Ford VSG-411, Service Manual

Page 1: ...VSG 4111413 ENGINE The SERVICE MANUAL I uwer Worldwide TM For Engines Produced 1993 and Later ...

Page 2: ...tands whenever a procedure requires you to be under the vehicle Be sure that the ignition switch is always in the OFF position unless otherwise required by the procedure 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 REVERSE engine OFF or NE...

Page 3: ...ing performed The various sections are indi cated in the index In addition each section is subdivided to include topics such as diagnosis and testing cleaning and inspection over haul removal and installation procedures disassembly and assem bly procedures and service specifications POWER PRODUCTS DIVISION GRI The Source for Power 28333 TELEGRAPH ROAD 300 Worldwide rev SOUTHFIELD MICHIGAN 48034 Th...

Page 4: ...Refinishing Cylinder Walls 01 11 Repairing Sand Holes or Porous Engine Castings 01 11 CLEANING AND INSPECTION 01 l 2 Intake Manifold 01 I 2 Exhaust Manifolds 01 l 2 Valve Rocker Arm and or Shaft Assembly 01 12 PushRods 01 12 SUBJECT PAGE Cylinder Heads 01 12 Tappets 01 14 Timing Chain and Sprockets 01 14 Camshaft 01 14 Camshaft Bores 01 I 4 Crankshaft 01 I 4 Flywheel 01 l 5 Connecting Rods 01 l 5 ...

Page 5: ...01 2 Basic Engine 01 2 BLANK ...

Page 6: ...rs when seeking information or ordering replacement parts for this engine Identification of the cylinder block and therefore of the basic engine type can be made by reference to the stampings on the left rear top edge of the cylinder block A SERIAL NUMBER B ENGINE CODE C ENGINE BUILD DATE The engine code will begin with a G This will indicate that it is a 1 I liter engine The engine build date fol...

Page 7: ...he crankshaft The common driving gear shared by the distributor and oil pump is located behind the second cam on the camshaft the eccentric cam driving the fuel pump is located between the sixth and seventh cams below the distributor The full flow oil filter is angled downwards and mounted directly on the oil pump The crankshaft is mounted in five bearings The crankshaft end play is determined by ...

Page 8: ...ll flow oil filter Oil pressure is regulated by a relief valve inside the pump The filtered oil passes through the center of the filter element then along a short passage right hand side of the engine to the oil pressure switch and through a transverse bore to the main oil gallery left hand side of the engine The crankshaft main bearings are fed directly from the main oil gallery and the camshaft ...

Page 9: ...indicator reading 6 Compare the total lift recorded on the indicator with specifications 7 To check the accuracy of the original indicator reading continue to rotate the crankshaft until the indicator reads zero If the lift on any lobe is below specified wear limits the camshaft and the valve lifters operating on the worn lobe s must be replaced 8 Remove the dial indicator and auxiliary starter sw...

Page 10: ... against the crankshaft flange and the indicator axis is parallel to the crankshaft axis 3 Zero the dial indicator Push the crankshaft forward and note the reading on the dial 4 If the end play exceeds the wear limit replace the thrust washers If the end play is less than the minimum limit inspect the thrust bearing faces for scratches burrs nicks or dirt Camshaft End Play Push the camshaft toward...

Page 11: ...ge and or bottom edge of the seat to reduce the width to specifications 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 TOP OF SEAT USE 30 WHEEL TO REMOVE STOCK FROM t BOTXXA OF SEAT I USE 60 WHEEL The fin...

Page 12: ... scores or nicks from the camshaft machined surfaces with a smooth oil stone Crankshaft Dress minor scores with an oil stone If the journals are severely marred or exceed the wear limit they should be refinished to size for the next undersize bearing Refinishing Journals Refinish the journals to give the proper clearance with the next undersize bearing If the journal will not clean up to maximum u...

Page 13: ...ore clearance conditions of the cylinder bore are within specified limits new piston rings will give satisfactory service If new rings are to be installed in a used cylinder that has not been refinished remove the cylinder wall glaze Refer to Cylinder Block Refinishing Cylinder Walls Be sure to clean the cylinder bore thoroughly 1 Calculate the size piston to be used by taking a cylinder bore chec...

Page 14: ...er bores use a lubricant mixture of equal parts of kerosene and SAE No 20 motor oil Operate the hone in such a way to produce a cross hatch finish on the cylinder bore The cross hatch pattern should be at an angle of approximately 30 degrees to the cylinder bore After the final operation in either of the two refinishing methods described and prior to checking the piston fit thoroughly clean and oi...

Page 15: ...ffing or abnormal wear If the pad is grooved replace the rocker arm Do not attempt to true this surface by grinding Check the adjusting nut s torque If not within specifications replace the nut s Check the rocker arm pad and fulcrum seat for excessive wear cracks nicks or burrs Push Rods Cleaning Clean the push rods in a suitable solvent Blow dry the push rod with compressed air Inspection Check t...

Page 16: ...ndicator point With the cylinder head gasket face up slide a new standard intake or exhaust valve into the valve guide to be checked until the tip of the valve stem is flush with the top of the valve guide Mount a dial test indicator on the cylinder head by the valve to be checked Position the plunger of the dial test indicator on the edge of the valve head and measure the valve head movement by a...

Page 17: ...r scoring and signs of abnormal wear Lobe pitting except in the general area of the lobe toe is not detrimental to the operation of the camshaft therefore the camshaft should not be replaced unless the lobe lift loss has exceeded specifications or pitting has occurred in the lobe lift area The lift of the camshaft lobes can be checked with the camshaft installed in the engine or on centers Refer t...

