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Home >> Mercury >> 1989 >> Topaz AWD L4-140 2.3L HSC (VIN X) >> Repair and Diagnosis >> Engine, Cooling and Exhaust >> Engine >> Engine Lubrication >> Technical Service Bulletins >> All Technical Service Bulletins >> Engine Rocker Arm Cover/Oil Pan Service - Revision >> Pages 21-08-6 Thru 21-08-9

Pages 21-08-6 Thru 21-08-9


1988/1989
21-08-6 Engine, 2.3L 21-08-6

REMOVAL AND INSTALLATION (Continued)

24. Connect pulse air hose to catalytic converter.
25. Place stabilizer bar and control arm assembly into position. Install control arm-to-body attaching bolts. Install stabilizer bar brackets and tighten all fasteners to specification.
26. Halfshaft assemblies must be installed at this time. Refer to Section 15-22.
27. Lower vehicle.
28. Remove Engine Support Tool D87L-6000-A or equivalent.
29. Connect any remaining electrical and vacuum lines.
30. Install heater hoses.
31. Install air conditioning discharge to suction lines to pump, if so equipped. Do not charge system at this time.
32. Connect fuel supply and return lines to engine.
33. Connect accelerator cable.
34. Install power steering pressure and return lines. Install bracket.
35. ATX only: Connect TV linkage at transaxle.
36. MTX only: Connect clutch cable to shift lever on transaxle. For clutch adjustment procedures, refer to Section 16-03.
37. Install radiator shroud and coolant fan assembly. Tighten attaching bolts to specification.
38. Install coil.
39. Connect coolant fan electrical connector.
40. Install upper radiator hose to engine.
41. ATX only: Connect transaxle cooler lines to rubber hoses below radiator.
42. Fill cooling system. Refer to Section 27-01.
43. Connect battery ground cable.
44. Install air cleaner assembly.
45. Install hood.
46. Charge air conditioning system, if so equipped. Refer to Section 36-32.
47. Check all fluid levels (power steering, ATX, MTX).
48. Start vehicle. Check for leaks.

SERVICE PROCEDURES

Engine In Vehicle
NOTE: These Removal and Installation procedures can be performed with the engine in the vehicle. Engine Oil Change (With Filter)
1. Apply parking brake and block wheels. Bring engine to normal operating temperature, and turn off.
2. Remove oil drain plug and inspect gasket. Replace gasket if damaged. Install oil drain plug, and tighten to specification.


3. Remove oil filter and discard. Clean gasket sealing surface at cylinder block. Coat gasket on filter with a light film of oil. Screw filter onto adapter on cylinder block until gasket contacts cylinder block sealing surface, then advance it an additional one-half turn.
4. Remove oil filler cap, and fill crankcase with specified amount, type and grade of oil. Install oil filler cap. Start engine and inspect for leaks. Correct as required.


Oil Pump Removal
1. Remove oil pan as outlined.
2. Remove oil pump attaching bolts and remove oil pump and intermediate driveshaft. Installation
1. Prime oil pump by filling inlet port of screen and cover assembly with engine oil. Rotate pump driveshaft until oil flows from outlet port.
2. If screen and cover assembly has been removed, replace gasket. Clean screen and flush out entire screen and cover assembly, Install screen and cover assembly by placing hole in strap over stud on oil pump cover. Tighten two attaching bolts with gasket to oil pump body. Tighten nut (holding strap to stud) to specification.
3. Position intermediate driveshaft into distributor socket.
4. Insert intermediate driveshaft into oil pump. Install pump and shaft as an assembly.
CAUTION: Do not attempt to force the pump into position if it will not seat. The shaft hex may be misaligned with the distributor shaft. To align, remove the oil pump and rotate the intermediate driveshaft into a new position.
5. Tighten the two oil pump attaching bolts to specification.
6. Install oil pan and all related parts. Refer to Oil Pan Installation.
7. Fill crankcase to proper level with recommended engine oil. Start engine and check for oil pressure. Operate engine at fast idle and check for oil leaks.


