Ford LSG 875, Service Manual

Page 1: ...1 Power Products A LSG 875 SERVICE MANUAL PPO 194 208 86 ...

Page 2: ... a The Engine Exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm ...

Page 3: ...pection overhaul removal and installation pro cedures disassembly and assembly procedures and service specifications GEOMETRIC RESULTS Power Products Division Geometric Results incorporated 19855 W Outer Drive Dearborn MI 48124 The descriptions and specifications contained in this manual were in effect at the time the book was released for printing Geometric Results incorporated reserves the right...

Page 4: ...ection l Use safety stands whenever a procedure requires you to be under the vehicle l Be sure that the ignition switch is always in the OFF position unless otherwise required by the procedure l Set the parking brake when working on the vehicle If you have an automatic transmission set it in PARK unless instructed otherwise for a specific operation If you have a manual transmission it should be in...

Page 5: ...t Manifolds 1 l 2 Valve Rocker Arm l 1 2 Push Rods l 12 Cylinder Heads l 1 3 Hydraulic Valve Lifters l 1 5 Crankshaft Vibration Damper and Spacer l 1 5 Timing Chain and Sprockets 1 l 5 Camshaft 1 l 5 Crankshaft 1 16 Flywheel 1 l 6 Connecting Rods l 1 7 Pistons Pins and Rings 1 l 7 SUBJECT PAGE CLEANING AND INSPECTION Cont d Main and Connecting Rod Bearings l 1 8 Cylinder Block l 19 Oil Pan 1 19 Oi...

Page 6: ...a white tape engine code label located on the front of the left rocker arm cover A typical label and an explanation of the codes are shown below If this tag is destroyed or painted over it will be very difficult to distinguish between the vari ous levels of engines that is for example to distinguish between the 460 standard output and low output or even standard rotation versus re verse rotation D...

Page 7: ...five main bearings All oil passages are closed with pipe plugs Main bearings are of intermediate copper lead material with an oil groove only in the upper half Crankshaft end thrust is controlled by the flanges of the center main bearing Cylinders are numbered from front to rear with 1 through 4 on the right bank and 5 through 8 on the left bank Each slipper skirt autothermic piston has two compre...

Page 8: ...eing incompressible acts as a solid member and transfers the lifting force to the plunger and push rod Because of the load im posed on the plunger by the push rod the oil in the compression chamber is subjected to in creased pressure This causes a slight leakage out of the chamber past the walls of the plunger The leakage flow is known as the calibrated leak down rate and is controlled by precise ...

Page 9: ...passages are drilled in the cylinder block from each main bearing to the camshaft bearing above it After lubricating the camshaft bearings the oil drains into the oil pan In addition to supplying oil for the camshaft bearings the main bearing lubrication system also lubricates the connecting rod bearings through grooves in the upper halves of the main bearings and passages drilled in the crankshaf...

Page 10: ...the rocker arm chamber Then it moves down past the push rods into the crankcase The ventilating air then flows to the rear of the crankcase and up to the rear section of the valve rocker arm cover sweeping any combustion by product fumes along with it The vapor laden air enters a spring loaded regulator valve which regulates the amount of airflow to meet changing operat ing conditions The air is t...

Page 11: ...PUSH RODS DIAL INDICATOR BE SURE TO PLACE 5 Zero the dial indicator Continue to rotate the crankshaft slowly until the push rod is in the fully raised position 6 Compare the total lift recorded on the indica tor with specifications 7 To check the accuracy of the original indica tor reading continue to rotate the crankshaft until the indicator reads zero If the lift on any lobe is below specified w...

Page 12: ...ximately one I tablespoon of engine oil on top of the pistons in the low reading cylinders Repeat compression pressure check on these cylinders 1 If compression improves considerably the piston rings are at fault 75 of the highest reading EXAMPLE After checking the compression pressures in all cylinders it was found that the highest read ing obtained was 196 psi The lowest pressure reading was 155...

Page 13: ...the valve lifter in the tester with the plunger facing upward Pour hydraulic tester fluid into the cup to a level that will cover the valve lifter assembly The fluid can be pur chased from the manufacturer of the tester Do not use kerosene for it will not provide an accurate test 3 Place a 5 16 inch steel ball in the plunger cup 4 Adjust the length of the ram so that the pointer is l 16 inch below...

Page 14: ...case ventilation system for restriction at the intake manifold or carburetor spacer If the system is not restricted further en gine component diagnosis will have to be con ducted to find the malfunction CRANKSHAFT END PLAY 1 Force the crankshaft toward the rear of the engine 2 Install a dial indicator so that the contact point rests against the crankshaft flange and the indicator axis is parallel ...

Page 15: ...d and release it Compare the dial indicator reading with specifications If the end play is excessive check the spacer for correct installation before it is removed if the spacer is correctly installed replace the thrust plate Remove the dial indicator TIMING CHAIN DEFLECTION 1 Rotate the crankshaft in a counterclockwise position as viewed from the front to take up the slack on the left side of the...

Page 16: ...aust gas leaks Inspect the manifolds for cracks damaged gasket surfaces or other defects that would make them unfit for further service VALVE ROCKER ARM Cleaning Clean all the parts thoroughly Make sure all oil passages are open Make sure the oil passage in the push rod end of the rocker arm is open Inspection Inspect the pad at the valve end of the rocker arm for indications of scuffing or abnorm...

Page 17: ...curate gauge Follow the instructions of the gauge manufacturer If the runout exceeds the wear limit reface the valve and valve seat Measure the valve seat width Reface any valve seat whose width is not within specifications Inspect the valve face and the edge of the valve head for pits grooves scores or other VALVE SEAT r3 RUNOUT GAUGE 081 P 6002 E A9624 1 A damage Inspect the stem for a bent cond...

Page 18: ...he reading by two the division factor for the tool Check the springs for proper pressure at the specified spring lengths Tool 65130DD Weak valve springs cause poor engine performance Replace any spring not within specifications Check each spring for squareness using a steel square and a flat surface Stand the spring and square on end on the flat surface Slide the spring up to the square Revolve th...

Page 19: ... which might damage the oil seal during installation or cause premature seal wear Do not use crocus cloth to the extent that the seal surface becomes polished A finely polished surface may pro duce poor sealing or cause premature seal wear Inspection Inspect the crankshaft damper or spacer oil seal surface for nicks sharp edges or burrs that might damage the oil seal during installation or cause p...

Page 20: ...in the bore of the crankshaft The bushing is pressed into the crankshaft and should not be loose In spect the inner surface of the bushing for wear or a bell mouth condition Check the ID of the bushing Replace the bushing if it is worn or damaged or the ID is not within specifications Inspect the pilot bearing ball bearing when so equipped for roughness evidence of over heating or loss of lubrican...

Page 21: ... If the bend and or twist exceeds specifications the connecting rod must be straightened or replaced PISTONS PINS AND RINGS Cleaning Remove deposits from the piston surfaces Clean gum or varnish from the piston skirt piston pins and rings with solvent Do not use a caustic cleaning solution or a wire brush to clean pistons Clean the ring grooves with a ring groove cleaner Make sure the oil ring slo...

Page 22: ...their causes are shown in the ex ample The copper lead bearing base may be visible through the bearing overlay This does not mean that the bearing is worn It is not nec essary to replace the bearing if the bearing clearance is within recommended limits Check the clearance of bearings that appear to be sat isfactory with Plastigage as detailed under Main and Connecting Rod Bearings SCRATCHES IMBEDD...

Page 23: ...ossible to re move the imperfections by honing the cylinder walls and installing new service piston rings providing the piston clearance is within specified limits t A Inspection check it for cracks Minute cracks not visible to After the block has been thoroughly cleaned the naked eye may be detected by coating the suspected area with a mixture of 25 kerosene and 75 light engine oil Wipe the part ...

Page 24: ...haft and rotor are replaceable only as an assem bly Check the drive shaft to housing bearing clearance by measuring the OD of the shaft and the ID of the housing bearing Inspect the relief valve spring for a collapsed or worn condition Check the relief valve spring tension If the spring tension is not within specifications and or the spring is worn or damaged replace the spring Check the relief va...

Page 25: ...the maximum limit remove enough stock from the top edge and or bottom edge of the seat to reduce the width to specifications and center On the valve seats of all engines use a 60 degree angle grinding wheel to remove stock from the bottom of the seats raise the seats and use a 30 degree angle wheel to remove stock from the top of the seats lower the seats TO REMOVE STOCK FROM BOTTOM OF SEAT USE 60...

