Filed Under (Ford) by admin on 06-04-2011
Engine Front Cover If the engine front cover (6019) is being removed to check timing chain deflection, refer to Timing Chain Deflection Procedure as outlined in Section 03-00. SPECIAL SERVICE TOOL(S) REQUIRED Description Crankshaft Damper Remover Vibration Damper and Seal Replacer T82L-6316-A Vibration Damper Remover Adapter Removal 1. Remove engine (6007) from vehicle. Refer to procedure in this section. 2. Loosen drive belt tensioner (6B209) and drive belt (8620) . 3. Remove water pump pulley retaining bolts and water pump pulley (8509) . 4. Remove retaining bolts and disconnect heater water outlet tube (18663) from water pump (8501) . 5. Disconnect electrical connector at camshaft position sensor. 6. Disconnect electrical connector at crankshaft position sensor (CKP sensor) (6C315) . 7. Remove retaining bolt and disconnect radiator lower hose tube (8291) from water pump . NOTE: If the vibration damper and crankshaft pulley have to be separated, mark the vibration damper and crankshaft pulley so that they may be reassembled in the same relative position. This is important as the vibration damper and crankshaft pulley are initially balanced as a unit. NOTE: If the vibration damper is being replaced, check if the original vibration damper has balance pins installed. If so, new balance pins (6A328 or equivalent) must be installed on the new vibration damper in the same position as the original vibration damper. The crankshaft pulley (new or original) must also be installed in the same relative position as originally installed. 8. Remove crankshaft pulley (6312) and vibration damper assembly using Crankshaft Damper Remover T58P-6316-D and Vibration Damper Remover Adapter T82L-6316-B. 9. Remove four retaining bolts and remove brace from A/C bracket and P/S bracket. 10. Remove oil bypass filter (6714) . Tool Number T58P-6316-D T82L-6316-B CAUTION: The engine front cover cannot be removed without lowering the oil pan (6675) . 11. Remove oil pan . Refer to procedure in this section. CAUTION: Do not overlook the engine front cover retaining bolt located behind the oil pump and filter body (6603) . The engine front cover will break if pried upon and all retaining bolts are not removed. 12. Remove engine front cover retaining bolts. It is not necessary to remove water pump . 13. Remove engine front cover and water pump as an assembly. 14. Remove engine front cover gasket and discard. Water Pump Tightening Sequence Installation NOTE: Lightly oil all bolt and stud bolt threads before installation except those specifying special sealant. 1. Clean gasket surfaces on the engine front cover and cylinder block (6010) . If reusing the engine front cover , replace crankshaft front seal (6700) . Refer to Crankshaft Pulley and/or Damper and/or Crankshaft Front Seal in this section. 2. If a new engine front cover is to be installed: Install oil pump and filter body . Clean water pump gasket surface. Position a new water pump housing gasket (8507) on the engine front cover and install water pump . Install water pump retaining bolts. Tighten to 20-30 Nm (15-22 lb-ft). 3. Lubricate crankshaft front seal with clean engine oil XO-10W30-QSP or -DSP or equivalent meeting Ford specification ESE-M2C153-E. NOTE: Gasket and Trim Adhesive D7AZ-19B508-B or equivalent meeting Ford specification ESE-M2G52-A is recommended to hold the engine front cover gasket (6020) in position while the engine front cover is installed. 4. Position a new engine front cover gasket on the cylinder block and install the engine front cover / water pump assembly using dowels for proper alignment. 5. Install the engine front cover retaining bolts. Tighten to 20-30 Nm (15-22 lb-ft). Install the capscrew (Part No. N804841) nearest the oil bypass filter flange last, and tighten last. Apply Loctite® or equivalent to bolt prior to installation. Refer to illustration under Step 13 of removal procedure. 6. Install oil pan as outlined. 7. Install oil bypass filter . 8. Coat pulley sealing surface with clean engine oil XO-10W30-QSP or -DSP or equivalent meeting Ford specification ESE-M2C153-E. NOTE: When using silicone rubber sealer, assembly must occur within 15 minutes after sealer application. After this time, the sealer may start to setup, and its sealing effectiveness may be reduced. 9. Apply a small amount of Silicone Gasket and Sealant F1AZ-19562-A or equivalent meeting Ford specification WSE-M4G320-A2 to crankshaft keyway. 10. Position crankshaft key (6B316) in the crankshaft keyway.
