EDI TSG-416 Service Manual Download Page 205

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TSG

‐

416

Engine

Controls

‐

REMOVAL AND INSTALLATION

Camshaft Position (CMP) Sensor -
Replacement

1. Disconnect battery ground cable -- refer

to section 6.

2. Remove or disconnect any component

to allow access and removal of the CMP
Sensor.

3.  Disconnect CMP electrical connector.
4.  Remove bolt and CMP Sensor.
5.  Reverse procedure to install:



Use a new o-ring seal



Lubricate o-ring with clean
engine oil prior to installation



Tighten bolt to 7 Nm (62 lb-in).

Crankshaft Position (CKP) Sensor -
Removal

1. Disconnect battery ground cable -- refer

to section 6.

2. Remove or disconnect any component

to allow access and removal of the CKP
Sensor.

3. Disconnect CKP electrical connector.

4. Remove

plug.

Crankshaft Position (CKP) Sensor -
Installation

1. Position CKP sensor and loosely install

the bolt.

2. Adjust the CKP sensor with the

alignment tool and tighten 2 bolts.



Tighten to 7 Nm (62 lb-in).

3. Connect CKP sensor electrical

connector

Summary of Contents for TSG-416

Page 1: ...EDI 1020120 Revision 0 December 2012 TSG 416 1 6 LITER INDUSTRIAL ENGINE SERVICE MANUAL Powertrain Assemblies Components Provided By Ford Component Sales...

Page 2: ...EDI 1020120 Revision 0 December 2012...

Page 3: ...lication is up to date and correct in all respects the right to change prices specifications and equipment at any time without notice is reserved Accordingly this publication is not to be regarded as...

Page 4: ...ly dangerous The electric cooling fan used on some installations is actuated automatically when the coolant reaches a specified temperature For this reason care should be taken to ensure that the igni...

Page 5: ...il Consumption 01 15 Oil Pressure Test 01 16 Valve Train Analysis Static 01 17 Valve Train Analysis Dynamic 01 17 Camshaft Love Lift 01 18 Hydraulic Valve Lash Adjuster 01 19 General Service Procedure...

Page 6: ...sh Adjuster Inspection 01 30 Valve Stem Diameter 01 31 Valve Stem to Valve Guide Clearance 01 31 Valve Inspection 01 31 Valve Guide Inner Diameter 01 32 Valve Guide Reaming 01 32 Valve Spring Installe...

Page 7: ...ersonal safety nor equipment integrity are compromised by the choice of methods tools or parts Notes Cautions and Warnings As you read through the procedures you will come across NOTES CAUTIONS and WA...

Page 8: ...rained in their use and are adequately supervised NOTE Observe all manufacturers instructions when using charging equipment CAUTION Batteries should not be charged in the vehicle or equipment May dama...

Page 9: ...in the U S and overseas it is important that you have as complete identification of the engine as possible in order to provide the correct replacement parts Review the list in the back of this book fo...

Page 10: ...TSG 416 GENERAL INFORMATION 01 6 DIAGNOSIS AND TESTING Special Tools Special Service Tools called by the procedures can be obtained by calling 1 800 ROTUNDA 1 800 768 8632...

Page 11: ...ious signs of mechanical and electrical damage Engine coolant leaks Engine oil leaks Fuel leaks Damaged or severely worn pads Loose mounting bolts studs and nuts Symptom Chart 3 If the inspection reve...

Page 12: ...TSG 416 GENERAL INFORMATION 01 8...

Page 13: ...TSG 416 GENERAL INFORMATION 01 9...

Page 14: ...uorescent additive must first be added to crankcase 3 Run the engine for 15 minutes Stop the engine and inspect all seal and gasket areas for leaks using the 12 Volt Master UV diagnostic Inspection Ki...

Page 15: ...ngine front cover gasket crankshaft front seal crankshaft rear oil seal Leakage Points with Flywheel Removed NOTE Air leakage in the area around a crankshaft rear oil seal does not necessarily indicat...

Page 16: ...inder is within 75 percent of the highest reading Refer to the Compression Pressure Limit Chart If one or more cylinders reads low squirt approximately one tablespoon of clean engine oil meeting Ford...

Page 17: ...or tests for engine oil leaks and checks the valve stem seals for leakage 1 Plug all crankcase openings except the one used for connecting the leakage detector 2 Connect the Engine Cylinder Leak Detec...

Page 18: ...ING A small but regular downscale flicking can mean one or more valves are not seating 8 WORN VALVE GUIDES When the needle oscillates swings back and forth over about a 13 kPa 4 in Hg range at idle sp...

Page 19: ...handbook It is also important that the engine oil is changed at the intervals specified Refer to the Engine Operator s handbook Oil Consumption Test The following diagnostic procedure is used to dete...

Page 20: ...akage Detection on page 13 This can help determine the source of oil consumption such as valves piston rings or other areas NOTE After determining if worn parts should be replaced make sure correct re...

Page 21: ...Check for plugged oil metering orifice in cylinder head oil reservoir if equipped Static checks engine off are to be made on the engine prior to the dynamic procedure Valve Train Analysis Dynamic Sta...

Page 22: ...n switch in the OFF position Bump the crankshaft over until the indicator is measuring on the base circle of the camshaft lobe in its lowest position If checking during engine assembly turn the cranks...

Page 23: ...adjusters can be tested with Hydraulic lash adjuster Leak down Tester to check the leak down rate The leak down rate specification is the time in seconds for the plunger to move a specified distance...

Page 24: ...t can be refinished wear limits are provided as an aid to making a decision Any component that fails to meet specifications and cannot be refinished must be replaced Camshaft Journal Diameter Measure...

