Products OWNER's INSTRUCTION BOOK — EDITION 2

Industrial Power Products OWNER'S INSTRUCTION BOOK — EDITION 2

FORD 2650 RANGE V4 AND V6 PETROL ENGINES

2653E — V4 — 1699 cc 2654E — V6 — 1998 cc 2655E — V6 — 2293 cc 2658E — V6 — 2792 cc 2658EI— V6 — 2792 cc

Ford policy is one of continuous improvement and whilst every effort is made to ensure that this publication is up to date and correct in all respects, the right to change prices, specifications and equipment at any time without notice is reserved. Accordingly this publication is not tyo be regarded

- as a description of any individual engine.

Rep’roduction in any manner, in whole or in part is prohibited without the express permission in writing of Ford Motor Company Ltd., Eagle Way, Brentwood, Essex CM13 3BW, England. FOREWORD . This book contains service instructions for 2650 Industrial engines manufactured by FORD—WERKE Range engines. AG, GERMANY, are available through Ford ENGINES FROM THE 2650 RANGE Industrial Power Products Dealers and Supervising The life of your engine unit and the delivery of the Ford Companies throughout the world. When in high performance built into it will depend on the x need of parts or service, see your local Authorised care it receives throughout its life. It is the Dealer. In the event of difficulties, communicate operator’s responsiblity to ensure that the directly with the Supervising Ford Company in maintenance operations outlined in this book are your area. A list of Ford Overseas Companies and carried out regularly after the specified hours of District Offices is given at the back of this book. operation have beeri reached. We consider it to be in your interests to enlist the aid of an authorised Ford Dealer not only when repairs are required, but also for regular maintenance.

R.H. Side view of V4 Engine V6 Engine with Fuel Injection System. CONTENTS CONTENTS Page N0. Page N0. Page No. Page No. 15 ADJUST IGNITION TIMING 26 Fuel Tank and Lines FOREWORD 1 0 RE-TIGHTEN THE SUMP,CYL:NDER HEAD 18 ADJUST THE IDLING SPEED SETTING 27 FAULT FINDING CHARTS V4 AND V6 EXTERNAL DRAWINGS INLET MANIFOLD AND ROCKER COVER 19 CHECK AND, IF NECESSARY, ADJUST 29 TIGHTENING TORQUES, ENGINES IDENTIFICATION BOLT VALVE CLEARANCES 30 GENERAL SPECIFICATIONS BEFORE OPERATION 10 CHANGE ENGINE on. 21 GENERAL MAINTENANCE 31 FORD COMPANIES AND DISTRICT OFFICES RUNNING-IN PROCEDURE 11 CHANGE ENGINE on. FILTER 21 COOLING SYSTEM STARTING THE ENGINE 11 CHECK LEVEL 0F BATTERY ACID AND, IF 22 LUBRICATION SYSTEM To start from cold NECESSARY,T0P-UP 23 Lubricants To restart when warm 11 CLEAN AND PROTECT BATTERY TERMiNALs 23 VENTI LATION SYSTEM To stop the engine 12 ADJUST FAN BELT 24 ELECTRICAL SYSTEM LUBRICATION AND MAINTENANCE 12 CLEAN FUEL LIFT PUMP 24 Battery SUMMARY 0F REGULAR MAINTENANCE 12 CLEAN VENTILATION VALVE AND DUCT REGULAR MAINTENANCE OPERATIONS 13 CLEAN 0R RENEW AIR CLEANER PAPER 25 Alternator CHECK LEVEL OF COOLANT AND,IF ELEMENT—CARBURETTOR ENeiNEs 25 Use of 'Jumper’ Cables NECESSARY,TOP-UP 13 RENEW AIR CLEANER—FUEL INJECTION 26 Starter Motor

