Ford Engine Repair Fundamentals Self Study

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engine
repair

engine
repair
fundamentals
self-study

COURSE CODE: 32S01S0

ORDER NUMBER: FCS-13031-REF

Ford Customer Service Division

Technical Training

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 IMPORTANT SAFETY NOTICE

Appropriate service methods and proper repair procedures are essential for the safe, reliable operation of all motor vehicles,
as well as the personal safety of the individual doing the work. This manual provides general directions for accomplishing
service and repair work with tested, effective techniques. Following them will help assure reliability.
There are numerous variations in procedures, techniques, tools and parts for servicing vehicles, as well as in the skill of the
individual doing the work. This manual cannot possibly anticipate all such variations and provide advice or cautions as to
each. Accordingly, anyone who departs from instructions provided in this manual must first establish that he compromises
neither his personal safety nor the vehicle integrity by his choice of methods, tools or parts.
As you read through the procedures, you will come across NOTES, CAUTIONS, and WARNINGS. Each one is there for a
specific purpose. NOTES give you added information that will help you to complete a particular procedure. CAUTIONS are
given to prevent you from making an error that could damage the vehicle. WARNINGS remind you to be especially careful
in those areas where carelessness can cause personal injury. The following list contains some general WARNINGS that
you should follow when you work on a vehicle.

• Always wear safety glasses for eye protection. • To prevent serious burns, avoid contact with hot metal
parts such as the radiator, exhaust manifold, tail pipe,
• Use safety stands whenever a procedure requires you to catalytic converter and muffler.
be under the vehicle.
• Do not smoke while working on the vehicle.
• Be sure that the ignition switch is always in the OFF
position, unless otherwise required by the procedure. • To avoid injury, always remove rings, watches, loose
hanging jewelry, and loose clothing before beginning to
• Set the parking brake when working on the vehicle. If you work on a vehicle. Tie long hair securely behind your
have an automatic transmission, set it in PARK unless head.
instructed otherwise for a specific service operation. If
you have a manual transmission it should be in RE- • Keep hands and other objects clear of the radiator fan
VERSE (engine OFF) or NEUTRAL (engine ON) unless blades. Electric cooling fans can start to operate at any
instructed otherwise for a specific service operation. time by an increase in underhood temperatures, even
though the ignition is in the OFF position. Therefore, care
• Operate the engine only in a well-ventilated area to avoid should be taken to ensure that the electric cooling fan is
the danger of carbon monoxide. completely disconnected when working under the hood.
• Keep yourself and your clothing away from moving parts
when the engine is running, especially the fan and belts.

The recommendations and suggestions contained in this manual are made to assist the dealer in improving his dealership parts
and/or service department operations. These recommendations and suggestions do not supersede or override the provisions of
the Warranty and Policy Manual, and in any cases where there may be a conflict, the provisions of the Warranty and Policy Manual
shall govern.

The descriptions, testing procedures, and specifications in this handbook were in effect at the time the handbook was
approved for printing. Ford Motor Company reserves the right to discontinue models at any time, or change specifications,
design, or testing procedures without notice and without incurring obligation. Any reference to brand names in this manual
is intended merely as an example of the types of tools, lubricants, materials, etc. recommended for use. Equivalents, if
available, may be used. The right is reserved to make changes at any time without notice.

WARNING: MANY BRAKE LININGS CONTAIN ASBESTOS FIBERS. WHEN WORKING ON BRAKE COMPONENTS, AVOID
BREATHING THE DUST. BREATHING THE ASBESTOS DUST CAN CAUSE ASBESTOSIS AND CANCER.
Breathing asbestos dust is harmful to your health.
Dust and dirt present on car wheel brake and clutch assemblies may contain asbestos fibers that are hazardous to your health
when made airborne by cleaning with compressed air or by dry brushing.
Wheel brake assemblies and clutch facings should be cleaned using a vacuum cleaner recommended for use with asbestos fibers.
Dust and dirt should be disposed of in a manner that prevents dust exposure, such as sealed bags. The bag must be labeled per
OSHA instructions and the trash hauler notified as to the contents of the bag.
If a vacuum bag suitable for asbestos is not available, cleaning should be done wet. If dust generation is still possible, technicians
should wear government approved toxic dust purifying respirators.
OSHA requires areas where asbestos dust generation is possible to be isolated and posted with warning signs. Only technicians
concerned with performing brake or clutch service should be present in the area.