Page 25: ...lift 4 Rotate the camshaft and subtract the lowest dial indicator reading from the highest dial indicator reading to figure the camshaft lobe lift Camshaft Runout NOTE Camshaft journals must be withi...

Page 26: ...g journal diameters in at least two directions If it is out of specification replace as necessary Crankshaft Main Bearing Journal Taper Measure each of the crankshaft main bearing journal diameters in...

Page 27: ...surface NOTE Do not turn the crankshaft while doing this procedure 3 Install and remove the crankshaft main bearing cap 4 Verify the crankshaft journal clearance If it is out of specification replace...

Page 28: ...haft thrust washers or thrust bearing Crankshaft Runout NOTE Crankshaft main bearing journals must be within specifications before checking runout Use the Dial Indicator with Bracketry to measure the...

Page 29: ...an the pistons or possible damage can occur 1 Clean and inspect the ring lands skirts pin bosses and the tops of the pistons If wear marks or polishing is found on the piston skirt check for a bent or...

Page 30: ...nt color Red in the lower third of the size range Blue in the middle third of the size range Yellow in the upper third of the size range Piston Ring End Gap CAUTION Use care when fitting piston rings...

Page 31: ...Connecting Rod Journal Taper Measure the crankshaft rod journal diameters in two directions perpendicular to one another at each end of the connecting rod journal The difference in the measurements f...

Page 32: ...rections at the points shown Verify the diameter is within specifications Connecting Rod Bushing Diameter Measure the inner diameter of the connecting rod bushing Verify the diameter is within specifi...

Page 33: ...UTION The connecting rod bolts are torque to yield and must be discarded and replaced after this diagnostic test 1 Remove the connecting rod bearing cap 2 Position a piece of Plastigage across the 3 b...

Page 34: ...ication D Both edges worn journal damaged E One edge worn journal tapered or bearing not seated F Roller Follower Inspection Inspect the roller for flat spots or scoring If any damage is found inspect...

Page 35: ...ve Stem Clearance Tool contacts the upper surface of the valve guide 2 Move the Valve Stem Clearance Tool toward the Dial Indicator and zero the Dial Indicator Move the Valve Stem Clearance Tool away...

Page 36: ...de Valve Guide Reaming 1 Use a hand reaming kit to ream the valve guide 2 Reface the valve seat 3 Clean the sharp edges left by reaming Valve Spring Installed Length Measure the installed length of ea...

Page 37: ...at the specified valve spring length Valve and Seat Refacing Measurements NOTE After grinding valves or valve seats check valve clearance Check the valve seat and valve angles Valve Seat Width Measure...

Page 38: ...el ring gear runout Oil Pump Gear Radial Clearance Measure the clearance between the rotor and the pump housing Oil Pump Rotor Inspection Inspect the oil pump rotor tips for damage or wear Oil Pump Si...

Page 39: ...one with the Engine Cylinder Hone Set at a speed of 300 500 rpm and a hone grit of 180 220 to provide the desired cylinder bore surface finish Cylinder Bore Cleaning CAUTION If these procedures are no...

Page 40: ...C 50 F 4 Sand or grind the repaired area to blend with the general contour of the surface 5 Paint the surface to match the rest of the cylinder block Cylinder Block Core Plug Replacement 1 Use a slide...

Page 41: ...ed the flanged edge must be below the chamfered edge of the bore to effectively seal the bore Use a fabricated tool to seat the cup type cylinder block core plug Cylinder Block Core Plug Expansion Typ...

Page 42: ...cylinder head or spark plug life 1 Clean the spark plug seat and threads 2 Start the tap into the spark plug hole being careful to keep it properly aligned As the tap begins to cut new threads apply...

Page 43: ...hole 7 Turn the mandrel body approximately one half turn counterclockwise and remove Exhaust Manifold Straightness Place the Straightedge across the exhaust manifold flanges and check for warping with...

Page 44: ...TION 01 40 SPECIFICATIONS NOTE Ford engines are designed to perform with engine oils that are licensed by the American Petroleum Institute API and oils carrying the most current API Classification SJ...

Page 45: ...l 02 23 Crankshaft Rear Oil Seal Installation 02 23 Camshaft Follower Hydraulic Lash Adjuster Removal 02 24 Camshaft Follower Hydraulic Lash Adjuster Installation 02 24 Oil Pan Removal 02 25 Oil Pan I...

Page 46: ...Disassembly 02 37 Subassemblies Cylinder Block 02 44 Piston Disassembly 02 45 Piston Assembly 02 45 Cylinder Head Disassembly 02 46 Cylinder Head Assembly 02 47 Assembly 02 48 SPECIFICATIONS 02 58 No...

Page 47: ...TSG 416 ENGINE 02 3 GENERAL INFORMATION Special Tools...

Page 48: ...TSG 416 ENGINE 02 4 Special Tools...

Page 49: ...ols fuel air mixture along with spark timing depending on information received from various sensors Intake Manifold The intake manifold is made of aluminum It consists of two pieces Cylinder Head The...

Page 50: ...TSG 416 ENGINE 02 6 Component Location...

Page 51: ...TSG 416 ENGINE 02 7 Component Location...

Page 52: ...TSG 416 ENGINE 02 8 Component Location...

Page 53: ...TSG 416 ENGINE 02 9 Component Location...

Page 54: ...hey were removed 2 Remove DIS coil and set aside refer to Section 03 3 Remove bolts 4 Remove valve cover and gasket Valve Cover Installation 1 Contact surfaces must be clean and free of oil 2 Install...

Page 55: ...engaged and the chain tensioned in order to keep timing links aligned If chain is allowed to slacken or disengage with sprocket the oil pump will have to be removed and the timing chain realigned refe...

Page 56: ...bearings caps and bolts finger tight 4 Tighten bolts in the sequence shown in 3 steps to 6 7 lb ft 8 10 Nm 5 Install camshaft sprocket with chain onto camshaft while maintaining tension on the chain C...

