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TSG-416 Service Manual

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1. 02 26 Pick up Tube Deflector Installation 1 12 2022 1000000 00 nnne Inneren nnn enne 02 26 Crankshaft Main Bearings Removal enne nnne ennemi rnnt nennen enne neis 02 27 Crankshaft Main Bearings Installation eene ennemis 02 27 Connecting Rod Bearings nn 02 28 Connecting Rod Bearings 0224 40 02 28 Biston Semi val ote edt dE rere De EDU ER edel 02 29 Piston Installation iiie el na a ea 02 30 Flywlieel RernoVal dee ect dte i ed tdi eee 02 31 Flywheel Installation nn a ne ree de dae ep nenne 02 31 Timing Chain and Sprockets 02 32 Timing Chain and Sprockets 02 33 Oil Level Indicator Removal 0007 nennt nnns 02 35 Oil Level Indicator Installation 02 35 Oil Filter and Adapter Removal ensem rn nnne nn nn nnn nn hene ESSEE 02 36 Oil Filter and Adapter Installation 02 36 DIECDTIJUPuI EE 02 37 Subassemblies Cylinder Block te 22 HE 02 44 Pistons Disasse pne i em 02 45 Piston Assembly cider liaud cedet ee dna e T nen eaae nexu da NEEN e che Duda er ne 02 45 Cylinder Head
2. 2 1 0 0 nennen nene a aer AN 02 46 Cylinder Head Assembly en lan asien 02 47 CIIJIb AME 02 48 Specificatlons iter a ER DIO 02 58 PRELIMINARY 02 1 TSG 416 ENGINE NOTE For engine diagnosis refer to Section 01 PRELIMINARY 02 2 TSG 416 ENGINE GENERAL INFORMATION Special Tools Valve Spring Compressor T81P 6513 A or Equivalent Seal Remover T92C 6700 CH or Equivalent Piston Ring Compressor D81L 6002 C or Equivalent Dial Indicator with Bracketry TOOL 4201 C or Equivalent Camshaft Bearing Set T65L 6250 A or Equivalent Cylinder Ridge Reamer T64L 6011 EA or Equivalent Connecting Rod Guide Tool T93P 6136 A or Equivalent Vibration Damper Remover Adapter T82L 6316 B or Equivalent Crankshaft Damper Remover T58P 6316 D or Equivalent Feeler Gauge D81L 4201 A or Equivalent PRELIMINARY 02 3 Special Tools TSG 416 ENGINE FPP10000 Impact Slide Hammer Valve Seal Tool 21 024 or T50T 100 A or Equivalent Equivalent FPP10035 Pound Inch Torque Wrench Extra space Purchase from Local Tool Dealer Spring Tester Extra space 303 006 or TOOL 6513 DD or Equivalent FPP10034 Valve Clearance Measuring Extra space Tool 100 002 or TOOL 6505 E or Equivalent Spring Testing Fixture Extra space 21 024 or Equivalent PRELIMINARY 02 4
3. 02 10 Gamishaft Removal etd iege eee E 02 11 Camshaft Jnstallattont TL M ERES 02 12 Valve Stem Seal Removal essen nee rre 02 13 Valve Stem Seal 02 14 Intake Manifold Removal enne enne menn n nnns nnn n nn nenne ntn nnn 02 15 Intake Manifold Installaton eene e nn enne nnn 02 15 Exhaust Manifold Hemoval 02 16 Exhaust Manifold Installation 02 16 ie nnzgar oEdcui 02 17 Cylinder Head Installation 2 2 2 1 01 0 r entretient dessine aa AEEA Aaa 02 19 er artuum mS 02 21 Oil P mp Installation T Q 02 22 Crankshaft Rear Oil Seal AEREE EEEE nennen 02 23 Crankshaft Rear Oil Seal Installation 02 23 Camshaft Follower Hydraulic Lash Adjuster Remowval sese 02 24 Camshaft Follower Hydraulic Lash Adjuster Installation 02 24 Oil Pan le LEE 02 25 Oil Pan Installation Ii e ERR la ek ieh 02 25 Pick up Tube Deflector
4. Connecting Rod Cleaning CAUTION Do not use a caustic cleaning solution or damage to connecting rods can occur NOTE The connecting rod large end is mechanically split or cracked to produce a unique parting face This produces a locking joint Parts are not interchangeable e Mark separate the parts and clean with solvent Clean the oil passages 03532 PRELIMINARY 01 29 TSG 416 GENERAL INFORMATION Connecting Rod Larger End Bore CAUTION The connecting rod bolts are torque to yield and must be discarded and replaced after this diagnostic test Measure the bore in two directions The difference is the connecting rod bore out of round Verify the out of round is within specification FPP03533 Piston Pin Diameter Measure the piston pin diameter in two directions at the points shown Verify the diameter is within specifications 03534 Connecting Rod Bushing Diameter Measure the inner diameter of the connecting rod bushing Verify the diameter is within specification 03535 Connecting Rod Bend Measure the connecting rod bend on a suitable alignment fixture Follow the instructions of the fixture manufacturer Verify the bend measurement is within specification 03536 Connecting Rod Twist Measure the connecting rod twist on a suitable alignment fixture Follow the instructions of the
5. TSG 416 ENGINE Description Cylinder Head The 1 6L 4 cylinder Zetec Rocam engine has been The Zetec Rocam engine cylinder head is entirely made developed with the highest technology Its main of aluminum which improves the thermal characteristics characteristics are and reduces weight The assembly is attached using a electronic controlled multipoint sequential injection multtlayersieel gasket and 12 Bols roller finger follower camshaft Oil Pan intake manifold made of aluminum The Zetec Rocam engine oil pan is made of steel The high resistance aluminum cylinder head gasket must always be replaced whenever the oil pan is removed Steeloil pan 3 iz FPP04115 Engine Identification Number The engine identification number is marked on the right side of the cylinder block as shown Fuel System The electronic fuel injection EFI system is electronically controlled by an ECM module which carefully controls 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 PRELIMINARY 02 5 TSG 416 ENGINE Component Location Positive Crankcase Ventilation PCV Valve Camshaft Position Cil Level Indicator CMP Sensor Cylinder Head Assembly Timing Chain Tensioner Arm Coolant Flow Control Module Oil Pressure Switch Cylinder Block Crankshaft P
