Engine System-General Information: Other Mercury Mountaineer II

Engine Oil Leaks

Note. When diagnosing engine oil leaks, the source and location of the leak must be positively identified prior to repair.

Prior to carrying out this procedure, clean all sealing surface areas with a suitable solvent to remove all traces of oil.

Engine Oil Leaks-Fluorescent Oil Additive Method

Use the UV Leak Detector Kit to carry out the following procedure for oil leak diagnosis.

1. Add gasoline engine oil dye. Use a minimum 14.8 ml (0.5 ounce) to a maximum 29.6 ml (1 ounce) of fluorescent additive to all engines. If the oil is not premixed, fluorescent additive must first be added to crankcase.
2. Run the engine for 15 minutes. Stop the engine and inspect all seal and gasket areas for leaks using the UV Leak Detector Kit. A clear bright yellow or orange area will identify the leak. For extremely small leaks, several hours may be required for the leak to appear.

Leakage Points-Underhood

Examine the following areas for oil leakage

1. valve cover gaskets
2. intake manifold gaskets
3. cylinder head gaskets
4. oil bypass filter
5. oil filter adapter
6. engine front cover
7. oil filter adapter and filter body
8. oil level indicator tube connection
9. oil pressure sensor

Leakage Points - Under Engine - With Vehicle on Hoist

1. oil pan gaskets (6710)
2. oil pan sealer
3. oil pan rear seal (6723)
4. engine front cover gasket
5. crankshaft front seal (6700)
6. crankshaft rear oil seal (6701)
7. crankshaft main bearing cap side bolts
8. oil filter adapter and filter body
9. oil cooler, if equipped

Leakage Points - With Transmission and Flywheel Removed

1. crankshaft rear oil seal
2. rear main bearing cap parting line
3. rear main bearing cap and seals
4. flywheel mounting bolt holes (with flywheel installed)
5. camshaft rear bearing covers (6266) or pipe plugs at the end of oil passages

Oil leaks at crimped seams in sheet metal parts and cracks in cast or stamped parts can be detected when using the dye method.

Cylinder Leakage Detection

When a cylinder produces a low reading, use of the Engine Cylinder Leak Detection/Air Pressurization Kit will be helpful in pinpointing the exact cause.

The leakage detector is inserted in the spark plug hole, the piston is brought up to dead center on the compression stroke, and compressed air is admitted.

Once the combustion chamber is pressurized, a special gauge included in the kit will read the percentage of leakage. Leakage exceeding 20 percent is excessive.

While the air pressure is retained in the cylinder, listen for the hiss of escaping air. A leak at the intake valve (6507) will be heard in the throttle body (9E926). A leak at the exhaust valve (6505) can be heard at the tail pipe. Leakage past the piston rings will be audible at the positive crankcase ventilation (PCV) connection. If air is passing through a blown head gasket to an adjacent Cylinder, the noise will be evident at the spark plug hole of the cylinder into which the air is leaking. Cracks in the cylinder block or gasket leakage into he cooling system may be detected by a stream of nibbles in the radiator (8005).

Excessive Engine Oil Consumption

The amount of oil an engine uses will vary with the way the vehicle is driven in addition to normal engine-to-engine variation. This is especially true during the first 16,100 km (10,000 miles) when a new engine is being broken in or until certain internal engine components become conditioned. Vehicles used in heavy- duty operation may use more oil.

The following are examples of heavy-duty operation

1. trailer towing applications
2. severe loading applications
3. sustained high-speed operation

Engines need oil to lubricate the following internal components

1. cylinder block cylinder walls
2. pistons and piston, pin and rings (6102)
3. intake and exhaust valve stems
4. intake and exhaust valve guides
5. all internal engine components

When the pistons move downward, a thin film of oil is left on the cylinder walls. As the vehicle is operated, some oil is also drawn into the combustion chambers past the intake and exhaust valve stem seals and burned.