Page 57: ...is returned to the same cylinder CAUTION The crankshaft may rotate when air pressure is applied Remove all objects from fan area such as lights extension cords etc 5 Turn on air supply and pressurize...

Page 58: ...or equivalent meeting Ford specification ESR M1C159 A to valve spring retainer key to hold in place during installation 3 With cylinder pressurized and using a suitable spring compressor tool install...

Page 59: ...il 4 Disconnect air intake tube 5 Remove bolts nuts and intake manifold assembly Intake Manifold Installation NOTE All contact surfaces must be clean and free from any old gasket material 1 Install a...

Page 60: ...et flange 3 Remove nuts exhaust manifold and gasket Exhaust Manifold Installation NOTE All contact surfaces must be clean and free from any old gasket material 1 Install a new gasket and exhaust manif...

Page 61: ...9 Remove oil level indicator tube bolt at cylinder head 10 Remove timing chain hydraulic tensioner 11 Rotate camshaft sprocket using tool 15 030A until the 2 copper links on timing chain are at 12 o c...

Page 62: ...18 CAUTION Be careful to avoid the bolts falling into the timing chain compartment 15 Remove 2 M8 bolts cylinder head and gasket 16 Carefully remove cylinder head and gasket while maintaining tension...

Page 63: ...chain is allowed to slacken or disengage with sprocket the oil pump will have to be removed and the timing chain realigned 2 Carefully install dowels a new gasket and cylinder head to the engine bloc...

Page 64: ...olts and nuts holding intake manifold to cylinder head Tighten to nuts and bolts to 13 lb ft 18 Nm 10 Install the coolant flow control module refer to Section 05 11 Install spark plugs and wires refer...

Page 65: ...pulley is pushed out of the oil pump prior to oil pump installation 1 Remove drive belt 2 Remove water pump refer to Section 05 3 Insert retaining clip BF9A 6606 AA between crankshaft pulley and oil p...

Page 66: ...outer bolts CAUTION Do not apply oil to shaft or seal Sealing lip along with all contact surfaces must be free of oil 2 Place oil pump and gasket onto crankshaft 3 Install pulley bolt and tighten to 9...

Page 67: ...t Rear Oil Seal Removal 1 Remove flywheel 2 Remove oil pan 3 Remove bolts and rear oil seal retainer Crankshaft Rear Oil Seal Installation 1 Install new rear seal and retainer using tool 21 046 2 Inst...

Page 68: ...follower over the lash adjuster 4 Lift out the hydraulic lash adjuster Camshaft Follower Hydraulic Lash Adjuster Installation NOTE All components must be kept clean and lubricated with clean engine oi...

Page 69: ...pan gasket and block must be free of oil Do not wait more than 5 minutes to install the oil pan gasket after sealer has been applied 1 Apply WSEM A4 sealer Loctite 5910 to the 4 positions as shown 2...

Page 70: ...2 Remove 4 nuts and1 bolt 3 Remove pick up tube 4 Remove oil deflector Pick up Tube Deflector Installation 1 Install oil deflector 2 Install pick up tube 3 Install 4 nuts and tighten to 14 lb ft 19 Nm...

Page 71: ...der block Crankshaft Main Bearings Installation NOTE All components must be clean and dried with compressed air or a lint free cloth Lubricate bearing to crankshaft contact surfaces with clean engine...

Page 72: ...ssembly up into bore 8 Remove upper bearing from connecting rod NOTE For bearing service refer to Section 01 Connecting Rod Bearings Installation NOTE Make sure bearing bore of connecting rod and cap...

Page 73: ...oth on the piston head to collect the cuttings 5 Remove any ridge and or deposits from the upper end of the cylinder bores using a ridge cutter Follow the instructions furnished by the tool manufactur...

Page 74: ...ton ring compressor and a hammer handle Avoid damage to the crankshaft bearing journals The arrow of the piston must point to the front of the engine The connecting rod has the cylinder number identif...

Page 75: ...lation 1 Install flywheel using special locking tool 21 168 2 Lubricate bolt threads with clean engine oil and tighten to 49 lb ft 67 Nm 3 Check flywheel runout at clutch disc surface maximum runout 0...

Page 76: ...ed links on the timing chain are still visible If not identify them as follows Turn engine until timing mark on camshaft sprocket is at 12 o clock Mark the two chain links left and right of that timin...

Page 77: ...the tensioner arm from the top of the engine Install bolts finger tight 2 Install crankshaft sprocket with key at 12 o clock position 3 Assemble drive chain through chain housing cavity from top of en...

Page 78: ...24 28 Nm 7 Using locking tool tighten camshaft sprocket bolt to 52 59 lb ft 70 80 Nm 8 Tighten hydraulic tensioner to 27 32 lb ft 36 44 Nm 9 Install valve cover Refer to Valve Cover Installation on pa...

Page 79: ...l 1 Remove bolt 2 Remove oil level indicator tube Oil Level Indicator Installation 1 Apply sealer WSK M2G 349 A4 Loctite 648 to lower end of oil level indicator tube 2 Install tube immediately into bo...

Page 80: ...1 Remove oil filter 2 Remove 3 bolts 3 Remove adapter and gasket Oil Filter and Adapter Installation 1 Install a new gasket 2 Lubricate oil seal on a new filter and install to adapter Tighten 1 1 2 t...

Page 81: ...ngine stand 2 Drain the engine oil NOTE Record drive belt routing and direction of travel for use during assembly 3 Loosen the tensioner pulley and remove the drive belt 4 Disconnect wiring at generat...

Page 82: ...the return connector NOTE Record routing of wiring harnesses and vacuum tubes so they may be returned to their original positions during assembly 9 Remove any vacuum hoses and wiring 10 Remove the coo...

