2018-2020 Ford F-150 & Raptor Complete Service Manual – PDF DOWNLOAD

7/24/2019

MITCHELL 1 ARTICLE - GENERAL INFORMATION Anti-Lock Brake Safety Precautions

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GENERAL INFORMATION Anti-Lock Brake Safety Precautions

* PLEASE READ THIS FIRST * This article is intended for general information purposes only. This information may not apply to all makes and models. If vehicle is equipped with Anti-Lock Brake System (ABS), refer to appropriate ANTI-LOCK BRAKE SYSTEM article in the BRAKES section for description, operation, depressurizing, testing, system bleeding, trouble shooting and servicing of specific system.

ANTI-LOCK BRAKE SAFETY PRECAUTIONS WARNING:

Failure to depressurize ABS could lead to physical injury.

NEVER open a bleeder valve or loosen a hydraulic line while ABS is pressurized.

NEVER disconnect or reconnect any electrical connectors while ignition is on. Damage to ABS control unit may result.

DO NOT attempt to bleed hydraulic system without first referring to the appropriate ANTILOCK BRAKE SYSTEM article in the BRAKES section.

Only use specially designed brake hoses/lines on ABS equipped vehicles.

DO NOT tap on speed sensor components (sensor, sensor rings). Sensor rings must be pressed into hubs, NOT hammered into hubs. Striking these components can cause demagnetization or a loss of polarization, affecting the accuracy of the speed signal returning to the ABS control unit.

DO NOT mix tire sizes. Increasing the width, as long as tires remain close to the original diameter, is acceptable. Rolling diameter must be identical for all 4 tires. Some manufacturers recommend tires of the same brand, style and type. Failure to follow this precaution may cause inaccurate wheel speed readings.

DO NOT contaminate speed sensor components with grease. Only use recommended coating, when system calls for an anti-corrosion coating.

When speed sensor components have been removed, ALWAYS check sensor-to-ring air gaps when applicable. These specifications can be found in each appropriate article.

ONLY use recommended brake fluids. DO NOT use silicone brake fluids in an ABS equipped vehicle.

When installing transmission devices (CB's, telephones, etc.) on ABS equipped vehicles, DO NOT locate the antenna near the ABS control unit (or any control unit).

Disconnect all on-board computers, when using electric welding equipment.

DO NOT expose the ABS control unit to prolonged periods of high heat (185 °F/85°C for 2 hours is generally considered a maximum limit).

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7/24/2019

MITCHELL 1 ARTICLE - GENERAL INFORMATION Clutch Trouble Shooting

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GENERAL INFORMATION Clutch Trouble Shooting

* PLEASE READ THIS FIRST * NOTE:

This is GENERAL information. This article is not intended to be specific to any unique situation or individual vehicle configuration. For modelspecific information see appropriate articles where available.

ALL MODELS NOTE:

This is GENERAL information. This article is not intended to be specific to any unique situation or individual vehicle configuration. For modelspecific information see appropriate articles where available.

CLUTCH TROUBLE SHOOTING Problem & Possible Cause Clutch Chatters/Grabs Incorrect Pedal Adjustment Worn Input Shaft Spline Binding Pressure Plate Binding Throw-Out Lever

Uneven Pressure Plate Contact With Flywheel Transmission Misaligned Worn Pressure Plate Oil-Saturated Disc Loose Engine Mounts Clutch Pedal Sticks Down Clutch Cable Binding Weak Pressure Plate Springs Binding Clutch Linkage Broken Clutch Pedal Return Spring Clutch Will Not Release Oil-Saturated Disc Defective Disc Face Disc Sticking on Input Shaft Splines Binding Pilot Bearing Faulty Clutch Master Cylinder file:///C:/in436340.html

Action Adjust Free Play Replace Input Shaft Replace Pressure Plate Check Throw-Out Lever, Check ThrowOut Bearing, Check Bearing Retainer Align/Replace Worn Parts Align Transmission Replace Clutch Assembly Replace Clutch Assembly, Repair Oil Leak Replace Engine Mounts Replace Clutch Cable Replace Clutch Assembly Lubricate Linkage Replace Return Spring Replace Clutch Assembly, Repair Oil Leak Replace Clutch Assembly Replace Disc/Input Shaft Replace Pilot Bearing Replace Master Cylinder

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Problem & Possible Cause Action MITCHELL 1 ARTICLE - GENERAL INFORMATION Clutch Trouble Shooting Faulty Clutch Slave Cylinder Replace Slave Cylinder Blown Clutch Hose Replace Hose Sticky Throw-Out Bearing Sleeve Clean/Lube Sleeve Clutch Cable Binding Replace Clutch Cable Broken/Loose Bellhousing Check Bellhousing Rattling/Squeaking Broken Throw-Out Lever Return Spring Replace Return Spring Faulty Throw-Out Bearing Replace Throw-Out Bearing Faulty Clutch Disc Replace Clutch Disc Faulty Pilot Bearing Replace Pilot Bearing Worn Throw-Out Bearing Replace Throw-Out Bearing Dry Bearing Retainer Slide For Throw-Out Bearing Sleeve Lubricate Slide Slipping Faulty Pressure Plate Replace Clutch Assembly Worn Clutch Disc Replace Clutch Assembly Incorrect Alignment Realign Clutch Assembly Faulty Clutch Slave Cylinder Replace Slave Cylinder No Pedal Pressure Leaky Hydraulic System Check Clutch Master Cylinder, Check Clutch Slave Cylinder Check Clutch Hose Broken Clutch Cable Replace Clutch Cable Faulty Throw-Out Lever Replace Throw-Out Lever Broken Clutch Linkage Repair Clutch Linkage Noisy Clutch Pedal Faulty Safety Switch Check/Replace Switch Noisy Self-Adj. Ratchet Replace Ratchet Dry Throw-Out Bearing Replace Throw-Out Bearing Dry Pilot Bearing Replace Pilot Bearing Worn Input Shaft Replace Input Shaft

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7/24/2019

MITCHELL 1 ARTICLE - GENERAL INFORMATION Commonly Used Abbreviations

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GENERAL INFORMATION Commonly Used Abbreviations

* PLEASE READ THIS FIRST * NOTE:

This article is intended for general information purposes only. This information may not apply to all makes and models. Not all abbreviations are covered as manufacturers add new ones every day.

"A" A Amperes ABS Anti-Lock Brakes ABRS Air Bag Restraint System AC Alternating Current A/C Air Conditioning ACCS A/C Cycling Switch ACCUM Accumulator ACCY Accessory ACT Air Charge Temperature Sensor ADJ Adjust or Adjustable ADV Advance AFS Airflow Sensor

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AI 7/24/2019

MITCHELL 1 ARTICLE - GENERAL INFORMATION Commonly Used Abbreviations

Air Injection AIR or A.I.R. Air Injection Reactor AIS Air Injection System Alt. Alternator or Altitude Amp./amp/amps Ampere ASCS Air Suction Control Solenoid ASD Auto Shutdown ASDM Air Bag System Diagnostic Module ASV Air Suction Valve A/T Automatic Transmission/Transaxle ATC Automatic Temperature Control ATDC After Top Dead Center ATF Automatic Transmission Fluid ATS Air Temperature Sensor Aux. Auxiliary Avg. Average file:///C:/in702588.html AXOD

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Automatic Transaxle Overdrive (Ford Models Only) 7/24/2019

MITCHELL 1 ARTICLE - GENERAL INFORMATION Commonly Used Abbreviations

"B" BAC By-Pass Air Control BAP Barometric Absolute Pressure Sensor BARO Barometric Batt.

Battery Bbl. Barrel (Example: 4-Bbl.) BCM Body Control Module BHP Brake Horsepower BMAP Barometric and Manifold Absolute Pressure Sensor BOO Brake On-Off Switch B/P Backpressure BPS Barometric Pressure Sensor BPT Backpressure Transducer BTDC Before Top Dead Center BTSI Brake Transmission Shift Interlock BTU British Thermal Unit file:///C:/in702588.html

BVSV

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Bimetallic Vacuum Switching Valve 7/24/2019

MITCHELL 1 ARTICLE - GENERAL INFORMATION Commonly Used Abbreviations

"C" ° C Celsius (Degrees) Calif.

California CANP Canister Purge CARB California Air Resources Board CAT Catalytic Converter CB Circuit Breaker CBD Closed Bowl Distributor cc cubic centimeter CCC Close Coupled Catalyst CCC Computer Command Control CCD Computer Controlled Dwell CCOT Cycling Clutch Orifice Tube CCW Counterclockwise CDI Capacitor Discharge Ignition CEC Computerized Engine Control file:///C:/in702588.html

CID

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Cubic Inch Displacement 7/24/2019

MITCHELL 1 ARTICLE - GENERAL INFORMATION Commonly Used Abbreviations

cm Centimeter CMP Camshaft Position Sensor CO Carbon Monoxide CO2 Carbon Dioxide Cont.

Continued CONV Convertible CP Canister Purge CKP Crankshaft Position Sensor CTS Coolant Temperature Sensor Cu. In. Cubic Inch CVC Constant Vacuum Control CV Check Valve or Constant Velocity CW Clockwise CYL or Cyl. Cylinder C3 I Computer Controlled Coil Ignition C4 file:///C:/in702588.html

Computer Controlled Catalytic Converter

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"D"

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MITCHELL 1 ARTICLE - GENERAL INFORMATION Commonly Used Abbreviations

"D" Drive DC Direct Current Or Discharge DDD Dual Diaphragm Distributor Def. Defrost Defog.

Defogger DERM Diagnostic Energy Reserve Module DFI Digital Fuel Injection Diag.

Diagnostic DTC Diagnostic Trouble Code DIC Driver Information Center DIS Distributorless Ignition System DIST Distribution DLC Data Link Connector DOC Diesel Oxidation Catalyst DOHC Double Overhead Cam DOT file:///C:/in702588.html

Department of Transportation

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DPF 7/24/2019

MITCHELL 1 ARTICLE - GENERAL INFORMATION Commonly Used Abbreviations

Diesel Particulate Filter DRB-II Diagnostic Readout Box DVOM Digital Volt-Ohmmeter

"E" EACV Electric Air Control Valve EATX Electronic Automatic Transaxle EBCM Electronic Brake Control Module EBL Electronic Back Light ECM Engine Control Module ECT Engine Coolant Temperature Sensor EDIS Electronic Distributorless Ignition System EEC Electronic Engine Control EECS Evaporative Emission Control System EEPROM Electronically Erasable PROM EFE Early Fuel Evaporation EGO Exhaust Gas Oxygen Sensor EGR file:///C:/in702588.html

Exhaust Gas Recirculation

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EOT 7/24/2019

MITCHELL 1 ARTICLE - GENERAL INFORMATION Commonly Used Abbreviations

Engine Oil Temperature ESA Electronic Spark Advance ESC Electronic Spark Control EST Electronic Spark Timing EVAP Fuel Evaporative System EVIC Electronic Vehicle Information Center EVP EGR Valve Position Sensor EWMA Exponentially Weighted Moving Average (MODE 6) Exc. Except

"F" ° F Fahrenheit (Degrees) F/B Fuse Block Fed. Federal FI Fuel Injection FICU Fuel Injection Control Unit FIPL Fuel Injector Pump Lever FLI file:///C:/in702588.html

Fuel Level Indicator

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FPR-VSV 7/24/2019

MITCHELL 1 ARTICLE - GENERAL INFORMATION Commonly Used Abbreviations

Fuel Pressure Regulator Vacuum Switching Valve Ft. Lbs. Foot Pounds FWD Front Wheel Drive

"G" g grams Gals. gallons GND or GRND Ground

"H" HAC High Altitude Compensation HC Hydrocarbons H/D Heavy Duty HO2S Heated Exhaust Gas Oxygen Sensor Hg Mercury Hgt. Height HLDT Headlight HO High Output HO2S Heated Oxygen Sensor file:///C:/in702588.html

HP

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High Performance 7/24/2019

MITCHELL 1 ARTICLE - GENERAL INFORMATION Commonly Used Abbreviations

HSC High Swirl Combustion HSO High Specific Output HTR Heater Hz Hertz (Cycles Per Second)

"I" IAC Idle Air Control IACV Idle Air Control Valve IAT Intake Air Temperature IC Integrated Circuit ID Identification I.D. Inside Diameter IFS Independant Front Suspension IFS Inertia Fuel Shutoff (Ford) Ign. Ignition IMRC Intake Manifold Runner Control In. Inches file:///C:/in702588.html

INCH Lbs.

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Inch Pounds 7/24/2019

MITCHELL 1 ARTICLE - GENERAL INFORMATION Commonly Used Abbreviations

in. Hg Inches of Mercury Inj. Injector IP Instrument Panel IRS Independant Rear Suspension ISC Idle Speed Control IVD Interactive Vehicle Dynamics (Ford) IVSV Idle Vacuum Switching Valve

"J" J/B Junction Block

"K" KAPWR Keep Alive Power k/ohms kilo-ohms (1000 ohms) kg Kilograms (weight) kg/cm2 Kilograms Per Square Centimeter KM/H Kilometers Per Hour KOEO Key On, Engine Off KOER file:///C:/in702588.html

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Key On, Engine Running 7/24/2019

MITCHELL 1 ARTICLE - GENERAL INFORMATION Commonly Used Abbreviations

KS Knock Sensor kW Kilowatt kV Kilovolt

"L" L Liter lbs. (Lbs. when used in table) Pounds LCD Liquid Crystal Display L/D Light Duty LDP Leak Detection Pump (Part of EVAP system.)

LED Light Emitting Diode LH Left Hand

"M" mA Milliamps MA or MAF Mass Airflow MAFS Mass Airflow Sensor MAP Manifold Absolute Pressure MAT file:///C:/in702588.html

Manifold Air Temperature

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Mem. 7/24/2019

MITCHELL 1 ARTICLE - GENERAL INFORMATION Commonly Used Abbreviations

Memory MEM-CAL Memory Calibration Chip mfd.

Microfarads MFI Multiport Fuel Injection MICU Multiplex Integrated Control Unit (Acura/Honda) MIL Malfunction Indicator Light MPI Multi-Point (Fuel) Injection mm Millimeters MPH Miles Per Hour mV Millivolts

"N" NA Not Available NAC NOx Adsorber Catalyst NCA No Color Available (Wiring Diagrams) NGS New Generation Star N.m Newton Meter No. file:///C:/in702588.html

Number

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Nos. 7/24/2019

MITCHELL 1 ARTICLE - GENERAL INFORMATION Commonly Used Abbreviations

Numbers NOx Oxides of Nitrogen

"O" O2 Oxygen OBD On-Board Diagnostics OC Oxidation Catalyst OD Overdrive O.D. Outside Diameter OHC Overhead Camshaft OSS Output Speed Sensor O/S Oversize oz.

Ounce ozs.

Ounces

"P" "P" Park P/C Printed Circuit PCM Powertrain Control Module file:///C:/in702588.html

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PCS 7/24/2019

MITCHELL 1 ARTICLE - GENERAL INFORMATION Commonly Used Abbreviations

Purge Control Solenoid PC-SOL Purge Control Solenoid PCV Positive Crankcase Ventilation PFI Port Fuel Injection PGM-FI Programmed Fuel Injection PID Parameter Identification PIP Profile Ignition Pick-up PNP Park Neutral Position Switch P/N Park/Neutral PRNDL Park Reverse Neutral Drive Low PROM Programmable Read-Only Memory psi Pounds Per Square Inch P/S Power Steering PSPS Power Steering Pressure Switch PTC Positive Temperature Coefficient PTO Power Take-Off file:///C:/in702588.html Pts.

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Pints 7/24/2019

MITCHELL 1 ARTICLE - GENERAL INFORMATION Commonly Used Abbreviations

Pwr. Power

"Q" Qts. Quarts

"R" RABS Rear Anti-Lock Brake System RECIRC Recirculation RH Right Hand RPM Revolutions Per Minute RWAL Rear Wheel Anti-Lock Brake RWD Rear Wheel Drive

"S" SAS Steering Angle Sensor SBC Single Bed Converter SBEC Single Board Engine Controller SDARS Satellite Digital Audio Radio Service SES Service Engine Soon SFI Sequential (Port) Fuel Injection

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SIL 7/24/2019

MITCHELL 1 ARTICLE - GENERAL INFORMATION Commonly Used Abbreviations

Shift Indicator Light SIR Supplemental Inflatable Restraint SOHC Single Overhead Cam SOL or Sol. Solenoid SPFI Sequential Port Fuel Injection SPK Spark Control SPOUT Spark Output SRI Service Reminder Indicator SRS Supplemental Restraint System (Air Bag) STAR Self-Test Automatic Readout STO Self-Test Output SUB-O2 Sub Oxygen Sensor Sw. Switch Sys. System

"T" TAB Thermactor Air By-Pass TAC file:///C:/in702588.html

Throttle Actuator Module

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TAD 7/24/2019

MITCHELL 1 ARTICLE - GENERAL INFORMATION Commonly Used Abbreviations

Thermactor Air Diverter TBC Body Control Module (General Motors) TBI Throttle Body Injection TCC Torque Converter Clutch TDC Top Dead Center Temp.

Temperature TFI Thick Film Ignition THERMAC Thermostatic Air Cleaner TPM Tire Pressure Monitor TPMS Tire Pressure Monitor System TPS Throttle Position Sensor/Switch TS Temperature Sensor TV Thermovalve TWC Three-Way Catalyst

"V" V Valve Vac. file:///C:/in702588.html

Vacuum

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VAF 7/24/2019

MITCHELL 1 ARTICLE - GENERAL INFORMATION Commonly Used Abbreviations

Vane Airflow VAPS Variable Assist Power Steering VCC Viscous Converter Clutch VCRM Variable Control Relay Module VIN Vehicle Identification Number VM Vacuum Modulator Volt.

Voltage VOM Volt-Ohmmeter (Analog) VRV Vacuum Regulator Valve VSS Vehicle Speed Sensor VSV Vacuum Switching Valve

"W" W/ With W/O Without WAC Wide Open Throttle A/C Switch WOT Wide Open Throttle

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MITCHELL 1 ARTICLE - GENERAL INFORMATION Commonly Used Abbreviations

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7/24/2019

MITCHELL 1 ARTICLE - GENERAL INFORMATION Drive Axle Noise Diagnosis

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GENERAL INFORMATION Drive Axle Noise Diagnosis

* PLEASE READ THIS FIRST * NOTE:

This is GENERAL information. This article is not intended to be specific to any unique situation or individual vehicle configuration. For modelspecific information see appropriate articles where available.

UNRELATED NOISES NOTE:

This is GENERAL information. This article is not intended to be specific to any unique situation or individual vehicle configuration. For modelspecific information see appropriate articles where available.

Some driveline trouble symptoms are also common to the engine, transmission, wheel bearings, tires and other parts of the vehicle. Make sure that cause of trouble actually is in the drive axle before adjusting, repairing, or replacing any parts.

NON-DRIVE AXLE NOISES NOTE:

This is GENERAL information. This article is not intended to be specific to any unique situation or individual vehicle configuration. For modelspecific information see appropriate articles where available.

A few conditions can sound just like drive axle noise and have to be considered in pre-diagnosis. The 4 most common noises are exhaust, tires, CV/universal joints and trim moldings.

In certain conditions, the pitch of exhaust gases may sound like gear whine. At other times, it may be mistaken for a wheel bearing rumble.

Tires, especially radial and snow tires, can have a high-pitched tread whine or roar, similar to gear noise.

Also, some non-standard tires with an unusual tread construction may emit a roar or whine.

Defective CV/universal joints may cause clicking noises or excessive driveline play that can be improperly diagnosed as drive axle problems.

Trim and moldings can also cause a whistling or whining noise. Ensure that none of these components are causing the noise before disassembling the drive axle.

GEAR NOISE NOTE:

This is GENERAL information. This article is not intended to be specific to any unique situation or individual vehicle configuration. For modelspecific information see appropriate articles where available.

A "howling" or "whining" noise from the ring and pinion gear can be caused by an improper gear pattern, gear damage, or improper bearing preload. It can occur at various speeds and driving conditions, or it can be continuous.

Before disassembling axle to diagnose and correct gear noise, make sure that tires, exhaust, and vehicle trim have been checked as possible causes.

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This is GENERAL information. This article is not intended to be specific

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to any unique situation or individual vehicle configuration. For modelMITCHELL 1 ARTICLE - GENERAL INFORMATION Axle Noise Diagnosis specific information see appropriate articlesDrive where available.

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This is a particular rattling noise that sounds like a stick against the spokes of a spinning bicycle wheel.

It occurs while decelerating from 40 MPH and usually can be heard until vehicle comes to a complete stop. The frequency varies with the speed of the vehicle.

A chuckle that occurs on the driving phase is usually caused by excessive clearance due to differential gear wear, or by a damaged tooth on the coast side of the pinion or ring gear. Even a very small tooth nick or a ridge on the edge of a gear tooth is enough to cause the noise.

This condition can be corrected simply by cleaning the gear tooth nick or ridge with a small grinding wheel. If either gear is damaged or scored badly, the gear set must be replaced. If metal has broken loose, the carrier and housing must be cleaned to remove particles that could cause damage.

KNOCK NOTE:

This is GENERAL information. This article is not intended to be specific to any unique situation or individual vehicle configuration. For modelspecific information see appropriate articles where available.

This is very similar to a chuckle, though it may be louder, and occur on acceleration of deceleration.

Knock can be caused by a gear tooth that is damaged on the drive side of the ring and pinion gears. Ring gear bolts that are hitting the carrier casting can cause knock. Knock can also be due to excessive end play in the axle shafts.

CLUNK NOTE:

This is GENERAL information. This article is not intended to be specific to any unique situation or individual vehicle configuration. For modelspecific information see appropriate articles where available.

Clunk is a metallic noise heard when an automatic transmission is engaged in Reverse or Drive, or when throttle is applied or released. It is caused by backlash somewhere in the driveline, but not necessarily in the axle. To determine whether driveline clunk is caused by the axle, check the total axle backlash as follows: 1. Raise vehicle on a frame or twinpost hoist so that drive wheels are free. Clamp a bar between axle companion flange and a part of the frame or body so that flange cannot move.

2. On conventional drive axles, lock the left wheel to keep it from turning. On all models, turn the right wheel slowly until it is felt to be in drive condition. Hold a chalk marker on side of tire about 12" from center of wheel. Turn wheel in the opposite direction until it is again felt to be in drive condition.

3. Measure the length of the chalk mark, which is the total axle backlash. If backlash is one inch or less, clunk will not be eliminated by overhauling drive axle.

BEARING WHINE NOTE:

This is GENERAL information. This article is not intended to be specific to any unique situation or individual vehicle configuration. For modelspecific information see appropriate articles where available.

Bearing whine is a high-pitched sound similar to a whistle. It is usually caused by malfunctioning pinion bearings. Pinion bearings operate at driveshaft speed. Roller wheel bearings may whine in a similar manner if they run completely dry of lubricant. Bearing noise will occur at all driving speeds. This distinguishes it from gear whine, which usually comes and goes as speed changes.

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to any unique situation or individual vehicle configuration. For modelMITCHELL 1 ARTICLE - GENERAL INFORMATION Axle Noise Diagnosis specific information see appropriate articlesDrive where available.

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Bearing rumble sounds like marbles being tumbled. It is usually caused by a malfunctioning wheel bearing. The lower pitch is because the wheel bearing turns at only about 1/3 of driveshaft speed.

CHATTER ON TURNS NOTE:

This is GENERAL information. This article is not intended to be specific to any unique situation or individual vehicle configuration. For modelspecific information see appropriate articles where available.

This is a condition where the whole front or rear vibrates when vehicle is moving. The vibration is easily felt and heard. Extra differential thrust washers installed during axle repair can cause a condition of partial lock-up that creates the chatter.

AXLE SHAFT NOISE NOTE:

This is GENERAL information. This article is not intended to be specific to any unique situation or individual vehicle configuration. For modelspecific information see appropriate articles where available.

Axle shaft noise is similar to gear noise and pinion bearing whine. Axle shaft bearing noise will normally distinguish itself from gear noise by occurring in all driving modes. Noise will persist with transmission in neutral while vehicle is moving at problem speed.

