a Ford 4 Engines 1971-73 PINTO 1600 cc ENGINES GENERAL SPECIFICATIONS. 96@3000 802400 197 1972-730, © = Horsepower, Torque ond Compression Ratio figures given for 1972 only. NET HORSEPOWER & TORQUE NOTE Horsepower and Torque figures given for 1972 are NET. NET Horsepower and Tor- {ve represent power af the flywheel when the engine iz installed in vehicle, with wide open throttle and all systems operating Such os, air cleaner, exhaust system, woter pump, generator, oi! pump and oir conditioning ENGINE IDENTIFICATION 2) Discennecthoses at the intake manifold and choke hous- Engine Identification may be established from the official IPE Disconnect temperature. gauge wire at sender unit, Vehicle Identification Number. This umber r= stamped on a‘netalie tab fastened to the instument panel close t0 pena fastened tote nstument pane cles {© 5) Disconnect exhaust poe and disconnect the showle ible from outside. The Identification Number contains !iNkage and distributor vacuum advance pipe from the car- eleven characters and digits. Example: ISI0X100001. The ureter. first digit determines the model year and {ih character establishes engine identification. 4) Remove thermostat, rocker arm cover and gasket. Re- Pinte Engine Engine Code shove rocker am shaft Boles evenly and remove rocker am ioe Ww asembiy. Remove push ods and Keep them incorrect order ‘sr proper replacement. pda entlen 5) Remove head bolts and remove head and gasket, CAU- See Engine Removal of end of ENGINE Section. TION” Do not ly ead fi on vis face as damage fo {pork plage or gosket surface can occur INTAKE MANIFOLD REMOVAL 1) After draining cooling system, remove ne air cleaner and disconnect the throttle shaft. from the carburetor. Disconnect the fuel line, decel valve pipe and vacuum Tine from the carburetor. 2) Disconnect the water outlet hose and the crankcase Vertilation hose from the intake manifold. Remove the attaching nut and bolts and remove the manifold. CYLINDER HEAD REMOVAL 1) After draining cooling system, disconnect hot air and crankcase ventilation hoses at the air cleaner. Remove “+—~FRONT 1F3004 air cleaner and disconnect the fuel line at the carburetor and fuel pump. CYLINDER HEAD TIGHTENING SEQUENCE VALVES, ‘Seat Valve Angle | Angle | Seat Width | Stem Diameter| Stem Clearance | Lift Engine & Valve 1600ce 1971 lot 1ag7 | ase | 442 | 055-060" | 3098-3105" | 0008..0027" | 2967" Exh u2aor | ase | see | 075-080" | 3089-3096" | 0017..0036"_| 3199" T9RTS__Iot 1502" | 44° | 45° | 050-085" | .3098.3105" | 008.0027" | .2967°0 Exh, v2aer_[_44e | ase | 070.085: 3089. 3096" | 0017..0036"_| ‘3199"@ © — 1973 3246" @ - 1973 3351" ‘ipo 200 Rapa ema CampaFord 4 Engines 1971-73 PINTO 1600 cc ENGINES (Cont.) VALVE ARRANGEMENT VALVE GUIDES. Valve guides may be either integral in the head or installed in the head az individual unites Io either case, the bores may be reamed to 015" oversize and valves with .015 oversize stems installed, NOTE ~ Intoke volves ore alum: nized ond must not, under ony circumstances be faced, ground or lopped in. Replace intoke volves thot ore burned Or pined, VALVE SEALS Insert valve into guide and fit rubber seal to the valve ‘stem with the open end to the:head, Seal is ‘etained by 3 Snap ring over the valve guide boss. VALVE SPRINGS PRESSURE (1BS.) Free 1600 ce wri 1973 VALVE SPRING ASSEMBLED HEIGHT Valve spring installed height is measured ftom the valve spring pad to the bottom of the retainer. Assembleg height Should be 1,263", If height not correct, valve spting shims may be installed to obtain correct height, If correct height ‘not obtainable with 1/16" shim, replace valve. ROCKER ARM ASSEMBLY Removal & Disassembly ~ Remove focker atm shaft attach ing bolts evenly, It off assembly, Remove cotter pin from fone end of shaft, slip flat washer, ctimped washer and Second flat washer off shaft. Rocker arm shaft supports, rocker arms and springs can’ now be removed from shaft. Reassembly & Instollotion ~ In proper sequence, place shaft supports, rocker arms and springs on shaft. The bolt hole in the rocker arm shaft support must be on the same Side as the tappet screw in the racker arm, Rocker arms are right and left handed, the rocker pads being inclines fowards the support. Place the assembly on the cylinder head and tighten bolts evenly in sequence, until proper torque (see Tightening Specifications) has been obtained. VALVE TAPPET ADJUSTMENT ‘Adjust valve tappet