2005 Ford Pickup F150 2005 GENERAL INFORMATION Engine System - General Information - F150 Pickup. 2005 GENERAL INFORMATION Engine System - General Information - F150 Pickup SPECIFICATIONS GENERAL SPECIFICATIONS GENERAL SPECIFICATIONS Item Specification Lubricants and Sealants SAE 5W-20 Premium Synthetic Blend WSS-M2C930-A Motor Oil XO-5W20-QSP Gasoline Engine Oil Dye 164-R3705 ESE-M99C103-B1 High Strength Threadlocker TA-26 WSK-M2G351-A6 DESCRIPTION AND OPERATION ENGINE CAUTION: When repairing engines, all parts must be contamination free. If contamination/foreign material is present when repairing an engine, premature engine failure can occur. NOTE: This article contains information, steps and procedures that may not be specific to your engine. This article covers general procedures and diagnosis and testing of the engine system, except for exhaust emission control devices, which are covered in the INTRODUCTION GASOLINE MODELS article in Engine Performance The engine incorporates the following features: * A closed positive crankcase ventilation (PCV) system, For additional information, refer to ENGINE EMISSION CONTROL « An evaporative emission control system. For additional information, refer to EVAPORATIVE EMISSIONS, Some engines incorporate a fail-safe cooling system. Refer to the ENGINE COOLING — F150 PICKUP for the procedure. The engine, fuel system, ignition system, emissions system and exhaust system all affect exhaust emission levels and must be maintained according to the maintenance schedule Refer to the scheduled Maintenance Guide in the owner's manual2005 Ford Pickup F150 2005 GENERAL INFORMATION Engine System - General Information - F150 Pickup. Correct engine identification is required to order parts. Refer to the ENGINE COOLIN F150 PICKUP DIAGNOSIS AND TESTING ENGINE ial Tool(s) SPECIAL TOOL CHART Commercially Available Leakdown Tester =) | $T1277-A Quick Disconnect Compression Tester 134-R0212 or equivalent LP oe $T1299-A Dial Indicator Gauge Adapter 303-007 (TOOL-6565-AB) or equivalent $11272-A Dial Indicator Gauge with Holding Fixture2005 Ford Pickup F150 2005 GENERAL INFORMATION Engine System - General Information - F150 Pickup. 100-002 (TOOL-4201-C) or equivalent Engine Cylinder Leak Detection/Air Pressurization Kit 014-00708 or equivalent $T1296-A Oil Pressure Gauge 303-088 (T73L-6600- A) $T1300-A UV Leak Detector Kit 164-R0756 or equivalent2005 Ford Pickup F150 2005 GENERAL INFORMATION Engine System - General Information - F150 Pickup. $T1297-A Vacuum/Pressure Tester 164-R0253 or equivalent Material MATERIAL CHART Item Specification Gasoline Engine Oil Dye 164-R3705 or equivalent ESE-M99C103-B1 SAE 5W-20 Premium Synthetic Blend Motor Oil XO-5W20-QSP or equivalent WSS-M2C930-A Inspection and Verification 1. Verify the customer concern by operating the engine to duplicate the condition. 2. VISUAL INSPECTION CHART Mechanical Visually inspect for obvious signs of mechanical damage. Refer to the following chart # Engine coolant leaks « Engine oil leaks Fuel leaks + Damaged or severely worn parts, + Loose mounting bolts, studs and nuts 3. If the inspection reveals obvious concerns that can be readily identified, repair as ne 4 SYMPTOM CHART. Symptom Chart SYMPTOM CHART r _ If the concerns remain after the inspection, determine the symptoms. GO to2005 Ford Pickup F150 2005 GENERAL INFORMATION Engine System - General Information - F150 Pickup. Condition Possible Sources Action « Difficult * Damaged « REFER to the INTRODUCTION - starting ignition system. GASOLINE article Damaged fuel system. Damaged starting system Damaged charging system/battery Burnt valve. Worn piston Worn piston rings. Worn cylinder. Damaged head gasket, Damaged cooling s « Refer to CHARGING SYSTEM - GENERAL INFORMATION * INSTALL anew valve « INSTALL a new piston « INSTALL new piston rings. « REPAIR or INSTALL a new cylinder block, « INSTALL a new head gasket. « REFER to the INTRODUCTION - -ASOLINE article + Poor idling Vacuum leaks. Malfunctioning or damaged ignition system. Malfunctioning or damaged fuel system. Damaged valve tappet or hydraulic lash adjuster. Incorreet valve- to-valve seat contact. Damaged head gasket, « REFER to the INTRODUCTION - GASOLINE article . + INSTALL anew valve tappet or hydraulic lash adjuster. « REPAIR or INSTALL a new valve or valve seat, « INSTALL a new head gasket « Abnormal combustion Malfunctioning or damaged fuel « REFER to the INTRODUCTION - GASOLINE article2005 Ford Pickup F150 2005 GENERAL INFORMATION Engine System - General Information - F150 Pickup. system, Malfunctioning or damaged ignition system. Malfunctioning or damaged air intake system. Damaged valve tappet or hydraulic lash adjuster, Burnt or sticking] valve. Weak or broken valve spring Carbon accumulation in combustion chamber, INSTALL a new valve tappet or hydraulic lash adjuster. REPAIR or INSTALL a new valve. INSTALL a new valve spring. ELIMINATE carbon buildup. Excessive oil consumption Leaking oil Malfunctioning PCV system Worn valve stem seal. Worn valve stem| or valve guide. Sticking piston rings. Worn piston ring groove, Worn piston or cylinder, REPAIR oil leakage. REPAIR or INSTALL new necessary components. INSTALL a new valve stem seal. INSTALL a new valve and valve guide REPAIR or INSTALL new piston rings. INSTALL a new piston and piston pin REPAIR or INSTALL a new piston or cylinder block. + Engine noise Leaking exhaust system. Incorrect drive belt tension. Malfunctioning generator REPAIR exhaust leakage. Refer to ENGINE - 4.6L (2V) and/or ENGINE - 5.4L (3V) . Refer to the GENERATOR AND REGULATOR -- F150 PICKUP for]2005 Ford Pickup F150 2005 GENERAL INFORMATION Engine System - General Information - F150 Pickup. bearing, Malfunctioning water pump bearing. Malfunctioning or damaged cooling system. Malfunctioning or damaged fuel system, Loose timing chain/belt. Damaged timing chain tensioner. Excessive main bearing clearance. Seized or heat damaged crankshaft main bearing Excessive crankshaft end play. Excessive connecting rod bearing clearance, Heat damaged connecting rod bearing Damaged connecting rod bushing. Worn cylinder the procedure. « Refer to ENGINE COOLING « REFER to the INTRODUCTION - GASOLINE article « ADJUST or INSTALL a new timing chain/belt. INSTALL a new timing chain tensioner CAUTION: Remove the cylinder heads before removing the crankshaft. Failure to do so can result in engine damage. INSTALL a new crankshaft main bearing, INSTALL a new crankshaft main bearing INSTALL a new thrust bearing or crankshaft. INSTALL a new connecting rod bearing or connecting rod. INSTALL a new connecting rod bearing INSTALL a new connecting rod bushing « REPAIR or INSTALL a new cylinder block.2005 Ford Pickup F150 2005 GENERAL INFORMATION Engine System - General Information - F150 Pickup. Wom piston or piston pin. Damaged piston rings. Bent connecting rod. Malfunctioning valve tappet or hydraulic lash adjuster, Broken valve spring Excessive valve guide clearance, « INSTALL a new piston or piston pin. « INSTALL new piston rings. « INSTALL a new connecting rod. « INSTALL a new valve tappet or hydraulic lash adjuster. « INSTALL a new valve spring. « ADJUST clearance or INSTALL a new valve guide or valve. « Insufficient power Malfunctioning or damaged ignition system. Malfunctioning or damaged fuel system, Malfunctioning or damaged air intake system. Damaged or plugged exhaust system, Incorrect tire size. Dragging brakes, Slipping transmission Malfunctioning valve tappet or hydraulic lash adjuster. « REFER to the INTRODUCTION - GASOLINE article « INSPECT exhaust system. » Refer to SUSPENSION SYS’ GENERAL INFORMATION « Refer to BRAKE SYSTEM- GENERAL INFORMATION « Refer to the MANUAL TRANSAXLE/TRANSMISSION AND CLUTCH - GENERAL INFORMATION - F150 article for the procedure. « INSTALL a new valve tappet or hydraulic lash adjuster.2005 Ford Pickup F150 2005 GENERAL INFORMATION Engine System - General Information - F150 Pickup. © Compression leakage at valve seat. Seized valve stem. Weak or broken valve spring. « Worn or damaged camshaft. Damaged head gasket. Cracked or distorted cylinder head. Damaged, worn or sticking piston ring(s). Worn or Component Tests Engine Oil Leaks damaged piston. REPAIR or INSTALL a new valve, valve seat or cylinder head. INSTALL a new valve. INSTALL a new valve spring. INSTALL a new camshaft. INSTALL a new head gasket. INSTALL a new cylinder head. REPAIR or INSTALL a new piston ring(s) INSTALL a new piston and piston pin. 