Page 26: ...ound if required If the valveiace runout is excessive and or to remove pits and grooves reface the valves to a true 44 degree angle Remove only enough stock to correct the runout or to clean up the pits and grooves If the edge of the valve head is less than l 32 inch thick after grinding replace the valve as the valve will run too hot in the en gine The interference fit of the valve and seat shoul...

Page 27: ...g to ob tain the proper clearance 2 If fitting a main bearing in the chassis posi tion a jack under counterweight adjoining bearing which is being checked Support crankshaft with jack so its weight will not compress Plastigage and provide an er roneous reading 3 Place a piece of Plastigage on bearing sur face across full width of bearing cap and about l 4 inch off center CHECK WIDTH OF PLACE PLAST...

Page 28: ...ston to be used by tak ing a cylinder bore check Follow the pro cedures outlined under Cleaning and Inspection 2 Select the proper size piston to provide the desired clearance refer to the specifica tions The piston should be measured 2 l 4 inches below the dome and at 90 to the piston pin bore 3 Make sure the piston and cylinder block are at room temperature 70 degrees F After any refinishing ope...

Page 29: ...ning so that the correct surface finish and pat tern are obtained For the proper use of the refinishing equip ment follow the instructions of the manufacturer Only experienced personnel should be allowed to perform this work Use a motor driven spring pressure type hone at a speed of 300 500 rpm Hones of grit sizes 180 220 will normally provide the desired bore surface finish of 1532 RMS When honin...

Page 30: ...e arrangement on the left bank is E l E I E I E I and on the right bank is I E I E I E I E A 1 52mm 0 060 inch shorter push rod or a 1 52mm 0 060 inch longer push rod are avail able for service to provide a means of compen sating for dimensional changes in the valve mechanism Valve stem to valve rocker arm clearance should be within specifications listed at the end of this Section With the hydraul...

Page 31: ...LATION SYSTEM 1 Removal 1 Disconnect the crankcase vent front hose from the air cleaner 2 Remove the air cleaner and intake duct as sembly If so equipped disconnect the oil filler pipe hose from the left rocker arm cover 3 Disconnect the crankcase vent rear hose from the carburetor spacer at the front of intake manifold Pull the hose and PCV valve out of the valve rocker arm cover Re move the PCV ...

Page 32: ...st No 7 Intake No 5 Exhaust No 8 Intake No 4 Exhaust Position the crankshaft in POSITION 2 and install the rocker arm fulcrum seat oil de flector and bolt on the following valves No 2 intake No 2 Exhaust No 4 intake No 3 Exhaust No 5 intake No 6 Exhaust No 6 Intake No 7 Exhaust Be sure that the fulcrum seat base is in serted in its slot on the cylinder head be fore tightening the fulcrum bolts Tig...

Page 33: ...stem to prevent valve from dropping into cylinder when air pressure in cylinder is shut off if piston is at bottom of cylinder Shut off air pressure Inspect valve stem for damage Rotate valve checking tip for eccentric movement Move valve up and down through normal travel in valve guide and check for binding If valve is damaged cylinder head must be removed for repairs tallation If valve proves sa...

Page 34: ...e sending unit and other connec tions as necessary Disengage wiring har ness from three clips at left valve rocker arm cover bolts and position wiring harness out of way 10 Remove coil and bracket assembly 11 Remove attaching bolts and nuts and re move intake manifold and carburetor as an assembly If necessary to pry manifold away from cylinder heads do not damage gasket sealing surfaces 12 Remove...

Page 35: ...joint the full width of the cylinder block seal mounting surface 4 corners 4 Install the cylinder head to manifold gaskets and the front and rear intake manifold to cyl inder block seals Apply a 1 6mm l 16 inch bead of sealer at the outer end of each in take manifold seal for the full width of the seal 9 Rotate crankshaft damper until No I piston is at TDC at end of compression stroke Position dis...

Page 36: ...arm covers Connect coil high tension lead to coil 16 Fill the cooling system 17 Start engine Check and adjust ignition tim ing Connect distributor vacuum line 18 Operate engine at fast idle and check for coolant leaks Recheck coolant level and refill as necessary 19 Allow engine to reach normal operating tem perature then re tighten the manifold attach ing nuts and bolts to specifications 20 Check...

Page 37: ...s to be installed 2 install push rods in original positions Apply Ford Polyethylene grease DOAZ 19584 A or equivalent to valve stem tips and push rod ends 3 Position the rocker arms over the push rods and tighten the bolts following the procedure under Valve Rocker Arm Installation 4 Install rocker arm covers following pro cedure under Rocker Arm and Cover Installation 5 Install intake manifold an...

Page 38: ...Installation 7 Perform valve clearance adjustment as de tailed under Valve Clearance Adjustment only if necessary 8 Apply oil resistant sealer to one side of new valve rocker arm cover gaskets Lay ce mented side of gaskets in place in covers Install covers 9 Install bolt attaching alternator bracket to right cylinder head Adjust alternator drive belt tension to specifications and tighten al ternat...

Page 39: ...s 4 Connect lower hose and by pass hose to water pump 5 Place the water pump pulley on the pump 6 Lower the fan into position Install the fan at taching bolts and the shroud attaching bolts Tighten the bolts to specifications 7 Rotate the alternator bracket into position and install the two attaching bolts and spac er Adjust the belt tension and tighten the at taching bolts to specification 8 Fill...

Page 40: ... distance between the reference point and the chain The deflection is the difference between the two measurements If the deflection exceeds specifications re place the timing chain and sprockets 13 If the timing chain and sprocket are to be removed crank the engine until timing marks are aligned 14 Remove camshaft sprocket cap bolt wash er two piece fuel pump eccentric and front oil slinger Slide ...

Page 41: ...en to specification 11 Install the crankshaft pulley 12 Coat new fuel pump gasket with oil resistant sealer and place on fuel pump Install fuel pump Connect fuel lines to fuel pump 1 3 Install water pump pulley and all drive belts 14 Position radiator and install attaching bolts Connect radiator upper and lower hoses at engine Connect oil cooler lines 15 Position the fan on the water pump and in s...

Page 42: ...iming Chain Check timing chain de flection before removal 2 Remove the intake manifold and carburetor as an assembly following the instructions under intake Manifold ways and remove the push rods in sequence 4 Remove the valve tappets with a magnet and place them in a rack in sequence If the tappets are stuck in bores use plier type Tool T52T 65000DJD or 6500 D to remove them Rotate the tappet bac...

Page 43: ...the radiator upper hose 11 Connect the fuel line to the carburetor 12 Install the coil and bracket assembly to in take manifold 13 Install the throttle linkage 14 Engage engine wiring harness in clips on left cylinder head and connect all wire termi nals Connect PCV valve and hose to right valve rocker arm cover 15 Install the distributor cap and connect the coil and spark plug wires 16 Place the ...

Page 44: ...lacing tool has a depth seating surface do not seat the tool against a non machined casting surface Expansion type core plugs are installed with the flanged edge inward The maximum diame ter of this plug is located at the base of the flange with the flange flaring inward It is imperative to push or drive the plug into the machined bore using a properly de signed tool Under no circumstances is the ...

Page 45: ...2 Remove the oil pump mounting bolts and re move the pump from the cylinder block Installation 1 Prime the oil pump by filling the inlet port with engine oil Rotate the pump shaft to dis tribute oil within the pump body 2 Install the distributor intermediate shaft in the oil pump rotor shaft 3 Insert the intermediate shaft into the distribu tor shaft hex bore Make certain that the in termediate sh...

Page 46: ...ealer to the area forward of the side seal groove Install the rear main bearing cap Torque the cap bolts to specifications 7 Install the oil pump and oil pan Fill the crankcase with the proper amount and vis cosity oil 8 Operate the engine and check for oil leaks APPLY 1 58mm l 16 IN 1 DIA BEAD OF D6AZ 19562 A OR B FROM FORWARD FACE SEALER AS INDICATED ON BEARING CAPItBOTH SIDES OF SLINGER GROOVE ...

Page 47: ...y fastened Remove the main bearing cap to which new bearings are to be installed 4 Insert the upper bearing removal tool Tool 6331 E in the oil hole in the crankshaft 5 Rotate the crankshaft in the direction of en gine rotation to force the bearing out of the block Installation 1 To install upper main bearing place plain end of bearing over shaft on locking tang side of block and partially install...

Page 48: ... half of bearing Hold the crankshaft forward and pry thrust bearing cap to rear This aligns thrust surfaces of both halves of bearing Retain forward pressure on crankshaft Tighten cap bolts to specifications IO Clean the oil pump inlet tube screen Prime the oil pump by filling the inlet opening with oil and rotating the pump shaft until oil emerges from the outlet opening Install the oil pump 11 I...

