remove spring retainer locks, spring retainer and spring. Remove valve stem oil seal.

Install new valve stem oil seal. Position spring over valve with tighter coils toward cylinder head. Compress spring and install retainer and locks. Reverse removal procedure to complete installation.

VALVE SPRING INSTALLED HEIGHT CHECK

1. Valve spring installed height should be measured with rocker arms removed. Measurement should be made from cylinder head spring pad to bottom side of valve spring retainer.
2. If height is not within specifications, install spacers between cylinder head spring pad and valve spring to obtain specified height. DO NOT install more spacers than necessary as stress will be placed upon valve springs and camshaft lobes.

VALVE SPRING INSTALLED HEIGHT SPECIFICATIONS

VALVE GUIDE SERVICING

Always use reamers in proper sequence (smallest first). Reface valve seat after valve guide has been reamed. After reaming, use scraper to break sharp corner at top inside diameter of valve guide bore. Valves are available with .008" (.20 mm), .016" (.41 mm) and .032" (.81 mm) oversize stems.

1. Remove oil pan. Drain cooling system and remove radiator. Remove air conditioning compressor and power steering bracket. Remove alternator, thermactor pump and remaining drive belts.
2. Remove fan. Remove water pump. Remove heater and radiator hoses. Remove drive pulley from crankshaft. Remove front cover retaining bolts. Lightly tap front cover with plastic hammer to break seal.
3. Remove front cover. If cover plate gasket needs replacement, remove 2 bolts and cover plate. Remove guide sleeves from front of block if necessary.

1. Apply sealing compound to engine block and back side of front cover plate. If removed, install guide sleeves with new sealing rings so that chamfered edge faces front cover. Place gasket and cover plate on engine, using 4 front cover bolts to align plate and gasket.
2. Install and tighten 2 cover plate-to-block bolts. Remove 4 front cover bolts. Apply sealing compound to front cover gasket. Place gasket on front cover. Place cover on engine and start front engine cover retaining bolts a few turns.
3. Center front cover with Front Cover Aligner (T74P-6019-A) in front cover seal. Tighten engine front cover attaching bolts. Reverse removal procedure to complete installation.

Drain cooling system. Remove radiator, crankshaft pulley and water pump drive belt. Using Seal Remover (1175-AC) and slide hammer, remove front cover oil seal from engine front cover.

Coat new front cover oil seal with Lubriplate. Slide oil seal and Seal Installer (T74P-6700-A) onto crankshaft. Drive oil seal in until installer contacts front cover. Reverse removal procedure to complete installation.

Drain cooling system and crankcase. Remove oil pan. Remove radiator. Remove water pump and engine front cover. Remove camshaft gear retaining bolt. Remove camshaft gear. Using gear puller and Shaft Protector (T71P-7137-H), remove crankshaft gear.

1. Align keyway in camshaft gear with key on camshaft. Slide gear onto camshaft and install camshaft gear retaining bolt. Ensure camshaft end play is correct.
2. Align keyway in crankshaft gear with key on crankshaft and timing marks on both gears. (Scheme 19) Slide gear onto crankshaft. Reverse removal procedure to complete installation.

Aligning Timing Marks on Timing Gears. Scheme 19

1. Disconnect negative battery cable. Drain crankcase. Remove radiator. Remove fan, spacer, drive belt and pulley.
2. Remove spark plug wires from spark plugs. Remove distributor cap and wires as an assembly. Disconnect distributor wiring harness and vacuum hose. Remove distributor.
3. Remove alternator and thermactor pump. Remove fuel lines, fuel filter and carburetor. Remove intake manifold. Remove valve covers and rocker arm shaft assemblies.
4. Remove push rods and keep in order for reinstallation in original locations. Remove tappets from bores and keep in order for reinstallation in original location. Remove oil pan. Remove crankshaft damper.
5. Remove water pump and engine front cover as an assembly. Remove camshaft gear attaching bolt and washer. Slide gear off of camshaft. Remove camshaft thrust plate. Carefully slide camshaft out of engine.

1. Coat camshaft journals and tappets with heavy engine oil. Apply Lubriplate to camshaft lobes. Carefully install camshaft into engine block.
2. Install camshaft thrust plate so main oil gallery is covered. Tighten bolts. Check camshaft end play. Align timing marks and install camshaft gear. Reverse removal procedure to install remaining components.