Copyright © 2000 Ford Motor Company Produced and Coordinated by

Technical Support Operations
Ford Customer Service Division

March, 2000
 CUSTOMER EXPECTATIONS
Customer Expectations: Service
1. Make it convenient to have my 5. Provide me with a clear and thorough
vehicle serviced at your dealership. explanation of the service performed.
2. The Service Advisor should 6. Call me within a reasonable amount of
demonstrate a genuine concern for time after my service visit to ensure that
my service needs. I'm completely satisfied.
3. Fix it right the first time. 7. Be responsive to questions or concerns
I bring to your attention.
4. Complete servicing my vehicle in a
timely and professional manner.

Expectation 3
“Fix It Right The First Time, on Time.”
Both service advisors and technicians are important players when it comes to Expectation
#3.
Why
Customers tell us “Fixing It Right The First Time, on Time” is one of the reasons they
would decide to return to a dealer to buy a vehicle and get their vehicles serviced.
Technician Training
It is our goal to help the technician acquire all of the skills and knowledge necessary to
“Fix It Right The First Time, on Time.” We refer to this as “competency.”
Technician’s Role
Acquire the skills and knowledge for competency in your specialty via:
STST New Model
– Self Study – Self Study
– FordStar Broadcasts – FordStar Broadcasts
– Ford Multimedia Training (FMT) – Instructor Led
– Instructor Led
The Benefits
The successful implementation of expectations means:
– Satisfied customers
– Repeat vehicle sales
– Repeat service sales
– Recognition that Ford and Lincoln/Mercury technicians are “the Best in the
Business”
 TABLE OF CONTENTS

INTRODUCTION ............................................................................................................................ Intro-1

Introduction ............................................................................................................................... Intro-1
Engine Repair Curriculum ......................................................................................................... Intro-2
Engine Repair Curriculum Path ................................................................................................. Intro-3
Course Description and Format ................................................................................................. Intro-4
LESSON 1: ENGINE FUNDAMENTALS ......................................................................................... 1-1
Objectives ........................................................................................................................................ 1-1
Contents ........................................................................................................................................... 1-1
Engine Fundamentals ...................................................................................................................... 1-2
Four-Stroke Operation ..................................................................................................................... 1-3
Intake Air System .......................................................................................................................... 1-10
Fuel System ................................................................................................................................... 1-13
Ignition System .............................................................................................................................. 1-14
Exhaust System ............................................................................................................................. 1-15
Exhaust Gas Recirculation (EGR) System .................................................................................... 1-16
Cooling System ............................................................................................................................. 1-17
Lubrication System ........................................................................................................................ 1-20
Positive Crankcase Ventilation (PCV) System .............................................................................. 1-23
Review Questions .......................................................................................................................... 1-25
LESSON 2: OIL AND LUBRICANTS ............................................................................................... 2-1
Objectives ........................................................................................................................................ 2-1
Contents ........................................................................................................................................... 2-1
Primary Purposes of Engine Oil ...................................................................................................... 2-2
Oil Properties ................................................................................................................................... 2-8
Rating Oils ..................................................................................................................................... 2-11
Additives ........................................................................................................................................ 2-12
Engine Damage.............................................................................................................................. 2-14
Review Questions .......................................................................................................................... 2-17
LESSON 3: FUELS ............................................................................................................................. 3-1
Objectives ........................................................................................................................................ 3-1
Contents ........................................................................................................................................... 3-1
Types of Fuels .................................................................................................................................. 3-2
Gasoline Additives ........................................................................................................................... 3-4
Additives That Do Not Improve Performance ................................................................................. 3-5
Alternative Fuels .............................................................................................................................. 3-9
Review Questions .......................................................................................................................... 3-11

Engine Repair Fundamentals March, 2000 i

TABLE OF CONTENTS

LESSON 4: COOLANT ...................................................................................................................... 4-1