If vehicle displays this noise condition, remove suspect axle shafts and replace axle bearings. Reevaluate vehicle for noise before removing any internal components.

VIBRATION NOTE:

This is GENERAL information. This article is not intended to be specific to any unique situation or individual vehicle configuration. For modelspecific information see appropriate articles where available.

Vibration is a high-frequency trembling, shaking or grinding condition (felt or heard) that may be constant or variable in level and con occur during the total operating speed range of the vehicle.

The types of vibrations that can be felt in the vehicle can be divided into 3 main groups: Vibrations of various unbalanced rotating parts of the vehicle.

Resonance vibrations of the body and frame structures caused by rotating of unbalance parts.

Tip-in moans of resonance vibrations from stressed engine or exhaust system mounts or driveline flexing modes.

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7/24/2019

MITCHELL 1 ARTICLE - GENERAL INFORMATION Electrostatic Discharge (ESD) Warning - Basic Information

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GENERAL INFORMATION Electrostatic Discharge (ESD) Warning - Basic Information

* PLEASE READ THIS FIRST * NOTE:

This article is intended for general information purposes only. Contents are generic in nature and all information may or may not apply to all vehicles.

INTRODUCTION NOTE:

This article is intended for general information purposes only. Contents are generic in nature and all information may or may not apply to all vehicles.

All Electrostatic Discharge (ESD) sensitive components contain solid state circuits (transistors, diodes, semiconductors) that may become damaged when contacted with an electrostatic charge. The following information applies to all ESD sensitive devices. The ESD symbol shown in Fig. Fig. 1 may be used on schematics to indicate which components are ESD sensitive. See Fig. 1. Although different manufactures may display different symbols to represent ESD sensitive devices, the handling and measuring precautions and procedures are the same.

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MITCHELL 1 ARTICLE - GENERAL INFORMATION Electrostatic Discharge (ESD) Warning - Basic Information

Fig. 1: Sample ESD Symbol

HANDLING STATIC-SENSITIVE CIRCUITS/DEVICES NOTE:

This article is intended for general information purposes only. Contents are generic in nature and all information may or may not apply to all vehicles.

When handling an electronic part that is ESD sensitive, the technician should follow these guidelines to reduce any possible electrostatic charge build-up on the technician's body and the electronic part.

1. Always touch a known good ground source before handling the part. This should be repeated while handling the part and more frequently after sitting down from a standing position, sliding across the seat or walking a distance.

2. Avoid touching electrical terminals of the part, unless instructed by a diagnostic procedure.

3. DO NOT open the package of a new part until it is time to install the part.

4. Before removing the part from its package, ground the package to a known good ground source.

CHECKING STATIC-SENSITIVE CIRCUITS/DEVICES NOTE:

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This article is intended for general information purposes only. Contents are generic in nature and all information may or may not apply to all vehicles.

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1. Solid State circuits in electronic devices are shown greatly simplified in schematics. See Fig. 2.

MITCHELL 1 ARTICLE - GENERAL INFORMATION Electrostatic Discharge resistance (ESD) Warningmeasurements - Basic Information Due to the simplification of the electronic devices on the schematic, could be misleading or could lead to an electrostatic discharge. Always follow the recommended diagnostic procedure.

Fig. 2: Sample Schematic Showing Typical ESD Sensitive Device 2. Only measure resistance at the terminals of the devices when instructed by the recommended diagnostic procedure.

3. When using a voltmeter, be sure to connect the ground lead first.

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7/24/2019

MITCHELL 1 ARTICLE - GENERAL INFORMATION Engine Displacement Conversion Table

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GENERAL INFORMATION Engine Displacement Conversion Table

CONVERSION TABLE LITER/CID CONVERSION Liter 1.0 1.0 1.0 1.1 1.1 1.1 1.2 1.2 1.2 1.2 1.3 1.3 1.3 1.3 1.3 1.3 1.4 1.4 1.4 1.5 1.5 1.5 1.6 1.6 1.6 1.6 1.6 1.6 1.7 1.7 1.7 1.8 1.8 1.8 1.8 1.8 1.9 1.9 1.9 1.9 2.0 2.0 file:///C:/in371330.html 2.0

CID 59 60 61 66 68 70 71 72 73 76 77 78 79 80 81 82 85 85 86 89 90 91 94 95 96 97 98 99 102 103 105 107 109 110 111 112 113 114 116 119 119 120 121

1/5

Liter 2.0 2.1 2.1 2.1 2.1 2.1 2.1 2.2 2.2 2.2 2.2 2.2 2.2 2.3 2.3 2.3 2.3 2.4 2.4 2.4 2.4 2.4 2.4 2.5 2.5 2.5 2.5 2.6 2.6 2.6 2.6 2.6 2.7 2.7 2.7 2.7 2.8 2.8 2.8 2.8 2.9 2.9 3.0 3.0 3.0 3.0 3.0 3.1 3.1 3.2 3.2 file:///C:/in371330.html 3.2 7/24/2019

MITCHELL 1 ARTICLE - GENERAL INFORMATION Engine Displacement Conversion Table

CID 122 125 126 128 129 130 131 132 133 134 135 136 137 138 140 141 143 143 144 145 146 147 149 150 151 152 153 155 156 157 158 159 162 163 164 167 168 170 171 173 174 179 180 181 182 183 184 191 192 193 194 195

2/5

Liter 3.2 3.2 3.2 3.3 3.3 3.3 3.3 3.4 3.4 3.4 3.5 3.5 3.5 3.5 3.5 3.5 3.6 3.6 3.7 3.7 3.7 3.8 3.8 3.8 3.8 3.8 3.8 3.9 3.9 3.9 4.0 4.0 4.0 4.0 4.1 4.1 4.2 4.2 4.3 4.3 4.3 4.3 4.3 4.4 4.4 4.4 4.5 4.5 4.5 4.6 4.6 file:///C:/in371330.html 4.6 7/24/2019

MITCHELL 1 ARTICLE - GENERAL INFORMATION Engine Displacement Conversion Table

CID 196 197 198 199 200 201 204 206 207 209 210 211 212 213 214 215 219 220 225 226 229 229 230 231 232 234 238 239 240 241 241 242 243 244 250 252 255 258 259 260 262 263 266 266 267 268 273 274 276 278 279 281

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Liter 4.6 4.7 4.7 4.7 4.7 4.8 4.8 4.9 4.9 4.9 5.0 5.0 5.0 5.0 5.1 5.2 5.2 5.3 5.4 5.4 5.4 5.5 5.5 5.6 5.6 5.7 5.7 5.7 5.8 5.8 5.9 5.9 5.9 5.9 6.0 6.0 6.1 6.1 6.2 6.2 6.3 6.4 6.4 6.4 6.5 6.6 6.6 6.6 6.6 6.7 6.8 file:///C:/in371330.html 6.8 7/24/2019

MITCHELL 1 ARTICLE - GENERAL INFORMATION Engine Displacement Conversion Table

CID 283 284 285 287 289 290 292 300 301 302 302 304 305 307 310 315 318 326 327 328 330 334 335 340 343 345 348 350 351 352 359 360 361 362 366 368 370 372 379 381 383 389 390 392 396 400 401 402 403 410 412 413

4/5

Liter 6.8 6.8 6.9 6.9 7.0 7.0 7.0 7.0 7.0 7.0 7.1 7.2 7.4 7.5 7.5 7.6 8.0 8.2 8.8 8.8 8.8 8.9 9.0 9.1 9.3 9.3 9.6 9.8 9.9 10.0

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MITCHELL 1 ARTICLE - GENERAL INFORMATION Engine Displacement Conversion Table

CID 414 415 420 421 425 426 427 428 429 430 432 440 454 455 460 462 488 500 534 537 538 540 549 555 568 570 588 600 605 611

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MITCHELL 1 ARTICLE - GENERAL INFORMATION Engine Overhaul Procedures

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GENERAL INFORMATION Engine Overhaul Procedures

* PLEASE READ THIS FIRST * NOTE:

Examples used in this article are general in nature and do not necessarily relate to a specific engine or system. Illustrations and procedures have been chosen to guide mechanic through engine overhaul process.

Descriptions of processes of cleaning, inspection, assembly and machine shop practice are included.

Always refer to appropriate engine overhaul article, if available, in the ENGINES section for complete overhaul procedures and specifications for the vehicle being repaired.

DESCRIPTION Examples used in this article are general in nature and do not necessarily relate to a specific engine or system. Illustrations and procedures have been chosen to guide mechanic through engine overhaul process. Descriptions of cleaning, inspection, and assembly processes are included.

ENGINE IDENTIFICATION Engine may be identified from Vehicle Identification Number (VIN) stamped on a metal tab. Metal tab may be located in different locations depending on manufacturer. Engine identification number or serial number is located on cylinder block. Location varies with each manufacturer.

INSPECTION PROCEDURES * PLEASE READ THIS FIRST * NOTE:

Examples used in this article are general in nature and do not necessarily relate to a specific engine or system. Illustrations and procedures have been chosen to guide mechanic through engine overhaul process.

Descriptions of processes of cleaning, inspection, assembly and machine shop practice are included.

Always refer to appropriate engine overhaul article, if available, in the ENGINES section for complete overhaul procedures and specifications for the vehicle being repaired.

GENERAL NOTE:

Examples used in this article are general in nature and do not necessarily relate to a specific engine or system. Illustrations and procedures have been chosen to guide mechanic through engine overhaul process.

Descriptions of processes of cleaning, inspection, assembly and machine shop practice are included.

Always refer to appropriate engine overhaul article, if available, in the ENGINES section for complete overhaul procedures and specifications for the vehicle being repaired.

Engine components must be inspected to meet manufacturer's specifications and tolerances during overhaul. Proper dimensions and tolerances must be met to obtain proper performance and maximum file:///C:/in323436.html engine life.

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Micrometers, depth gauges and dial indicator are used for checking tolerances during engine overhaul.

MITCHELL 1 ARTICLEand - GENERAL INFORMATION Engine Overhaul Magnaglo, dye-check, ultrasonic x-ray inspection procedures areProcedures used for parts inspection.

7/24/2019 Magnaflux,

MAGNETIC PARTICLE INSPECTION NOTE:

Examples used in this article are general in nature and do not necessarily relate to a specific engine or system. Illustrations and procedures have been chosen to guide mechanic through engine overhaul process.

Descriptions of processes of cleaning, inspection, assembly and machine shop practice are included.

Always refer to appropriate engine overhaul article, if available, in the ENGINES section for complete overhaul procedures and specifications for the vehicle being repaired.

Magnaflux & Magnaglo

Magnaflux is an inspection technique used to locate material flaws and stress cracks. Component is subjected to a strong magnetic field. Entire component or a localized area can be magnetized.

Component is coated with either a wet or dry material that contains fine magnetic particles.

Cracks which are outlined by the particles cause an interruption of magnetic field. Dry powder method of Magnaflux can be used in normal lighting and crack appears as a bright line.

Fluorescent liquid is used along with a Black light in the Magnaglo Magnaflux system. Darkened room is required for this procedure. The crack will appear as a glowing line. Complete demagnetizing of component upon completion is required on both procedures. Magnetic particle inspection applies to ferrous materials only.

PENETRANT INSPECTION NOTE:

Examples used in this article are general in nature and do not necessarily relate to a specific engine or system. Illustrations and procedures have been chosen to guide mechanic through engine overhaul process.

Descriptions of processes of cleaning, inspection, assembly and machine shop practice are included.

Always refer to appropriate engine overhaul article, if available, in the ENGINES section for complete overhaul procedures and specifications for the vehicle being repaired.

Zyglo

The Zyglo process coats material with a fluorescent dye penetrant. Component is often warmed to expand cracks that will be penetrated by the dye. Using darkened room and Black light, component is inspected for cracks. Crack will glow brightly.

Developing solution is often used to enhance results. Parts made of any material, such as aluminum cylinder heads or plastics, may be tested using this process.

Dye Check

Penetrating dye is sprayed on the previously cleaned component. Dye is left on component for 5-45 minutes, depending upon material density. Component is then wiped clean and sprayed with a developing solution. Surface cracks will show up as a bright line.

ULTRASONIC INSPECTION NOTE: file:///C:/in323436.html

Examples used in this article are general in nature and do not necessarily relate to a specific engine or system. Illustrations and procedures have been chosen to guide mechanic through engine overhaul process.

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Descriptions of processes of cleaning, inspection, assembly and machine MITCHELL ARTICLE - GENERAL INFORMATION Engine Overhaul Procedures shop practice are 1included.

Always refer to appropriate engine overhaul article, if available, in the ENGINES section for complete overhaul procedures and specifications for the vehicle being repaired.

If an expensive part is suspected of internal cracking, ultrasonic testing is used. Sound waves are used for component inspection.

X-RAY INSPECTION NOTE:

Examples used in this article are general in nature and do not necessarily relate to a specific engine or system. Illustrations and procedures have been chosen to guide mechanic through engine overhaul process.

Descriptions of processes of cleaning, inspection, assembly and machine shop practice are included.

Always refer to appropriate engine overhaul article, if available, in the ENGINES section for complete overhaul procedures and specifications for the vehicle being repaired.

This form of inspection is used on highly stressed components. X-ray inspection may be used to detect internal and external flaws in any material.

PRESSURE TESTING NOTE:

Examples used in this article are general in nature and do not necessarily relate to a specific engine or system. Illustrations and procedures have been chosen to guide mechanic through engine overhaul process.

Descriptions of processes of cleaning, inspection, assembly and machine shop practice are included.

Always refer to appropriate engine overhaul article, if available, in the ENGINES section for complete overhaul procedures and specifications for the vehicle being repaired.

Cylinder heads can be tested for cracks using a pressure tester. Pressure testing is performed by plugging all but one of the holes of cylinder head and injecting air or water into the open passage.

Leaks are indicated by the appearance of wet or damp areas when using water. When air is used, it is necessary to spray the head surface with a soap solution. Bubbles will indicate a leak. Cylinder head may also be submerged in water heated to specified temperature to check for cracks created during heat expansion.

CLEANING PROCEDURES * PLEASE READ THIS FIRST * NOTE:

Examples used in this article are general in nature and do not necessarily relate to a specific engine or system. Illustrations and procedures have been chosen to guide mechanic through engine overhaul process.

Descriptions of processes of cleaning, inspection, assembly and machine shop practice are included.

Always refer to appropriate engine overhaul article, if available, in the ENGINES section for complete overhaul procedures and specifications for the vehicle being repaired.

GENERAL file:///C:/in323436.html

NOTE:

Examples used in this article are general in nature and do not necessarily

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relate to a specific engine or system. Illustrations and procedures have MITCHELL 1 ARTICLE - GENERALthrough INFORMATION Engine Overhaul Procedures been chosen to guide mechanic engine overhaul process.

Descriptions of processes of cleaning, inspection, assembly and machine shop practice are included.

Always refer to appropriate engine overhaul article, if available, in the ENGINES section for complete overhaul procedures and specifications for the vehicle being repaired.

All components of an engine do not have the same cleaning requirements. Physical methods include bead blasting and manual removal. Chemical methods include solvent blast, solvent tank, hot tank, cold tank and steam cleaning of components.

BEAD BLASTING NOTE:

Examples used in this article are general in nature and do not necessarily relate to a specific engine or system. Illustrations and procedures have been chosen to guide mechanic through engine overhaul process.

Descriptions of processes of cleaning, inspection, assembly and machine shop practice are included.

Always refer to appropriate engine overhaul article, if available, in the ENGINES section for complete overhaul procedures and specifications for the vehicle being repaired.

Manual removal of deposits may be required prior to bead blasting, followed by some other cleaning method. Carbon, paint and rust may be removed using bead blasting method. Components must be free of oil and grease prior to bead blasting. Beads will stick to grease or oil soaked areas causing area not to be cleaned.

Use air pressure to remove all trapped residual beads from component after cleaning. After cleaning internal engine parts made of aluminum, wash thoroughly with hot soapy water. Component must be thoroughly cleaned as glass beads will enter engine oil resulting in bearing damage.

CHEMICAL CLEANING NOTE:

Examples used in this article are general in nature and do not necessarily relate to a specific engine or system. Illustrations and procedures have been chosen to guide mechanic through engine overhaul process.

Descriptions of processes of cleaning, inspection, assembly and machine shop practice are included.

Always refer to appropriate engine overhaul article, if available, in the ENGINES section for complete overhaul procedures and specifications for the vehicle being repaired.

Solvent tank is used for cleaning oily residue from components. Solvent blasting sprays solvent through a siphon gun using compressed air.

The hot tank, using heated caustic solvents, is used for cleaning ferrous materials only. DO NOT clean aluminum parts such as cylinder heads, bearings or other soft metals using the hot tank. After cleaning, flush parts with hot water.

A non-ferrous part will be ruined and caustic solution will be diluted if placed in the hot tank. Always use eye protection and gloves when using the hot tank.

Use of a cold tank is for cleaning aluminum cylinder heads, carburetors and other soft metals. A less caustic and unheated solution is used. Parts may be left in the tank for several hours without damage.

After cleaning, flush parts with hot water.

Steam cleaning, with boiling hot water sprayed at high pressure, is recommended as the final cleaning process when using either hot or cold tank cleaning. file:///C:/in323436.html

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COMPONENT CLEANING

7/24/2019

MITCHELL 1 ARTICLE - GENERAL INFORMATION Engine Overhaul Procedures

* PLEASE READ THIS FIRST * NOTE:

Examples used in this article are general in nature and do not necessarily relate to a specific engine or system. Illustrations and procedures have been chosen to guide mechanic through engine overhaul process.

Descriptions of processes of cleaning, inspection, assembly and machine shop practice are included.

Always refer to appropriate engine overhaul article, if available, in the ENGINES section for complete overhaul procedures and specifications for the vehicle being repaired.

SHEET METAL PARTS NOTE:

Examples used in this article are general in nature and do not necessarily relate to a specific engine or system. Illustrations and procedures have been chosen to guide mechanic through engine overhaul process.

Descriptions of processes of cleaning, inspection, assembly and machine shop practice are included.

Always refer to appropriate engine overhaul article, if available, in the ENGINES section for complete overhaul procedures and specifications for the vehicle being repaired.

Examples of sheet metal parts are rocker covers, front and side covers, oil pan and bellhousing dust cover. Glass bead blasting or hot tank may be used for cleaning.

Ensure all mating surfaces are flat. Deformed surfaces should be straightened. Check all sheet metal parts for cracks and dents.

INTAKE & EXHAUST MANIFOLDS NOTE:

Examples used in this article are general in nature and do not necessarily relate to a specific engine or system. Illustrations and procedures have been chosen to guide mechanic through engine overhaul process.

Descriptions of processes of cleaning, inspection, assembly and machine shop practice are included.

Always refer to appropriate engine overhaul article, if available, in the ENGINES section for complete overhaul procedures and specifications for the vehicle being repaired.

Using solvent cleaning or bead blasting, clean manifolds for inspection. If intake manifold has an exhaust crossover, all carbon deposits must be removed. Inspect manifolds for cracks, burned or eroded areas, corrosion and damage to fasteners.

Exhaust heat and products of combustion cause threads of fasteners to corrode. Replace studs and bolts as necessary. On "V" type intake manifolds, sheet metal oil shield must be removed for proper cleaning and inspection. Ensure all manifold parting surfaces are flat and free of burrs.

CYLINDER HEAD REPLACEMENT * PLEASE READ THIS FIRST * NOTE:

file:///C:/in323436.html

Examples used in this article are general in nature and do not necessarily relate to a specific engine or system. Illustrations and procedures have been chosen to guide mechanic through engine overhaul process.

Descriptions of processes of cleaning, inspection, assembly and machine shop practice are included.

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Always refer to appropriate engine overhaul article, if available, in the MITCHELL 1for ARTICLE - GENERAL INFORMATION Engine Overhaul Procedures ENGINES section complete overhaul procedures and specifications for the vehicle being repaired.

REMOVAL NOTE:

Examples used in this article are general in nature and do not necessarily relate to a specific engine or system. Illustrations and procedures have been chosen to guide mechanic through engine overhaul process.

Descriptions of processes of cleaning, inspection, assembly and machine shop practice are included.

Always refer to appropriate engine overhaul article, if available, in the ENGINES section for complete overhaul procedures and specifications for the vehicle being repaired.

Remove intake and exhaust manifolds and valve cover. Cylinder head and camshaft carrier bolts (if equipped) should be removed only when engine is cold. On many aluminum cylinder heads, removal while hot will cause cylinder head warpage. Mark rocker arm or overhead cam components for location.

Remove rocker arm components or overhead cam components. Components must be installed in original location. Individual design rocker arms may utilize shafts, ball-type pedestal mounts or no rocker arms.

For all design types, wire components together and identify according to corresponding valve. Remove cylinder head bolts. Note length and location. Some applications require cylinder head bolts be removed in proper sequence to prevent cylinder head damage. See Fig. 1. Remove cylinder head.

INSTALLATION NOTE:

Examples used in this article are general in nature and do not necessarily relate to a specific engine or system. Illustrations and procedures have been chosen to guide mechanic through engine overhaul process.

Descriptions of processes of cleaning, inspection, assembly and machine shop practice are included.

Always refer to appropriate engine overhaul article, if available, in the ENGINES section for complete overhaul procedures and specifications for the vehicle being repaired.

Ensure all surfaces and head bolts are clean. Check that head bolt holes of cylinder block are clean and dry to prevent block damage when bolts are tightened. Clean threads with tap to ensure accurate bolt torque.

Install head gasket on cylinder block. Some manufacturers may recommend sealant be applied to head gasket prior to installation. Note that all holes are aligned. Some gasket applications may be marked so that certain area faces upward. Install cylinder head using care not to damage head gasket. Ensure cylinder head is fully seated on cylinder block.

Some applications require head bolts be coated with sealant prior to installation. This is done if head bolts are exposed to coolant passages. Some applications require head bolts be coated with light coat of engine oil.

Install head bolts. Head bolts should be tightened in proper steps and sequence to specification. See Fig. 1. Install remaining components. Tighten all bolts to specification. Adjust valves if required. See VALVE ADJUSTMENT. NOTE:

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Some manufacturers require that head bolts be retightened after specified amount of operation. This must be done to prevent head gasket failure.

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MITCHELL 1 ARTICLE - GENERAL INFORMATION Engine Overhaul Procedures

Fig. 1: Typical Cylinder Head Tightening or Loosening Sequence VALVE ADJUSTMENT NOTE:

Examples used in this article are general in nature and do not necessarily relate to a specific engine or system. Illustrations and procedures have been chosen to guide mechanic through engine overhaul process.

Descriptions of processes of cleaning, inspection, assembly and machine shop practice are included.

Always refer to appropriate engine overhaul article, if available, in the ENGINES section for complete overhaul procedures and specifications for the vehicle being repaired.

Engine specifications will indicate valve train clearance and temperature at which adjustment is to be made on most models. In most cases, adjustment will be made with a cold engine. In some cases, both a cold and a hot clearance will be given for maintenance convenience.

On some models, adjustment is not required. Rocker arms are tightened to specification and valve lash is automatically set. On some models with push rod actuated valve train, adjustment is made at push rod end of rocker arm while other models do not require adjustment.

Clearance will be checked between tip of rocker arm and tip of valve stem in proper sequence using a feeler gauge. Adjustment is made by rotating adjusting screw until proper clearance is obtained. Lock nut is then tightened. Engine will be rotated to obtain all valve adjustments to manufacturer's specifications.

Some models require hydraulic lifter to be bled down and clearance measured. Push rods of different length can be used to obtain proper clearance. Clearance will be checked between tip of rocker arm and tip of valve stem in proper sequence using a feeler gauge.

Overhead cam engines designed without rocker arms actuate valves directly on a cam follower. A hardened, removable disc is installed between the cam lobe and lifter. Clearance will be checked between cam heel and adjusting disc in proper sequence using a feeler gauge. Engine will be rotated to obtain all valve adjustments.

On overhead cam engines designed with rocker arms, adjustment is made at valve end of rocker arm.