Oil Pan Removal
1. Disconnect battery ground cable.
2. Raise vehicle.
3. Drain crankcase.
4. Drain coolant by removing lower radiator hose.


1988/1989
21-08-7 Engine, 2.3L 21-08-7




SERVICE PROCEDURES (Continued)

5. Remove roll restrictor (MTX). Refer to Engine Removal.

6. Disconnect starter cable.

7. Remove starter.

8. Disconnect exhaust pipe from oil pan.

9. Remove engine coolant tube located at lower radiator hose, at water pump and at tabs of oil pan. Position air conditioner line off to side.

10. Remove oil pan.

Installation

1. Remove all traces of RTV sealant from engine and oil pan.

2. Clean block rails, front cover, rear cover retainer, and oil pan thoroughly with DuPont(R) Freon (TF) or equivalent solvent.

3. Remove and clean oil pump pick-up tube and screen assembly. After cleaning, install tube and screen assembly.
4. Apply RTV E8AZ-19562-A Sealer or equivalent in the oil pan groove. Completely fill the oil pan groove with sealer. Sealer bead should be 5 mm (.200 inch) wide and 2.0-3.8 mm (.080-.150 inch) high (above the oil pan surface) in all areas except the half-rounds. The half-rounds should have a 5 mm (.200 inch) wide and 3.8- 5.1 mm (.150-.200 inch) high (above the oil pan surface) bead.
Caution: Use adequate ventilation when applying sealer
NOTE: Applying RTV in excess of the specified amount will not improve the sealing of the oil pan, and could cause the oil pickup screen to become plugged with RTV.
5. Immediately (within 5 minutes) install oil pan against cylinder block to prevent RTV from skinning over.
NOTE: RTV needs to cure completely before coming in contact with any engine oil, about one (1) hour cure time at (65-75~ F).
6. Install oil pan bolts lightly until the two oil panto-transmission bolts can be installed.

NOTE: If oil pan is installed on engine outside of vehicle, a transaxle case or equivalent fixture must be bolted to the block to line the oil pan up, flush with the rear face of block.

7. Install two oil pan-to-transaxle bolts. Tighten to 40-54 N-m (30-39 ft.lbs.) to align oil pan with transaxle. Loosen bolts one-half turn.

8. Tighten all oil pan flange bolts to 20-30 N-m (14.7-22.1 ft.lbs.).

9. Tighten two oil pan-to-transmission bolts to 40-54 N-m (30-39 ft.lbs.).

10. If required, rework exhaust bracket to fit to oil pan.

11. Replace water inlet tube O-ring and install tube.

12. Install roll restrictor (MTX). Refer to Engine Installation.

13. Lower vehicle.

14. Install engine oil and coolant.

15. Connect battery ground cable.

16. Start engine and check for leaks

1988/1989
21-08-8 Engine, 2.3L 21-08-8

SERVICE PROCEDURES (Continued)

Water Pump Inlet Tube Assembly Removal
1. Open and secure hood.
2. Install protective fender covers.
3. Disconnect battery ground cable.
4. Remove radiator cap.
5. Raise vehicle.
6. Position drain pan below radiator under lower radiator hose.
7. Remove one water pump inlet tube screw and washer from bracket located below water pump and remove two screws securing inlet tube to oil pan.
8. Loosen clamp, disconnect lower radiator hose from radiator, and drain engine coolant. Installation
1. Clean surfaces of inlet tube and water pump where new O-ring gasket is to be installed. Carefully position the inlet tube with new O-ring gasket to water pump, and secure bracket below water pump.
2. Install lower radiator hose to radiator.
3. Install two screws attaching inlet tube to oil pan. Tighten both screws to 8-11 N-m (6-8 ft.lbs.).
4. Install heater return hose to water pump inlet tube.
5. Lower vehicle.
6. Connect battery ground cable.
7. Replace engine coolant. Operate engine until normal operating temperature is reached. Check for leaks and check coolant level.


