Ford LRG-423 Service Manual Download

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Summary of Contents for LRG-423

Page 1: ... a LRG 423 Power 2 3LITRE Products INDUSTRIAL ENGINE Worldwide TM SERVICE MANUAL ...

Page 2: ......

Page 3: ...tion 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 TM SOUTHFIELD MICHIGAN 48034 The descriptions and specifications contained in this manual were in effect at the time the book was released for printing Power Products Division GRI reserves the right to...

Page 4: ...nd Play 13 Timing Belt 2 3L 14 Camshaft Timing and Cylinder Identification CID Timing Check 14 Crankshaft End Play 15 Connecting Rod Side Clearance 15 Cylinder Block 15 Cleaning and Inspection 15 Cylinder Block Distortion 15 Cylinder Head Deck Flatness 15 Main Bearing Bore Alignment 15 Cylinder Walls Refinishing 16 Cleaning 16 SUBJECT PAGE SERVICE PROCEDURES Cont d Inspection 16 Cylinder Bore 16 C...

Page 5: ...d Flatness 28 Valve Seat Runout 28 Valve Stem to Valve Guide Clearance 28 Valves Select Fitting 29 Valve Guides Reaming 29 Valve Seats Refacing 29 Valves Inspection 30 Valves Refacing 30 Valve Spring Tension 31 Valve Spring Squareness 31 Camshaft Follower 2 3L 31 Cleaning 31 Inspection 31 Intake Manifold 31 Cleaning 31 Inspection 31 Exhaust Manifold 32 Cleaning 32 Inspection 32 SPECIFICATIONS 32 S...

Page 6: ...THE POSSIBILITY OF PERSONAL INJURY OR DAMAGE DO NOT OPERATETHE ENGINE UNTILTHE FAN BLADE 8600 HAS FIRST BEEN EXAMINED FOR POSSIBLE CRACKS OR SEPARATION CAUTION Use of abrasive grinding discs to remove gasket material from the engine sealing surfaces during repair procedures can contribute to engine damage and wear Airborne debris and abrasive grit from the grinding disc may enter the engine throug...

Page 7: ...PLACE valve and or valve seat contact l Damaged cylinder head gasket l REPLACE cylinder head gasket l Malfunctioning or damaged fuel l REFER to section on Fuel System system l Malfunctioning or damaged ignition l REFER to section on Ignition system System l Damaged hydraulic valve tappet l REPLACE hydraulic valve tappet l Damaged hydraulic valve tappet l REPLACE cylinder block bore l Burnt or stic...

Page 8: ...nce or REPLACE valve guide stem l Malfunctioning or damaged cooling l REFER to section on Cooling system System l Malfunctioning or damaged fuel l REFER to section on Fuel System system l Leaking exhaust system l SERVICE exhaust leakage l Improper drive belt tension l REFER to section on Access ry Drivebelts l Malfunctioning generator bearing l REFER to section on Chargi g System l Loose timing be...

Page 9: ...d fluorescent additive must be added to crankcase first 3 Run engine for 15 minutes Stop engine and inspect all seal and gasket areas for leaks using Rotunda Oil Leak Detector Y 112 R0021 part of 112 R0030 Kit Lamp or equivalent A clear bright yellow or orange area will identify leak For extremely small leaks several hours may be required for the leak to appear 4 If necessary pressurize main oil g...

Page 10: ...rrect viscosity and at proper level and battery 10655 is properly charged Operate the engine until it is at normal operating temperature Turn off ignition switch 11572 then remove all spark plugs 12405 Set throttle plates in wide open position Install a compression gauge such as Rotunda Compression Tester 059 R0009 or equivalent in No 1 cylinder Install an auxiliary starter switch in starting circ...

Page 11: ...inder listen for the hiss of escaping air A leak by the intake valve 6507 will be audible in the carburetor A leak by the exhaust valve 6505 can be heard at the exhaust pipe Leakage past the rings will be audible at the positive crankcase ventilation PCV connection If air is passing through a blown gasket to an adjacent cylinder the noise will be evident at the spark plug hole of the cylinder into...

Page 12: ... drops to 0 kPa 0 in Hg Upon deceleration needle runs slightly above 74 kPa 22 in Hg STICKING VALVE S When the needle dotted remains steady at a normal vacuum but occasionally flicks sharp fast movement down and back about 13 kPa 4 in Hg one or more valves may be sticking BURNED OR WARPED VALVES A regular evenly spaced downscale flicking of the needle indicates one or more burned or warped valves ...

Page 13: ...ted KEEP THE OIL IN THIS RANGE Al 7629 E 5 Perform engine oil consumption test as follows a Drain engine oil Remove and replace oil filter Using 0 95 liter 1 U S quart less than recommended refill crankcase with recommended quality of oil b Run the engine for three minutes 10 minutes if cold then turn engine off Allow oil to drain into the oil pan for an additional five minutes engine should be le...

Page 14: ...ver and tube 6622 l Excessive main bearing clearance 0 Excessive connecting rod bearing clearance ValveTrain Analysis Static Engine Off Rocker Arm Camshaft Follower Cover Removed NOTE Static Valve Train Analysis with the engine off is to be performed before Dynamic Valve Train Analysis which is performed with engine running NOTE Remove valve cover 6582 as outlined in this section Check for damaged...

Page 15: ...tion switch with the borescope in the spark plug hole or Intake Valve Deposit Rating System attempt to view the valve while rotating the engine Damage to the borescope or engine may result Use a remote starter switch to bump the engine over until the intake valve 6507 is fully open in the cylinder to be inspected 6 CAUTION Do not power the borescope light source from a vehicle battery 10655 while ...

Page 16: ...e down cam lift and repeat for the rest of the cam lobes If any lobe s lift is below the minimum lift specified in Section 02 replace the camshaft Hydraulic Valve Tappet Lash Adjuster The hydraulic lash adjusters used in the overhead cam 2 3L engine are zero lash hydraulic devices similar in construction and operation to the hydraulic valve tappets 6500 used on push rod engines They are cleaned in...

Page 17: ...indicated when the two timing marks are aligned 4 If the triangle timing mark cannot be properly aligned set the timing mark of the crankshaft damper assemblv on TC of the outer timing the two timing marks are aligned cover Remove the crankshaft damper assembly a The timing mark on the crankshaft damper and outer timing cover as outlined in Section 02 0 C VIEW IN CIRCLE A NOTE B TO PAN RAIL VIEW I...

Page 18: ...olvent Make sure all oil and dirt is cleaned from the cylinder block Make sure all oil passageways are clean A rifle cleaning brush is useful for this purpose Use a long thin screwdriver to scrape the bottom of the water jackets through the openings in the top deck to make sure all scale and deposits are removed Most engines have a dead spot at the back of the block where the coolant makes a U tur...

Page 19: ...erosene and 75 percent light engine oil Wipe the bore dry and immediately apply a coating of zinc oxide dissolved in wood alcohol Do not use rubbing alcohol as a substitute If cracks are present the coating will become discolored at the damaged area Replace the cylinder block if it is cracked Magnafluxing may also be used Check for cylinder wall glazing When refinished the cylinder bore is given a...

Page 20: ...ore clearance found in Specifications in Section 02 PISTON 6108 PISTON TO CYLINDER 1 f CLEARANCE Al 4479 B Cylinder Wall Honing Hone the cylinder bore l When reinstalling a piston with new rings l To resize a cylinder to accept a service parts piston going into it 1 Measure the diameter of the piston on the thrust side at right angles to the piston pin 254mm 1 OOinch below the oil ring groove 2 Me...

Page 21: ...f this plug is located at the base of the flange with the flange flaring inward CAUTION It is imperative to push or drive the plug into the machined bore using a properly designed tool Under no circumstances is the plug to be driven using a tool that contacts the crowned portion of the plug This method will expand the plug prior to installation and may damage the plug and or plug bore When install...

Page 22: ...ecting Rod Bearing A Fatigue Failure Craters or Pockets B Improper Seating Bright Polished Sections c Dirt Scratching lmbedding D Overlay Wiped Out Lack of Oil or Improper Clearance E Hourglass Overlay Gone from Edges F Radius Ride G Overlay Gone from Mating Edge One Side Only Rod Cap Shift Crankshaft Main or Connecting Rod Bearings Fitting Plastigage Method 1 Clean crankshaft journals Inspect jou...

Page 23: ...hten cap bolts to specifications found in the specifications section 8 Repeat procedure for remaining bearings that require replacement Bore Gauge Method 1 2 3 4 5 6 7 8 Install bearings in the cylinder block 6010 and bearing caps Install crankshaft and tighten main bearings cap bolts to the specified torque as outlined in Section 02 Remove bearing caps and crankshaft Reinstall bearing caps with b...

Page 24: ...ithout connecting rods pistons or flywheel 6375 installed to check end play Crankshaft Main Journals and Connecting Rod Journals Inspect the main journal and crankpin journal diameters Measure the diameter of each journal at two different points in the directions as shown JOURNAL Al 4474 A Refer to Section 02 for crankshaft journal specifications Journals Refinishing NOTE Polish direction is clock...

Page 25: ...p and a new Service Parts piston select fitted to the refurbished bore 2 Hone the cylinder if necessary to restore a proper crosshatch pattern so new rings can seat Remove as little of the cylinder wall as possible 3 After any necessary honing of the cylinder bore check that the piston to bore clearance is to specification If the clearance is too great measure the cylinder bore diameter to determi...

Page 26: ... Attempting to wind them on by hand may put a deep scratch in the piston or break the ring Using a piston ring expander install the piston rings starting with the oil control rings Make sure rings are installed right side up Refer to instructions with the ring set 9 Rotate the rings so the end gaps are NOT lined up but are spaced properly as shown FRONT A281 1 C 10 Using a feeler gauge recheck pis...