6. Base exposed poor lubrication D Both edges worn journal damaged E One edge worn journal tapered or bearing not seated F 03517 PRELIMINARY 01 25 TSG 416 GENERAL INFORMATION Crankshaft End Play Special Tool s Dial Indicator with Bracketry TOOL 4201 C or Equivalent m M S FPP10026 Special Service Tools called for by the procedures can be obtained by calling 1 800 ROTUNDA 1 800 768 8632 1 Measure the crankshaft end play Use the Dial Indicator with Bracketry to measure crankshaft end play 2 Position the crankshaft to the rear of the cylinder block 3 Zero the Dial Indicator with Bracketry FPP03518 4 Move the crankshaft to the front of the cylinder block Note and record the camshaft end play If camshaft end play exceeds specifications re place the crankshaft thrust washers or thrust bearing Crankshaft Runout Special Tool s Use the Dial Indicator with Bracketry to measure the crankshaft runout e Rotate the crankshaft and subtract the lowest dial indicator reading from the highest dial indicator reading to figure the crankshaft runout If it is out of specification replace as necessary 03519 Cylinder Bore Taper Measure the cylinder bore at the top and bottom Verify the cylinder bore is within the wear limit The difference indicates the cylinder bore taper Bore the
7. Connecting Rod Bearings Installation NOTE Make sure bearing bore of connecting rod and cap and bearing journal are clean Lubricate wear surfaces with clean engine oil 1 Insert upper bearing into connecting rod 2 Insert lower bearing into cap CAUTION Do not scratch journal with connecting rod bolts 3 Install cap and bolts Tighten bolts in 2 steps Step 1 9 Ib ft 12 5 Nm Step2 22 Ib ft 30 Nm 41 94 2 4 Install deflector and pick up tube Refer to Pick up Tube Deflector Installation on page 26 5 Install oil pan Refer to Oil Pan Installation on page 25 PRELIMINARY 02 28 TSG 416 ENGINE Piston Removal 6 Remove 2 bolts connecting rod cap and lower bearing 1 Remove oil pan Refer to Oil Pan Removal on page 25 2 Remove pick up tube and deflector Refer to Pick up Tube Deflector Removal on page 26 3 Remove cylinder head assembly Refer to Cylinder Head Removal on page 17 CAUTION Never cut into the ring travel area in excess of 0 8mm 1 32 inch when removing ridges 4 Turn crankshaft until piston to be removed is at the bottom of its travel and place a cloth 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 manufacturer Cylinder Ridge Reamer T64L 6011 EA FPP04072 CAUTION Avoid damage
8. 01 22 Gamshaft Journal Glearance ER eite eH eite i 01 22 Gamshatt Surface ansteigen eier 01 22 Gamshaft Lobe itt EE 01 23 GamshiattRurout zc t rer e DRE Per ten NE e ERO 01 23 Carmishatt End Play nne an eie iut eue nisu a 01 23 Crankshaft Main Bearing Journal Diameter 01 24 Crankshaft Main Bearing Journal aper 01 24 Crankshaft Main Bearing Journal Oearance emen 01 25 Bearing Inspector zn dE EE 01 25 Grankshaft End Play Teien niet 01 26 Crankshaft RUROUE Lait o ee D a E Edi e P I UR EE PU I 01 26 eet dni Geet Meg e n e nem tere e ORT EU 01 26 Cylinder Bore Ouko ROUN 5 noe teo e a EE Sng ii ede 01 27 Piston Inspection i ete tette Lo 01 27 01 27 Piston to Cylinder Bore Clearance 1 111 E tenes snnt 01 27 Pist rr Selectiona err RARO m BI 01 28 01 28 Piston Ring to Groove nennen nnn en enne 01 29 Crankshaft Connecting Rod Journal Diameter 01 29 Crankshaft Connecting Rod Journal 01 29 Goriniectirig Rod Cleaning ect ctus tg tete ohren hide 01 29 Connecting Ro
9. 4 Install 3 bolts and tighten to 15 Ib ft 20 Nm PRELIMINARY 02 36 TSG 416 ENGINE DISASSEMBLY 3 Loosen the tensioner pulley and remove the drive belt 1 Install engine on an engine stand Tension Pulley FPPO4154 Generator FPP01527 2 Drain the engine oil NOTE Record drive belt routing and direction of travel 4 Disconnect wiring at generator for use during assembly 5 Remove the generator 6 Remove the generator support Water Pump Generator FPP02537 PRELIMINARY 02 37 TSG 416 ENGINE 7 Remove oil level indicator tube 10 Remove the coolant flow control module 8 Remove the return connector M Coolant Flow Level Indicator IECH Control Module Coolant Return Connector pue 3 S ug NIT A 11 Remove the intake manifold assembly NOTE Record routing of wiring harnesses and vacuum tubes so they may be returned to their original positions Intake Manifold during assembly Assembly 20 9 Remove vacuum hoses wiring Wiring Harness Vacuum Hose PRELIMINARY 02 38 TSG 416 ENGINE 12 Remove the oil filter and support assembly 16 Remove the valve cover assembly PCV Valve CMP Sensor Valve Cover 13 oil pressure switch 14 Remove crankshaft position CKP sensor CKP Sensor PRELIMINARY 02 39 TSG 416 ENGINE 18 Remove 3 bolts and the water pump pulley
10. FPPO4153 PRELIMINARY 02 33 TSG 416 ENGINE 6 Tighten guide and tensioner arm bolts to 18 21 Ib ft 8 Tighten hydraulic tensioner to 27 32 Ib ft 36 44 24 28 Nm Nm Tensioner Arm Chain Guide Hydraulic Tensioner FPP04135 04153 7 Using 22 locking tool tighten camshaft sprocket 9 oil pan water pump 22 bolt to 52 59 Ib ft 70 80 Nm 10 Install valve cover Refer to Valve Cover Installation on page 10 11 Install oil pump assembly Refer to Oil Pump Installation on page 22 Locking Tool 12 15 030A 43 14 15 FPPO4132 PRELIMINARY 02 34 TSG 416 ENGINE Oil Level Indicator 04098 Cil Level Indicator Removal Cil Level Indicator Installation 1 1 Apply sealer WSK M2G 349 A4 Loctite 648 to 2 Remove bolt lower end of oil level indicator tube 2 Install tube immediately into bore 3 Install bolt and tighten to 15 Ib ft 20 Nm 4 3 Remove oil level indicator amp tube PRELIMINARY 02 35 TSG 416 ENGINE Gasket Cil Filter FPP04092 Oil Filter and Adapter Removal Oil Filter and Adapter Installation NOTE Place oil drain pan under oil filter to catch oil drainage 1 Install a new gasket 2 Lubricate oil seal on a new filter and install to 1 adapter Tighten 1 1 2 to 1 3 4 turns after first 2 Remove oil filter contact 3 Remove 3 bolts 3 Install filter adapter to block 4 Remove adapter and gasket
11. Install a new gasket and exhaust manifold Install nuts Tighten to 11 Ib ft 15 Nm Connect exhaust at outlet flange Tighten flange nuts to xx Ib ft xx Nm Dou sies oon o c Install any wiring and vacuum hoses that were removed Connect and route as they were removed PRELIMINARY 02 16 TSG 416 ENGINE Cylinder Head Removal 1 Drain engine oil refer to Operator Handbook 2 Drain engine coolant refer to Section 05 3 Remove any necessary wiring and vacuum hoses Mark connections and routing as necessary to assure they are returned as they were removed 4 Remove valve cover Refer to Valve Cover Removal on page 10 5 Remove spark plugs and wires 6 Remove the coolant flow control module refer to Section 05 Coolant Flow Control Module 7 Remove bolts and nuts holding intake manifold to cylinder head Move aside 8 Remove heat shield 9 Remove nuts at exhaust manifold Move aside 10 Remove oil level indicator tube bolt at cylinder head 11 Remove timing chain hydraulic tensioner Hydraulic Tensioner FPPO4135 12 Rotate camshaft sprocket using tool 15 030A until the 2 copper links on timing chain are at 12 o clock Copper Links 12 O clock 04136 13 Using tool 15 030A to lock camshaft sprocket remove bolt CAUTION During cylinder head removal the timing chain must be held up with a wire with constant tension in order to keep timing links
