303-00 Motor – informações gerais

Engine System - General Information 303-00-1 303-00-1 . SECTION 303-00 Engine System - General Information VEHICLE APPLICATION: 2011.50 Ranger CONTENTS GENERAL PROCEDURES Camshaft Bearing Journal Diameter.................................................................................. Camshaft Bearing Journal Clearance................................................................................. Camshaft End Play............................................................................................................. Camshaft Surface Inspection............................................................................................. Camshaft Lobe Lift.............................................................................................................. Crankshaft Main Bearing Journal Clearance...................................................................... Crankshaft Main Bearing Journal Diameter........................................................................ Crankshaft End Play........................................................................................................... Cylinder Bore Taper............................................................................................................ Piston Inspection................................................................................................................ Piston Pin to Bore Diameter............................................................................................... Piston Diameter.................................................................................................................. Piston Ring End Gap.......................................................................................................... Piston Ring-to-Groove Clearance....................................................................................... Piston Pin Diameter............................................................................................................ Connecting Rod Large End Bore........................................................................................ Valve Stem Diameter.......................................................................................................... Valve Seat Inspection......................................................................................................... Flywheel Inspection............................................................................................................ Flywheel Clutch Surface Inspection................................................................................... Cylinder Head Distortion..................................................................................................... Cylinder Block Distortion..................................................................................................... Exhaust Manifold Cleaning and Inspection........................................................................ Bearing Inspection.............................................................................................................. PAGE 303-00-2 303-00-3 303-00-4 303-00-5 303-00-6 303-00-7 303-00-8 303-00-9 303-00-10 303-00-11 303-00-12 303-00-13 303-00-14 303-00-15 303-00-16 303-00-17 303-00-18 303-00-19 303-00-20 303-00-21 303-00-22 303-00-23 303-00-24 303-00-25

Engine System - General Information 303-00-2 303-00-2 GENERAL PROCEDURES Camshaft Bearing Journal Diameter 1. Determine the diameter of the camshaft journals. ‡ Using a micrometer measure the diameter at 90 degrees intervals to determine if the journals are out-of-round. ‡ Measure at two different points on the journal to determine if there is any tapering. ‡ If the measurements are out of the specified range, install a new camshaft. V102093

Engine System - General Information 303-00-3 303-00-3 GENERAL PROCEDURES Camshaft Bearing Journal Clearance 1. NOTE: Make sure that the following stages are followed exactly. The tappets or followers must be removed to carry out this measurement. NOTE: Make sure that the camshaft is to specification. NOTE: The bearing caps and journals should be free from engine oil and dirt. Position on a width of plastigage on the bearing cap. ‡ Insert the camshaft, without lubrication, into the cylinder head. ‡ Position a plastigage strip, which should be equal to the width of the bearing cap, on the bearing journal. ELE0000649 2. Following the tightening specification, install the camshaft bearing caps. Refer to the corresponding Section 303-01. 3. NOTE: Do not strike the bearing caps. Remove the camshaft bearing caps, refer to the corresponding Section 303-01. 4. Using the Plastigage, read off the measurement. ‡ Compare the width of plastigage with the plastigage scale. ‡ The value that is read off is the bearing clearance. ELE0000597

Engine System - General Information 303-00-4 303-00-4 GENERAL PROCEDURES Camshaft End Play 1. NOTE: Make sure that the camshaft is to specification. Using a Dial Indicator Gauge, measure the end play. ‡ Slide the camshaft in both directions. Read and note the maximum and minimum values on the Dial Indicator Gauge. ‡ End play maximum value minus minimum value ‡ If the measurement is out of specification, install new components. V2102091

Engine System - General Information 303-00-5 303-00-5 GENERAL PROCEDURES Camshaft Surface Inspection 1. Inspect the camshaft lobes for pitting or damage in the active area. Minor pitting is acceptable outside the active area. 45 GA3936A

Engine System - General Information 303-00-6 303-00-6 GENERAL PROCEDURES Camshaft Lobe Lift 1. Determine the cam lift. ‡ Using a micrometer measure the cam in two directions. ‡ The difference between the two measurements is the cam lift. V2102096

Engine System - General Information 303-00-7 303-00-7 GENERAL PROCEDURES Crankshaft Main Bearing Journal Clearance 1. Information not available at time of going to press.

Engine System - General Information 303-00-8 303-00-8 GENERAL PROCEDURES Crankshaft Main Bearing Journal Diameter General Equipment Micrometer 1. Measure the diameter of the main bearing journals and the big-end bearing journals. ‡ Repeat the measurement with the micrometer offset by 90°, in order to determine any eccentricity which may be present. ‡ Measure the journal at two different positions to determine any conicity which may be present. 2 1 AA2535C

Engine System - General Information 303-00- 303-00- GENERAL PROCEDURES Crankshaft End Play General Equipment Dial indicator Dial indicator fixture 1. Determine the end float ‡ Place on the dial indicator and bracket . ‡ Determine the end float by raising the crankshaft with the aid of a screwdriver. ‡ If necessary, correct the end float by using new thrust half washers. ELM2101729

Engine System - General Information 303-00-10 303-00-10 GENERAL PROCEDURES Cylinder Bore Taper 1. NOTE: The main bearing caps or lower crankcase must be in place and tightened to the specified torque; however, the bearing shells should not be installed. Measure the cylinder bore with an internal micrometer. ‡ Carry out the measurements in different directions and at different heights to determine if there is any out-of-roundness or tapering. ‡ If the measurement is out of the specified range, install a new block or hone out the cylinder block (if aplicable/allowed). m m A B C ELE0008659