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 appe:2005 Ford Pickup F150 2005 GENERAL INFORMATION Engine System - General Information - F150 Pickup. Leakage Points - Underhood Examine the following areas for oil leakage: * Valve cover gaskets « Intake manifold gaskets * Cylinder head gaskets « Oil bypass filter « Oil filter adapter « Engine front cover « Oil filter adapter and filter body # Oil level indicator tube connection « Oil pressure sensor Leakage Points - Under Engine - With Vehicle on Hoist « Oil pan gaskets # Oil pan sealer # Oil pan rear seal « Engine front cover gasket # Crankshaft front seal « Crankshaft rear oil seal « Crankshaft main bearing cap side bolts # Oil filter adapter and filter body * Oil cooler, if equipped Leakage Points - With Transmission and Flywheel Removed « Crankshaft rear oil seal « Rear main bearing cap parting line « Rear main bearing cap and seals « Flywheel mounting bolt holes (with flywheel installed) + Camshaft rear bearing covers 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 Compression Test - Compression Gauge Check 1, Make sure the oil in the crankcase is of the correct viscosity and at the correct level and that the battery is correctly charged. Operate the vehicle until the engine is at normal2005 Ford Pickup F150 2005 GENERAL INFORMATION Engine System - General Information - F150 Pickup. operating temperature. Turn the ignition switch to the OFF position, then remove all the spark plugs. 2. Set the throttle plates in the wide-open position. 3. Install a compression gauge such as the Compression Tester in the No, 1 cylinder. 4. Install an auxiliary starter switch in the starting circuit. With the ignition switch in the OFF position, and using the auxiliary starter switch, crank the engine a minimum of five compression strokes and record the highest reading. Note the approximate number of compression strokes required to obtain the highest reading 5. Repeat the test on each cylinder, cranking the engine approximately the same number Compression Test - Test Results The indicated compression pressures are considered within specification if the lowest reading cylinder is at least 75 percent of the highest reading. Refer to the COMPRESSION PRESSURE LIMIT CHART Compression Pressure Limit Chart Maximum| Pressure Pressure Maximum Pressure Pressure M jum Pressure Maximum Pressure Minimum| Pressure 924 kPa (134 psi) 696 kPa (101 psi) 1131 kPa (164 psi) 848 kPa (123 psi) 1338 kPa (194 psi) 1000 kPa (146 psi) 1544 kPa (224 psi) 1158 kPa (168 psi) 938 kPa (136 psi) 703 kPa (102 psi) 1145 kPa (166 psi) 855 kPa (124 psi) 1351 kPa (196 psi) 1014 kPa (147 psi) 1558 kPa (226 psi) 1165 kPa (169 psi) 952 kPa (138 psi) 717 kPa (104 psi) 1158 kPa (168 psi) 869 kPa (126 psi) 1365 kPa (198 psi) 1020 kPa (148 psi) 1572 kPa (228 psi) 1179 kPa (171 psi) 965 kPa (140 psi) 724 kPa (106 psi) 1172 kPa (170 psi) 876 kPa (127 psi) 1379 kPa (200 psi) 1034 kPa (150 psi) 1586 kPa (230 psi) 1186 kPa (172 psi) 979 kPa (142 psi) 738 kPa (107 psi) 1186 kPa (172 psi) 889 kPa (129 psi) 1303 kPa (202 psi) 1041 kPa (151 psi) 1600 kPa (232 psi) 1200 kPa (174 psi) 933 kPa (144 psi) 745 kPa (109 psi) 1200 kPa (174 psi) 903 kPa (131 psi) 1407 kPa (204 psi) 1055 kPa (153 psi) 1055 kPa (153 psi) 1207 kPa (175 psi) 1007 kPa (146 psi) 758 kPa (110 psi) 1214 kPa (176 psi) 910 kPa (132 psi) 1420 kPa (206 psi) 1062 kPa (154 psi) 1627 kPa (154 psi) 1220 kPa (177 psi) 1020 kPa (148 psi) 765 kPa (111 psi) 1227 kPa (178 psi) 917 kPa (133 psi) 1434 kPa (208 psi) 1075 kPa (156 psi) 1641 kPa (238 psi) 1227 kPa (178 psi) 1034 kPa (150 psi) 779 kPa (113 psi) 1241 kPa (180 psi) 931 kPa (135 psi) 1448 kPa (210 psi) 1083 kPa (157 psi) 1655 kPa (240 psi) 1241 kPa (180 psi) 1048 kPa (152 psi) 786 kPa (114 psi) 1255 kPa (182 psi) 936 kPa (136 psi) 1462 kPa (212 psi) 1089 kPa (158 psi) 1669 kPa (242 psi) 1248 kPa (181 psi)2005 Ford Pickup F150 2005 GENERAL INFORMATION Engine System - General Information - F150 Pickup. 1062 kPa | 793 kPa | 1269 kPa | 952 kPa | 1476 kPa | 1103 kPa| 1682 kPa | 1262 kPa (154 psi) | (115 psi) | (184 psi) | (138 psi) | (214 psi) | (160 psi) | (244 psi) | (183 psi) 1076 kPa | 807 kPa | 1282 kPa | 965 kPa | 1489 kPa | 1117 kPa| 1696 kPa | 1269 kPa (156 psi) | (117 psi) | (186 psi) | (140 psi) | (216 psi) | (162 psi) | (246 psi) | (184 psi) 1089 kPa | 814 kPa | 1296 kPa | 972 kPa | 1503 kPa | 1124 kPa] 1710 kPa | 1202 kPa (158 psi) | (118 psi) | (188 psi) | (141 psi) | (218 psi) | (163 psi) | (248 psi) | (186 psi) 1103 kPa | 827kPa | 1310 kPa| 979 kPa | 1517 kPa | 1138 kPa | 1724 kPa | 1289 kPa (160 psi) | (120 psi) | (190 psi) | (142 psi) | (220 psi) | (165 psi) | (250 psi) | (187 psi) 110 kPa | 834 kPa | 1324kPa | 993 kPa | 1631 kPa|1145kPa]— - : (161 psi) | (121 psi) | (192 psi) | (14 psi) | (222 psi) | (166 psi) If one or more cylinders reads low, squirt approximately one tablespoon of engine oil on top of the pistons in the low-reading cylinders. Repeat the compression pressure check on these cylinders Compression Test - Interpreting Compression Readings 1. Ifcompr e faulty 2. If compression does not improve, valves are sticking or seating incorrectly. 3. If two adjacent cylinders indicate low compression pressures and squirting oil on each piston does not increase compression, the head gasket may be leaking between cylinders. Engine oil or coolant in cylinders could result from this condition. on improves considerably, piston rin Use the COMPRESSION PRESSURE LIMIT CHART when checking cylinder compression so that the lowest reading is within 75 percent of the highest reading. 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 will be heard in the throttle body. A leak at the exhaust valve 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 the cooling system may be detected by a stream of bubbles in the radiator.2005 Ford Pickup F150 2005 GENERAL INFORMATION Engine System - General Information - F150 Pickup. Excessive Engine Oil Consumption Nearly all engines consume oil, which is essential for normal lubrication of the cylinder bore walls and pistons and rings. Determining the level of oil consumption may require testing by recording how much oil is being added over a given set of miles. Customer driving habits greatly influence oil consumption. Mileage accumulated during towing or heavy loading generates extra heat. Frequent short trips, stop-and-go type traffic or extensive idling, prevent the engine from reaching normal operating temperature. This prevents component clearances from reaching specified operating ranges The following diagnostic procedure may be utilized to determine internal oil consumption. Make sure that the concern is related to internal oil consumption, and not external leakage, which also consumes oil. Verify there are no leaks before carrying out the test. Once verified, the rate of internal oil consumption can be tested. A new engine may require extra oil in the early stages of operation. Internal piston-to-bore clearances and sealing characteristics improve as the engine breaks in. Engines are designed for close tolerances and do not require break-in oils or additives. Use the oil specified in the Owner Guide. Ambient temperatures may determine the oil viscosity specification. Verify that the correct oil is being used for the vehicle in the geographic region in which it is driven. ic Pre-checks 1. For persistent complaints of oil consumption, interview the customer to determine the oil consumption characteristics. If possible, determine the brand and grade of oil currently in the oil pan. Look at the oil filter or oil-change station tags to determine if. Ford-recommended maintenance schedules have been followed. Make sure that the oil has been changed at the specified mileage intervals. If vehicle mileage is past the first recommended drain interval, the OEM production filter should have been changed. 