ENGINES 26 Electrical Connections

14 CLEAN AND ADJUST 0R,RENEw CONTACT BREAKERS ENGI NE IDENTIFICATION Starting the Engine TO STOP THE ENGINE To do this, disconnect the upper carburettor A code identifying the cubic capacity and the TO START FROM COLD 1. Switch off the engine by means of'the ignition to heater hose at the automatic choke casing. level is on a machined lug compression stamped 1. Disconnect the driven equipment. key. Fill the cooling system, preferably with soft cast i nto the left hand bank of the cylinder block If the halt is likely to be of duration the fuel water to minimise corrosion, until water 2. Open the fuel tank tap (where fitted). some just a bove the fuel lift pump aperture. tank tap off. the automatic choke casing (where fitted) should be turned escapes from 3. On carburettor engines only, completely connection. Reconnect the hose. Where MWB indicates 1,7 litre model 2653E LC open and close the throttle twice to engage LUBRICATION AND MAINTENANCE freezing is anticipated anti-freeze should be MYE indicates 1,7 litre model 2653E HC the automatic choke. added to the system as detailed on page 21. The importance of correct lubrication, periodic indicates litre model 2654E. NYM 2,0 4. Switch on the ignition and operate the starter. inspection and adjustment cannot be over— YYH indicates 2,3 litre model 2655E. 3. Fill the engine sump to the full mark on the The engine will now run at an increased idling emphasised. On it will depend, to a very large PYA indicates 2,8 litre model 2658E. dipstick with the correct grade of lubricant. speed which will return to normal when the extent, the service which the engine will give. PRB indicates 2,8 litre model 2658E I. See page 23. correct operating temperature has been reached. Regular attention to the points mentioned in the 4. Ensure that the battery is topped up and fully Operation next few pages will be amply repaid in long life, Before charged. 1. Before operating a new engine it should be and reliability. thoroughly inspected to ensure that during Running-In Procedure Your Authorised Ford Dealer is equipped with it has not suffered TO RESTART WHEN WARM transit and installation specialised‘equipment and highly trained mechanics or reconditioned engine mu st not be run at to affect its subsequent A new damage likely 1. Open the throttle or governor control slightly. and he will be pleased to advise of the full the first hours, you Controls and instruments should high speeds or on load for 30 operation. maintenance schemes available. but the loads and speed be increased to a 2. Switch on the ignition and operate the starter be studied carefully in order that their may over this period. After the first 50 hours motor. For convenience, lubrication and maintenance work functions may be thoroughly understood. maximum out running, a general check—over must be carried If, however, the engine fails to start proceed as has been divided into the following periods:— Open the cooling system drain cocks and as detailed under REGULAR MAINTENANCE. for normal cold starting. » flush the cooling system with clean water. CIose the drain cocks. The system must be NOTE: Do not operate the engine at full speed and/ — vented for filling. ortpower immediately from cold these should be progressively built up. SUMMARY OE REGULAR MAINTENANCE REGULAR MAINTENANCE OPERATIONS After first After first After every page Daily 50 hrs or 100 hrs or 100 hrs or No_ 2,500 krns 5,000 kms 5,000 kms Check level of engine oil and, if necessary, top-up. (1,500 mls) (3,000 mls) (3,000 mls) Ensure that the equipment is standing level.

9 Check level of engine oil and, if necessary, top-up X Withdraw the dipstick and wipe it with a clean rag. top-up 9 Check level of coolant and, if necessary, X Replace it fully and withdraw again. The mark 10 Retighten the sump, cylinder head, inlet manifold and ,made by the oil on the dipstick scale (Fig. 1) will rocker cover bolts. X X indicate the engine oil level. If oil should ‘ necessary, 1O Change engine oil. X X X be added, via the filler in the RH rocker cover. 11 Change engine oil filter. X X

1 1 Check level of battery acid and, if necessary, top-up. X X \k 1 1 Clean and protect the battery terminals. X X Check level of coolant and, if necessary, top-up. 12 Adjust fan belt. X X Fig. 1 Checking engine oil level. Make sure that the water in the radiator has cooled 12 Clean fuel lift pump X X down and then remove the radiator cap SLOWLY. 12 ‘ Clean ventilation valve and duct X X Top-up with coolant to 13 to 25 mm (0,5 to 1 in) 13 Clean or renew air cleaner paper element. X X below the radiator filler neck. Soft water should 14 Clean and adjust or, if necessary, renew sparking plugs. X X preferably be used to limit corrosion. If the system 14 Oil distributor lubricating felt. X X has been previously filled with an anti-freeze 14 Adjust or, if necessary, renew contact breakers solution it should be topped up with a solution Of (4 cylinder engines only) X X the same concentration. Replace the filler cap and 15 Adjust ignition timing. X X tighten securely. 18 Adjust idling speed setting. X X 19 Check and, if necessary, adjust valve clearances X X

NOTE: The above Service Schedule gives the changing the engine oil, at an interim period. Your maximum recommended service periods. Since operating experience is the best guide for operating conditions can vary, it may be found determining this time. advisable to carry out some operations, for example, Retighten the sump, cylinder head, inlet manifold Change engine oil filter

and rocker cover bolts Unscrew and remove the old oil filter canister In the case of a new engine, or after new gaskets with the aid of a suitable strap wrench (See Fig. 3)

have been fitted, it will be necessary to retighten‘ Remove all traces of dirt from the oil filter mount the sump, cylinder head, inlet manifold and flange on the cylinder block, taking care not to rocker cover bolts to the correct torque (See Page dislodge any dirt particles into the cylinder block 29) to compensate for initial gasket settling. _oi| passages. Screw on the new unit ensuring that' rubber sealing ring is correctly located. To avoid distortion the cylinder head bolts should be tightened in the order shown in .Fig. 2. On Check level of battery acid and, if necessary, top-L initial assembly the bolts specified above are tightened in stages (See Page 29) but when re- The electrolyte level should be 6 to 9 mm (0,25 be' tightening, it will to to only necessary torque to 0,38 in) above the top of the plates. The level T/3/27 the final figure. may be raised, if necessary, by the addition of Fig. 2 Cylinder head bolt tightening sequence distilled water. Change engine oil Clean and protect battery terminals Make sure that the equipment is standing level with the engine switched off and preferably hot. If corroded, clean the battery terminals (See Fig. 4 Remove the drain plug from the oil pan and drain with an ammonia solution and coat them with the oil into a suitable container. petroleum jelly for future protection.