Page 49: ...pump following procedures in this section 2 Remove any ridge and or deposits from up per end of cylinder bores as follows Turn the crankshaft until the piston to be re moved is at bottom of its travel Place a cloth on 3 Make sure that all connecting rod caps are marked so they can be installed in their orig inal positions 4 Turn the crankshaft until the connecting rod being removed is down 5 Remov...

Page 50: ...NG COMPRESSION RING FRONT OF ENGINE A28 WA 6 After the bearings have been fitted apply a light coat of engine oil to the journals and bearings 7 Turn the crankshaft throw to the bottom of the stroke Push the piston all the way down until the connecting rod bearing seats on the crankshaft journal 8 Install the connecting rod cap Be sure con necting rod bolt heads are properly seated in the connecti...

Page 51: ...on Remove the bolt and washer from the end of the crankshaft Install a puller on the crank shaft vibration damper and remove damper and spacer Remove Woodruff key Remove the cylinder front cover and water pump as an assembly Check the timing chain deflection Remove the timing chain sprockets and key Invert the engine on a work stand Remove the flywheel and the engine rear cover plate Remove the oi...

Page 52: ...heck the crankshaft end play 18 install new bearing inserts in the connecting rods and caps Check the clearance of each bearing 19 After the connecting rod bearings have been fitted apply a light coat of engine oil to the journals and bearings 20 Turn the crankshaft throw to the bottom of its stroke Push the piston all the way down until the rod bearing seats on the crankshaft journal 21 Install t...

Page 53: ...amshaft rear bearing bore plug Remove camshaft bearings Installation 6 Install the camshaft crankshaft flywheel and related parts following appropriate pro cedures in this part except do not check I Select the proper size expanding collet and connecting rod and main bearing back up nut and assemble on expanding clearances mandrel With the expanding cotlet coi lapsed install the collet in the camsh...

Page 54: ...tainers springs stem seals and valves Discard stem seals Clean and inspect cylinder head s and relat ed components using pertinent procedures in this section Refer to Page I 21 and 1 22 for repair pro cedures for cylinder heads and valves Assembly Lubricate all valves valve stems and valve guides with engine oil The valve tips are to have Ford Polyethylene grease DOAZ 19584 A or equivalent applied...

Page 55: ...rod and indentation notch in piston positioned in illustration RIGHT BANK NOTCH TOWARD LEFT BANK FRONT OF ENGINE 811 C R NUMBERED SIDE OF ROD A29754 RIGHT BANK NOTCH TOWARD INBOARD SIDE OF PISTON LEFT BANK 9 l C R 2 3 4 5 NUMBERED SIDE OF ROD A10402 1A Start the piston pin in the piston and the connecting rod Using an arbor press press the piston pin through the piston and con necting rod until th...

Page 56: ...of all serviceable parts and assemblies 2 Position the new cylinder assembly in a work stand and install the cylinder head lo cating dowels and block drain plugs 3 Transfer all serviceable parts removed from the old cylinder assembly following the pro cedures given under Removal and Installation 4 Check all assembly clearances and correct as necessary CYLINDER BLOCK Before replacing a cylinder blo...

Page 57: ... pick up coil This signal is connected to the ignition module by the wiring harness The occurrence of the signal to the ignition mod ule in relation to initial spark timing is controlled by centrifugal and vacuum mechanisms The cen trifugal advance mechanism controls spark timing in response to the engine RPM The vacuum mechanism controls spark timing in response to engine load The centrifugal adv...

Page 58: ...e ignition module performs the function of turning off current flow through the ignition coil in response to a control signal In the Duraspark II ignition system this control signal comes from the distributor stator assembly DURASPARK II IGNITION MODULE 12A199 VACUUM ADVANCE STATOR ROLL PIN BLUE GROMMET DURASPARK II DISTRIBUTOR HOUSING CENTRIFUGAL ADVANCE WO832C B4187 1A ...

Page 59: ...ion Module 6 Distributor Stator Assembly of a The secondary circuit consists of the 1 Battery 2 Ignition Coil Secondary Winding 3 Distributor Rotor 4 Distributor Cap 5 Ignition Wires 6 Ignition Switch 7 Ballast Resistor Start Bypass Wires 8 Spark Plugs IGNITION SWITCH IS I BALLAST RESISTOR I I STARTFR RF1A START BYPASS y I BATTERY I t TAt 3 A y ABAT I I IGNITION WIRES Cd 4P ROTOR IGNITION MODULE 8...

Page 60: ...stments are limited to initial timing and spark plug gap on Duraspark II systems INITIAL IGNITION TIMING The timing marks and their locations are illus trated on page 2 18 For checking and adjusting the ignition timing with a scope refer to the scope manufacturer s instructions To check and adjust the timing with a timing light proceed as follows 1 Clean and mark the specified timing mark with cha...

Page 61: ...ferred to in this part relate to the colors of the ignition module wires When work ing with a wiring harness the wires must be traced back to the ignition module for proper color identification l When instructed to inspect a wiring harness both a visual inspection and a continuity test should be performed l When making measurements on a wiring har ness or connector it is good practice to wiggle th...

Page 62: ...e switch goes from Run carbon tracking lack of to Off position silicone compound l Remove spark tester reconnect coil wire to CHECK for roll pin distributor cap securing armature to sleeve in distributor CHECK that ORANGE and PURPLE wires are COAT COMPLETE SURFACE OF not crossed between ROTOR BLADE TIP WITH distributor and ignition SILICONE COMPOUND 1132 THICK module No Sparks GO to 3 THIS SURFACE...

Page 63: ... pin to contact Less than 90 percent of Refer to wiring diagram electrical ground battery voltage Inspect wiring harness between module and 2 Attach negative VOM lead to distributor base ignition switch 3 Measure battery voltage Worn or damaged ignition switch 4 Measure voltage at straight pin with ignition switch in Run position 5 Turn ignition switch to Off position 6 Remove straight pin IGNITIO...

Page 64: ...intermittent or not in 2 Disconnect and inspect ignition coil connector ignition system GO to 5 3 Measure ballast resistor between BAIT terminal of ignition coil connector and wiring harness connector Less than 0 8 or greater Replace ballast resistor mating with RED module wire than 1 6 ohms 4 Reconnect all connectors IGNITION MODULE STARTER RELAY DISTRIBUTOR NOTE WIRE SEQUENCE HAS BEEN ARRANGED T...

Page 65: ...straight pins to contact and connector s in electrical ground faulty circuit s 4 Measure battery voltage Worn or damaged 5 Following table below measure voltage at points ignition switch listed with ignition switch in position shown NOTE l Attach negative VOM lead to distributor base l Wiggle wires in wiring harness when measuring WIRE CIRCUIT IGN SWITCH TERMINAL POSITION RED RUN RUN WHITE START S...

Page 66: ...TARTER RELAY GREEN I TACH DISTRIBUTOR 13 yq IGNITION MODULE NOTE WIRE SEQUENCE HASBEENARRANGED TO SIMPLIFY SCHEMATIC 7 DISTRIBUTOR STATOR ASSEMBLY AND WIRING HARNESS 1 Separate ignition module four wire connector Inspect for dirt corrosion and damage 400 to 1 300 ohms Test result OK GO to 8 2 Measure stator assembly and wiring harness resistance between wiring harness terminals mating with ORANGE ...

Page 67: ...e wires and ground 3 Reconnect four wire connector Greater than 70 000 ohms Test result OK GO to 9 Less than 70 000 ohms Inspect wiring harness between module connector and distributor including distributor grommet DISTRIBUTOR 9 IGNITION COIL SECONDARY RESISTANCE 1 Disconnect and inspect ignition coil connector and 7 700 to 10 500 ohms Test result OK coil wire GO to 10 2 Measure secondary resistan...

Page 68: ...pect wiring harness between ignition module and coil BALLAST RED IGNITION RESISTOR j I I l WHITE STARTER RELAY DISTRIBUTOR 0 CO w9 0 GREEN IGNITION MODULE NOTE WIRE SEQUENCE HAS BEEN ARRANGED TO SIMPLIFY SCHEMATIC e DISTRIBUTOR BASE A6366 C 11 1 DISTRIBUTOR STATOR ASSEMBLY 1 Separate distributor connector from harness inspect for dirt corrosion and damage 2 Measure stator assembly resistance acros...

Page 69: ...IRCUIT CONTINUITY 1 Carefully insert small straight pin in module GREEN Greater than 1 5 volts GO to 14 wire CAUTION Do not allow straight pin to contact electrical ground 1 5 volts or less Inspect wiring harness and connectors between 2 Attach negative VOM lead to distributor base ignition module and coil 3 Turn ignition switch to Run position 4 Measure voltage at GREEN module wire 5 Turn ignitio...