2. Ask how the most current mileage was accumulated. That is, determine whether the vehicle was driven under the following conditions: Extended idling or curbside engine operation Stop-and-go traffic or taxi operation Towing a trailer or vehicle loaded heavily Frequent short trips (engine not up to normal operating temperature) . « Excessive throttling or high engine-rpm driving 3. Verify that there are no external leaks. If necessary, review the diagnostic procedure under ENGINE OIL LEAKS. 4, Inspect the crankcase ventilation system for: # Disconnected hoses at the valve cover or throttle body. + Loose or missing valve cover fill cap.2005 Ford Pickup F150 2005 GENERAL INFORMATION Engine System - General Information - F150 Pickup. ‘* Missing or incorrectly seated engine oil level indicator. ‘* Incorrect or dirty PCV valve * A PCV valve grommet unseated in the valve cover (if so equipped) 5. Inspect for signs of sludge. Sludge affects PCV performance and can plug or restrict cylinder head drainback wells. It can also increase oil pressure by restricting passages and reducing the drainback capability of piston oil control rings. Sludge can result from either excessive water ingestion in the crankcase or operation at extremely high crankcase temperatures. 6. Inspect the air filter for dirt, sludge or damage. A hole in the filter element will allow unfiltered air to bypass into the air induction system. This can cause premature internal wear (engine dusting), allowing oil to escape past rings, pistons, valves and guides. 7. If the engine is pot or was recently shut down, wait at least 5 minutes to allow the oil to is requirement has been followed. Adding oil without this wait period can cause an overfill condition, leading to excessive oil consumption and foaming which may cause engine damage. 8. Make sure the oil level indicator (dipstick) is correctly and fully seated in the indicator tube. Remove the oil level indicator and record the oil level. Detailed Pre-checks 1. Check the thermostat opening temperature to make sure that the cooling system is operating at the specified temperature. If it is low, internal engine parts are not running at specified internal operating clearances 2. Verify the spark plugs are not oil saturated. Oil leaking into one or more cylinders will appear as an oil soaked condition on the plug. If a plug is saturated, a compression check may be necessary at the conclusion of the oil consumption test. Oil ynsumption Test Once all of the previous conditions are met, carry out an oil consumption test 1. Drain the engine oil and remove the oil filter. Install a new manufacturer-specified oil filter, Make sure the vehicle is positioned on a level surface. Refill the oil pan to a level one quart (liter) less than the specified fill level, using manufacturer-specified oil 2. Run the engine for 3 minutes (if hot) or 10 minutes (if cold). Allow for a minimum 5- minute drainback period and then record the oil level shown on the oil level indicator. Place a mark on the backside of the oil level indicator noting the oil level location 3. Add the final 1 quart (liter) to complete the normal oil fill. Restart the engine and allow it to idle for 2 minutes. Shut the engine down. 4. After a 5-minute drainback period, record the location of the oil level again. Mark the oil level indicator with the new oil level location. (Note: Both marks should be very close to the MIN-MAX upper and lower limits or the upper and lower holes on the oil2005 Ford Pickup F150 2005 GENERAL INFORMATION Engine System - General Information - F150 Pickup. Post Checks, Evaluation and Ci 1 level indicator. These marks will exactly measure the engine's use of oil, with a one quart differential between the new marks.) Demonstrate to the customer that the factory-calibrated marks on the dipstick are where the oil should fall after an oil change with the specified fill amount. Explain however, that this may vary slightly between MIN-MAX or the upper and lower holes on the oil level indicator. Record the vehicle mileage. Advise the customer that oil level indicator readings must be taken every 320 km (200 miles) or weekly, using the revised marks as drawn. Remind the customer that the engine needs a minimum 5-minute drainback for an accurate reading and that the oil evel indicator must be firmly seated in the tube prior to taking the reading. When the subsequent indicator readings demonstrate a full quart (liter) has been used, record the vehicle mileage. The mileage driven between the 2 readings should not be less than 2,400 km (1,500 miles). The drive cycle the vehicle has been operated under must be considered when making this calculation. It may be necessary to have the customer bring the vehicle in for a periodic oil level indicator reading to closely monitor oil usage. rective Action If test results indicate excessive oil consumption, carry out a cylinder compression test. The cylinder compression test should be carried out with a fully charged battery and all spark plugs removed. See the COMPRESSION PRI URE LIMIT CHART for pressure range limits. Compression should be consistent across all cylinders. For additional information, refer to the COMPRESSION TEST - COMPRESSION GAUGE CHECK. If compression tested within the specifications found in this article, the excessive oil consumption may be due to wear on the valve guides, valves or valve seals. ‘A cylinder leak detection test can be carried out using an Engine Cylinder Leak Detection/Air Pressurization Kit. This can help identify valves, piston rings, or worn valve guides/valve stems, inoperative valve stem seals or other related areas as the source of oil consumption. NOTE: An oil-soaked appearance on the porcelain tips of the spark plugs also indicates excessive oil use. A typical engine with normal oil consumption will exhibit a light tan to brown appearance. See SPARK PLUG INSPECTION for details. A single or adjoining, multiple cylinder leak can be traced by viewing the tips. If an internal engine part is isolated as the root cause, determine if the repair will exceed cost limits and proceed with a repair strategy as required. Once corrective action to engine is complete and verifying that all pre-check items were eliminated in the original diagnosis, repeat the OIL CONSUMPTION TEST as2005 Ford Pickup F150 2005 GENERAL INFORMATION Engine System - General Information - F150 Pickup. described above and verify consumption results Intake Manifold Vacuum Test Bring the engine to normal operating temperature. Connect the Vacuum/Pressure Tester to the intake manifold. Run the engine at the specified idle speed. The vacuum gauge should read between 51-74 kPa (15-22 in-Hg) depending upon the engine condition and the altitude at which the test is performed. Subtract 4.0193 kPa (1 in-Hg) from the specified reading for every 304.8 m (1,000 feet) of elevation above sea level. The reading should be steady. If necessary, adjust the gauge damper control (where used) if the needle is fluttering rapidly. Adjust the damper until the needle moves easily without excessive flutter. Intake Manifold Vacuum Test - Interpreting Vacuum Gauge Readings ‘A careful study of the vacuum gauge reading while the engine is