Page 83: ...move the oil filter and support assembly 13 Remove oil pressure switch 14 Remove crankshaft position CKP sensor 15 Remove the flywheel and flywheel plate 16 Remove the valve cover assembly 17 Loosen t...

Page 84: ...ntamination 20 Remove bolts gasket and oil pan 21 Turn the engine over 180 22 Remove 4 nuts 1 bolt oil pick up tube and oil deflector 23 Insert retaining clip BF9A 6606 AA between crankshaft pulley an...

Page 85: ...ocket is at 12 o clock Mark the two chain links left and right of that timing mark Mark the single chain link that is positioned on the crankshaft sprocket timing mark 27 Remove the hydraulic tensione...

Page 86: ...M11 cylinder head bolts in 3 phases in the sequence shown 32 Remove 2 M8 bolts cylinder head and gasket 33 Remove crankshaft rear seal retainer NOTE Mark piston and cap so they may be returned to thei...

Page 87: ...urned to their original positions 35 Remove bolts caps and crankshaft lower main bearings in the sequence shown 36 Carefully remove the crankshaft and install it vertically on the flywheel to avoid wa...

Page 88: ...crankcase cylinder head camshaft crankshaft and bearings Refer to Section 01 Discard gaskets and O Rings and replace with new ones unless otherwise instructed Cylinder Block 1 Remove the core plugs if...

Page 89: ...sing a suitable piston ring expander 3 Remove piston pin Piston Assembly NOTE Apply a light coat of clean engine oil contact surfaces 1 Assemble piston to connecting rod 2 Install piston rings using a...

Page 90: ...aft bearing caps evenly in the sequence shown 2 Remove camshaft 3 Remove roller followers 4 Remove lash adjusters 5 Remove spark plugs 6 Remove all valve components using a suitable valve spring compr...

Page 91: ...21 024 optional T95P 6565A 4 Using a suitable spring compressor tool install valve springs retainers and locks 5 Check that spring installed height is 35 2 1mm 6 Install lash adjusters 7 Install rolle...

Page 92: ...pper bearings 3 Assemble the lower main bearings into caps Lubricate the wear surfaces and the bolt threads with clean engine oil NOTE The main bearing caps are numbered and must be assembled to corre...

Page 93: ...th clean engine oil 9 Install connecting rod caps with bearings lubricate wear surface and tighten bolts in 2 steps Step 1 9 lb ft 12 5 Nm Step 2 22 lb ft 30 Nm 10 Install a new rear seal and retainer...

Page 94: ...the engine Install bolts finger tight 17 Install crankshaft sprocket with key at 12 o clock position 18 Assemble drive chain through chain housing cavity from top of engine and onto crankshaft sprocke...

Page 95: ...haft sprocket bolt to 59 lb ft 70 80 Nm 23 Tighten hydraulic tensioner to 27 32 lb ft 36 44 Nm CAUTION The oil pump pulley and sealer are provided as an assembly kept together by a clip no BF9A 6606 A...

Page 96: ...Install pulley bolt and tighten to 92 lb ft 125 Nm 27 Remove clip 28 Install oil pump housing bolts finger tight CAUTION The oil pump housing must be positioned during tightening of the oil pump hous...

Page 97: ...12 Nm 35 Install oil deflector 36 Install oil pick up tube 37 Tighten nuts to 14 lb ft 19 Nm Tighten bolt to 7 lb ft 9 5 Nm 38 Apply WSEM A4 sealer Loctite 5910 to the 4 positions as shown CAUTION The...

Page 98: ...s in the sequence shown enough for gasket settlement 5 lb ft 7 Nm 7 lb ft 10 Nm 42 Install the oil pan drain plug Tighten to 18 lb ft 25 Nm 43 Install flywheel using special locking tool 21 168 44 Lub...

Page 99: ...7 lb ft 9 Nm 48 Apply grease WSD M13P8 A1 or equivalent to spark plug threads 49 Install spark plugs and tighten to 10 13 lb ft 13 17 Nm 50 Install oil filter support with new filter Tighten bolts to...

Page 100: ...ow control module and gasket Tighten bolts to 7 lb ft 10 Nm 55 Apply sealer WSK M2G 349 A4 Loctite 648 to lower end of oil level indicator tube Install immediately and tighten bolt to 15 lb ft 20 Nm 5...

Page 101: ...59 Pry tensioner pulley as shown and install drive belt 60 Install engine wiring and vacuum hoses 61 Fill engine with clean engine oil of the correct type and quantity NOTE Ford Power Products indust...

Page 102: ...YSTEM Max Oil Pressure Hot 2500RPM 40 60 psi Oil Type SAE 5W30 API classification SJ Service oil fill 4 2 Liter 4 4quarts including filter Oil Filter Type X56E 6714 D1A COOLING SYSTEM Thermostat Type...

Page 103: ...eral Information 03 2 Description 03 3 Operation 03 3 Wiring Diagram 03 4 Diagnosis and Testing Spark Plug Inspection 03 5 Removal and Installation Ignition Coil Replacement 03 6 Spark Plug Removal 03...

Page 104: ...hese inputs the GCP module computes spark strategy spark advance to obtain optimum engine performance for correct input conditions through the following outputs Ignition Coil pack Spark Plugs WARNING...

Page 105: ...crankshaft position and speed information comes to the GCP from the Crankshaft Position CKP Sensor mounted near the crankshaft pulley The CKP Sensor is triggered by teeth on a trigger wheel located on...

Page 106: ...TSG 416 IGNITION SYSTEM 03 4 Wiring Diagram...

Page 107: ...TSG 416 IGNITION SYSTEM 03 5 DIAGNOSIS AND TESTING Spark Plug Inspection Inspect the spark plug tip as in the chart below...