Page 70: ... IGNITION l s w r r c H A BALLAST RED RESISTOR I RO A WHITE 4 BA lT GKPN o 0 2 IGNITION MODULE TACH GREEN DISTRIBUTOR NOTE WIRE SEQUENCE HASBEENARRANGED TO SIMPLIFY SCHEMATIC 15 DISTRIBUTOR GROUND CIRCUIT CONTINUITY 1 Separate distributor connector from harness Less than one ohm Test result OK Inspect for dirt corrosion and damage Inspect wiring harness 2 Attach one lead of VOM to distributor base...

Page 71: ... bolt and clamp do not tighten 2 If engine was not rotated while distributor was removed and original distributor is being replaced a Position distributor in engine with rotor and distributor aligning with previously scribed mark Armature and stator assembly poles should also align if distributor is fully seat ed in block and properly installed Crank engine if necessary to fully seat distributor i...

Page 72: ...utor rotor and cap Check that ignition wires are securely connected to cap and spark plugs 7 Check initial timing DIAPHRAGM ASSEMBLY Removal 1 Disconnect diaphragm assembly vacuum hose 2 Remove diaphragm assembly attaching screws 2 and identification tag 3 Disengage diaphragm rod from stator assem bly pin and remove diaphragm assembly Installation 1 Adjust new diaphragm assembly per instruc tions ...

Page 73: ...quivalent 1 Attach each wire to proper terminal of distribu tor cap Be certain wires are fully seated on terminals 2 Remove wire separators from old wire set and install them on new set in approximately same position 3 Connect wires to proper spark plugs Install ignition coil wire Be certain all wires are fully seated on terminals SPARK PLUGS Removal 1 Remove spark plug wire from spark plug using ...

Page 74: ...rn boots Replace as necessary IGNITION COIL Wipe coil tower with a clean cloth dampened with soap and water Remove any soap film and dry with compressed air Inspect for cracks car bon tracking and dirt CYLINDER NUMBERING AND DISTRIBUTOR LOCATION FRONT v DISTRIBUTOR FIRING ORDER AND DISTRIBUTOR ROTATION STANDARD ROTATION CAP CLlP f B PoS T oN G FRONT w FIRING ORDER 7 51 l 5 4 2 6 3 7 8 REVERSE ROTA...

Page 75: ...ECTIVE FUEL PUMP TOO RICH A FUEL MIXTURE IMPROPERLY OPERAT ING HEAT RISER OR EXCESSIVE IDLING CAN BE CLEANED 1DENTlFlED BY LIGHT TAN OR GRAY DEPOSITS ON THE FIRING TIP IDENTIFIED BY MELTED ELECTRODES AND POSSIBLY BLISTERED INSULATOR METALIC DEPOSfTS ON INSULATOR INDICATE ENGINE DAMAGE CAUSED BY WRONG TYPE OF FUEL INCORRECT IGNITION TIMING OR ADVANCE 00 HOT A PLUG BURNT VALVES OR ENGINE OVERHEATING...

Page 76: ...assembly and the condenser in position and install the retain ing screws 2 Align and adjust the breaker point assembly 3 Connect the primary and condenser wires to the breaker point assembly 4 Install the rotor and the distributor cap Cap must be properly positioned on locator BREAKER PLATE AND SUB PLATE Removal 1 Remove the distributor cap and rotor 2 Working from the inside of the distributor pu...

Page 77: ...TOR Removal 1 Remove the air cleaner Disconnect the pri mary wire from the coil Remove the distrib utor cap 2 Scribe a mark on the distributor body and the cylinder block indicating the position of the body in the block and scribe another mark on the distributor body indicating the position of the rotor These marks can be used as guides when installing the distribu tor in a correctly timed engine ...

Page 78: ...breaker point assembly and the con denser out of the distributor 4 Working from the inside of the distributor pull the primary wire through the opening in the distributor 10 If the gear and shaft are to be used again mark the gear and the shaft so that the pin holes can be easily aligned for as sembly Remove the gear roll pin and then remove the gear 11 Remove the shaft collar roll pin 12 invert t...

Page 79: ...ck with SAE IOW engine oil 14 Install the weight springs Be sure that the marked spring is attached to the marked spring brackets 15 Place the breaker point and condenser plate in position and install the retaining screws 16 Working from the inside of the distributor push the primary wire through the opening in the distributor housing 7 Place the breaker point assembly and the condenser in positio...

Page 80: ... the distributor at approximately 1000 engine rpm 3 Adjust the breaker point gap until the dwell angle is to specifications DISTRIBUTOR SPARK ADVANCE TEST The spark advance is checked to determine if the ignition timing advances in proper relation to engine speed and load 1 Check the contact dwell If the contact dwell or the breaker point gap is not within specifi cations adjust the breaker points...

Page 81: ...the carburetor The basic part number for all carburetors is 9510 To procure replacement parts it is necessary to know the part number prefix and suffix PART NO PREFIX PART NO SUFFIX INDICATES NEW RA I L iiqiiijqd DESIGN CHANCE YEAR MONTH DAY ASSEMBLY CODE v1290 1 P EXAMPLE JULY G 21 1986 The fuel pump is bolted to the left side of the cylinder front cover It is mechanically operated by an eccentri...

Page 82: ...g weak improperly l Cam eccentric worn or undersize l Dirt in fuel tank and or lines l Fuel tank vent restricted l Fittings loose or cracked l Fuel pump screen clogged l Diaphragm ruptured Low Fuel Pump Volume with l Fuel filter clogged l Restriction in fuel supply line to Normal Pressure l Fuel pump to carburetor inlet line obstructed crimped or leaks fuel pump Fuel Pump Leaks l Diaphragm defecti...

Page 83: ...level or float setting properly or worn needle and or seat l Restriction in main fuel passage l Excessively dirty air cleaner l Air leak between the carburetor and the manifold caused by loose l Incorrect accelerating pump stroke mounting bolts or defective gasket adjustment l Restricted air bleeds l Air leak at the throttle shaft caused by a worn throttle shaft l Worn or damaged main metering jet...

Page 84: ...ondition the pump should be replaced If the pump pressure is within specifications perform the tests for fuel capacity volume FUEL OUTLET HOSE HOSE RESTR ICTOR PRESSURE GAUGE URETOR FUEL INLET PORT UEL FILTER FUEL INLET LIN TO CARBURETO FUEL CONTAINER Capacity Volume Test With the fuel pump pressure within specifica tions test the capacity volume as follows 1 Operate the engine at the specified id...

Page 85: ...the metering block are the main jets the power valve and the various fuel and air passages and restrictions The idle mix ture adjusting screws are found on the side of Connected to the metering block on the main the metering block body is the fuel bowl assembly Inside the fuel bowl are the fuel inlet screen fuel inlet needle and seat assembly float and lever assembly and accelerating pump Found on...

Page 86: ... the float to its proper level A bumper spring is placed under the float hinge to stabilize the movement of the float assembly The fuel bowl is vented internally through the vent tube NEEDLE SEAT ASS T start the engine when cold and a slightly richer than normal mixture for cold engine operation The 2300 carburetor is equipped with a manual choke or an electrically heated automatic choke FLOAT BUM...

Page 87: ...fuel it responds faster to changes in venturi vacuum and vaporizes more easily when discharged into the airstream The amount of air fuel mixture flowing to the intake manifold is regulated by the throttle plate posi tion which also regulates the engine speed and power output BOOSTER VENTURI MAIN JET MA N WELL MAIN WELL 11 8 FUEL AIR BLEEDS AIR FUEL POWER FUEL SYSTEM During high power operation the...

Page 88: ...ck ball or valve onto its seat preventing fuel flow back into the fuel bowl The diaphragm pressure also forces fuel through a short passage in the fuel bowl and into the long diagonal passage in the metering body It then flows into the main body passage to the pump discharged chamber Fuel pressure causes the discharge needle to unseat and fuel is discharged into the venturi When the accelerator is...

Page 89: ... adjust ment to be able to start the engine Be sure the engine is thoroughly warmed up Adjust the curb idle speed to specifica tion by turning the throttle stop screw in to 3 Turn the idle mixture adjustment screws in ward until the engine speed begins to drop due to a lean mixture Next turn the screws outward until the engine speed begins to drop due to an excessively rich mixture Then turn the s...

Page 90: ... pump stroke has been set to help keep the exhaust emission level of the en gine within the specified limits The additional holes provided for pump stroke adjustment are for adjusting the stroke for specific engine ap plications The stroke should not be changed from the original setting If the pump stroke has been changed from the specified setting refer to the following instructions to correct th...