idling will help pinpoint trouble areas, Always conduct other appropriate tests before arriving at a final diagnostic decision. Vacuum gauge readings, although helpful, must be interpreted carefully. Most vacuum gauges have a normal band indicated on the gauge face. The following are potential gauge readings. Some are normal; others should be investigated further.2005 Ford Pickup F150 2005 GENERAL INFORMATION Engine System - General Information - F150 Pickup. A26227-A i Fig. 1: Identifying Potential Vacuum Gauge Readings2005 Ford Pickup F150 2005 GENERAL INFORMATION Engine System - General Information - F150 Pickup. Courtesy of FORD MOTOR CO. NORMAL READING: Needle between 51-74 kPa (15-22 in-Hg) and holding steady. NORMAL READING DURING RAPID ACCELERATION AND DECELERATION: When the engine is rapidly accelerated (dotted needle), the needle will drop to a low reading (not to zero). When the throttle is suddenly released, the needle will snap back up to a higher than normal figure. NORMAL FOR HIGH-LIFT CAMSHAFT WITH LARGE OVERLAP: The needle will register as low as 51 kPa (15 in-Hg) but will be relatively steady. Some oscillation is normal WORN RINGS OR DILUTED OIL: When the engine is accelerated (dotted needle), the needle drops to 0 kPa (0 in-Hg). Upon deceleration, the needle runs slightly above 74 kPa (22 in-Hg). STICKING VALVES: When the needle (dotted) remains steady at a normal vacuum but occasionally flicks (sharp, fast movement) down and back about 13 kPa (4 in-Hg), one or more valves may be sticking. BURNED OR WARPED VALVES: A regular, evenly-spaced, downscale flicking of the needle indicates one or more burned or warped valves. Insufficient hydraulic lash adjuster or hydraulic lash adjuster (HLA) clearance will also cause this reaction. POOR VALVE SEATING: A small but regular downscale flicking can mean one or more valves are not seating. WORN VALVE GUIDES: When the needle oscillates over about a 13 kPa (4 in-Hg) range at idle speed, the valve guides could be worm. As engine speed increases, the needle will become steady if guides are responsible. WEAK VALVE SPRINGS: When the needle oscillation becomes more violent as engine RPM is increased, weak valve springs are indicated. The reading at idle could be relatively steady. LATE VALVE TIMING: A steady but low reading could be caused by late valve timing. IGNITION TIMING RETARDING: Retarded ignition timing will produce a steady but somewhat low reading. INSUFFICIENT SPARK PLUG GAP: When spark plugs are gapped too close, a regular, small pulsation of the needle can occur. INTAKE LEAK: A low, steady reading can be caused by an intake manifold or throttle body gasket leak. BLOWN HEAD GASKET: A regular drop of fair magnitude can be caused by a blown head gasket or warped cylinder head-to-cylinder block surface. RESTRICTED EXHAUST STEM: When the engine is first started and is idled, the reading may be normal, but as the engine rpm is increased, the back pressure caused by a clogged muffler, kinked tail pipe or other concerns will cause the needle to slowly drop to 0 kPa (0 in-Hg). The needle then may slowly rise. Excessive exhaust clogging2005 Ford Pickup F150 2005 GENERAL INFORMATION Engine System - General Information - F150 Pickup. will cause the needle to drop to a low point even if the engine is only idling. 16. When vacuum leaks are indicated, search out and correct the cause, Excess air leaking into the system will upset the fuel mixture and cause concerns such as rough idle, missing on acceleration or burned valves. If the leak exists in an accessory unit such as the power brake booster, the unit will not function correctly, Always fix vacuum leaks. Oil Pressure Test Disconnect and remove the oil pressure sensor from the engine. Connect the Oil Pressure Gauge to the oil pressure sender oil galley port. Run the engine until normal operating temperature is reached. Run the engine at the specified rpm and record the gauge reading. The oil pressure should be within specifications; refer to the specification chart in the appropriate engine article. 6. If the pressure is not within specification, check the following possible sources; Insufficient oil * Oil leakage « Worn or damaged oil pump ene we # Oil pump screen cover and tube « Excessive main bearing clearance « Excessive connecting rod bearing clearance Valve Train Anal is - Engine Off - Valve Cover 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 # Check for loose mounting bolts, studs and nuts. # Check for plugged oil feed in the rocker arms or cylinder head Valve Train Analys - Engine Off, Camshaft Roller Followers and Hydraulic Lash Adjusters, Overhead Camshaft Check for loose mounting bolts on camshaft carriers. « Check for plugged oil feed in the camshaft roller followers, lash adjusters or cylinder heads, Valve Train Analysis - Engine Off, Camshaft - Engines # Check for broken or damaged parts. Valve Train Analysis - Engine Off, Push Rods2005 Ford Pickup F150 2005 GENERAL INFORMATION Engine System - General Information - F150 Pickup. * Check for bent push rods and restricted oil passage. Valve Train Analysis - Valve es « Check for broken or damaged parts. Valve Train Analysis - Engine Off, Valve Spring Retainer and Valve Spring Retainer Keys # Check for correct seating of the valve spring retainer key on the valve stem and in valve spring retainer. « Check for correct seating on the valve stem. Valve Train Analysis - Engine Off, Valves and Cylinder Head « Check for plugged oil drain back holes. * Check for worn or damaged valve tips. # Check for missing or damaged guide-mounted valve stem seal. # Check for damaged hydraulic lash adjuster * Check installed valve spring height. « Check for missing or worn valve spring seats. * 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, Valves and Cylinder Head # Check for plugged oil drain back holes. + Check for missing or damaged valve stem seals or guide mounted valve stem seals. « 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 off, some oil splash may overshoot camshaft roller followers. Valve Train Analysis - Engine Running, Camshaft Lobe Lift - ONC Engines Check the lift of each camshaft lobe in consecutive order and make a note of the readings. 1. Remove the valve covers. 2, Remove the spark plugs.2005 Ford Pickup F150 2005 GENERAL INFORMATION Engine System - General Information - F150 Pickup. 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 hydraulic lash adjuster. 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. N0013962 Fig. 2: Checking Camshaft Lobe Lift Courtesy of FORD MOTOR CO, 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), w 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 | through 6. NOTE: If the lift on any lobe is below specified service limits, install a new camshaft, and new camshaft roller followers. 7. Remove the Dial Indicator Gauge with Holding Fixture. 8. Install the spark plugs.2005 Ford Pickup F150 2005 GENERAL INFORMATION Engine System - General Information - F150 Pickup. 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. 1, Remove the valve covers. 2. Remove the rocker arm seat bolts, rocker arm seats and the rocker arms. N0013989 Fig. 3: Identify g Valve Tapper Is Seated Against Camshaft Courtesy of FORD MOTOR CO. 3. Make sure the valve taper is seated against the camshaft. Install (1) the 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 the push rod and in the same plane as the valve tappet push rod movement. 4. Remove the spark plugs. Connect an auxiliary starter switch in the starting circuit, Crank the engine with the ignition switch in the OFF position. Bump the crankshaft over until the valve tappet is on the base circle of the camshaft lobe. At this point, the valve tappet will be in its lowest position. If checking during engine assembly, turn the crankshaft using a socket and ratchet. 