Ensure valve to be adjusted is riding on heel of cam on all engines. Clearance will be checked between tip of rocker arm and tip of valve stem in proper sequence using a feeler gauge. Adjustment is made by rotating adjusting screw until proper clearance is obtained. Lock nut is then tightened. Engine will be rotated to obtain all valve adjustments to manufacturer's specifications.

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CYLINDER HEAD OVERHAUL

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MITCHELL 1 ARTICLE - GENERAL INFORMATION Engine Overhaul Procedures

* PLEASE READ THIS FIRST * NOTE:

Examples used in this article are general in nature and do not necessarily relate to a specific engine or system. Illustrations and procedures have been chosen to guide mechanic through engine overhaul process.

Descriptions of processes of cleaning, inspection, assembly and machine shop practice are included.

Always refer to appropriate engine overhaul article, if available, in the ENGINES section for complete overhaul procedures and specifications for the vehicle being repaired.

CYLINDER HEAD DISASSEMBLY NOTE:

Examples used in this article are general in nature and do not necessarily relate to a specific engine or system. Illustrations and procedures have been chosen to guide mechanic through engine overhaul process.

Descriptions of processes of cleaning, inspection, assembly and machine shop practice are included.

Always refer to appropriate engine overhaul article, if available, in the ENGINES section for complete overhaul procedures and specifications for the vehicle being repaired.

Mark valves for location. Using valve spring compressor, compress valve springs. Remove valve locks.

Carefully release spring compressor. Remove retainer or rotator, valve spring, spring seat and valve. See Fig. 2.

Fig. 2: Exploded View of Valve Assemblies CYLINDER HEAD CLEANING & INSPECTION NOTE: file:///C:/in323436.html

Examples used in this article are general in nature and do not necessarily relate to a specific engine or system. Illustrations and procedures have

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been chosen to guide mechanic through engine overhaul process.

MITCHELL 1 ARTICLE - GENERAL INFORMATION Engine Overhaul Proceduresand machine Descriptions of processes of cleaning, inspection, assembly shop practice are included.

Always refer to appropriate engine overhaul article, if available, in the ENGINES section for complete overhaul procedures and specifications for the vehicle being repaired.

Clean cylinder head and valve components using approved cleaning methods. Inspect cylinder head for cracks, damage or warped gasket surface. Place straightedge across gasket surface. Determine clearance at center of straightedge. Measure across both diagonals, longitudinal center line and across cylinder head at several points. See Fig. 3.

On cast iron cylinder heads, if warpage exceeds .003" (.08 mm) in a 6" span, or .006" (.15 mm) over total length, cylinder head must be resurfaced. On most aluminum cylinder heads, if warpage exceeds .002" (.05 mm) in any area, cylinder head must be resurfaced. Warpage specification may vary by manufacturer. If warpage exceeds specification on some cylinder heads, cylinder head must be replaced.

Cylinder head thickness should be measured to determine amount of material which can be removed before replacement is required. Cylinder head thickness must not be less than the manufacturer's specification.

If cylinder head required resurfacing, it may not align properly with intake manifold. On "V" type engines, misalignment is corrected by machining intake manifold surface that contacts cylinder head.

Cylinder head may be machined on surface that contacts intake manifold. Using oil stone, remove burrs or scratches from all sealing surfaces.

Fig. 3: Checking Cylinder Head for Warpage VALVE SPRINGS NOTE:

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Examples used in this article are general in nature and do not necessarily relate to a specific engine or system. Illustrations and procedures have been chosen to guide mechanic through engine overhaul process.

Descriptions of processes of cleaning, inspection, assembly and machine shop practice are included.

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Always refer to appropriate engine overhaul article, if available, in the MITCHELL 1for ARTICLE - GENERAL INFORMATION Engine Overhaul Procedures ENGINES section complete overhaul procedures and specifications for the vehicle being repaired.

Inspect valve springs for corroded or pitted valve spring surfaces which may lead to breakage. Polished spring ends caused by a rotating spring indicate that spring surge has occurred. Replace springs showing evidence of these conditions.

Inspect valve springs for squareness using a 90-degree straightedge. See Fig. 4. Replace valve spring if out-of-square exceeds manufacturer's specification.

Fig. 4: Checking Valve Spring Squareness Using vernier caliper, measure free length of all valve springs. Replace springs if not within specification. Using valve spring tester, test valve spring pressure at installed and compressed heights.

See Fig. 5.

Usually compressed height is installed height minus valve lift. Replace valve spring if not within specification. It is recommended to replace all valve springs when overhauling cylinder head. Valve springs may need to be installed with color coded end or small coils at specified area according to manufacturer.

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MITCHELL 1 ARTICLE - GENERAL INFORMATION Engine Overhaul Procedures

Fig. 5: Checking Valve Spring Pressure VALVE GUIDE NOTE:

Examples used in this article are general in nature and do not necessarily relate to a specific engine or system. Illustrations and procedures have been chosen to guide mechanic through engine overhaul process.

Descriptions of processes of cleaning, inspection, assembly and machine shop practice are included.

Always refer to appropriate engine overhaul article, if available, in the ENGINES section for complete overhaul procedures and specifications for the vehicle being repaired.

Measuring Valve Guide Clearance

Check valve stem-to-guide clearance. Ensure valve stem diameter is within specification. Install valve in valve guide. Install dial indicator assembly on cylinder head with tip resting against valve stem just above valve guide. See Fig. 6.

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MITCHELL 1 ARTICLE - GENERAL INFORMATION Engine Overhaul Procedures

Fig. 6: Measuring Valve Stem-to-Guide Clearance Lower valve approximately 1/16" below valve seat. Push valve stem against valve guide as far as possible. Adjust dial indicator to zero. Push valve stem in opposite direction and note reading. Clearance must be within specification.

If valve guide clearance exceeds specification, valves with oversize stems may be used and valve guides are reamed to larger size or valve guide must be replaced. On some applications, a false guide is installed, then reamed to proper specification. Valve guide reamer set is used to ream valve guide to obtain proper clearance for new valve.

Reaming Valve Guide

Select proper reamer for size of valve stem. Reamer must be of proper length to provide clean cut through entire length of valve guide. Install reamer in valve guide and rotate to cut valve guide. See Fig. 7.

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MITCHELL 1 ARTICLE - GENERAL INFORMATION Engine Overhaul Procedures

Fig. 7: Reaming Valve Guides Replacing Valve Guide

Replace valve guide if clearance exceeds specification. Valve guides are either pressed, hammered or shrunk in place, depending upon cylinder head design and type of metal used.

Remove valve guide from cylinder head by pressing or tapping on a stepped drift. See Fig. 8. Once valve guide is installed, distance from cylinder head to top of valve guide must be checked. This distance must be within specification.

Aluminum heads are often heated before installing valve guide. Valve guide is sometimes cooled in dry ice prior to installation. Combination of a heated cylinder head and cooled valve guide ensures a tight guide fit upon assembly. The new guide must be reamed to specification. file:///C:/in323436.html

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MITCHELL 1 ARTICLE - GENERAL INFORMATION Engine Overhaul Procedures

Fig. 8: Typical Valve Guide Remover & Installer VALVES & VALVE SEATS NOTE:

Examples used in this article are general in nature and do not necessarily relate to a specific engine or system. Illustrations and procedures have been chosen to guide mechanic through engine overhaul process.

Descriptions of processes of cleaning, inspection, assembly and machine shop practice are included.

Always refer to appropriate engine overhaul article, if available, in the ENGINES section for complete overhaul procedures and specifications for the vehicle being repaired.

Valve Grinding

Valve stem O.D. should be measured in several areas to indicate amount of wear. Replace valve if not within specification. Valve margin area should be measured to ensure that valve can be ground. See Fig. 9.

If valve margin is less than specification, the valves will be burned. Valve must be replaced. Due to minimum margin dimensions during manufacture, some new type valves cannot be reground. Some manufacturers use stellite coated valves that must NOT be machined. Valves can only be lapped into valve seat.

CAUTION:

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Some valves are sodium filled. Extreme care must be used when disposing of damaged or worn sodium-filled valves.

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MITCHELL 1 ARTICLE - GENERAL INFORMATION Engine Overhaul Procedures

Fig. 9: Measuring Valve Head Margin Resurface valve to proper angle specification using valve grinding machine. Follow manufacturer's instructions for valve grinding machine. Specifications may indicate a different valve face angle than seat angle. Measure valve margin after grinding. Replace valve if not within specification. Valve stem tip can be refinished using valve grinding machine.

Valve Lapping

During valve lapping of recently designed valves, be sure to follow manufacturer's recommendations.

Surface hardening and materials used with some valves do not permit lapping. Lapping process will remove excessive amounts of the hardened surface.

Valve lapping is done to ensure adequate sealing between valve face and seat. Use either a hand drill or lapping stick with suction cup attached.

Moisten and attach suction cup to valve. Lubricate valve stem and guide. Apply a thin coat of fine valve grinding compound between valve and seat. Rotate lapping tool between the palms or with hand drill.

Lift valve upward off the seat and change position often. This is done to prevent grooving of valve seat.

Lap valve until a smooth polished seat is obtained. Thoroughly clean grinding compound from components. Valve-to-valve seat concentricity should be checked. See VALVE SEAT CONCENTRICITY. CAUTION:

Valve guides must be in good condition and free of carbon deposits prior to valve seat grinding. Some engines contain an induction hardened valve seat. Excessive material removal will damage valve seats.

Valve Seat Grinding

Select coarse stone of correct size and angle for seat to be ground. Ensure stone is true and has a smooth surface. Select correct size pilot for valve guide dimension. Install pilot in valve guide. Lightly lubricate pilot shaft. Install stone on pilot. Move stone off and on the seat approximately 2 times per second during grinding operation.

Select a fine stone to finish grinding operation. Various angle grinding stones are used to center and narrow the valve seat as required. See Fig. 10. file:///C:/in323436.html

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MITCHELL 1 ARTICLE - GENERAL INFORMATION Engine Overhaul Procedures

Fig. 10: Adjusting Valve Seat Width Valve Seat Replacement

Replacement of valve seat inserts is done by cutting out the old insert and machining an oversize insert bore. Replacement oversize insert is usually cooled and the cylinder head is sometimes warmed. Valve seat is pressed into the head. This operation requires specialized machine shop equipment.

Valve Seat Concentricity

Using dial gauge, install gauge pilot in valve guide. Position gauge arm on the valve seat. Adjust dial indicator to zero. Rotate arm 360 degrees and note reading. Runout should not exceed specification.

To check valve-to-valve seat concentricity, coat valve face lightly with Prussian Blue dye. Install valve and rotate it on valve seat. If pattern is even and entire seat is coated at valve contact point, valve is concentric with the valve seat.

CYLINDER HEAD REASSEMBLY NOTE:

Examples used in this article are general in nature and do not necessarily relate to a specific engine or system. Illustrations and procedures have been chosen to guide mechanic through engine overhaul process.

Descriptions of processes of cleaning, inspection, assembly and machine shop practice are included.

Always refer to appropriate engine overhaul article, if available, in the ENGINES section for complete overhaul procedures and specifications for the vehicle being repaired.

Valve Stem Installed Height

Valve stem installed height must be checked when new valves are installed or when valves or valve seats have been ground. Install valve in valve guide. Measure distance from tip of valve stem to spring seat. file:///C:/in323436.html 16/47 See Fig. 11. Distance must be within specification to allow sufficient clearance for valve operation.

Remove valve and grind valve stem tip if height exceeds specification. Valve tips are surface hardened.

MITCHELL - GENERAL INFORMATION Procedures NOT remove more than .010" (.251 ARTICLE mm) from tip. Chamfer sharpEngine edgeOverhaul of reground valve tip.

Recheck valve stem installed height.

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Fig. 11: Measuring Valve Stem Installed Height VALVE STEM OIL SEALS NOTE:

Examples used in this article are general in nature and do not necessarily relate to a specific engine or system. Illustrations and procedures have been chosen to guide mechanic through engine overhaul process.

Descriptions of processes of cleaning, inspection, assembly and machine shop practice are included.

Always refer to appropriate engine overhaul article, if available, in the ENGINES section for complete overhaul procedures and specifications for the vehicle being repaired.

Valve stem oil seals must be installed on valve stem. See Fig. 2. Seals are needed due to pressure differential at the ends of valve guides. Atmospheric pressure above intake guide, combined with manifold vacuum below guide, causes oil to be drawn into the cylinder.

Exhaust guides also have pressure differential created by exhaust gas flowing past the guide, creating a low pressure area. This low pressure area draws oil into the exhaust system.

Some manufacturers require that special color code or specified height valve stem oil seal be installed in designated area.

Replacement (On-Vehicle)

Mark rocker arm or overhead cam components for location. Remove rocker arm components or overhead cam components. Components must be installed in original location. Remove spark plugs.

Valve stem oil seals may be replaced by holding valves against seats using air pressure. file:///C:/in323436.html

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Air pressure must be installed in cylinder using an adapter for spark plug hole. An adapter can be MITCHELL 1 ARTICLE - GENERAL Overhaul Procedures by welding air hose connection to spark plugINFORMATION body with Engine porcelain removed.

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Rotate engine until piston is at top of stroke. Install adapter in spark plug hole. Apply a minimum of 140 psi (9.8 kg/cm2 ) line pressure to adapter. Air pressure should hold valve closed. If air pressure does not hold valve closed, check for damaged or bent valve. Cylinder head must be removed for service.

Using valve spring compressor, compress valve springs. Remove valve locks. Carefully release spring compressor. Remove retainer or rotator and valve spring. Remove valve stem oil seal.

If oversize valves have been installed, oversize oil seals must be used. Coat valve stem with engine oil.

Install protective sleeve over end of valve stem. Install new oil seal over valve stem and seat on valve guide. Remove protective sleeve. Install spring seat, valve spring and retainer or rotator. Compress spring and install valve locks. Remove spring compressor. Ensure valve locks are fully seated.

Install rocker arms or overhead cam components. Tighten all bolts to specification. Adjust valves if required. Remove adapter. Install spark plugs, valve cover and gasket.

VALVE SPRING INSTALLED HEIGHT NOTE:

Examples used in this article are general in nature and do not necessarily relate to a specific engine or system. Illustrations and procedures have been chosen to guide mechanic through engine overhaul process.

Descriptions of processes of cleaning, inspection, assembly and machine shop practice are included.

Always refer to appropriate engine overhaul article, if available, in the ENGINES section for complete overhaul procedures and specifications for the vehicle being repaired.

Valve spring installed height should be checked during reassembly. Measure height from lower edge of valve spring to the upper edge. DO NOT include valve spring seat or retainer. Distance must be within specification. If valves and/or seats have been ground, a valve spring shim may be required to correct spring height. See Fig. 12.

Fig. 12: Measuring Valve Spring Installed Height ROCKER ARMS & ASSEMBLIES

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Examples used in this article are general in nature and do not necessarily ARTICLE - GENERAL INFORMATION Engine Overhaul relate to a MITCHELL specific1 engine or system.

Illustrations and Procedures procedures have been chosen to guide mechanic through engine overhaul process.

Descriptions of processes of cleaning, inspection, assembly and machine shop practice are included.

Always refer to appropriate engine overhaul article, if available, in the ENGINES section for complete overhaul procedures and specifications for the vehicle being repaired.

Rocker Studs

Rocker studs are either threaded or pressed in place. Threaded studs are removed by locking 2 nuts on the stud. Unscrew the stud by turning the jam nut. Coat new stud threads with Loctite and install.

Tighten to specification.

Pressed-in stud can be removed using a stud puller. Ream stud bore to proper specification and press in a new oversize stud. Pressed-in studs are often replaced by cutting threads in the stud bore to accept a threaded stud.

Rocker Arms & Shafts

Mark rocker arms for location. Remove rocker arm retaining bolts. Remove rocker arms. Inspect rocker arms, shafts, bushings and pivot balls (if equipped) for excessive wear. Inspect rocker arms for wear in valve stem contact area. Measure rocker arm bushing I.D. Replace bushings if excessively worn.

The rocker arm valve stem contact point may be reground, using special fixture for valve grinding machine. Remove minimum amount of material as possible. Ensure all oil passages are clear. Install rocker arm components in original location. Ensure rocker arm is properly seated in push rod. Tighten bolts to specification. Adjust valves if required. See VALVE ADJUSTMENT. PUSH RODS NOTE:

Examples used in this article are general in nature and do not necessarily relate to a specific engine or system. Illustrations and procedures have been chosen to guide mechanic through engine overhaul process.

Descriptions of processes of cleaning, inspection, assembly and machine shop practice are included.

Always refer to appropriate engine overhaul article, if available, in the ENGINES section for complete overhaul procedures and specifications for the vehicle being repaired.

Remove rocker arms. Mark push rods for location. Remove push rods. Push rods can be steel or aluminum, solid or hollow. Hollow push rods must be internally cleaned to ensure oil passage to rocker arms is cleaned. Check push rods for damage, such as loose ends on steel tipped aluminum types.

Check push rod for straightness. Roll push rod on a flat surface. Using feeler gauge, check clearance at center. Replace push rod if bent. The push rod can also be supported at each end and rotated. A dial indicator is used to detect a bent area in the push rod.

Lubricate ends of push rod and install push rod in original location. Ensure push rod is properly seated in lifter. Install rocker arm. Tighten bolts to specification. Adjust valves if required. See VALVE ADJUSTMENT. LIFTERS NOTE:

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Examples used in this article are general in nature and do not necessarily relate to a specific engine or system. Illustrations and procedures have been chosen to guide mechanic through engine overhaul process.

Descriptions of processes of cleaning, inspection, assembly and machine shop practice are included.

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Always refer to appropriate engine overhaul article, if available, in the MITCHELL 1for ARTICLE - GENERAL INFORMATION Engine Overhaul Procedures ENGINES section complete overhaul procedures and specifications for the vehicle being repaired.

Hydraulic Lifters

Before replacing a hydraulic lifter for noisy operation, ensure noise is not caused by worn rocker arms or valve tips. Also ensure sufficient oil pressure exists. Hydraulic lifters must be installed in original location. Remove rocker arm assembly and push rod. Mark components for location. Some applications require intake manifold, cylinder head or lifter cover removal. Remove lifter retainer plate (if used). To remove lifters, use a hydraulic lifter remover or magnet. Different type lifters are used. See Fig. 13.

On sticking lifters, disassemble and clean lifter. DO NOT mix lifter components or positions. Parts are select-fitted and are not interchangeable. Inspect all components for wear. Note amount of wear in lifter body-to-camshaft contact area. Surface must have smooth and convex contact face. If wear is apparent, carefully inspect cam lobe.

Inspect push rod contact area and lifter body for scoring or signs of wear. If body is scored, inspect lifter bore for damage and lack of lubrication. On roller type lifters, inspect roller for flaking, pitting, loss of needle bearings and roughness during rotation.

Measure lifter body O.D. in several areas. Measure lifter bore I.D. Ensure components or oil clearance is within specification. Some models offer oversize lifters. Replace lifter if damaged.

If lifter check valve is not operating, obstructions may be preventing it from closing or valve spring may be broken. Clean or replace components as necessary.

Check plunger operation. Plunger should drop to bottom of the body by its own weight when assembled dry. If plunger is not free, soak lifter in solvent to dissolve deposits.

Lifter leak-down test can be performed on lifter. Lifter must be filled with special test oil. New lifters contain special test oil. Using lifter leak-down tester, perform leak-down test following manufacturer's instructions. If leak-down time is not within specifications, replace lifter assembly.

Lifters should be soaked in clean engine oil several hours prior to installation. Coat lifter base, roller (if equipped) and lifter body with ample amount of Molykote or camshaft lubricant. See Fig. 13. Install lifter in original location. Install remaining components. Valve lash adjustment is not required on most hydraulic lifters. Preload of hydraulic lifter is automatic. Some models may require adjustment.

NOTE:

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Some manufacturers require that a crankcase conditioner be added to engine oil and engine operated for specified amount of time to aid in lifter break-in procedure if new lifters or camshaft are installed.

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MITCHELL 1 ARTICLE - GENERAL INFORMATION Engine Overhaul Procedures

Fig. 13: Typical Hydraulic Valve Lifter Assemblies Mechanical Lifters

Lifter assemblies must be installed in original locations. Remove rocker arm assembly and push rod.

Mark components for location. Some applications require intake manifold or lifter cover removal.

Remove lifter retainer plate (if used). To remove lifters, use lifter remover or magnet.

Inspect push rod contact area and lifter body for scoring or signs of wear. If body is scored, inspect lifter bore for damage and lack of lubrication. Note amount of wear in lifter body-to-camshaft contact area.

Surface must have smooth and convex contact face. If wear is apparent, carefully inspect cam lobe.

Coat lifter base, roller (if equipped) and lifter body with ample amount of Molykote or camshaft lubricant. Install lifter in original location. Install remaining components. Tighten bolts to specification.

Adjust valves. See VALVE ADJUSTMENT.

PISTONS, CONNECTING RODS & BEARINGS file:///C:/in323436.html

* PLEASE READ THIS FIRST *

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Examples used in this article are general in nature and do not necessarily ARTICLE - GENERAL INFORMATION Engine Overhaul Procedures relate to a MITCHELL specific1 engine or system. Illustrations and procedures have been chosen to guide mechanic through engine overhaul process.

Descriptions of processes of cleaning, inspection, assembly and machine shop practice are included.

Always refer to appropriate engine overhaul article, if available, in the ENGINES section for complete overhaul procedures and specifications for the vehicle being repaired.

RIDGE REMOVAL NOTE:

Examples used in this article are general in nature and do not necessarily relate to a specific engine or system. Illustrations and procedures have been chosen to guide mechanic through engine overhaul process.

Descriptions of processes of cleaning, inspection, assembly and machine shop practice are included.

Always refer to appropriate engine overhaul article, if available, in the ENGINES section for complete overhaul procedures and specifications for the vehicle being repaired.

Ridge in cylinder wall must be removed prior to piston removal. Failure to remove ridge prior to removing pistons will cause piston damage in piston ring lands or grooves.

With piston at bottom dead center, place rag in bore to trap metal chips. Install ridge reamer in cylinder bore. Adjust ridge reamer using manufacturer's instructions. Remove ridge using ridge reamer. DO NOT remove an excessive amount of material. Ensure ridge is completely removed.

PISTON & CONNECTING ROD REMOVAL NOTE:

Examples used in this article are general in nature and do not necessarily relate to a specific engine or system. Illustrations and procedures have been chosen to guide mechanic through engine overhaul process.

Descriptions of processes of cleaning, inspection, assembly and machine shop practice are included.

Always refer to appropriate engine overhaul article, if available, in the ENGINES section for complete overhaul procedures and specifications for the vehicle being repaired.

Note top of piston. Some pistons may contain a notch, arrow or be marked FRONT. Piston must be installed in proper direction to prevent damage with valve operation.

Check that connecting rod and cap are numbered for cylinder location and which side of cylinder block the number faces. Proper cap and connecting rod must be installed together. Connecting rod cap must be installed on connecting rod in proper direction to ensure bearing lock procedure. Mark connecting rod and cap if necessary. Pistons must be installed in original location.

Remove cap retaining nuts or bolts. Remove bearing cap. Install tubing protectors on connecting rod bolts. This protects cylinder walls from scoring during removal. Ensure proper removal of ridge. Push piston and connecting rod from cylinder. Connecting rod boss can be tapped with a wooden dowel or hammer handle to aid in removal.

PISTON & CONNECTING ROD NOTE:

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Examples used in this article are general in nature and do not necessarily relate to a specific engine or system. Illustrations and procedures have been chosen to guide mechanic through engine overhaul process.

Descriptions of processes of cleaning, inspection, assembly and machine shop practice are included.

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Always refer to appropriate engine overhaul article, if available, in the MITCHELL 1for ARTICLE - GENERAL INFORMATION Engine Overhaul Procedures ENGINES section complete overhaul procedures and specifications for the vehicle being repaired.

Disassembly

Using ring expander, remove piston rings. Remove piston pin retaining rings (if equipped). Note direction of piston installation on connecting rod. On pressed type piston pins, special fixtures and procedures according to manufacturer must be used to remove piston pins. Follow manufacturer's recommendations to avoid piston distortion or breakage.