Replace the drain plug. If it is desired to change the oil filter this should be done prior to filling the sump with the correct quantity and grade of engine oil. — Clean fuel lift pump — carburettor engines Clean or renew air cleaner paper element carburettor engines Disconnect and plug the fuel inlet hose. Unscrew the filter cover fixing screw and remove the cover, Remove the air cleaner top cover and lift out taking note of the condition and position of all the paper element. Clean the air cleaner casing sealing rings. The filter screen can now be with- being careful to avoid dirt particles entering the drawn for cleaning. The reassembly is simply a carburettor venturi. If the old element is still reversal of the dismantling procedure. serviceable it may be cleaned by thorough shaking, checked for perforations, by viewing with a bright Clean ventilation valve and duct light held inside, and replaced in the air cleaner casing. If the old element is found to be in need of Disconnect, at the valve end, the ventilation hose replacement a new Ford filter element should be connecting the ventilation valve to the L.H. rocker 37/61 N, fitted and the cover replaced. cover. Unscrew and remove the ventilation valve Fig. Air cleaner — fuel injection engines Fig. 5 Fan belt adjustment 6 assembly and clean it thoroughly in paraffin. Check the A — Front securing clips Renew air cleaner element — fuel injection engines. 1. Adjusting strap bolt 2. Pivot bolt operation of the valve and the condition of the B — Air intake pipe

threads. Before replacing it, the duct in the car- 1. Disconnect battery.

burettor sandwich plate, leading from the valve 2. Unclip cleaner (two clips at each end) from to the inlet tract, should also be thoroughly housing. Fig. 6 shows front clips. cleaned. This can be facilitated by unscrewing Adjust fan belt 3. Partially remove cleaner, detach intake pipe the horizontal plug at the end of the duct. Re- and remove cleaner ahd filter assembly, The fah belt should have 13 in) free Fig, 7. mm (0,5 . assembly is a reversal of the dismantling procedure. movement when measured midway between the 4. Discard air cleaner element. fan and alternator pulleys (See Fig. 5). Insert new air cleaner element. If adjustment is required slacken the two pivot Place assembly in position and refit intake pipe. bolts and the adjusting strap bolt. Move the alter- 7. . Ensure filter and cleaner are correctly located nator to give the correct belt tension and retighten onto housing and secure four clips. the bolts. 8. Reconnect battery. 12 Clean and adjust if sparking Fig. 8 Crankshaft timing or, necessary, renew Adjust or, if necessary, renew contact breakers Adjust ignition timing plugs marks - 4 cyl. Contact breaker type distributors are now fitted The timing is indicated by a notch in the crank- Disconnect the high tension leads the 3° from to the 2653E four cylinder engines only and are of shaft pulley and a scale marked in divisions on sparking plugs and using a proper sparking plug Bosch manufacture. the cylinder front cover (Fig. 8 ,— 4 cylinder spanner, to avoid damaging the insulator, remove engines. Fig. 9 —— 6 cylinder engines). The 2654E/5E/8E and 8E| six cylinder engines are the plugs. If the plugs are still serviceable, clean equipped with ’breakerless' distributors If the distributor has been removed from the the plug porcelain and remove all carbon from v engine, rotate the crankshaft in the running ' manufactured either Bosch or Motorcraft. the electrodes. by The Bosch distributor has a dark red cap and the direction so that No. 1 piston (front right hand Sparking plug gaps should be checked with feeler Motorcraft distributor has a blue cap; they are bank) is at the correct number of degrees BTDC gauges and, if necessary, set to give a gap of 0,6 not adjustable except for timing purposes. on the firing stroke i.e. both valves closed; see mm (0,025 in). ‘General Specifications' on Page 30 for the relevant Refit the plugs and leads. Bosch distributors — To renew the contact setting. breakers, disconnect the short lead connecting the Oil distributor lubricating felt Ensure that the distributor is in good condition contact breakers with the low tension terminal and that the contact breaker points (where Remove the distributor cap and rotor and apply by pulling-off the blade connection at the terminal 'applicable) are correctly gapped. two drops of oil to the felt in the distributor pad end. Unscrew the screw securing the contact shaft. Set the rotor arm pointing towards the dot at the breaker assembly to the distributor base plate and periphery of the distributor (Fig. 10 — Motor- On distributors fitted with contact breaker points, discard the old contact breaker and lead assembly. craft distributor, Fig. || — Bosch distributor). applyxa film of petroleum jelly to the contact Simply reverse this dismantling procedure to fit I breaker cam. the new set of contact breakers. Fit the distributor so that the vacuum unit is approximately at right angles to the crankshaft Reassemble the distributor. To adjust the contact breakers ensure that the axis and pointing towards the right hand cylinder moving contact breaker‘heel is on the highest bank (Fig. 13 — 4 cylinder engines, Fig.w‘l4 — part of the cam, and, with the adjustment screw 6 cylinder engines). If difficulty is experienced in loosened, move the fixed contact to give a engaging the distributor gear, the unit should be clearance of 0,4 to 0,5 (0,016 to 0,020 in). mm rotated slowly back and forth until the teeth Tighten the adjusting screw and recheck the gap. Fig. 9 Crankshaft timing marks — 6 cyl. engage correctly.