6. Zero the dial indicator, Continue to rotate the crankshaft slowly until the valve tappet is2005 Ford Pickup F150 2005 GENERAL INFORMATION Engine System - General Information - F150 Pickup. in the fully-raised position (highest indicator reading) NOTE: If lift on any lobe is below specified service limits, install a new camshaft and new valve tappets. 7, Remove the Dial Indicator with Holding Fixture, the Dial Indicator Gauge Adapter and the auxiliary starter switch 8. Install the rocker arms, the rocker arm seats and the rocker arm seat bolts. 9. Install the valve covers. 10. Install the spark plugs. Valve Train Analysis - Engine Running, Valve Tappet, Valve tappet noise can be caused by any of the following: « Ext Incorrectly functioning valve tappet « Air in lubrication system « Excessive valve guide wear ive valve tappet gap (collapsed) « Low oil pressure Excessive collapsed valve tappet gap can be caused by loose rocker arm seat bolts or nuts, incorrect initial adjustment or wear of the valve tappet face, or worn roller valve tappet, push rod, rocker arm, rocker arm seat or valve tip. With the valve tappet collapsed, check the gap between the valve tip and the rocker arm to determine if any other valve train parts are damaged, worn or out of adjustment. GENERAL PROCEDURES SPROCKETS WARNING: To avoid the possibility of personal injury or damage to the vehicle, do not operate the engine with the hood open until the fan blade has been examined for possible cracks and separation. NOTE: Specifications show the expected minimum or maximum condition. NOTE: If a component fails to meet the specifications, it is necessary to install a new component or refinish. If the component can be refinished, wear limits are provided as an2005 Ford Pickup F150 2005 GENERAL INFORMATION Engine System - General Information - F150 Pickup. aid to making a decision. A new component must be installed for any component that fails to meet specifications and cannot be refinished. AAS866-A Fig. 4: Inspecting Timing Chain And Sprockets Courtesy of FORD MOTOR CO. 1. Inspect the timing chain/belt and the sprockets. Install new components as necessary PUSH ROD CLEANING AND INSPECTION 1. Clean the push rods in a suitable solvent. Blow out the oil passage in the push rods with compressed air CAUTION: Do not attempt to straighten push rods.2005 Ford Pickup F150 2005 GENERAL INFORMATION Engine System - General Information - F150 Pickup. AA4257-A Fig. 5: Checking Ends Of Push Rods For Nicks, Grooves, Roughness Or Excessive Wear Courtesy of FORD MOTOR CO. 2. Check the ends of the push rods for nicks, grooves, roughness or excessive wear. Install new push rods as necessary. « 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. 3. If the push rod is bent beyond specifications, install a new push rod. ROCKER ARM CLEANING AND INSPECTION 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 is open CAUTION: Do not attempt to true surfaces by grinding. Check the rocker arm pad, side rails and seat for excessive wear, cracks, nicks or burrs. Check the rocker arm seat bolt for stripped or broken threads. Install new components as necessary or possible damage may occur. 3. Inspect the rocker arm push rod bore for nicks, scratches, scores or scuffs. Install new components as necessary.2005 Ford Pickup F150 2005 GENERAL INFORMATION Engine System - General Information - F150 Pickup. é _ Fig. 6: Inspecting Rocker Arm Push Rod Bore For Nicks, Scratches, Scores Or Scuffs Courtesy of FORD MOTOR CO. 4. Inspect the pad at the valve end of the rocker arm for indications of scuffing or abnormal wear. If the pad is grooved, install a new rocker arm CAMSHAFT BEARING JOURNAL DIAMETER 1. Measure each camshaft journal diameter in 2 directions. « If out of specification, install new components as necessary2005 Ford Pickup F150 2005 GENERAL INFORMATION Engine System - General Information - F150 Pickup. 7 a 1 <2-| Fig. 7: Locating Areas For Measuring Camshaft Journal Diameter Courtesy of FORD MOTOR CO. CAMSHAFT JOURNAL TO BEARING CLEARANCE - PUSH ROD ENGIN! METHOD MICROMETER NOTE: The camshaft journals must meet specifications before checking camshaft journal clearance.2005 Ford Pickup F150 2005 GENERAL INFORMATION Engine System - General Information - F150 Pickup. oO 98 0026934 Fig. 8: Measuring Camshaft Bearing In 2 Directions Courtesy of FORD MOTOR CO. 1. Measure each camshaft bearing in 2 directions « Subtract the camshaft journal diameter from the camshaft bearing diameter.2005 Ford Pickup F150 2005 GENERAL INFORMATION Engine System - General Information - F150 Pickup. CAMSHAFT BEAR! JOURNAL CLEARANCE NOTE: The camshaft journals must meet specifications before checking camshaft journal clearance. 1, Remove the camshaft bearing cap and lay Plastigage across the surface. __ PRS FH} oO OSS eee NSN AA3651-A Fig. 9: Measuring Plastigage Across Bearing Surface Courtesy of FORD MOTOR CO. NOTE: Do not turn the camshaft while carrying out this procedure. 2. Position the camshaft bearing cap and install the bolts. Use Plastigage to verify the camshaft journal clearance. « If out of specification, install new components as necessary CAMSHAFT END PLAY - PUSH ROD EN' SPECIAL TOOL CHART Dial Indicator Gauge with Holding Fixture 100-002 (TOOL-4201-C) or equivalent2005 Ford Pickup F150 2005 GENERAL INFORMATION Engine System - General Information - F150 Pickup. ST1214-A eye we Remove the valve tappets. Use a Dial Indicator Gauge with Holding Fixture to measure camshaft end play Position the camshaft to the rear of the cylinder block. Zero the indicator. Move the camshaft to the front of the cylinder block. Note and record the camshaft end play « If the camshaft end play exceeds specifications, install a new camshaft thrust plate.2005 Ford Pickup F150 2005 GENERAL INFORMATION Engine System - General Information - F150 Pickup. AA3686-A Fig. 10: Measuring Camshaft End Play Courtesy of FORD MOTOR CO. CAMSHAFT END PLAY - OHC EN SPECIAL TOOL CHART Dial Indicator Gauge with Holding Fixture gr 100-002 (TOOL-4201-C) or equivalent et ST1214-A 1. Use a Dial Indicator Gauge with Holding Fixture to measure camshaft end play 2. Position the camshaft to the rear of the cylinder head.2005 Ford Pickup F150 2005 GENERAL INFORMATION Engine System - General Information - F150 Pickup. 3. Zero the indicator. 4. 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. « If camshaft end play exceeds specification after camshaft installation, install a new cylinder head Fig. 11: Using Dial Indicator Gauge With Holding Fixture To Measure Camshaft End Play Courtesy of FORD MOTOR CO. CAMSHAFT SURFACE INSPECTION 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.2005 Ford Pickup F150 2005 GENERAL INFORMATION Engine System - General Information - F150 Pickup. Fig. 12: Inspecting Camshaft Lobes Courtesy of FORD MOTOR CO. CAMSHAFT LOBE LIFT SPECIAL TOOL CHART Dial Indicator Gauge with Holding Fixture ey 100-002 (TOOL-4201-C) or equivalent OD $T1214-A 1 Use a Dial Indicator Gauge with Holding Fixture 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 ig Camshaft Lobe Lift Courtesy of FORD MOTOR CO. CAMSHAF RUNOUT2005 Ford Pickup F150 2005 GENERAL INFORMATION Engine System - General Information - F150 Pickup. SPECIAL TOOL CHART Dial Indicator Gauge with Holding Fixture 100-002 (TOOL-4201-C) or equivalent woe $T1214-A NOTE: Camshaft journals must be within specifications before checking runout. DA0351-A. Fig. 14: Measuring Camshaft Runout Courtesy of FORD MOTOR CO. 1. Use a Dial Indicator Gauge with Holding Fixture to measure the camshaft runout « Rotate the camshaft and subtract the lowest indicator reading from the highest indicator reading, e For additional information. refer to the specification chart in the appropriate2005 Ford Pickup F150 2005 GENERAL INFORMATION Engine System - General Information - F150 Pickup. engine article If out of specification, install new component CRANKSHAFT MAIN BEARING JOURNAL DIAMETER 1, Measure each of the crankshaft main bearing journal diameters in at least 2 directions, « If out of specification, install new components as necess ry | fan 1 AA2535-C Fig. 15: Identifying Crankshaft Main Bearing Journal Diameter Measurements Courtesy of FORD MOTOR CO. CRANKSHAFT MAIN BEAR! JOURNAL TAPER AND OUT-OF-ROUND 1. Measure each of the crankshaft main bearing journal diameters in at least 2 directions at each end of the main bearing journal « If out of specification, install new components as necess ry2005 Ford Pickup F150 2005 GENERAL INFORMATION Engine System - General Information - F150 Pickup. AA3700-B Fig. 16: Measuring Crankshaft Journal Diameters Courtesy of FORD MOTOR CO. CRANKSHAFT MAIN BEARING JOURNAL-TO-BEARING CLEARANCE NOTE: Crankshaft main bearing journals must be within specifications before checking journal clearance. 