Page 18: ... be readily identified A shiny surface on either pin boss side of the piston usually indicates that a connecting rod is bent Abnormal connecting rod bearing wear can be caused by either a bent connecting rod worn or damaged crankpin or a tapered connecting rod bore Twisted connecting rods will not create an identifiable wear pattern but badly twisted rods will disturb the action of the entire pist...

Page 19: ...ximately 57 2 mm 2 l 4 inches below the dome and at 90 degrees to the piston pin bore Check the ring side clearance Replace piston pins showing signs of fracture etching or wear Check the piston pin fit in the piston and rod Refer to Piston and Connecting Rod Assembly Check the OD of the piston pin and the ID of the pin bore in the piston Replace any piston pin or piston that is not within specifi...

Page 20: ...iston to cylinder bore clearance CENTER LINE OF ENGINE A AT RloHf AWLETO CENTER LME ff ENOWE 8 PARALLEL TO CENTER LMOF 1 OUT OF ROUND DIFFERENCE BETWEEN A AND 8 2 TAPER DIFFERENCE BETWEEN THE A MEASUREMENT AT TOP OF CYLINOER BORE AND THE A MEASUREMENT AT BOTTOM OF CYLINDER BORE A 1A Refinish cylinders that are deeply scored and or when out of round and or taper exceed the wear limits If the cylind...

Page 21: ... and outer race The outer race shaft and rotor are replaceable only as an assembly 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 is worn or damaged replace the spring Check the relief valve piston for scores an...

Page 22: ...ead engaging the push rods with the adjusting screws Install and tighten the bolts evenly to specifications 4 Adjust the valve clearance to specifications 5 Ensure that the mating surfaces on the cylinder head and rocker cover are free from all traces of the old gasket material 6 Position the rocker cover and gasket on the cylinder head and secure with the attaching screws Torque the screws to spe...

Page 23: ...t of the way Disconnect the water outlet and crankcase ventilation hoses at the intake manifold Disconnect the wire from the temperature gauge sending unit Detach the exhaust pipe Disconnect the throttle rod choke cable and the distributor vacuum advance hose from the carburetor Disconnect the throttle linkage at the governor and position out of the way Remove the governor mounting bolts and remov...

Page 24: ...ake valves not having the Ford oval on the stem EXHAUST VALVE SEAL 3 Install valve spring and damper assembly over the valve then install spring retainer Compress spring and install retainer key locks 4 Measure the assembled height of the valve spring from the underside of the spring to the underside of the spring retainer If the assembled height is not within specification valve spring load loss ...

Page 25: ...ower hose from the water pump 6 Remove bolts securing water pump to cylinder block and remove the pump and gasket Installation 1 Make sure that the mating faces of cylinder block and pump are clean 2 Position the pump and gasket on the cylinder block and secure with the attaching bolts 3 Position lower hose on water pump and tighten the clamp 4 Position the pulley and fan and secure with bolts Tor...

Page 26: ...nd torque the attaching bolts to specification 8 Install the water pump pulley and fan Install the governor and fan belts and adjust the tension of the belts to specifications using Tool T63L 8620 A 9 Install the radiator 10 Install the radiator upper and lower hoses and tighten the clamps 11 Refill the radiator 12 Start engine and check for oil and water leaks Adjusting Valve Clearances 1 Only tu...

Page 27: ...he belts 4 Remove the fan and water pump pulley 5 Remove the oil and fuel pumps from the cylinder block 6 Disconnect the spark plug wires from the plugs 7 Remove the rocker arm cover attaching screws and rocker cover Clean all gasket material from rocker arm cover and cylinder head 8 Remove the rocker arm shaft support bolts evenly and lift off the rocker arm shaft 9 Lift the push rods from their ...

Page 28: ...rm shaft assembly making sure that the cupped ends of the push rods engage the adjusting screws Tighten the rocker arm shaft attaching bolts evenly to specification 16 Adjust the valve clearances to specification 17 Install the rocker arm cover and a new gasket and secure with attaching screws and torque to specifications 18 Connect the vacuum advance line to the carburetor 19 Connect wires to spa...

Page 29: ... the oil filter to the oil pump assembly 3 Check the oil level and add oil if necessary 4 Start the engine and check for oil leaks Oil Pan Removal 1 Drain the crankcase 2 Remove the oil level dipstick 3 Remove the three bolts and remove the starter motor 4 Remove the oil pan attaching bolts and remove the pan and gasket Installation 1 Clean the oil pump inlet tube and screen assembly 2 Clean the g...

Page 30: ...lace a cloth on the piston dome to collect the cuttings Remove any ridge and or deposits from the upper end of the cylinder bore with a ridge cutter Follow the instructions furnished by the tool manufacturer Never cut into the ring travel area in excess of 0 8 mm 1132inch when removing ridges Make sure all the connecting rod caps are marked so that they can be installed in their original positions...

Page 31: ...ll the cylinder head and related parts Adjust the valve clearance as described in this Section Fill and bleed the cooling system Fill the crankcase Start the engine and check for oil pressure Operate the engine at fast idle and check for oil and coolant leaks Operate the engine until engine temperatures have stabilized Check and adjust the ignition timing Adjust the engine idle speed and fuel mixt...

Page 32: ... manufacturer Never cut into the ring travel area in excess of 0 8 mm l 32 inch when removing ridge 21 Invert the engine on the stand and remove the oil pan and gaskets 22 23 24 25 26 Remove the oil pick up tube and screen Remove the flywheel and tear engine plate Remove the tear bearing retainer Remove the timing chain tensioner Remove the camshaft sprocket and timinq chain 27 28 29 30 31 32 33 3...