Engine System - General Information 303-00-11 303-00-11 GENERAL PROCEDURES Piston Inspection 1. CAUTION: Do not use any aggressive cleaning fluid or a wire brush to clean the piston. Carry out a visual inspection. ‡ Clean the piston skirt, pin bush, ring grooves and crown and check for wear or cracks. ‡ If there are signs of wear on the piston skirt, check whether the connecting rod is twisted or bent. V2102130

Engine System - General Information 303-00-12 303-00-12 GENERAL PROCEDURES Piston Pin to Bore Diameter 1. NOTE: The piston and piston pin form a matched pair. Do not mix up the components. Measure the diameter of the piston pin bore. ‡ Measure the diameter in two directions. ‡ If the values are not to specification, install both a new piston and a new piston pin. xXX Y V2102132

Engine System - General Information 303-00-13 303-00-13 GENERAL PROCEDURES Piston Diameter General Equipment Micrometer 1. NOTE: Mark the piston to make sure the piston is installed correctly. Using a Micrometer measure the piston diameter. I A V 2 1 0 2 1 0 3

Engine System - General Information 303-00-14 303-00-14 GENERAL PROCEDURES Piston Ring End Gap 1. CAUTION: Do not mix up the piston rings. Install the piston rings in the same position and location. Take the piston ring and use a piston without rings to push the piston ring about 30 mm into the cylinder bore. V2102136 2. Using the Feeler Gauge, measure the piston ring gap. V2102104

Engine System - General Information 303-00-15 303-00-15 GENERAL PROCEDURES Piston Ring-to-Groove Clearance General Equipment Feeler Gauge 1. NOTE: The piston ring must protrude from the piston groove. To determine the piston ring clearance, insert the Feeler Gauge right to the back of the groove, behind the wear ridge. Using the Feeler Gauge , measure the piston ring clearance. ELM2103771

Engine System - General Information 303-00-16 303-00-16 GENERAL PROCEDURES Piston Pin Diameter 1. NOTE: The piston and piston pin are a matched pair. Do not mix up the components. Measure the piston pin diameter. ‡ Measure the diameter in two directions. ‡ If the values are not to specification, install a new piston and a new piston pin. V2102137

Engine System - General Information 303-00-17 303-00-17 GENERAL PROCEDURES Connecting Rod Large End Bore 1. Measure the bearing bore in two directions. The difference is the connecting rod bore out-of-round. Verify the out-of-round and the bearing bore is within specification. GA3934A

Engine System - General Information 303-00-18 303-00-18 GENERAL PROCEDURES Valve Stem Diameter 1. Using a micrometer measure the diameter of the valve stems. ‡ If the measurements are not to specification, install a new valve. V2102139

Engine System - General Information 303-00-19 303-00-19 GENERAL PROCEDURES Valve Seat Inspection General Equipment Valve seat width scale 1. Measure the width of the valve seat. ‡ Measure the valve seat width using the Valve seat width scale. ‡ If the value is not to specification rework the valve seat. I A V 2 1 0 2 1 4 1

Engine System - General Information 303-00-20 303-00-20 GENERAL PROCEDURES Flywheel Inspection 1. Inspect the flywheel. If there is evidence of the following, install a new flywheel. 1. Cracks. 2. Worn ring gear teeth. 3. Chipped or cracked ring gear teeth. 2 3 1 GA3930A

Engine System - General Information 303-00-21 303-00-21 GENERAL PROCEDURES Flywheel Clutch Surface Inspection 1. Check the flywheel for: ‡ burning ‡ grooves ‡ cracks ‡ Renew the flywheel if necessary. W1601010

Engine System - General Information 303-00-22 303-00-22 GENERAL PROCEDURES Cylinder Head Distortion General Equipment Feeler gauge Straight edge 1. Using a straight edge and feeler gauge, measure the cylinder head distortion. ‡ Measure the mating face distortion. ‡ Refer to Specifications in the appropriate engine section. V2102122

Engine System - General Information 303-00-23 303-00-23 GENERAL PROCEDURES Cylinder Block Distortion 1. Using a Straight Edge and a Feeler Gauge, measure the cylinder block/cylinder head distortion. ‡ Measure the mating face distortion. ‡ If the value is not to specification rework the mating face (if allowed). ELE0009440

Engine System - General Information 303-00-24 303-00-24 GENERAL PROCEDURES Exhaust Manifold Cleaning and Inspection 1. Inspect the cylinder head joining flanges of the exhaust manifold for evidence of exhaust gas leaks. 2. Inspect the exhaust manifold for cracks, damaged gasket surfaces, or other damage that would make it unfit for further use.

Engine System - General Information 303-00-25 303-00-25 GENERAL PROCEDURES Bearing Inspection 1. Inspect bearings for the following defects. 1. Cratering - fatigue failure 2. Spot polishing - incorrect seating. 3. Imbedded dirt engine oil. 4. Scratching - dirty engine oil. 5. Base exposed - poor lubrication. 6. Both edges worn - journal damaged. 7. One edge worn - journal tapered or bearing not seated. 1 2 3 4 5 6 7 GA3940A