Cleaning

Remove all carbon and varnish from piston. Pistons and connecting rods may be cleaned in cold type chemical tank. Using ring groove cleaner, clean all deposits from ring grooves. Ensure all deposits are cleaned from ring grooves to prevent ring breakage or sticking. DO NOT attempt to clean pistons with wire brush.

Inspection

Inspect pistons for nicks, scoring, cracks or damage in ring areas. Connecting rod should be checked for cracks using Magnaflux procedure. Piston diameter must be measured in manufacturer's specified area.

Using telescopic gauge and micrometer, measure piston pin bore of piston in 2 areas, 90 degrees apart.

This is done to check diameter and out-of-round.

Install proper bearing cap on connecting rod. Ensure bearing cap is installed in proper location. Tighten bolts or nuts to specification. Using inside micrometer, measure inside diameter in 2 areas, 90 degrees apart.

Connecting rod I.D. and out-of-round must be within specification. Measure piston pin bore I.D. and piston pin O.D. All components must be within specification. Subtract piston pin diameter from piston pin bore in piston and connecting rod to determine proper fit.

Connecting rod length must be measured from center of crankshaft journal inside diameter to center of piston pin bushing using proper caliper. Connecting rods must be the same length. Connecting rods should be checked on an alignment fixture for bent or twisted condition. Replace all components which are damaged or not within specification.

PISTON & CYLINDER BORE FIT NOTE:

Examples used in this article are general in nature and do not necessarily relate to a specific engine or system. Illustrations and procedures have been chosen to guide mechanic through engine overhaul process.

Descriptions of processes of cleaning, inspection, assembly and machine shop practice are included.

Always refer to appropriate engine overhaul article, if available, in the ENGINES section for complete overhaul procedures and specifications for the vehicle being repaired.

Ensure cylinder is checked for taper, out-of-round and properly honed prior to checking piston and cylinder bore fit. See CYLINDER BLOCK. Using dial bore gauge, measure cylinder bore.

Measure piston skirt diameter at 90 degree angle to piston pin at specified area by manufacturer.

Subtract piston diameter from cylinder bore diameter to determine piston-to-cylinder clearance.

Clearance must be within specification. Mark piston for proper cylinder location.

ASSEMBLING PISTON & CONNECTING ROD NOTE: file:///C:/in323436.html

Examples used in this article are general in nature and do not necessarily relate to a specific engine or system. Illustrations and procedures have 23/47 been chosen to guide mechanic through engine overhaul process.

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Descriptions of processes of cleaning, inspection, assembly and machine MITCHELL ARTICLE - GENERAL INFORMATION Engine Overhaul Procedures shop practice are 1included.

Always refer to appropriate engine overhaul article, if available, in the ENGINES section for complete overhaul procedures and specifications for the vehicle being repaired.

Install piston on connecting rod for corresponding cylinder. Ensure reference marking on top of piston corresponds with connecting rod and cap number. See Fig. 14.

Lubricate piston pin and install in connecting rod. Ensure piston pin retainers are fully seated (if equipped). On pressed type piston pins, follow manufacturer's recommended procedure to avoid distortion or breakage.

Fig. 14: Installing Typical Piston Pin CHECKING PISTON RING CLEARANCES NOTE:

Examples used in this article are general in nature and do not necessarily relate to a specific engine or system. Illustrations and procedures have been chosen to guide mechanic through engine overhaul process.

Descriptions of processes of cleaning, inspection, assembly and machine shop practice are included.

Always refer to appropriate engine overhaul article, if available, in the ENGINES section for complete overhaul procedures and specifications for the vehicle being repaired.

Piston rings must be checked for side clearance and end gap. To check end gap, install piston ring in cylinder in which it is to be installed. Using an inverted piston, push ring to bottom of cylinder in smallest cylinder diameter. file:///C:/in323436.html

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Using feeler gauge, check ring end gap. See Fig. 15. Piston ring end gap must be within specification.

MITCHELL 1 ARTICLE - GENERAL INFORMATION Engine Overhaul Procedures breakage will occur if insufficient ring end gap exists.

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Some manufacturers permit correcting insufficient ring end gap by using a fine file while other manufacturers recommend using another ring set. Mark rings for proper cylinder installation after checking end gap.

Fig. 15: Checking Piston Ring End Gap For checking side clearance, install rings on piston. Using feeler gauge, measure clearance between piston ring and piston ring land. Check side clearance in several areas around piston. Side clearance must be within specification.

If side clearance is excessive, piston ring grooves can be machined to accept oversize piston rings (if available). Normal practice is to replace piston.

PISTON & CONNECTING ROD INSTALLATION NOTE:

Examples used in this article are general in nature and do not necessarily relate to a specific engine or system. Illustrations and procedures have been chosen to guide mechanic through engine overhaul process.

Descriptions of processes of cleaning, inspection, assembly and machine shop practice are included.

Always refer to appropriate engine overhaul article, if available, in the ENGINES section for complete overhaul procedures and specifications for the vehicle being repaired.

Cylinders must be honed prior to piston installation. See CYLINDER HONING under CYLINDER BLOCK. Install upper connecting rod bearings. Lubricate upper bearings with engine oil. Install lower bearings in 25/47 rod caps. Ensure bearing tabs are properly seated. Position piston ring gaps according to manufacturer's

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recommendations. See Fig. 16. Lubricate pistons, rings and cylinder walls.

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MITCHELL 1 ARTICLE - GENERAL INFORMATION Engine Overhaul Procedures

Fig. 16: Positioning Typical Piston Ring End Gap Install ring compressor. Use care not to rotate piston rings. Compress rings with ring compressor. Install plastic tubing protectors over connecting rod bolts. Install piston and connecting rod assembly. Ensure piston notch, arrow or FRONT mark is toward front of engine. See Fig. 17.

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MITCHELL 1 ARTICLE - GENERAL INFORMATION Engine Overhaul Procedures

Fig. 17: Installing Piston & Connecting Rod Assembly Carefully tap piston into cylinder until rod bearing is seated on crankshaft journal. Remove protectors.

Install rod cap and bearing. Lightly tighten connecting rod bolts. Repeat procedure for remaining cylinders. Check bearing clearance. See MAIN & CONNECTING ROD BEARING CLEARANCE. Once clearance is checked, lubricate journals and bearings. Install bearing caps. Ensure marks are aligned on connecting rod and cap. Tighten rod nuts or bolts to specification. Ensure rod moves freely on crankshaft. Check connecting rod side clearance. See CONNECTING ROD SIDE CLEARANCE. CONNECTING ROD SIDE CLEARANCE NOTE:

Examples used in this article are general in nature and do not necessarily relate to a specific engine or system. Illustrations and procedures have been chosen to guide mechanic through engine overhaul process.

Descriptions of processes of cleaning, inspection, assembly and machine shop practice are included.

Always refer to appropriate engine overhaul article, if available, in the ENGINES section for complete overhaul procedures and specifications for the vehicle being repaired.

Position connecting rod toward one side of crankshaft as far as possible. Using feeler gauge, measure clearance between side of connecting rod and crankshaft. See Fig. 18. Clearance must be within specification.

Check for improper bearing installation, wrong bearing cap or insufficient bearing clearance if side clearance is insufficient. Connecting rod may require machining to obtain proper clearance. Excessive clearance usually indicates excessive wear at crankshaft. Crankshaft must be repaired or replaced.

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Fig. 18: Measuring Connecting Rod Side Clearance MAIN & CONNECTING ROD BEARING CLEARANCE NOTE:

Examples used in this article are general in nature and do not necessarily relate to a specific engine or system. Illustrations and procedures have been chosen to guide mechanic through engine overhaul process.

Descriptions of processes of cleaning, inspection, assembly and machine shop practice are included.

Always refer to appropriate engine overhaul article, if available, in the ENGINES section for complete overhaul procedures and specifications for the vehicle being repaired.

Plastigage Method

Plastigage method may be used to determine bearing clearance. Plastigage can be used with an engine in service or during reassembly. Plastigage material is oil soluble.

Ensure journals and bearings are free of oil or solvent. Oil or solvent will dissolve material and false reading will be obtained. Install small piece of Plastigage along full length of bearing journal. Install bearing cap in original location. Tighten bolts to specification.

CAUTION:

DO NOT rotate crankshaft while Plastigage is installed. Bearing clearance will not be obtained if crankshaft is rotated.

Remove bearing cap. Compare Plastigage width with scale on Plastigage container to determine bearing clearance. See Fig. 19. Rotate crankshaft 90 degrees. Repeat procedure. This is done to check journal eccentricity. This procedure can be used to check oil clearance on both connecting rod and main bearings.

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Fig. 19: Measuring Bearing Clearance Micrometer & Telescopic Gauge Method

A micrometer is used to determine journal diameter, taper and out-of-round dimensions of the crankshaft. See CLEANING & INSPECTION under CRANKSHAFT & MAIN BEARINGS in this article.

With crankshaft removed, install bearings and caps in original location on cylinder block. Tighten bolts to specification. On connecting rods, install bearings and caps on connecting rods. Install proper connecting rod cap on corresponding rod. Ensure bearing cap is installed in original location. Tighten bolts to specification.

Using a telescopic gauge and micrometer or inside micrometer, measure inside diameter of connecting rod and main bearings bores. Subtract each crankshaft journal diameter from the corresponding inside bearing bore diameter. This is the bearing clearance.

CRANKSHAFT & MAIN BEARINGS * PLEASE READ THIS FIRST * NOTE:

Examples used in this article are general in nature and do not necessarily relate to a specific engine or system. Illustrations and procedures have been chosen to guide mechanic through engine overhaul process.

Descriptions of processes of cleaning, inspection, assembly and machine shop practice are included.

Always refer to appropriate engine overhaul article, if available, in the ENGINES section for complete overhaul procedures and specifications for the vehicle being repaired.

REMOVAL

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Examples used in this article are general in nature and do not necessarily ARTICLE - GENERAL INFORMATION Engine Overhaul relate to a MITCHELL specific1 engine or system.

Illustrations and Procedures procedures have been chosen to guide mechanic through engine overhaul process.

Descriptions of processes of cleaning, inspection, assembly and machine shop practice are included.

Always refer to appropriate engine overhaul article, if available, in the ENGINES section for complete overhaul procedures and specifications for the vehicle being repaired.

Ensure all main bearing caps are marked for location on cylinder block. Some main bearing caps have an arrow stamped on them. The arrow must face timing belt or timing chain end of engine. Remove main bearing cap bolts. Remove main bearing caps. Carefully remove crankshaft. Use care not to bind crankshaft in cylinder block during removal.

CLEANING & INSPECTION NOTE:

Examples used in this article are general in nature and do not necessarily relate to a specific engine or system. Illustrations and procedures have been chosen to guide mechanic through engine overhaul process.

Descriptions of processes of cleaning, inspection, assembly and machine shop practice are included.

Always refer to appropriate engine overhaul article, if available, in the ENGINES section for complete overhaul procedures and specifications for the vehicle being repaired.

Thoroughly clean crankshaft using solvent. Dry with compressed air. Ensure all oil passages are clear and free of sludge, rust, dirt and metal chips.

Inspect crankshaft for scoring and nicks. Inspect crankshaft for cracks using Magnaflux procedure.

Inspect rear seal area for grooving or damage. Inspect bolt hole threads for damage. If pilot bearing or bushing is used, check pilot bearing or bushing fit in crankshaft. Inspect crankshaft gear for damaged or cracked teeth. Replace gear if damaged. Ensure oil passage plugs are tight (if equipped).

Using micrometer, measure all journals in 4 areas to determine journal taper, out-of-round and undersize. See Fig. 20. Some crankshafts can be reground to the next largest undersize, depending on the amount of wear or damage. Crankshafts with rolled fillet cannot be reground and must be replaced.

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Fig. 20: Measuring Crankshaft Journals Crankshaft journal runout should be checked. Install crankshaft in "V" blocks or bench center. Position dial indicator with tip resting on the main bearing journal area. See Fig. 21. Rotate crankshaft and note reading. Journal runout must not exceed specification. Repeat procedure on all main bearing journals.

Crankshaft must be replaced if runout exceeds specification.

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Fig. 21: Measuring Crankshaft Main Bearing Journal Runout 7/24/2019

MITCHELL 1 ARTICLE - GENERAL INFORMATION Engine Overhaul Procedures

INSTALLATION NOTE:

Examples used in this article are general in nature and do not necessarily relate to a specific engine or system. Illustrations and procedures have been chosen to guide mechanic through engine overhaul process.

Descriptions of processes of cleaning, inspection, assembly and machine shop practice are included.

Always refer to appropriate engine overhaul article, if available, in the ENGINES section for complete overhaul procedures and specifications for the vehicle being repaired.

Install upper main bearing in cylinder block. Ensure lock tab is properly located in cylinder block. Install bearings in main bearing caps. Ensure all oil passages are aligned. Install rear seal (if removed).

Ensure crankshaft journals are clean. Lubricate upper main bearings with clean engine oil. Carefully install crankshaft. Check each main bearing clearance using Plastigage method. See MAIN & CONNECTING ROD BEARING CLEARANCE. Once clearance is checked, lubricate lower main bearing and journals. Install main bearing caps in original location. Install rear seal in rear main bearing cap (if removed). Some rear main bearing caps require sealant to be applied in corners to prevent oil leakage.

Install and tighten all bolts except thrust bearing cap to specification. Tighten thrust bearing cap bolts finger tight only. Some models require that thrust bearing be aligned. On most applications, crankshaft must be moved rearward then forward. Procedure may vary with manufacturer. Thrust bearing cap is then tightened to specification. Ensure crankshaft rotates freely. Crankshaft end play should be checked.

See CRANKSHAFT END PLAY. CRANKSHAFT END PLAY NOTE:

Examples used in this article are general in nature and do not necessarily relate to a specific engine or system. Illustrations and procedures have been chosen to guide mechanic through engine overhaul process.

Descriptions of processes of cleaning, inspection, assembly and machine shop practice are included.

Always refer to appropriate engine overhaul article, if available, in the ENGINES section for complete overhaul procedures and specifications for the vehicle being repaired.

Dial Indicator Method

Crankshaft end play can be checked using dial indicator. Mount dial indicator on rear of cylinder block.

Position dial indicator tip against rear of crankshaft. Ensure tip is resting against flat surface.

Pry crankshaft rearward. Adjust dial indicator to zero. Pry crankshaft forward and note reading.

Crankshaft end play must be within specification. If end play is not within specification, check for faulty thrust bearing installation or worn crankshaft. Some applications offer oversize thrust bearings.

Feeler Gauge Method

Crankshaft end play can be checked using feeler gauge. Pry crankshaft rearward. Pry crankshaft forward. Using feeler gauge, measure clearance between crankshaft and thrust bearing surface. See Fig. 22.

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Fig. 22: Checking Crankshaft End Play Crankshaft end play must be within specification. If end play is not within specification, check for faulty thrust bearing installation or worn crankshaft. Some applications offer oversize thrust bearings.

CYLINDER BLOCK NOTE:

Examples used in this article are general in nature and do not necessarily relate to a specific engine or system. Illustrations and procedures have been chosen to guide mechanic through engine overhaul process.

Descriptions of processes of cleaning, inspection, assembly and machine shop practice are included.

Always refer to appropriate engine overhaul article, if available, in the ENGINES section for complete overhaul procedures and specifications for the vehicle being repaired.

Block Cleaning

Only cast cylinder blocks should be hot tank cleaned. Aluminum cylinder blocks should be cleaned using cold tank method. Cylinder block is cleaned in order to remove carbon deposits, gasket residue and water jacket scale. Remove oil gallery plugs, freeze plugs and cam bearings before cleaning block.

Block Inspection

Visually inspect the block. Check suspected areas for cracks using the Dye Penetrant inspection method.

Block may be checked for cracks using the Magnaflux method.

Cracks are most commonly found at the bottom of cylinders, main bearing saddles, near expansion plugs and between cylinders and water jackets. Inspect lifter bores for damage. Inspect all head bolt holes for damaged threads. Threads should be cleaned using tap to ensure proper head bolt torque. Consult machine shop concerning possible welding and machining (if required). file:///C:/in323436.html 33/47

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MITCHELL 1 ARTICLE - GENERAL INFORMATION Engine Overhaul Procedures

Inspect bore for scoring or roughness. Cylinder bore is dimensionally checked for out-of-round and taper using dial bore gauge. For determining out-of-round, measure cylinder parallel and perpendicular to the block center line. Difference in the 2 readings is the bore out-of-round. Cylinder bore must be checked at top, middle and bottom of piston travel area.

Bore taper is obtained by measuring bore at the top and bottom. If wear has exceeded allowable limits, block must be honed or bored to next available oversize piston dimension.

Cylinder Honing

Cylinder must be properly honed to allow new piston rings to properly seat. Cross-hatching at correct angle and depth is critical to lubrication of cylinder walls and pistons.

A flexible drive hone and power drill are commonly used. Drive hone must be lubricated during operation. Mix equal parts of kerosene and SAE 20W engine oil for lubrication.

Apply lubrication to cylinder wall. Operate cylinder hone from top to bottom of cylinder using even strokes to produce 45 degree cross-hatch pattern on the cylinder wall. DO NOT allow cylinder hone to extend below cylinder during operation.

Recheck bore dimension after final honing. Wash cylinder wall with hot soapy water to remove abrasive particles. Blow dry with compressed air. Coat cleaned cylinder walls with lubricating oil.

Deck Warpage

Check deck for damage or warped gasket surface. Place a straightedge across gasket surface of the deck.

Using feeler gauge, measure clearance at center of straightedge. Measure across width and length of cylinder block at several points.

If warpage exceeds specifications, deck must be resurfaced. If warpage exceeds manufacturer's maximum tolerance for material removal, replace block.

NOTE:

Some manufacturers recommend that a total amount of material (cylinder head and cylinder block) can only be removed before components must be replaced.

Deck Height

Distance from crankshaft center line to block deck is called the deck height. Measure and record front and rear main journals of crankshaft. To compute this distance, install crankshaft and retain with center main bearing and cap only. Measure distance from crankshaft journal to block deck, parallel to cylinder center line.

Add one half of main bearing journal diameter to distance from crankshaft journal to block deck. This dimension should be checked at front and rear of cylinder block. Both readings should be the same.

If difference exceeds specification, cylinder block must be repaired or replaced. Deck height and warpage should be corrected at the same time.

Main Bearing Bore & Alignment

For checking main bearing bore, remove all bearings from cylinder block and main bearing caps. Install main bearing caps in original location. Tighten bolts to specification. Using inside micrometer, measure main bearing bore in 2 areas 90 degrees apart. Determine bore size and out-of-round. If diameter is not within specification, block must be align-bored.

For checking alignment, place a straightedge along center line of main bearing saddles. Check for clearance between straightedge and main bearing saddles. Block must be align-bored if clearance exists.

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Drill hole in center of expansion plug. Remove with screwdriver or punch. Use care not to damage MITCHELL 1 ARTICLE - GENERAL INFORMATION Engine Overhaul Procedures surface.

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Expansion Plug Installation

Ensure sealing surface is free of burrs. Coat expansion plug with sealer. Using wooden dowel or pipe of slightly smaller diameter, install expansion plug. Ensure expansion plug is evenly located.

Oil Gallery Plug Removal

Remove threaded oil gallery plugs using appropriate wrench. Soft press-in plugs are removed by drilling into plug and installing a sheet metal screw. Remove plug with slide hammer or pliers.

Oil Gallery Plug Installation

Ensure threads or sealing surface is clean. Coat threaded oil gallery plugs with sealer and install.

Replacement soft press-in plugs are installed with a hammer and drift.

CAMSHAFT * PLEASE READ THIS FIRST * NOTE:

Examples used in this article are general in nature and do not necessarily relate to a specific engine or system. Illustrations and procedures have been chosen to guide mechanic through engine overhaul process.

Descriptions of processes of cleaning, inspection, assembly and machine shop practice are included.

Always refer to appropriate engine overhaul article, if available, in the ENGINES section for complete overhaul procedures and specifications for the vehicle being repaired.

CLEANING & INSPECTION NOTE:

Examples used in this article are general in nature and do not necessarily relate to a specific engine or system. Illustrations and procedures have been chosen to guide mechanic through engine overhaul process.

Descriptions of processes of cleaning, inspection, assembly and machine shop practice are included.

Always refer to appropriate engine overhaul article, if available, in the ENGINES section for complete overhaul procedures and specifications for the vehicle being repaired.

Clean camshaft with solvent. Ensure all oil passages are clear. Inspect cam lobes and bearing journals for pitting, flaking or scoring. Using micrometer, measure bearing journal O.D. Support camshaft at each end with "V" blocks. Position dial indicator with tip resting on center bearing journal. Rotate camshaft and note camshaft runout reading. If reading exceeds specification, replace camshaft.

Check cam lobe lift by measuring base circle of camshaft using micrometer. Measure again at 90-degree angle to tip of cam lobe. Cam lift can be determined by subtracting base circle diameter from tip of cam lobe measurement.

Different lift dimensions are given for intake and exhaust cam lobes. Reading must be within specification. Replace camshaft if cam lobes or bearing journals are not within specification.

Inspect camshaft gear for chipped, eroded or damaged teeth. Replace gear if damaged. On camshafts using thrust plate, measure distance between thrust plate and camshaft shoulder. Replace thrust plate if not within specification. file:///C:/in323436.html CAMSHAFT

BEARINGS

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Examples used in this article are general in nature and do not necessarily ARTICLE - GENERAL INFORMATION Engine Overhaul Procedures relate to a MITCHELL specific1 engine or system. Illustrations and procedures have been chosen to guide mechanic through engine overhaul process.

Descriptions of processes of cleaning, inspection, assembly and machine shop practice are included.

Always refer to appropriate engine overhaul article, if available, in the ENGINES section for complete overhaul procedures and specifications for the vehicle being repaired.

Removal & Installation

Remove camshaft rear plug. Camshaft bearing remover is assembled with shoulder resting against bearing to be removed according to manufacturer's instructions. Tighten puller nut until bearing is removed. Remove remaining bearings, leaving front and rear bearings until last. These bearings act as a guide for camshaft bearing remover.

To install new bearings, puller is rearranged to pull bearings toward the center of block. Ensure all lubrication passages of bearing are aligned with cylinder block. Coat new camshaft rear plug with sealant. Install camshaft rear plug. Ensure plug is even in cylinder block.

CAMSHAFT INSTALLATION NOTE:

Examples used in this article are general in nature and do not necessarily relate to a specific engine or system. Illustrations and procedures have been chosen to guide mechanic through engine overhaul process.

Descriptions of processes of cleaning, inspection, assembly and machine shop practice are included.

Always refer to appropriate engine overhaul article, if available, in the ENGINES section for complete overhaul procedures and specifications for the vehicle being repaired.

Lubricate bearing surfaces and cam lobes with ample amount of Molykote or camshaft lubricant.

Carefully install camshaft. Use care not to damage bearing journals during installation. Install thrust plate retaining bolts (if equipped). Tighten bolts to specification. On overhead camshafts, install bearing caps in original location. Tighten bolts to specification. On all applications, check camshaft end play.

CAMSHAFT END PLAY NOTE:

Examples used in this article are general in nature and do not necessarily relate to a specific engine or system. Illustrations and procedures have been chosen to guide mechanic through engine overhaul process.

Descriptions of processes of cleaning, inspection, assembly and machine shop practice are included.

Always refer to appropriate engine overhaul article, if available, in the ENGINES section for complete overhaul procedures and specifications for the vehicle being repaired.

Using dial indicator, check camshaft end play. Position dial indicator on front of engine block or cylinder head. Position indicator tip against camshaft. Push camshaft toward rear of cylinder head or engine and adjust indicator to zero.

Move camshaft forward and note reading. Camshaft end play must be within specification. End play may be adjusted by relocating gear, shimming thrust plate or replacing thrust plate depending on each manufacturer.

TIMING CHAINS & BELTS * PLEASE READ THIS FIRST * file:///C:/in323436.html

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NOTE: 7/24/2019

Examples used in this article are general in nature and do not necessarily ARTICLE - GENERAL INFORMATION Engine Overhaul relate to a MITCHELL specific1 engine or system.