Page 33: ...rain plug and oil pressure sending unit 3 Place the upper main bearing inserts in position in the bore with the tang fitting in the slot provided 4 Install the lower main bearing inserts in the bearing caps 5 Carefully lower the crankshaft into place Be careful not to damage the bearing surfaces Check the clearance of each main bearing following the procedures in the Overhaul Section 6 Install the...

Page 34: ...necting rod bearings and check the clearances as detailed in the Overhaul Section 21 Oil the hearings and journals with engine oil and install the connecting rod bearing caps Tighten the bolts to specification Check the connecting rod side clearance 22 Rotate the engine to the inverted position Replace the oil pump pick up tube and screen Press the tubes to the full depth of the counter bored hole...

Page 35: ...43 Remove engine from stand Oil Pump Disassembly 1 Remove the filter 2 Remove the end plate and withdraw the rubber O ring from the groove in the pump body 3 If it is necessary to replace the rotor assembly remove the outer rotor then drive out the retaining pin securing the gear to the shaft and pull off the gear 4 Remove the inner rotor and shaft 5 Drill a small hole and insert a self threading ...

Page 36: ... 02 8 Engine Temperature 02 4 DIS Cleaning and Inspection 02 8 Fuel Octane Level Adjustment 02 4 Spark Plugs 02 8 Ignition Coil Driver 02 4 Ignition Coil 02 8 Sensor Fail Safe 02 4 Ignition Wires 02 8 Cranking Mode 02 4 Spark Plug Inspection Chart 02 9 Run Mode 02 4 DIS Engine Harness Checks 02 10 Transient Mode 02 4 Spark Timing 02 I 0 Overspeed Mode 02 4 Engine Coolant Temperature SERVICE ADJUST...

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Page 38: ...ust The spark in the benefits of the high compression swirl design Because timing is set for life inherently in the design of the engine exhaust cylinder is wasted but little of the coil energy is lost and there are no moving parts in the ignition system itself no maintenance is required except for periodic spark plug The spark strategy is based on sensors and manifold checks The system provides f...

Page 39: ...f engine operating speed within which the ignition timing is at a static position The static spark advance is fixed at IO degrees BTDC up to 250 RPM Run Mode In this mode the RPM is above 250 and the spark advance is calculated in three main sections which are added together The ICM sections are Base Spark Advance BSA plus Spark Advance Offset Temperature SAOT plus Spark Advance Offset Detonation ...

Page 40: ...and visually check spark plug high tension leads and check for secure fit replace if necessary The ICM must be mounted above the intake manifold vacuum fitting to prevent fuel from entering the ICM chamber The connecting rubber hose must be compatible with gasoline and be as short as possible It is recommended that a fuel vapor trap be used in line in the connecting hose ...

Page 41: ...llation 1 Position coil assembly secure with three screws 2 Connect HT leads at coil ensuring that locking tabs snap into position NOTE HT connections at coil are marked 1 to 4 It is important that each HT lead is connected in correct sequence 3 Connect ignition coil multiplug 4 Connect battery ground lead Start engine and check coil operation Engine Speed Sensor Removal 1 Disconnect battery groun...

Page 42: ... radiator cap Remove temperature sensor multiplug located below the intake manifold To remove multiplug pull on multiplug do not pull on wiring Unscrew sensor from intake manifold Installation 1 Install sensor into inlet manifold do not overtighten sensor Connect multiplug ensuring that locking tabs snap into position 2 Replace radiator drain plug and refill system with correct solution Remove rub...

Page 43: ...ss plug from the ICM module Pins 1 and 5 are not used and therefore do not have female connectors in the 12 pin harness connector plug 2 Check the following circuits with the volt ohmmeter with the sensors connected per the chart on page 12 with reference to the wiring diagram on page 14 If the DIS Engine Harness checks are not to the chart specifications page 12 complete the following l Remove th...

Page 44: ...UG OPERATING HEAT RISER OR EXCESSIVE IDLING CAN BE CLEANED IDENTIFIED BY SEVERELY ERODED OR WORN ELECTRODES CAUSED BY NORMAL WEAR iHOULD BE REPLACED IDENTIFIED BY LIGHT TAN OR GRAY DEPOStTS ON THE FlRlNG TIP IDENTIFIED BY DARK GRAY BLACK YELLOW OR TAN DEPOSITS OR A FUSED GLAZED COATING ON THE INSULATOR TIP CAUSED BY HIGHLY LEADED GASOLINE REPLACE THE PLUG IDENTIFIED BY MELTED IDENTIFIED BY A WHITE...

Page 45: ...n A Column B Sensor Harness C F Sensor Ohms It 5 Ohms 5 Loop between Pins 6 and 7 closed or open None E 1 22 481 000 1 491 000 I Ground Pin 7 Retard Base Spark by l 2 degrees I 20 I 4 I 271 200 1 281 200 I 1 10 I 14 I 158 000 1 168 000 I Ground Pin 6 Retard Base Spark by 2 4 degrees IO I32 I 95 000 1 105 000 I I 10 I 50 I 58 750 1 68 750 I Ground Pins 6 and 7 Retard Base Spark by 6 8 degrees I 20 ...

Page 46: ...02 I 1 lanition Svstem Distributorless 02 I 1 DIAGNOSING AND TESTING DIS Continued 0 w r 7 ...

Page 47: ...een I White I 57 ICM to Battery Ground I I8 I Black I I 16M ICM Pin 8 to Splice I I8 I Red I Green I 6 ICM Spark Retard 2 OS1 1181 Brown I I 6 ICM Spark Retard 4 OS2 1181 Brown I I ICM to Resistor I I8 I Brown I White I 354 265 264 152 730 170 57P 57s 57T 57V 38 32 21 ICM to Crankshaft Position Sensor CKP I8 I Green I ICM to Crankshaft Position Sensor CKP I8 I White I ACC Terminal of Ign SW to Gen...