12. Repair exhaust leakage Improper drive belt tension Refer to Section 05 Malfunctioning generator bearing Refer to Section 06 for diagnosis and testing of the generator Loose timing chain belt Adjust or replace timing chain belt Damaged timing belt tensioner Replace timing belt tensioner Malfunctioning water pump bearing Replace water pump Insufficient Power Malfunctioning hydraulic lash adjuster or hydraulic lash adjuster Replace hydraulic lash adjuster or hydraulic lash adjuster Damaged hydraulic lash adjuster guide or hydraulic lash adjuster Replace hydraulic lash adjuster guide or hydraulic lash adjuster Compression leakage at valve seat Repair or replace valve valve seat or cylinder head Seized valve stem Replace valve stem Weak or broken valve spring Replace valve spring Damaged cylinder head gasket Replace cylinder head gasket Cracked or distorted cylinder head Replace cylinder head Damaged worn or sticking piston ring s Repair or replace piston ring s Worn or damaged piston Replace piston Malfunctioning or damaged fuel system Refer to Section 04 Malfunctioning or damaged ignition system Refer to Section 03 Damaged or plugged exhaust system Repair or replace exhaust system PRELIMINARY 01 12 TSG 416 GENERAL INFORMATION Engine Oil Leaks NOTE
13. Replace hydraulic lash adjuster guide or hydraulic lash adjuster Improper valve to valve seat contact Replace valve or valve seat Damaged cylinder head gasket Replace cylinder head gasket Malfunctioning or damaged fuel system Refer to Section 04 of this manual Malfunctioning or damaged ignition system Refer to Section 03 of this manual Malfunctioning or damaged IAC motor or system Refer to Section 03 of this manual Abnormal combustion Damaged hydraulic lash adjuster or hydraulic lash adjuster Replace hydraulic lash adjuster or hydraulic lash adjuster Damaged hydraulic lash adjuster guide or hydraulic lash adjuster Replace hydraulic lash adjuster guide or hydraulic lash adjuster Burnt or sticking valve Repair or replace valve Weak or broken valve spring Replace valve spring Carbon accumulation in combustion chamber Eliminate carbon buildup Malfunctioning or damaged fuel system Refer to Section 04 of this manual Malfunctioning or damaged ignition system Refer to Section 03 of this manual Excessive Oil Consumption Worn piston ring groove Replace piston and pin Sticking piston rings Repair or replace piston rings Worn piston or cylinders Repair or replace piston or cylinder blocks Worn valve stem seal Replace valve stem seal Worn valve stem or valve guide Replace valve stem and
14. The chamfer on the camshaft bearing caps must be facing the chain housing Rotate camshaft so keyway will align with sprocket 5 Carefully install camshaft bearings caps and bolts finger tight 6 Tighten bolts in the sequence shown in 3 steps to 6 7 Ib ft 8 10 Nm Hi l Dos SE ON D i CS Sion E 26 Sion P rn 1772 LP FPPO4133 7 Install camshaft sprocket with chain onto camshaft while maintaining tension on the chain CAUTION The camshaft sprocket and chain must remain 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 refer to timing chain assembly xxx 8 Using tool 15 0304 install bolt and tighten to 52 59 Ib ft 70 80 Nm Locking Tool 15 030A FPPO4132 9 Install valve cover Refer to Valve Cover Installation on page 10 PRELIMINARY 02 12 TSG 416 ENGINE Valve Stem Seal Removal NOTE Ifthe valve or valve seat has not been damaged the valve spring seal retainer or keys may be replaced by holding the affected valve closed using compressed air Use an appropriate air line tool installed in the spark plug hole A minimum of 965 kPa 140 psi line pressure is required If air pressure does not hold the valve shut the valve is damaged or burned and the cylinder head must be removed and service
15. 21 046 Special Tool FPPO4143 Rear Seal Retainer NOTE Rear seal retainer comes on a plastic sleeve Link plastic sleeve to crankshaft 34mm and push retainer to crankshaft Plastic pins at rear side of retainer must fit to corresponding block bores Remove plastic sleeve when done 11 Turn engine 180 to prepare for cylinder head installation NOTE The contact surface of the cylinder head and block must be clean and free of oil Use new cylinder head bolts and lubricate the threads 12 Rotate crankshaft so all pistons are below top dead center TDC 13 Install dowels and new cylinder head gasket to the engine block 14 Carefully install the cylinder head onto the gasket 8 Bolts Cylinder Head PRELIMINARY 02 49 TSG 416 ENGINE 15 Install new bolts using the sequence shown in the following 3 steps Step 1 tighten M11 bolts to 29 5 Ib ft 40 Nm Step2 tighten M8 bolts to 11 Ib ft 15 Nm 45 Step tighten M11 bolts additional 120 Tightening Sequence 16 Install the chain guide and the tensioner arm from the top of the engine Install bolts finger tight Tensioner Arm Chain Guide FPPO4153 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 sprocket Align timing mark with coppere
16. Bolt FPP04140 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 housing bolts so that the sealing flange of the oil pump housing is within 0 008 in 0 20 mm of the block bottom sealing flanges 29 Tighten 2 outer oil pump housing bolts to 15 Ib ft 20 Nm Outer Bolts FPPO4141 30 Tighten remaining oil pump housing bolts to 15 Ib ft 20 Nm FPPO4142 Remaining Bolts PRELIMINARY 02 52 TSG 416 ENGINE 31 Install water pump 35 Install oil deflector 32 Install bolts and tighten to 7 Ib ft 10 Nm 36 Install oil pick up tube Oil Pick up Tube Water Pump Oil Deflector 33 Install water pump pulley 34 Install bolts and tighten to 9 Ib ft 12 Nm 37 Tighten nuts to 14 Ib ft 19 Nm Tighten bolt to 7 Ib ft 9 5 Nm 38 Apply WSEM A4 sealer Loctite 5910 to the 4 positions as shown CAUTION The contact surfaces of oil 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 PRELIMINARY 02 53 TSG 416 ENGINE 39 Install the oil pan and bolts finger tight 42 Install the oil pan drain plug Tighten to 18 Ib ft 25 Nm 43 Install flywheel using special locking tool 21 168 40 Align oil pan with rear portion of engine block Flywheel Straight Edge Oil Pan 41