CAMSHAFT END PLAY CHECK

1. Remove engine front cover. Push camshaft toward rear of engine. Install dial indicator so that indicator plunger is on camshaft gear attaching bolt.
2. Zero dial indicator. Using large screwdriver between camshaft gear and engine block, move camshaft forward and release it. Read dial indicator.
3. If dial indicator reading is greater than .009" (.29 mm), replace thrust plate and/or spacer ring behind camshaft gear. Remove dial indicator from engine. Reinstall engine front cover.

CAM LOBE LIFT CHECK

1. Remove air cleaner. Remove valve cover. Using vernier caliper, measure both distance "A" and "B" of each cam lobe. (Scheme 20) Distance "A" minus distance "B" is cam lobe lift.
2. Check lift of each lobe in consecutive order and note all readings. If readings are not within specifications, replace camshaft and all rocker arms.

Measuring Cam Lobe Lift. Scheme 20

1. Remove engine from vehicle and place on engine stand. Remove flywheel. Remove camshaft. Remove rear bearing bore plug.
2. Using Camshaft Bearing Remover/Installer (T71P-6250-A), remove camshaft bearings from engine block. Use Adapter Tube (T72C-6250) when removing front and rear bearings.

1. Install camshaft bearings in engine block using camshaft bearing remover/installer. When installing bearing, ensure that oil hole in bearing is aligned with oil hole in engine block.
2. Oil hole alignment of number 2 and 3 bearings can be checked by inserting piece of welding rod through engine block oil gallery and camshaft bearing. Reverse removal procedure to complete installation.

OIL PAN

1. Disconnect negative battery cable. Remove air cleaner assembly. Remove fan shroud and position over fan. Remove distributor cap and position away from firewall. Remove distributor from engine.
2. Remove front engine mount attaching nuts. Remove engine dipstick tube. Raise vehicle. Drain engine oil. On models with automatic transmissions, remove fill tube from pan and plug hole. On all models, remove oil filter.
3. Disconnect exhaust pipes at manifolds. Disconnect oil cooler bracket and lower cooler. Remove starter. Disconnect front stabilizer bar and position forward. Place jack under engine and raise engine as far as possible.
4. Place wood blocks between engine mounts and frame. Lower engine and remove jack. Remove oil pan attaching bolts and lower pan.

1. Drain cooling system and crankcase. Remove intake manifold, cylinder heads, oil pan and oil pump.
2. Rotate crankshaft until piston to be removed is at bottom of stroke. Place cloth on top of piston to collect cuttings. Remove any ridges or deposits from upper end of cylinder bore.
3. Ensure that all connecting rods and rod caps are marked so that they can be installed in their original locations. Remove connecting rod nuts and cap.
4. Push piston out through top of engine block using hammer handle. Remove bearing inserts from connecting rod and cap.

Scheme 21

1. Apply light engine oil to piston rings, piston and cylinder walls. Ensure that ring gaps are properly spaced around piston. Install piston ring compressor on piston. (Scheme 21) (Scheme 21): Correctly Spacing Piston Ring Gaps
2. Using hammer handle, push piston into cylinder block until top of piston is just below top of cylinder block. Carefully guide connecting rod onto crankshaft journal. Indentation notch on head of piston faces front of engine. NOTE: Ensure piston and rod assembly is returned to same cylinder from which it was removed.
3. Apply light coat of engine oil to journals and bearings. Install connecting rod cap and tighten nuts. Numbers on connecting rod and bearing cap must be on same side of assembled rod and face left side of engine.

FITTING PISTONS

Note. Make all measurements with piston and block at normal room temperature of 70°F (21°C).

1. Measure piston skirt 90° to piston pin axis. Measure cylinder bore 90° to crankshaft centerline, at top, middle and bottom of bore. Use these measurements to determine piston-to-cylinder bore clearance.
2. Measure cylinder bore 90° to crankshaft centerline at top of bore (below ring travel) and at bottom of bore (above ring travel). These measurements determine cylinder taper. Taper (difference between 2 measurements) must not exceed .010" (.25 mm).
3. Measure cylinder bore at center of piston travel, 90° to crankshaft centerline. Measure bore at center of piston travel in-line with crankshaft centerline. Out-of-round is difference between 2 measurements, and must not exceed .005" (.13 mm).
4. If taper or out-of-round are beyond limits, or cylinder walls are deeply scored, hone or bore cylinders for installation of new pistons. After cylinders have been honed or bored, measure cylinder diameter. Select proper piston to obtain specified piston-to-cylinder bore clearance.