clearance to the following specifications Intake Valves ~ Hot .010"; Cold 008.010" Exhaust Valves — Hot 017"; Cold .018-.020" To correctly check and adjust tappet clearances, turn the crankshaft until the valves listed in the first column of the following table are fully open. Then adjust the valves, listed in the second column of the table. Valves Open Adjust Valves Lae 348 2k 587 jaa 186 Sar Ded PISTONS, PINS, RINGS PISTONS, PINS RINGS, Engine OClearance | Piston Fit RodFir_| Rings | End Gap | Side Clearance 1600 ce 171 (0016.0022" | .0001..0003" | .0001-.0003"} 182 | 009.014" | .0016-.0036" 3” | 009-014" | 0018-0038" 1972.73, .0016.0022 | .0001..0003" (0001-.0003"] 1&2 | 009.014" | 0016-0036" 3° | 009.014" | 0018-0038" © ~ No. 4 Bore ,0019-,0024' PISTON PIN INSTALLATION After correctly installing piston rings on pistons, assem- ble the piston to the connecting rod. Be sure that the “Front” marking on the rod is on the some side of the ‘assembly os the arrow in the piston crown. Heat the piston fn water of oi! prior to inserting the piston pin, Retain the piston pin with the snap ringer FITTING PISTONS 1) Measure cylinder bore 2 11/32" from top face of ey! inder Block, across the axis of the crankshaft, 2) Check piston clearance in bore by inserting a piston ull seale'tool with a /s" wide Blade (feeler gauge) 002 thick into the cylinder bore the full length of the blade. Slide the piston, crown first, into the cylinder and wap the feeler blade at the largest diameter of the piston. 3) Hold the piston steady (without side thrust) and with- Graw the feeler Blade with a steady pull on the piston pull scale, observing the pounds pull required to remove the feeler blade. if piston clearance is correct, 7 to I! Tbs. pull will be required to withdraw the feeler blade. ‘ipo 200 Rapa ema Campa5-44 Ford 4 Engines 1971-73 PINTO 1600 cc ENGINES (Cont.) (MAIN BEARINGS Engine 1600 ee 1971 1972.73 OL PAN REMOVAL See Oil Pan Removal ot end of ENGINE Section Journal Diam. | Clearance 2:1253-2.1261" 2.1253.2.1261" (0008-.0015" .0005-.0015" MAIN BEARING Crankshaft is supported by five main bearings. The inter mediate and ear” bearing caps are identical, but their positions must not be interchanged. When disassembling an Engine, make sure that bearing caps are numbered (with the exception of the tear bearing). The rear main cap is not numbered. “All caps must be fitted with cast arrows, pointing forwards. Use Plastigage to determine crankshaft clearance in bear- ings. If bearing clearance using standard bearings is excessive, a 002" undersized bearing may be used in combination with a standard bearing. If .002" undersized bearings are used on more than one journal, they must be positioned in the cylinder block rather than in the bear~ Ing cap. If the standard and .002" undersize combination does not bring the bearing clearance within. specified mits (see Specifications), the crankshaft will have to be refinished and undersize bearings installed, CONNECTING ROD NUMBERS Rod number is stamped on lower end of rod and its bear- ing €ap, on the camshaft side, When a piston and rod assembly Is installed with the numbers together it will be in its original position in the engine assembly. it Is advisable, when femowing piston and rod assemblies. to be sure each rod is stamped. Stamp any rod without 3 eylinder number on 1, REAR MAIN BEARING OIL SEAL 1) Remove transmission, clutch pressure plate and fly- wheel. Remove oil pan (see Oi! Pan Removal), Remove the rear oil seal retainer, 2) Install new seal in carrier using a suitable remover/ Teplacer tool (Ford T70P-6168). 3) With a new gasket on the carrier, use a suitable joint ing compound at the ends and fit the carrier to the block rear face. Use the remover/replacer tool to align the seal fon the crankshaft seal surface, With the tool in place, Ughten the carrier bolts evenly and remove the tooly Re place the oi! pan, using new gaskets and jointing compound. ENGINE FRONT COVER & OIL SEAL 1) Drain cooling system, disconnect radiator hoses at engine and remove radiator. Remove fan belt, fan and water pump pulley. CRANKSHAFT MAIN & CONNECTING ROD BEARINGS CONNECTING ROD BEARINGS OSideplay .004..010" 004-010" Journal Diam. | Clearance 003.011" 003.011" 1.9368-1.9376" |.0001..0015" 1.9368-1.9376" | 0904-.0015" 2) Remove the water pump, then use a suitable puller and Temove the crankshaft pulley. Remove the front cover, 3) Install