Repair 7

Ford debuted its Mustang in 1965. Just three years later, it introduced a new engine, the so-called 302, or 5.0 liter V8 engine, a member of Fords Windsor engine family. This performance-oriented engine was available until the end of the 1970s.

History

Ford introduced the 5.0 liter, or 302-cubic-inch, engine in 1968 in anticipation of emissions standards established by the federal government in the 1970s. It remained an available engine in the Mustang until 1973. It was reinstated in 1975 and ended its run in Mustangs in 1979.

Cylinder Head to Engine Block

The bolts joining the cylinder head and the engine block require three distinct applications of torque executed in a helical sequence. The bolts require first 45 foot-pounds of torque, then 55 foot-pounds and finally 70 foot-pounds of torque. You should wait about 15 minutes between each step to allow the bolts to settle and stretch.

Other Specifications

The intake manifold bolts to the cylinder head in three stages: first to 12 foot-pounds, second to 20 foot-pounds, and third to 22 foot-pounds of torque. In 5.0 liter engines manufactured in 1969 and 1970, the rocker arm stud bolts to the cylinder head with 70 foot-pounds of torque. The valve cover bolts to the cylinder head with 4 foot-pounds of torque.

A torque wrench is a hand tool that has a gauge indicating specific torques being applied to a bolt or nut. They are helpful in the the construction and repair of auto engines, where specific fasteners have specific torques. Too much or too little torque may cause the engine to emit noise. Michigan Industrial Tools is one company that makes these instruments. Most torque wrenches operate in a similar manner.

Instructions

1

Check your repair manual for the specific torque of the bolt you are tightening.

2

Loosen the fastening bolt at the bottom of the wrenchs handle by turning it counter-clockwise.

3

Rotate the handle until it matches the desired torque measurement.

4

Tighten the fastening bolt by turning it clockwise to secure the handle.

5

Place the head of the torque wrench over the head of the nut. Hold the head of the wrench with one hand and the handle with the other.

6

Turn the wrench until the bolt is tightened. When it reaches the specified torque, the wrench will make an audible click and no longer tighten.

Under-torqued hardware may loosen during use, while over-torqued hardware may fail or damage the assembly it is attached to. Torque wrenches provide the means to measure safe, exact tightening force on hardware to prevent such occurrences. These precision tools must be routinely calibrated and certified for continued reliable operation.

Purpose

Like any tool, torque wrenches wear over time. Depending on the type, they may contain tiny gears, teeth, springs, gauges and other moving parts. The more the tool is used, the quicker these parts need to be inspected and replaced.

Frequency

The recommended calibration frequency of torque wrenches varies by manufacturer. Six months to one year is the prevalent calibration cycle. The International Organization of Standards (ISO) 6789:2003 does not use calendar time to recommend calibration, instead providing a calibration standard of 5,000 cycles.

Procedure

Torque wrench calibration and certification involves a thorough inspection and test of the tool. Precise pressure is applied to the wrench while its effectiveness is measured. If the tool does not indicate proper torque at the specified pressure, it is cleaned, repaired and retested.

Chrysler Motors manufactured many engines independently and also collaborated with other motor companies to manufacture engines. One of the engines manufactured in collaboration was the 2.0 DOHC engine created during the 1980s. The 1988 Dodge Colt Vista Wagon featured the 2.0 G63B engine.

Camshaft Torque Specifications

The 2.0 DOHCs had two outer cap bolts connecting the camshaft to the cylinder head with 18 foot-pounds of torque and three inner cap bolts with 8.75 foot-pounds of torque. The bolt connecting the camshaft position sensor to the camshaft had 2.5 foot-pounds of torque, while the bolt connecting the camshaft position sensor to the cylinder head had 7.08 foot-pounds of torque.