Page 48: ...ETARD 4 GROUND WIRE TO PIN 7 TO RETARD 10 GROUND WIRE TO PIN 6 TO RETARD 18 GROUND WIRE TO PIN 6 7 l THE UESC MODULE MUST BE MOUNTED SOMEWHAT ABOVE THE LEVEL OF THE INTAKE MANIFOLD THIS IS SO THAT FUEL OR CONDENSED FUEL VAPORS CANNOT DRAIN THRU THE VACUUM LINE INTO THE MODULE DURING OPERATION OR STORAGE l WIRE 354 CONTAINS A 10 KQ SERIES RESISTOR FROM THE RESISTOR TO THE ECT SENSOR CONNECTOR THIS ...

Page 49: ... 1 ICM to Splice I I8 I Yellow I Black I 359 I ICM to ECT Sensor Ground I 8 I Green I White I 57 I ICM to Battery Ground 1181 Black I I 16 I ICM Pin 8 to Splice 1 18 1 Red I Green 1 6 ICM Spark Retard 2 OS1 ICM Spark Retard 4 OS2 18 Brown 18 Brown 6 354 I ICM to Resistor I I8 I Brown I White I 265 ICM to Crankshaft Position Sensor CKP 1 18 Green 264 ICM to Crankshaft Position Sensor CKP I I8 I Whi...

Page 50: ... UESC MODULE MUST BE MOUNTED SOMEWHAT ABOVE THE LEVEL OF THE INTAKE MANIFOLD THIS IS SO THAT FUEL OR CONDENSED FUEL VAPORS CANNOT DRAIN THRU THE VACUUM LINE INTO THE MODULE DURING OPERATION OR STORAGE l WIRE 354 CONTAINS A 10 KQ SERIES RESISTOR FROM THE RESISTOR TO THE ECT SENSOR CONNECTOR THIS CIRCUIT IS CALLED 354A 850A 16C 852A S TERMINAL STARTER RELAY ENGINE GROUND 0 57 TO ENGINE COOLANT TEMPE...

Page 51: ...neral Information 03 4 FUEL PUMP 03 5 Description 03 5 Diagnosis and Testing 03 5 Pressure Tests 03 5 Capacity Volume Test 03 5 REMOVAL AND INSTALLATION 03 6 Fuel Pump Assembly 03 6 ZENITH MODEL 33 CARBURETOR 03 7 Operation and Service 03 f Fuel Supply System 03 7 Idle System 03 7 High Speed System 03 8 Accelerating Pump System 03 9 Disassembly 03 l 1 Cleaning and Inspection 03 l 1 Assembly of Air...

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Page 53: ...nd a single barrel carburetor with either a manual choke or an automatic choke It also has a screen filter located in the fuel inlet Identification The carburetor is identified on the main body near the fuel inlet The basic part number for all carburetors is 9510 To procure parts it is necessary to know the part number prefix and suffix FGJL AA PART NO PREFIX PART NO SUFFIX ...

Page 54: ... and the line from the fuel pump to the tank should be blown out Air leakage in the fuel inlet line can cause low fuel pump pressure and volume A restricted fuel tank vent can cause low fuel pump pressure and volume and can result in collapsed inlet hoses or a collapsed fuel tank High or low pressure are the two most likely fuel pump troubles that will affect engine performance Low pressure will c...

Page 55: ...maller than 5 59 mm 0 220 in 3 Position the flexible fuel outlet hose and the restrictor so the fuel can be discharged into the graduated container 4 Before taking a pressure reading operate the engine at the specified idle rpm and vent the system into the container by opening the hose restrictor momentarily 5 Close the hose restrictor allow the pressure to stabilize and note the reading If the pu...

Page 56: ...esistant sealer to both sides of a new gasket and to the threads on the attaching bolts Position the new gasket on the pump flange and hold the pump in position against the mounting pad Make sure the rocker arm is riding on the camshaft eccentric Turn engine over until the fuel pump eccentric is on the low side of the stroke Press the pump tight against the pad install the attaching screws and alt...

Page 57: ...s until sufficient velocity is built up in the main venturi to operate the main system This system consists of the idle discharge holes the idle adjusting needle the passage or channel between the idle jet and the discharge holes the idle air bleed and the idle jet and pickup tubes At idling speeds manifold vacuum is transmitted through the primary idle discharge hole to the idle jet through a pas...

Page 58: ...ystem also controls the mixture at part throttle speed The main jet controls fuel delivery from about one quarter to three quarters throttle opening To maintain a proper mixture ratio a small amount of air is admitted through the well vent There are also air bleed holes located in the well tube at a point below the level of fuel in the well Introducing air into the well tube below the level of fue...

Page 59: ...n additional fuel must be supplied instantly The supply of that extra fuel is the job of the accelerating pump system ACCELERATING JET SPRING PROTECTOR CHANNEL ACCELERATING SYSTEM The accelerating system consists of the pump diaphragm assembly accelerating jet intake check valve and three parts making up the refill check The pump is vacuum operated In this system the pump diaphragm is pulled again...

Page 60: ...03 l 0 Fuel System 03 I 0 ZENITH MODEL 33CARBURETOR Continued ...

Page 61: ... channel plug 50 into vacuum channel flush with surface 2 Drive cup plug 4 into end of choke shaft hole opposite choke lever 3 Insert choke shaft 53 with milled flat toward top Item Description 30 Plate Throttle 31 Welch Plug Vacuum Spark 32 Tube Vacuum Spark 33 Seal Throttle Shaft 34 Lever Shaft Throttle 35 Screw Idle Stop 36 Plug Throttle Body 37 Gasket Pump Diaphragm 38 Protector Diaphragm 39 S...