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2005 Ford Pickup F150 2005 GENERAL INFORMATION Engine System - General Information - F150 Pickup. GA0197-A Fig. 17: Locating Plastigage Across Crankshaft Main Bearing Surface Cou y of FORD MOTOR CO. NOTE: Do not turn the crankshaft while carrying out this procedure. Install and remove the crankshaft main bearing cap. Verify the crankshaft journal clearance « If out of specification, install new components as necessary2005 Ford Pickup F150 2005 GENERAL INFORMATION Engine System - General Information - F150 Pickup. AA2536-A Fig. 18: Measuring Plastigage Across Crankshaft Journal Surface Courtesy of FORD MOTOR CO. CRANKSHAFT END PLAY SPECIAL TOOL CHART Dial Indicator Gauge with Holding Fixture gr 100-002 (TOOL-4201-C) or equivalent OD et $T1214-A 1. Use a Dial Indicator Gauge with Holding Fixture to measure crankshaft end play2005 Ford Pickup F150 2005 GENERAL INFORMATION Engine System - General Information - F150 Pickup. Position the crankshaft to the rear of the cylinder block. wn Zero the indicator. 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 or crankshaft thrust main bearing. = AA3776-A Fig. 19: Measuring Crankshaft End Play Courtesy of FORD MOTOR CO. CRANKSHAFT RUNOUT SPECIAL TOOL CHART Dial Indicator Gauge with Holding Fixture 100-002 (TOOL-4201-C) or equivalent2005 Ford Pickup F150 2005 GENERAL INFORMATION Engine System - General Information - F150 Pickup. woth et - ox Z ST1214-A NOTE: Crankshaft main bearing journals must be within specifications before checking runout. DAO356-A Fig. 20: Measuring Crankshaft Runout Courtesy of FORD MOTOR CO. I. Use the Dial Indicator Gauge with Holding Fixture to measure the crankshaft runout. # 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.2005 Ford Pickup F150 2005 GENERAL INFORMATION Engine System - General Information - F150 Pickup. CONNECTING ROD BEARING JOURNAL TAPER AND OUT-OF-ROUND 1. Measure the crankshaft connecting rod journal diameters in 2 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. « If out of specification, install new components as neces O! ) AA3700-B Fig. 21: Measuring Crankshaft Journal Diameters Courtesy of FORD MOTOR CO. CYLINDER BORE TAPER 1, Measure the cylinder bore at the top, middle and bottom of piston ring travel in 2 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 limit2005 Ford Pickup F150 2005 GENERAL INFORMATION Engine System - General Information - F150 Pickup. Fig. 22: Identifying Cylinder Bore Measuring Directions Courtesy of FORD MOTOR CO. CYLINDER BORE OUT-OF-ROUND 1. Measure the cylinder bore in 2 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. —~2 tL Oe V VW A A O S ADO Lf AA3778-A Fig. 23: Identifying Cylinder Bore Out-Of-Round Measuring Directions Courtesy of FORD MOTOR CO.2005 Ford Pickup F150 2005 GENERAL INFORMATION Engine System - General Information - F150 Pickup. PISTON INSPECTION SPECIAL TOOL CHART Scraper, Piston Ring Groove 303-D033 (D81L-6002-D) or equivalent @ O ST1279-A CAUTION: Do not use a caustic cleaning solution or a wire brush to clean the pistons or damage can occur. 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. S—@ N0013963 Fig. 24: Cleaning And Inspecting Ring Lands, Skirts, Pin Bosses And Tops Of Pistons Courtesy of FORD MOTOR CO.2005 Ford Pickup F150 2005 GENERAL INFORMATION Engine System - General Information - F150 Pickup. 2. Use the Piston Ring Groove Scraper to clean the piston ring grooves. ¢ Make sure the oil ring holes are clean. Fig. 25: Cleaning Piston Ring Grooves Courtesy of FORD MOTOR CO. PISTON PIN TO BORE DIAMETER WARNING: Cover the end of the pin bore with a hand or shop rag when removing the retainer ring, since it has a tendency to spring out. Wear eye protection. Failure to follow instructions may result in personal injury. NOTE: Piston and piston pins are a matched set and should not be interchanged.2005 Ford Pickup F150 2005 GENERAL INFORMATION Engine System - General Information - F150 Pickup. AA3779-A Fig. 26: Identifying Piston Pin Retainer Ring Courtesy of FORD MOTOR CO.2005 Ford Pickup F150 2005 GENERAL INFORMATION Engine System - General Information - F150 Pickup. AA1064-A Fig. 27: Identifying Directions For Measuring Piston Pin Bore Diameter Courtesy of FORD MOTOR CO. 1. Measure the piston pin bore diameter in 2 directions on each side. Verify the diameter is within specification. « If out of specification, install new components as necessary PISTON DIAMETER 1. Measure the piston diameter 90 degrees from the piston pin and 42 mm (1.65 in) down from the top of the piston at the point indicated. If out of specification, install new components as necessary2005 Ford Pickup F150 2005 GENERAL INFORMATION Engine System - General Information - F150 Pickup. Fig. 28: Measuring Piston Diameter Courtesy of FORD MOTOR CO. 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. 1, Select a piston size based on the cylinder bore Fig. 29: Identifying Cylinder Bore Measuring Directio Courtesy of FORD MOTOR CO. NOTE: For precision fit, new pistons are divided into 3 categories (grade sizes). A paint spot on the new pistons indicates the grade size. Choose the piston with the correct paint color after measuring the cylinder bore diameter.2005 Ford Pickup F150 2005 GENERAL INFORMATION Engine System - General Information - F150 Pickup. AA3691-A Fig. 30: Identifying Piston Grade Size Courtesy of FORD MOTOR CO. 2. Choose the piston with the correct paint color PISTON RING END GAP CAUTION: Use care when fitting piston rings to avoid possible damage to the piston ring or the cylinder bore. CAUTION: Piston rings should not be transferred from one piston to another. NOTE: Cylinder bore must be within specification for taper and out-of- round. 1, Use a piston without rings to push a piston ring in a cylinder to the bottom of ring travel2005 Ford Pickup F150 2005 GENERAL INFORMATION Engine System - General Information - F150 Pickup. AA3692-B Fig. 31: Pushing Piston Ring In Cylinder To Bottom Of Ring Travel Courtesy of FORD MOTOR CO. 2. Use a feeler gauge to measure the top piston ring end gap and the second piston ring end gap.2005 Ford Pickup F150 2005 GENERAL INFORMATION Engine System - General Information - F150 Pickup. eC 0 ¥ DA0363-A Ja Fig. 32: Measuring Piston Ring End Gap Courtesy of FORD MOTOR CO, PISTON RING-TO-GROOVE CLEARANCE 1, Inspect the piston for ring land damage or accelerated wear.2005 Ford Pickup F150 2005 GENERAL INFORMATION Engine System - General Information - F150 Pickup. AA3693-B Fig, 33: Identifying Piston Courtesy of FORD MOTOR CO. 2. Measure the piston ring-to-groove clearance. © If out of specification, install new components as necessary2005 Ford Pickup F150 2005 GENERAL INFORMATION Engine System - General Information - F150 Pickup. AA2879-A Fig. 34: Measuring Piston Ring-To-Groove Clearance Courtesy of FORD MOTOR CO. PISTON PIN DIAMETER 1. Measure the piston pin diameter in 2 directions at the points shown. Verify the diameter is within specification. « If out of specification, install new components as necessary2005 Ford Pickup F150 2005 GENERAL INFORMATION Engine System - General Information - F150 Pickup. Fig. 35: Measuring Piston Pin Diameter Courtesy of FORD MOTOR CO. CONNECTING ROD CLEANING CAUTION: Do not use a caustic cleaning solution or damage to connecting rods can occur. NOTE: The connecting rod large end is a matched set. The connecting rod cap must be installed on the original connecting rod in the original position. Do not reverse the cap. Parts are not interchangeable.2005 Ford Pickup F150 2005 GENERAL INFORMATION Engine System - General Information - F150 Pickup. A25409-A . 