Page 108: ...mpound to the inside of coil Spark Plug Removal 1 Remove ignition coil Refer to Ignition Coil Replacement on page 6 of this section 2 Loosen spark plugs and remove any dirt or foreign material from sp...

Page 109: ...STEM 03 7 SPECIFICATIONS GENERAL SPECIFICATIONS Firing Order 1 3 4 2 Spark Plug Type 5G5E 12405 AA Gap 1 06 1 16 mm 0 042 0 046 in TORQUE SPECIFICATIONS Description Nm Lb ft Lb in Spark Plugs 15 11 13...

Page 110: ...mptom Chart 04 21 Fuel Pressure Check 04 21 Fuel Pump Check 04 21 Fuel Block Check 04 22 General Service Procedures 04 23 Spring Lock Coupling Type I Disconnect 04 23 Spring Lock Coupling Type I Conne...

Page 111: ...THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY WARNING THESE PROCEDURES INVOLVE FUEL HANDLING BE PREPARED FOR FUEL SPILLAGE AT ALL TIMES AND ALWAYS OBSERVE FUEL HANDLING PRECAUTIONS FAILURE TO FOLL...

Page 112: ...id which opens a valve to allow fuel delivery into the cylinder Camshaft Position CMP Sensor The Camshaft Position CMP Sensor is mounted in the camshaft cover This signal is sent to the GCP which uses...

Page 113: ...sure and also to relieve fuel pressure prior to component replacement The GCP controls the amount of fuel air delivery refer to the Electronic Engine Control section for further information Fuel Syste...

Page 114: ...TSG 416 FUEL SYSTEM 04 5 Wiring Diagrams Revision Level The following wiring schematics are taken from the wiring diagram listed below Fuel Injectors Actuat or Data Link...

Page 115: ...TSG 416 FUEL SYSTEM 04 6 Connector DLC...

Page 116: ...s circulated through the DEPR Operation The dry fuel vapor carburetor is a device by which fuel can be added to passing air flow The amount of fuel added is related to the amount of air passing throug...

Page 117: ...gulator the DEPR monitors and controls the vapor pressure to the mixer in reference to the inlet air pressure to the carburetor mixer The DEPR receives a pressure command from the GCP called Delta P w...

Page 118: ...TSG 416 FUEL SYSTEM 04 9 Wiring Diagrams Revision Level The following wiring schematics are taken from the wiring diagram labeled below Engine Controls Dry Fuel DEPR...

Page 119: ...rts but has rough idle Page 14 Engine idles with rough acceleration at load Page 14 Engine is unable to reach full power Page 14 Overall power loss Page 12 Engines misses Page 14 Backfire Page 16 Emis...

Page 120: ...ank to the fuel lock off valve Are there any leaks present 3 Inspect the Fuel system for any loose wires or hoses Yes No Repair or replace as necessary Go to step 4 Key OFF Check the fuel lockoff conn...

Page 121: ...fused for possible cause Go to step 5 Key OFF Disconnect lock off valve connector from harness Key ON Using a high impedance DVOM check for 12 volt supply at the harness connector Is the voltage less...

Page 122: ...ne Restrictions The vehicle specifications table specifies the fuel line to be a certain size If the fuel line from the tank to the fuel lock is not the proper size or any valves or fittings with flow...

Page 123: ...y Check wiring connectors and fuses for possible causes View page 9 of this section for wiring Go to step 4 Key OFF Disconnect DEPR electrical connector Key ON Check pins 3 and 6 for 12 volt supply in...

Page 124: ...s possible that a backfire may have caused the fuel valve to partially come off of its retainer and restrict fuel check the mixer fuel valves see section 475 1 for disassembly Fuel Line Restrictions T...

Page 125: ...pply voltage Yes No 12 volt DEPR circuit is open shorted to gnd or the GCP module is faulty Check wiring connectors and fuses for possible causes View page 9 of this section for wiring Go to step 4 Ke...

Page 126: ...to step 2 Remove air filter Start the engine and re check emission levels Has the rich emission failure been eliminated 2 Check the carburetor air valve for binding Yes No Replace the mixer Go to Ste...

Page 127: ...en shorted to ground or the GCP module is faulty Check wiring connectors and fuses for possible cause Go to step 3 Key Off Disconnect fuellock connector from harness Key On Using a high impedance DVOM...

Page 128: ...r is functioning properly Go to step 3 Engine OFF Install a pressure gauge on the Primary Pressure Test port Start and idle the engine Did you measure 3 5psi 3 Check the carburetor air valve for bindi...

Page 129: ...ing Yes No Replace the mixer May be electronic check that the CAM and crank sensor are not damaged and as well as all wiring Ensure all coils are firing Check if faults are present with the GCP diagno...

Page 130: ...Fuel Pressure Check WARNING REFER TO WARNINGS AT THE BEGINNING OF THIS SECTION 1 Connect to the GCP display 2 Put the key in the on position 3 On the faults page check the fuel pressure by cycling the...

Page 131: ...damage this component Replace if known fuel contamination Grounding out the fuel pump can cause the fuel pump to output 120psia If this is done and the GCP display does not read the higher pressure t...

Page 132: ...fuel tube clicks into place when installing the tube To make sure that the fuel tube is fully seated pull on the tube 2 Lubricate the o ring seals with clean engine oil 3 Install the quick connect cou...

Page 133: ...into place when installing the tube To make sure that the fuel tube is fully seated pull on the tube 2 Lubricate the o ring seals with clean engine oil 3 Release the locking tab and install the quick...

Page 134: ...le 2 Remove and or disconnect components to allow access and removal of the fuel rail injectors Label if necessary to allow for correct reinstallation CAUTION After disconnecting fuel lines plug the e...