Page 27: ...iston pin 6135 or a tapered connecting rod crankshaft pin Twisted connecting rods can create an identifiable piston skirt wear pattern but badly twisted rods will disturb the action of the entire piston rings and connecting rod assembly and may be the cause of excessive oil consumption Check the connecting rods for bend or twist on a suitable alignment fixture Follow the instructions of the fixtur...

Page 28: ...4 Slowly rotate camshaft to determine overall runout If runout exceeds 0 03mm 0 0012 in replace camshaft n DIAL INDICATOR Al 4453 B Cam Lobe Lift Camshaft Removed There are two ways of measuring cam lobe lift with the camshaft bearing 6261 removed with a vernier caliper camshaft bearing or on a lathe or cam grinder with a dial indicator The second method is more accurate With Calipers 1 Inspect ca...

Page 29: ...heck the leakdown rate The leakdown rate specification is the time in seconds for the plunger to move a specified distance of its travel while under a 22 7 kg 50 lb load Test the valve tappets as follows Remove lash adjusters or tappets 1 NOTE Do not mix parts from different valve tappets 6500 Parts are select fitted and are not interchangeable NOTE Tappets cannot be checked with engine oil in the...

Page 30: ...perfections of this type can be dressed down using an oil stone Replace the cylinder head if it is cracked The following inspection procedures are for a cylinder head that is to be completely overhauled For individual repair operations use only the pertinent inspection procedure Spark Plug Thread Service NOTE The use of power or air driven tools is not approved for the installation of tapersets Da...

Page 31: ...cylinder head gasket surface k 1 Al5267 A Valve Seat Runout Check the valve seat runout with Valve Seat Runout Gauge D81 P 6002 E or equivalent as illustrated below Follow the instructions of the gauge manufacturer If the runout exceeds the wear limit reface the valve and valve seat For specifications refer to Section 02 VALVE SEAT RUNOUT GAUGE 08 1P 6002 E A72754 Valve Stem to Valve Guide Clearan...

Page 32: ...all standard size valve stem oil seal When replacing a standard size valve with an oversize valve always use the reamer in sequence smallest oversize first and then next smallest etc so as not to overload the reamers Always reface the valve seat after the valve guide has been reamed and use a suitable scraper to break the sharp corner inside diameter at the top of the valve guide NOTE The interfer...

Page 33: ...f the blue is transferred to the top edge of the valve face lower the valve seat If the blue is transferred to the bottom edge of the valve face raise the valve seat Valves Inspection The critical inspection points and tolerances of the valve are illustrated below Inspect the valve stem for bends and the end of the stem for grooves or scoring Inspect the valve face and the edge of the valve head f...

Page 34: ...g Squareness Check each valve spring for squareness using a steel square and a flat surface Stand the valve spring and square on end of the flat surface Slide the valve spring up to the square Revolve the valve spring slowly and observe the space between the top coil of the valve spring and the square Refer to the illustration below I I I I h I I CHECK CLOSED COIL END DOWNWARD A851 7 A Refer to Sp...

Page 35: ...d outlet sealing surfaces of the exhaust manifold Inspection Inspect the cylinder head joining flanges of the exhaust manifold for evidence of exhaust gas leaks Inspect the exhaust manifold for cracks damaged gasket surfaces or other damage that would make it unfit for further service A warped or cracked exhaust manifold must be replaced ...

Page 36: ... 0 076mm 0 003 in Variation EFEzs 0 076mm 0 003 in Maximum Allowable Cylinder Bore Taper 0 127mm 0 005 in Maximum Allowable Cylinder Bore Out of Round 0 127mm 0 005 in GENERAL ENGINE SPECIFICATIONS Cont d Item Dimension Measuring Point for Piston Diameter Below Oil Ring Groove 25 4mm 1 OOin IMaximum Allowable Crankshaft Runout I0 05mm 0 002 in 1 Maximum Piston Clearance 1 0 076mm 0 003 in I IMaxim...

Page 37: ... Seat Runout Gauge 1 D81 L 6002 B 1 Plastigage 1 D87C 77000 A I Transmission Test Adapter 1 TOOL 6500 E 1 Hydraulic Tappet Leakdown Tester I 1 TOOL 6505 E 1 Valve Stem Clearance Tool 1 TOOL 651 3 DD I Valve Clutch Spring Tester ROTUNDA EQUIPMENT Model Description 1 112 R0030 I Oil Leak Detector Kit 1 059 R0009 I Compression Tester I 014 00705 I Pressurization Kit I 1059 00008 I Vacuum Pressure Tes...

Page 38: ...mshaft Timing Belt Outer Cover I6 Installation 16 Camshaft Timing Belt Inner Cover I7 Removal 17 Installation 17 CamshaftTiming Belt I8 Removal I 8 Installation 20 Camshaft and Oil Pump Sprocket 21 Removal 2 I Installation 22 Crankshaft Sprocket 22 Removal 2 2 Installation 22 2 3L ENGINE SERVICE Cont d Timing BeltTensioner 22 Removal 2 2 Installation 22 Camshaft 2 3 Removal 2 3 Installation 25 Cam...

Page 39: ...gs 53 Removal 5 3 Installation 53 DISASSEMBLY AND ASSEMBLY Subassemblies 55 Cylinder Head 55 Disassembly 55 Assembly 57 DISASSEMBLY AND ASSEMBLY Cont d Piston and Piston Pins 60 Disassembly 60 Assembly 6 0 Cylinder Block Assembly 60 Disassembly 60 Assembly 60 Hydraulic Lash Adjuster 61 Disassembly and Assembly 61 Cylinder Block Bare 61 Disassembly 61 Assembly 61 Adjustments 61 Valve Clearance Hydr...

Page 40: ... rod engine The cylinder head has drilled oil passages to provide engine oil pressure to the lash adjusters NOTE A set of metric wrenches is required to service the 2 3L engine 2 3L Engine PPDA23920 A Item Part Number Description 5246 10153 8501 12450 9424 Exhaust Pipe Generator Mounting Bracket also mounts ignition coil Water Pump Governor Intake Manifold 19510 Carburetor WARNING TO AVOID THE POS...

Page 41: ... an integral pulse wheel which provides timing information to the crankshaft position sensor 6C315 mounted in the engine front cover 6019 PULSE WHEEL PART CRANKSHAFT PULLEY CRANKSHAFT DAMPER FACE DOWN 6312 GAP IN TEETH PROVIDES POSITION REFERENCE FOR NUMBER ONE PISTON A239960A Camshaft The camshaft 6251 operates the engine valves and l Is located in the cylinder head 6049 l Is supported by four be...

Page 42: ...ion and aid in oil cooling Oil Pan The oil pump is a rotor type with an inner rotor which turns inside of an off center outer ring The oil pump is located in the front of the cylinder block and is driven by the timing belt through a sprocket identical to the camshaft sprocket 6256 Oil Pump Location Outer Timing Belt Cover Timing Belt and Oil Pump Sprocket Removed INNER TIMING BELT COVER CYLINDER B...

Page 43: ...02 6 Engine Service 2 3L 02 6 DESCRIPTION AND OPERATION Continued Lubrication System 4 w fT SECTION B SECTION A L SECTION A 0 35 A239234 ...

Page 44: ...ck Part of 6010 15 Rear Drain Back Part of 6010 16 Head Supply Passageway Part of 6010 17 6714 Oil Filter 18 6049 Cylinder Head Item Part Number 19 20 6250 21 6049 22 6010 23 24 25 87071 SlOO 26 87072 SIOO 27 28 6205 29 6303 30 31 32 33 34 6700 35 36 Description Camshaft Lobe to Cam Follower Passage Part of 6250 Camshaft Cylinder Head Cylinder Block Oil Inlet Part of 6010 Gerotor Set Part of 6621 ...

Page 45: ... a linkage system The governor through the linkage limits carburetor throttle plate opening This provides regulation and control of engine rpm during operating engine loads The governor is attached to a bracket bolted to the lower left front of the engine block and is slotted for belt adjustment A single V type belt and pulley are used to operate the governor Electronic Governor The electronic gov...

Page 46: ...02 9 Engine Service 2 3L 02 9 2 3L ENGINE SERVICE 2 3L OHC Engine Components Top 0 B 0 15 0 B PPDA24000 A ...

Page 47: ...S Bolt M12 1 75 x 45 34 6278 Camshaft Sprocket Washer 35 6256 Camshaft Sprocket 36 6700 Crankshaft Front Seal 37 6250 Camshaft Item Part Number Description 38 8594 Water Outlet Connection 39 N800025SlOO M8 1 25 x 18 40 8575 Water Thermostat 41 8255 Thermostat Gasket 42 6507 Intake Valve 43 6505 Exhaust Valve 44 6049 Cylinder Head 45 9278 Engine Oil Pressure Sender 46 6A222 Camshaft Retaining Plate...

Page 48: ...02 I 1 Engine Service 2 3L 02 l 1 2 3L ENGINE SERVICE Continued 2 3L OHC Engine Components Bottom PPDA24001 A ...

Page 49: ... Cat Part of 6010 44 Rear Main Bearing Cap Part of 6010 45 6333 Crankshaft Main Bearing Upper No 1 Color Code Blue tern Part Number Description 46 6333 Crankshaft Main Bearing Upper 3 Places 47 6337 Crankshaft Thrust Main Bearing 48 87338S8 Pipe Plug 318 18 49 N605890 S2 Bolt M6 1 x 14 50 6A630 Cylinder Block Ventilation Baffle 51 N60589242 Bolt M6 1 x 20 52 6C315 Crankshaft Position Sensor 53 N80...