The following is a partial list of conditions that can affect oil consumption rates

1. engine duty cycle
2. operator driving habits
3. ambient temperature
4. quality and viscosity of the oil

Operation under varying conditions can frequently be misleading. A vehicle that has been run for several thousand miles on short trips or in below-freezing ambient temperatures may have consumed a "normal" amount of oil. However, when checking the engine oil level, it may measure up to the FULL or MAX on the oil level dipstick due to dilution (condensation and fuel) in the engine crankcase. The vehicle might then be driven at high speeds on the highway where the condensation and fuel boil off. The next time the engine oil is checked, it may appear that a liter (quart) of oil was used in about 160 km (100 miles). This perceived 160 km (100 miles) per liter (quart) oil consumption rate causes customer concern even though the actual overall oil consumption rate is lower.

Make sure the selected engine oil meets the current recommended API performance category with SAE viscosity grade as shown in the vehicle Owner's Guide. It is also important that the engine oil is changed at the intervals specified. Refer to the vehicle Owner's Guide.

Valve Train Analysis - Engine Off - Valve Dover Removed

Check for damaged or severely worn parts and correct assembly. Make sure correct parts are used with the static engine analysis as follows.

Valve Train Analysis - Engine Off, Rocker Arm

1. Check for loose mounting bolts, studs and nuts.
2. Check for plugged oil feed in the rocker arms (6564) or cylinder head.

Valve Train Analysis - Engine Off, Camshaft Roller Followers and Hydraulic Lash Adjusters, Overhead Camshaft

1. Check for loose mounting bolts on camshaft carriers.
2. Check for plugged oil feed in the camshaft roller followers, lash adjusters or cylinder heads.

Valve Train Analysis - Engine Off, Camshaft - Engines

1. Check for broken or damaged parts.

Valve Train Analysis - Engine Off, Push rods

1. Check for bent push rods (6565) and restricted oil passage.

Valve Train Analysis - Valve Springs

1. Check for broken or damaged parts.

Valve Train Analysis - Engine Off, Valve Spring Retainer and Valve Spring Retainer Keys

1. Check for correct seating of the valve spring retainer key (6518) on the valve stem and in valve spring retainer (6514).
2. Check for correct seating on the valve stem.

Valve Train Analysis - Engine Off, Valves and Cylinder Head

1. Check for plugged oil drain back holes.
2. Check for worn or damaged valve tips.
3. Check for missing or damaged guide-mounted valve stem seal.
4. Check collapsed valve tappet gap.
5. Check installed valve spring height.
6. Check for missing or worn valve spring seats.
7. Check for plugged oil metering orifice in cylinder head oil reservoir (if equipped).

Static checks (engine off) are to be made on the engine prior to the dynamic procedure.

Valve Train Analysis - Engine Running

1. Start the engine and, while idling, check for correct operation of all parts. Check the following

Valve Train Analysis - Engine Running, Valves and Cylinder Head

1. Check for plugged oil drain back holes.
2. Check for missing or damaged valve stem seals or guide-mounted valve stem seals.
3. Check for a plugged oil metering orifice in the cylinder head oil reservoir (4.6L engine only).

If insufficient oiling is suspected, check oil passages for blockage, then accelerate the engine to 1,200 rpm with the transmission in NEUTRAL and the engine at normal operating temperature. Oil should spurt from the rocker arm oil holes such that valve tips and camshaft roller followers are well oiled. With the valve covers (6582) off, some oil splash may overshoot camshaft roller followers.

Valve Train Analysis - Engine Running, Camshaft Lobe Lift-OHC Engines

Check the lift of each camshaft lobe in consecutive order and make a note of the readings.

Scheme 18

1. Remove the valve covers.
2. Remove the spark plugs.
3. Install the Dial Indicator Gauge with Holding Fixture so the rounded tip of indicator is on top of the camshaft lobe and on the same plane as the valve tappet.
4. Rotate the crankshaft using a breaker bar and socket attached to the crankshaft pulley retainer bolt. Rotate the crankshaft until the base circle of the camshaft lobe is reached.
5. Zero the dial indicator. Continue to rotate the crankshaft until the (1) high-lift point of the camshaft lobe is in the fully-raised position (highest indicator reading).
6. To check the accuracy of the original indicator reading, continue to rotate crankshaft until the (2) base circle is reached. The indicator reading should be zero. If zero reading is not obtained, repeat Steps 1 through 6.
7. Remove the Dial Indicator Gauge with Holding Fixture.
8. Install the spark plugs.
9. Install the valve covers.