Page 62: ...nstall the fuel valve seat 19 and washer 18 making sure that the fuel valve enters the seat properly the valve will enter the seat more easily if the float is held in the up position and tighten securely Insert float axle clip 11 in slot to bear against axle ends Holding axle in place raise float by applying light finger pressure to the float bracket Float pontoons should be approximately level wh...

Page 63: ... opened to accelerate the air fuel mixture has to be enriched The action of the accelerator pump provides momentary enrichment but additional richness is required since the engine is cold This added richness is provided by the action of the pull off system The opening of the throttle valve causes a drop in intake manifold vacuum which is transmitted to the diaphragm or piston With the lower vacuum...

Page 64: ...n 0 8 mm l 32 inch of but not touching the choke bore r 3 If the choke plate does not meet this dimension loosen the three cover plate screws to rotate the cover as necessary and repeat steps 1 and 2 4 If the carburetor temperature is other than 21 C 7O F make the following correction l Set the choke plate as described in steps 2 and 3 l Readjust the cover plate to compensate for the deviation fro...

Page 65: ...SUBJECT PAGE SUBJECT PAGE DESCRIPTION AND OPERATION Exhaust Gas Recirculation EGR Valve Crankcase Emission Control System DIAGNOSIS AND TESTING Symptoms of EGR System Malfunctions Rough Idle f Surge Stall or Won t Start f Detonation Spark Knock Poor Fuel Economy 13A 3 3A 3 3A 6 13A 7 3A 7 13A 7 13A 7 13A 7 13A 7 EGR System Gas Flow Test 03A 7 Diaphragm Leak Test 03A 7 EGR Valve Leakage Check 03A 8...

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Page 67: ...the cylinders to reduce the combustion temperature This reduces the formation of an atmospheric pollutant known as oxides of nitrogen NOx CARBURETOR SPACER EGR VALVE EGR TUBE INTAKE MANIFOLD The EGR valve is a vacuum operated flow control valve It is attached to the carburetor by an EGR valve adapter Between the EGR valve adapter and the carburetor is a spacer which has gaskets on both sides ...

Page 68: ... RESTRICTOR G GASKET H EGR SPACER The EGR valve is operated by a vacuum signal from the carburetor which actuates the valve diaphragm As the vacuum increases sufficiently to overcome the diaphragm spring the valve is opened allowing EGR flow The amount of flow is dependent on the location of a tapered pintle which is a direct result of the vacuum signal ...

Page 69: ...losed throttle the EGR port is blocked from vacuum At wide open throttle EGR vacuum is weak to zero and will cause the EGR valve to close for maximum engine power Note that at idle when EGR vacuum is off the EGR system is least needed because NOx formation is at a minimum THROT TLE PLATE OFF IDLE POSITION HIGH VACUUM FLOW TO EGR HlGH INTAKE MANIFOLD VACUUM m VACUUM Under certain circumstances the ...

Page 70: ...t can cut off vacuum to the EGR valve when the engine is cold and connect vacuum to the EGR valve when the engine is warm Crankcase Emission Control System The Crankcase Emission Control System consists of an oil filler cap including PCV valve with two connecting hoses one of which passes to the inlet manifold and the other to the air cleaner The result is a closed ventilation system in which the ...

Page 71: ...n the vacuum source On engines with high spark advance detonation is serious enough to destroy an engine Diagnose the condition by performing the tests in this section EGR System Gas Flow Test The exhaust gas flow test must be made with the engine idling and hot It tells you if the gas flow passages are open 1 Remove the vacuum line from the valve diaphragm Plug the line to prevent a vacuum leak o...

Page 72: ...rise at off idle decrease at half throttle and go to zero at closed throttle If the source vacuum is okay test the PVS and inspect the hoses If the source vacuum is not okay check for an obstruction in the carburetor or for a vacuum leak caused by loose mounting CARBURETOR EGR HOSE Testing the 2 Port PVS Valve The Z port PVS valve is okay if it blocks vacuum from the EGR valve when the engine is c...

Page 73: ...at the EGR restrictor into the spacer block A small amount of grease may be applied to the EGR restrictor prior to installation This will ensure that the EGR restrictor does not become dislodged during the installation of the EGR valve gasket and the EGR valve Do not allow grease to block the hole in the EGR restrictor 2 Install the EGR valve gasket 3 Install the EGR valve 4 Install the two EGR va...

Page 74: ...nections 04 6 Electrical Testing Precautions 04 6 Output Voltage Test 04 6 Regulator Bypass Test 04 7 Key Off Check 04 7 Regulator Sense Voltage 04 7 External Circuit Tests 04 8 Field Voltage Test 04 8 Initial Excitation Circuits 04 9 SUBJECT PAGE Regulator Input Test 04 9 Generator Brush Check 04 10 Field Ground and Open Tests 04 10 Field Voltage Test 04 I 0 Overcharging 04 l 1 Generator Disassem...

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Page 76: ...is belt driven from the engine Current is supplied from the generator regulator system to the rotating field of the generator through two brushes to two slip rings The generator produces power in the form of alternating current The alternating current is rectified to direct current by six diodes The generator regulator automatically adjusts the generator field current to maintain the generator out...

Page 77: ...04 4 Chargina System 04 4 DESCRIPTION AND OPERATION Continued REGULATOR GROUND WIRE TOR ...

Page 78: ...HAN YOUR BACK TO PREVENT MUSCLE STRAINS AND BE CAREFUL NOT TO DROP THEM POSSIBLE BREAKAGE OR TO SPILL THE CONTENTS SULFURIC ACID CAUTION 12 volt starting motors can be damaged beyond repair if connected to a 24 volt power supply two 12 volt batteries in series or a 24 volt motor generator set even when cranking loads are relatively light Extensive starting motor damage is more likely if the starte...