14 15 Fig. Distributor and As the un'it is pushed home the rotor will rotate On four cylinder engines, turn the complete 14 plug lead in an anti-clockwise direction, due to the helical distributor as necessary to align the rotor arm positions — driving gear. On six cylinder engines fitted with Fit the dot on the distributor periphery — see Fig. 11 6 cylinder engines. Motorcraft distributors, remove the rotor arm Fit the distributor locking plate and finger tighten and, if necessary, turn the complete distributor the retaining bo|t((Fig. 13). until the No. 1 rotor segment aligns with the 'On 4 cylinder engines, the ignition timing can be marks on the coil trigger housing — see Fig. 12. set as follows:— On six cylinder engines fitted with Bosch dis— I tributors, remove the rotor arm and, where Check that the engine timing marks are still aligned necessary turn the complete distributor until all with No. 1 piston at the specified No. of degrees six rotor segments align with all six trigger points. BTDC on the firing stroke (See Page 30). Replace‘the rotor in either case. Disconnect the low tension leads from the coil and connect a bulb of the same voltage rating as

Fig. 15 Distributor and plug lead positions — 4 cylinder engines.

Fig. 12 No. 1 rotor segment lined up with marks on trigger housing. Fig. 1 1 Rotor alignment Bosch distributor Fig. 13 The distributor locking plate and bolt — — ' A Trigger coil hoysing 4 cylinder engines B -—- No. 1 rotor segment 16 17 engine assemblies, are fitted with tamper proofed the coil across them. Switch on the ignition and fuel control equipment. rotate the distributor body clockwise until the lamp is lit and then anti-clockwise until it is just .The fuel injection equipment and carburettors are extinguished. Tighten the distributor locking plate fitted with seals over the mixtu re control screws bolt and replace the cap and leads as shown in which should only be removed by authorised Fig 15. 'dealers equipped with emission measurement _ I _ tlmlng On 6 cylinder engines a stroboscoplc , equipment. light must be used to set the ignition timing The idle speed adjustment screw can, however, accurately; the correct method is as follows:— be adjusted by the operator and its location can be Use a piece of white chalk to ’highlight’ the crank- identified by reference to Figs. 16 and 17. shaft pulley timing notch. The idling speed should always be set with the Disconnect and plug vacuum pipes. Connect timing engine at normal operating temperatu re. Fig. 16 Idling speed adjustment — twin as per manufacturers instructions, venturi carburettor light to engine Engines fitted with carburettors should have an Fig. 18 Adjusting the valve clearances to idle at specified .idle start engine and allow idling speed of 800 i 25 rpm. To adjust the valve speed.. clearances remove the rocker Engines fitted with fuel injection equipment cover fixing bolts and both rocker covers. Turn the Check ignition timing. Refer to General Specifi— should have an idling speed of 900 i 25 rpm engine over until the valve to be adjusted is in the cations on Page 30. when fitted with manual transmissions and 850 i correct pOSition and adjust the clearance with the To adjust timing, stop engine, loosen distributor 25 rpm when fitted with automatic transmissions. aid of feeler gaugés and a suitable ring spanner. See 8 clamp bolt using Tool No. 21—079 and rotate Fig. 18. Turn the self locking adjuster clockwise complete assembly. Tighten clamp and recheck Check and, if necessary, adjust valve clearances to decrease and anti-clockwise to increase the timing. The valve clearances should be checked when the clearance. engine is cold. The specified clearances for all the To obtain the correct adjustment sequence, for idling setting Adjust the speed in engines the 2650 range are 0,35 mm (0,014 in) four cylinder engines, consider cylinders 1 and 4 In order to conform to ECE R15 01 regulations. fér the inlet valves and 0,40 mm (0,016 in) for the to be paired together — likewise cylinders 2 and 3 concerning emission control, all 2650 range engines exhaust valves. (See Fig. 15 for cylinder identification). IFig. — 17 Idling speed adjustrﬁent fuel injection equipment derived from current production automotive