Exhaust and Intake Torque Specifications

The bolts connecting the fuel rail to the intake manifold had 16.25 foot-pounds of torque. The bolts connecting the intake manifold to the cylinder head had 212 foot-pounds of torque, and the bolts connecting the throttle body to the intake manifold had 16.67 foot-pounds of torque. The bolts connecting the exhaust manifold to the cylinder head had 16 foot-pounds of torque, and the bolts connecting the exhaust manifold to the exhaust pipe had 20 foot-pounds of torque. The bolts connecting the heat shield to the exhaust manifold had 8.75 foot-pounds of torque.

Engine Specifications

The 2.0 DOHC V4 engine had a peak horsepower of 96 and a peak torque of 113 foot-pounds. The engine had a bore and stroke of 3.35 and 3.46 inches, respectively, and a compression ratio of 8.5 to 1. The engine had a displacement of 122 cubic inches, or 2.0 liters.

A cars engine needs a pathway, as well as a power amplifier, to move torque from the engine to the transmission, which propels a vehicle forward. A torque converter is the device that provides this.

Identification

The torque converter is situated between the engine and transmission. It functions as a multiplier for the power generated from the engine to the motion of the transmission. It also helps muffle vibration from the drivetrain and engine components.

Features

The torque converter is a completely sealed assembly, which does not allow for any maintenance or servicing. But there is a way to test it called a stall test. Turn the car on and make sure the parking brake is engaged, as well as securing the wheels by chocking them. Press both the brake and accelerator pedal down together and see what RPM the car reaches. Check the typical RPM the vehicle usually achieves with the vehicle manufacturer. If it is lower than mandated, the torque converter may be slipping.

Warning

This stall test tends to put strain on the transmission. It is recommended to only perform this test in five second intervals.

An induction motor works on the principle that a current is created in a coil through which a magnet (magnetic field) is moved. The current is then able to drive a motor.

Problems with Torque Ripple

In applications like actuator motors for power steering in your car, torque pulsations or ripples can affect the power in the steering mechanisms or cause unwanted noise that bothers the driver. This ripple or pulsation must be dealt with in the induction actuator motor.

Causes of Torque Ripple

This torque ripple is caused as the magnetic field in the induction motor changes direction and consequently the current in the coil also reverses polarity. This problem has also been prevalent in brushless electric motors.

Research into Torque Ripple

Places like the University of Ohio are working on ways to eliminate or minimize torque ripple in induction and electric motors. Researchers feel that the torque ripple is basically a design problem and that it can be reduced or totally eliminated by creating the correct design geometry on the motor.

The Jetta is a small family sedan that was first introduced by Volkswagen Group in 1979. Over the years, five generations of Jetta have been released and the car has become the bestselling VW car in North America. For the 2000 model year, Volkswagon offered three different engines for the Jetta, each with its own head bolt torque specifications.

1.8L Turbo

Volkswagons 1.8-liter Turbo engine has 10 head bolts arranged in pairs across the engine. The bolts should first be pre-tightened to a specification of 40 Newton Meters (Nm), starting with the middle two bolts and proceeding in sequence out towards either the left or right end of the engine. The bolts should then be tightened again in the same sequential order by making a one-quarter turn of the wrench, and then tightened once again with another one-quarter turn.

2.8L V6

There are 20 head bolts arranged in three lines across Volkswagons 2.8-liter V6 engine. The bolts should first be pre-tightened in sequence to a specification of 50 Newton Meters (N-m), starting with the first bolt that is situated in the center of the engine block between cylinders 3 and 4. Proceed tightening the bolts in sequence out towards either the left or right end of the engine. The bolts should then be tightened again in the same sequential order by making a one-quarter turn of the wrench, and then tightened once again with another one-quarter turn.

2.0L L4

Volkswagons 2.0-liter L4 engine has 10 bolts that are arranged in pairs across the engine. The bolts should first be pre-tightened in sequence to a specification of 40 Newton Meters (N-m), starting with the middle two bolts and proceeding in sequence out towards either left or right end of the engine. The bolts should then be tightened again in the same sequential order by making a one-quarter turn using a box wrench, and then tightened again with another one-quarter turn.

Tools and Equipment

AST 3452 A is the model of the wrench required for tightening the head bolts on VW engines. This wrench can be used on most 1998 and later VW and Audi engines.