Illustrations and Procedures procedures have been chosen to guide mechanic through engine overhaul process.

Descriptions of processes of cleaning, inspection, assembly and machine shop practice are included.

Always refer to appropriate engine overhaul article, if available, in the ENGINES section for complete overhaul procedures and specifications for the vehicle being repaired.

TIMING CHAINS NOTE:

Examples used in this article are general in nature and do not necessarily relate to a specific engine or system. Illustrations and procedures have been chosen to guide mechanic through engine overhaul process.

Descriptions of processes of cleaning, inspection, assembly and machine shop practice are included.

Always refer to appropriate engine overhaul article, if available, in the ENGINES section for complete overhaul procedures and specifications for the vehicle being repaired.

Timing chains will stretch during operation. Limits are placed upon amount of stretch before replacement is required. Timing chain stretch will alter ignition timing and valve timing.

To check timing chain stretch, rotate crankshaft to eliminate slack from one side of timing chain. Mark reference point on cylinder block. Rotate crankshaft in opposite direction to eliminate slack from remaining side of timing chain. Force other side of chain outward and measure distance between reference point and timing chain. See Fig. 23. Replace timing chain and gears if not within specification.

Fig. 23: Measuring Timing Chain Stretch file:///C:/in323436.html

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Timing chains must be installed so timing marks on camshaft gear and crankshaft gear are aligned MITCHELL 1 ARTICLE - GENERAL INFORMATION Engine Overhaul Procedures to manufacturer. See Fig. 24.

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Fig. 24: Typical Gear Timing Mark Alignment TIMING BELTS NOTE:

Examples used in this article are general in nature and do not necessarily relate to a specific engine or system. Illustrations and procedures have been chosen to guide mechanic through engine overhaul process.

Descriptions of processes of cleaning, inspection, assembly and machine shop practice are included.

Always refer to appropriate engine overhaul article, if available, in the ENGINES section for complete overhaul procedures and specifications for the vehicle being repaired.

Cogged tooth belts are commonly used on overhead cam engines. Inspect belt teeth for rounded corners or cracking. Replace belt if it is cracked, damaged, missing teeth or oil soaked.

Used timing belt must be installed in original direction of rotation. Inspect all sprocket teeth for wear.

Replace all worn sprockets. Sprockets are marked for timing purposes. Engine is positioned so that crankshaft sprocket mark will be upward. Camshaft sprocket is aligned with reference mark on cylinder head or timing belt cover and then timing belt can be installed. See Fig. 25.

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MITCHELL 1 ARTICLE - GENERAL INFORMATION Engine Overhaul Procedures

Fig. 25: Typical Camshaft Belt Sprocket Alignment TENSION ADJUSTMENT NOTE:

Examples used in this article are general in nature and do not necessarily relate to a specific engine or system. Illustrations and procedures have been chosen to guide mechanic through engine overhaul process.

Descriptions of processes of cleaning, inspection, assembly and machine shop practice are included.

Always refer to appropriate engine overhaul article, if available, in the ENGINES section for complete overhaul procedures and specifications for the vehicle being repaired.

If guide rails are used with spring loaded tensioners, ensure at least half of original rail thickness remains. Spring loaded tensioner should be inspected for damage.

Ensure all timing marks are aligned. Adjust belt tension using manufacturer's recommendations. Belt tension may require checking using tension gauge. See Fig. 26.

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MITCHELL 1 ARTICLE - GENERAL INFORMATION Engine Overhaul Procedures

Fig. 26: Adjusting Typical Timing Belt Tension

TIMING GEARS * PLEASE READ THIS FIRST * NOTE:

Examples used in this article are general in nature and do not necessarily relate to a specific engine or system. Illustrations and procedures have been chosen to guide mechanic through engine overhaul process.

Descriptions of processes of cleaning, inspection, assembly and machine shop practice are included.

Always refer to appropriate engine overhaul article, if available, in the ENGINES section for complete overhaul procedures and specifications for the vehicle being repaired.

TIMING GEAR BACKLASH & RUNOUT NOTE: file:///C:/in323436.html

Examples used in this article are general in nature and do not necessarily relate to a specific engine or system. Illustrations and procedures have been chosen to guide mechanic through engine overhaul process.

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Descriptions of processes of cleaning, inspection, assembly and machine MITCHELL ARTICLE - GENERAL INFORMATION Engine Overhaul Procedures shop practice are 1included.

Always refer to appropriate engine overhaul article, if available, in the ENGINES section for complete overhaul procedures and specifications for the vehicle being repaired.

On engines where camshaft gear operates directly on crankshaft gear, gear backlash and runout must be checked. To check backlash, install dial indicator with tip resting on tooth of camshaft gear. Rotate camshaft gear as far as possible. Adjust indicator to zero. Rotate camshaft gear in opposite direction as far as possible and note reading.

To determine timing gear runout, mount dial indicator with tip resting on face edge of camshaft gear.

Adjust indicator to zero. Rotate camshaft gear 360 degrees and note reading. If backlash or runout exceeds specification, replace camshaft and/or crankshaft gear.

REAR MAIN OIL SEAL INSTALLATION NOTE:

Examples used in this article are general in nature and do not necessarily relate to a specific engine or system. Illustrations and procedures have been chosen to guide mechanic through engine overhaul process.

Descriptions of processes of cleaning, inspection, assembly and machine shop practice are included.

Always refer to appropriate engine overhaul article, if available, in the ENGINES section for complete overhaul procedures and specifications for the vehicle being repaired.

One-Piece Type Seal

For one-piece type oil seal installation, coat block contact surface of seal with sealer if seal is not factory coated. Ensure seal surface is free of burrs. Lubricate seal lip with engine oil and press seal into place using proper oil seal installer. See Fig. 27.

Fig. 27: Installing Typical One-Piece Oil Seal file:///C:/in323436.html Rope Type Seal

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For rope type rear main oil seal installation, press seal lightly into seat area. Using seal installer, fully MITCHELL 1 ARTICLE - GENERAL INFORMATION Engine Overhaul Procedures seal in bearing cap or cylinder block.

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Trim seal ends even with cylinder block parting surface. Some applications require sealer to be applied on main bearing cap before installing. See Fig. 28.

Fig. 28: Installing Typical Rope Seal Split-Rubber Type Seal

Follow manufacturer's procedures when installing split-rubber type rear main oil seals. Installation procedures vary with manufacturer and engine type. See Fig. 29.

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Fig. 29: Installing Typical Split-Rubber Seal

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OIL PUMP

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MITCHELL 1 ARTICLE - GENERAL INFORMATION Engine Overhaul Procedures

* PLEASE READ THIS FIRST * NOTE:

Examples used in this article are general in nature and do not necessarily relate to a specific engine or system. Illustrations and procedures have been chosen to guide mechanic through engine overhaul process.

Descriptions of processes of cleaning, inspection, assembly and machine shop practice are included.

Always refer to appropriate engine overhaul article, if available, in the ENGINES section for complete overhaul procedures and specifications for the vehicle being repaired.

ROTOR TYPE NOTE:

Examples used in this article are general in nature and do not necessarily relate to a specific engine or system. Illustrations and procedures have been chosen to guide mechanic through engine overhaul process.

Descriptions of processes of cleaning, inspection, assembly and machine shop practice are included.

Always refer to appropriate engine overhaul article, if available, in the ENGINES section for complete overhaul procedures and specifications for the vehicle being repaired.

Mark oil pump rotor locations before removing. See Fig. 30. Remove outer rotor and measure thickness and diameter. Measure inner rotor thickness. Inspect shaft for scoring or wear. Inspect rotors for pitting or damage. Inspect cover for grooving or wear. Replace worn or damaged components.

Measure outer rotor-to-body clearance. Replace pump assembly if clearance exceeds specification.

Measure clearance between rotors. See Fig. 31. Replace shaft and both rotors if clearance exceeds specification.

Install rotors in pump body. Position straightedge across pump body. Using feeler gauge, measure clearance between rotors and straightedge. Pump cover wear is measured using a straightedge and feeler gauge. Replace pump if clearance exceeds specification.

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Fig. 30: Typical Rotor Type Oil Pump 7/24/2019

MITCHELL 1 ARTICLE - GENERAL INFORMATION Engine Overhaul Procedures

Fig. 31: Measuring Rotor Clearance GEAR TYPE NOTE:

Examples used in this article are general in nature and do not necessarily relate to a specific engine or system. Illustrations and procedures have been chosen to guide mechanic through engine overhaul process.

Descriptions of processes of cleaning, inspection, assembly and machine shop practice are included.

Always refer to appropriate engine overhaul article, if available, in the ENGINES section for complete overhaul procedures and specifications for the vehicle being repaired.

Mark oil pump gear location before removing. See Fig. 32. Remove gears from pump body. Inspect gears for pitting or damage. Inspect cover for grooving or wear. Measure gear diameter and length.

Measure gear housing cavity depth and diameter. See Fig. 33. Replace worn or damaged components.

Pump cover wear is measured using a straightedge and feeler gauge. Replace pump or components if warpage or wear exceeds specification, or mating surface of pump cover is scratched or grooved.

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MITCHELL 1 ARTICLE - GENERAL INFORMATION Engine Overhaul Procedures

Fig. 32: Typical Gear Type Oil Pump

Fig. 33: Measuring Oil Pump Gear Cavity

BREAK-IN PROCEDURE * PLEASE READ THIS FIRST *

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Examples used in this article are general in nature and do not necessarily ARTICLE - GENERAL INFORMATION Engine Overhaul relate to a MITCHELL specific1 engine or system.

Illustrations and Procedures procedures have been chosen to guide mechanic through engine overhaul process.

Descriptions of processes of cleaning, inspection, assembly and machine shop practice are included.

Always refer to appropriate engine overhaul article, if available, in the ENGINES section for complete overhaul procedures and specifications for the vehicle being repaired.

ENGINE PRE-OILING NOTE:

Examples used in this article are general in nature and do not necessarily relate to a specific engine or system. Illustrations and procedures have been chosen to guide mechanic through engine overhaul process.

Descriptions of processes of cleaning, inspection, assembly and machine shop practice are included.

Always refer to appropriate engine overhaul article, if available, in the ENGINES section for complete overhaul procedures and specifications for the vehicle being repaired.

Pre-oil engine prior to operation to prevent engine damage. Lightly oiled oil pump will cavitate unless oil pump cavities are filled with engine oil or petroleum jelly.

Engine pre-oiling can be done using pressure oiler (if available). Connect pressure oiler to cylinder block oil passage such as oil pressure sending unit. Operate pressure oiler long enough to ensure correct amount of oil has filled crankcase. Check oil level while pre-oiling.

If pressure oiler is not available, disconnect ignition system. Remove oil pressure sending unit and replace with oil pressure test gauge. Using starter motor, rotate engine starter until gauge shows normal oil pressure for several seconds. DO NOT crank engine for more than 30 seconds to avoid starter motor damage. Ensure oil pressure has reached the most distant point from the oil pump.

NOTE:

If new lifters or camshaft are installed, some manufacturers require that a crankcase conditioner be added to engine oil. The engine should be operated for specified amount of time to aid in lifter break-in procedure.

INITIAL START-UP NOTE:

Examples used in this article are general in nature and do not necessarily relate to a specific engine or system. Illustrations and procedures have been chosen to guide mechanic through engine overhaul process.

Descriptions of processes of cleaning, inspection, assembly and machine shop practice are included.

Always refer to appropriate engine overhaul article, if available, in the ENGINES section for complete overhaul procedures and specifications for the vehicle being repaired.

Start engine and operate engine at low speed while checking for coolant, fuel and oil leaks. Stop engine.

Recheck coolant and oil level. Adjust if necessary.

CAMSHAFT NOTE:

file:///C:/in323436.html

Examples used in this article are general in nature and do not necessarily relate to a specific engine or system. Illustrations and procedures have been chosen to guide mechanic through engine overhaul process.

Descriptions of processes of cleaning, inspection, assembly and machine shop practice are included.

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Always refer to appropriate engine overhaul article, if available, in the MITCHELL 1for ARTICLE - GENERAL INFORMATION Engine Overhaul Procedures ENGINES section complete overhaul procedures and specifications for the vehicle being repaired.

Break-in procedure is required when new or reground camshaft has been installed. Operate and maintain engine speed between 1500-2500 RPM for approximately 30 minutes. Procedure may vary due to manufacturer's recommendations.

PISTON RINGS NOTE:

Examples used in this article are general in nature and do not necessarily relate to a specific engine or system. Illustrations and procedures have been chosen to guide mechanic through engine overhaul process.

Descriptions of processes of cleaning, inspection, assembly and machine shop practice are included.

Always refer to appropriate engine overhaul article, if available, in the ENGINES section for complete overhaul procedures and specifications for the vehicle being repaired.

Piston rings require a break-in procedure to ensure seating of rings to cylinder walls. Serious damage may occur to rings if correct procedures are not followed.

Extremely high piston ring temperatures are obtained during break-in process. If rings are exposed to excessively high RPM or high cylinder pressures, ring damage can occur. Follow piston ring manufacturer's recommended break-in procedure.

FINAL ADJUSTMENTS NOTE:

Examples used in this article are general in nature and do not necessarily relate to a specific engine or system. Illustrations and procedures have been chosen to guide mechanic through engine overhaul process.

Descriptions of processes of cleaning, inspection, assembly and machine shop practice are included.

Always refer to appropriate engine overhaul article, if available, in the ENGINES section for complete overhaul procedures and specifications for the vehicle being repaired.

Check or adjust ignition timing and dwell (if applicable). Adjust valves (if necessary). Adjust idle speed and mixture. Retighten cylinder heads (if required). If cylinder head or block is aluminum, retighten bolts when engine is cold. Follow the engine manufacturer's recommended break-in procedure and maintenance schedule for new engines.

NOTE:

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Some manufacturers require that head bolts be retightened after specified amount of operation. This must be done to prevent head gasket failure.

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MITCHELL 1 ARTICLE - GENERAL INFORMATION Engine Performance Diagnostic Routine Outline

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GENERAL INFORMATION Engine Performance Diagnostic Routine Outline

* PLEASE READ THIS FIRST * NOTE:

This article is generic in nature and all information does not apply to all vehicles. For vehicle specific information, see the appropriate articles in the ENGINE PERFORMANCE category.

WHERE DOES DRIVEABILITY DIAGNOSIS START? PERFORM BASIC INSPECTION NOTE:

This article is generic in nature and all information does not apply to all vehicles. For vehicle specific information, see the appropriate articles in the ENGINE PERFORMANCE category.

1. Verify Customer Complaint 2. Check for Relevant Technical Service Bulletins (TSBs) 3. Perform Visual Inspection (See Basic Diagnostic Procedures) 4. Test Engine Sub-Systems (See Basic Diagnostic Procedures) Mechanical Condition (Compression) Ignition Output Fuel Delivery 5. Check Air Induction System For Leaks 6. Check & Adjust Basic Engine Settings(See On-Vehicle Adjustments) Ignition Timing Idle Speed CHECK FOR TROUBLE CODES NOTE:

This article is generic in nature and all information does not apply to all vehicles. For vehicle specific information, see the appropriate articles in the ENGINE PERFORMANCE category.

1. Check for Diagnostic Trouble Codes (DTCs).(See Self-Diagnostics) 2. Repair cause of DTCs. 3. Clear PCM memory and repeat self-test.

DIAGNOSE SYMPTOM NOTE:

This article is generic in nature and all information does not apply to all vehicles. For vehicle specific information, see the appropriate articles in the ENGINE PERFORMANCE category.

1. If no self-diagnostics available, or no trouble codes present, identify symptom.

2. See trouble shooting procedure to identify problem. (See Trouble Shooting - No Codes) TEST SYSTEM NOTE: file:///C:/in848682.html

This article is generic in nature and all information does not apply to all vehicles. For vehicle specific information, see the appropriate articles in the ENGINE PERFORMANCE category.

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1. Perform required tests. (See Systems & Component Testing) 1 ARTICLE - GENERAL INFORMATION Engine Performance Diagnostic Routine Outline 2. Verify complaintMITCHELL is repaired.

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MITCHELL 1 ARTICLE - GENERAL INFORMATION Engine Performance Safety Precautions

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GENERAL INFORMATION Engine Performance Safety Precautions

Always refer to Emission Decal in engine compartment before servicing vehicle. If manual and decal differ, always use decal specifications.

Do not allow or create a condition of misfire in more than one cylinder for an extended period of time. Damage to converter may occur due to loading converter with unburned air/fuel mixture.

Always turn ignition off and disconnect negative battery cable BEFORE disconnecting or connecting computer or other electrical components.

DO NOT drop or shock electrical components such as computer, airflow meter, etc.

DO NOT use fuel system cleaning compounds that are not recommended by the manufacturer.

Damage to gaskets, diaphragm materials and catalytic converter may result.

Before performing a compression test or cranking engine using a remote starter switch, disconnect coil wire from distributor and secure it to a good engine ground, or disable ignition.

Before disconnecting any fuel system component, ensure fuel system pressure is released.

Use a shop towel to absorb any spilled fuel to prevent fire.

DO NOT create sparks or have an open flame near battery.

If any fuel system components such as hoses or clamps are replaced, ensure they are replaced with components designed for fuel system use.

Always reassemble throttle body components with new gaskets, "O" rings and seals.

If equipped with an inertia switch, DO NOT reset switch until fuel system has been inspected for leaks.

Wear safety goggles when drilling or grinding.

Wear proper clothing which protects against chemicals and other hazards.

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7/24/2019

MITCHELL 1 ARTICLE - GENERAL INFORMATION English-Metric Conversion Chart

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GENERAL INFORMATION English-Metric Conversion Chart

METRIC CONVERSIONS Metric conversions are making life more difficult for the mechanic. In addition to increasing the number of tools required, metric-dimensioned nuts and bolts are used alongside English components in many new vehicles. The mechanic has to decide which tool to use, slowing down the job. The tool problem can be solved by trial and error, but some metric conversions aren't so simple.

Converting temperature, lengths or volumes requires a calculator and conversion charts, or else a very nimble mind. Conversion charts are only part of the answer though, because they don't help you "think" metric, or "visualize" what you are converting. The following examples are intended to help you "see" metric sizes: LENGTH Meters are the standard unit of length in the metric system. The smaller units are 10ths (decimeter), 100ths (centimeter), and 1000ths (millimeter) of a meter. These common examples might help you to visualize the metric units: A meter is slightly longer than a yard (about 40 inches).

An aspirin tablet is about one centimeter across (.4 inches).

A millimeter is about the thickness of a dime.

VOLUME The metric weight system is based on the gram, with the most common unit being the kilogram (1000 grams). Our comparable units are ounces and pounds: A kilogram is about 2.2 pounds.

A kilogram is about 2.2 pounds.

TORQUE Torque is somewhat complicated. The term describes the amount of effort exerted to turn something. A chosen unit of weight or force is applied to a lever of standard length. The resulting leverage is called torque. In our standard system, we use the weight of one pound applied to a lever a foot long, resulting in the unit called a foot-pound. A smaller unit is the inch-pound (the lever is one inch long). Metric units include the meter kilogram (lever one meter long with a kilogram of weight applied) and the Newtonmeter (lever one meter long with force of one Newton applied). Some conversions are: A meter kilogram is about 7.2 foot pounds.

A foot pound is about 1.4 Newton-meters.

A centimeter kilogram (cmkg) is equal to .9 inch pounds.

PRESSURE Pressure is another complicated measurement. Pressure is described as a force or weight applied to a given area. Our common unit is pounds per square inch. Metric units can be expressed in several ways.

One is the kilogram per square centimeter (kg/cm2 ). Another unit of pressure is the Pascal (force of one Newton on an area of one square meter), which equals about 4 ounces on a square yard. Since this is a very small amount of pressure, we usually see the kiloPascal, or kPa (1000 Pascals). Another common automotive term for pressure is the bar (used by German manufacturers), which equals 10 Pascals.

Thoroughly confused? Try the examples below: file:///C:/in411372.html

Atmospheric pressure at sea level is about 14.7 psi.

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Atmospheric pressure at sea level is about 1 bar.

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MITCHELL 1 ARTICLE - GENERAL INFORMATION English-Metric Conversion Chart

Atmospheric pressure at sea level is about 1 kg/cm2 .

One pound per square inch is about 7 kPa.

CONVERSION FACTORS CONVERSION FORMULA To Convert LENGTH Millimeters (mm) Inches Meters (M) Meters (M) Feet Kilometers (Km) AREA Square Centimeters (cm2 ) Square Inches VOLUME Cubic Centimeters Cubic Inches Liters Cubic Inches Liters Quarts Liters Pints Liters Ounces WEIGHT Grams Ounces Kilograms Pounds WORK Centimeter Kilograms Pounds/Sq. Inch Bar Pounds/Sq. Inch Atmosphere Pounds/Sq. Inch TEMPERATURE Centigrade Degrees Fahrenheit Degrees EQUIVALENCIES Inches 1/64 1/32 3/64 1/16 5/64 file:///C:/in411372.html

To

Multiply By Inches Millimeters Inches Feet Meters Miles Square Inches

.03937 25.4 39.37 3.28084 .3048 .62137 .155

Square Centimeters

6.45159

Cubic Inches Cubic Centimeters Cubic Inches Liters Quarts Liters Pints Liters Ounces Liters

.06103 16.38703 61.025 .01639 1.05672 .94633 2.11344 .47317 33.81497 .02957

Ounces Grams Pounds Kilograms

.03527 28.34953 2.20462 .45359

Inch Pounds Kilograms/Sq. Centimeter Pounds/Sq. Inch Bar Pounds/Sq. Inch Atmosphere

.8676 .07031 14.504 .06895 14.696 .06805

Fahrenheit Degrees

(C°x9 /5 )+32

Centigrade Degrees

(F°-32)x5 /9

Decimals .016 .031 .047 .063 .078

mm .397 .794 1.191 1.588 1.984

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Inches 3/32 7/64 1/8 9/64 5/32 11/64 3/16 13/64 7/32 15/64 1/4 17/64 9/32 19/64 5/16 21/64 11/32 23/64 3/8 25/64 13/32 27/64 7/16 29/64 15/32 31/64 1/2 33/64 17/32 35/64 9/16 37/64 19/32 39/64 5/8 41/64 21/32 43/64 11/16 45/64 23/32 47/64 3/4 49/64 25/32 51/64 13/16 53/64 27/32 55/64 7/8 file:///C:/in411372.html 57/64 7/24/2019

Decimals .094 .109 .125 .141 .156 .172 .188 .203 .219 .234 .250 .266 .281 .297 .313 .328 .344 .359 .375 .391 .406 .422 .438 .453 .469 .484 .500 .516 .531 .547 .563 .578 .594 .609 .625 .641 .656 .672 .687 .703 .719 .734 .750 .766 .781 .797 .813 .828 .844 .859 .875 .891

MITCHELL 1 ARTICLE - GENERAL INFORMATION English-Metric Conversion Chart

mm 2.381 2.778 3.175 3.572 3.969 4.366 4.763 5.159 5.556 5.953 6.350 6.747 7.144 7.541 7.938 8.334 8.731 9.128 9.525 9.992 10.319 10.716 11.113 11.509 11.906 12.303 12.700 13.097 13.494 13.891 14.288 14.684 15.081 15.478 15.875 16.272 16.669 17.066 17.463 17.859 18.256 18.653 19.050 19.447 19.844 20.241 20.638 21.034 21.431 21.828 22.225 22.622

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Inches 29/32 59/64 15/16 61/64 31/32 63/64 1

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Decimals .906 .922 .938 .953 .969 .984 1.000

MITCHELL 1 ARTICLE - GENERAL INFORMATION English-Metric Conversion Chart

mm 23.019 23.416 23.813 24.209 24.606 25.003 25.400

Release June 2019

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MITCHELL 1 ARTICLE - GENERAL INFORMATION Gear Tooth Contact Patterns

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GENERAL INFORMATION Gear Tooth Contact Patterns

* PLEASE READ THIS FIRST * NOTE:

This is GENERAL information. This article is not intended to be specific to any unique situation or individual vehicle configuration. For modelspecific information see appropriate articles where available.

