Escort L4-116 1.9L SOHC HO (1989)
Intake Manifold: Technical Service Bulletins
Engine - Intake Manifold Cleaning Before Installation
Article No.
00-18-8
09/04/00
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Engine-1.9L-Cleaning intake manifold procedure during remanufactured longblock or shortblock installation
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engine-1.9L-Premature failure of remanufactured longblock and shortblock-service tip
Ford: 1985-1996 Escort
Mercury: 1985-1987 Lynx
ISSUE
Premature failure may occur on the 1 .9L Motorcraft Remanufactured Longblock Assembly (-6V012-) and Shortblock Assembly (-6V009-) due to
ingestion of foreign objects remaining in the transferred intake system from the original failed engine.
ACTION
When installing a 1 .9L Motorcraft remanufactured longblock or shortblock, it is imperative that the transferred intake manifold be completely
dismantled and cleaned. Any objects that are allowed to remain in the intake plenum and/or runners will be ingested by the new engine, causing
premature failure. Refer to the following Service Information for details.
SERVICE INFORMATION
Completely disassemble, inspect and clean the intake system prior to transferring to the new 1 .9L Motorcraft Remanufactured Longblock or Shortblock.
It is also recommended that the following installation tips be followed when installing any Motorcraft Remanufactured Engine product:
1.
At the time of receipt of the engine, inspect the engine for any shipping damage and verify that you have received the correct part.
2.
Clean or replace all tinware (e.g., valve covers, oil pan, front cover), intake and exhaust manifolds, filters, PCV valve, and sensors before
transferring to the remanufactured engine. (Engine failures due to contamination and foreign material in the combustion chamber or oil pump are
not warrantable.) Engines with large intake manifold plenums like the 1 .9L are prone to leaving engine debris in the manifolds. Extreme care must
be taken when installing a replacement engine. Debris from the original failed engine collects in the intake and exhaust manifolds and will transfer
to the replacement engine on start up.
3.
Ensure that the exhaust system is in good working order. Check for exhaust restrictions.
4.
Ensure that the cooling system is in good working condition. It is recommended that the radiator be powerflushed, cleaned or replaced. Check the
water pump and replace if necessary with a new water pump. Check all belts and hoses and replace as necessary. Ensure proper fill level and
install a new thermostat. (Engine failures due to overheating are not warrantable.)
5.
Ensure that the fuel pump is in good working condition. Replace with a new fuel pump if fuel pressure or volume do not meet specifications.
6.
Prime the oil pump and replace the oil pickup screen.
7.
Mechanically prime the oiling system. Failure to do so will lead to early bearing failure. (Bearing failures due to dry starts are not warrantable.)
8.
Ensure that items such as distributors, carburetors and fuel injectors meet factory specification. (Engine failures due to detonation, pre-ignition or
fuel wash are not warrantable)
9.
When installing the flex plate or flywheel, do not use an impact wrench. Excessive torque on the flex plate or flywheel bolts will distort the
crankshaft oil seal journal and cause the rear main seal to leak. Use a torque wrench and torque to specification. Use a sealer on flywheel and flex
plate bolts on engines where the bolt holes in the crankshaft are drilled through into the crankcase.
10.
It is recommended that a complete tune up be performed and all ignition components be inspected and replaced as necessary.
11.
Start the engine and run until the thermostat has opened and all trapped air in the cooling system is bled off.
12.
Adjust ignition timing and idle speed to specification as appropriate.
13.
Check for oil and coolant leaks and road test.
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