18 19 . . GENERAL MAINTENANCE With the inlet va|ve of No. 1' cylmder open adjust » The following section outlines the inlet valve of Non 4 cylinder and Vice versa_ some features of W_ ‘ general maintenance which will be of value to the It h th e eX haUSt V8 I Ve of No - 1 cylinder Open I _ o perator_ No. 4 and adjust the exhaust valve of cylinder V vice versa. Treat cylinders 2 and 3 In the same way. cooling (Figs I System 19 & 20) To obtain the adjustment sequence for six cylinder To obtain the engine life its I maximum service engines, consider cylinders 1 and 5, cylinders 4 operating temperature must be maintained by an and 3 and cylinders 2 and.6 to be paired together efficient cooling system. (See Fig. 14 for cylinder identification) and the radiator fins proceed as for 4 cy|inder engines. Kneep clear of obstructions at a t'mes‘ When all valves have been adjusted correctly u _ I examine the condition of the rocker cover gaskets Pmtec? the COQIIPQ SYStem Wltlh antI-freeze when °peratm9 corjd't'ons warrant- Ant" and, if necessary, renew. Replace the rocker covers MOtorCKaft — Plus life If rocker cover gaskets freeze ha? loqg Characteristics and and check for leaks. new > If the concentration Is kept above 45% strength, have been ﬁtted the ﬁxing bolts Wm require 7m it will provide adequate retorquing after 50 hours running. protection and inhibiting for up to two years. NOTE:— Never run an engine when the cooling

mm , system is empty. Never top up a very low radiator or re-fill the Fig. 19 V4 Cooling system cooling system with cold is (Single acting thermostat situated in water outlet) water when the engine hot otherwise damage could be caused.

The radiator is normally equipped with a pressure Fig- 20 V6 C°°“"9 SYStem cap. It is dangerous to remove this when the (Double acting thermostat situated in water inlet) system is very hot. Even when slightly hot remove with caution, alowing all pressure to be relieved

‘ and all steam to escape before completely

‘ 21 20 removing the cap. The LUBRICATION SYSTEM dipstick (Fig. 1) provides some guide to the condition of the oil. An additive type of oil keeps The lubrication system should be maint'ained is of the force feed type, the lubricating oil being soot in suspension, and even a small amount of regularly with the correct grade of lubricant as circulated to the engine bearings under priessure by soot causes the oil to darken rapidly. However, speciﬁed in the maintenance summary. The system an oil pump driven from the camshaft (Fig.21 & 22); if the dipstick is found to be heavily coated with sludge, then obviously the oil should be changed. The presence of beads of moisture on the valve -/rockers, as seen through’ the oil filler cap aperture, indicates adverse running conditions. When this occurs, more frequent draining and renewal of the oil is highly desirable.

—23°C —12°C 0°C 16°C 32°C

Fig. 23 Engine ventilation system

in the cleanest possible conditions. When changing —10°F or topping-up +10°F +32°F +60°F +90°F the engine oil, use only clean receptacles. Do not allow the oil to come into contact with the rubber hoses on the engine. LUBRICANTS VENTILATION The oil used must meet Ford Specification SYSTEM SSM—2C—9001AA and must be of the viscosity 2650 range engines are equipped with a closed shOwn below to suit the ambient temperature. ventilation system (Fig. 23). C/6A/57 Lubricating oil cleanliness is vital for the successful C/éA/Sé Fresh air, drawn through the air cleaner operation of inlet spout Fig. 22 V6 lubrication system your engine. The oil should be stored Fig. 21 V4 lubrication system passes through a flame-proof filter element and 22 23 After starting do not disconnect the ’jumper’ leads that it freeze, causing damage to ALTERNATOR thence into the engine, via a short hose attached to possibility may to keep the while the engine is running at over 1000 rpm (or the container. Take care, therefore, is on a bracket on the right of the the right hand rocker cover. The air then passes Thi's mounted — specific fast idle). as fully charged as possible block (viewed from the flywheel) and is through the engine and is drawn, through a battery cy_lmder at 21°C (70°F). driven the crankshaft fan belt. is pressure sensitive valve, into the inlet tract, via gravity 1,275 from by the CAUTION: Since explosive hydrogen gas always left hand rocker present, sparks or flames should not be aHowed another short hose attached to the The charging rate is adjusted automatically by an near the battery. When using battery ’jumper’ cover. Special precautions should be taken when Internal regulator to provide sufficient electric cables, the cables should always be attached to the operating in cold climates to prevent the battery r‘current to the charged under efficient engine ventilation is keep battery fully In this way first the of falling below the conditions indicated booster battery to reduce possibility crankcase fumes are reconsumed state from normal operating conditions. guaranteed and sparks near a charged by the following specific gravities: battery. by the engine. Alternator bearings are lubricated for life at —1 8°C (0° F) 1,200 specific gravity at assgmbly and therefore require no lubrication —29°C (—20°F) ELECTRICAL SYSTEM 1,245 specific gravity at malntenance. —35°C (—30° BATTERY 1,265 specific gravity at F). USE OF 'JUIVIPER’ CABLES A NEGATIVE EARTH SYSTEM IS USED ON should not be allowed to become ALL THE ENGINES IN THIS RANGE. The battery To avoid the possibility of extensive damage to or to stand in a run-down unduly discharged, your charging system it is important to observe the correct battery terminal is Ensure that the condition. 'jumper’ the following points when using battery cables connected to a good earth on the framework of the battery filler plugs and connections tight, to start an engine having a discharged battery. The equipment. Keep and the top of the battery clean. Wiping the positive (+) terminals of the batteries must be water for battery use should be kept in Distilled battery with a rag moistened with ammonia will connected through one cable (usually red), and the non-corrodible vessels. In cold clean, covered counteract the effect of any of the solution which negative (—) terminals connected through the other water only immediately before weather, add may’ be on the outside of the battery. A coating cable (see Fig. 24). Fig. 24 Correct connection of Booster Battery the engine, so that the charging will mix running of a good grade of petroleum jelly will protect this will prevent the water and electrolyte: the terminals from corrosion. freezing. . weather If the battery is allowed to stand in frosty is a in an unduly discharged condition there 25 24 ENGINE FAULT FINDING CHARTS STARTE R MOTOR ENGINE WILL NOT START