36: g Connecting Rod Cap Is A Matched Set Courtesy of FORD MOTOR CO. 1, Mark and separate the parts and clean with solvent, Clean the oil passages CONNECTING ROD LARGE END BORE 1. Tighten the bolts to specification, then measure the bore in 2 directions. The difference is the connecting rod bore out-of-round, Verify the out-of-round is within specification If out of specification, install new components as nec ry2005 Ford Pickup F150 2005 GENERAL INFORMATION Engine System - General Information - F150 Pickup. Fig. 37: Measuring Connecting Rod Large End Bore Courtesy of FORD MOTOR CO. CONNECTING ROD BUSHING DIAMETER 1. Use a telescoping gauge to determine the inner diameter of the connecting rod bushing, if equipped Fig. 38: Measuring Inner Diameter Of Connecting Rod Bushing Courtesy of FORD MOTOR CO. 2. Measure the telescoping gauge with a micrometers. Verify the diameter is within specification. « If out of specification, install new components as necessary pep fO8 NoOS1614 NSE Fig. 39: Measuring Telescoping Gauge Using Micrometer Courtesy of FORD MOTOR CO. CONNECTING ROD BEND2005 Ford Pickup F150 2005 GENERAL INFORMATION Engine System - General Information - F150 Pickup. 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, « If out of specification, install new components as necessary. AA3695-A Fig. 40: Measuring Connecting Rod Bend Courtesy of FORD MOTOR CO. CONNECTING ROD TWIST 1. Measure the connecting rod twist on a suitable alignment fixture. Follow the instructions of the fixture manufacturer. Verify the measurement is within specification. « If out of specification, install new components as necessary2005 Ford Pickup F150 2005 GENERAL INFORMATION Engine System - General Information - F150 Pickup. AA3696-A Fig. 41: Measuring Connecting Rod Twist Courtesy of FORD MOTOR CO. PISTON WRIST PIN SIDE CLEARANCE 1. Measure the clearance between the connecting rod and the piston. Verify the measurement is within specification. « If out of specification, install new components as necessary2005 Ford Pickup F150 2005 GENERAL INFORMATION Engine System - General Information - F150 Pickup. DA0372-A Fig. 42: Measuring Clearance Between Connecting Rod And Piston Courtesy of FORD MOTOR CO. CONNECTING ROD BEARING JOURNAL-TO-BEARING CLEARANCE NOTE: The crankshaft connecting rod journals must be within specifications to check the connecting rod bearing journal clearance. 1. Remove the connecting rod bearing cap. 2. Position a piece of Plastigage across the bearing surface.2005 Ford Pickup F150 2005 GENERAL INFORMATION Engine System - General Information - F150 Pickup. “A A26377-A Fig. 43: Positioning Piece Of Plasticgage Across Bearing Surface Courtesy of FORD MOTOR CO. NOTE: Do not turn the crankshaft during this step. 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. « If out of specification, install new components as necessary2005 Ford Pickup F150 2005 GENERAL INFORMATION Engine System - General Information - F150 Pickup. DA0373-A Fig. 44: Measuring Plastigage To Get Connecting Rod Bearing Journal Clearance Courtesy of FORD MOTOR CO. ROLLER FOLLOWER INSPECTION Push rod engines 1. Inspect the roller for flat spots or scoring. If any damage is found, inspect the camshaft lobes and valve tappet for damage.2005 Ford Pickup F150 2005 GENERAL INFORMATION Engine System - General Information - F150 Pickup. wr” Fig. 45: Inspecting Roller For Flat Spots Or Scoring (Push Rod Engines) Courtesy of FORD MOTOR CO. AA3786-A OHC engines 46: Inspecting Roller Follower For Flat Spots/Scoring Courtesy of FORD MOTOR CO. VALVE TAPPET INSPECTION2005 Ford Pickup F150 2005 GENERAL INFORMATION Engine System - General Information - F150 Pickup. 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 AA3787-A Fig. 47: Inspecting Hydraulic Valve Tappet And Roller For Damage (Push Rod Engines) Courtesy of FORD MOTOR CO. OHC engines2005 Ford Pickup F150 2005 GENERAL INFORMATION Engine System - General Information - F150 Pickup. 48: Identifying Roller Follower/Valve Tappet Courtesy of FORD MOTOR CO. VALVE STEM DIAMETER 1. Measure the diameter of each intake and exhaust valve stem at the points s the diameter is within specification. « If out of specification, install new components as necessary own. Verify bit AA2510-C Fig. 49: Measuring Diameter Of Valve Stem Courtesy of FORD MOTOR CO. VALVE STEM TO VALVE GUIDE CLEARANCE SPECIAL TOOL CHART Dial Indicator with Bracketry 100-0022005 Ford Pickup F150 2005 GENERAL INFORMATION Engine System - General Information - F150 Pickup. (TOOL-4201-C) or equivalent et = Se $T1214-A Valve Guide Clearance Gauge 303-004 (TOOL-6505-E) or equivalent $T1251-A NOTE: Valve stem diameter must be within specifications before checking valve stem to valve guide clearance. NOTE: If necessary, use a magnetic base.2005 Ford Pickup F150 2005 GENERAL INFORMATION Engine System - General Information - F150 Pickup. AA3790-B Fig. 50: Measuring Valve Stem To Valve Guide Clearance Courtesy of FORD MOTOR CO. 1. Install a valve clearance gauge on the valve stem and install a dial indicator. Lower the valve until the valve clearance gauge contacts the upper surface of the valve guide. 2. Move the valve clearance gauge toward the indicator and zero the indicator. Move the valve clearance gauge 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 INSPECTION 1. Inspect the following valve areas 1. The end of the stem for grooves or scoring 2. The valve face and the edge for pits, grooves or scores 3. The valve head for signs of burning, erosion, warpage and cracking 4. The valve margin for wear2005 Ford Pickup F150 2005 GENERAL INFORMATION Engine System - General Information - F150 Pickup. NOQ013964 Fig. 51: Inspecting Valve For Damage Courtesy of FORD MOTOR CO. VALVE GUIDE INNER DIAMETER NOTE: Valve guides tend to wear in an hourglass pattern. The ball gauge can be inserted into the combustion chamber side of the valve guide if necessary. Fig. 52: Measuring Valve Guide Inner Diameter Courtesy of FORD MOTOR CO. 1. Use a ball gauge to determine the inner diameter of the valve guides in 2 directions at2005 Ford Pickup F150 2005 GENERAL INFORMATION Engine System - General Information - F150 Pickup. the top, middle and bottom of the valve guide. 