Water Pump Removal
1. Drain engine coolant.
2. Disconnect battery ground cable.
3. Loosen water pump idler pulley and remove belt from water pump pulley.
4. Remove water pump inlet tube as outlined.
5. Remove three water pump retaining bolts.
Installation
1. Clean both gasket mating surfaces on water pump and cylinder block.
2. Install three water pump retaining bolts and tighten to specification.
3. Connect water pump inlet tube on water pump as outlined.
4. Install water pump belt on pulley and adjust tension to specification.
5. Connect battery ground cable.
6. Replace engine coolant. Operate engine until normal operating temperature is reached. Check for leaks and recheck coolant level.




Rocker Arm Cover Removal
1. Open and secure hood.
2. Position protective fender aprons.
3. Disconnect PCV and hose and set aside.
4. Remove the nine rocker arm cover bolts.
5. Clean both cylinder head and rocker arm cover gasket mating surfaces. Installation

1. Clean rocker cover rail on cylinder head and remove all traces of foreign material.

2. If the "mold in place gasket" is damaged by a cut and/or nick of about 1/8 inch (maximum of two (2) places), fill in the damaged area with RTV sealer E8AZ-19562-A and install the rocker arm cover assembly.
CAUTION: Use adequate ventilation when applying sealer.

1988/1989
21-08-8A Engine, 2.3L 21-08-8A

SERVICE PROCEDURES (Continued)

Rocker Arm Cover Removal (Continued)

3. If the mold-in-place gasket is damaged by cuts longer than 1/8 inch, or by more than three nicks or cuts (any size), replace the entire rocker arm cover assembly.

4. If damaged, replace rubber isolator(s) Part No. (E83Z-6C518-A) or washer, bolt and rubber isolator assemby, Ppart No. (E93Z-6C519-A).

5. Reinstall rocker cover assembly and tighten all bolts to 8-11.5 Nm (5.9-8.5 lb-ft).

NOTE: Always put one (1) drop of adhesive thread lock(ESE-M2G260-AA) on bolts if they are reused. Only new bolts have pre-applied adhesive. Failure to do so may result in an oil leak.


6. Connect PCV hose into rocker arm cover.

7. Remove aprons.

8. Start engine and run at fast idle. Check for oil leaks.

NOTE: RTV needs to cure completely before coming in contact with any engine oil, about one (1) hour cure time at (65-75 F) ambient termperature.

1988/1989
21-08-9 Engine, 2.3L 21-08-9




SERVICE PROCEDURES (Continued)

Intake and Exhaust Manifolds Removal
1. Open and secure hood.
2. Disconnect battery ground cable.
3. Drain cooling system.
4. Remove accelerator cable.
5. Remove air cleaner assembly and heat stove tube at heat shield.
6. Remove required vacuum lines and electrical connections.
7. Disconnect three exhaust pipe-to-exhaust manifold retaining nuts.
8. Remove exhaust manifold heat shroud assembly.
9. Disconnect EGO sensor wire at connector.
10. Disconnect throttle linkage.
11. Disconnect speed control cable, if so equipped.
12. Disconnect fuel supply and return lines at rubber connector.
13. Disconnect EGR tube at EGR valve.
14. Remove intake manifold.
15. Remove exhaust manifold. Installation
1. Position exhaust manifold to cylinder head using Exhaust Manifold Alignment Studs T84P- 6065-B or equivalent in holes 2 and 3.

2. Install attaching bolts in remaining holes.
3. Run down attaching bolts until snug, then remove guide studs and install attaching bolts in holes 2 and 3.
4. Tighten all exhaust manifold bolts in two steps:
7-10 N-m (5-7 ft.lbs.) then 27-41 N-m (20-30 ft.lbs.) using standard tightening sequence.
5. Install intake manifold gasket and bolts and tighten to specification.
6. Connect EGO sensor wire at connector.
7. Connect EGR tube to EGR valve.
8. Install exhaust manifold studs.
9. Connect exhaust pipe to exhaust manifold.
10. Connect fuel supply and return lines to electrical connectors.
11. Install vacuum lines.
12. Install air cleaner assembly and heat shroud assembly.
13. Install accelerator cable.
14. Install speed control cable, if so equipped.
15. Connect battery ground cable.
16. Fill cooling system, 17. Start engine and check for leaks.
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