new oil seal in cover using suitable tool, When replacing front cover, align the cover to the cylinder block with an aligning tool, Tighten cover bolts evenly and then Femove aligning tool CAMSHAFT Engine 1600¢e 1971-73 1.5597-1.5605" | .0010..0023" | int. 2108" Exh. 2176" © ~ Weer timit.006 CHECKING CAM LOBE LIFT Check lift of each camshaft lobe in consecutive order as follows 1) Remove rocker arm shaft assembly, making sure each push rod is in the valve lifter socket. Install a dial indi {cator $0 thar the ball socket adapter of the sndveator rests fn the end of push rod and in the same plane as the push VALVE TIMING MARKS. ‘ipo 200 Rapa ema CampaFord 4 Engines 1971-73 PINTO 1600 cc ENGINES (Cont.) CAMSHAFT & TIMING CHAIN Camshaft ~ Engine must be temoved from vehicle to re= place camshaft bearings of camshaft(see Engine Removal), Replacement of camshaft or bearinge requires that front andar crankshaft oi! seals also be replaced, Use suitable bearing remover replacer tool and adapters to install new bearings. The splits in the new bearings should be up wards and outwards at 45" to the vertical. Front and rear bearings are approximately 3/4” wide, the front having an additional oi! hole for the rocker atm shaft oil feed, and the center bushing 18 approximately 5/8" wide. Timing Chain — Single rom, with automatic mechanical tensioner. Tensioner has synthetic rubber pad that tuns Girectly on rollers of chain. NOTE ~ Do not dress surface Of pod to remove grooves worn im by chain inks. Camshatt fang crankshaft sprockets have timing marks indented on face of sprocket, Wen replacing ming chain, be sure timing marks are’ correctly aligned (see illustration). In- Stall new cranksoaft front oil seal in front engine cover before replacing cover, ENGINE OILING Type System — Full force feed with full-flow oil filter. Cronkease Copacity ~ 3 Qts. Add ' Qt with filter change. Oi! Pressure (Hot) ~ 35-40 Lbs. « 2000 RPM Pressure Relief Valve ~ Not adjustable. ‘ol PUMP, ‘Two types of pumps are used in production; a "vane-type" and fan "eccentric bi-rotor type". Pumps ore directly in terchangeoble, differing only in their internal design. Pumps may be identified on the engine by the difference in their end covers. The eccentric bi-otor has four recesses cast in the cover, the vane type being flat. Either type may be removed withthe engine in place by removing three bolts attaching the cil pump ond filter assembly and withdrawing the assembly from the engine. Oil Pump Specifications ~ Rotor Type Max. Clearance, Inner & Outer Rotors Max. Clearance, Outer Rotarto Housing Max: Clearance, Face of Rotors to race ofiousing Relief Valve Spring Tension 21.0 758.5 Los. Clearance, Shaft to Housing Beaving Clearance, Relief Valve. End Clearance, Rotor Assembiy Clearance (Radial), Outer Race i Housing Oil Pump Specifications ~ Vane Type Max. Clearance, Face of Rotor & Vanes to HoUsiag FACE nen Max, Clearance, Side of Rotor to Side of Housing Max. Clearance, Vane to Pump Body Max, Clearance, Vane to Side af Locating Graove TIGHTENING SPECIFICATIONS Applicetion Fr. Lbs. Cylinder Head Bolts @ Main Bearing Caps 5:70 Connecting Rod Bolts 30:35 Crankshaft Pulley Bolt 6.28 Flywheel to Crankshaft Bolts 50.55, Rocker Arm Shaft Support 25.30 Camshaft Sprocket to Camshaft ns Front Engine Cover 7 Exhaust Manifold to Cyi. Head Studs. vsnvcen 912 Exhaust Manifold to Cyl. Head Nuts isa Exhaust Manifold to Cyl, Head 312 Intake Manifold to Cyl. Head Boits is, Intake Manifold to yl, Head Nuts 15, ltake Manifold to Cyl. Head Studs 312 O11 Pump to Cy1, Block 1315. O11 Pan to Cyl, Block Bolts rs D Tappet Adjusting Self Lock Screws os Water Pump to Cyl. Block (%") 57 Water Pump to Cyl. Block (5/16) is. Decel Valve Adaptor to Manifold 3033, Decel Valve Adaptor to Decel Valve 27330 = Step one, 5 Ft. Ibs. Step two, 25 Ft, Ibs. Step three, 52 Ft, Ibs. Step four, 65-70 Fr, Ibs, = Step one, finger tighten corner bolts. Step two, ighten all Bolts enough to clamp gasket. Step three, tighten all to 7 Ft Ibs, ENGINE NOTES PINTAKE VALVE CAUTION — Intoxe valve faces are ‘aluminized and must NOT, under any circumstances be faced ground of lapped in. Replace intake valves that core burned or pitted. Je NEW OIL FUMP ASSEMBLY: Where necessary to re- reve & tendency of oil pressure busld up, a new 0! pur with a deeper ‘elie! valve bore uw the pump body +s ‘variable, {Part No. DWF Z 6600 C\ ‘ipo 200 Rapa ema Campa