2. Measure the ball gauge with a micrometer. Noose Fig. 53: Measuring Ball Gauge Wit Courtesy of FORD MOTOR CO. Micrometer 3. If the valve guide is not within specifications, ream the valve guide and install a valve with an oversize stem or remove the valve guide and install a new valve guide. VALVE GUIDE REAMING 1. Use a hand-reaming kit to ream the valve guide.2005 Ford Pickup F150 2005 GENERAL INFORMATION Engine System - General Information - F150 Pickup. Fig. 54: Rea Guide Using Hand-Reaming Kit Courtesy of FORD MOTOR CO. 2. Reface the valve seat Clean the sharp edges left by reaming. VALVE SPRING INSTALLED LENGTH 1. Measure the installed length of each valve spring. « If out of specification, install new components.2005 Ford Pickup F150 2005 GENERAL INFORMATION Engine System - General Information - F150 Pickup. SF AA3424-A Fig. 55: Measuring Installed Length Of Valve Spring Courtesy of FORD MOTOR CO. VALVE SPRING FREE LENGTH Measure the free length of each valve spring. If out of specification, install new components as necessary2005 Ford Pickup F150 2005 GENERAL INFORMATION Engine System - General Information - F150 Pickup. DA0379-A Fig. 56: Measuring Free Length Of Valve Spring Courtesy of FORD MOTOR CO. VALVE - SPRING SQUARENESS NOTE: This procedure only applies to cylindrical valve springs. ae ea _ S E PII Wey) ‘oor2028 Fig. 57: Measuring Valve Spring Out-Of-Square Courtesy of FORD MOTOR CO. 1, Measure the out-of-square on each valve spring, « Tum 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 VALVE SPRING STRENGTH2005 Ford Pickup F150 2005 GENERAL INFORMATION Engine System - General Information - F150 Pickup. SPECIAL TOOL CHART Pressure Gauge, Valve/Cluteh Spring 303- 006 (TOOL-6513-DD) or equivalent ST1278-A 1, Use a Valve/Clutch Spring Pressure Gauge to check the valve spring for correct strength at the specified valve spring length. « If out of specification, install new components as necessary DA0381-A Fig. 58: Measuring Valve Spring Strength Courtesy of FORD MOTOR CO. VALVE SEAT INSPECTION2005 Ford Pickup F150 2005 GENERAL INFORMATION Engine System - General Information - F150 Pickup. Valve and Seat Refacing Measurements CAUTION: After grinding valves or valve seats, check valve clearance. 1. Check the valve head and seat. © Check valve angles, Check margin width. « Be sure margin width is within specification. = - AA3652-C : Identifying Valve Margin Width Courtesy of FORD MOTOR CO. 2. Inspect for abnormalities on the valve face and seat. VALVE SEAT WIDTH 1, Measure the valve s at 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.2005 Ford Pickup F150 2005 GENERAL INFORMATION Engine System - General Information - F150 Pickup. DA0383-A Fig. 60: Measuring Valve Seat Width Courtesy of FORD MOTOR CO. VALVE SEAT RUNOUT. L. Use a valve seat runout gauge to check valve seat runout.2005 Ford Pickup F150 2005 GENERAL INFORMATION Engine System - General Information - F150 Pickup. DAO3B5-A — S. Fig. 61: Measuring Valve Seat Runout Courtesy of FORD MOTOR CO. CYLINDER HEAD DISTORTION SPECIAL TOOL CHART Feeler Gauge Set 303-D027 (D81L-4201- S A) or equivalent $T1271-A Straight Edge 303-D039 (D83L-4201-a) or —— equivalent ST1246-A2005 Ford Pickup F150 2005 GENERAL INFORMATION Engine System - General Information - F150 Pickup. NOTE: Make sure all cylinder head surfaces are clear of any gasket material, RTV, oil and coolant. The cylinder head surface must be clean and dry before running a flatness check. NOTE: Use a straight edge that is calibrated by the manufacturer to be flat with 0.005 mm (0.0002 in) per running foot length. For example, if the straight edge is 61 cm (24 in) long, the machined edge must be flat with 0.010 mm (0.0004 in) from end to end. Fig. 62: Inspecting Cylinder Head For Flatness Courtesy of FORD MOTOR CO. 1. Using a straight edge and a feeler gauge, inspect the cylinder head for flatness in the sequence shown, If the cylinder head is distorted, install a new cylinder head CYLINDER BORE CLEANING CAUTION: If these procedures are not followed, rusting of the cylinder bores may occur. 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.2005 Ford Pickup F150 2005 GENERAL INFORMATION Engine System - General Information - F150 Pickup. CYLINDER BLOCK CORE PLUG REPLACEMENT SPECIAL TOOL CHART aod Slide Hammer 100-001 (TS0T-100-A) ST1185-A MATERIAL CHART Ttem Specification Threadlock 262 TA-26 or equivalent WSK-M2G351-A6 L. Usea slide hammer or tools suitable to remove the cylinder block core plug. GA0393-A Fig. 63: Removing Cylinder Block Core Plug Using Slide Hammer Courtesy of FORD MOTOR CO, 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2005 Ford Pickup F150 2005 GENERAL INFORMATION Engine System - General Information - F150 Pickup. oversize plug, NOTE: Oversize plugs are identified by the OS stamped in the flat located on the cup side of the plug. 3. Coat the cylinder block core plug and bore lightly with Threadlock 262 and install the cylinder block core plug Cup-Type CAUTION: Use care during this procedure so as not to disturb or distort the cup sealing surface. CAUTION: When installed, the flanged edge must be below the chamfered edge of the bore to effectively seal the bore. Fig. 64: Seating Cup-Type Cylinder Block Core Plug Courtesy of FORD MOTOR CO. L. Use tool suitable to seat the cup-type cylinder block core plug. Expansion-Type2005 Ford Pickup F150 2005 GENERAL INFORMATION Engine System - General Information - F150 Pickup. CAUTION: Do not contact the crown when installing an expansion-type cylinder block core plug. This could expand the plug before seating and result in leakage. quy AA3699-B Fig. 65: Seating Expansion-Type Cylinder Block Core Plug Courtesy of FORD MOTOR CO. 1. Use tool suitable to seat the expansion-type cylinder block core plug SPARK PLUG INSPECTION 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.2005 Ford Pickup F150 2005 GENERAL INFORMATION Engine System - General Information - F150 Pickup. ABO0037-A Fig, 66: Identifying Spark Plug With Bridged Gap Courtesy of FORD MOTOR CO. 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.2005 Ford Pickup F150 2005 GENERAL INFORMATION Engine System - General Information - F150 Pickup. ABO036-A Fig. 67: Identifying Oil Fouled Spark Plug Courtesy of FORD MOTOR CO. 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.2005 Ford Pickup F150 2005 GENERAL INFORMATION Engine System - General Information - F150 Pickup. ABO040-A Fig. 68: Identifying Spark Plug Carbon Fouling Courtesy of FORD MOTOR CO. 4. Inspect for normal burning. Check for light tan or gray deposits on the firing tip.2005 Ford Pickup F150 2005 GENERAL INFORMATION Engine System - General Information - F150 Pickup. ABO0039-A Fig, 69: Identifying Normal Burning Spark Plug Courtesy of FORD MOTOR CO. 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.2005 Ford Pickup F150 2005 GENERAL INFORMATION Engine System - General Information - F150 Pickup. ABO038-A Fig. 70: Identifying Spark Plug With Pre-Ignition Condition Courtesy of FORD MOTOR CO. Inspect for overheating, identified by 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.2005 Ford Pickup F150 2005 GENERAL INFORMATION Engine System - General Information - F150 Pickup. ABO0042-A Fig, 71: Identifying Overheated Spark Plug Courtesy of FORD MOTOR CO. 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2005 Ford Pickup F150 2005 GENERAL INFORMATION Engine System - General Information - F150 Pickup. ABO041-A Fig, 72: Identifying Fused Deposits On Spark Plug Courtesy of FORD MOTOR CO. EXHAUST MANIFOLD CLEANING AND INSPECTION SPECIAL TOOL CHART Straight Edge 303-D039 (D83L-4201-A) _—— or equivalent S$T1246-4 1. Clean the exhaust manifold using a suitable solvent. Use a plastic scraping tool to clean the gasket sealing surfaces2005 Ford Pickup F150 2005 GENERAL INFORMATION Engine System - General Information - F150 Pickup. NOTE: New exhaust manifold gaskets, nuts and/or bolts must be installed when an exhaust manifold is serviced. A26498-B Fig. 73: Checking Exhaust Manifold Sealing Surface For Warpage Courtesy of FORD MOTOR CO. 2. Using the special tool (or a precision straight edge) and a feeler gauge, check the exhaust manifold sealing surface for warpage. If the warpage is greater than 0.76 mm (0.0299 in), install a new exhaust manifold. BEARING INSPECTION 1. Inspect bearings for the following defects. Possible causes are shown 1. Cratering - fatigue failure .. Spot polishing - incorrect seating. Imbedded dirt engine oil Scratching - dirty engine oil. . Base exposed - poor lubrication. Both edges worn - journal damaged AAWwWRYN . One edge worn - journal tapered or bearing not seated2005 Ford Pickup F150 2005 GENERAL INFORMATION Engine System - General Information - F150 Pickup. NO013966 Fig. 74: Inspecting Bearings Courtesy of FORD MOTOR CO.