Page 135: ...stallation 1 Inspect gasket and install a new one if necessary 2 Position actuator onto studs 3 Install nuts Tighten to 8 ft lb 4 Reconnect electrical connectors 5 Reconnect accelerator cable 6 Reconn...

Page 136: ...not damaged Tighten to 6 6lb ft 3 Mount the mixer to the mixer adapter using the four short M6x1 0 bolts Ensure the gasket on the mixer is not damaged Tighten to 6 6 lb ft 4 Mount the DEPR to the mixe...

Page 137: ...Operational Check 05 7 General Service Procedures Draining the Cooling System 05 8 Flushing the Cooling System 05 8 Filling the Cooling System 05 8 Removal and Installation Drive Belt Removal 05 9 Dri...

Page 138: ...ircumstances should the engine be started without liquid in the cooling system This may cause permanent damage to the engine CAUTION The use of straight water as a coolant will cause permanent damage...

Page 139: ...s hot It also replenishes coolant back to the system as it cools The degas bottle allows air separation during operation which reduces engine hot spots The coolant pump circulates the coolant through...

Page 140: ...ution an excellent leak detector If this type of solution is not being used in the cooling system a vegetable dye may be added to aid in locating external leakage Coolant Inspection WARNING REFER TO C...

Page 141: ...o 50 of the rib height is also not a concern except it can result in excessive noise If heavy deposits are apparent resulting in noise and belt instability install a new belt Drive belt squeal that is...

Page 142: ...check for cracked intake manifold blown head gaskets warped head or block gasket surfaces cracked cylinder head or engine block Engine Overheats Low coolant level Loose fan belt Pressure cap Radiator...

Page 143: ...radiator cap to the pressure tester using an adapter NOTE If the plunger of the pressure tester is depressed too fast an incorrect pressure reading will result 3 Slowly pump the pressure tester until...

Page 144: ...thod Various types of flushing equipment are available Follow manufacturer s operating instructions Filling the Cooling System WARNING REFER TO CAUTIONS AND WARNINGS AT THE BEGINNING OF THIS SECTION C...

Page 145: ...s Refer to Visual Inspection of this section Drive Belt Installation 1 Route belt correctly and tighten the tensioner onto belt 2 Run engine for a minute and then turn off 3 Recheck belt routing and g...

Page 146: ...er outlet connection Radiator Hose Installation 1 Position the clamps at least 1 8 inch from each end of the hose 2 Coat the connection areas with an approved water resistant sealer and slide the hose...

Page 147: ...has lowered in temperature to below 110 F 2 Drain the radiator so coolant level is below the thermostat Refer to Draining the Cooling System of this section 3 Remove or disconnect components as necess...

Page 148: ...ction 2 Remove or disconnect components as necessary to gain access to the coolant pump 3 Remove the drive belt Refer to Drive Belt Installation of this section 4 Remove 3 bolts and coolant pump pulle...

Page 149: ...r to Draining the Cooling System of this section 2 Remove or disconnect components as necessary to gain access to the outlet pipe 3 Disconnect hoses from outlet pipe 4 Disconnect electrical connector...

Page 150: ...Drain the cooling system Refer to Draining the Cooling System of this section 2 Remove or disconnect components as necessary to gain access to the bypass hose 3 Disconnect the coolant bypass hose fro...

Page 151: ...ressure Test 138 kPa 20 psi Thermostat start to open temperature 82 C 180 F Thermostat full open temperature 97 C 205 F Coolant Specification WSS M97B51 A1 Motorcraft Premium Gold Engine Coolant TORQU...

Page 152: ...06 6 Battery Drain Test 06 7 Battery Load Test 06 7 Generator Output Test 06 8 Generator Voltage Test 06 8 General Service Procedures Battery Cleaning and Inspection 06 9 Battery Tools 06 9 Battery C...

Page 153: ...IER OR WITH YOUR HANDS ON OPPOSITE CORNERS EXCESSIVE PRESSURE ON THE END WALLS COULD CAUSE ACID TO SPEW THROUGH THE VENT CAPS RESULTING IN PERSONAL INJURY WARNING IT IS ESSENTIAL THAT THE WIRING CONNE...

Page 154: ...g out or reducing temporary high voltages within the electrical system Operation With the ignition on voltage is applied to the voltage regulator This turns the regulator on allowing current to flow f...

Page 155: ...TSG 416 CHARGING SYSTEM 06 4 Wiring Diagram Revision Level The following wiring schematics are taken from the wiring diagram labeled below Charging System...

Page 156: ...voltage OCV of 12 4 volts Batteries with an OCV of 12 volts or less are either completely discharged or have a dead cell Check the generator drive belt tension This will cause low generator output Che...

Page 157: ...tion to generator voltage regulator or battery Loose fuse or poor connection in A circuit Loose brush holder screw Voltage regulator Generator Repair as necessary Battery over charging battery voltage...

Page 158: ...and post The meter should have a 10 amp capability NOTE If after this next step the meter settings need to be switched or the test leads need to be moved to another jack the jumper wire must be reins...

Page 159: ...the charging system NOTE Turn off all lamps and accessories 1 Switch the tester to ammeter function 2 Connect the positive and negative leads of the tester to the battery 3 Connect current probe to ge...

Page 160: ...attery terminal With the jaws gripping the underside of the cable clamp pull the clamp up by means of pressure exerted against the top of the battery terminal Proper use of this tool avoids the damagi...

Page 161: ...n some cases may not accept charge at the normal charger setting When batteries are in this condition charging can be started by use of the dead battery switch on chargers so equipped To determine whe...