Valve Train Analysis - Engine Running, Camshaft Lobe Lift-Push Rod Engine

Check the lift of each lobe in consecutive order and make a note of the readings.

Scheme 19

1. Remove the valve covers.
2. Remove the rocker arm seat bolts, rocker arm seat (6A528) and rocker arms.
3. Make sure the valve tappet is seated against camshaft (6250). Install (1) Dial Indicator Gauge with Holding Fixture so the ball socket adapter of the indicator is on top of the valve tappet or (2) Dial Indicator Gauge Adapter is on top of push rod and in same plane as valve tappet push rod movement.
4. Remove the spark plugs.
5. Connect an auxiliary starter switch in the starting circuit. Crank the engine with ignition switch in OFF position. Bump crankshaft over until valve tappet is on base circle of camshaft lobe. At this point, valve tappet will be in its lowest position. If checking during engine assembly, turn crankshaft using a socket or ratchet.
6. Zero the dial indicator. Continue to rotate crankshaft slowly until valve tappet is in fully-raised position (highest indicator reading).
7. Remove the Dial Indicator with Holding Fixture, Dial Indicator Gauge Adapter, and auxiliary starter switch.
8. Install rocker arm seats, rocker arms and rocker arm seat bolts.
9. Install valve covers.
10. Install spark plugs.

Valve Train Analysis - Engine Running, Valve Tappet

Valve tappet noise can be caused by any of the following

1. excessive valve tappet gap (collapsed)
2. incorrectly functioning valve tappet
3. air in lubrication system
4. excessive valve guide wear
5. low oil pressure

Excessive collapsed valve tappet gap can be caused by loose rocker arm seat bolts/nuts, incorrect initial adjustment or wear of valve tappet face, or worn roller valve tappets, push rod (6565), rocker arm (6564), rocker arm seat or valve tip. With valve tappet collapsed, check gap between the valve tip and the rocker arm to determine if any other valve train parts are damaged, worn or out of adjustment.

SPROCKETS

1. Inspect the timing chain/belt and the sprockets. Install new components as necessary. Refer to the appropriate ENGINE article for the procedure. An incorrectly functioning valve tappet can be sticking, caused by contaminants or varnish inside the tappet. The tappet can have a check valve that is not functioning correctly, which can be caused by an obstruction, such as dirt or chips that prevent the check valve from closing, or a broken check valve spring. A tappet with a leakdown time out of specification can cause tappet noise. If no other cause for noisy valve tappets can be found, the leakdown rate should be checked and new valve tappets installed if found to be out of specification. Assembled valve tappets can be tested with Hydraulic Lash Adjuster Leakdown Tester to check the leakdown rate. The leakdown rate specification is the time in seconds for the plunger to move a specified distance while under a 22.7 kg (50 lb) load. Air bubbles in the lubrication system will prevent the valve tappet from supporting the valve spring load. This can be caused by too high or too low an oil level in the oil pan or by air being drawn into the system through a hole, crack or leaking gasket on the oil pump screen cover and tube.

ROCKER ARMS - CLEANING

1. Clean all parts thoroughly. Make sure all oil passages are open.
2. Make sure oil passage in the push rod/valve tappet end of the rocker arm (6564) is open.

PUSH RODS - CLEANING

1. Clean the push rods (6565) in a suitable solvent. Blow out the oil passage in the push rods with compressed air.

Scheme 20

1. CAUTION: Do not attempt to straighten push rods. Check the ends of the push rods for nicks, grooves, roughness or excessive wear. Install new push rods as necessary. Refer to the appropriate ENGINE article for the procedure. The push rods can be checked for straightness while they are installed in the engine by rotating them with the valve closed. They also can be checked using a Dial Indicator with Bracketry.
2. If the push rod is bent beyond specifications, install a new push rod. Refer to the appropriate ENGINE article for the procedure.