The starter motor is mounted on the left hand side Starter does not ______._Starter cranks “W" of the engine (viewed from the flywheel) and it crank engine We “My $3M ermma5’???s oose Eiéfizflséilfié’cfl‘dm I . requires no attention beyond seeing that the cable Faulty starter sthch ———-————J Connections dirty Wrong 'grade of oil connections are clean and tight, the commutator is Starter drive dirty ___—- Faulty starter motor Faulty starter motor I._—.____l '

renewed when - kept clean and the brushes are ,GNrrION FUELSYSTEM necessary. No spark at plug gaps l No Petrol in Carburettor

ELECTRICAL CONNECTIONS V Spark plugs oiled up Spark plug‘lnsulators cracked Air leak in patrol line Periodically check all electrical connections to D'STRIBUTOR Blockage in carburettor pipe line ensure that they are clean and secure and that no Faulty fuel lift pump No spark at plug leads leads show signs of fraying. I Cracked Petrol in Carburettor ‘rotor_—___ ‘ FUEL TANK AND LINES Loose low tension lead____—‘ Faulty distributor cap____ Jets choked _,_____ cable adjustment“ 0r worn COHtBCt breaker points Incorrect choked ' time to time the fuel should be drained Dirty — From Faulty condenser or connections _.__ Air leak in inlet manifold completely and the system flushed to prevent the Carbon brush not making contact ' Water in petrol ‘ Dirt in carburettor accumulation of dirt. COIL No spark at HT lead

Coil burnt out _—__— High tension lead loose or broken Battery m” down swut'ch Batterv Low tension lead loose or broken Faulty Ignmon ——‘——— . ——-——-C Contact breaker pomts not opening or— closing LT circuit ____—‘ l

Note: References to cqntact breaker points apply to 4 cylinder engines only. Listed carburettor faults are not applicable to the 2658El engine — suspected faults In the petrol injection equipment should be referred to your Ford Dealer.

27 ENGINE FAULT FINDING CHARTS TIGHTENING TORQUES ENGINE IGNITION I m9?! Nm kgf MISFIRES I m lbf ft in carburettor ValveWsticking —— High tension leads to spark plugs shorting Water t choked Valves burnt — Incorrect spacing of spark plug points Fuel line partly Mam Begring Cap 88 to 102 9 Valve spring broken 0 to 1O 4 _Cracked spark plug insulator Fuel lift pump pressure low valve Cap 3,4, Li— Fuel lift pump filter choked Incorrect clearance 28 to 34 2:9 to Low tension lead loose ,groannnkeschgrfltg-éod g? :2 g: -— Faulty or damp distributor cap Needle valve faulty or dirty 41 to 49 4,2 to Geaerar 5,0 30 to 36 camShaft 41 ENGINE STARTS V, to 49 4,2 to 5,0 30 to 36 IGNITION CARBURETTOR AND STOPS Fl yWham 64t069 6,5 to71 _ I I 47t 51 — Low tension connection loose Fuel Iin‘e blocked Thre_aded Plug In Cylinder Block Front Face 61 Faulty ignition switch contacts Water in fuel 6 0 4% contact breaker points Needle valve sticking —Dirty glirlnFl’EghCover 13 to 16 1,3 to 1,7 Fuel lift pump faulty 9,5 to 12 No fuel 14to 16 1,4to1,7 L— 10to12 Air leaks OilPump cove 8,8to 13 0,9 to1,3 rl 65t095 ROCke r 5de esta 41 to 47 4,2 to 4,9 3i) to 35' ENGINE RUNS ON MECHANICAL _ _ CARBUR ETTOR I Pan FULL THROTTLE ONLY m Initially 3,9 to 6,8 0,4 to 0,7 2 9 to 5 O —- Slow-running jet blocked Valve sticking I 1o mins 5'0 7'0 I Slow—running adjusting screw incorrectly adjusted Valve burnt Aftgr 6,8 to 9,5 0,7 to 1,0 to Valve spring broken Rocker ‘Cover InItIally 3,9 to 6,8 2’9 5’0 0 ' 4 to O ' 7 to ENGINE DOES NOT ' ' CARBUR ETTOR MECHANICAL AND IGNITION After 10 mins 6,8 to 9,5 GIVE FULL POWER _ g'zotto47do — Fuel supply faultv Ignition retarded Cylmder Head Initially 43 to 54 2:3 :2 gg I tension lead shorting Air leaks in inlet manifold High or bad seating After 10mins 54 to 68 Jet partly choked Valve burnt 5,5 to 7:0 4o t: 50 Incorrect valve clearance Aftgr 20 mlns 87 to 106 9,0 to 11,0 Faulty distributor cap _ 64 to 78 L— I n I et Manlfold Imtlally Wrong distributor fitted 3,9 to 7,1 0,4 to 0 8 2 9 to 5 2 2'5 ENGINE RUNS After 10mins 20to 24 2 1 to 18' ENGINE KNOCKS‘ _ 11h IMPERFECTLY — Weak mixture Temperatutre Sender Umt 12 to 16 to 1'6 too — Fuel feed faulty Timing too far advanced 1:2 9 o 12 — Excessive carbon deposit Spark Plugs 2'1 Inlet valve(s) not closing 28 to 38 3,0 to 4,0 to 28 — Ignition timing incorrect Loose bearing or piston Carbu rettor flooding Spark plug leads crossed. £