17. Clean crankcase and all subassemblies of all foreign material Scrape or wire brush RTV sealant from mating surfaces Surfaces must be kept oil free for good adhesion of fresh RTV seal during reassembly NOTE For cleaning and service information on 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 necessary FPPO4162 4 Coolant and oil galleries must be free of dirt and deposits FPP04161 5 Refer to Section 01 for cleaning amp servicing cylinder block and core plug installation 2 Remove oil gallery plugs 6 Reinstall oil gallery plugs Oil Gallery Plugs PRELIMINARY 02 44 TSG 416 ENGINE Piston Disassembly NOTE Store components to ensure assembly with the same rod and installation in the same cylinders from which they were removed Refer to Section 01 for piston inspection and servicing 1 Remove the connecting rod bearing from the connecting rod and cap 2 Remove the piston rings using a suitable piston ring expander Ring Expander 04163 4 Piston Assembly NOTE Apply a light coat of clean engine oil contact surfaces 2 Install piston rings using a suitable piston ring expander Ta FPPO4164 NOTE Check piston ring end gap and side clearance refer to Section 01 3 Install bearings i
18. EQUIPMENT MOVEMENT OPERATE THE ENGINE ONLY IN A WELL VENTILATED AREA TO AVOID THE DANGER OF CARBON MONOXIDE e KEEP YOURSELF AND YOUR CLOTHING AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING ESPECIALLY THE FAN BELTS TOPREVENT SERIOUS BURNS AVOID CONTACT WITH HOT METAL PARTS SUCH AS THE RADIATOR EXHAUST MANIFOLD TAIL PIPE CATALYTIC CONVERTER AND MUFFLER DONOT SMOKE WHILE WORKING ON THE EQUIPMENT e ALWAYS REMOVE RINGS WATCHES LOOSE HANGING JEWELRY AND LOOSE CLOTHING BEFORE BEGINNING TO WORK ON THE EQUIPMENT TIE LONG HAIR SECURELY BEHIND THE HEAD e KEEP HANDS AND OTHER OBJECTS CLEAR OF THE RADIATOR FAN BLADES ELECTRIC COOLING FANS CAN START TO OPERATE AT ANY TIME BY AN INCREASE IN UNDERHOOD TEMPERATURES EVEN THOUGH THE IGNITION IS IN THE OFF POSITION THEREFORE CARE SHOULD BE TAKEN TO ENSURE THAT THE ELECTRIC COOLING FAN IS COMPLETELY DISCONNECTED WHEN WORKING UNDER THE HOOD PRELIMINARY 01 4 TSG 416 GENERAL INFORMATION Battery Handling and Charging The handling and correct use of lead acid batteries is not as hazardous provided that sensible precautions are observed and that operatives have been trained in their use and are adequately supervised It is important that all labelling on the battery is carefully read understood and complied with The format of the following symbols and labels is common to most brands of lead acid battery SHIELD EYES DANGERIPOISON FLUSH EVES EXPLOSIVE S SULPHURIC ACID CAN C
19. Honing should be done when fitting new piston rings or to remove minor surface PRELIMINARY 01 36 TSG 416 GENERAL INFORMATION Cylinder Block Repair Cast Iron Porosity Defects CAUTION Do not attempt to repair cracks areas where temperature will exceed 260 C 500 F or ar eas exposed to engine coolant or oil These areas will not repair and could cause future failure FPP03561 Repair porosity defects with an epoxy sealer meeting Ford specification M3D35 A E 1 Clean the surface to be repaired to a bright oil free metal surface 2 Chamfer or undercut the repair area to a greater depth than the rest of the cleaned surface Solid metal must surround the area to be repaired 3 Apply the epoxy sealer and heat cure with a 250 watt lamp placed 254 mm 10 inches from the repaired surface or air dry for 10 12 hours at a temperature above 10 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 Special Tool s Impact Slide Hammer T50T 100 A Be FPP10000 Special Service Tools called for by the procedures can be obtained by calling 1 800 ROTUNDA 1 800 768 8632 1 Use a slide hammer or tools suitable to remove the cylinder block core plug FPPO4161 2 Inspect the cylinder block plug bore for any damage tha
20. Leakage Points with Flywheel Removed NOTE Air leakage in the area around a crankshaft rear oil seal does not necessarily indicate a crankshaft rear oil seal leak However if no other cause can be found for oil leakage assume that the crankshaft rear oil seal is the cause of the oil leak NOTE Light foaming equally around valve cover bolts and crankshaft seals is not detrimental no repairs are required crankshaft rear oil seal rear main bearing cap parting line rear main bearing cap and seals e flywheel mounting bolt holes with flywheel installed camshaft rear bearing covers or pipe plugs at the end of oil passages Oil leaks at crimped seams in sheet metal parts and cracks in cast or stamped parts can be detected when pressurizing the crankcase PRELIMINARY 01 13 TSG 416 GENERAL INFORMATION Compression Tests Compression Gauge Check 1 Make sure the oil in the crankcase is of the correct viscosity and at the proper level and that the battery is properly charged Operate until the engine is at normal operating temperature Turn the ignition Switch to the OFF position then remove all the spark plugs 2 Set the throttle plates in the wide open position Install a Compression Tester in the No 1 cylinder 4 Install an auxiliary starter switch in the starting circuit With the ignition switch in the OFF position and using the auxiliary starter switch crank the engine a minimum of five compression