Scheme 21

1. Measure each camshaft journal diameter in two directions. If out of specification, install new components as necessary. Refer to the appropriate ENGINE article for the procedure.

CAMSHAFT JOURNAL - CLEARANCE, PUSH ROD ENGINE, MICROMETER METHOD

1. Measure each camshaft bearing (6261) in two directions. Subtract the camshaft journal diameter from the camshaft bearing diameter.

Scheme 22

Note. The camshaft journals must meet specifications before checking camshaft journal clearance.

1. Remove the camshaft bearing cap and lay Plastigage across the surface. Refer to the appropriate ENGINE article for the procedure.
2. Position the camshaft bearing cap and install the bolts. Refer to the appropriate ENGINE article for the procedure.
3. Use Plastigage to verify the camshaft journal clearance. If out of specification, install new components as necessary. Refer to the appropriate ENGINE article for the procedure.

Scheme 23

Scheme 24

1. Remove the valve tappets. Refer to the appropriate ENGINE article for the procedure.
2. Use a Dial Indicator with Bracketry to measure camshaft end play.
3. Position the camshaft to the rear of the cylinder block.
4. Zero the indicator.
5. Move the camshaft to the front of the cylinder block. Note and record the camshaft end play. If camshaft end play exceeds specifications, install a new camshaft thrust plate (6269).

Scheme 25

Scheme 26

1. Remove the roller followers. Refer to the appropriate ENGINE article for the procedure.
2. Use a Dial Indicator with Bracketry to measure camshaft end play.
3. Position the camshaft to the rear of the cylinder head.
4. Zero the indicator.
5. Move the camshaft to the front of the cylinder head. Note and record the camshaft end play. If camshaft end play exceeds specifications, install new camshaft and recheck end play. Refer to the appropriate ENGINE article for the procedure. If camshaft end play exceeds specification after camshaft installation, install a new cylinder head. Refer to the appropriate ENGINE article for the procedure.

Scheme 27

1. Inspect camshaft lobes for pitting or damage in the contact area. Minor pitting is acceptable outside the contact area. If excessive pitting or damage is present, install new components as necessary. Refer to the appropriate ENGINE article for the procedure.

Scheme 28

Scheme 29

1. Use a Dial Indicator with Bracketry to measure camshaft intake/exhaust lobe lift. Rotate the camshaft and subtract the lowest indicator reading from the highest indicator reading to figure the camshaft lobe lift. For additional information, refer to SPECIFICATIONS in the appropriate ENGINE article .

Scheme 30

1. Use a Dial Indicator with Bracketry to measure the camshaft runout. Rotate the camshaft and subtract the lowest indicator reading from the highest indicator reading. For additional information, refer to the specification chart in the appropriate ENGINE article. If out of specification, install new components as necessary. Refer to the appropriate ENGINE article for the procedure.

Scheme 31

1. Measure each of the crankshaft main bearing journal diameters in at least two directions. Refer to the appropriate ENGINE article for the procedure. If out of specification, install new components as necessary. Refer to the appropriate ENGINE article for the procedure.

Scheme 32

1. Measure each of the crankshaft main bearing journal diameters in at least two directions at each end of the main bearing journal. Refer to the appropriate ENGINE article for the procedure. If out of specification, install new components as necessary. Refer to the appropriate ENGINE article for the procedure.

Scheme 33

Note. Crankshaft main bearing journals must be within specifications before checking journal clearance.

Scheme 34

Scheme 35

1. Remove the crankshaft main bearing caps and crankshaft main bearing.
2. Lay a piece of Plastigage across the face of each crankshaft main bearing surface.
3. Install and remove the crankshaft main bearing cap.
4. Verify the crankshaft journal clearance. Refer to the appropriate ENGINE article for the procedure. If out of specification, install new components as necessary. Refer to the appropriate ENGINE article for the procedure.