Note: References to contact breaker points apply to 4 cylinder engines only. — faults in the fuel injection Listed carburettor faults are not applicable to the 2658El engine suspected system should be referred to your Ford Dealer. 28 29 GENERAL SPECIFICATION FORD COMPANIES AND DISTRICT OFFICES Ford service facilities are available in nearly every' country of the world. Service in each country is covered by a network of Authorised Ford Dealers. As these are too numerous to 2653E(LC 81 HC) 265E 2655E 2658E 2658E| mention here, we have restricted the fol lowing list to overseas Ford Companies together with' District Offices and the areas they supervise. Type V4 V6 V6 V6 V6 FORD Bore (mm) 90- .84 90 ——- 93 COMPANY ADDRESSES

Stroke (mm) 66,8 ——— 60.14 ——.—-— 68.5 Ford Motor Argentina S.A. Henry Fordinkatu 6 Ford Motor Co. of New Zealand Ford Motor Company (Switzerland) SA Casilla Correo 696 P.O. Box 46 1998 2293 ——— 2792‘ P.O. Box 30012 Kurvenstrasse 35 Volume (cc) 1699 Swept Casilla Central SF 00101 Helsinki 10 Lower Hutt CH 8021 Zurich, Switzerland. —-———— Buenos Aires, Argentina. Finiand. Comp Ratio 7,75:1 & 8,7511 9:1 ——— 9.2:1 Wellington, New Zealand. Ford Lio Ho Motor Co. Ltd. 1T3iwan) Firing Order 1342 142536 Ford Motor Company of Australia (PTY) Ltd. Ford (France) S.A. Ford Motor (Norge) A.S. P.O. Box 26486 Private Mail Bag 6 B.P. No. 90 1410 Kolbotn Taiwan ROC. Valve Clearance (Hot) ‘ Campbellfield 92 Rueil-Malmaison Norway. Victoria 3061 , Australia. France. Inlet 0,350mm (0,014in) Ford Motor Co. (Thailand) Ltd. Ford Philippines Incorporated G.P.O. Box 2701 0,400mm. (0,01 Gin) Ford Motor Co. (Austria) AG Exhaust Ford-Werke A.G. P.0. Box 415 Bangkok, Thailand. Rainerstrase 27 5 Koln Merkenich Makati Commercial Center ' Fuel Octane Rating 90 8t 97 97 P.0. Box 2 Industriestrasse, Germany. Makati Ford Motor Co‘ Ltd. 5021 Fuel Injection Salzburg, Austria. 'Rizal Carburettor (Downdraft) Twin Venturi D708 Industrial Products Sales Dept. Ford ltaliana S.P_A. Philippines. Royal Oak Way South lbf/in’) Ford Oil Pressure (Normal 3,2 to 3,9 bar (3,2 to 4,0 kgf/cm2 or 46 to 57 Motor Co. (Belgium) S.A. Viale Pasteur No. 8/10 V Daventry, Postbus 37 P.O. Box 10058 Ford Lusitana S.A.R.L. Northants NN11 5NT, England. Running) 32030 Antwerp, Belgium. 00144 Rome EUR Avenida de Serlin 4C Oil Filter Capacity 0,4 litre (0.7 pint) Italy. Apartado 2248 Ford (Uraguay) S.A. Ford Willys Do Brazil S.A. Lisboa 2, Portugal. Casilla de Correo 296 4.25 litre (7.5 pint) Caixa Postal 8610 Sump Capacity (inc 3,75 litre (6,6 pint) Ford Motor Company of Japan Montevideo, Uruguay. Sao Paulo, Brazil. Checker Building Ford Motor Company Private Ltd. Filter) 5-29 Akasaka l8 Chome Bukit Timah P.O. Box 4047 Ford Motor Company Ford Motor Company of Canada Ltd. Minato-Ku, Coolant 8V2 Milestone Bukit Timah Road Industrial Engine Operations Optimum National Parts Depot Tokyo 107, Japan‘ Singapore 21. Ford Parts and Service Division 90° 8000 Dixie Road Operating Temperature C(195° F) 300 Renaissance Center Bramalea Ford 12° Motor Company S.A. Ford Motor Company of South Africa (PTY) Ltd. P.O. Box 43338, Detroit 9° ' Ignition Advance (Static) 6° BTDC BTDC BRDC Ontario, Canada. Paseo de Ia Reforma 333 P.O. Box 788 Michigan 48243, U.S.A. Apartado 39 Bis. Port Elizabeth, South Africa. Plug 81 AGR22 Spark Type (Motorcraft) AGR32 AGR22 Ford Motor Company A.S. Mexico I.D.F. Mexico. Ford Motor de Venezuela S‘A. Sluseﬁolmen 1 in) Ford Motor Plug Gap 0,6mm (0,025 N.V. Nederlandsche Ford Company A/B Apartado 354 2450 Copenhagen S.V. Automobiel Fack Valencia, Venezuela. Denmark. Fabriek Contact Breaker Gap 0,4 to 0,5 mm (0,016 to 0,020 in) 3102-50 Postbus 795 Stockholm 27 Sweden. Engine Weight (Dry) 128 kg (282 lb) 160 kg (352 lb) ___175 kg (386 |b)——— Amsterdam, Netherlands.