21. NOTE When removing oil pan always keep the engine in its normal upright position to avoid contamination 20 Remove bolts gasket and oil pan Oil Pan 1 i i FPP04089 21 Turn the engine over 180 22 Remove 4 nuts 1 bolt oil pick up tube and oil deflector Oil Pick up Tube 1 Deflector lt Ke L GC 1 23 Insert retaining clip BF9A 6606 AA between crankshaft pulley and oil pump to prevent pulley axial movement 24 Remove crankshaft pulley bolt NOTE Identify oil pump bolts so they may be returned to their original positions 25 Remove 6 oil pump bolts and oil pump Retaining Clip BF9A 6606 AA PRELIMINARY 02 40 TSG 416 ENGINE 26 Check to see if coppered links on the timing chain 28 Using tool 15 030A to lock camshaft sprocket are still visible If not identify them as follows remove bolt and camshaft sprocket Turn engine until timing mark on camshaft sprocket is at 12 o clock e Mark the two chain links left and right of that tim ing mark Mark the single chain link that is positioned on Locking Tool the crankshaft sprocket timing mark 15 030A Copper Links FPPO4132 29 Remove timing chain and crankshaft sprocket 30 Remove tensioner arm and chain guide Crankshaft Sprocket Timing Chain Copper Link 27 Remove the hydraulic tensioner Hydraul
22. air supply and air hose e air pressure gauge that registers pressure 4 kPa 1 psi increments airline shutoff valve appropriate fittings to attach the above parts to oil fill grommet hole and crankcase ventilation tube appropriate plugs to seal any openings leading to the crankcase e asolution of liquid detergent and water to be applied with a suitable applicator such as a squirt bottle or brush Fabricate the air supply hose to include the air line shutoff valve and the appropriate adapter to permit the airto enter the engine through the crankcase ventilation tube Fabricate the air pressure gauge to a suitable adapter for installation on the engine at the oil filler opening Testing Procedure e Open the air supply valve until the pressure gauge maintains 34 kPa 5 psi Inspect sealed or gasketed areas for leaks by applying a solution of liquid detergent and water over areas for formation of bubbles which indicates leakage Leakage Points Above Engine Examine the following areas for oil leakage valve cover gaskets intake manifold gaskets cylinder head gaskets Oil bypass filter Oillevel indicator tube connection Oil pressure sensor Leakage Points Under Engine e Oil pan gaskets oil pan sealer oil pan rear seal engine front cover gasket crankshaft front seal crankshaft rear oil seal crankshaft main bearing cap side bolts oil pump and filter body
23. aligned at crankshaft If chain is allowed to slacken or disengage with sprocket the oil pump will have to be removed and the timing chain realigned refer to timing chain assembly xxx 14 Remove camshaft sprocket from chain while maintaining tension on the chain using a wire 15 Remove the M11 cylinder head bolts in 3 phases in the sequence shown PRELIMINARY 02 17 TSG 416 ENGINE CAUTION Be careful to avoid the bolts falling into the timing chain compartment 16 Remove 2 8 bolts cylinder head and gasket 8 Bolts Cylinder Head 17 Carefully remove cylinder head and gasket while maintaining tension on timing chain Gasket FPPO4138 Timing Chain PRELIMINARY 02 18 TSG 416 ENGINE Cylinder Head Installation 3 Install new bolts using the sequence shown in the NOTE The contact surface of the cylinder head and PRS ER block must be clean and free of oil Use new cylinder Step 1 tighten M11 bolts to 29 5 Ib ft 40 Nm head bolts and lubricate the threads Step 2 tighten M8 bolts to 11 Ib ft 15 Nm 45 Step 3 tighten M11 bolts additional 120 1 Rotate crankshaft so all pistons are below top dead center TDC CAUTION During cylinder head installation the timing chain must be held up with a wire with constant tension in order to keep timing links aligned at crankshaft If chain is allowed to slacken or disengage with
24. be interpreted carefully Most vacuum gauges have a normal band indicated on the gauge face The following are potential gauge readings Some are normal others should be investigated further 1 4 4 4 7 e 10 3 e 1 15 03503 1 NORMAL READING Needle between 51 74 kPa 15 22 in Hg and holding steady 2 NORMAL READING DURING RAPID ACCELERATION AND DEACCELERATION When the engine is rapidly accelerated dotted needle the needle will drop to a low reading not to zero When the throttle is suddenly released the needle will snap back up to a higher than normal figure 3 NORMAL FOR HIGH LIFT CAMSHAFT WITH LARGE OVERLAP The needle will register as low as 51 kPa 15 in Hg but will be relatively steady Some oscillation is normal 4 WORN RINGS OR DILUTED OIL When the engine is accelerated dotted needle the needle drops to 0 kPa 0 in Hg Upon deceleration the needle runs slightly above 74 kPa 22 in Hg 5 STICKING VALVES 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 6 BURNED OR WARPED VALVES A regular evenly spaced downscale flicking of the needle indicates one or more burned or warped valves Insufficient hydraulic lash adjuster or hydraulic lash adjuster HLA clearance will also cause this reaction 7 POOR VALVE S
25. connecting rod Top of Piston Ring Lands Skirts Pin Bosses 03522 2 Use the Piston Ring Groove Cleaner to clean the piston ring grooves Piston to Cylinder Bore Clearance Subtract the piston diameter from the cylinder bore diameter to find the piston to cylinder bore clearance PRELIMINARY 01 27 TSG 416 GENERAL INFORMATION Piston Selection CAUTION Use care when fitting piston rings to i ET avoid possible damage to the piston ring or the cyl NOTE The cylinder bore must be within the inder bore specifications for taper and out of round before fitting a piston CAUTION Piston rings should not be transferred f iston t ther t t t 1 Select a piston size based on the cylinder bore Cvllndor Worm Gr piston Sito Prevent vemage te NOTE Cylinder bore must be within specification for taper and out of round to fit piston rings CH e O 1 Use a piston without rings to push a piston ring in a cylinder to the bottom of ring travel O FPP03525 mn bei NOTE For precision fit new pistons are divided into three categories within each size range based on their relative position within the range A paint spot on the 03527 new pistons indicates the position within the size range 2 Use a feeler gauge to measure the top piston ring end gap and the second piston ring end gap FPP03526 03528 2 C