Scheme 36

Scheme 37

1. Measure the crankshaft end play. Use a Dial Indicator with Bracketry to measure crankshaft end play.
2. Position the crankshaft to the rear of the cylinder block.
3. Zero the indicator.
4. Move the crankshaft to the front of the cylinder block. Note and record the crankshaft end play. If crankshaft end play exceeds specifications, install a new crankshaft thrust washer (6334) or crankshaft thrust main bearing (6337). Refer to the appropriate ENGINE article for the procedure.

Scheme 38

1. Use the Dial Indicator with Bracketry to measure the crankshaft runout. For additional information, refer to Specifications in the appropriate ENGINE article. Rotate the crankshaft and subtract the lowest dial indicator reading from the highest dial indicator reading to figure the crankshaft runout. If it is out of specification, install new components as necessary. Refer to the appropriate ENGINE article for the procedure.

Scheme 39

1. Measure the crankshaft connecting rod journal diameters in two directions perpendicular to one another at each end of the connecting rod journal. The difference in the measurements from one end to the other is the taper. Verify measurement is within the wear limit. Refer to the appropriate ENGINE article for the procedure. If out of specification, install new components as necessary. Refer to the appropriate ENGINE article for the procedure.

Scheme 40

1. Measure the cylinder bore at the top, middle, and bottom of piston ring travel in two directions as indicated. Verify the cylinder bore is within the wear limit. The difference indicates the cylinder bore taper. Bore the cylinder to the next oversize. Refer to the appropriate ENGINE article for the procedure.

CYLINDER BORE - OUT - OF - ROUND

Measure the cylinder bore in two directions. The difference is the out-of-round. Verify the out-of-round is within the wear limit and bore the cylinder to the next oversize limit.

Scheme 41

1. Refer to the appropriate ENGINE article for the procedure.

Scheme 42

Scheme 43

Scheme 44

1. Clean and inspect the (1) ring lands, (2) skirts, (3) pin bosses, and the (4) tops of the pistons. If wear marks, scores or glazing is found on the piston skirt, check for a bent or twisted connecting rod.
2. Use the Piston Ring Groove Cleaner to clean the piston ring grooves. Make sure the oil ring holes are clean.

PISTON - PIN TO BORE DIAMETER

1. Measure the piston pin bore diameter in two directions on each side. Verify the diameter is within specification. If out of specification, install new components as necessary. Refer to the appropriate ENGINE article for the procedure.

Scheme 45

1. Measure the piston diameter 90 degrees from the piston pin at the point indicated. Refer to the appropriate ENGINE article for the procedure. If out of specification, install new components as necessary. Refer to the appropriate ENGINE article for the procedure.

PISTON - TO CYLINDER BORE CLEARANCE

1. Subtract the piston diameter from the cylinder bore diameter to find the piston-to-cylinder bore clearance.

PISTON - SELECTION

Note. The cylinder bore must be within the specifications for taper and out-of- round before fitting a piston.

Scheme 46

1. Select a piston size based on the cylinder bore.
2. Choose the piston with the correct paint color. Refer to the appropriate ENGINE article for the procedure.

PISTON - RING END GAP

Note. Cylinder bore must be within specification for taper and out-of-round.

Scheme 47

Scheme 48

1. Use a piston without rings to push a piston ring in a cylinder to the bottom of ring travel.
2. Use a feeler gauge to measure the top piston ring end gap and the second piston ring end gap. Refer to the appropriate ENGINE article for the procedure.

Scheme 49

Scheme 50

1. Inspect the piston for ring land damage or accelerated wear.
2. Measure the piston ring-to-groove clearance. Refer to the appropriate ENGINE article for the procedure. If out of specification. install new components as necessary. Refer to the appropriate ENGINE article for the procedure.

Scheme 51

1. Measure the piston pin diameter in two directions at the points shown. Verify the diameter is within specification. Refer to the appropriate ENGINE article for the procedure. If out of specification, install new components as necessary. Refer to the appropriate ENGINE article for the procedure.