Page 79: ...ngine is running 2 Do not disconnect the generator field terminal or the regulator connection while the engine is running 3 Do not short the generator field terminal or field lead to ground 4 Disconnect the battery ground terminal before removing the generator or the generator brush holder assembly 5 Never reverse polarity when charging or replacing the battery Output Voltage Test Perform this tes...

Page 80: ...or circuit for low output although the problem may still be partly or entirely in the generator Possible generator problems include Defective output or field diodes Excess resistance in the field circuit which includes the regulator Excess resistance in the charging circuit external to the generator Key Off Check 1 Key OFF 2 Remove the jumper between the R and F terminals if present 3 Connect the ...

Page 81: ...re than 0 2 volt excess resistance is present in the generator output lead or in the battery positive cable or connections Check for wire or cable damage or for loose or dirty connections 2 Measure the voltage from the battery negative terminal to ground It should be zero If it is more than 0 2 volt check the ground circuit The following connections must be clean and tight l Generator mounting bol...

Page 82: ...an open in the excitation circuit Normally initial excitation current is drawn through both paths but either one will pass sufficient current if the other is open If the excitation resistor is open or higher in value than it should be there will still be excitation current to magnetize the field at startup but the voltage at the field terminal will be lower because of the larger voltage drop throu...

Page 83: ...or sticky movement 6 Clean and free up the brushes or replace the assembly 7 While the brush holder is out release belt tension to allow free rotation of the rotor and clean the slip rings with crocus cloth or fine abrasive Field Ground and Open Tests This test uses an ohmmeter to check for opens or shorts to ground in the field 1 Touch the meter probes to either of the slip rings and to ground If...

Page 84: ...he regulator sense voltage at the R terminal is lower than the output voltage by more than 0 5 volt due to a defective diode trio a good regulator will increase field current and generator output in an effort to bring the sense voltage up to regulating value Whether and to what extent the system will overcharge will depend on the nature and degree of the field diode failure as field current must p...

Page 85: ... only and tighten the adjusting arm to generator bolt belt should be within specifications Specifications 4 Check the belt tension using Tool T63L 8620 A Section Adjust the belt for specified tension 2 If the belt is not within specification loosen the 5 Tighten all mounting bolts generator mounting bolt to a snug position and loosen the adjusting arm bolts ...

Page 86: ...and remove the generator Installation 1 Install the generator wiring connector Position the generator to the engine and install the spacer if used and the generator mounting bolt Tighten the bolt only finger tight 2 Install the adjustment arm to generator attaching bolt 3 Position the belt on the pulley and adjust the belt tension using Tool T63L 8620 A Apply pressure on the generator front housin...

Page 87: ...shaft and press bearing from shaft 9 Remove rectifier diode assembly retaining screws and lift out stator and rectifier assembly 10 Unsolder stator to rectifier connections using a pair of pliers as a heat sink to reduce heat spread to diodes STATOR CONNECT10 Releasing Front Bearing Retainer To remove the front bearing which is pressed on the rotor shaft it must first be removed from the front hou...

Page 88: ... race is prevented from turning by a snug fit in the recess plus the added friction of a rubber seal ring in a groove in the recess Replace the seal ring whenever the generator is disassembled Assembly 1 Resolder stator to rectifier Use a pair of pliers as a heat sink to reduce heat spread to diodes STATOR CONNECT10 2 Position stator and rectifier assembly in rear housing and install retaining scr...

Page 89: ... if bench testing is not available re install the generator to the engine 1 Install and connect the generator 2 Apply proper tension to the drive belt 3 Make sure the battery cable connections are tight 4 Key ON 5 With the engine running at 1000 to 1200 rpm measure the voltage from the output terminal to ground GENERATOR VOLTMETER 6 Gradually increase the electrical load while observing the voltag...

Page 90: ...CT PAGE DESCRIPTION AND OPERATION 05 3 TESTING 05 4 Road Service 05 4 On Engine Testing 05 4 Starter Cranking Circuit Test 05 4 Starter Load Test 05 5 Starter Solenoid Test 05 5 Bench Tests 05 5 Starter No Load Test 05 5 Armature Open Circuit Test 05 6 Armature and Field Grounded Circuit Test 05 6 SUBJECT PAGE REMOVAL AND INSTALLATION 05 7 OVERHAUL 05 8 Disassembly 05 8 Cleaning and Inspection 05 ...

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Page 92: ... sufficient magnetic attraction to pull the solenoid plunger into the solenoid Engine cranking occurs when the starter solenoid on the starter is energized through the starter control ignition switch When energized the solenoid shifts the starting motor pinion into mesh with the engine flywheel ring gear Simultaneously the main contacts of the solenoid are closed and battery current is directed to...

Page 93: ...on coil to prevent the engine from starting Connect a remote control switch between the battery terminal of the starter relay and the S terminal of the relay STARTER CRANKING CIRCUIT TEST The voltage drop in the circuit will be indicated by the voltmeter 0 to 2 volt range Maximum allowable voltage drop should be 1 With the voltmeter negative lead connected to the starter terminal and the positive ...

Page 94: ...OSTAT REMOTE CONTROL STARTER SWITCH POSITIVE LEADS Starter Solenoid Test If the solenoid does not pull in in the Starter Load Test measure the voltage between the starter mounted solenoid switch terminal and ground with the ignition switch closed If the voltage is 10 or more volts a worn or damaged solenoid is indicated Remove the starter assembly for solenoid replacement Bench Tests Starter No Lo...