INSPECTION NOTE:

This is GENERAL information. This article is not intended to be specific to any unique situation or individual vehicle configuration. For modelspecific information see appropriate articles where available.

Wipe lubricant from internal parts. Rotate gears and inspect for wear or damage. Mount dial indicator to housing and check backlash at several points around ring gear. Backlash must be within specification at all points. If no defects are found, check gear tooth pattern contact.

NOTE:

Drive pattern should be well centered on ring gear teeth. Coast pattern should be centered, but may be slightly toward toe of ring gear teeth.

GEAR TOOTH CONTACT PATTERN NOTE:

This is GENERAL information. This article is not intended to be specific to any unique situation or individual vehicle configuration. For modelspecific information see appropriate articles where available.

1. Paint ring gear teeth with marking compound. Wrap cloth or rope around drive pinion flange to act as brake. Rotate gear until clear contact pattern is obtained.

2. Contact pattern will indicate whether correct pinion bearing mounting shim has been installed and if drive gear backlash has been set properly. Backlash between drive gear pinion must be maintained within specified limits until correct tooth pattern is obtained.

ADJUSTMENTS NOTE:

This is GENERAL information. This article is not intended to be specific to any unique situation or individual vehicle configuration. For modelspecific information see appropriate articles where available.

GEAR BACKLASH & PINION SHIM CHANGES NOTE:

This is GENERAL information. This article is not intended to be specific to any unique situation or individual vehicle configuration. For modelspecific information see appropriate articles where available.

1. With no change in backlash, moving pinion further from ring gear moves drive pattern toward heel and top of tooth, and moves coast pattern toward toe and top of tooth.

2. With no change in backlash, moving pinion closer to ring gear moves drive pattern toward toe and bottom of tooth, and moves coast pattern toward heel and bottom of tooth.

3. With no change in pinion shim thickness, an increase in backlash moves ring gear further from pinion. Both drive and coast patterns move toward heel and top of tooth.

4. With no change in pinion shim thickness, a decrease in backlash moves ring gear closer to pinion gear. Both drive and coast patterns move toward toe and bottom of tooth. file:///C:/in386912.html

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MITCHELL 1 ARTICLE - GENERAL INFORMATION Gear Tooth Contact Patterns

Fig. 1: Drive Axle Gear Tooth Patterns

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MITCHELL 1 ARTICLE - GENERAL INFORMATION General Cooling System Service

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GENERAL INFORMATION General Cooling System Service

* PLEASE READ THIS FIRST * This article is generic in nature and all information does not apply to all vehicles including those without a liquid cooling system. For vehicle specific information, see the appropriate articles in the ENGINE category.

DESCRIPTION The liquid cooling system consists of a radiator, water pump, thermostat, electric or belt-driven cooling fan, pressure cap, heater, and various connecting hoses and cooling passages in the engine block and cylinder head.

MAINTENANCE DRAINING Remove radiator cap and open heater control valve to maximum heat position. Open drain cocks or remove plugs in bottom of radiator and engine block. In-line engines usually have one plug or drain cock, while "V" type engines have 2, one in each bank of cylinders.

FLUSHING CAUTION:

Some manufacturers use an aluminum and plastic radiator. Flushing solution must be compatible with aluminum.

Radiator

Connect flushing gun to water outlet of radiator. Disconnect water inlet hose. To prevent flooding engine, use a hose connected to radiator inlet. Use air in short bursts to prevent damage to radiator.

Continue flushing until water runs clear.

Engine Block

To flush engine, remove thermostat. Connect flushing gun to water outlet of radiator. Use air in short bursts to prevent damage to radiator. Continue flushing until water runs clear.

REFILLING To prevent air from being trapped in engine block, engine should be running when refilling cooling system. After system is full, continue running engine until thermostat is open, then recheck fill level. Do not overfill system.

TESTING THERMOSTAT 1. Remove and inspect thermostat for corrosion and proper seating of valve. If okay, suspend thermostat and thermometer in a 50/50 mixture of coolant and water. See Fig. 1. DO NOT allow thermostat or thermometer to touch bottom or container. Heat water until thermostat begins to open.

2. Read temperature on thermometer. This is the initial opening temperature and should be within specification. Continue heating water until thermostat is fully open and note temperature. This is the fully open temperature. If either reading is not to specification, replace thermostat. file:///C:/in184202.html

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Fig. 1: Testing Thermostat in Coolant/Water Solution PRESSURE TESTING A pressure tester is used to check both radiator cap and complete cooling system. Follow pressure tester manufacturer instructions and test components as follows: Radiator Cap

Visually inspect radiator cap. If cap looks okay, connect pressure tester to cap. See Fig. 2. Pressurize tester to full radiator cap specification. Replace cap if it fails to hold pressure.

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Fig. 2: Pressure Testing Radiator Cap Cooling System

1. Turn ignition off and allow engine to cool. Ensure radiator if filled to correct level. Remove cap and attach pressure tester to radiator. Pressurize tester to full radiator rating specification.

2. If pressure drops, check for external leaks. If no leaks are found, start engine and allow to idle. If pressure builds up immediately, check cylinder head and block for cracks. If pressure does not build up immediately, go to next step.

CAUTION:

DO NOT allow excess pressure to build in cooling system or damage may result.

3. Using pressure tester, pump cooling system up to pressure specified on radiator cap. If pump gauge pointer vibrates, compression or combustion leak into cooling system is indicated. Isolate leak by shorting each spark plug wire to cylinder block. Gauge pointer vibration will stop or decrease when leaking cylinder is shorted.

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Back To Article

2018 GENERAL INFORMATION General Information - F150

DESCRIPTION AND OPERATION ABOUT THIS SERVICE INFORMATION Introduction

WARNING:

Before beginning any service procedure, refer to Health and Safety Precautions. Failure to follow this instruction may result in serious personal injury.

For additional information, refer to: Health and Safety Precautions.

This service information describes and directs repair procedures specified by Ford Motor Company for the vehicle. Critical health and safety precautions are included. Anyone who deviates from these instructions risks compromising personal safety or vehicle integrity.

CONTENT Contents may include: Specifications Fluid capacities, component specifications and torque values not covered in other procedures Description and Operation Overview of the system, component locations, and system operation Diagnosis and Testing Symptom charts, DTC charts and diagnostic tests See the Diagnosis and Testing Information General Procedures Service adjustments, electronic programming and other special procedures Removal and Installation Component removal and installation instructions Removal Component removal instructions Installation Component installation instructions Disassembly and Assembly Component disassembly and assembly instructions Disassembly file:///C:/in755846.html

and Assembly of Subassemblies

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IMPORTANT INFORMATION General Information contains the following important information: Critical Health and Safety Precautions - service safety precautions applicable to the entire manual.

For additional information, refer to: Health and Safety Precautions.

A Symbols Glossary - definitions of the action directed by each symbol. For additional information, refer to: Symbols Glossary.

Diagnostic Methods - support information for diagnostics. For additional information, refer to: Diagnostic Methods.

Warnings, Notices and Notes WARNINGS

Warnings provide information to avoid personal injury and to make sure service actions on critical safety systems are performed correctly. Warnings that apply to an entire system or Description and Operation, Health and Safety Precautions. For additional information, refer to: Health and Safety Precautions.

NOTICES (in some publications, CAUTIONS)

Notices provide information to avoid damage to the vehicle or a component.

NOTES

Notes provide information critical for a complete and effective repair.

Warnings, Notices, or Notes that apply to an entire procedure will be placed at the beginning of the procedure. Warnings, Notices, or Notes that apply to a single step are placed at the beginning of the step.

Those that apply to a group of steps will be placed at the first step requiring it.

Safety Relevant Systems

Repair of a vehicle safety relevant system is to be achieved only by replacement of the failed component(s), unless specified otherwise in the procedure. Repair of a vehicle safety relevant system component should not be attempted.

If directed during assembly of system components, lubricate any seal(s) only with the specified material.

Failure to follow this instruction may result in seal failure and leakage.

Specified Chemicals or Materials

Throughout this manual, chemicals or materials are specified that must be used to properly complete a service procedure or diagnostic step. In the event a specific material is not readily available, a substitute material meeting the same specification may be used. Ford has not reviewed third party products for compliance with environmental, health or safety regulations and is not responsible for their use. Use of third party products is at your own risk. Additionally, such products may cause degraded performance, premature failures, and/or vehicle component damage. All chemicals or materials used for vehicle servicing should be checked for compliance with local environmental and health and safety regulations.

LH and RH Designations

All LH and RH designations are oriented from the driver's seat position looking forward.

Vehicle LH and RH definition

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Item 1 2

Part Number -

Description LH (left-hand) RH (right-hand)

All LH and RH engine designations are oriented from the flywheel position looking toward the crankshaft pulley.

Powertrain LH and RH definition

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Item 1 2 3 4

Part Number -

Description Front RH (right-hand) Rear LH (left-hand)

Standard Practices

The following rules apply, unless specified differently in the procedure: FASTENERS

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GENERAL INFORMATION General Information - F150 highlighted yellow) are shown in- the

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Replace fasteners with torque angle specifications (those tightened a specified number of degrees).

Examples of self-locking nuts and bolts

Item 1 2 3 4 5 6 7

Part Number -

Description Completely coated self-locking bolt Partially coated self-locking bolt Self-locking bolt with a locking washer Self-locking nut with a plastic locking insert Self-locking nut with thread deformation (3 indentations) Self-locking nut with thread deformation (to oval shape) Self-locking nut with integrated locking ring

THREAD FORMING FASTENERS

The following is a general description of best practices to be followed during handling of thread forming fasteners and mating components.

Manual Torque Application

Hand tools are required for installation of a thread forming fastener. Do NOT use power tools, as the possibility for over-torqueing or stripped threads exists. If a fastener is over-torqued, the joint can fail.

Hand Start Fasteners in Reverse

To avoid the possibility of cross-threading pre-existing threads during fastener replacement, begin by first hand-inserting the new fastener and rotating counter-clockwise. This reverse rotation allows for the location of existing fastener threads to ensure the fastener does not cross-thread upon thread reengagement. Once the existing fastener threads are located, hand-start individual fasteners manually until finger tight.

Risks of Over-Torque

Consult the appropriate procedure when torquing thread forming fasteners and follow torque specification as listed. Make sure the fastener is fully seated against the mating component with no gap

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during reassembly.

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Corrosion

During fastener replacement, inspect both fastener and mating component for signs of rust or other corrosion. If corrosion is found, replace corroded components with new components.

Stripped Threads

If internal (mating component) threads or external (fastener) threads appear stripped or galled, replace both fastener and mating component. When tightening, if minimum torque is not reached, internal threads on mating component may have stripped. Remove the fastener to inspect and replace mating component if stripped threads are found.

Face Seals

When replacing fasteners, inspect mating component surface for debris, damage, disturbance, wear, or abrasion and replace any seals or gaskets if damage is found.

SEALS AND GASKETS

Replace seals and gaskets, unless specified differently in the procedure.

EXTERIOR TRIM PARTS

Replace exterior trim parts fastened with glue or adhesive tape, unless specified differently in the procedure.

Mechanical Procedures

Illustrations in this manual may be used instead of written step instructions. Color-coding (see color scheme illustration) is used to communicate the required step action or actions. Service action icons may be used to add information regarding the required action. For additional information, refer to: Symbols Glossary.

Illustration Color-coding

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Item

Part Number

1

-

2

-

3

-

4

-

5

-

6

-

Description Blue - Target or primary component to be removed/installed (or disassembled/assembled).

Green - Components that need to be removed prior to or installed after the target/primary.

Brown - Components that need to be removed prior to or installed after the target/primary.

Yellow - Components to be set aside for access, but not removed. Also highlighted areas to inspect or adjust.

Magenta - Electrical connectors and fasteners such as nuts, bolts, clamps, or clips to be: detached, attached, loosened, moved, removed or installed.

Pale Blue - Special tool(s), general equipment, or common tools used in an uncommon way.

Other color coding Alternating Blue and White Chemical, adhesive or sealer apply areas Red Sectioned or cut-away areas Grey file:///C:/in755846.htmlBackground

components shown for location information

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Components that must be removed or installed in a specific sequence are identified with a numbered callout. Any associated step text is numbered accordingly.

Simple procedure example showing color-coding and task sequence.

Black arrows are used to draw attention to components (usually fasteners). Arrows with multiples specified (here, x2) identify an identical number of fasteners or items. Callouts (numbers inside circles) show a required sequence or tightening torque.

In the illustration, the callouts indicate the removal sequence, which is reversed for installation . The yellow coloring of the hose indicates it is to be positioned aside (not removed). Two identical (magentacolored) fasteners are indicated by the x2 arrow. The fasteners in this illustration require different torques (same torque for the x2 fasteners) so numbered callouts are used to identify them with torque values in the associated step text. The (magenta-colored) hose clamp is another fastener to be removed.

Examples of fastener removal sequence and an identical service action for 12 fasteners. Other possible symbols are shown on the right in illustration.

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Example of fastener sequence information with two persons required for the service action

HIDDEN DETAILS

Separate detail boxes or transparent components may be used to show hidden items in an illustration.

Example of hidden fastener information

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Service action icons may be used to add information regarding the required action. For additional information, refer to: Symbols Glossary.

Location symbols show the location of a component or system on the vehicle.

Example of service action icons pointing to highlighted components.

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Movement arrows and service action icons show three dimensional or rotational movements.

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Measurement symbols provide the information required to perform a specific measurement.

These symbols may include specific values.

SPECIAL TOOLS, EQUIPMENT, MATERIALS AND TORQUE VALUES

When Ford special tools are required for the procedure, the tool and tool number are shown in an illustration. Special tool numbers, general equipment, materials or torque values for the procedure step are shown in the text steps.

Example of special service tool and symbol used to hold the gear shift in the required gear position. Other possible symbols are shown on the right in illustration.

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Example of two illustrations used together with sequence steps, service action icons and special service tools

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Tool symbols direct the use of standard tools. The tool size or dimension may be specified.

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HEALTH AND SAFETY SYMBOLS

Some procedures may contain health and safety symbols that are associated with a specific service action. For additional information, refer to: Symbols Glossary. Always read and understand all health and safety precautions found in Health and Safety Precautions.

ISO warning symbols may be used to indicate potential hazards.

These symbols prohibit various hazardous actions

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These symbols direct the use of personal protection equipment

Diagnosis and Testing Information ELEMENTS OF DIAGNOSIS AND TESTING

Diagnosis and Testing may include: Preliminary Inspection In older manuals, Inspection and Verification Symptom Chart DTC Chart Pinpoint Tests file:///C:/in755846.html Component Tests

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Some diagnostics may be contained in Symptom Based Diagnostics. Some engine performance and 1 ARTICLE - 2018 GENERAL INFORMATION General Information - F150 diagnostics may beMITCHELL placed in a separately in ENGINE CONTROLS - POWERTRAIN DTC CHARTS & DESCRIPTIONS (DIESEL) or ENGINE CONTROLS - POWERTRAIN DTC CHARTS & DESCRIPTIONS (EXCEPT DIESEL & HYBRID) .

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MODULE NAMES MATCH THE DIAGNOSTIC SCAN TOOL

Module names and PID names in this manual match the Ford diagnostic scan tool: IDS. The same diagnostic scan tool module name is found in some DTC definitions (for example, U024B Lost Communication with Seat Control Module "G").

MODULE DESCRIPTIVE NAMES

A descriptive name is sometimes added to the diagnostic scan tool name to clarify module function. The descriptive name will be followed by the diagnostic scan tool acronym in brackets.

Example: "Driver Active Motion Seat Module [SCMG]".

Driver Active Motion Seat Module is the descriptive name added to clarify the function of the SCMG. The SCMG acronym is used by diagnostic scan tool, defined as "Seat Control Module G".

BATTERY AND BATTERY CHARGING HEALTH AND SAFETY PRECAUTIONS WARNING:

Batteries contain sulfuric acid and produce explosive gases. Work in a well-ventilated area. Do not allow the battery to come in contact with flames, sparks or burning substances. Avoid contact with skin, eyes or clothing. Shield eyes when working near the battery to protect against possible splashing of acid solution. In case of acid contact with skin or eyes, flush immediately with water for a minimum of 15 minutes, then get prompt medical attention. If acid is swallowed, call a physician immediately. Failure to follow these instructions may result in serious personal injury.

WARNING:

Always lift a plastic-cased battery with a battery carrier or with hands on opposite corners. Excessive pressure on the battery end walls may cause acid to flow through the vent caps, resulting in personal injury and/or damage to the vehicle or battery.

WARNING:

Battery posts, terminals and related accessories contain lead and lead components. Wash hands after handling. Failure to follow these instructions may result in serious personal injury.

BODY REPAIR HEALTH AND SAFETY AND GENERAL PRECAUTIONS WARNING:

Always refer to Material Safety Data Sheet (MSDS) when handling chemicals and wear protective equipment as directed. Examples may include but are not limited to respirators and chemically resistant gloves.

Failure to follow these instructions may result in serious personal injury.

WARNING:

Always wear protective equipment including eye protection with side shields, and a dust mask when sanding or grinding. Failure to follow these instructions may result in serious personal injury.

WARNING:

Do not carry out body side sectioning repairs in areas of door hinge or striker anchoring points. Welding within 50 mm (1.96 in) of door hinge or striker locations may compromise structural integrity during a collision.

Failure to follow these instructions may result in serious injury to vehicle occupant(s).

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WARNING:

Invisible ultraviolet and infrared rays emitted in welding can injure

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unprotected eyes and skin. Always use protection such as a welder's MITCHELL 1 ARTICLE - 2018 GENERAL INFORMATION General Information - F150 helmet with dark-colored filter lenses of the correct density.

Electric welding will produce intense radiation, therefore, filter plate lenses of the deepest shade providing adequate visibility are recommended. It is strongly recommended that persons working in the weld area wear flash safety goggles. Also wear protective clothing. Failure to follow these instructions may result in serious personal injury.

WARNING:

All safety belt components must be inspected and corrected as part of any collision repair. Inspect all safety belt components as prescribed by Safety Belt Inspection and Repair After a Collision found in GENERAL PROCEDURES . Failure to follow this instruction may result in incorrect operation of the safety belt system and increase the risk of serious personal injury or death in a crash.

WARNING:

If a vehicle has been in a crash, inspect the restraints control module (RCM) and the impact sensor (if equipped) mounting areas for deformation. If damaged, restore the mounting areas to the original production configuration. A new RCM and sensors must be installed whether or not the air bags have deployed. Failure to follow these instructions may result in serious personal injury or death in a crash.

WARNING:

Collision damage repair must conform to the instructions contained in this service information. Replacement components must be new, genuine Ford Motor Company parts. Recycled, salvaged, aftermarket or reconditioned parts (including body parts, wheels or safety restraint components) are not authorized by Ford.

Departure from the instructions provided in this manual, including alternate repair methods or the use of substitute components, risks compromising crash safety. Failure to follow these instructions may adversely affect structural integrity and crash safety performance, which could result in serious personal injury to vehicle occupants in a crash.

BRAKE AND CLUTCH SYSTEMS HEALTH AND SAFETY PRECAUTIONS Brake and Clutch Systems Health and Safety Precautions WARNING:

Do not breathe dust or use compressed air to blow dust from storage containers or friction components. Remove dust using governmentapproved techniques. Friction component dust may be a cancer and lung disease hazard. Exposure to potentially hazardous components may occur if dusts are created during repair of friction components, such as brake pads and clutch discs. Exposure may also cause irritation to skin, eyes and respiratory tract, and may cause allergic reactions and/or may lead to other chronic health effects. If irritation persists, seek medical attention or advice. Failure to follow these instructions may result in serious personal injury.

NOTE:

If the brake fluid is spilled on the paintwork, the affected area must be immediately washed down with cold water.

CLIMATE CONTROL SYSTEM HEALTH AND SAFETY PRECAUTIONS WARNING:

Air conditioning liquid refrigerant R-134a and R-1234yf are capable of harming eyes or freezing skin. Always wear safety goggles and avoid contact with liquid refrigerant. Failure to follow these instructions may result in serious personal injury.

WARNING:

Air conditioning refrigerant R-134a and R-1234yf gases are capable of displacing the air necessary for breathing in a confined space and can produce toxic gasses if burned at high temperatures. Do not release a

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large quantity of R-134a or R-1234yf gas within a confined space or allow MITCHELL to 1 ARTICLE - 2018 GENERAL INFORMATION General as Information - F150 Consult it to be exposed a high temperature flame (such a torch). the Material Safety Data Sheet (MSDS) for further information. Failure to follow these instructions may result in serious personal injury or death.

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WARNING:

Use extreme care and observe all safety and service precautions related to the use of refrigerants as outlined on refrigerant tank and on recovery and charging equipment. Failure to follow these instructions may result in serious personal injury.

WARNING:

Before disconnecting any heater water hoses, shut OFF the engine and wait until engine is fully cool. Failure to comply with this warning may result in serious injury or burns from hot liquid escaping from the engine cooling system.

WARNING:

The electric booster heater may become hot during use and can burn unprotected skin. Allow enough time for the heater to cool before servicing. Failure to follow this instruction may result in serious personal injury.

DIAGNOSTIC METHODS Effective Diagnostic Techniques

NOTE:

Do not use this document in place of Ford-prescribed Symptom Based Diagnostics or Service Information diagnostics. Diagnostic Methods is intended to provide Ford vehicle diagnostic information only for support of Ford-prescribed diagnostics.

The following diagnostic process is critical for consistently successful diagnoses. Random methods work inconsistently and often lead to multiple repairs and the accompanying frustration.

Understand and verify the symptom .

Understanding a symptom requires understanding normal operation.

Duplicate the concern. Recreate the same conditions that demonstrated the original concern (road testing may be necessary).

Determine the responsible system .

Gather data, such as a visual inspection and an OASIS report.

Perform system tests, such as pressure tests or DTC retrieval.

Identify the responsible component .

Test the suspect component and related parts.

Determine the root cause Examine related components (wiring faults, misalignments, incorrect adjustments) that may be the actual cause or may have caused the component failure.

Repair all related faults to avoid repeat failures.

Verify the repair has corrected the concern (and not created any new ones) using the identical conditions that demonstrated the original concern.

Diagnostic Scan Tool Testing

Network Test

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Recommended Practices: Refer to COMMUNICATIONS NETWORK , to diagnose a network outage or no response from an individual module (or modules).

Diagnostic Trouble Code Retrieval Generally, a good diagnostic strategy is to resolve all on-demand codes related to the system concern.

Retrieving all continuous DTCs can also be beneficial to understand historic issues or issues outside of the suspect system that may be affecting your concern. On-demand testing should be done to ensure the fault represented by a continuous DTC is still present.

Continuous Memory Diagnostic Trouble Codes Modules that produce diagnostic trouble codes have a program that evaluates system conditions, normally while the vehicle or system is in use. Module inputs can be checked for values indicating an electrical fault with the monitoring circuit or component. Module outputs can be monitored for correct function. Codes are stored when predefined limits are exceeded and retained even if the ignition is turned off (generally a DTC is retained for 40+ ignition cycles). Not all continuous codes have a matching on-demand code - and vice versa. This varies with different modules. For example, some network communication codes are continuous only. It is important to note that the presence of a continuous DTC does not guarantee that the fault currently exists.

Clearing Continuous Memory Diagnostic Trouble Codes Continuous Memory DTCs caused by the issue being repaired or created during the diagnosis and repair must be cleared or they will confuse future diagnosis. NOTE: Do not clear DTCs from unresolved vehicle issues.

Ford On-Demand Diagnostic Trouble Codes Ford Motor Company modules have a unique feature that performs a special diagnostic program at the request of the technician (using a diagnostic scan tool). This "On-demand" diagnostic program can exercise system outputs not normally running when the car is parked and record observed faults. These diagnostic codes are communicated to the scan tool, but are not recorded in module memory. An ondemand test is an effective tool for evaluating real input and output conditions during module activity activity that might not normally be occurring during service bay conditions. For example, an air suspension module on-demand test can run the compressor, vent the system, and observe the report from the height sensor even when the car is already at correct trim height and not requiring height adjustment.