CONNECTING ROD - CLEANING

1. Mark and separate the parts and clean with solvent. Clean the oil passages.

Scheme 52

1. Tighten the bolts to specification, then measure the bore in two directions. The difference is the connecting rod bore out-of-round. Verify the out-of-round is within specification. Refer to the appropriate section in Group 303 for the procedure. If out of specification, install new components as necessary. Refer to the appropriate ENGINE article for the procedure.

CONNECTING ROD - BUSHING DIAMETER

Measure the inner diameter of the connecting rod bushing, if equipped. Verify the diameter is within specification.

Scheme 53

1. Refer to the appropriate ENGINE article for the procedure.
2. If out of specification, install new components as necessary. Refer to the appropriate ENGINE article for the procedure.

Scheme 54

1. Measure the connecting rod bend on a suitable alignment fixture. Follow the instructions of the fixture manufacturer. Verify the bend measurement is within specification. Refer to the appropriate ENGINE article for the procedure. If out of specification, install new components as necessary. Refer to the appropriate ENGINE article for the procedure.

Scheme 55

1. Measure the connecting rod twist on a suitable alignment fixture. Follow the instructions of the fixture manufacturer. Verify the measurement is within specification. Refer to the appropriate ENGINE article for the procedure. If out of specification, install new components as necessary. Refer to the appropriate ENGINE article for the procedure.

Scheme 56

1. Measure the clearance between the connecting rod and the piston. Verify the measurement is within specification. Refer to the appropriate ENGINE article for the procedure. If out of specification, install new components as necessary. Refer to the appropriate ENGINE article for the procedure.

Scheme 57

Note. The crankshaft connecting rod journals must be within specifications to check the connecting rod bearing journal clearance.

Scheme 58

Scheme 59

1. Remove the connecting rod bearing cap.
2. Position a piece of Plastigage across the bearing surface.
3. Install and tighten to specifications, then remove the connecting rod bearing cap.
4. Measure the Plastigage to get the connecting rod bearing journal clearance. The Plastigage should be smooth and flat. A changing width indicates a tapered or damaged connecting rod or connecting rod bearing. Refer to the appropriate ENGINE article for the procedure. If out of specification, install new components as necessary. Refer to the appropriate ENGINE article for the procedure.

Scheme 60

1. Inspect the roller for flat spots or scoring. If any damage is found, inspect the camshaft lobes and valve tappet for damage.

Scheme 61

Push rod engines

1. Inspect the hydraulic valve tappet and roller for damage. If any damage is found, inspect the camshaft lobes and valves for damage.

Scheme 62

Scheme 63

VALVE - STEM DIAMETER

1. Measure the diameter of each intake and exhaust valve stem at the points shown. Verify the diameter is within specification. Refer to the appropriate ENGINE article for the procedure. If out of specification, install new components as necessary. Refer to the appropriate ENGINE article for the procedure.

Scheme 64

Scheme 65

Note. Valve stem diameter must be within specifications before checking valve stem to valve guide clearance.

Scheme 66

1. NOTE: If necessary, use a magnetic base. Install a Valve Stem Clearance Tool on the valve stem and install a Dial Indicator with Bracketry. Lower the valve until the Valve Stem Clearance Tool contacts the upper surface of the valve guide.
2. Move the Valve Stem Clearance Tool toward the indicator and zero the indicator. Move the Valve Stem Clearance Tool away from the indicator and note the reading. The reading will be DOUBLE the valve stem-to-valve guide clearance. Valves with oversize stems will need to be installed if out of specification.

VALVE - SPRING INSTALLED LENGTH

1. Measure the installed length of each valve spring. Refer to the appropriate ENGINE article for the procedure. If out of specification, install new components. Refer to the appropriate ENGINE article for the procedure.

Scheme 67

VALVE - SPRING FREE LENGTH

1. Measure the free length of each valve spring. Refer to the appropriate ENGINE article for the procedure. If out of specification, install new components as necessary. Refer to the appropriate ENGINE article for the procedure.

Scheme 68

VALVE - SPRING SQUARENESS

1. Measure the out-of-square on each valve spring. Turn the valve spring and observe the space between the top of the valve spring and the square. Install a new valve spring if out of square. Refer to the appropriate ENGINE article for the procedure.