Page 91: ...ight plug removed and the engine run ning because the pressure in the line will spray fuel out and present a fire hazard 2 Turn the adjusting nut approximately l 2 turn in to lower the fuel level below specifications l 6 turn of the adjusting nut depending on the direction of rotation will raise or lower the float assembly at the fuel level sight plug opening 3 64 inch 3 Tighten the lock screw and...

Page 92: ...the fuel bowl gasket and baffle and metering block and gasket Discard the gaskets Installation 1 If the fuel bowl or metering block is being replaced transfer the parts 2 Position the new metering block gasket on the dowels on the back of the metering block 3 Lay the metering block in place on the main body 4 Position the baffle and new fuel bowl gasket on the metering block 5 Place the fuel bowl ...

Page 93: ...king on the carburetor and to prevent damage to the throttle plates install bolts about 2 l 4 inches long of the correct diam eter through the carburetor attaching bolt holes with a nut above and below the flange or install carburetor legs Use a separate container for the component parts of the various assemblies to facilitate cleaning inspection and assembly The following is a step by step sequen...

Page 94: ...ke valve is bent or damaged DO NOT remove NOTE The choke plate screws are staked to prevent loosening and care is necessary to avoid breaking or stripping the threads in the choke shaft If necessary to remove plate re move staking with a file before loosening screws 3 Remove the accelerating pump discharge nozzle from the main body 4 Invert the main body and let the accelerating pump discharge nee...

Page 95: ... parts Check the metal float s if so equipped for leaks by holding it under water that has been heated to just below the boiling point Bubbles will appear if there is a leak If float leaks re place it Replace the float if the arm needle con tact point is grooved If the float s is serviceable polish the needle contact surface of the arm with crocus cloth or steel wool Replace the float shaft s if i...

Page 96: ...slide them into the throttle body Install the re tainer on each end of the shaft Referring to the lines scribed on the throttle plates install the plates in their proper location with the screws snug but not tight Close the throttle plates and hold the throttle body up to the light Little or no light should show between 2 3 4 5m 6 the throttle plates and the throttle bores If the throttle plates a...

Page 97: ...he choke plate shaft in the air horn Position the choke rod in the choke plate shaft lever and over the spring 6 Position the choke plate poppet valve over the retaining screws then position the choke plate on top of the poppet valve 7 Place the spacers over the screws then position the flat spring over the screws so that the curved portion is down Install the attaching nuts 8 Invert the main body...

Page 98: ...el inlet needle and seat as sembly in the fuel bowl through the top of the bowl Position the adjusting nut gasket and nut on the fuel inlet needle and seat Align the flat on the ID of the nut with the flat on the OD of the fuel inlet needle and seat assembly 8 Adjust the float so that the top of the float is parallel with the top of the fuel bowl with the fuel bowl inverted see Adjustment 9 Instal...

Page 99: ...3 I 9 FUEL SYSTEM 349 MODEL 2300 2 V CARBURETOR Continued SPRING SCREW 0 0 I I I 0 I k A 0 0 0 I I 84 25 I 6 43 64 e ...

Page 100: ...YSTEMS Index Number 62 63 64 65 66 69 70 72 73 74 76 78 79 80 81 84 86 87 88 93 95 96 97 104 105 110 115 119 Part Name Fast Idle Cam Lev Ser Spring Throttle Stop Screw Spring Pump Diaphragm Return Spring Fast Idle Cam Lev Spring Pump Oper Lev Adj Spring Float Spring Choke Thermostat Shaft Nut Fuel Valve Seat Adj Nut Choke Therm Lever Spacer Fast Idle Cam Assembly Choke Rod Choke Therm Shaft Nut L ...

Page 101: ...rimary fuel inlet fitting to A SI the secondary fuel bowl The transfer tube is sealed at either end with an 0 ring NOTE When adjusting the fuel level on the secondary side of the 4V units it is neces sary to run the engine for two or three min utes to stabilize the fuel level A very small amount of fuel is used from the secondary side at idle and it is easy to make a false low adjustment of the fu...

Page 102: ... transfer slot The air fuel mixture from the idle passage IDLE AIR BLEED 1 H 1 RESTRICTION PASSAGE qf d py MAIN JET l E ADJUSTING NEEDLE ELI iDLE H TRANSFER IDLE PASSAGE DISCHARGE IDLE DLE PASSAGE TRANSFER DISCHARGE SLOT HOLE CURB IDLE AIR BLEED CURB IDLE SYSTEM and the transfer slot supplies the necessary fuel to operate the engine at lower speeds and loads A low pressure or partial vacuum is cre...

Page 103: ...r certain engines The booster venturi in this series of car buretors are not replaceable although many carburetors use separate booster castings that are permanently installed in the main body casting BOOSTER GE E AIR BLEED POWER ENRICHMENT SYSTEM PRIMARY During high speed or heavy load operation when manifold vacuum is low the power system provides added fuel for power operation A vac uum passage...

Page 104: ...re The diaphragm type pump is located in the bottom of the primary fuel bowl Locating the pump in the bottom of the fuel bowl assures a more solid charge of fuel fewer bubbles When the throttle is opened the pump link age actuated by a cam on the throttle lever forces the pump diaphragm up As the di aphragm moves up the pressure forces the pump inlet check ball or valve onto its seat thereby preve...

Page 105: ... cial applications INTEGRAL AUTOMATIC CHOKE When the accelerator pedal is depressed and released the choke thermostatic spring pushes the choke valve to a fully or partially closed posi tion and the fast idle cam to a corresponding fast idle position A cold engine at lower tem peratures will allow the choke valve to close completely and the fast idle cam to move to its top step A manifold vacuum p...

Page 106: ...e secondary venturi is channeled to the top of the secondary diaphragm The bottom of the diaphragm is open to atmospheric pressure At higher speeds and higher primary venturi vac uum the diaphragm operating through a rod and secondary throttle lever will commence to open the secondary throttle valves This action will start to compress the secondary throttle valves This action will start to compres...

Page 107: ...ering body is attached to the carburetor body with six clutch head screws Fixed main metering restrictions are located in the bottom of the metering body Fuel for the idle and idle transfer system as well as fuel for the main metering system enters the main well through these restrictions Idle fuel wells branch off of each main well Fuel travels up the idle well through an idle restriction where i...

Page 108: ... if used 2 Remove choke fast idle lever screw and lev er remove E clip fast idle cam and lever if used 3 Remove secondary vacuum diaphragm as sembly from carburetor body if used 4 Remove four fuel bowl screws and primary fuel bowl assembly by sliding straight off transfer tube ACCEL A ACCEtERATOR PUMP LEVER tRY THROTTLE 5 Remove primary metering body by sliding straight off dowels or balance tube ...

Page 109: ...YSTEMS Continued F PRIMARY SEC0 UEL TRANSFER TI THROTTLE LEVER lNDARY THROTTLE CONNECTOR LINK PRIMARY FUEL BOWL IMARY HIGH EED BLEEDS lOSTER VENT URIS SECONDARY SECONDARY vVACUUM DIAPHRAGM FUEL BALANCE C I FUEL BbWL PUMPLF ATING iwsr ss c i GASKET ...

Page 110: ...LE AND SEAT ASSEMBLY AND LEVER FLOAT RING PBdsfT SECONDARY FUEL BOWL BALANCE TUBE SECONDAFiY METERING BODY MT 1 5455 12 Remove the plastic accelerator pump inlet check valve NOTE The ball type inlet check valve is not removable 13 Remove secondary fuel bowl from car buretor body NOTE Disassembly of the secondary fuel bowl is similar to the primary bowl The fuel inlet baffles are not interchangeabl...

Page 111: ...ve pump discharge nozzle retaining screw then lift out discharge nozzle Re move gaskets from nozzle top and bottom 0 RING 4 BALANCE TUBE PLATE BODY y MT f548 7 invert carburetor and drop out pump dis charge needle from discharge passage 17 Invert carburetor and remove the throttle body attaching screws Remove the throttle body and gasket Remove accelerator pump operating lever adjusting screw and ...

Page 112: ... you are using the correct metering body gasket and that bowl gasket is not covering the accelerator pump passage Primary Fuel Bowl 1 Install plastic accelerator pump check valve in fuel bowl if used 2 If ball type check ball clearance under re taining bar is proper 3 Install pump diaphragm return spring di aphragm and pump cover Be sure di aphragm is centered and contact button is toward pump lev...