Filed Under (Ford) by admin on 16-10-2010
REMOVAL NOTE: The oil pump and valve body are removed as an assembly. 1. Disconnect battery ground cable, then remove battery, battery tray, and remote air cleaner. 2. Position supply hoses, vacuum hoses, and wiring away from pump and valve body cover. 3. Remove shift lever. 4. On models equipped with Anti-lock Brake System (ABS) , remove splash shield cover, then disconnect brake reservoir hose and cap to prevent contamination. 5. On all models, remove EGR bracket attaching bolts, then install lifting eye. 6. Remove throttle body bracket attaching bolt, install lifting eye, then using suitable equipment support engine. 7. Remove lefthand transaxle mount. 8. Remove transaxle side pan upper attaching bolts. 9. Raise and support vehicle. 10. Remove lefthand front wheel and tire assembly. 11. Remove inner fender cover and position aside, then disconnect ride height sensor. 12. Remove rear transaxle mount attaching bolt. 13. Loosen but do not remove two lefthand subframe attaching bolts. 14. Remove two engine support mount attaching bolts. 15. Remove four lefthand engine support attaching bolts, then remove the engine support. 16. Position suitable drain pan, then remove remaining transaxle side pan attaching bolts and remove pan. 17. Using suitable screwdriver, place manual shift shaft in Park position. 18. Disconnect upper bulkhead electrical connector wiring retainer clip from valve body. 19. Disconnect electrical connectors. Oil Pump And Valve Body Bolt Removal 20. Remove valve body attaching bolts, then disengage linkage and remove valve body. NOTE: Do not remove oil pump cover attaching bolts. INSTALLATION 1. Install new pump and valve body to chain cover gasket. 2. Slide pump and valve body onto pump shaft. 3. Rotate pump and valve body assembly toward dash panel, then engage manual valve link with manual valve. 4. Slightly rotate pump and valve body assembly to engage oil pump shaft splines with oil pump rotor splines. Valve body should slide flush with chain cover. A suitable 7/8 inch deep well socket on crankshaft pulley may be required for complete engagement. 5. On models less anti-skid, if engagement is not as indicated in step 4, proceed as follows: a. Remove manual valve from valve body. b. Rotate assembly to allow full engagement, up to 360° . c. After full engagement, return assembly to installed position, then install manual valve.
Filed Under (Ford) by admin on 17-03-2011
NOTE: Hydraulic valve lifters are used; no valve adjustment is required. When valve and/or valve seat is machined, valve clearance is reduced and may cause improper valve operation. Different length push rods are available for correcting clearance. Valve lifter must be collapsed to check valve clearance. 1. With valve cover removed, position piston No. 1 at TDC of compression stroke. Completely collapse cylinder No. 1 intake valve lifter and hold valve lifter collapsed. Using feeler gauge, measure clearance between rocker arm and valve stem. 2. Clearance should be within specification. Refer to COLLAPSED VALVE LIFTER CLEARANCE table. Replace push rod, if necessary, to obtain correct clearance. 3. Position crankshaft as specified. See, in this article, VALVE CLEARANCE CHECKING SEQUENCE table, and check appropriate valves. Replace push rods if clearance is not within specification. 4. If push rod(s) is replaced, ensure corresponding cylinder piston is below TDC. It will be necessary to loosen or remove rocker arm to replace push rod. CAUTION: DO NOT operate or crank engine after installing push rod until valve lifter has leaked down to normal operating position. COLLAPSED VALVE LIFTER CLEARANCE
Filed Under (Ford) by admin on 25-02-2011
1. Remove the torque converter clutch (TCC) solenoid and the shift solenoid. 1. Remove the retaining bolt. 2. Remove the shift solenoid. 3. Remove the TCC solenoid. 2. Remove the 2 reinforcement plates. 1. Remove the bolts. 2. Remove the plates. 3. Remove the separator plate and discard the gaskets. 4. NOTE: Note the location of the eight coasting booster valve shuttle balls for assembly. Remove the 8 coasting booster valve shuttle balls. 5. Remove the converter drain back valve and solenoid pressure supply screen. 6. Remove the main control valve body cover plate. 1. Remove the 13 main control valve body cover plate bolts. 2. Remove the main control valve body cover plate. Assembly NOTE: Inspect the shift solenoid O-rings and TCC solenoid O-rings for damage. 1. Install the valve body cover plate. 1. Position the valve body cover plate gasket and cover plate. 2. Loosely install the 2 guide pin bolts. 3. Loosely install the remaining bolts. 2. Tighten all the bolts in the sequence shown. 3. Install the 8 coasting booster valve shuttle balls.