FITTING RINGS

1. Select proper ring set for size of cylinder bore. Position ring in cylinder bore in which it is going to be used.
2. Push ring down into bore to area where normal ring wear is not encountered. Use piston to position ring so that it is square with cylinder wall.
3. Measure gap between ends of ring using feeler gauge. If ring gap is either less or greater than specified, smaller or larger ring will have to be used.
4. Check side clearance of compression rings with feeler gauge inserted between ring and lower edge of ring land on piston. Feeler gauge should slide freely around entire circumference of piston without binding.
5. If feeler gauge binds because of high spots on lower land of piston, piston should be replaced.

Using an arbor press and Piston Pin Remover/Installer (T68P-6135-A and T72C-6135), press piston pin from piston and connecting rod.

Apply light coat of oil to all parts that are to be assembled. Assemble piston and connecting rod. Using arbor press and piston pin remover/installer, press piston pin through piston and connecting rod until centered in connecting rod. (Scheme 22)

Correct Positioning of Piston and Connecting Rod. Scheme 22

1. Drain crankcase. Remove oil pan and oil pump. Rotate crankshaft until connecting rod being worked on is at bottom of stroke. Mark cap and rod for reassembly if not already marked. Remove rod cap from rod. Remove bearing inserts.
2. Inspect bearings for wear or scuffing. Use Plastigage method to determine bearing wear and clearance. If standard bearings are being replaced with new bearings, try to obtain minimum specified clearance.
3. Bearings can be selectively fitted to obtain desired clearance. If standard bearing will not give proper clearance, try half of .001" (.03 mm) or .002" (.05 mm) undersize bearing in combination with half of standard bearing to obtain clearance.

1. Ensure bearing inserts and bearing bore of connecting rod are clean. Clean crankshaft journal. Install bearing inserts in connecting rod and cap. Ensure tang on bearing fits slot on rod.
2. Apply engine oil to bearing inserts and crankshaft journal. Pull rod down snugly to journal and install rod cap. Tighten rod nuts. Check side clearance between connecting rods on common journals.
3. Clean oil pump intake screen and prime oil pump. Turn pump shaft until oil comes out of outlet. Install oil pump and pan. Start engine and check for leaks.

1. If rear main bearing is to be replaced, remove engine and place on stand. If rear main bearing is not to be replaced, remaining bearings can be replaced with engine in vehicle. Drain crankcase.
2. Remove oil pan and oil pump. Remove one bearing cap at a time, leaving others securely fastened. Insert Upper Bearing Remover/Installer (6331-E) in oil hole of journal. (Scheme 23)
3. Rotate crankshaft slowly in direction of normal operation and force upper bearing insert out of block. Ensure 4 thrust washers on No. 3 bearing are in good condition. Clean journals. Check journals and bearing inserts for wear or damage.

Installation of Upper Main Bearing Remover/Installer. Scheme 23

1. Coat new bearing with heavy engine oil. Place smooth end (without tang) of bearing insert over crankshaft on locking tang side of block. Partially install bearing insert.
2. Install upper bearing installer/remover in journal oil hole. Slowly rotate crankshaft in opposite direction of normal engine rotation. Stop when bearing tang is fully seated in block slot.
3. Remove bearing installer. Select fit lower bearing insert using Plastigage method. Coat bearing insert and journal with heavy engine oil. Install main bearing cap and tighten bolts.
4. When replacing rear main bearing, coat rear portion of bearing cap flats with sealer. DO NOT put sealer on flats where cap bolts come through. Replace rear main cap wedge seals at this time, 1 in cap groove and 1 in block front cover.
5. Install oil pump after priming. Install oil pan and fill crankcase. Check for leaks after engine is running.

THRUST BEARING ALIGNMENT

Loosen bolts on number 3 main bearing cap. Pry crankshaft toward front of engine. With prying pressure on crankshaft, tighten main bearing cap bolts.