Page 50: ...n place on cylinder head 3 Install valve cover Alternately tighten bolts to 9 13 Nom 84 120 lb in 4 Snap ignition wiring harness and ignition cables back into place in brackets attached to valve cover 5 If removed install oil filler cap 6 Start engine and check for leaks A239299A Item i B Part Number 6766 N805087 S2 6582 6049 6584 Description Oil Filler Cap Screw M6 1 xl 5 Valve Cover Cylinder Hea...

Page 51: ...d and serviced Refer to the engine service section Removal 1 2 3 4 5 6 7 8 Remove the valve cover 6582 as outlined in this section Rotate the camshaft 6250 so the roller finger follower for the valve to be serviced is on the heel of the cam Using Valve Spring Compressor T95T 6565 A compress and hold down the valve spring Slide out the roller finger follower over the lash adjuster Replace spark plu...

Page 52: ...oper cylinder Release air pressure and remove air adapter Install spark plug in proper cylinder Grease contact surfaces of roller finger follower with Ford Multi Purpose Grease DOAZ 19584 AA or equivalent meeting Ford specification ESR Ml Cl 59 A Using Valve Spring Compressor T95T 6565 A compress and hold down the valve and spring Slide the roller finger follower into place over valve and lash adj...

Page 53: ...aining screw and tighten to 8 12 Nom 70 106 lb in 3 Install water pump pulley and fan snug bolts but do not tighten 4 Install drive belt 5 Using flex handle rotate drive belt tensioner position drive belt and rest tensioner pulley on belt 6 Tighten four clutch and pulley to water pump bolts to 18 22 Nom 13 I 6 lb ft Item Part Number Description 1 6EOll Outer Timing Belt Cover Assembly 2 8594 Water...

Page 54: ...of engine and stud 2 Install nut and bolt and tighten to 8 12 Nom 72 l 08 lb in 3 Tighten stud to 20 30 Nom 15 22 lb ft 4 Install oil pump sprocket as outlined in this section 5 Install timing belt tensioner as outlined in this section Tighten M8 bolt to 22 27 Nom 16 20 lb ft and Ml0 bolts 3 to 40 55 Nom 29 40 lb ft 6 Install timing belt as outlined in this section FRONT OF ENGINE A23960 A Item Pa...

Page 55: ...tempt to relieve tension on belt Loosen timing belt spring pivot bolt Do not remove 5 Hold tensioner with Camshaft Belt Tension Adjusting Tool T74P 6254 A A239349A Item 1 6256 2 6L273 3 T74P 6254 A 4 6268 5 6K254 6 6256 7 N800112 s100 6K282 Part Number L 6 While holding tensioner loosen adjusting bolt and gradually release spring tension 7 Using adjusting tool rotate tensioner against spring press...

Page 56: ...et Camshaft Cylinder Head Bolt M8 1 25 x 20 Timing Belt Tensioner Bolt Timing Belt Tensioner Spring Belt Tensioner Assembly Stud Part of 6049 Crankshaft Crankshaft Sprocket Oil Pump 15 16 17 18 19 20 A B C Part Number 6E005 6256 N600313 S2 Description Inner Timing Belt Cover Oil Pump Sprocket Washer Part of N600313 S2 Bolt MlO 1 5 x 40 Recess Part of 6306 Crankshaft Keyway Tighten to 70 95 Nom 51 ...

Page 57: ... Align triangle on camshaft sprocket with triangle on inner timing belt cover Timing Mark Alignment Item 1 2 3 4 5 6 7 8 9 IO Part Number 6256 N801658 S 6K282 6K254 6256 6303 6306 Description Camshaft Sprocket Pointer Triangle Part of Camshaft Sprocket Pointer Triangle on Inner Timing Belt Cover Stud M8 x 1 25 Spring Pivot Bolt Stud Part of 6K254 Timing Belt Tensioner Oil Pump Sprocket Crankshaft ...

Page 58: ...sioner assembly against belt with torque wrench up to 40 45 Nom 29 33 lb ft and tighten adjusting bolt Tighten adjusting bolt to 35 45 Nom 26 33 lb ft Tighten spring pivot bolt to 40 55 Nom 29 40 lb ft Install outer timing belt cover as outlined in this section Camshaft and Oil Pump Sprocket NOTE Removal and installation steps are the same for both camshaft and oil pump 6600 sprockets SPECIAL SERV...

Page 59: ...A Camshaft Belt Tensioner Tool T74P 6256 B Removal 1 Remove outer timing belt cover as outlined in this section 2 Remove timing belt as outlined in this section 3 NOTE Belt tensioner assembly is under spring tension Hold tensioner by prying against spring pressure with Belt Tensioner Adjusting Tool T74P 6254 A Remove adjustment bolt which goes through slot in base of tensioner 4 Release pressure 5...

Page 60: ...ressor T95T 6565 A Cam Sprocket Holding Removing Tool T74P 6256 B Front Seals Replacer T74P 6150 A Front Cover Seal Remover T74P 6700 B Remove outer timing belt cover as outlined in this section Remove valve cover 6582 as outlined in this section Rotate the camshaft 6250 so the rocker arm 6564 is on the heel of its cam Using Valve Spring Compressor T95T 6565 A compress valve springs 6513 and remov...

Page 61: ... Description 6700 Camshaft Front Seal 6250 Camshaft 6049 Cylinder Head 6261 Camshaft Bearing 6505 Exhaust Valve 6529 Roller Finger Follower 6507 Intake Valve I I Item Part Number Description 8 N604465 S 9 6A222 10 T74P 6150 A A Pan Head Screw M6 1 x 16 Camshaft Retaining Plate Cam and Auxiliary Shaft Seal Replacer Tighten to 8 12 Nom 72 108 Lb In ...

Page 62: ...haft and Oil Pump Oil Seal NOTE The camshaft and oil pump shaft seals are each replaced in the same manner with the same tools after the respective sprocket has been removed NOTE Always use a new attaching bolt when replacing the camshaft sprocket or use Teflon or equivalent sealing tape on the threads of the old bolt SPECIAL SERVICE TOOL S REQUIRED Description Tool Number Cam Sprocket Holding Rem...

Page 63: ... 6303 5 Slide crankshaft sprocket off of crankshaft 6 Remove key from crankshaft 7 NOTE When positioning Front Cover Seal Remover T74P 6700 B make sure jaws are gripping the thin edge of the seal tightly before operating the jack screw portion of the tool Install Front Cover Seal Remover T74P 6700 B making sure jaws are gripping the thin edge of the seal 8 Remove seal 9 Clean journal of debris Ins...

Page 64: ... section 17 18 19 20 21 22 23 24 25 26 27 Remove timing belt tensioner adjuster bolt spring pivot bolt timing belt tensioner spring and tensioner Remove front engine lifting eye 17A084 Remove retaining bolts and intake manifold Remove rear engine lifting eye Remove the eight exhaust manifold 9430 retaining bolts and studs 6 bolts 2 studs Remove cylinder head retaining bolts 10 Remove the cylinder ...

Page 65: ...Sequence According to Procedure in Text 4 Install valve cover and valve cover gasket 6584 Tighten retaining bolts to 9 13 Nom 80 U 5 lb in A23929 A Item Part Number 6766 6582 6049 6584 Description Oil Filler Cap Screw M6 1 x 15 Valve Cover Cylinder Head Valve Cover Gasket Tighten Until Ratchet Click Is Heard or Felt Tighten to 9 13 Nom 80 l 15 Lb In 5 Install intake manifold and gasket Tighten ret...

Page 66: ...fold retaining bolts and or stud bolts Tighten the bolts in sequence in two steps 20 30 Nom 15 22 lb ft then 48 68 Nom 35 50 Ib ft PPDA23950 P I I Item Part Number Description 1 6049 Cylinder Head 2 N802209 SlOO Bolt MIO 1 5 x 55 7 Places 3 17A084 Engine Lifting Eye Rear 4 N620482 S2 Nut Ml O l 5 5 N802884 SIOO Stud MlO 1 5 x MIO 1 5 x 84 I I Item Part Number Description Exhaust Manifold Exhaust M...

Page 67: ... tube to generator bracket bolts to 9 12 Nom 84 108 lb in 14 Install lower radiator hose 15 Install generator Tighten generator to bracket bolts to 40 55 Nom 29 40 lb ft 16 Connect upper radiator hose and heater water hose and tighten hose clamps 8287 19 Using flex handle rotate drive belt tensioner position drive belt and rest tensioner pulley on drive belt 20 Tighten four fan and pulley to water...

Page 68: ...m Part Number Description 8290 N606676 S2 87056 SIOO 10153 8501 Water Pump Inlet Tube Screw and Washer Assembly M6 1 x 22 5 O Ring Generator Mounting Bracket Water Pump Tighten to 9 l 2 Nom 84 l 08 Lb In 8 Remove water pump 8501 retaining bolts and remove water pump 9 Clean water pump gasket surface of cylinder block ...

Page 69: ...nstall water pump inlet tube in water pump Tighten water inlet tube to generator bracket bolts to 9 12 Nom 84 108 lb in Install lower radiator hose to water pump Install heater water hose to the water pump inlet tube Install water pump pulley and fan and tighten bolts finger tight Using half inch drive handle rotate drive belt tensioner and install drive belt Tighten fan and water pump pulley bolt...

Page 70: ...0 Start engine and check for leaks Intake Manifold Removal NOTE If removing the intake manifold 9424 for access to other components only the carburetor 9510 may remain attached 1 2 3 4 6 7 8 9 10 11 12 13 14 Disconnect the battery ground cable 14301 Remove the air cleaner 9600 assembly Drain the coolant M97B18 from the radiator to a level lower than the intake manifold Loosen the heater hose clamp...