Page 113: ...scribing assembly primary metering body do so now Press gaskets down firmly on dowels not only to hold them in place but to prevent bowl gasket from interfering with the float 2 Install eight bowl screw gaskets on the screws NOT IN THE RECESSES 3 Carefully install primary metering body over balance tube if used and press firmly on dowels 4 Install fuel bowl on metering body position ing pump lever...

Page 114: ...uge between adjusting nut and lever 2 If adjustment is necessary adjust pump override screw until correct clearance has been obtained 3 There must be no free movement of pump lever when throttle lever is at curb idle PUMP OVERRIDE ADJUSTING SCREW b6 7H ADJUSTING SECONDARY THROTTLE STOP IF USED Back the secondary throttle stop screw out un til the secondary throttle valves are closed in the throttl...

Page 115: ... or occasional misfire will turn an en gine that is a minor emitter into gross emitter 2 Check for vacuum leaks vacuum lines or manifold LOW IDLE SPEED ADJUSTMENT With engine at correct operating temperature and condition as in above procedure and curb idle adjusted to specifications proceed as follows 1 Set the low idle speed to specifications by adjusting the low idle speed adjusting screw 3 Tur...

Page 116: ...ANALYZER is recommended that the various equipment There are a number of infra red and ultra vio let exhaust gas analyzers in use in all parts of the country Instructions for use of this equip manufacturer s instructions be followed for all idle adjustments EXPLODED VIEW MODEL 4160 32 16 j 153y5c 95 164 IC I 11 1 100 2 I 10 _ 2 136 65 62 4 ...

Page 117: ...eck Bail Sec 151 Choke Rod Retainer 27 Throt Plate Screw Primary 91 Pump Inlet Check Bail 152 Throt Connecting Rod Cotter Pin 28 Throt Plate Screw Secondary 92 Throttle Lever Ball 154 Thermostat Housing Clamp 29 Pump Lever Adjusting Screw 95 Sec Diaphragm Housing Cover 157 Air Vent Rod Clamp 30 Pump Discharge Nozzle Screw 98 Secondary Metering Body Plate 161 Filter Screen 33 Pump Cam Lock Screw 99...

Page 118: ... set value current is cut off to the warning lamp This circuit is not included in the regulator for The warning lamp control circuit passes current vehicles equipped with an ammeter rather than to the warning lamp when the ignition switch is in the warning lamp the Run position and there is no alternator voltage at terminal S When the voltage at S rises to a pre The alternator produces power in th...

Page 119: ...NAL ELECTRONIC JI c VOLTAGE REGULATOR x J FIELD TERMINAL ORANGE LT BLUE J2227 2E ALTERNATOR BATTERY TERMINAL OF STARTER RELAY YELLOW WHITE p DOT I NOT USED 0 o WITH AMMETER I BATTERY FUSE LINK II ORANGE BAT I Y IGNITION I TERMINAL I h DIODE s I IGNITION SWITCH 40 60 AMP ALTS STATOR WINDINGS STATOR TERMIN A t i GREEN RED STRIPE ELECTRONIC I VOLTAGE REGULATOR x m L b LLJ ORANGEILT SLIP RINGS J2228 2...

Page 120: ...ble on these units The new solid state regulators being used in conjunction with other new components in the charging system that must be properly matched to prevent damage to the charging system are as follows 1 A new alternator with higher field current requirement 2 A new warning indicator lamp shunt resistor 3 The alternator to regulator wiring harness is changed to incorporate a new regulator...

Page 121: ...tch on engine run ning alternator light is off 1 If the charge indicator light does not come on with the ignition key in the On position and the engine not running disconnect the wiring plug connector at the regulator and connect a jumper wire from the I terminal of the regulator wiring plug to the negative battery post cable clamp 2 If the charge indicator light does not go on check the bulb for ...

Page 122: ...attery it is impor tant to give it a thorough examination to determine if it has been damaged Remove battery cable clamps negative terminal first Check for dirty or corroded connections and loose battery posts Remove holddowns and heat shields and inspect for broken or cracked case or cover If worn or damaged loose or broken post or cracked case or cover replace battery Ampere Discharge Rate Hours...

Page 123: ...inal is approx imately 1 5 to 2 5 volts This test evaluates excitation circuit If voltage at regulator terminal is 5 0 to 7 0 volts open rotor field circuit 75 to 1 1 volts grounded rotor circuit 8 5 to 10 0 volts open in regulator s load circuit 0 volts open ignition switch or excitation resistor If test results are uncertain go to Test 2 Test 2 Ignition On Engine Not Running The voltage regulato...

Page 124: ...alter nator and not the ground stud Always disconnect the connector plug from the regulator before checking alternator out put with test probes or a jumper wire Always disconnect the connector plug from the regulator before removing the regulator mounting screws Removing the connector from an un grounded regulator with the igni tion switch on will destroy the regulator Never attempt to polarize or...

Page 125: ...LD CIRCUIT IS GROUNDED REPLACE REGULATOR ALSO JUMPER A TO F TERMINAL AT REGULATOR WIRING CONNECTOR VOLTAGE SHOULD READ A MIN IMUM OF l 2 VOLT OVER BASE READING WITH LOAD TEST CON DITIIONS IN EFFECT LESS THAN 112 VOLT REMOVE JUMPER FROM A AND F TERMINALS B UT LEAVE REGULATOR DISCON NECTED JUMPER BAT TO FLD TERMINALS AT ALTER NATOR VOLTAGE SHOULD READ A MINIMUM OF l 2 VOLT OVER BASE READING WITH LOA...

Page 126: ... the regulator wiring plug to the regulator Under Voltage Tests 1 If the voltage does not indicate more than l 2 volt above base voltage disconnect wiring plug from regulator and connect an ohmmeter from F terminal of plug to ground Meter should indicate more than 2 4 ohms If less than 2 4 ohms is indicated service grounded field current in wire or alternator and repeat Load Test above 2 If ohmmet...

Page 127: ...he ignition switch to the reg ulator wiring plug 4 Connect the positive voltmeter lead to the positive battery cable terminal connect reg ulator wiring plug to regulator and repeat the Load Test S and I Circuit With Indicator Light 1 Disconnect the regulator wiring plug and in stall a jumper wire between the A and F terminals 2 With the engine idling connect the negative voltmeter lead to the batt...

Page 128: ...her type of tester is used A reading in both directions indicates a bad positive diode a grounded positive diode plate or a grounded BAT terminal OHMMETER A 2 Perform the same test using the STA and GND terminals A reading in both directions indicates either a grounded stator winding a bad negative diode a grounded stator termi nal a grounded positive diode plate or a grounded BAT terminal 3 If th...

Page 129: ...rly Remove the stator from the alternator and disconnect from the rectifier assembly refer to Disassembly procedure in this section Set the ohmmeter Multiply By knob at 1000 1 Connect the ohmmeter probes to one of the stator leads and to the stator laminated core Be sure that the probe makes a good elec trical connection with the stator core The meter should show an infinite reading no meter movem...

Page 130: ...ING A BATTERY IN AN ENCLOSED SPACE AL WAYS PROVIDE VENTILATION AND SHIELD YOUR EYES WARNING KEEP OUT OF REACH OF CHIL DREN BATTERIES CONTAIN SULFURIC ACID AVOID CONTACT WITH SKIN EYES OR CLOTHING ALSO SHIELD YOUR EYES WHEN WORKING NEAR THE BATTERY TO PROTECT AGAINST POSSIBLE SPLASHING OF THE ACID SOLUTION IN CASE OF ACID CONTACT WITH SKIN EYES OR CLOTHING FLUSH IMMEDIATELY WITH WATER FOR A MINIMUM...

Page 131: ... Remove the stator and rectifier assembly from the rear housing RADIO NOISE BA I TERY TERMINAL SUPPRESSION INSULATOR ON TOP OF CAPACITOR 8 Remove the brush holder the brushes and the brush terminal insulator from the rear housing 9 Using a suitable arbor press remove the bearing from the rear housing Support the housing close to the bearing boss to prevent damage to the housing 10 Clamp the front ...

Page 132: ...als and with needle nose pliers pull stator lead terminals upwards from the rectifier assembly While the terminals are still hot shake the molten solder from the terminals I lOA SCREWS 37920 1 s FAN SPACER AA I vn344 J1166 2Q 19 Disconnect the stator phase lead from the rectifier assembly as follows Flat type integrated rectifier Remove the stator terminal screw by pressing it straight out of the ...

Page 133: ...ing end of the rotor shaft and rotate the bearing Make the same check for noise looseness or roughness as was made for the front bearing inspect the rollers and cage for damage Re place the bearing if these conditions exist or if the lubricant is lost or contaminated 5 Check the pulley and fan for excessive looseness on the rotor shaft Replace any pulley or fan that is loose or bent out of shape 6...