Page 95: ...The test will determine if the winding insulation has failed permitting a conductor to touch the frame or armature core To determine if the armature windings are grounded make the connection as shown If the voltmeter indicates any voltage the windings are grounded Grounded field windings can be detected by first disconnecting the grounded end of the winding where it terminates at the frame then ma...

Page 96: ...als on plate and start the mounting bolts the solenoid 2 Snug the starting motor mounting bolts while holding 3 Remove the starter mounting bolts and remove the the starter squarely against the mounting surface and starter assembly fully inserted into the pilot hole Tighten the mounting bolts 3 Connect the cable and wires to the terminals on the solenoid Connect the battery ground cable ...

Page 97: ... collar from over C clip Remove C clip from its groove and slide thrust collar and drive pinion assembly off armature shaft 1 Cleaning and Inspection Do not wash the drive because the solvent will wash out the lubricant causing the drive to slip Use a brush or compressed air to clean the drive 2 3 4 field coils armature commutator armature shaft front end plate and rear end housing Wash all other ...

Page 98: ...9 OVERHAUL Continued Item Description Starter motor Bolt Solenoid Bushing Brush set Brushholder Item 7 8 9 10 11 12 Description Brush spring Brush end bushing Through bolt kit Armature insstallation kit Drive assembly Bushing ...

Page 99: ... Brush will be positively located when through bolts are installed 6 7 8 Position four brushes in their respective brush holder locations and retain with brush springs Guide commutator end housing into position sliding rubber insulator into commutator housing cut out and locating two through bolts through housing holes Secure commutator end housing with two nuts and washers or two through bolts as...

Page 100: ...the United Technologies permanent magnet starter This starter has a pinion gear which is actuated by inertial force in place of a starter solenoid When the starter is energized inertia causes the pinion gear to move out along a spirally threaded shaft and engage the flywheel When the engine has started the starter motor is de energized and spring tension causes the pinion gear to move away from th...

Page 101: ...he notch in the drive end plate matches the raised crimp on the inside edge of the starter body This alignment is also shown on the outside of the starter by a raised line on the drive end plate and a corresponding mark on the starter body If the armature has been partially or totally removed from the starter body make sure the brushes are properly seated before re installing the armature BRUSHES ...

Page 102: ...werful magnets and will be attracted to them A firm side to side wiggle near the heads of the bolts may be necessary in order to engage the bolts with their threaded holes 3 Install the pinion 4 Install the spring retainer 5 Install the spring 6 Install the flat washer 7 Install the hex nut ...

Page 103: ...M 04 I SECTION 06 Governor SUBJECT PAGE SUBJECT PAGE DESCRIPTION AND OPERATION ADJUSTMENTS Preliminary Checks Oil Level Belt Tension Throttle Control Rod RPM Adjustments High Speed Spread or Sensitivity 16 3 16 4 16 4 16 4 16 4 16 4 16 4 16 4 16 4 Increase Spread 06 4 Decrease Spread 06 5 Low Speed 06 5 No Load Surge 06 5 REMOVAL AND INSTALLATION 06 6 ELECTRONIC DESCRIPTION AND OPERATION 06 7 ELEC...

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Page 105: ...the engine and is belt driven from the engine accessory pulley A direct mechanical linkage from the governor throttle control lever to the carburetor throttle lever limits carburetor action to the governor setting As the engine speed the rotation of the governor shaft increases However a spring retards or limits the movement of the weights until centrifugal force overcomes the spring tension At th...

Page 106: ...sen the control rod ball joint locknuts remove the rod from the carburetor throttle lever and adjust the length of the rod with the ball joints 4 Install the throttle control rod on the carburetor throttle lever and recheck the gap Tighten the locknuts CAUTION Be sure the throttle control rod is properly installed with the long end at the governor to prevent binding on the ignition wires RPM Adjus...

Page 107: ...led Increase the engine speed with the hand throttle or variable speed lever to 75 rpm lower than the maximum no load desired control rpm conditions 3 Readjust the governor high speed stop screw to maintain the correct high speed under load Low Speed 1 Attach a tachometer and move the hand throttle or variable speed lever to the closed position 2 Adjust the carburetor idle speed screw to obtain th...

Page 108: ...ey Remove governor to bracket attaching bolts and remove governor 1 Position the governor to the mounting bracket and install the attaching bolts snugly 2 Position drive belt to governor pulley and move the governor away from the engine to tighten the belt Tighten the attaching bolts 3 Adjust the belt tension 4 Connect the governor to carburetor throttle control rod Adjust the rod as described pre...

Page 109: ... the control panel of the machine These governors are isochronous in operation these is no governor droop The governor maintains the same engine speed from no load to full load operation Each controller The carburetor is a Zenith model 33 offered with either a manual or automatic choke It is spring loaded to keep carburetor at its minimum fuel position when no power is applied The feature causes t...

Page 110: ...a DC voltmeter check between the purple wire and chassis battery ground The voltmeter should read 12 volts 2 volts If the voltage is low disconnect the 8 pin connector from the controller and check continuity between the wiring harness pins E F to their respective actuator terminals If there is no continuity check for openings in the wires Using a voltmeter check for battery voltage from controlle...

Page 111: ...engine speed begins to decrease Slowly turr the idle mixture screw counterclockwise CCW until the engine speed begins to decrease Now turn the idle mixture screw clockwise CW until maximum idle speed is achieved The idle mixture is now adjusted Disconnect the connector from the controller and consult the engine repair manual NAMEPLATE L 4 A BAT B BAT C DIS IGN 101 6 D DIS IGN I4 0001 E ACTUATOR F ...