26. convenient Adjust the air pressure to approximately 34 kPa 5 psi 3 Using a solution of liquid soap and water brush the solution along the gasket sealing surfaces and bearing seals Look for bubbles or foam 4 Remove the spark plugs and rotate the crankshaft slowly with a wrench Check for large amounts of air escaping into the cylinders as each intake valve and exhaust valve opens 5 The spark plugs on the leaking cylinders will probably show deposits of burned oil Intake Manifold Vacuum Test Bring the engine to normal operating temperature Connect the Vacuum Pressure Tester to the intake manifold Run the engine at the specified idle speed The vacuum gauge should read between 51 74 kPa 15 22 in Hg depending upon the engine condition and the altitude at which the test is performed Subtract 4 0193 kPa 1 in Hg from the specified reading for every 304 8 m 1 000 feet of elevation above sea level The reading should be steady If necessary adjust the gauge damper control where used if the needle is fluttering rapidly Adjust the damper until the needle moves easily without excessive flutter PRELIMINARY 01 15 TSG 416 GENERAL INFORMATION Interpreting Vacuum Gauge Readings A careful study of the vacuum gauge reading while the engine is idling will help pinpoint trouble areas Always conduct other appropriate tests before arriving at a final diagnostic decision Vacuum gauge readings although helpful must
27. engine Connect the Engine Oil Pressure Gauge and Transmission Test Adapter to the oil pressure sender oil gallery port Runthe engine until normal operating temperature is reached Run the engine at 3000 rpm and record the gauge reading The oil pressure should be within specifications If the pressure is not within specification check the following possible sources insufficient oil oilleakage worn or damaged oil pump oil pump screen cover and tube excessive main bearing clearance excessive connecting rod bearing clearance PRELIMINARY 01 18 TSG 416 GENERAL INFORMATION Valve Train Analysis Static With engine off and valve cover removed check for damaged or severely worn parts and correct assembly Make sure correct parts are used with the static engine analysis as follows Rocker Arm e Check for loose mounting bolts studs and nuts e Check for plugged oil feed the rocker arms or cylinder head Camshaft Roller Followers and Hydraulic Lash Adjusters e Check for loose mounting bolts on camshaft carriers e Check for plugged oil feed in the camshaft roller followers hydraulic lash adjusters HLA or cylinder heads Camshaft e Check for broken or damaged parts Check the bolts on the intake manifold Valve Springs e Check for broken or damaged parts Valve Spring Retainer and Valve Spring Retainer Keys e Check for proper seating of the valve spring r
28. fixture manufacturer Verify the measurement is within specification FPP03537 PRELIMINARY 01 30 TSG 416 GENERAL INFORMATION Connecting Rod Piston Pin Side Clearance 3 Install and torque to specifications then remove the connecting rod bearing cap 4 Measure the Plastigage to get the connecting rod bearing journal clearance The Plastigage should be smooth and flat A change width indicates a tapered or damaged connecting rod bearing or connecting rod Measure the clearance between the connecting rod and the piston Verify the measurement is within specification FPP03538 03540 Connecting Rod Journal Clearance Special Tool s Plastigage amp D81L 6002 B or Equivalent Special Service Tools called for by the procedures can be obtained by calling FPP 1003 1 800 ROTUNDA 1 800 768 8632 NOTE The crankshaft connecting rod journals must be within specifications to check the connecting rod bearing journal clearances CAUTION 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 bearing surface NOTE Do not turn the crankshaft during this step PRELIMINARY 01 31 TSG 416 GENERAL INFORMATION Bearing Inspection Inspect bearings for the following defects Possible
29. guide Leaking oil Repair oil leakage PRELIMINARY 01 11 TSG 416 GENERAL INFORMATION Condition Possible Source Action Engine Noise Excessive main bearing oil clearance Adjust clearance or replace main bearing Seized or heat damaged main bearing Replace main bearing Excessive crankshaft end play Replace crankshaft thrust main bearing Excessive connecting rod bearing oil clearance Replace connecting rod Heat damaged connecting rod bearing Replace connecting rod bearing Damaged connecting rod bushing Replace connecting rod bushing Worn cylinder Repair or replace cylinder blocks Worn piston or piston pin Replace piston or piston pin Damaged piston rings Replace piston rings Bent connecting rod Replace connecting rod Malfunctioning hydraulic lash adjuster or hydraulic lash adjuster Replace hydraulic lash adjuster or hydraulic lash adjuster Excessive hydraulic lash adjuster or hydraulic lash adjuster clearance Adjust clearance or replace hydraulic lash adjuster guide or hydraulic lash adjuster Broken valve spring Replace valve spring Excessive valve guide clearance Repair clearance or replace valve guide stem Malfunctioning or damaged cooling system Refer to Section 05 Malfunctioning or damaged fuel system Refer to Section 04 Leaking exhaust system
30. next step 14 Check the positive crankcase ventilation PCV system Make sure the system is not plugged 15 Check for plugged oil drain back holes in the cylinder heads and cylinder blocks 16 If the condition still exists after performing the above steps proceed to next step 17 Perform a cylinder compression test or perform a cylinder leak detection test with Engine Cylinder Leak Detection Air Pressurization Kit 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 replacement parts are used 18 Check valve guides for excessive guide clearances REPLACE all valve stem seals after verifying valve guide clearance 19 Worn or damaged internal engine components can cause excessive oil consumption Small deposits of oil on the tips of spark plugs can be a clue to internal oil consumption If internal oil consumption still persists proceed as follows Remove the engine from the vehicle and place it on an engine work stand Remove the intake manifolds cylinder heads oil pan and oil pump Check piston ring clearance ring gap and ring orientation Repair as required Check for excessive bearing clearance Repair as required 20 Perform the oil consumption test to confirm the oil consumption concern has been resolved Cil Pressure Test 1 Disconnect and remove the oil pressure sensor from the