Network Communication Diagnostic Trouble Codes Network DTCs (U-prefix codes) are often a result of intermittent concerns such as damaged wiring or low battery voltage occurrences. Additionally, vehicle repair procedures (such as module reprogramming or diagnostics with modules disconnected) often set network DTCs. Replacing a module to resolve a network DTC is unlikely to resolve the concern. To prevent recurrence of intermittent network concerns, inspect all network wiring, especially in-line and module connectors. Test the vehicle battery to make sure the vehicle voltage will be stable.

Recommended practice: Clear the DTC and retest. If the DTC repeats, test the vehicle communication network.

DTC Nomenclature (SAE J2012 and ISO 14229) Many modules use 5-character DTCs followed by a 2-character failure-type code. The failure-type (sometimes called "fault byte") codes provide information about specific fault conditions such as opens or shorts to ground. Continuous memory DTCs have an additional 2-character DTC status code suffix to assist in determining DTC history.

Integrated Diagnostic System Scan Tool Usage

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Diagnostic System Scan Tool Does Not Communicate With The Vehicle Communication Module

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1. Check the Vehicle Communication Module connection and power from the DLC. MITCHELL 1 ARTICLE - 2018 GENERAL INFORMATION General Information - F150 2. Check the communication between the scan tool and the Vehicle Communication Module.

3. Follow scan tool instructions to retry.

If The Integrated Diagnostic System Scan Tool Does Not Communicate With The Vehicle The IDS scan tool first attempts to communicate with the PCM. After establishing communication with the PCM, the scan tool then attempts to communicate with all other modules on the vehicle.

1. Verify the scan tool operation with a known good vehicle.

2. Verify the ignition is ON. 3. If an IDS session cannot be established with the vehicle, (IDS may state "No communication can be established with the PCM"): Choose "NO" when the scan tool prompts to retry communication.

Enter a PCM engineering part number, tear tag, or calibration number to identify the vehicle and start a session. These identifying numbers may be found: The PCM engineering part number and the 4-character tear tag are printed on the PCM label.

(PTS website users only) The PCM engineering part number can be determined from OASIS using the VIN. Choose "HVBoM" from the OASIS tab menu and search Powertrain engine modules for the PCM engineering part number (If the first character is a "P" in the part number, enter only the characters following the "P" into IDS).

Establish a session based on the PCM information (above).

4. Using the tool box menu, run the network test.

Determine if all modules on the network are unresponsive or if only the PCM does not communicate.

Recommended practice: Refer to COMMUNICATIONS NETWORK , to diagnose the network outage or no response from the PCM. Measuring Automotive Circuits

Wiring Pin (Terminal) Fit And The Use Of Rotunda Flex Probes To avoid wiring pin (terminal) damage, Rotunda Flex Probes NUD105-R025D or Terminal Probe Kit 29-011A must be used to connect test equipment or jumper wires to pins (terminals).

Male to female pin (terminal) fit is critical for correct connection and durability.

Pin (terminal) fit may be checked by using the mating pin (terminal) to test for normal separation force (a damaged pin or terminal will have very low separation force from the mating pin or terminal) Correctly checking the separation force of small pins (terminals) may require removal of the connector terminal guide/retainer if it adds drag to the pin (terminal) insertion or removal Replace damaged connectors or pins (terminals). For additional information, refer to: Wire Terminal Inspection and Removal.

Checking Power-Providing Circuits Measuring a power wire with the intended load disconnected using a Digital Multimeter (DMM) will only find open circuits (open fuse or wire).

Recommended practice: Circuits carrying approximately 200-1000 mA* may be loaded with a file:///C:/in755846.html 250-350 mA test light. Measure circuit voltage with a Digital Multimeter (DMM) while the test

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light is connected and illuminated. A reduction in the voltage present during test-light-loading MITCHELL 1 ARTICLE - 2018 GENERAL INFORMATION General Information - F150 indicates excessive circuit resistance.

Recommended practice: Circuits carrying more than one ampere* should be loaded with a device requiring similar current (e.g., a headlamp bulb may be effective). A reduction in the voltage present during loading indicates excessive resistance. *Circuit current is matched to wire gauge/size; Examples: Conductor sizes of 24 gauge (.5 mm) or smaller are generally used to carry approximately 1 ampere (1000 mA) or less. Use of the test light to load these circuits is appropriate.

Conductor sizes of 20 gauge (.8 mm) or larger are generally used to carry approximately 5 amperes (5000 mA) or more. Match the substitute load (measure substitute load current first as necessary) to this current level.

Checking Ground-Providing Circuits The best method of checking ground circuits is to measure the circuit voltage drop during component operation (or attempted operation).

An ohmmeter may be accurately used if the battery has been disconnected.

Recommended practice: Expect less than 2 ohms for most small diameter (18 gauge and smaller) wires.

Ohmmeter accuracy is limited to circuits carrying less than approximately 5 amperes (this is due to the fact that very small resistances, undetectable by a Digital Multimeter (DMM), cause significant voltage loss in higher current circuits).

Digital Multimeter (DMM) ohmmeter readings are easily corrupted by the normal voltage present (battery connected) in many ground circuits.

Recommended practice: Reverse the leads and check for changes in the measurement.

Reversing the Digital Multimeter (DMM) lead connections should never change the resistance measurement (unless the circuit contains a semi-conductor). Measurement (nonsemi-conductor) differences when leads are interchanged at the test points indicate invalid test results. The presence of voltage corrupts the reading, and causes the meter reading to change when the leads are reversed.

Checking Circuit Continuity Recommended practice: Expect less than 2 ohms of resistance for most wires.

Ohmmeter low-resistance resolution (approximately 0.1 ohm) limits its use to circuits carrying less than approximately 5 amperes. This is due to the fact that very small resistances, below the resolution of a Digital Multimeter (DMM), cause significant voltage loss in higher current circuits.

The Digital Multimeter (DMM) applies a small amount of voltage to the circuit or component to calculate resistance. As a result, Digital Multimeter (DMM) ohmmeters are very sensitive to any level of voltage present. Voltage present in the circuit will corrupt the Digital Multimeter (DMM) reading.

Checking For Unintended Continuity (Shorts) To Other Circuits A Digital Multimeter (DMM) ohmmeter may be used to detect undesired circuit connections to: Ground Other unpowered circuits Recommended practice: Expect greater than 10, 000 ohms of resistance between two separate circuits; the best result is an open circuit Digital Multimeter (DMM) indication (no detected resistance).

Shorts to voltage are checked with a voltmeter Recommended practice: Turn ignition on (with battery connected) and measure the circuit for file:///C:/in755846.html any voltage present (none should be present)

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Back-probing should be a testing method of last resort. It should only be employed where a diagnostic step requires a circuit to be tested under actual operating conditions. Back-probing is a risky testing method due to the uncertainty of the probe connection and the possibility of damaging terminals.

Do not force test leads or other probes into connectors. Adequate care must be exercised to avoid connector terminal damage while ensuring that good electrical contact is made with the circuit or terminal. Failure to follow these instructions may cause damage to wiring, terminals, or connectors and subsequent electrical faults.

Use back probes specifically designed for the purpose to assist in making a good test connection and to prevent connector or terminal damage during back-probing.

Do not test for the presence of voltage at a single point where zero volts is a possible result (you cannot tell the difference between a bad probe contact and a zero volt result).

Do not test for continuity/opens (using an ohmmeter) between two points (you cannot tell the difference between bad probe contacts and an open circuit).

Back-probing may be used where the circuit must be analyzed with the voltage-drop method (if the circuit carries greater than 5 amperes and no other means of testing will definitively eliminate circuit resistance as a possible fault). A zero-volt result indicates incorrect test conditions (no current flow) or bad back-probe connections.

Occasionally, module failure mode behavior will change the operation of a circuit when it is opened for testing. Back-probing is an acceptable remedy for these testing dilemmas.

Circuit Analysis Using Jumper Wires (Creating Substitute Circuits) Jumper wires may be employed for circuit analysis.

Cautions: Always use fused jumper wires - the recommended universal-testing jumper wire fuse is 2-5 amperes; larger fuse ratings should be used only in special circumstances.

Use flex probes or equivalent to prevent connector terminal damage (flex probes are not intended to carry higher currents necessary to operate motors such as a cooling fan or blower motor).

Follow appropriate service information testing directions when using jumper wires to avoid component or harness damage due to incorrect jumper connections.

Never repair a circuit by adding a new wire in parallel to the old one (overlaying the circuit) without fully understanding what caused the circuit to fail. Always find, examine, and repair the fault to correct the root cause and to repair any adjacent wiring that has been damaged.

Checking Modules Generally, module failure rate is very low and therefore replacement modules usually do not resolve the root cause. Incorrect replacement of a module is often the result of inadequate testing.

Understand the correct module function.

Make sure programmable parameters are set correctly for the function in question (Refer to MODULE COMMUNICATIONS NETWORK (1 OF 2) or MODULE COMMUNICATIONS NETWORK (2 OF 2) for more information).

Resolve DTCs first - as directed by Diagnostic Routines.

Test all inputs, both hard-wired and networked.

Test outputs (see "Checking module switching circuits" below). file:///C:/in755846.htmlCheck

applicable TSBs for module software changes (flash programming).

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Checking module switching circuits.

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MITCHELL 1 ARTICLE - 2018 GENERAL INFORMATION General Information - F150

Using the scan tool module-output command function (for example, IDS Output State Control) to activate components is a fast way to confirm an output is capable of being switched on by the module. Testing that reveals normal module-output function confirms the need to analyze the module inputs.

Don't apply ground or power directly to module-switched components with jumper wires (unless directed by appropriate service information), as the component could be damaged by a direct connection to ground/power.

DIESEL FUEL SYSTEM HEALTH AND SAFETY PRECAUTIONS WARNING:

Do not work on the fuel system until the pressure has been released and the engine has cooled. Fuel in the high-pressure fuel system is hot and under very high pressure. High-pressure fuel may cause cuts and contact with hot fuel may cause burns. Failure to follow these instructions may result in serious personal injury.

ENGINE COOLING SYSTEM HEALTH AND SAFETY PRECAUTIONS WARNING:

Always allow the engine to cool before opening the cooling system. Do not unscrew the coolant pressure relief cap when the engine is operating or the cooling system is hot. The cooling system is under pressure; steam and hot liquid can come out forcefully when the cap is loosened slightly. Failure to follow these instructions may result in serious personal injury.

GASOLINE AND GASOLINE-ETHANOL FUEL SYSTEMS HEALTH AND SAFETY PRECAUTIONS WARNING:

Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury.

WARNING:

Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.

WARNING:

Clean all fuel residue from the engine compartment. If not removed, fuel residue may ignite when the engine is returned to operation. Failure to follow this instruction may result in serious personal injury.

WARNING:

Do not carry personal electronic devices such as cell phones, pagers or audio equipment of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.

WARNING:

Always disconnect the battery ground cable at the battery when working on an evaporative emission (EVAP) system or fuel-related component.

Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.

WARNING:

When handling fuel, always observe fuel handling precautions and be prepared in the event of fuel spillage. Spilled fuel may be ignited by hot vehicle components or other ignition sources. Failure to follow these instructions may result in serious personal injury.

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WARNING:

Remove the fuel filler cap slowly. The fuel system may be under pressure.

1 ARTICLE - 2018 GENERAL INFORMATION General Information - F150 If the fuelMITCHELL filler cap is venting vapor or if you hear a hissing sound, wait until it stops before completely removing the fuel filler cap. Otherwise, fuel may spray out. Failure to follow these instructions may result in serious personal injury.

WARNING:

Avoid contact with fuel during a visual inspection for fuel leaks with the engine running. Do not work on the fuel system until the pressure has been released and the engine has cooled. Fuel in the high-pressure fuel system is hot and under very high pressure. High-pressure fuel may cause cuts and contact with hot fuel may cause burns. Failure to follow these instructions may result in serious personal injury.

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HEALTH AND SAFETY PRECAUTIONS Review carefully the information below before beginning any repair. Following these warnings is a list of specific system warnings that must be reviewed before beginning work on any listed system.

WARNING:

Vehicles with scheduled remote start technology may start at any time.

Make sure the scheduled remote start system is disabled when servicing or working in close proximity to rotating engine parts. Remote start features should be disabled via the instrument cluster settings. Refer to information display, settings in the owner's manual. Failure to follow this instruction may result in serious personal injury.

WARNING:

Wear eye and ear protection when servicing a vehicle. Failure to follow this instruction may result in serious personal injury.

WARNING:

Wear protective gloves when handling components or parts that have pointed or sharp edges. Failure to follow this instruction may result in serious personal injury.

WARNING:

Chemicals or materials specified in this manual, if used improperly, may present a personal health hazard. Always consult the material safety information sheet before using any material specified by this manual.

Failure to follow this instruction may result in serious personal injury.

WARNING:

Do not work under the hood of a vehicle with a damaged cooling fan, as it can separate during operation. With the ignition OFF, inspect all cooling fans for damage, cracks or separation and replace with a new fan as necessary. Failure to follow this instruction may result in serious personal injury.

WARNING:

Cooling fans may run with the ignition off. Disable the fans before working nearby. On electric vehicles, disconnect the charging cable to prevent unexpected fan operation. Failure to follow this instruction may result in personal injury.

WARNING:

Vehicles with engine auto start-stop technology may start automatically with the ignition on. Make sure the ignition is off when servicing or working in close proximity to rotating engine parts. Failure to follow this instruction may result in serious personal injury.

WARNING:

Serious injury may occur if the engine is accidently started by another person during service work. Remove the key from the vehicle to prevent unauthorized starts. Failure to follow this instruction may result in serious personal injury.

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modifications. Identify the correct jacking points in JACKING AND 1 ARTICLE - 2018 GENERAL Information LIFTING -MITCHELL OVERVIEW . Position the INFORMATION vehicle onGeneral a hard, level- F150 surface. After jacking, always support vehicle with jack stands. Never get under a vehicle supported only by a jack. Set the parking brake and block all wheels remaining on the ground. Failure to follow these instructions may result in unintended vehicle movement and serious personal injury or death.

WARNING:

Before raising the vehicle on a hoist, make sure the hoist capacity is adequate for the vehicle weight, including any vehicle cargo or modifications. Always position the hoist lift arms as shown in JACKING AND LIFTING - OVERVIEW . Do not use the engine to power the drive wheels unless all drive wheels are elevated off the ground. Incorrect hoist arm positioning or drive wheels in contact with the ground can cause unintended vehicle movement. Failure to follow these instructions may result in serious personal injury or death.

WARNING:

Removal of heavy components (such as engines, transmissions or axles) while the vehicle is lifted on a hoist may create a dangerous weight imbalance. Restrain the vehicle on the hoist with chains or straps to prevent vehicle movement. Failure to follow this instruction may result in serious personal injury or death.

WARNING:

Always secure transmission, transfer case, and axle assemblies to their service jack. Avoid obstructions while lowering and raising the jack.

Improperly secured assemblies or contact with obstructions may cause the assembly to fall off the jack, which could result in serious personal injury.

WARNING:

Always secure engines, transmissions, or other heavy components to the support fixture with straps and wooden support blocks. Improperly secured assemblies could fall off the fixture, resulting in serious personal injury.

WARNING:

Never support an engine by the intake or exhaust manifolds. The engine may drop suddenly. Failure to follow this instruction may result in serious personal injury.

WARNING:

Turn off (disable) the power running boards (if equipped) before jacking, lifting or placing any object under the vehicle. Never place your hand between the power running board and the vehicle. Extended power running boards will retract when doors are closed. Failure to follow these instructions may result in serious personal injury.

WARNING:

Keep solvents away from ignition sources. Solvents may be flammable and can ignite or explode if not handled correctly. Failure to follow this instruction may result in serious personal injury.

WARNING:

Use tools, not fingers, to hold flange nuts. Flange nuts may slip or spin unexpectedly when removing fasteners. Failure to follow this instruction may result in injured fingers.

Carefully review the safety warnings for each system using the links below before beginning any service or repair.

For additional information, refer to: High Voltage System Health and Safety Precautions - Overview.

For additional information, refer to: Climate Control System Health and Safety Precautions. file:///C:/in755846.html For additional

information, refer to: Battery and Battery Charging Health and Safety Precautions.

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For additional information, refer to: Brake and Clutch Systems Health and Safety Precautions.

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For additional information, refer to: Body Repair Health and Safety and General Precautions.

For additional information, refer to: Engine Cooling System Health and Safety Precautions.

For additional information, refer to: Gasoline and Gasoline-Ethanol Fuel Systems Health and Safety Precautions.

For additional information, refer to: Diesel Fuel System Health and Safety Precautions.

For additional information, refer to: Liquefied Petroleum Gas (LPG) and Compressed Natural Gas (CNG) Fuel Systems Health and Safety Precautions.

For additional information, refer to: Pyrotechnic Device Health and Safety Precautions.

For additional information, refer to: Wheel and Tire Health and Safety Precautions.

HIGH VOLTAGE SYSTEM HEALTH AND SAFETY PRECAUTIONS - OVERVIEW WARNING:

Service of the high voltage system on this vehicle is restricted to qualified personnel. The required qualifications vary by region. Always observe local laws and legislative directives regarding electric vehicle service. Failure to follow this instruction may result in serious personal injury or death.

WARNING:

To prevent the risk of high-voltage shock, always follow precisely all warnings and service instructions including instructions to depower the system. The high-voltage system utilizes approximately 300V DC, provided through high-voltage cables to its components and modules.

The high-voltage cables and wiring are identified by orange harness tape or orange wire covering. All high-voltage components are marked with high-voltage warning labels with a high-voltage symbol. Failure to follow these instructions may result in serious personal injury or death.

WARNING:

Never install the service disconnect plug when a high-voltage service cover is removed. Always install the cover prior to connecting the service disconnect plug. The cover prevents inadvertent contact with the high voltage which is present at several points under the cover. Failure to follow these instructions may result in serious personal injury or death.

WARNING:

Disconnect the 12V battery before servicing the direct current to alternating current (DC-AC) inverter or alternating current (AC) powerpoint to prevent the risk of high voltage shock. Failure to follow this instruction may result in serious personal injury.

LIQUEFIED PETROLEUM GAS (LPG) AND COMPRESSED NATURAL GAS (CNG) FUEL SYSTEMS HEALTH AND SAFETY PRECAUTIONS WARNING:

Service of Compressed Natural Gas (CNG) or Liquefied Petroleum Gas (LPG) vehicle systems is restricted to qualified personnel and authorized workshops. The required qualifications vary by region. Always observe local laws and legislative directives regarding CNG or LPG vehicle service. Failure to follow this instruction may result in serious personal injury or death.

WARNING:

Compressed Natural Gas (CNG) or Liquefied Petroleum Gas (LPG) is highly flammable and toxic when contained in unventilated work areas.

Work in a dedicated area with good ventilation and no sources of ignition.

Failure to follow these instructions may result in serious personal injury or death.

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Liquefied Petroleum Gas (LPG) is capable of harming eyes or freezing MITCHELL 1 ARTICLE - 2018protection GENERAL INFORMATION General Information - F150 skin. Always wear personal gear, including safety goggles and gloves to avoid contact with liquid gas. Failure to follow these instructions may result in serious personal injury.

WARNING:

Always observe local regulations regarding storage or indoor parking of Liquefied Petroleum Gas (LPG) vehicles. Do not park vehicles near sources of heat, ignition or unventilated open pits. Failure to follow these instructions may result in serious personal injury.

WARNING:

Liquefied Petroleum Gas (LPG) is heavier than air and will collect in low points in a building, such as drains or work pits. Never discharge a tank inside a building. If possible, tanks should be discharged beforehand by running the vehicle. Any discharge of gas must be done outside in wellventilated flat areas. Failure to follow these instructions may result in the accumulation of combustible gas, which could cause personal injury or death in a fire or explosion.

WARNING:

Extreme heat such as paint drying ovens will cause an increase in Compressed Natural Gas (CNG) or Liquefied Petroleum Gas (LPG) fuel tank pressure. The fuel tank must be removed before using paint drying ovens with temperatures above 60°C. Failure to follow this instruction may result in a release of combustible gas, which could cause personal injury or death in a fire or explosion.

WARNING:

Liquefied Petroleum Gas (LPG) may present a personal health hazard if handled improperly. Always consult the LPG material safety information sheet before servicing a LPG vehicle. Failure to follow this instruction may result in serious personal injury or death.

PYROTECHNIC DEVICE HEALTH AND SAFETY PRECAUTIONS WARNING:

Service and handling of Pyrotechnic Components is restricted to qualified personnel. The required qualifications vary by region. Always observe local laws and legislative directives regarding Pyrotechnic Components service and handling. Failure to follow this instruction may result in serious personal injury or death.

WARNING:

Always carry a live airbag with the deployment door, trim cover or tear seam pointed away from the body. Do not place a live airbag down with the deployment door, trim cover or tear seam facing down. Failure to follow these instructions may result in serious personal injury in the event of an accidental deployment.

WARNING:

Always carry or transport a live safety belt inflator with the safety belt buckle bolt installed in the inflator tube hand tight. Failure to follow this instruction may result in serious personal injury in the event of an accidental deployment.

WARNING:

Deploy all supplemental restraint system (SRS) devices (air bags, pretensioners, load limiters, etc.) outdoors with all personnel at least 9 meters (30 feet) away to make sure of personal safety. Due to the loud report which occurs when an SRS device is deployed, hearing protection is required. Failure to follow these instructions may result in serious personal injury.

WARNING:

Do not bleach or re-dye the safety belt webbing, as the webbing may weaken. Failure to follow this instruction may increase the risk of serious personal injury or death in a crash.

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If a vehicle has been in a crash, inspect the restraints control module MITCHELL 1 ARTICLE - 2018 GENERAL INFORMATION General Information F150 (RCM) and the impact sensor (if equipped) mounting areas- for deformation. If damaged, restore the mounting areas to the original production configuration. A new RCM and sensors must be installed whether or not the airbags have deployed. Failure to follow these instructions may result in serious personal injury or death in a crash.

WARNING:

All safety belt components must be inspected and corrected as part of any collision repair. Inspect all safety belt components as prescribed by Safety Belt Inspection and Repair After a Collision found in JACKING AND LIFTING - OVERVIEW . Failure to follow this instruction may result in incorrect operation of the safety belt system and increase the risk of serious personal injury or death in a crash.

WARNING:

Anytime the Safety Canopy or side air curtain has deployed, a new headliner and new roof pillar upper trim panels with attaching hardware must be installed. Make sure the headliner includes the word AIRBAG where it meets each roof B-pillar trim panel. Remove any other damaged components or hardware and replace with new. Always use new torqueprevailing type J-nuts when installing the Safety Canopy. Failure to follow these instructions may result in the Safety Canopy or side air curtain deploying incorrectly and increases the risk of serious personal injury or death in a crash.

WARNING:

Do not repair or service restraint component connector terminals. If restraint connector terminals need repair, replace with the service connector pigtails. Failure to follow this instruction may result in incorrect operation of the vehicle safety restraint, which increases the risk of serious personal injury or death in a crash.

WARNING:

Never disassemble or tamper with seat belt deployable components, including pretensioners, load limiters and inflators. Never back probe deployable device electrical connectors. Tampering or back probing may cause an accidental deployment and result in personal injury or death.

WARNING:

Never tamper with, repair, or modify a Restraints Control Module (RCM) or any other Supplemental Restraint System (SRS) component. Failure to follow this instruction may result in incorrect operation of the Supplemental Restraint System (SRS), which increases the risk of serious personal injury or death in a crash.

WARNING:

Never probe the electrical connectors on airbag, Safety Canopy or side air curtain assemblies. Failure to follow this instruction may result in the accidental deployment of these assemblies, which increases the risk of serious personal injury or death.

WARNING:

Do not handle, move or change the original horizontal mounting position of the restraints control module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow this instruction may result in the accidental deployment of the Safety Canopy and cause serious personal injury or death.

WARNING:

Do not obstruct or place objects in the deployment path of the Safety Canopy or side air curtain assembly. Never insert any type of fastener or tie strap around any portion of the Safety Canopy, side air curtain assembly, or related interior trim panel. Failure to follow this instruction may result in the Safety Canopy or side airbag curtain deploying incorrectly and increases the risk of serious personal injury or death in a crash.