Page 71: ...fold bolt stud threads 3 Install a new intake manifold gasket 9439 CYLINDER HEAD ASSEMBLY 6049 8 4 1 5 I B FRONT OF ENGINE V6293 B 6 Install the PCV valve into the oil separator Install the vacuum line from the ignition control module 4 Position the intake manifold to the cylinder head Install four manifold upper retaining bolts studs 7 Connect the governor throttle control rod if used finger tigh...

Page 72: ...r base gasket 9447 from the intake manifold 9424 NOTE If the carburetor is not being serviced and is going to be placed back on the intake manifold do not turn the carburetor upside down This may cause any float bowl sediment to restrict or clog carburetor passages or prevent the inlet needle and seat assembly from closing The carburetor s operation may be affected Installation 1 Clean and inspect...

Page 73: ... ENGINE PPDOOOl Part Number Description 1 9A520 2 N800896 S2 3 N620041 S51 4 9510 Fuel Inlet Fitting Stud M8x1 25x1 25 38 2 places Nut M8x1 25 2 places Carburetor Part Number Description 5 9447 6 9424 A Carburetor Base Gasket Intake Manifold Tighten to 20 30 Nom 15 22 Ib ft ...

Page 74: ...nifold fasteners must be tightened in two stages Tighten fasteners to 20 30 Nom 15 22 lb ft during the first stage 5 Retighten fasteners to 60 80 Nom 44 59 lb ft during the second stage 6 Position rear engine lifting eye on studs and install retaining nuts and tighten to 20 30 Nom 15 22 lb ft Install exhaust pipe and bracket PPDA23950 A Item l Part Description Part Number Item Number Description 6...

Page 75: ... 6010 and ear on oil pump 6620 as shown to loosen oil pump 7 Remove oil pump and oil pump to cylinder block gasket 6659 8 Clean surfaces of oil pump and cylinder block OIL PUMP CYLINDER BLOCK EAR ON 6600 6010 OIL PUMP 1 r LONG SCREWDRIVER PPDA23956 A Installation NOTE Inspect and clean oil pump hole in the cylinder block before installing the oil pump 1 If original oil pump is to be reused install...

Page 76: ...oes Toward Cylinder Block Crankshaft Rear Oil Seal SPECIAL SERVICE TOOL S REQUIRED Description I Tool Number I Jet Plug Remover Rear Main Seal Replacer T77L 9533 B T82L 670 1 A Removal 1 NOTE Clean exterior surface of crankshaft rear oil seal 6701 and cylinder block 6010 before removing crankshaft rear oil seal 6701 Using a sharp awl punch one hole into the seal metal surface between the seal lip ...

Page 77: ...per parts usage Installation of the wrong part will result in an inoperative oil pressure indicating system and a damaged sender unit or gauge 1 Make sure the ignition switch is turned off 2 Disconnect the wire at the sender terminal 3 Remove the oil pressure sender 9278 from the cylinder head 6049 4 Apply Pipe Sealant with Teflon D8AZ 19554 A or equivalent meeting Ford specification WSK M2G350 A2...

Page 78: ...kshaft damper bolt 13 Remove four bolts engine front cover and gasket 4 Remove crankshaft damper 5 Remove crankshaft sprocket 6306 6 Remove oil pump sprocket bolt Using Cam Sprocket Holding Removing Tool T74P 6256 B remove oil pump sprocket 7 Remove stud screw nut and timing belt tensioner 8 Remove two screws and water pump inlet tube 8290 9 Remove one screw and crankshaft position sensor 6C351 IO...

Page 79: ...ls Replacer T74P 6150 A and press into place using vibration damper bolt Remove bolt and tool Install a new oil pan gasket and the oil pan as outlined in this section Install inner timing belt cover Tighten inner timing belt cover bolts to 8 12 Nom 72 l 08 lb in Install crankshaft position sensor 6C315 and tighten bolt to 8 12 Nom 72 l 08 lb in Part Number 6303 6010 Description Dowel Bushing Part ...

Page 80: ...22 5 O Ring 12 Install crankshaft sprocket crankshaft damper washer and bolt Tighten bolt to 125 l 65 Nom 92 l 21 lb ft 13 Install oil pump sprocket and tighten bolt to 40 55 Nom 29 40 lb ft 14 Align sprockets and install timing belt as outlined in this section I I Item Part Number Description 4 10153 5 8501 A Generator Mounting Bracke Water Pump Tighten to 9 l 2 Nom 84 l 08 Lb In 15 Install outer...

Page 81: ... and oil pan gasket surfaces OIL PAN GASKET 6675 FRONT OF VEHICLE A239514 Installation 1 Apply Silicone Gasket and Sealant Fl AZ l 9562 A or equivalent meeting Ford specification WSE M4G320 A2 in six places at joints between engine front cover 6019 and the cylinder block and rear main bearing cap and engine block as shown 2 Install a new oil pan gasket to the oil pan and position the oil pan to th...

Page 82: ...e of Rear Main Cap Is Hidden 3 install and tighten the oil pan retaining bolts to 14 l 6 Nom 132 144 lb in Oil Pump Screen Cover and Tube Removal 1 Remove oil pan 6675 as outlined in this section 2 Remove nut two screws oil pump screen cover and tube 6622 and oil pump inlet tube gasket 6626 Installation 1 Thoroughly clean oil pump screen cover and tube 2 Clean all mounting surfaces 3 Install oil p...

Page 83: ...elt Tensioner Tool and remove adjusting bolt Relax tensioner spring Remove timing belt Install T74P 6256 B Cam Sprocket Holding Removing Tool on oil pump sprocket Remove oil pump sprocket bolt and washer Install puller part of T74P 6256 B Cam Sprocket Holding Removing Tool Remove oil pump sprocket Slide crankshaft sprocket 6306 off crankshaft 6303 Remove inner timing belt cover Remove oil pan scre...

Page 84: ...etighten to 102 115 Nom 75 85 lb ft Rear Main Bearing Cap Sealing 10 Check crankshaft end play as outlined in Section 01 11 Attach piston and rod assemblies to crankshaft For each assembly a Put a piece of hose or other protector over connecting rod bolts 6214 to protect the crankshaft journal b Place the crankshaft journal for the piston being installed at the bottom of its stroke by rotating the...

Page 85: ...one Gasket and Sealant Fl AZ l 9562 A or equivalent meeting Ford specification WSE M4G320 A2 at joints between front engine cover and cylinder block and rear main cap and cylinder block as shown Oil Pan 1952 A Item Part Number N806378 S36 6675 6730 N806379 S36 19562 6010 6019 Description Bolt M6 1 x 27 5 16 Places Oil Pan Oil Pan Drain Plug M8 Bolt M6 1 x 57 5 Silicone Gasket and Sealant Cylinder ...

Page 86: ...asher finger tight 23 Prime oil pump 24 Install Cam Sprocket Holding Removing Tool T74P 6256 B on sprocket Tighten bolt to 40 55 Nom 29 40 lb ft Remove tool 25 install and adjust timing belt as outlined in this section 26 Install crankshaft position sensor 6C351 and tighten bolt to 8 12 Nom 72 108 lb in 27 Install outer timing belt cover Snap tabs into slot Install screw and tighten to 8 12 Nom 72...

Page 87: ...0026 inch for bearings 2 5 Rear Main Bearing Cap Area Sealing 9 If clearance is OK lubricate bearings with Super Premium Motor Oil X0 5W30 QSP or equivalent meeting Ford specification ESE M2C153 E and reinstall cap 10 Apply a 7mm 0 27 inch dot of Silicone Gasket and Sealant Fl AZ l 9562 A or equivalent meeting Ford specification WSE M4G320 A2 on each side of cylinder block as shown in illustration...

Page 88: ...as outlined in this section CAUTION Never cut into the ring travel area in excess of 0 8mm l 32 inch when removing ridges Remove any ridges and or deposits from the upper end of the cylinder bores as follows Turn the crankshaft until the piston to be removed is at the bottom of its travel and place a cloth on the piston head to collect the cuttings Remove any ridge and or deposits from the upper e...

Page 89: ...spaced properly as shown FRONT A281 1 c 6 Check the ring side clearance as outlined in the engine service section Side clearance for both compression rings should be 0 041 0 084mm 0 016 0 0033 inch and snug fit for the oil control rrng 7 Put a piece of hose or other protector over connecting rod bolt 6214 to protect crankshaft journal 8 Rotate crankshaft 6303 so journal for piston 6108 to be insta...

Page 90: ...en cover and tube 6622 as outlined in this section Rotate crankshaft 6303 until connecting rod and bearing being serviced is placed at the bottom of its stroke Remove two connecting rod nuts Remove connecting rod cap Push piston and connecting rod assembly up into bore Remove bearing insert from connecting rod Remove bearing insert from connecting rod cap Inspect connecting rod bearings 6211 as ou...

Page 91: ...G M2C153 E 9 Install connecting rod cap IO Hand start connecting rod nuts 6212 until nuts are flush with ends of connecting rod bolts 11 Alternately tighten connecting rod nuts to 34 41 Nom 2530 lb ft Then alternately tighten again to a final torque of 41 49 Nom 30 36 lb ft 12 Install oil pump screen cover and tube as outlined in this section 13 Install oil pan as outlined in this section 14 Insta...

Page 92: ...49 as outlined in this section 2 Remove the deposits from the combustion chambers with scraper and wire brush 3 Mount cylinder head on bench fixture Cylinder Head Assembly 4 5 6 7 8 9 IO 11 Rotate the camshaft 6250 so the cam follower to be removed is on the heel of its cam Using Valve Spring Compressor T95T 6565 A compress and hold down the valve spring 6513 Slide out the cam follower over the la...