Page 112: ...SIS AND TESTING Continued B d b BATTERY SPEED III ACTUATOR A SELECT COIL 1 23 45 678 1 I I I I I I I A BC DE F G H E ACTUATOR F ACTUATOR G SPDSELA H SPDSELB TACHLEAD BATTERY 1b DIS MODULE 1 2345678 I 1 I 1 1 1 1 1 A B C D E F G H CONNECTOR ...

Page 113: ...05 l IGNITION SYSTEM DISTRIBUTORLESS 02 1 GOVERNOR 06 l FUEL SYSTEM 03 1 COOLING SYSTEM 07 l EMISSION CONTROL SYSTEM 03A 1 SPECIFICATIONS 08 l CHARGING SYSTEM 04 1 SECTION 07 Cooling System SUBJECT PAGE SUBJECT PAGE DESCRIPTION AND OPERATION 07 3 ADJUSTMENTS 07 4 Drive Belt 07 4 Belt Tension 07 4 ...

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Page 115: ...rough the cored passages to cool the entire length of each cylinder wall Upon reaching the rear of the cylinder block the coolant is directed upward into the cylinder head where seats it cools the combustion chambers valves and valve The coolant from the cylinder head flows past the thermostat if it is open through the coolant outlet housing and into the top of the radiator Another passage in the ...

Page 116: ...fe of the belt Therefore it is recommended that a belt tension gauge be used to check and adjust the belt tension Any belt that has been operated for a minimum of 10 minutes is considered a used belt and when adjusted it must be adjusted to the used tension shown in the specifications 2 If adjustment is necessary loosen the generator mounting and adjusting arm bolts Move the generator toward or aw...

Page 117: ...ISTRIBUTORLESS 02 l GOVERNOR 06 I FUEL SYSTEM 03 I COOLING SYSTEM 07 l EMISSION CONTROL SYSTEM 03A 1 SPECIFICATIONS 08 I CHARGING SYSTEM 04 l SECTION 08 Specifications SUBJECT PAGE SUBJECT PAGE SPECIFICATIONS 08 3 Special Service Tools 08 8 Engine Model Years 1993 08 3 Conversion Factors 08 8 Torque Specifications 08 8 ...

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Page 119: ...911 O 2 9122 in Out of Round Maximum Wear Limit 0 038 mm 0 0015 in 0 127 mm 0 005 in ITaper Maximum I 0 0254 mm 0 0010 in Wear Limit Main Bearing Bore Standard Oversize Camshaft Bearing Bore Standard 0 254 mm 0 010 in 60 623 60 636 mm 2 3868 2 3872 in 61 003 61 016 mm 2 4017 2 4022 in 42 888 42 918 mm 1 6886 1 6896 in Oversize 43 396 43 420 mm 1 7086 I 7094 in Cylinder Block Liner Bore Diameter 1 ...

Page 120: ...I L and 1 3L Bearing I D 1 I L and 1 3L Bearing Clearance Standard Bearing 1 I and 1 3L 39 615 39 636 mm 1 5596 1 5605 in 39 662 39 713 mm 1 5615 l 5635 in 0 026 0 067 mm 0 001 0 002 in I Wear Limit I 0 0762 mm 0 003 in I Camshaft Thrust Plate Thickness 1 I L and 1 3L End Play Cam Lift 1 I L Intake Exhaust Camshaft Lift 1 3L Intake Exhaust Drive 1 I L and 1 3L Connecting Rod Piston Pin Bore 1 I L ...

Page 121: ...ndard Bore Ring Gap b 0 25 0 45 mm 0 01 O 0 01 7 in Bottom Compression Ring Standard Bore Ring Gap IT1 0 25 0 45 mm 0 01 O 0 017 in 1 Oil Ring Standard Bore Ring Gap b 0 20 0 40 mm 0 008 0 015 in Cylinder Head 1 Maximum permissible cylinder head distortion 1 I L and 1 3L Measured over a distance of 26 mm 0 04 mm 0 0015 in Measured over a distance of 152 mm 0 08 mm 0 003 in Measured over the entire...

Page 122: ...L and 1 3L Intake Exhaust Spring Assembled Height Pad to Retainer I 41 O mm 1 61 in 33 22 mm 1 308 in Spring Load at Assembled Height 270 newtons 60 7 lb Tappet Diameter Block Bore Clearance to Block I 13 081 I 3 094 mm 0 5150 0 5155 in 13 11 O l 3 143 mm 0 5162 0 5174 in I 0 016 0 062 mm 0 007 0 0024 in Rocker Shaft Diameter I 15 82 l 5 85 mm 0 6229 0 6240 in Rocker Bore I 15 875 I 5 913 mm 0 625...

Page 123: ...imum 0 50 I OOOhm I High Tension Leads 30 000 Ohms Max per Lead Belt Tension Alternator New 351 449 N 79 l 01 Ibs Used Reset Minimum 249 334 N 56 75 Ibs Governor New Used Reset Minimum 334 N 75 Ibs 222 N 50 Ibs Fuel System I I L and 1 3L Unleaded 1986 Pump Delivery Pressure Starter Current Draw 87 Octane 0 24 0 38 Bar 3 5 5 5 psi Normal Engine Cranking Maximum Load at Stall No Load 175 amps 410 am...

Page 124: ...nches Liter x 61 024 r Quarts Liter x 1 0567 I Inches Millimeter x 0 03937 Pounds Newton x 0 2248 Ft lbs Torque NewtonaMeter x 0 7376 Oil Pump Pickup Tube Bracket Oil Pan Step 1 Alphabetical 20 to 25 15 l 8 6 to 8 5 6 Step 2 Numerical 8toll 6 8 Step 3 Alphabetical Retorque after engine has warmed up 15 minutes at 1000 rpm Oil Pan Plug Oil Pressure Switch Temperature Sender Rocker Shaft Pedestals C...