Page 162: ...lts and position the generator aside 5 Disconnect electrical connector 6 Remove generator 7 Reverse procedure to install Tighten generator bolts to 25 Nm 18 lb ft Tighten B terminal to 8 Nm 71 lb in V...

Page 163: ...GING SYSTEM 06 12 Generator Pulley Replacement 1 Remove generator assembly Refer to Generator Replacement of this section 2 Remove nut 3 Remove pulley 4 Reverse procedure to install Tighten nut to 109...

Page 164: ...lateral or twisting forces Such forces could cause major damage to the internal components of the battery and leakage at the terminals 1 Remove battery cables from battery terminals battery ground cab...

Page 165: ...600 RPM 2 72 1 drive ratio Battery Motorcraft 12 volt 750 CCA Battery charging voltage 13 15 5 volts TORQUE SPECIFICATIONS Description Nm Lb ft Lb in Generator Mounting bolts 25 18 Regulator attachme...

Page 166: ...Limp Home Mode Strategy 08 25 Intermittent MIL 08 26 Malfunction indicator light MIL DTC Retrieval procedure 08 27 Diagnosis and using a personal computer 08 27 Visual Inspection 08 36 Intermittent p...

Page 167: ...duces a reliable transition when switching fuels Certified closed loop dry fuel control Configurable inputs available based on customer requirements Configurable outputs available based on ECT RPM or...

Page 168: ...protect the user and engine from hazards such as over speed over temperature over voltage low oil pressure unauthorized tampering over cranking starter motor The GCP controls the following Fuel meter...

Page 169: ...mber of degrees after top dead center on the power stroke The Camshaft Position CMP Sensor sends a CMP signal to the GCP The GCP uses this signal as a sync pulse to trigger the injectors in the proper...

Page 170: ...CP and measures the voltage The signal voltage will be high when the engine is cold and low when the engine is hot By measuring the voltage the GCP calculates the engine coolant temperature Engine coo...

Page 171: ...amber mixture The 4 wire HO2S indicates whether the air fuel ratio is rich or lean with respect to stoichiometry The signal from this sensor contains valid air fuel ratio information only when the sen...

Page 172: ...tuator The Throttle Position TP Sensor is a dual track rotary potentiometer that uses a variable resistive element which is packaged inside a plastic housing The resistive element varies linearly and...

Page 173: ...xygen is in the exhaust gas The GCP changes the air fuel ratio to the engine by controlling the amount of time that the fuel injector is ON The best mixture to minimize exhaust emissions is 14 7 parts...

Page 174: ...ogether This pressure differential is based on the vacuum in the intake manifold of the engine which is directly related to load DEPR Direct Electronic Pressure Regulator The DEPR controls the fuel tr...

Page 175: ...ss maintenance Remote mounting capability No mechanical load on the engine Elimination of mechanical timing adjustments Increased available ignition coil saturation time The coil on plug design has in...

Page 176: ...its unless instructed to do so When measuring voltages use only a digital voltmeter with an input impedance of at least 10 megohms Do not employ any non standard practices such as charging the battery...

Page 177: ...TSG 416 Engine Controls 08 12 Diagrams and Schematics Symbols...

Page 178: ...TSG 416 Engine Controls 08 13 GCP Power Distribution Box Part of 5210070 Engine Wiring Harness...

Page 179: ...TSG 416 Engine Controls 08 14 Wire Colors Revision Level The following wiring schematics are taken from the wiring diagram labeled below...

Page 180: ...TSG 416 Engine Controls 08 15 Power Distribution...

Page 181: ...TSG 416 Engine Controls 08 16 Ignition System...

Page 182: ...TSG 416 Engine Controls 08 17 Starting System...

Page 183: ...TSG 416 Engine Controls 08 18 Charging System...

Page 184: ...TSG 416 Engine Controls 08 19 Engine Controls Sensors 1 of 2...

Page 185: ...TSG 416 Engine Controls 08 20 Engine Controls Sensors 2 of 2...

Page 186: ...TSG 416 Engine Controls 08 21 Fuel Injectors...

Page 187: ...TSG 416 Engine Controls 08 22 Engine Controls Actuator Data Link Connector DLC...

Page 188: ...TSG 416 Engine Controls 08 23 Engine Controls Dry Fuel DEPR...

Page 189: ...stem located in this section Diagnostic Trouble Codes can be cleared from memory with a laptop computer or by turning the ignition key to the OFF position and removing the FORD system main power fuse...

Page 190: ...oltage DTC 2115 FPP1 higher than IVS limit DTC 2139 FPP1 lower than IVS limit DTC 2116 FPP2 higher than IVS limit DTC 2140 FPP2 lower than IVS limit DTC 2126 FPP1 higher than FPP2 DTC 2121 FPP1 lower...

Page 191: ...after replacement refer to MIL circuit test procedure Once MIL bulb illumination has been verified or established DTCs can be extracted from the MIL as follows DTC Extraction KOEO short the STI circu...

Page 192: ...TSG 416 Engine Controls 08 27 Interface Hook Up For a connection to a laptop use the below ECOM cable 5080050 ECOM Cable Software CD...

Page 193: ...ill display the contents of the CD as shown Double click GCP_Display folder Double click the PC_Display folder Double click the GCP_Display icon You will now see a welcome screen Click next A screen w...

Page 194: ...boot your system The software is now installed on your system in a folder called GCP Display Refer now to Using Technicians GCP Software in this Section Using GCP Software Menu Functions You can begin...

Page 195: ...ng useful information If the fault occurred during the current key cycle If the fault caused current engine shutdown How many key cycles since the fault was active Snapshot Data explained later Flight...

Page 196: ...ading Sensor Actuator Values Most applicable sensor and actuator values are displayed on the Gauges Screen The display shows the voltage the FORD system GCP is reading and for sensors the sensor value...