Page 134: ...ten sion by inserting a piece of stiff wire through the brush holder 11 Position the brush holder in the rear housing and install the a aching screws Tighten the screws to 1 9 2 8 Nom 17 25 ft lb Press the brush holder firmly against the housing while tightening the screws Make sure the ground brush wiring eyelet is positioned under the screw before tightening 12 Connect the stator phase lead to t...

Page 135: ... 35 60 in lb 22 Remove the wire holding the brushes CAUTION This step is important so that reg ulator will not be damaged ADJUSTMENTS DRIVE BELT The fan drive belt should be properly adjusted at all times A loose drive belt can cause improper alternator fan and water pump operation A belt that is too tight places a severe strain on the water pump and alternator bearings A properly tensioned drive ...

Page 136: ...d current is used to maintain the movable pole shoe in the fully seated position during the time that the starter is cranking the engine Turning the ignition key to the Start position actuates the starter relay through the starter con trol circuit The starter relay then connects the battery to the starter Vehicles equipped with an automatic transmis sion have a neutral start switch in the starter ...

Page 137: ... positive terminal of discharged battery and the other end to the positive terminal of the booster battery 5 Connect one end of the other cable to nega tive terminal of good battery 6 Connect other end of cable to engine bolthead or similar good contact spot on the vehicle being started NOT to negative terminal of battery 7 Make sure jumper cables are not in the way of moving engine parts 8 Start ...

Page 138: ...nd check armature shaft for corrosion clean or replace If no corro sion repair starter or replace the starter drive STARTER LOAD TEST Conduct this test if the starter cranks slowly and a comparison of the current output with specifica tions is desired Connect the test equipment as shown Be sure that no current is flowing through the ammeter and heavy duty carbon pile rheostat portion of the cir cu...

Page 139: ...EGATIVE LEAD i x VOLTMETER POSITIVE LEAD TOUCH TO COMMUTATOR J1088 1F 0 A KEEP BOTH FIELD BRUSHES AND HOLDING COIL GROUND LEAD AWAY FROM FRAME I 6 CONNECT VOLTMETER JUMPER L ARMATURE OPEN CIRCUIT TEST An open circuit armature may sometimes be detected by examining the commutator for evi dence of burning A spot burned on the com mutator is caused by an arc formed every time the commutator segment c...

Page 140: ...ture shaft and remove the starter drive gear assembly 4 Remove the brush end plate and insulator assembly 5 Remove brushes from plastic brush holder and lift out brush holder Note location of brush holder with respect to end terminal 6 Remove the two screws retaining the ground brushes to frame The 4 inch starter has cop per rivets 7 On the field coil that operates the starter drive gear actuating...

Page 141: ...ASSEMBLY Continued COVER ASSEMBLY 11060 COVER SCREW r 38g6 4 ASSEMBLY SCREW POLE PIECE 1 1415 ARTING CONTACT 1134 116 GROMMET HOLDER BRUSH INSULATOR 1 38 SPRING BRUSH MOTOR DRIVE ASSEMBLY ___ 11130 CORE ASSEMBLY 11005 POLE PIECE 11120 J3567 2A ...

Page 142: ...it are available All other assemblies are round turn it down to be replaced rather than repaired 6 DIAL INDICATOR TOOL 4201 C Examine the wear pattern on the starter drive teeth The pinion teeth must penetrate to a depth greater than one half the ring gear tooth depth to eliminate premature ring gear and starter drive failure ROTATE ARMATURE SHAFTS ON BEARING SURFACES 7 Replace starter drives and ...

Page 143: ... slot Install and tighten the through ring Install a new stop retainer bolts to 6 21 8 47 Nom 55 75 in lb Do not 8 Install the armature in the starter frame pinch brush leads when installing end plate Install pivot pin 9 Partially fill the drive end housing bearing bore with Grease ESB MIC 63 A or equivalent 12 Position the drive gear plunger lever cover on approximately l 4 full Position the star...

Page 144: ... 11 Secure the starter in a vise and connect the starter to a battery to check its operation ARMATURE REPLACEMENT 1 Remove starter drive plunger lever cover re tainer screw and remove cover 2 Remove the through bolts the drive end housing plunger lever and the drive plunger lever return spring brush end plate Remove brushes and lift out brush holder 3 Remove the pivot pin retaining the starter gea...

Page 145: ...ables will result in slower than normal cranking speeds and may even prevent the starter from cranking the engine Typical Starter Shown The starting system includes the permanent magnet gear reduction starter motor with a solenoid actuated drive the battery a remote control starter switch part of the ignition switch the starter relay the heavy circuit wiring and may include starter lock out device...

Page 146: ...E VEHICLE TO BE STARTED DISCONNECTING THE BATTERY COULD DAMAGE THE VEHICLE S ELECTRONIC SYSTEM Negative Grounded Battery WARNING TO AVOID ANY POSSIBILITY OF INJURY USE PARTICULAR CARE WHEN CONNECTING A BOOSTER BATTERY TO A DISCHARGED BATTERY 1 Position vehicles so jumper cables will reach being careful that vehicles do not touch 2 Make jumper cable connections l Connect one end of first jumper cab...

Page 147: ...may not be heard POSSIBLE SOURCE 0 Open fuse l Low battery a Defective remote relay l Open circuit or high resistance in external feed circuit to starter solenoid l Defective starter ACTION e Check fuse continuity e Refer to appropriate battery service manual o Go to Test B o Go to Test A a Replace starter See removal and installation procedure Unusual starter noise during starter overrun l Starte...

Page 148: ... STEP RESULT b ACTION TO TAKE Al 1 CHECK FOR VOLTAGE TO STARTER l Key OFF Transmission in Neutral Yes b GO to A2 0 Check for voltage between starter B terminal and starter drive housing No b CHECK wire connections 0 Is voltage OK 12 12 45V between battery and starter solenoid and the ground circuit for open or short A2 1 CHECK STARTER MOTOR l Key OFF Transmission in Neutral Yes b CHECK connections...

Page 149: ...ART Transmission in Neutral Yes b REFER to Starter System l Check for voltage at output terminal of remote relay Diagnosis in this section l Is voltage OK No b Defective remote relay REMOVE and REPLACE relay FPP03 Starter Load Test Conduct this test if the starter cranks slowly and it is desired to compare current to specifications 1 Connect Rotunda Starting and Charging Tester 078 00005 or equiva...

Page 150: ...test will uncover such conditions as open or shorted windings or rubbing armature The starter can be tested at no load on the test bench only 1 Make test connections with Rotunda Starting and Charging Tester 078 00005 or equivalent cables connected to starter large enough to carry high current the same as in the vehicle The starter will run at no load Be sure that no current is flowing through amm...

Page 151: ... STARTER NOTE THE HEAVY GAUGE INPUT LEAD CONNECTED TO THE STARTER SOLENOID IS HOT AT ALL TIMES MAKE SURE THE PROTECTIVE CAP IS INSTALLED OVER THE TERMINAL AND IS REPLACED AFTER SERVICE 1 Disconnect the negative battery ground cable 2 Disconnect starter cable and push on connector from starter solenoid CAUTION When disconnecting hardshell connector at S terminal grasp the plastic shell and pull off...

Page 152: ...nd the solenoid blade terminal at the starter to avoid use of the 12 wire If done voltage is generated to the solenoid by the spinning starter after release of the start key or button causing the starter to remain engaged resulting in failure REMOVAL AND INSTALLATION Continued FIELD WOUND STARTER MOTOR SOLENOID SOLENOID BLADE TERMINAL STARTER PERMANENT I MAGNET TERMINAL STARTER COVER ...

Page 153: ...om drive Remove drive and gear assembly from drive end housing 4 Remove drive lever from drive assembly Remove stop ring and retainer from driveshaft then remove drive assembly from shaft Push C ring off driveshaft and separate gear assembly from driveshaft 5 Remove brush plate screws and brush end plate from motor frame Remove brush assembly and push armature out of frame Cleaning and Inspection ...

Page 154: ...e to bearing bore in brush end plate Push back grommet onto frame and attach brush end with brush plate screws Tighten to 2 3 3 4 Nom 20 30 in lb 2 Apply grease to driveshaft spline and place stationary gear assembly over driveshaft Install armature thrust washer and push C ring onto driveshaft Place drive assembly onto shaft and install stop ring and retainer Attach drive lever to drive assembly ...