Page 93: ...It is not necessary to remove sprocket from camshaft unless camshaft or sprocket is to be serviced Install Cam Sprocket Holding Removing Tool T74P 6256 B on sprocket Using tool to hold sprocket remove bolt and washer 13 Install threaded puller insert in Cam Sprocket Holding Removing Tool T74P 6256 B and remove sprocket 14 Remove tool from sprocket 15 NOTE When positioning Front Cover Seal Remover ...

Page 94: ...250 A REMOVAL A21 11O A Assembly 1 Clean and inspect cylinder head cam followers valve springs and valves as outlined in the Section 01 2 CAUTION Failure to use the correct expanding collet can cause severe bearing damage NOTE The camshaft bearings are available pre finished to size and require no reaming for standard and 0 08mm 0 003 inch undersize journal diameters NOTE Make sure to align oil ho...

Page 95: ...ront Seal 2 6250 Camshaft 3 6049 Cylinder Head 4 6261 Camshaft Bearing 5 6505 Exhaust Valve 6 6564 Rocker Arm Description Item 7 6507 8 N604465 5 9 6613 10 T74P 6150 A A Part Number Description Intake Valve Pan Head Screw M6 1 x 16 Auxiliary Shaft Retaining Plate Cam and Auxiliary Shaft Seal Replacer Tighten to 8 12 Nom 72 l 08 Lb In ...

Page 96: ......

Page 97: ...ress and Piston Pin Removing and Installing Set T68P 6135 A NOTCH POINTING TOWARD FRONT OF ENGINE NUMBER ON LEFT SIDE OF ROD A24339 A 2 Install the piston rings using a suitable piston ring expander Check the end gap of all piston rings They must be within specifications of 0 203 0 406mm 0 008 0 016 inch for top ring 0 33 0 50mm 0 013 0 019 inch for second ring and 0 254 0 762mm 0 01 O 0 030 inch ...

Page 98: ...n 3 Remove oil gallery pipe plugs 4 NOTE A rifle cleaning brush is helpful for cleaning engine oil galleries Clean cylinder block and inspect as outlined in the engine service section Assembly 1 If using new or reconditioned cylinder block uncrate and clean preservative materials according to the supplier s instructions 2 Position the new cylinder block in a work stand and install all serviceable ...

Page 99: ...haft timing can be checked without removal of the cover or any other parts NOTE Camshaft and timing belt sprockets turn one revolution for every two revolutions of the crankshaft NOTE If the timing belt has greater than 3 000 hours or five years of use replace it Refer to the service procedures in this section 1 2 Remove the rubber access cap in front of the camshaft sprocket from the outer timing...

Page 100: ...IEW B VIEW A PPDA24014 A I I Item Part Number Description 1 2 Triangle Mark on Camshaft Sprocket Part of 6256 Triangle Mark on Inner Timing Belt Cover Part of 6019 I I Item Part Number Description 3 4 A TDC Mark on Outer Timing Belt Cover Part of 6019 Mark Line on Crankshaft Pulley Part of 6316 Check Timing According to Text ...

Page 101: ... loosening spring pivot bolt will break Crankshaft Belt Tension Adjusting Tool T74P 6254 A when relieving tension on the belt If belt timing or tension is incorrect loosen timing belt spring pivot bolt Hold tensioner with Camshaft Belt Tension Adjusting Tool T74P 6254 A While holding tensioner loosen adjusting bolt and gradually release spring tension PPDA23934 A Item Part Number Description 1 625...

Page 102: ...6K282 Timing Belt Tensioner Bolt 6L273 Timing Belt Tensioner Spring 6K254 Belt Tensioner Assembly N808049 SIOZ Stud Part of 6049 6303 Crankshaft 6306 Crankshaft Sprocket Item 14 15 16 17 18 19 A B C Part Number 6600 6019 6256 6278 N600313 S2 Description Oil Pump Inner Timing Belt Cover Oil Pump Sprocket Camshaft Sprocket Washer Bolt MIO 1 5 x 40 Recess Part of 6306 Tighten to 70 95 Nom 52 70 Lb Ft...

Page 103: ...gn triangle on camshaft sprocket with triangle on inner timing belt cover c Tighten adjusting bolt to hold tensioner in released position Timing Mark Alignment G C VIEW IN CIRCLEA 1 NOTE OF KEYWAY MUST BE 90 TO PAN RAIL VIEW IN CIRCLE B PPDA21101 B Item Part Number 6256 N808049 S102 6K282 6K254 6303 6306 N806700 S Description Item Camshaft Sprocket Pointer Triangle Part of Camshaft Sprocket Pointe...

Page 104: ...elt may jump a cog putting camshaft out of time Rotate crankshaft two revolutions clockwise Bring crankshaft slowly without stopping to number one cylinder firing position keyway directly up 18 Recheck timing mark alignment Repeat the above steps if timing marks are no longer properly aligned 19 Rotate tensioner assembly against bolt with torque wrench up to 40 45 Nom 29 33 lb ft and tighten adjus...

Page 105: ... Closed 57 63 1 56 Free Length Approximate 2 02 Assembled Height 1 54 1 58 Service Limit 5 Pressure Loss Specified Length Out of Square Service Limit 5 64 0 078 Rocker Arm Cam Follower Ratio I 86 l Item I Specification I Valve Tappet Lifter or Adjuster Diameter Standard Clearance to Bore Service Limit Hydraulic Leak Down Rate 1 Collapsed Tappet Gap Allowable I Desired 0 8422 0 8427 0 0007 0 0027 0...

Page 106: ...Diameter 2 1720 2 1728 In Out of Round Limit 0 0004 In Taper Limit 0 0004 In Length Center to Center 5 4558 5 4591 Alignment Bore to Bore Max Difference 4 Twist 0 003 Bend 0 0015 Side Clearance Assembled to Crank Standard 0 0035 0 0115 Service Limit 0 014 PISTON AND RINGS SPECIFICATIONS Item Service Piston Diameter 5 Specification 95 968 95 993mm 3 7783 3 7792 In Piston to Bore Clearance Select Fi...

Page 107: ...Cover to M 6 I I 9 13 Cylinder Head I 84 120 Lb In I Spark Plug to Cylinder M 14 Head I I TORQUE SPECIFICATIONS SPECIAL APPLICATIONS Cont d Torque Item Size Nom Lb Ft Engine Coolant 11 24 8 18 Temperature Sending Unit to Block Crankshaft Position M6 8 12 6 9 Sensor Bolt Water Jacket Drain Plug 16 24 12 18 to Block Water Pump to Block Bolt M 8 20 30 15 22 Oil Pump Bolt M 6 10 14 88 124 Lb In Water ...

Page 108: ... Nom 50 60 lb ft l Step 2 102 1 15 Nom 75 85 lb ft 15 l 2 turn after gasket contacts surface oil gasket 16 Then rotate to position 17 If a Service piston is to be installed it will be necessary to select fit the new piston to the bore Honing of the cylinder bore will probably be necessary in order to accomplish the proper fit Engine Operating Speeds Low idle speed 700 800 rpm l Maximum engine oper...

Page 109: ...oner Tool t Holding Removing T74P 6306 A Crankshaft Sprocket Remover Valve Stem Seal Installer Rear Main Seal Replacer Valve Stem Seal Replacer SPECIAL SERVICETOOLS DESIRED r Tool Number I Description I 1 D81 L 6500 A 1 Blind Hole Puller 1 D79L 6731 B I Oil Filter Wrench 4201 G I Dial Indicator I 1 TOOL 4201 C I Dial Indicator with Bracketry I ROTUNDA EQUIPMENT Model Description 1 021 00045 I Belt...

Page 110: ... DISTRIBUTORLESS IGNITION SYSTEM ADJUSTMENTS AND SPECIFICATIONS Ignition Adjustments 17 Spark Plugs 17 Ignition Timing 17 Ignition Specifications 17 Ignition Special Service Tools Equipment 17 FUEL SYSTEM DESCRIPTION AND OPERATION Carburetor Identification 18 Electric Fuel Pump 18 FUEL SYSTEM DIAGNOSING AND TESTING Electrical 19 Fuel Supply and Pressure 19 FUEL PUMP SERVICE AND MAINTENANCE 20 FUEL...

Page 111: ...M DESCRIPTION AND OPERATION 65 COOLING SYSTEM DIAGNOSING ANDTESTING Diagnosis 66 General Test Procedures 66 Visual Inspection 66 Cooling System Pressure Test 66 Radiator Cap Pressure Test 67 Thermostat Test Thermostat Removed 66 COOLING SYSTEM REMOVAL AND INSTALLATION Cooling Fan 69 Removal 69 Installation 69 Fan Drive Belt 69 Removal 69 Installation 69 Radiator Hose 69 Removal 69 Installation 69 ...

Page 112: ...park advance to obtain optimum engine performance for correct input conditions Operation With this system the electronic control module monitors the engine load speed and operating temperature and decides what degree of spark advance is correct for all of the operating conditions Because timing is set for life inherently in the design of the engine and there are no moving parts in the ignition sys...

Page 113: ...m line connects the transducer to the engine intake manifold The engine vacuum is proportional to its load Engine Temperature The Engine Coolant Temperature Sensor ECTS sends engine temperature information to the UESC The ECTS is located above the thermostat at the front of the engine Fuel Octane Level Adjustment In the event that the engine is operated on dry fuels such as natural gas compressed ...

Page 114: ... For example a non generator set engine operating on gasoline with no load and neither pins 6 or 7 grounded will show a spark advance of approximately 9 degrees BTDC at low idle and 34 degrees BTDC at a high no load idle of 2500 RPM Let us say that the non generator set engine is now switched over to operate on natural gas As the chart indicates a level 3 advance should be used for natural gas A l...