Scheme 69

Scheme 70

1. Use a Valve/Clutch Spring Tester to check the valve spring for correct strength at the specified valve spring length. For additional information, refer to Specifications in the appropriate ENGINE article. If out of specification, install new components as necessary. Refer to the appropriate ENGINE article for the procedure.

Scheme 71

Valve and Seat Refacing Measurements

Scheme 72

1. Check the valve head and seat. Check valve angles. Check margin width. Refer to the appropriate ENGINE article for the procedure. Be sure margin width is within specification.
2. Inspect for abnormalities on the valve face and seat.

VALVE - SEAT WIDTH

1. Measure the valve seat width. If necessary, grind the valve seat to specification. Measure the intake valve seat width. Measure the exhaust valve seat width. Recheck the valve spring installed length after the seats have been ground, and shim the valve springs as necessary to achieve the correct installed spring length. Refer to the appropriate ENGINE article for the procedure.

Scheme 73

VALVE - SEAT RUNOUT

1. Use the Valve Seat Runout Gauge to check valve seat runout.

Scheme 74

Scheme 75

1. Use a straight edge and a feeler gauge to inspect the cylinder head for flatness. If the cylinder head is distorted, install a new cylinder head.

Scheme 76

CYLINDER BORE - CLEANING

1. Clean the cylinder bores with soap or detergent and water.
2. Thoroughly rinse with clean water and wipe dry with a clean, lint-free cloth.
3. Use a clean, lint-free cloth and lubricate the cylinder bores. Use clean engine oil meeting Ford specification.

Scheme 77

Scheme 78

Scheme 79

1. Use a slide hammer or tools suitable to remove the cylinder block core plug.
2. Inspect the cylinder block plug bore for any damage that would interfere with the correct sealing of the plug. If the cylinder block plug bore is damaged, bore for the next oversize plug.
3. Coat the cylinder block core plug and bore lightly with Threadlock R 262 and install the cylinder block core plug.

Cup-Type

1. Use a tool suitable to seat the cup-type cylinder block core plug.

Scheme 80

Expansion-Type

1. Use tool suitable to seat the expansion-type cylinder block core plug.

Scheme 81

Scheme 82

Scheme 83

Scheme 84

Scheme 85

Scheme 86

Scheme 87

1. Inspect the spark plug for a bridged gap. Check for deposit build-up closing the gap between the electrodes. Deposits are caused by oil or carbon fouling. Clean the spark plug.
2. Check for oil fouling. Check for wet, black deposits on the insulator shell bore electrodes, caused by excessive oil entering the combustion chamber through worn rings and pistons, excessive valve-to-guide clearance or worn or loose bearings. Correct the oil leak concern. Install a new spark plug.
3. Inspect for carbon fouling. Look for black, dry, fluffy carbon deposits on the insulator tips, exposed shell surfaces and electrodes, caused by a spark plug with an incorrect heat range, dirty air cleaner. too rich a fuel mixture or excessive idling. Clean the spark plug.
4. Inspect for normal burning. Check for light tan or gray deposits on the firing tip.
5. Inspect for pre-ignition. identified by melted electrodes and a possibly damaged insulator. Metallic deposits on the insulator indicate engine damage. This may be caused by incorrect ignition timing, wrong type of fuel or the unauthorized installation of a heli-coil insert in place of the spark plug threads. Install a new spark plug.
6. Inspect for overheating, identified by a white or light gray spots and with bluish-burnt appearance of electrodes. This is caused by engine overheating. wrong type of fuel, loose spark plugs, spark plugs with an incorrect heat range. low fuel pump pressure or incorrect ignition timing. Install a new spark plug.
7. Inspect for fused deposits, identified by melted or spotty deposits resembling bubbles or blisters. These are caused by sudden acceleration. Clean the spark plug.

Scheme 88

1. Place a straight edge across the exhaust manifold flanges and check for warping with a feeler gauge.

Scheme 89