Attachment III
HEAD GASKET REPLACEMENTAFFECTED VEHICLES:
1994-1995 COUGAR, MUSTANG AND THUNDERBIRD EQUIPPED WITH 3.8L ENGINE
The following service guidelines. in addition to Service Manual references, are being provided to assist technicians in completing an effective and robust repair.
SERVICE GUIDELINES
1. Verify one of the following conditions is present prior to initiating a repair on an affected vehicle.
^ Persistent and/or chronic engine overheating.
^ Heavy white smoke evident from the exhaust tailpipe.
^ Flashing "Low Coolant" instrument panel light, even after coolant refill.
^ Constant loss of engine coolant.
2. Before performing any removal procedure, use shop air to remove any debris from the top of the engine. This is critical in order to prevent even small amounts of foreign material from entering the engine upon teardown, which may jeopardize the proper functioning of the engine after repairs are completed.
3. Remove the cylinder head and clean the gasket surfaces following the procedure outlined in Section 03-01 of the appropriate Service Manual.
^ Place a clean shop towel in the valley of the engine in order to prevent contaminants from entering the oil system.
^ Refer to Technical Service Bulletin # 93-23-14 for approved Ford service procedures for cleaning gasket surfaces.
^ Do not use a Surface Reconditioning Disk (pad/cookie) or other fiber abrasive to clean the head gasket surfaces. Fibers from the disk could get into the oil and oil pan, and the fibers will migrate and clog the oil by-pass valve and cause major engine failure. Engine warranty claims after such a repair may be subject to scrutiny.
^ Some engine assemblies replaced underwarranty have been found with internal contamination. This condition may be traceable to a previous repair involving removal of valve cover(s), intake manifold(s), cylinder head(s) and/or front engine cover. Scuffed pistons/bores, excessively worn crankshaft/camshaft bearings, low oil pressure, engine knocking and excessive oil consumption can result from improper engine gasket preparation.
4. Using a cylinder bore gauge or a telescoping gauge (T-gauge) in conjunction with an outside micrometer, measure the bore diameter of one cylinder bore on each bank of the engine. See Figure 1. Follow the instructions provided by the bore gauge manufacturer.
^ If the cylinder bore measures 96.799 - 96.830 mm (3.8110 - 3.8122 inches), use Cylinder Head Gasket Kit F5PZ-6051-CA to reassemble the engine.
^ If the cylinder bore measures greater than 96.830 mm (3.8122 inches) call the Recall Hotline at 1-800-325-5621 to order a set of overbore-size head gaskets. Use the remaining parts from Head Gasket Kit F5PZ-6051-CA but DO NOT use the head gaskets provided in the kit. The overbore-size head gaskets MUST be used in place of those provided in the F5PZ-6051-CA head gasket kit.
5. Check the cylinder head gasket surface for flatness using a straight edge and a feeler gauge. The surface must be flat to within 0.18 mm (0.007 in.). If it is necessary to refinish the gasket surface, do not plane or grind off more than 0.25 mm (0.010 in.). See Figure 2.
6. Reassemble and tighten the new head bolts to the following specifications: Tighten all bolts in numerical sequence, as shown in Figure 3, in three steps as follows:
^ 20 Nm (15 lb-ft).
^ 40 Nm (30 lb-ft).
^ 50 Nm (37 lb-ft).
CAUTION
Do not loosen all of the bolts at the same time. Work on one bolt at a time in the sequence shown In Figure 3. Failure to loosen bolts in proper sequence could cause cylinder head to warp.
7. In numerical sequence, as shown in Figure 3, retighten the bolts per the following steps:
LONG BOLTS:
a. Loosen the long bolt and back out 2-3 turns.
b. Retighten the long bolt to 40-50 Nm (30-37 lb-ft)
c. Rotate the long bolt an additional 175-185 degrees (approximately 1/2 turn).
d. Go to the next bolt in sequence.
SHORT BOLTS:
a. Loosen the short bolt and back out 2-3 turns.
b. Retighten the short bolt to 20-30 Nm (15-22 lb-ft).
c. Rotate the short bolt an additional 175-185 degrees (approximately 1/2 turn).
d. Go to the next bolt in sequence.
NOTE:
Using Metal Surface Cleaner F4AZ-19A536-A or equivalent meeting Ford specification ESE-M2G52-A clean the sealing surfaces of the cylinder head and intake manifold.
8. Apply a dab of Gasket and Trim Adhesive F3AZ-19B508-AA or equivalent meeting Ford specification ESR-M1171P-A and ESE-M2G52-A to each cylinder head mating surface. Press the new intake manifold gaskets into place using locating pins as necessary to aid in assembly.
Apply a 3-4 mm (1/8 in.) bead of Silicone Rubber F4AZ-19562-B or equivalent meeting Ford specification WSE-M4G323-A1 at each corner where the cylinder heads join the cylinder block. See Figure 4.
9. Replace the oil filter and fill the crankcase with the appropriate amount of Motorcraft 5W30 engine oil.
10. Insert a garden hose into the thermostat housing (thermostat removed) and flush the engine using a strong stream of fresh water for approximately 10 minutes. Water will drain out of the lower radiator hose. Insert the garden hose into the upper radiator hose and flush the radiator for two (2) minutes. Water will drain out of the lower radiator hose connection and radiator draincock. Flush the coolant overflow bottle for two-three (2-3) minutes to clean. After flushing is complete, allow the cooling system to completely drain. Clean the thermostat housing and manifold mating surfaces and install a new gasket when installing the thermostat. Inspect the upper radiator hose for damage and replace, if necessary. If re-using the upper radiator hose, remove and discard the constant tension clamp and install a new screw clamp (383525-S) on the hose to ensure proper sealing. Connect the upper radiator hose to the thermostat housing, positioning the clamp between the alignment marks on the hose. Tighten the clamp to 3 Nm (26 lb-in).
11. Inspect the lower radiator hose for damage and replace, if necessary. If re-using the lower radiator hose, discard the constant tension clamp and install a new screw clamp (383525-S) on the hose to ensure proper sealing. Connect the lower radiator hose to the radiator, positioning the clamp between the alignment marks on the hose. Tighten the clamp to 3 Nm (26 lb-in). Close the radiator draincock.
12. Add 6 quarts of new coolant (-19549-) to the radiator. Fill the remainder of the radiator with water to the top of the filler neck. Fill the overflow bottle with water to the cold fill line.
13. Operate the engine for several minutes and then recheck the hoses and connections for leaks. Top off the cooling system, as necessary.