Objectives ........................................................................................................................................ 4-1
Contents ........................................................................................................................................... 4-1
Purpose of Coolant .......................................................................................................................... 4-2
Types of Coolant .............................................................................................................................. 4-3
Review Questions ............................................................................................................................ 4-9
LESSON 5: SEALANTS .................................................................................................................... 5-1
Objectives ........................................................................................................................................ 5-1
Contents ........................................................................................................................................... 5-1
Sealants ............................................................................................................................................ 5-2
Review Questions ............................................................................................................................ 5-7
ANSWERS TO REVIEW QUESTIONS
Lesson 1 ............................................................................................................................... Answers-1
Lesson 2 ............................................................................................................................... Answers-3
Lesson 3 ............................................................................................................................... Answers-5
Lesson 4 ............................................................................................................................... Answers-7
Lesson 5 ............................................................................................................................... Answers-9

ii March, 2000 Engine Repair Fundamentals

 INTRODUCTION

INTRODUCTION
The Engine Fundamentals self-study is the first course of the Engine Repair Curriculum. Since this course sets
the building blocks for the other courses, it is important that it be completed first. It is also important that all
prerequisite courses be completed prior to taking this self-study, as this will lead to a better understanding of the
material presented.
This course has two main goals. The first goal is to introduce you to the basic engine theory of operation. The
second goal is to provide an understanding of the symptom-to-system-to-component-to-cause diagnostic process.
As you learn new information, try to relate the new knowledge to the basic engine systems as a whole. Think
about the cause-and-effect relationships between the subsystems and components. Understanding the cause-and-
effect relationships will help you in diagnosis. This course will include information related to basic engine
systems. Some of the topics that will be covered in this course include the following:
l Four-stroke operation
l Intake air system

l Fuel system
l Ignition system
l Exhaust system

l Exhaust gas recirculation (EGR) system

l Cooling system
Although you may be familiar with some of these topics, it is essential that you, as a professional engine
technician, have a thorough understanding and mastery of this information. You will find that mastery learning
is necessary to diagnose and service the latest engine systems.

Engine Repair Fundamentals March, 2000 Intro-1

INTRODUCTION

ENGINE REPAIR CURRICULUM

Each course found in the Engine Repair Curriculum is one of the following types:
l Self-study – This type of course is a self-paced program. The technician is responsible for learning the material
on his or her own. The training material consists of a reference book and an accompanying videotape. The
videotape is designed to support the material in the reference book and should not be used on its own.
l Ford Multimedia Training (FMT) – This type of course is also self-paced. The multimedia course allows the
technician to interact with the training materials. The multimedia course allows the technician to utilize the
knowledge attained in the self-study course. The FMT concentrates on relationships, such as the cause-and-
effect relationships between symptoms and components.
l Classroom – The classroom course allows for practical, real-world application of skills and knowledge learned
in the other courses.
There are five courses in the Basic Engine Curriculum. Please refer to the Engine Repair Curriculum Path that
follows.

Course Codes
These courses may be found in the STARS planner using the following course codes:

Engine Performance
l Engine Repair Fundamentals – Self-Study .................................................................. Course code: 32S01S0
l Automotive Measuring Tools – FMT .......................................................................... Course code: 32S02M0
l Base Engine Operation and Diagnosis ......................................................................... Course code: 32S03M0

l Engine Repair – Classroom .......................................................................................... Course code: 32S05T0

l Servicing New Engine Designs – Fordstar .................................................................. Course code: 32S06F0

Why Training?
1. Customers bring vehicles to the dealership because they want the best service possible. They believe that no
other technician besides you, a Ford trained technician, could know their vehicle better.
2. Customers expect a dealership to “Fix It Right The First Time, On Time.”

So, how do you live up to the customer’s expectations? The answer is continuous training. Training allows you to
gain efficiency. Efficiency makes you an asset to the customer, the dealer, and yourself. Training promotes job
security and allows you to learn the “latest and greatest” technology and service procedures.

Intro-2 March, 2000 Engine Repair Fundamentals

Ford Engine Repair Fundamentals Self Study
Full download: http://manualplace.com/download/ford-engine-repair-fundamentals-self-study/ INTRODUCTION

ENGINE REPAIR CURRICULUM PATH

ENGINE REPAIR
CURRICULUM PATH
1 Engine Repair
Fundamentals –
SS
2 Automotive
Measuring Tools –
FMT
2
Base Engine
Operation and Diagnosis –
FMT
4 Engine
Repair –
Classroom
3 Servicing New
Engine Designs –
FORDSTAR

Legend Prerequisites
– NVH – (Classroom)
1 = Self Study (SS)
– Basic Electrical Part 1 – (Self Study)
2 = Ford Multimedia Training (FMT) – Basic Electrical Part 2 – (FMT)
– Basic Electrical Part 3 – (Classroom)
3 = FORDSTAR
– Electronics Part 1 – (Self Study)
4 = Instructor Led – Classroom – Electronics Part 2 – (FMT)
– Electronics Part 3 – (Classroom)

Engine Repair Fundamentals March, 2000 Intro-3

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