Filed Under (Suzuki) by admin on 26-05-2011
NOTE: Samurai & Sidekick 1) Remove rocker cover. Rotate crankshaft until zero degree (TDC) timing mark of timing belt cover is in line with timing mark on crankshaft pulley. 2) Cylinder No. 1 should be at TDC on compression stroke. Remove distributor cap, and ensure rotor is pointed upward at distributor hold-down bolt and to No. 1 terminal of distributor cap. If not as described, rotate crankshaft 360 degrees. 3) Measure valve clearance between adjustment screw and valve stem using thickness gauge. Check intake valve clearance of cylinders No. 1 and 2 and exhaust valve clearance of cylinders No. 1 and 3. 4) Turn crankshaft one complete revolution (360 degrees). Check intake valve clearance of cylinders No. 3 and 4 and exhaust valve clearance of cylinders No. 2 and 4. Ensure clearance is within specification. See VALVE CLEARANCE SPECIFICATIONS table. 5) If clearance adjustment is necessary, loosen lock nut and turn adjusting screw. After adjusting clearance, tighten adjusting Swift DOHC uses hydraulic lifters. Adjustment is not required. screw lock nut to 11-14 ft. lbs. (15-19 N.m) on Samurai or 90-108 INCH lbs. (10-13 N.m) on Sidekick. On all models, recheck clearance. VALVE CLEARANCE SPECIFICATIONS TABLE ¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡ Application SOHC Engines Samurai, Sidekick 8-Valve TBI & Swift (1) Engine Cold Exhaust ……………………. .006-.008 (.15-.20) Intake …………………….. .005-.007 (.13-.17) Engine Hot Exhaust ……………………. .010-.012 (.25-.30) Intake …………………….. .009-.011 (.23-.27) Sidekick 16-Valve PFI Engine Cold Exhaust & Intake ………….. .0031-.0047 (.08-.12) Engine Hot Exhaust & Intake ………….. .0047-.0063 (.12-.16) DOHC Engine Swift (1) …………………………………. (2) (1) – Swift is available with 1.3L DOHC and SOHC engines. (2) – Hydraulic valve lash adjusters are used. Adjustment is not required. ¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡ Swift SOHC 1) Remove rocker cover. Remove right side inner fender apron extension to enable timing marks to be seen. Align crankshaft pulley timing mark with TDC mark on timing belt cover. 2) Remove distributor cap. Ensure rotor is pointing upward toward distributor hold-down bolt and to No. 1 terminal of distributor cap. If not as described, rotate crankshaft 360 degrees. 3) Measure valve clearance between adjustment screw and valve stem using thickness gauge. Check intake valve clearance of cylinders No. 1 and 2 and exhaust valve clearance of cylinders No. 1 and 3. Turn crankshaft one complete revolution (360 degrees). Check intake valve clearance of cylinders No. 3 and 4 and exhaust valve clearance of cylinders No. 2 and 4. 4) Ensure clearance is within specification. See VALVE CLEARANCE SPECIFICATIONS table. If clearance adjustment is necessary, loosen lock nut and turn adjusting screw. Hold adjusting screw while tightening lock nut to 11-14 ft. lbs. (15-19 N.m). Recheck clearance. In. (mm)