Page 115: ...lectrical troubleshooting on conventional starting and charging systems l 12 volt timing light Rotunda 059 00006 This timing light uses an inductive pickup for convenience and safety on 12 volt systems This timing light includes a tachometer which reads from zero to 3000 RPM Diagnosing If the DIS Engine Harness checks are not to the chart specifications complete the following l Remove the wire har...

Page 116: ... to 9 Ohm 2 Continuity Engine Spark Advance Circuit 7 to 9 Ohm 2 Infinity Open Level 2 Advance 6 6 to 9 Ohm 2 Continuity Engine Spark Advance Circuit 7 to 9 Ohm 2 Continuity Level 3 Advance 7 8 to 9 20 VDC 3 12 VDC UESC Power Supply Circuit 8 11 to 12 Ohm 0 5 I 3 Coil Primary Circuit 1 ECTS brass only portion in 32 F ice water For the complete range of ECTS values see the following page 2 Details ...

Page 117: ...istance Ohms 5 30 22 496 051 20 4 209 816 I 10 I 14 1 160 313 I I 0 I 32 r 95 851 I I 10 I 50 I 58 987 I I 20 1 68 1 37 340 I I 30 I 86 I 24 253 I I 40 I 104 I 16 113 I I 50 I 122 I 10 926 I I 60 1 140 I 7 548 I I 70 1 158 1 5 335 I I 80 1 176 1 3 837 I 11 194 I 2 804 I I 100 I 212 I 2 080 I 110 230 1 564 120 248 1 191 130 266 918 140 284 715 150 302 563 ...

Page 118: ...UESC TO ECTS UESC SPARK ADVANCE UESC SPARK ADVANCE UESC TO SPLICE WITH 16C 161 UESC TO BAT GROUND BLANK NO WIRE UESC TO SPLICE WITH 95A 95B UESC TO SPLICE WITH 96A 96B IGN SWITCH TO SPLICE 16C 16M SPLICE TO DIS COIL 1 SPLICE TO ELECTRONIC GOVERNOR OR TACHOMETER SPLICE TO DIS COIL 2 SPLICE TO ELECTRONIC GOVERNOR OR TACHOMETER GA 18 18 18 18 18 18 18 18 18 18 18 18 18 18 18 BASIC COLOR DK BLUE GRAY ...

Page 119: ...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 Crankshaft Position Sensor Removal 1 Disconnect battery ground cable 2 Disconnect multiplug from sensor Remove engine speed sensor one ...

Page 120: ...ion Remove rubber blanking cap on water outlet When coolant is evident refit blanking cap Fill container to maximum mark 2 Place a clean drain tray below engine under allowing time for air in system to bubble through radiator drain plug and remove drain plug To Install radiator cap assist draining remove radiator cap Drain sufficient coolant to lower the level below the temperature sensor 3 Remove...

Page 121: ...r hose 8B273 and heater water hose 18C266 from water pump inlet tube 8290 6 Remove two bolts and water pump inlet tube 8290 Remove O ring from water pump inlet tube 8290 PPDB5769 A Item 1 2 3 4 5 6 7 A B Part Number 8620 68209 N60676 S2 10153 8290 N606068 S 10300 Description Drive Belt Drive Belt Tensioner Screw M6 1 x 22 5 Generator Mounting Bracket Water Pump Inlet Tube Bolt MIO 1 5 x 80 Generat...

Page 122: ...TION t SCREW SENSOR 6C315 605892 S2 8 12 Narn 106 LB IN 6019 ER A23933 A 3 Connect crankshaft position sensor 6C315 4 Install new O ring on water pump inlet tube 8274 5 Install water pump inlet tube 8274 into water pump 8501 6 Install water pump inlet tube to generator bracket bolts and tighten to 9 12 Nom 84 l 08 lb in 7 Install lower radiator hose 88273 and heater water hose 18C266 on water pump...

Page 123: ...t with a slight side to side twist Do not pull on the spark plug wire set 12259 2 Disconnect the engine wiring harness 12A200 electrical connector from the ignition coil 12029 3 Remove the four ignition coil retaining screws 4 Remove the ignition coil 12029 04 v10045 P Item 1 2 3 Part Number 12259 12029 N606502 S36 Description Spark Plug Wire Set Ignition Coil Bolt M5 0 8 x 37 I I Item Part Number...

Page 124: ...ght side to side twist to disconnect the spark plug wire set 12259 from the ignition coil Do not pull on the spark plug wire set 12259 Installation 1 Apply an even coating of Silicone Dielectric Compound WA 1 0 D7AZ 19A331 A or equivalent meeting Ford specification ESE Ml Cl 71 A to the entire interior surface of the spark plug boot 2 Squeeze locking tabs on coil retainer and push down on boot wit...

Page 125: ... IDENTIFIED BY DEPOSIT BUILD UP CLOSING GAP BETWEEN ELECTRODES CAUSED BY OIL OR CARBON FOULING REPLACE PLUG OR IF DEPOSITS ARE NOT EXCESSIVE THE PLUG CAN BE CLEANED OIL FOULED IDENTIFIED BY WET BLACK DEPOSITS ON THE INSULATOR SHELL BORE ELECTRODES CAUSED BY EXCESSIVE OIL ENTERING COMBUSTION CHAMBER THROUGH WORN RINGS AND PISTONS EXCESSIVE CLEARANCE BETWEEN VALVE GUIDES AND STEMS OR WORN OR LOOSE B...

Page 126: ...L S REQUIRED Description Tool Number Spark Plug Wire Remover T74P 6666 A Base ignition timing is preset at 9 degrees I degree BTDC at 750 rpm and is not adjustable Ignition Specifications IGNITION SYSTEM SPECIFICATIONS 1 l ii 1 Plug Type 1 Plug Gap AWSF52C 1 07 I 17mm 042 046 in TORQUE SPECIFICATIONS Description 1 Nom 1 Lb Ft 1 Lb In 1 Spark Plugs Coil Mounting Screws 9 20 7 15 5 7 44 62 1 Cranksh...

Page 127: ...r Zenith Model 33 carburetor will be used to provide necessary fuel for combustion Carburetor Identification The carburetor identification tag is attached to the upper body of 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 MOTORCRAFT D9JL A A5 A30 PPDOOIO Electric Fuel Pump The electric fuel pu...

Page 128: ...S FOUND AND THE ELECTRICAL SUPPLY GROUND AND FUEL SUPPLY TO THE PUMP AS DESCRIBED ABOVE ARE VERIFIED ALL RIGHT REPLACE THE PUMP ASSEMBLY 6 Start the engine and allow it to come up to operating temperature 7 Set the throttle control to high idle Place as full a load onto the engine as possible 8 Fuel pressure should be maintained at a minimum of 4 PSI 9 If fuel pressure cannot be maintained verify ...

Page 129: ... To service the filter take off the base plate and gasket by removing the three cap screws Then with clean hands lift the filter out handling it by the edges Clean by blowing air through the filter from the inside to the outside Reinstall the filter gasket plate and cap screws 0 TO SERVICE FILTER TAKE OFF BASE PLATE AND GASKET BY REMOVING 3 CAP SCREWS PPDOOI 1 ...

Page 130: ...03 21 Auxiliary Systems 03 21 FUEL PUMP SPECIFICATIONS Item Specification Shutoff pressure 6 7 5 PSI Maximum current draw 1 5 Amp Minimum flow 4 PSI 12V input 1 3 qt minute 2 6 pint minute ...

Page 131: ... a sticking choke plate float or float valve or a fuel inlet needle held off its seat either by improper seating or dirt particles A punctured or leaking float admitting fuel becomes gas logged causing a heavy float high fuel level and flooding If flooding does occur disassemble the carburetor observe the operation and condition of components and repair or replace as necessary A ruptured accelerat...

Page 132: ...st repair or replace as necessary Inconsistent Idle Speed Inconsistent idle speed is mostly a throttle related problem An incorrect throttle linkage adjustment a binding throttle linkage a sticking throttle shaft or a loose throttle shaft in the throttle body or bore can cause inconsistent idle speed A sticking fuel inlet needle can also cause this problem Repair replace or adjust as necessary Red...

Page 133: ...ntain a proper level in the fuel chamber equal to the fuel demand of the engine according to its speed and load Idle System The idle system supplies fuel to run the engine at curb idle and also slow speeds 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...

Page 134: ...se allows a richer mixture As the throttle plate opens extra fuel is discharged from the secondary idle discharge holes as the throttle plate passes them This hole is precisely located from the closed throttle plate with the size and location depending on fuel requirements As the throttle plate is opened wider the idle system gradually ceases to function The delivery of fuel through the high speed...

Page 135: ...ain jet a well vent and a well tube This system 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...

Page 136: ... chamber is open to atmospheric pressure consequently the greater pressure in the float chamber will cause the fuel to flow from the fuel bowl through the main jet into the main well and well tube Air admitted through bleed holes in the well tube an amount measured by the well vent is mixed with the fuel This mixture of fuel from the main well tube passes through the discharge tube in the venturi ...

Page 137: ...rushes through the carburetor into the intake manifold and to the engine This air is lighter than the liquid fuel and gets into motion more quickly That means that the air reaches the cylinders of the engine before the first charge of fuel supplied by the high speed system A lean mixture would result momentarily in this case and to counteract the condition additional fuel must be supplied instantl...

Page 138: ...refill check The pump is vacuum operated In this system the pump diaphragm is pulled against the pump spring by the engine manifold vacuum When the throttle is opened the pull on the diaphragm drops allowing the spring to push the diaphragm against the fuel causing it to discharge through the accelerator jet This amount may be varied by adjusting the travel of the pump spring Such adjustment is ma...