31. sprocket the oil pump will have to be removed and the timing chain realigned refer to timing chain assembly xxx 2 Carefully install dowels a new gasket and cylinder head to the engine block while maintaining tension on the timing chain 8 Bolts Cylinder Head Tightening Sequence 4 Carefully install sprocket into timing chain aligning timing mark with 2 copper links Copper Links 12 O clock 04136 CAUTION Be careful to avoid the bolts falling into the timing chain compartment PRELIMINARY 02 19 TSG 416 ENGINE 5 Using tool 15 0304 install camshaft sprocket bolt 11 Install the coolant flow control module refer to Tighten to 92 Ib ft 125 Nm Section 05 Coolant Flow Control Module Locking Tool 15 030A FPPO4132 12 Install spark plugs and wires refer to Section 03 13 Install valve cover Refer to Valve Cover 6 Install hydraulic tensioner and tighten to 30 Ib ft 40 Removal on page 10 Nm 14 Install and route any wiring and vacuum hoses removed 15 Fill engine with correct type and quantity of coolant Hydraulic refer to Section 05 Tensioner 16 Fill engine with correct type and quantity of engine oil refer to Operator Handbook FPPO4135 7 Install oil level indicator bolt Tighten to 15 Ib ft 20 Nm 8 Install exhaust manifold and nuts Tighten nuts to 11 Ib ft 1
32. two chain links left and right of that tim ing mark Markthe single chain link that is positioned on the crankshaft sprocket timing mark FPP04135 9 Using tool 15 030A to lock camshaft sprocket Copper Links remove bolt and camshaft sprocket Timing MarK Locking Tool 15 030A FPPO4132 Copper Link PRELIMINARY 02 32 TSG 416 ENGINE 10 Remove timing chain and crankshaft sprocket 2 Install crankshaft sprocket with key at 12 o clock position 11 Remove tensioner arm and chain guide if necessary 3 Assemble drive chain through chain housing cavity from top of engine and onto crankshaft sprocket Align timing mark with coppered link on drive chain Crankshaft Sprocket Timing Chain Timing Mark 12 O clock Position FPPO4084 Coppered Link Chain Guide Camshaft Sprocket 4 Insert camshaft sprocket into chain and assemble to camshaft Position camshaft key at 12 o clock and align timing mark between 2 coppered links on drive chain Timing Chain and Sprockets Installation NOTE components must be clean and dried with compressed air or a lint free cloth Lubricate with clean Coppered Links engine oil 12 O clock Position 1 Install the if removed chain guide and the tensioner arm from the top of the engine Install bolts finger tight Tensioner Arm Chain Guide Timing Mark 5 Install camshaft sprocket bolt and hydraulic tensioner finger tight
33. 1 21 TSG 416 GENERAL INFORMATION GENERAL SERVICE PROCEDURES WARNING AVOID THE POSSIBILITY OF PERSONAL INJURY OR DAMAGE TO THE EQUIPMENT DO NOT OPERATE THE ENGINE WITH THE HOOD OPEN UNTIL THE FAN BLADE HAS BEEN EXAMINED FOR POSSIBLE CRACKS AND SEPARATION NOTE Specifications show the expected minimum or maximum condition NOTE If a component fails to meet the specifications it is necessary to replace or refinish If the component 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 each camshaft journal diameter in two directions e Ifitis out of specification replace as necessary 03508 Camshaft Journal Clearance NOTE The camshaft journals must meet specifications before checking camshaft journal clearance Measure each camshaft bearing in two directions e Subtract the camshaft journal diameter from the camshaft bearing diameter FPP04126 Camshaft Lobe Surface Inspect camshaft lobes for pitting or damage in the active area Minor pitting is acceptable outside the active area Active Area u on un 7 MU PRELIMINARY 01 22 TSG 416 GENERAL INFORMATION Camshaft Lobe Lift Special Tool s Camshaft Runout Special Tool s Dial Indicator with Bracketry TOOL 4201 C or
34. 5 Nm 9 Install heat shield 10 Install bolts and nuts holding intake manifold to cylinder head Tighten to nuts and bolts to 13 Ib ft 18 Nm PRELIMINARY 02 20 TSG 416 ENGINE Oil Pump Removal CAUTION The oil pump pulley and sealer are provided as an assembly kept together by a clip no BF9A 6606 AA Do not remove clip until oil pump is installed If pulley is pushed out of the oil pump prior to oil pump installation it will have to be repaired or replaced Remove drive belt refer to xx 1 2 3 Remove water pump refer to Section 05 4 Insert retaining clip BF9A 6606 AA between crankshaft pulley and oil pump to prevent pulley axial movement Retaining Clip BF9A 6606 AA Oil Pump 5 Remove crankshaft pulley bolt NOTE Identify oil pump bolts so they may be returned to their original positions 6 Remove 6 oil pump bolts oil pump and gasket PRELIMINARY 02 21 TSG 416 ENGINE Oil Pump Installation NOTE Contact surfaces of the oil pump and block must be clean and free of oil CAUTION The oil pump pulley and sealer are provided as an assembly kept together by a clip no BF9A 6606 AA Do not remove clip until oil pump is installed If pulley is pushed out of the oil pump prior to oil pump installation it will have to be repaired or replaced 1 Assemble gasket onto oil pump housing guiding it with 2 outer bolts FPP04139 CAUTION Do not apply oil t
35. 7 1220 146 110 176 132 206 154 154 177 1020 765 1227 917 1434 1075 1641 1227 148 111 178 133 208 156 238 178 1034 779 1241 931 1448 1083 1655 1241 150 113 180 135 210 157 240 180 1048 786 1225 936 1462 1089 1669 1248 152 114 182 136 212 158 242 181 1062 793 1269 952 1476 1103 1682 1262 154 115 184 138 214 160 244 183 1076 807 1282 965 1489 1117 1696 1269 156 117 186 140 216 162 246 184 1089 814 1296 972 1503 1124 1710 1202 158 118 188 141 218 163 248 186 1103 872 1310 979 1517 1138 1724 1289 160 120 190 142 220 165 250 187 1110 834 1324 993 1631 1145 161 121 192 144 222 166 Interpreting Compression Readings 1 If compression improves considerably with the addition of oil piston rings are faulty 2 If compression does not improve with oil valves are sticking or seating improperly 3 If two adjacent cylinders indicate low compression pressures and squirting oil on each piston does not increase compression the head gasket may be leaking between cylinders Engine oil or coolant in cylinders could result from this condition Use the Compression Pressure Limit Chart when checking cylinder compression so that the lowest reading is within 75 percent of the highest reading PRELIMINARY 01 14 TSG 416 GENERAL INFORMATI