1. Remove transmission from vehicle. Remove pressure plate and clutch disc, if equipped. Remove flywheel, flywheel housing and rear plate.
2. Punch 2 holes in rear main bearing oil seal. Punch holes directly opposite of each other and just above bearing cap-to-block split. Install sheet metal screw in each hole.
3. Using 2 large screwdrivers, pry on both screws at same time until seal is removed from engine block. It may be necessary to use wood blocks as fulcrum points when prying seal out.

1. Coat outside diameter of oil seal with engine oil. Coat inside diameter of oil seal with Lubriplate.
2. Using Seal Installer (T72C-6165), drive oil seal into engine block until seal is firmly seated. Reverse removal procedure to complete installation.

ENGINE OILING SYSTEM

System is pressure fed from rotor-type oil pump. Oil flows through oil filter before entering main oil gallery. (Scheme 24)

Engine Oiling System. Scheme 24

CRANKCASE CAPACITY

Crankcase capacity is 4 quarts (3.8L). Add 1 quart (.9L) when oil filter is replaced.

OIL FILTER

Oil filter should be replaced every 7500 miles.

NORMAL OIL PRESSURE

Normal oil pressure with engine hot and running at 2000 RPM should be 40-60 psi (2.8-4.2 kg/cm 2 ).

OIL PRESSURE REGULATOR VALVE

Oil pressure regulator valve is located in oil pump body. Valve is nonadjustable.

Remove oil pan. Remove bolt attaching oil pick-up screen support arm to main bearing cap. Remove oil pump attaching bolts. Remove oil pump and oil pump drive shaft from engine.

Inspection

1. Clean all parts in solvent and dry thoroughly with compressed air. Ensure that all dirt or metal particles are removed from pressure relief valve chamber.
2. Check inside of pump housing, outer race, and rotor assembly for excessive wear or damage. Check mating surface of pump cover for wear. If pump cover mating surface is excessively worn, scored or grooved, replace pump assembly.
3. Measure rotor tip clearance between inner and outer rotors. Remove rotor assembly from pump and place on flat surface. Feeler gauge must be inserted at least.5" (13 mm) into space between inner and outer rotors. (Scheme 25) If rotor tip clearance exceeds specification, pump assembly must be replaced.

Checking Inner Rotor Tip Clearance Place rotor assembly on flat surface when measuring. Scheme 25

Fill and prime oil pump with oil before installation. Rotate pump shaft to fill pump body with oil. Install pump drive shaft with pointed end up. Reverse removal procedure to install all components.

OIL PUMP SPECIFICATIONS

OIL PUMP SPECIFICATIONS

Scheme 26

1. Drain cooling system. Disconnect lower radiator hose and heater return hose from water inlet housing.
2. Remove fan and fan clutch assembly using Fan Clutch Holder and Nut Wrench (T83T-6312-A and B). (Scheme 26) Water pump hub and fan clutch nut have left-hand threads. (Scheme 26): Removing Fan & Fan Clutch Assembly Fan clutch-to-pump hub nut has left-hand thread.
3. Loosen alternator mounting bolts and remove drive belt. On models with A/C, remove alternator and bracket. On all models, remove water pump pulley.
4. Remove water pump attaching bolts. Note different bolt lengths for reinstallation in correct location. Remove water pump assembly, water inlet housing and thermostat from front of engine.

To install, reverse removal procedure.

Note. For further information on cooling systems, see appropriate ENGINE COOLING SYSTEMS article.

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

GENERAL ENGINE SPECIFICATIONS

GENERAL ENGINE SPECIFICATIONS

VALVE SPECIFICATIONS

VALVE SPECIFICATIONS

PISTON/PIN/RING SPECIFICATIONS

PISTONS, PINS & RINGS SPECIFICATIONS

BEARING SPECIFICATIONS

CRANKSHAFT MAIN & CONNECTING ROD BEARINGS SPECS

VALVE SPRING SPECIFICATIONS

VALVE SPRINGS SPECIFICATIONS

CAMSHAFT SPECIFICATIONS

CAMSHAFT SPECIFICATIONS

See also:
• ENGINE OVERHAUL PROCEDURES - GENERAL INFORMATION
• VALVE CLEARANCE ADJUSTMENT
• TORQUE SPECIFICATIONS