Page 197: ...the desired time interval and sample interval for the plot by stopping the plot and typing in a new intervals The plot can be saved to the PC by stopping the plot and clicking File then SAVE When savi...

Page 198: ...is running above 1000 RPM the spark output will stay disabled for 5 seconds and then reset This test mode has a timeout of 10 seconds Record the rpm drop related to each spark output disabled The Spar...

Page 199: ...f the foot pedal as a percentage FPP volts display the voltage that the GCP is reading from the FPP sensor TPS Command displays the commanded throttle position expressed as a percentage which is being...

Page 200: ...aw If no evidence of a problem is found after visual inspection has been performed proceed to Diagnostic System Check Intermittent Problems NOTE An intermittent problem may or may not turn on the MIL...

Page 201: ...e Engine Cranks But No Start Faulty OEM Drivers Safety Shut Off Seat Switch Coil Power Loss GCP Ground Loss GCP Power Loss Severe Vacuum Leak Dry Fuel Air Inlet Restriction Air Inlet Leak Dry Fuel Fue...

Page 202: ...iming Compression Loss Hesitation Stumble Low Fuel Pressure Spark Plugs Fouled MAP Sensor Vacuum Signal Loss Surge Low Fuel Pressure Map Sensor Failure Application or Ancillary System Momentarily Bind...

Page 203: ...m Concerns Trapped Air Worn Drive Belt Worn Water Pump Stuck Thermostat Plugged Radiator Internal External Dry Fuel System Running Rich Exhaust System Concerns visible smoke Black Smoke Blue Smoke Ign...

Page 204: ...nction Indicator Lamp MIL the following sequence will be flashed 123 will flash 3 times to indicate the beginning of the flash code display sequence Any active DTC s will flash 3 times each 123 will f...

Page 205: ...l Lubricate o ring with clean engine oil prior to installation Tighten bolt to 7 Nm 62 lb in Crankshaft Position CKP Sensor Removal 1 Disconnect battery ground cable refer to section 6 2 Remove or dis...

Page 206: ...lean engine oil Torque 30 Nm Installation 1 To install reverse the removal procedure Heated Oxygen Sensor HO2S Replacement 2 Disconnect battery ground cable refer to section 6 3 Remove or disconnect a...

Page 207: ...t be installed 4 Remove bolt and KS sensor and discard sensor 5 Reverse procedure to install Install a new KS sensor Tighten bolt to 20 Nm 15 lb ft Temperature Manifold Absolute Pressure TMAP Sensor R...

Page 208: ...onnect battery ground cable refer to section 6 2 Disconnect the connector from the throttle 3 Remove the bolts from the throttle to the intake manifold 4 NOTE The gasket is to be reused unless damaged...

Page 209: ...on 09 2 Nomenclature for Bolts 09 2 Bolt Strength Identification 09 3 Hex Nut Strength Identification 09 3 Other Types of Parts 09 4 English Metric conversion 09 5 Decimal and Metric Equivalents 09 6...

Page 210: ...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 to ensure that the proper re...

Page 211: ...ing number of slashes represent increasing strength Metric System Metric mm bolts Identification class numbers correspond to bolt strength increasing numbers represent increasing strength Common metri...

Page 212: ...ES OF 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 identificatio...

Page 213: ...TSG 416 METRICS 09 5 ENGLISH METRIC CONVERSION...

Page 214: ...TSG 416 METRICS 09 6 DECIMAL AND METRIC EQUIVALENTS TORQUE CONVERSION...

Page 215: ...MINOLOGY LIST Certain Ford Component names have been changed in this Service Manual to conform to Society of Automotive Engineers SAE directive J1930 SAE J1930 standardizes automotive component names...

Page 216: ...TSG 416 METRICS 09 8...

Page 217: ...TSG 416 METRICS 09 9...

Page 218: ...TSG 416 METRICS 09 10...

Page 219: ...TSG 416 METRICS 09 11...

Page 220: ...TSG 416 METRICS 09 12...

Page 221: ...TSG 416 METRICS 09 13...

Page 222: ...TSG 416 METRICS 09 14...

Page 223: ...GREAT BRITAIN Hendy Power School Lane Chandlers Ford Industrial Estate Eastleigh Hampshire SO53 4DG England 44 2380 579 800 44 2380 271 471 Power Torque Engineering Herald Way Binly Conventry Warwich...

Page 224: ...DELAWARE Engine Distributors Inc 400 University Court Blackwood NJ 08012 1 800 220 2700 FLORIDA Engine Distributors Inc 259 Ellis Rd South Jacksonville FL 32254 1 800 220 2700 Engine Distributors Inc...

Page 225: ...erson Industrial Engines Co 5532 Center Street Ohmaha NE 68106 402 558 8700 NEVADA Southwest Power Products 5143 W Roosevelt Phoenix AX 85043 602 269 3581 NEW HAMPSHIRE Engine Distributors Inc 41 Pope...

Page 226: ...sboro AR 72401 1 800 562 8049 TEXAS M G Bryan 1906 S Great S W Parkway Grand Prairie TX 75051 972 623 4300 UTAH Perkins Pacific 6100 S 6th Way Ridgefield WA 98642 877 877 3311 WASHINGTON Perkins Pacif...

Page 227: ...IA Simson Maxwell 1605 Kebet Way Port C BC Canada V3C 5W9 1 800 374 6766 Simson Maxwell 12 4131 Mostar Road Nanaimo BC Canada V9T 5P8 1 800 374 6766 Simson Maxwell 1846 Quinn Street Prince George BC C...

Page 228: ...1 856 228 7298 1 856 228 5657 fax parts service 1 856 228 5531 fax sales EDI Worldwide Service Engine Distributors Inc 400 University Court Blackwood NJ 08012 Service Warranty 1 800 220 2700...

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