Page 155: ... Remove brush end plate screws brush end plate and brush assembly from starter frame Remove armature from frame 4 Install new armature in frame Apply a thin coating of ESF M 1C2 18 A Grease or equivalent low temperature grease on both ends of armature shaft and pinion 5 Install brush assembly Using tool make sure that brushes fit over commutator Push black grommet onto frame Apply grease to bearin...

Page 156: ...EQUIPMENT I Tool Number 1 Description I I078 00005 IStarting and Charging Tester I TOOL TO ASSEMBLE BRUSH HOLDERTO ARMATURE PRESS FIT w BRUSH HOLDER ASSEMBLY 0 A MANdREL MAT L MlCAATA LL221 TAN TYPE FBL STK 1318 DIA A LG 0 1 REQ D B BUSHING UNIVERSAL HEADLESS TYPE PRESS FIT BUSHING CAT NO GS 93 471 472 I D 7518 O D 750 LG 1 REQ D ...

Page 157: ...EW LEVEL HIGH SPEED ADJUSTMENT SCREW w TROUBLESHOOTING MECHANICAL GOVERNOR To troubleshoot a governor with a full load surge first increase the spread between full and no load If this does not help shorten the throttle rod two or three turns Then check for an exces sively rich or lean fuel air mixture at the carburetor Also look for vacuum leaks There are two other conditions that can cause this p...

Page 158: ...governor is so equipped or with the carburetor idle speed adjust ment screw Move the hand throttle or variable speed lever to the closed position Turn the adjustment screw in or out until you can maintain the desired speed SPREAD ADJUSTMENT Proper governor operation requires a difference between full load and no load governed speed This is called spread or sensitivity Too small an RPM spread betwe...

Page 159: ...eze may be used and diluted with an equal quantity of water Ordinary tap water may be used in an emer gency except in areas where the water is known to be exceptionally hard or to have a high alkali content The cooling system should be drained and flushed and the proper mixture of anti freeze added as soon as possible however To avoid possible overheating in very hot weather do not use mixtures wi...

Page 160: ...tor cap 7 If bubbles continue and the pressure drops below 10 psi for engines with a 13 psi sys tem or below 5 psi for a 7 psi system the radiator cap is not holding pressure Re lease pressure and wash cap in clean water to dislodge any foreign matter from the valves Check the rubber sealing surface of the cap and also the cap sealing surface in the radiator neck Inspect the cam lock flanges on bo...

Page 161: ...t and the mounting bolts Install the tension gauge and check the belt tension THERMOSTAT REPLACEMENT Do not attempt to repair the thermostat It should be replaced if it is not operating prop erly Check the thermostat before installing it following the procedure under Thermostat Testing Removal 1 Drain the cooling system so that the coolant level is below the thermostat 2 Remove the water outlet ho...

Page 162: ... solvents will not properly clean the cooling system for effi cient operation it will be necessary to use the pressure flushing method Various types of flushing equipment are avail able If pressure flushing is used make sure the cylinder head bolts are properly tightened to pre vent possible water leakage into the cylinders Always remove the thermostat prior to pressure flushing A pulsating or rev...

Page 163: ...in Head Diameter Standard 1 626 1 627 Depth From Roof of Combustion Chamber 253 254 NOTE Insert must be chilled in liquid nitrogen or dry ice and alcohol prior to installation Gasket Surface Flatness 0 003 inch in any 6 inches or 0 006 inch overall Gasket Surface Finish RMS 61 150 Hydraulic Lifter Leakdown Rate lo 50 Seconds at l 16 inch plunger travel Hydraulic Lifter Collapsed Gap Clearance I Al...

Page 164: ... Crankshaft Free End Play 0 004 0 008 Bushing Clearance Interference Press Fit Service Limit 0 012 PISTON RINGS UN BEARINGS Top Compression Ring Width 0 077 0 078 Crankshaft Clearance Bottom Compression Ring Width 0 077 0 078 Desired 0 0008 0 0015 Top Compression Ring Side Allowable Clearance 0 0025 0 0045 No 1 0 0008 0 0020 Service Limit 0 006 No 2 3 4 5 0 0008 0 0025 Bottom Compression Ring Side...

Page 165: ...ce 95 122 I 70 90 Oil Pan Baffle Nut I 30 43 I 22 32 24 33 1 17 25 Oil Pump to Cylinder Block I 30 43 1 22 32 Pulley to Damper Bolt I 48 67 I 35 50 Rocker Arm Bolt to Cylinder Head I 25 33 1 18 25 Spark Plug to Cylinder Head Water Outlet Housing I 14 20 I 10 15 30 43 I 22 32 Water Pump to Front Cover I 20 28 1 15 21 Alternator Bracket to Water Pump Bolt I 44 61 I 35 50 Intake Manifold Vacuum Fitti...

Page 166: ...000 6 9 10 1000 6 9 15 1000 6 9 20 MARINE DISTRIBUTOR E5JL EA FA IBM 7020 B C CENTRIFUGAL ADVANCE Set the test stand to OO at 250 rpm and 0 inches vacuum L rpm Advance Vacuum Distributor Degrees Inches of Mercury 500 0 0 750 4 6 l 0 1000 6 7 I 2 0 1500 8 1 2 10 l 2 0 2000 11 13 0 l FUEL SYSTEM 1 COOLING SYSTEM Fuel Pump Static Pressure 500 rpm 6 0 8 0 Minimum Fuel Pump Volume Flow 500 rpm l 1 Pint...

Page 167: ...ening l 4 l 4 Heater Ohms 10 ohms 140 C 10 ohms 140 C 10 ohms 140 C Supplier Halley Halley Holley Holley Supplier I D Number R 7996A R 8970 R 9394 R 50399A Carburetor Model 2300 2300 416OC 416OC 416OC Air Cleaner Studs Flame Arrester 30 in lbs Throttle Plate and Secondary Plate Screws Stake 10 in lbs Air Horn Main Body Screws 10 in lbs Fuel Inlet Seat 10 in lbs Choke Housing Screws 5 in lbs Main J...

Page 168: ...tory vehicle performance replace ment fasteners used should be of the correct strength as well as the correct nominal diameter thread pitch length and finish Most original equipment fasteners English system or metric are identified with markings or numbers indicating the strength of the fastener These markings are described in the pages that follow Attention to these markings is important in assur...

Page 169: ...al distinguishable from the slash SAE English grade system The length of all bolts is measured from the underside of the head to the end BOLT STRENGTH IDENTIFICATION ENGLISH INCH SYSTEM Grade 1 or 2 Grade 5 Grade 8 English Inch bolts Identification marks correspond to bolt strength increasing number of slashesrepresent increasing strength METRIC SYSTEM Metric bolts Identification class numbers cor...

Page 170: ... paint daub on hex fiat Increasing numbers represent increasing strength OTHER TYPESOF PARTS Metric identification schemes vary by type of part most often a variation of that used of bolts and nuts Note that many types of English and metric fasteners carry no special identification if they are otherwise unique Stamped U Nuts b 9 0 0 Tapping thread forming and certain other case hardened screws Stu...

Page 171: ...128 375 9 525 390625 9 922 40625 10 319 421875 10 716 4375 11 113 453125 11 509 46875 11 906 484375 12 303 200 12 7 33164 17132 35 64 9116 37 64 19132 39164 518 41 I64 21 I32 43164 llll6 45164 23132 47164 314 49164 25132 51164 13116 53164 27132 55164 718 57164 29132 59164 15116 61I64 31 I32 63164 1 515625 53125 546875 5625 578125 59375 609375 625 640625 65625 671875 6875 703125 71875 734375 750 76...

Page 172: ...r kilopascals kPa PRESSURE or STRESS kilopascals kPa ENERGY or WORK kilowatt hour joules J one W s LIGHT umens meter2 lmlm2 FUEL PERFORMANCE kilometers liter km l liters kilometer l km VELOCITY kilometedhr km h LENGTH millimeters mm kilometers km AREA millimeters2 mm2 VOLUME MASS FORCE ...

Page 173: ... 3 20 a 14 8 20 27 1 25 18 4 25 33 9 30 22 1 30 40 7 35 25 8 35 47 5 40 29 5 40 54 2 50 36 9 45 61 0 60 44 3 50 67 8 70 51 6 55 74 6 80 59 0 60 81 4 90 66 4 65 88 1 100 73 8 70 94 9 110 81 1 75 101 7 120 88 5 80 108 5 130 95 9 90 122 0 140 103 3 100 135 6 150 110 6 110 149 1 160 118 0 120 162 7 170 125 4 130 176 3 180 132 8 140 189 8 190 140 1 150 203 4 200 147 5 160 216 9 225 166 0 170 230 5 250 ...