30 'FORD DISTRICT SUPERVISING THE FORD DISTRICT SUPERVIsiNG THE > OFFICES FOLLOWING COUNTRIES OFFICES FOLLOWING COUNTRIES

Ford of Europe Inc. Afghanistan Libya Ford Asia-Pacific Inc. Bhutan Indonesia ‘ Républic Mid-East & African Algeria Malagasy British W. Pacific ls. . Korea 33 Albert Rd Ma1awi SalesOpérations Andorra Melbourne Burma Laos Angola Mali Cambodia Maldive I‘s. 169 Kings Rd. Victoria 3004 Malta Brentwood Ascension |s. Fiji Nepal Australia; Mauritania Essex Bah rain French W. Eaciﬁc ls. Society |s. ' CM14 4EN Bangladesh Mauritius Guam Solomon |s. Morocco England. 'Benin Hong Kong 81 Macao Sri Lanka Burundi Mozambique Tahiti India ' Niger Thailand Cameroon Indian Ocean |s. ' Nigeria Vietnam Canary |s. Cape' Verde |s. Oman Ford Motor Co. Bahamas Haiti Central African Empire Pakistgn Caribbean Dist. Office Barbados Jamaica Genie/Melina Qatar Call Box CD Bermuda . Netherlands Antilles Chad Reunion Caparra Heights Station British W. Indies Puéno Rico Congo Rhodesia Sa'n Juan Cayman |s. St. Pierre & Miquelon Cyprus Rwanda Puerto Riga 00922 Dominican Republic ' Surinam Diibouti Saint Helena' French Guiana Trinidad . Egypt Sao Tome 81 Principe Indies French W. Vir'gin U.S. |s. Equatorial Guinea Saudi Arabia Guyana Virgin |s. Ethiopa Senegal Gabon Seychelles Central American British Honduras Guatemala Gambia Sierra Leone District Office Columbia Honduras Ghana Somalia Apartato Postal F Cos‘a Rica Nicaragua Gibraltar Sudan Panama 4 Ecuador Panama Greece Syria ‘ Republii: de Panama. El Salvador Guinea-Bissau Tanzania Guinea Republic Togo South American ' Bolivia Paraguay Iceland Tunisia District Office‘ Chile Peru Iran Turkey Ford Motor Co. del Peru S.A. Iraq Uganda Panamaricana Norte, km 8 Israel Upper Volta Casilla No 4407 Lirna 1 Ivory Coast United Arab Emirates Peru. Jordan Yemen, Arab Republic Kenya Yemen Pgoples Dem. Rep. Kuwait Zambia , Lebanon Zaire

Liberia

Published by:— Ford Motor Co. Ltd., Data & Specifiéations Dept, South Ockendon, Eséex, E‘ngland DSL1022102

'February Printed in England by Clifford—Thames Printing Co. Ltd., Shenfield, Essex. CO 38010 1979 _.a.ﬂ . u