Page 139: ...03 30 Auxiliary Systems 03 30 ZENITH MODEL 33 CARBURETOR OPERATION AND SERVICE Continued 52 Y BP 0 6 PPD0015 ...

Page 140: ... Plug Idle Channel 26 Spring Idle Adj Screw 27 Screw Idle Adjusting 28 Screw L Washer Throttle Plate 29 Gasket Manifold Flange 30 Plate Throttle ITEM DESCRIPTION 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 Spring Accelerator Pump 40 Cover Accelerator Pump 4...

Page 141: ...er idle port d Idle channel plug 25 flush e Welch plug 31 over spark vacuum port f Spark vacuum tube 32 to approximately 9 l 6 from casting g Throttle body plug 36 flush h Pump check valve 42 flush using tool c151 53 2 3 4 5 6 7 8 9 10 11 12 13 14 i Well tube 44 making sure that end openings align with notch in casting at top and fuel channel at bottom Slide seal 33 over throttle shaft with lip to...

Page 142: ...t inside the large hole in the intake gasket 8 and on top of the smaller washer 48 Lower air intake carefully onto bowl and fasten securely and evenly using attaching screws 5 Place accelerator pump diaphragm 37 in place on body with bagged section into cavity Insert diaphragm protector 38 into end of spring 39 and install spring with protector against diaphragm Place cover 40 over spring and comp...

Page 143: ...ightly richer than normal mixture for cold engine operation The 1940 carburetor is equipped with a manually operated choke Fuel Inlet System All fuel enters the fuel bowl through the fuel inlet in the carburetor main body The fuel inlet needle has a Viton tip which seats directly into the fuel inlet fitting The needle is retained by a cap which permits fuel to flow out of holes in the side of the ...

Page 144: ...the air fuel mixture Power Fuel System The power fuel system consists of a power valve installed near the center of the carburetor main body and a vacuum piston installed in the fuel bowl cover A vacuum passage leads from the top of the piston down to the manifold flange When manifold vacuum is high the vacuum piston is raised to the top of its cylinder and the spring in the piston is compressed F...

Page 145: ...tment the entire carburetor assembly must be removed from the intake manifold and all connections to the carburetor disconnected Remove the fuel bowl cover from the carburetor main body assembly and drain the fuel from the fuel bowl Invert the carburetor assembly Place a straightedge across the surface of the fuel bowl The toes of the floats the portion of the float that hangs farthest from the fu...

Page 146: ...the carburetor 7 Remove the carburetor and carburetor base gasket 9447 from the intake manifold 9424 NOTE If the carburetor is not being serviced and is going to be placed back on the intake manifold do not turn the carburetor upside down This may cause any float bowl sediment to restrict or clog carburetor passages or prevent the inlet needle and seat assembly from closing The carburetor s operat...

Page 147: ...om an old triangle file remove all the staking from the vacuum piston retainer With a suitable puller or long nosed pliers and support remove the vacuum piston assembly 8 Remove bowl vent valve from rod if so equipped The rod cannot be removed 9 Remove hot idle compensator valve cover valve and gasket from cover if so equipped CAUTION Unless the choke valve is bent or damaged DO NOT REMOVE the cho...

Page 148: ...tic parts in the cleaning solution During cleaning the bowl cover should be placed on top of the other parts in the gasket with the main well tube projecting upward and protected It is a part of the bowl cover and cannot be replaced Blow out passages with low pressure air Assembly Except for the following vacuum piston staking operation and testing the pump discharge valve reassembly is the revers...

Page 149: ...stall the main jet and power valve with the proper tools If the valve is leaking remove the hexagon weight and lightly stake the seat with the old ball using a suitable punch or drift Throw the old ball valve away and install the new ball from the kit at the proper time during reassembly Install the float shaft in the float lever and insert assembly in the float shaft cradle Insert the retaining s...

Page 150: ...03 41 Auxiliary Systems 03 41 HOLLEY ONE BARREL CARBURETOR MODEL 1940 Continued HOLLY MODEL 1940 EXPLODED VIEW ...

Page 151: ...mbly 27 Throttle Return Spring Bushing 28 Idle Adjusting Needle 29 Float Hinge Assembly 30 Float Hinge Shaft 31 Fuel Inlet Needle Seat Assembly 33 Spark Fitting ITEM DESCRIPTION 35 Main Jet 37 Power Valve Assembly 38 Power Valve Piston Assembly 39 Pump Rod Seal 40 Pump Piston Cup 41 Pump Discharge Valve 42 Pump Piston Stem 50 Float Shaft Retainer 52 Fast Idle Adjusting Screw Spring 53 Throttle Adj...

Page 152: ...s STARTER MOTOR ASSY I w PPD0036 Sequence Of Operation 1 The ignition switch is turned to the START position 2 A remote starter relay is energized which provides voltage to the starter solenoid The starter solenoid is energized creating a magnetic field in the solenoid coil 3 The iron plunger core is drawn into the solenoid coil 4 A lever connected to the drive assembly engages the drive pinion ge...

Page 153: ...e r cables will re being careful that vehicles do not touch Make jumper cable connections a Connect one end of first jumper cable to positive terminal of discharged battery and other end of positive terminal of booster battery ach b Connect one end of second jumper cable to negative terminal of booster battery Connect other end to an engine bolthead or good metallic contact spot on engine of equip...

Page 154: ...ircuit to starter solenoid l Defective starter l Replace starter See removal and installation procedure Unusual starter noise during starter overrun l Starter not mounted flush cocked l Noise from other components l Ring gear tooth damage or excessive ring gear runout l Defective starter l Realign starter on transmission bell housing l Investigate other power train accessory noise contributors l R...

Page 155: ... voltage OK RESULT b Yes No b b Yes No Yes No ACTION TO TAKE Go to A2 CHECK wire connections between battery and starter solenoid and the ground circuit for open or short CHECK connections from output of starter relay to S terminal for open or short Defective starter REPLACE starter ACTION TO TAKE Go to B2 REPAIR ground GO to B2 GO to B3 Open circuit or high resistance exists in external circuit w...

Page 156: ...t The starter no load 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 A 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 ...

Page 157: ...g the commutator for evidence of burning A burn spot on the commutator is caused by an arc formed every time the commutator segment connected to the open circuit winding passes under a brush Grounded Armature Test This test will determine if the winding insulation has been damaged permitting a conductor to touch the frame or armature core To determine if the armature windings are grounded check wi...

Page 158: ...ket and a 22 inch long extension Access is in front of and along side the right hand front engine mount 3 Tighten the lower bolt to 21 27 Nom 15 20 ft lb 4 Connect starter solenoid connector Be careful to push straight on and make sure connector locks in position with a notable click or detent 5 Install starter cable nut to starter terminal Tighten to 9 l 3 Nom 80 I 20 in lb 6 Replace red solenoid...

Page 159: ...rge round electrical terminal and 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 ESSF 1 IA004 TERMINAL SOLENOID BLADE TERMINAL STARTER MOTOR SOLENOID AB PERMANENT I MAGNET TERMINAL STARTER COVER PPD0043 ...

Page 160: ... 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 Cleaning and Inspection CAUTION Do not wash the drive because the solvent will wash out the lubricant causing drive to slip Use a brush or compressed air to clean the drive...

Page 161: ...sing bearing bore approximately one quarter full Install drive gear assembly into housing making sure to line up bolt holes in gear assembly and housing Place gear retainer over gear assembly Install housing seal assembly into drive end housing 5 Position starter frame to housing and install through bolts Tighten to 5 0 9 5 Nom 45 84 in lb 6 Correctly position solenoid to housing ensuring that sol...

Page 162: ...nd housing Instal housi I leve w r support and housing seal in drive end Position starter frame to housing and install through bolts Tighten to 5 0 9 5 Nom 45 84 in lb Install solenoid Refer to Assembly 5 Remove positive brush connector from solenoid motor M terminal Remove through bolts and separate motor from gear assembly and drive end housing Remove brush end plate screws brush end plate and b...

Page 163: ...Lb Ft 1 1 Brush Plate Screw I 2 3 3 4 1 20 30 1 Starter Motor Starter Brushes Current Normal Draw Under Engine Min Stall Motor Normal Cranking Torque I Max No Diameter Load Speed 5 Volts Load Load Mfg Length Spring Tension mm Inches Amps RPM Nom Lb Ft Amps Amps mm Inches N 02 78 3 140 200 200 250 14 7 11 0 800 70 10 16 8 0 66 18 64 Maximum Commutator runout is 0 12mm 0 005 inch Maximum starting ci...

Page 164: ... Tool Number Description I 078 00005 I Starting and Charging Tester I TOOL TO ASSEMBLE BRUSH HOLDER TO ARMATURE PRESS FIT 3 80 e 83 BRUSH HOLOER ASSEMBLY 0 A MANDREL MAT L MICAATA LL22 1 TAN TYPE FBL 0 6 STK l3 8 DIA A LG 1 REQ O BUSHING UNIVERSAL HEAOLESS TYPE PRESS FIT BUSHING CAT NO GS 93 471 472 I D 7518 0 0 750 LG 1 REQ O PPD0046 ...

Page 165: ...buretor throttle lever limits carburetor action to the governor setting As the engine speed increases the rotation of the governor shaft increases Centrifugal force causes the weights to move outward as 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 this time the weights are forced ...

Page 166: ... open position stop It should be l 32 to l l 6 inch wide Belt Tension 3 If adjustment is necessary loosen 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 Belt tension should be checked on a cold belt...