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Occupant Classification System (OCS) parts are calibrated as an 1 ARTICLE GENERAL INFORMATION General Informationthey - F150are sold. assemblyMITCHELL and must only- 2018 be replaced in the configuration Never separate parts of an assembly. Failure to follow this instruction may result in incorrect operation of the OCS and increases the risk of serious personal injury or death in a crash.

WARNING:

Never allow oil, grease, water or foreign contaminants to get on/in the occupant classification system (OCS) components or electrical connectors. Failure to follow this instruction may result in incorrect operation of the OCS and increases the risk of serious personal injury or death in a crash.

WARNING:

Always tighten the fasteners of the restraints control module (RCM) and impact sensor (if equipped) to the specified torque. Failure to do so may result in incorrect restraint system operation, which increases the risk of personal injury or death in a crash.

WARNING:

Always carry a live Safety Canopy or side air curtain assembly with the tear seam pointed away from your body. Failure to follow this instruction may result in serious personal injury or death in the event of an accidental deployment.

WARNING:

Do not paint any airbag trim covers or deployment doors. Paint may cause the airbag to deploy incorrectly. Failure to follow this instruction may increase the risk of serious personal injury or death in a crash.

WARNING:

Always carry the live hood actuator by holding it around the cylinder with the mounting bracket up and with the cap pointing away from the body.

Always place the live hood actuator on its side with the cap pointing away from people. Never place anything in front of the cap. Failure to follow these instructions may result in serious personal injury in the event of an accidental deployment.

WARNING:

If a vehicle has been in a pedestrian impact, inspect the impact sensor mounting areas for damage. If damaged, a new bumper cover must be installed. New pedestrian impact sensors must be installed. Failure to follow these instructions may result in serious personal injury or death in a pedestrian impact.

WARNING:

Do not repair or service pedestrian protection system component connector terminals. If pedestrian protection system connector terminals need repair, replace with the service connector pigtails. Failure to follow this instruction may result in incorrect operation of the vehicle pedestrian protection system, which increases the risk of serious personal injury or death in a pedestrian impact.

WARNING:

Never tamper with, repair, or modify a pedestrian protection system component. Failure to follow this instruction may result in incorrect operation of the pedestrian protection system, which increases the risk of serious personal injury or death in a pedestrian impact.

WARNING:

Never probe the electrical connectors on pedestrian protection system pyrotechnic assemblies. Failure to follow this instruction may result in the accidental deployment of these assemblies, which increases the risk of serious personal injury or death.

WARNING:

Pyrotechnic components are very hot immediately after deployment and might be covered with pyrotechnic residuals. Do not handle pyrotechnic components immediately after deployment. Always wear protective gloves, safety glasses and breathing protection to prevent skin contact

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and inhaling of pyrotechnic residuals. Failure to follow this instruction MITCHELL 1 ARTICLE - 2018 GENERAL INFORMATION General Information - F150 may result in serious personnel injury.

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SYMBOLS GLOSSARY Symbols are used inside the graphics and in the text area to enhance the information display.

Movement Symbols Movement symbols provide detailed information to a required component movement. These component movements can be rotational or 1-3 dimensional movements.

Item 1 2 3 4 5 6 7 8

Part Number -

Description Minor component movement clockwise/counterclockwise Major component movement clockwise/counterclockwise Component movement to the left/right/up/down Component movement towards/away 3 dimensional component movement 2 dimensional component movement 3 dimensional component rotation 3 dimensional component cycling

Turn Symbols Turn symbols are used to provide further information on the direction or angle of component turns.

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Item 1 2 3 4 5 6 7 8

MITCHELL 1 ARTICLE - 2018 GENERAL INFORMATION General Information - F150

Part Number -

Description Turn the component clockwise through 45° Turn the component counterclockwise through 45° Turn the component clockwise through 90° Turn the component counterclockwise through 90° Turn the component clockwise through 180° Turn the component counterclockwise through 180° Turn the component clockwise through 2 complete turns Turn the component counterclockwise through 2 complete turns

Steering Wheel Symbols Steering wheel symbols are used to provide further information to a required steering wheel position or steering column lock status.

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Item 1 2 3 4 5 6 7

MITCHELL 1 ARTICLE - 2018 GENERAL INFORMATION General Information - F150

Part Number -

Description Steering wheel in straight ahead position Steering column lock locked Steering column lock unlocked Turn the steering wheel to the 90° left position Turn the steering wheel to the 90° right position Turn the steering wheel to the left-hand end position Turn the steering wheel to the right-hand end position

Body Types Body type symbols are used to identify different body configurations.

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MITCHELL 1 ARTICLE - 2018 GENERAL INFORMATION General Information - F150

Item 1 2 3 4 5 6 7 8 9 10 11

Part Number -

Description 3, 4, 5-door body style Wagon body style Sports utility vehicle body style Coupe body style Convertible body style Van body style 3, 4, 5-door body style - Top View Wagon body style - Top View Underview Right-hand drive (RHD) vehicle Left-hand drive (LHD) vehicle

Gearshift lever and selector lever position symbols Gearshift lever and selector lever position symbols are used to show the lever position that is required to be selected to carry out a procedure step.

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Item Part Number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 file:///C:/in755846.html 15 -

MITCHELL 1 ARTICLE - 2018 GENERAL INFORMATION General Information - F150

Description Replaced by symbol 9 Replaced by symbol 10 Replaced by symbol 11 Replaced by symbol 12 Replaced by symbol 12 Replaced by symbol 14 Replaced by symbol 15 Replaced by symbol 16 Set the selector lever to the park (P) position Set the selector lever to the reverse (R) position Set the selector lever to the neutral (N) position Set the selector lever to the drive (D) position Set the selector lever to the drive (S) position Set the selector lever to the drive (M) position Set the selector lever to the drive (-) position

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Item 16 17 18

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Part Number -

Description Set the selector lever to the drive (+) position Set the gearshift lever to the neutral (N) position Further gearshift lever positions that may appear in illustrations

MITCHELL 1 ARTICLE - 2018 GENERAL INFORMATION General Information - F150

Screwdriver symbols The screwdriver symbols are used to show which screwdriver bit is recommended to carry out a procedure step.

Item Part Number 1 2 3 4 5 file:///C:/in755846.html 6 -

Description Screwdriver Cross bladed screwdriver / Cross bladed Bit Socket Flat bladed screwdriver / Flat bladed Bit Socket Hexagonal screwdriver / Hexagonal Bit Socket TORX screwdriver / TORX Bit Socket Polydrive screwdriver / Polydrive Bit Socket

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Item Part Number 7 -

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Description MITCHELL 1 ARTICLE - 2018 GENERAL INFORMATION General Information - F150

Ball drive hex bit

Pliers symbols The pliers symbols are used to show which pliers is recommended to carry out a procedure step.

Item 1 2 3 4 5 6 7 file:///C:/in755846.html

Part Number -

Drill symbols

Description Combination pliers Side cutter pliers Securing ring - inner Securing ring - outer Hose clamp pliers Locking pliers Long nose pliers 38/61

The drill symbols are used to show which type and size of drill bit is recommended to carry out a MITCHELL 1 ARTICLE - 2018 GENERAL INFORMATION General Information - F150 step.

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Item 1 2 3 4 5 6 7

Part Number -

Description Drill bit with a specified diameter Hole saw with a specified diameter Stepped drill bit with a specified diameter Tap with a specified diameter Die with a specified diameter Scraper for circular holes Scraper for straight edges

Cutting tool symbols The cutting tool symbols are used to show which type of cutting tool is recommended to carry out a procedure step.

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MITCHELL 1 ARTICLE - 2018 GENERAL INFORMATION General Information - F150

Item 1 2 3 4 5 6 7 8 9 10

Part Number -

Description Cutting knife Air body saw Scissors Grinder Jig saw Plasma cutter Sanding Paper Wire brush Belt Sander Tin Snipes

Apply Chemical or load symbols The apply chemical or load symbols are used to show where to apply which type of chemical or load to carry out a procedure step. file:///C:/in755846.html

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Item Part Number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 file:///C:/in755846.html 15 -

MITCHELL 1 ARTICLE - 2018 GENERAL INFORMATION General Information - F150

Description Apply the substance from the specified tube Apply the substance from the specified cartridge Apply the specified chemical with a brush Apply the specified load to the specified component Apply a bead with a specific diameter from the specified tube Apply a bead with a specific diameter from the specified cartridge Apply the specified chemical with a roller Apply hot glue to the specified component Apply the specified amount of fluid from the fluid can Apply fluid from the fluid can Clean the specified component with the specified material Apply a broken bead from the specified tube Apply the specified chemical from a spray can Apply the specified lubricant to the specified component Apply spot welds to the specified component

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Item 16 17 18

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Part Number

Description Apply a continuous weld to the specified component Handle the fluid using a syringe Extract the specified amount of fluid using a syringe

MITCHELL 1 ARTICLE - 2018 GENERAL INFORMATION General Information - F150

-

Measurement symbols The measurement symbols are used to show where to measure which type of measurement to carry out a procedure step.

Part Number

Item 1 2 3 4

-

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Description Measure the current using a digital multimeter Measure the voltage using a digital multimeter Measure the resistance using a digital multimeter Measure the length/distance

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Part Number

Item 7/24/2019 5 6 7 8 9

-

10

-

11 12 13 14 15

-

Description MITCHELL 1 ARTICLE - 2018 GENERAL INFORMATION General Information - F150 Check that the specified pressure is available using a suitable pressure gauge Measure the pressure at the specified port using a suitable pressure gauge Measure the time using a suitable stopwatch Wait for the specified period of time The specified task requires the specified minimum temperature The specified task requires the specified maximum temperature not to be exceeded The specified task requires the specified temperature range The specified task requires the specified temperature Measure and check for the specified value using a dial indicator gauge Measure and check for the specified MAX value using a dial indicator gauge Measure and check for the specified MIN value using a dial indicator gauge

General equipment symbols The general equipment symbols are used to show where to use which type of general equipment to carry out a procedure step.

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Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 file:///C:/in755846.html 15 -

MITCHELL 1 ARTICLE - 2018 GENERAL INFORMATION General Information - F150

Part Number

Description Hot air gun Soldering iron Scraper Scriber Securing strap File with a specified size Center punch Marker Mallet Hose clamp Interior trim remover Vacuum cleaner Strap wrench Wedge Pin Punch

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Item 16 17 18 -

Part Number

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Air blow gun Relocate and support the component C-clamp

Item 1

Description

MITCHELL 1 ARTICLE - 2018 GENERAL INFORMATION General Information - F150

Part Number -

Description Plastic scraper

Welding symbols These symbols indicate the type of welding to be used.

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Item Part Number 1 2 3 4 5 6 -

MITCHELL 1 ARTICLE - 2018 GENERAL INFORMATION General Information - F150

Description Metal inert gas (MIG) / Metal active gas (MAG) welding equipment Metal inert gas (MIG) welding equipment Metal inert gas (MIG) brazing equipment Apply a continuous weld to the specified component Apply spot welds to the specified component C-clamp

Drilling and grinding symbols These symbols indicate the type of drilling or grinding to be used.

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MITCHELL 1 ARTICLE - 2018 GENERAL INFORMATION General Information - F150

Item Part Number Description 1 Drill through first body layer with a suitable diameter 2 Drill through first body layer with the specified diameter 3 Drill through the indicated number of body layers with a suitable diameter 4 Drill through the indicated number of body layers with the specified diameter 5 Drill through the indicated number of body layers with a suitable diameter 6 Drill through the indicated number of body layers with the specified diameter 7 Drill through all body layers with a suitable diameter 8 Drill through all body layers with the specified diameter 9 Grind one layer 10 Grind two layers 11 Grind to last layer 12 Grind all layers 13 Material thickness > Xmm file:///C:/in755846.html Material symbols

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The material symbols are used to show where to use which type of material to carry out a procedure 7/24/2019 step.

MITCHELL 1 ARTICLE - 2018 GENERAL INFORMATION General Information - F150

Item 1 2 3

Part Number -

Description Remove/Install the specified blind rivet Apply tape to the specified component/area Remove/Install the specified cable tie

Miscellaneous symbols These symbols provide further information that is required to carry out a procedure step.

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MITCHELL 1 ARTICLE - 2018 GENERAL INFORMATION General Information - F150

Part Number

Item 1 2

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3

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Description Set the ignition switch to the 0 position Set the ignition switch to the II position The procedure step requires the aid of the specified number of supporting technicians Self contained breathing apparatus General prohibition used in combination with another symbol Do not use power tools Visual check Noise check Dispose the specified component Replaced by item 9 (Dispose the specified component) Set the engine speed to the specified value Fully apply the parking brake lever Fully release the parking brake lever

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Part Number

Item 7/24/2019 14 15 16

-

Description MITCHELL 1 ARTICLE - 2018 GENERAL INFORMATION General Information - F150 Do not dispose of batteries into the waste bin Visual check using a mirror Area/component must be dry

Mandatory Protective equipment - Health and safety symbols The protective equipment symbols advise to use a mandatory protective equipment to avoid or at least reduce possible health and safety risks.

Item 1 2 3 4 5 6

Part Number -

Description Wear protective gloves Wear face guard Wear safety goggles Wear ear protectors Wear safety goggles and ear protectors Wear a respirator

Prohibition - Health and safety symbols and component damage The prohibition symbols are used to prohibit the specified actions to avoid or at least reduce possible component damage and health and safety risks. file:///C:/in755846.html

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MITCHELL 1 ARTICLE - 2018 GENERAL INFORMATION General Information - F150

Item 1 2 3 4 5 6 7

Part Number -

Description General prohibition symbol No naked flames No smoking No water Do not touch Do not switch No grinding

Warning symbols - Health and safety and component damage The warning symbols are used to advise on hazardous conditions to avoid or at least reduce possible component damage and health and safety risks.

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MITCHELL 1 ARTICLE - 2018 GENERAL INFORMATION General Information - F150

Part Number

Item 1 2 3 4 5 6 7 8 9 10 11 12

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13

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Description Hazardous voltage/Electrical shock/Electrocution Fire Hazard/Highly flammable Burn hazard/Hot surface Automatic start-up Toxic Explosive material Battery hazard Corrosive material Lifting hazard Hand crush/Force from above Cutting of fingers or hand Pressure hazard Invisible laser radiation. Do not view directly with optical instruments (magnifiers). Class 1M laser product

Control Diagram symbols - Description and Operation procedures These symbols provide further information on the type of connectivity, direction of flow or type of data bus of a system.

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MITCHELL 1 ARTICLE - 2018 GENERAL INFORMATION General Information - F150

Item 1 2 3 4

Part Number -

Description Mid-speed Controller Area Network (CAN) High-speed Controller Area Network (CAN) Local Interconnect Network (LIN) Wires crossing not connected

WHEEL AND TIRE HEALTH AND SAFETY PRECAUTIONS WARNING:

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WARNING:

Never inflate a tire that has been run flat without first removing the tire from the wheel to inspect for damage. A damaged tire can fail during inflation. Failure to follow this instruction may result in serious personal injury.

Do not mount tube-type tires on tubeless wheels or tubeless tires on

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tube-type wheels. Incorrect combinations could result in tire separation MITCHELL 1 ARTICLE - 2018 INFORMATION Information - F150 from wheel and may result inGENERAL serious injury toGeneral vehicle occupant(s).

WARNING:

Cracked wheels can be dangerous. Deflate tires on cracked wheels prior to removal of wheels from the vehicle. Failure to follow this instruction may result in serious personal injury.

WARNING:

Retighten wheel nuts within 160 km (100 mi) after a wheel is reinstalled.

For dual rear wheel (DRW) only, a second retightening is required within 800 km (500 mi). Wheels can loosen after initial tightening. Failure to follow this instruction may result in serious injury to vehicle occupant(s).

WARNING:

Always match the tire size to the wheel size during assembly. Incorrect matching can result in tire bead damage or tire separation from the wheel. Failure to follow this instruction may result in serious personal injury to technician or vehicle occupant(s).

WARNING:

Do not weld or peen wheels. A wheel needing such repairs must have a new wheel installed. Failure to follow these instructions may result in wheel failure and serious personal injury.

DIAGNOSIS AND TESTING DIAGNOSTIC TROUBLE CODE CHARTS Master DTC Index

Module ABS module

ACM

APIM

ATCM BECMB BCM CCM file:///C:/in755846.html

Section REFER to: Anti-Lock Brake System (ABS) and Stability Control .

For audio without SYNC®, REFER to: Information and Entertainment System Vehicles Without: SYNC. For SYNC® without touchscreen, REFER to: Information and Entertainment System Vehicles With: SYNC Without Touchscreen.

For touchscreen display, REFER to: Information and Entertainment System - Vehicles With: Touchscreen Display.

For Bang & Olufsen audio system, REFER to: Information and Entertainment System Vehicles With: Bang and Olufsen Audio System.

For SYNC® without touchscreen, REFER to: Information and Entertainment System Vehicles With: SYNC Without Touchscreen.

For touchscreen display, REFER to: Information and Entertainment System - Vehicles With: Touchscreen Display.

For Bang & Olufsen audio system, REFER to: Information and Entertainment System Vehicles With: Bang and Olufsen Audio System.

REFER to: Four-Wheel Drive Systems - Raptor, Vehicles With: 4HI-LOC Torque on Demand Transfer Case .

REFER to: Airbag Supplemental Restraint System (SRS) .

REFER to: Body Control Module (BCM) .

REFER to: Cruise Control .

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Module 7/24/2019

DACMC

DC/ DC converter control module (voltage quality module [VQM]) DDM DSM DSP

FCIM

FCDIM

GWM HSWM HUD module IPMA IPMB IPC OCSM PAM

PCM

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PDM

Section For touchscreen display, REFER to: Information and Entertainment System - Vehicles With: Touchscreen Display.

For Bang & Olufsen audio system, REFER to: Information and Entertainment System Vehicles With: Bang and Olufsen Audio System.

REFER to: Direct Current/Direct Current (DC/DC) Converter Control Module .

REFER to: Locks, Latches and Entry Systems .

REFER to: Front Seats .

REFER to: Information and Entertainment System - Vehicles With: Bang and Olufsen Audio System.

For audio without SYNC®, REFER to: Information and Entertainment System Vehicles Without: SYNC. For SYNC® without touchscreen, REFER to: Information and Entertainment System Vehicles With: SYNC Without Touchscreen.

For touchscreen display, REFER to: Information and Entertainment System - Vehicles With: Touchscreen Display.

For Bang & Olufsen audio system, REFER to: Information and Entertainment System Vehicles With: Bang and Olufsen Audio System.

For audio without SYNC®, REFER to: Information and Entertainment System Vehicles Without: SYNC. For SYNC® without touchscreen, REFER to: Information and Entertainment System Vehicles With: SYNC Without Touchscreen.

REFER to: Communications Network .

REFER to: Steering Wheel and Column Electrical Components .

REFER to: Collision Warning and Collision Avoidance System .

REFER to: Lane Keeping System .

REFER to: Parking Aid - Vehicles With: Parking Aid Camera.

REFER to: Instrumentation, Message Center and Warning Chimes .

REFER to: Airbag Supplemental Restraint System (SRS) - Raptor .

REFER to: Airbag Supplemental Restraint System (SRS) .

REFER to: Parking Aid - Vehicles With: Rear Parking Aid. For 2.7L EcoBoost, REFER to: Electronic Engine Controls - 2.7L EcoBoost (238kW/324PS).

For 3.0L Diesel, REFER to: Electronic Engine Controls - 3.0L Power Stroke Diesel.

For 3.3L TiVCT, REFER to: Electronic Engine Controls - 3.3L Duratec - V6.

For 3.5L EcoBoost, REFER to: Electronic Engine Controls - 3.5L EcoBoost (272kW/370PS).

For 5.0L TiVCT, REFER to: Electronic Engine Controls - 5.0L 32V Ti-VCT. REFER to: Locks, Latches and Entry Systems .

MITCHELL 1 ARTICLE - 2018 GENERAL INFORMATION General Information - F150

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PRB module PSCM

Section REFER to: Power Running Board (PRB) .

REFER to: Power Steering .

REFER to: Airbag Supplemental Restraint System (SRS) - Raptor .

REFER to: Airbag Supplemental Restraint System (SRS) .

REFER to: Tire Pressure Monitoring System (TPMS) .

REFER to: Steering Wheel and Column Electrical Components .

REFER to: Front Seats .

REFER to: Front Seats .

REFER to: Front Seats .

REFER to: Blind Spot Information System .

REFER to: Blind Spot Information System .

REFER to: Auxiliary Brake System - Vehicles With: Trailer Brake Control .

For 2-speed torque-on-demand transfer case, REFER to: Four-Wheel Drive Systems - Vehicles With: 2-Speed Torque On Demand Transfer Case .

For 2-speed torque-on-demand/4HI-LOC (Raptor), REFER to: Four-Wheel Drive Systems - Raptor, Vehicles With: 4HI-LOC Torque on Demand Transfer Case .

For electronic shift transfer case, REFER to: FourWheel Drive Systems - Vehicles With: Electronic Shift Transfer Case .

REFER to: Trailer Lamps .

For touchscreen display, REFER to: Information and Entertainment System - Vehicles With: Touchscreen Display.

For Bang & Olufsen audio system, REFER to: Information and Entertainment System Vehicles With: Bang and Olufsen Audio System.

For 3.5L gas engine, REFER to: Diagnostic Trouble Code (DTC) Charts and Pinpoint Tests - 3.5L EcoBoost (272kW/370PS) .

For 3.0L diesel engine, REFER to: Diagnostic Trouble Code (DTC) Charts and Pinpoint Tests - 3.0L Power Stroke Diesel .

MITCHELL 1 ARTICLE - 2018 GENERAL INFORMATION General Information - F150

RCM RTM SCCM SCME SCMG SCMH SODL SODR TBM

TCCM

TRM

TCU

TCM

GENERAL PROCEDURES WIRE TERMINAL INSPECTION AND REMOVAL For information on Ford Color Coded Illustrations refer to OEM COLOR CODING .

Disconnect 1. WARNING:

Before beginning any service procedure, refer to Health and Safety Precautions. Failure to follow this instruction may result in serious personal injury.

Refer to: Health and Safety Precautions.

NOTE:

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To avoid wiring pin (terminal) damage, Rotunda Flex Probes NUD105-R025D or Terminal Probe Kit 29-011A must be used to

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connect test equipment or jumper wires to pins (terminals).

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MITCHELL 1 ARTICLE - 2018 GENERAL INFORMATION General Information - F150

Male to female pin (terminal) fit is critical for correct connection and durability.

Pin (terminal) fit may be checked by using the mating pin (terminal) to test for normal separation force (a damaged pin or terminal will have very low separation force from the mating pin or terminal).

Correctly checking the separation force of small pins (terminals) may require removal of the connector terminal guide/retainer if it adds drag to the pin (terminal) insertion or removal.

For more detail on the replacement of damaged connectors or pins (terminals) refer to the video below.

2.

3. NOTE:

NOTE:

The connector hard-shell information, which is measured in millimeters is the distance from the front face of the connector to the engagement point on the terminal release tang. Mark the listed distance on the terminal removal tool prior to removing the terminal.

The dimensions of the connector hard-shell and the connector terminals release tang are listed above the corresponding graphics.

4. Audio Front Control Module (ACM), Body Control Module (BCM) and Instrument Panel Cluster (IPC) Electrical Connector Callout 1 2

Connector External terminal release tang Electrical connector locking tab

5. Audio Front Control Module (ACM), Front Controls Interface Module (FCIM), Gateway Module A (GWM), and Heating, Ventilation and Air Conditioning (HVAC) Control Module Electrical Connector Callout 1 2

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Connector Distance to release tang - 0.2953in (7.5mm) (inner terminal) - 0.4646in (11.8mm) (outer terminal) Terminal width size - 0.0244in (.62mm) (inner terminal) - 0.1102in (2.8mm) (outer terminal)

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Please Download the Complete service Manual From the Link Below : https://www.dropbox.com/s/mpxgidti84im7ap/2018-2020%20Ford%20F150%20%26%20Raptor%20Complete%20Service%20Manual%20%20%281%29.pdf?dl=1