Page 167: ...D SURGE ADJUSTMENT PPD0048 4 Adjust the high speed stop screw on the governor to attain the desired maximum engine speed Do not exceed the recommended maximum rpm 5 Tighten the locknut Sensitivity or Droop Proper governor operation requires a difference between full load and no load governed speed Too small an rpm spread between the two speeds will cause governor hunting and surging Too large a sp...

Page 168: ...t the screw to move the spring closer to the lever hub Tighten the locknuts 2 Recheck governor operation under load and no load conditions 3 Readjust the governor high speed stop screw to maintain the correct high speed under load installed Increase the engine speed with the hand throttle or variable speed lever to 75 rpm lower than the maximum no load desired control rpm NOTE At this point if the...

Page 169: ...from governor pulley Remove governor to bracket attaching bolts and remove governor 5 Position the governor to the mounting bracket and install the attaching bolts snugly Position drive belt to governor pulley and move the governor away from the engine to tighten the belt Tighten the attaching bolts Adjust the belt tension Connect the governor to carburetor throttle control rod Adjust the rod as d...

Page 170: ...ame engine speed from no load to full load operation Each controller can be programmed with up to four separate engine speeds The carburetor and actuator are integrated into one unit The carburetor is a Zenith model 33 offered with either a manual or automatic choke It is spring loaded to keep the carburetor at its minimum fuel position when no power is applied This feature causes the carburetor t...

Page 171: ...ler and check the actuator and actuator wiring for grounds and shorts NOTE Check wiring before replacing controller Bad wiring might destroy the new controller II Engine doesn t change speeds Ill Engine is hunting 1 Incorrect engine speed 1 Engine is misfiring due to idle mixture mis adjustment This causes engine hunt at no load condition 2 Engine is misfiring Check continuity across actuator wire...

Page 172: ...0 5 75r o40 PPD0051 Dimensions in mm inches in brackets 1 Calibration Initial speed settings as well as other parameters can be set using a special interface connector and an IBM compatible PC 286 minimum with 640K RAM of which 512K of conventional RAM must be available Also required is a 1 44 Meg High Density floppy drive and a VGA graphic display Programming of the controller is covered in a sep...

Page 173: ...NIC DIAGNOSING AND TESTING Continued Basic Wiring Diagram DYNl 10851 Controller 1123456781 1 1 I I I 1 1 1 1 ABCDEFGH II I G SPOSELA H SPOSELB I I nr Coil LJ PPD0052 Wiring for DIS Ignition Tach Lead 1 23 4 5 6 7 81 I I I I I I I I ABCDEFGH PPD0053 ...

Page 174: ...ugh 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 it cools the combustion chambers valves and valve seats 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 he...

Page 175: ...es etc l Closed thermostat l Test replace if necessary l Fan drive clutch l Test replace if necessary l Ignition 0 Check timing and advance Adjust as required l Temp gauge or cold light l Check electrical circuits and repair as required Refer to Volume 3 l Engine 0 Check water pump block for blockage l Coolant mixture l l 2 water and l 2 permanent antifreeze mixture l Open thermostat l Test replac...

Page 176: ... valve hose if applicable thermostat housing gasket and radiator Also refer to engine system checks if a leak cannot be located in the cooling system Any leaks which are found must be corrected and the system rechecked If the system holds pressure proceed to Step 9 9 Release the system pressure by loosening the radiator cap and remove the adapter Reinstall the temperature sending unit check coolan...

Page 177: ...lity of the cooling system to reach normal operating temperature the thermostat should be checked for leakage This may be done by holding the thermostat up to the lighted background Leakage of light all around the thermostat valve thermostat at room temperature indicates that the thermostat is unacceptable and should be replaced It is possible on some thermostats that a slight leakage of light at ...

Page 178: ...e and water mixture Operate the engine for several minutes then check the hoses and connections for leaks Thermostat Removal 1 Drain the radiator so that the coolant level is below the thermostat 2 Disconnect the heater return hose at the thermostat housing located on the left front lower side of engine 3 Remove the coolant outlet housing retainer bolts Pull the elbow away from the cylinder head o...

Page 179: ...ciency and avoids overheating Always remove the thermostat prior to pressure flushing A pulsating or reversed direction of flushing water flow will loosen sediment more quickly than a steady flow in the normal direction of coolant flow In severe cases where cleaning solvents will not properly clean the cooling system for efficient operation it will be necessary to use the pressure flushing method ...

Page 180: ...nter than in the summer allowing for better battery recharge GENERATOR 10346 GENERATOR PULLEY 44 Circuit Description Battery Positive Voltage B Output The generator output circuit 38 BWO is supplied through the battery positive voltage B output connection to the battery and electrical system The B circuit is hot at all times This circuit is protected by a fuse link I Circuit The I circuit or ignit...

Page 181: ... condition resulting in an open circuit or high resistance can cause erratic or intermittent charging system concerns 4 Check the battery voltage If the voltage is less than 12 3 volts with the engine and all accessories off charge battery before proceeding In order to check the generator the use of Rotunda Starting and Charging System Tester 078 00005 VAT 40 or equivalent is recommended Generator...

Page 182: ...l Loose connection to generator voltage l Go to Pinpoint Test C regulator battery l Loose fuse or poor connection in Circuit 36 Y W l Loose brush holder screw l Voltage regulator l Generator l Battery over charging Battery voltage l Voltage drop in A Circuit 36 Y W l Go to Pinpoint Test D greater than 15 5 volts l Voltage drop in I Circuit 904 LG R l Poor ground l Voltage regulator l Generator l I...

Page 183: ... C 38 290 and 37 and t REPLACE if required If OK REPAIR open in Circuits 38 290 and 37 A3 CHECK FOR OPEN A CIRCUIT l Measure voltage at test point A on the voltage Yes b GO to A4 regulator l Is voltage at test point A equal to battery voltage No b CHECK fuse or fuse link in Circuit 36 and REPLACE if required If OK REPAIR open in Circuit 36 Y W A4 1 CHECK FOR OPEN FIELD CIRCUIT l Measure voltage at...

Page 184: ...90 and 37 CHECK fuse link in Circuits 38 290 and 37 and the connections between the battery and under hood fuse box REPLACE voltage regulator REPLACE generator REPLACE generator CHECK for worn brushes less than 8mm long or open brush leads and REPLACE if required If OK REPLACE voltage regulator PINPOINTTEST B INDICATOR LAMP ON ENGINE RUNNING I TEST STEP RESULT b ACTION TO TAKE 1 Bl 1 CHECK FOR OPE...

Page 185: ...ator Is voltage at test point F equal to battery voltage c 3 1 CHECK FOR LOOSE A CIRCUIT FUSE l Start engine l Check the generator fuse loose connection by wiggling the fuse with the engine running l Does indicator lamp flicker c 4 CHECK A CIRCUIT CONNECTIONS l With engine running connect test point A on the voltage regulator to the positive battery post using a jumper wire l Does indicator lamp f...

Page 186: ...t test point F equal to battery voltage Yes b No b Generator is OK REPLACE voltage regulator GO to D5 D5 1 CHECK FOR GROUNDED SLIP RING I l Remove generator from vehicle l Remove voltage regulator l Measure resistance from each generator slip ring to the generator housing l Is resistance from either slip ring to housing less than 200 ohms Yes b No b If grease or dirt has accumulated near the slip ...

Page 187: ...E KNOWN GOOD GENERATOR Yes b No b Generator is OK INSTALL original part CHECK other accessories to find the cause of the noise REPLACE generator l Remove generator and replace with a known good generator l Is noise present with known good part PINPOINT TEST G RADIO INTERFERENCE TEST STEP RESULT b Gl 1 VERIFY RADIO INTERFERENCE ACTION TO TAKE Generator is OK Interference is occurring elsewhere in t...

Page 188: ...03 79 Auxiliary Systems GENERATOR DIAGNOSIS ANDTESTING Continued I 0 0 4 I s 9 V PPD0059 ...

Page 189: ...Ground to Voltmeter Ground I 18 1 Black I I 578 I Voltmeter Ground to Splice with Circuits 57 57D I 8 I Black I I 57C I Ground Ignition Harness Connector to Main Ground Terminal I 8 I Black I I 570 I Ground Fuel Pump Relay to Splice with Circuits 57 57B I 18 I Black I I 169 I Carburetor Solenoid to Splice with circuits 169A 361 I 8 I Blue I Red I 169A 1 Ignition Switch IGN Terminal to Splice with ...

Page 190: ...e voltage regulator 5 Remove wiring connector bracket 6 Loosen the drive belt tensioner 68209 and remove the drive belt 7 Remove the bolts holding the voltage regulator to the generator bracket 1OA313 8 Remove the voltage regulator from the generator bracket Installation 1 Position the voltage regulator on the generator bracket 2 Install the bolts and tighten to 40 55 Nom 30 40 ft lb 3 Install the...

Page 191: ...w Depress the generator brushes into the generator brush holder l Hold the generator brushes in position by inserting a standard size paper clip or equivalent through both the location hole in the voltage regulator and through the holes in the generator brush holders Install the voltage regulator and generator brush holder to the generator with attaching screws l Remove paper clip or equivalent fr...

Page 192: ...44 Generator Pulley Alternator Pulley 10346 Generator Alternator Description Nom Lb Ft Mounting Bracket Bolts 40 55 30 40 Wire Attaching Nut 9 12 6 5 9 Regulator Ground Screw 1 7 2 8 15 25 10351 1OA313 14301 Generator Brush Holder Generator Bracket Battery Ground Cable Alternator Mounting Parts CHARGING SYSTEM SPECIAL SERVICE TOOLS EQUIPMENT ROTUNDA EQUIPMENT I 14305 1 Generator Voltage 1 I 6007 6...

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Ford LRG-423, Service Manual

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