36. 7 4 132 7 Fuel Pump Part ZU1L 9350 AA Pressure 40 psi Normal psi Max LUBRICATION SYSTEM Max Hot 2500 rpm 275 79 413 69 kPa 40 60 Pressure psi Oil Type SAE 5W30 WSS M2C205 A API classification SJ Service Oil fill 4 2 Liter 4 44 quarts capacity
37. AUSE IMMEDIATELY S BLINDNESS OR SEVERE BURNS WITH WA E SMOKING LACIBE GET MEDICAL Eis RY SE PROTEEGER LES EVITER LES SULFURIQUE HELP FAST YEUX LES 8 ETINCELLES PEUT CAUSER LA CS RINCER LES YEUX A PEUVENT BLESSER C ET LES FLAMMES CECITE OU DES L EAU IMMEDIATEMENT RENDRE AVEUGLE DFENSE DE FUMER BRULURES GRAVES CONSULTER UN MEDECIN RAPIDEMENT KEEP OUT OF REACH OF CHILDREN TENIR HORS DE LA PORTEE DES ENFANTS 01101 Read relevant instructions Explosive gases Keep away from on children oe Eye protection must be WORN Do not dispose of as NS CZ household waste CN gt smoking or naked flames Pb 3 Recycle via a C gt recognized disposal CS Qu mr Corrosive acid RECYCLE Electrical current may Flush eyes cause injury to immediately when personnel contacted with acid Caution important notice NOTE Observe all manufacturers instructions when using charging equipment CAUTION Batteries should not be charged in the vehicle or equipment May damage electrical components PRELIMINARY 01 5 TSG 416 GENERAL INFORMATION Forward This book contains operating and maintenance instructions for the engine s listed on the title page The life of your engine unit and the delivery of the high performance built into it will depend on the care it receives throughout its life It is the operator s responsibility to ensure
38. Cylinder Head Check for plugged oil drain back holes Check for missing or damaged valve stem seals or guide mounted valve stem seals If insufficient oiling is suspected check oil passages for blockage then accelerate the engine to 1200 rpm with the PTO in NEUTRAL or load removed and the engine at normal operating temperature Oil should spurt from the rocker arm oil holes such that valve tips and camshaft roller followers are well oiled With the valve covers off some oil splash may overshoot camshaft roller followers PRELIMINARY 01 19 TSG 416 GENERAL INFORMATION Camshaft Lobe Lift Check the lift of each lobe in consecutive order and make a note of the readings 1 Remove the valve covers 2 Install the dial Indicator with Bracketry so the plunger is on top of the camshaft lobe and in the same plane as the camshaft lobe movement FPPO3511 3 Remove the spark plugs 4 Connect an auxiliary starter switch in the starting circuit Crank the engine with the ignition switch in the OFF position Bump the crankshaft over until the indicator plunger is on the base circle of the camshaft lobe At this point the lobe lift will be in its lowest position If checking during engine assembly turn the crankshaft using a socket or ratchet 5 Zero the dial indicator Continue to rotate the crankshaft slowly until the camshaft lobe is in the fully raised position highest indicator reading NOTE If the
39. EATING A small but regular downscale flicking can mean one or more valves are not seating 8 WORN VALVE GUIDES When the needle oscillates over about a 13 kPa 4 in Hg range at idle speed the valve guides could be worn As engine speed increases the needle will become steady if guides are responsible 9 WEAK VALVE SPRINGS When the needle oscillation becomes more violent as engine rpm is increased weak valve springs are indicated The reading at idle could be relatively steady 10 LATE VALVE TIMING A steady but low reading could be caused by late valve timing 11 IGNITION TIMING RETARDING Retarded ignition timing will produce a steady but somewhat low reading 12 INSUFFICIENT SPARK PLUG GAP When spark plugs are gapped too close a regular small pulsation of the needle can occur 13 INTAKE LEAK A low steady reading can be caused by an intake manifold or throttle body gasket leak 14 BLOWN HEAD GASKET A regular drop of fair magnitude can be caused by a blown head gasket or warped cylinder head to cylinder block surface 15 RESTRICTED EXHAUST SYSTEM When the engine is first started and is idled the reading may be normal but as the engine rpm is increased the back pressure caused by a clogged muffler kinked tail pipe or other concerns will cause the needle to slowly drop to 0 kPa 0 in Hg The needle then may slowly rise Excessive exhaust clogging will cause the needle to drop to a low point even if the engine
40. Equivalent m M S FPP10026 Special Service Tools called for by the procedures can be obtained by calling 1 800 ROTUNDA 1 800 768 8632 Dial Indicator with Bracketry TOOL 4201 C or Equivalent 7987 2 S FPP10026 Special Service Tools called for by the procedures can be obtained by calling 1 800 ROTUNDA 1 800 768 8632 1 Use the Dial Indicator with Bracketry to measure camshaft intake lobe lift FPPO3511 2 Rotate the camshaft and subtract the lowest dial indicator reading from the highest dial indicator reading to figure the camshaft lobe lift 3 Use the Dial Indicator with Bracketry to measure camshaft exhaust lobe lift 4 Rotate the camshaft and subtract the lowest dial indicator reading from the highest dial indicator reading to figure the camshaft lobe lift NOTE Camshaft journals must be within specifications before checking runout e Use the Dial Indicator with Bracketry to measure the camshaft runout e Rotate the camshaft and subtract the lowest dial indicator reading from the highest dial indicator reading gut V 03512 Camshaft End Play Move camshaft to the rear Zero dial indicator Move camshaft to the front Compare end play with specifications Dial Indicator 04127 PRELIMINARY 01 23 TSG 416 GENERAL INFORMATION Crankshaft Main Bearing Journal Diamet
41. For engine disassembly assembly installation adjustment procedures and specifications refer to Section 02 To maintain the required performance level the fuel system ignition system and engine must be kept in good operating condition and meet recommended adjustment specifications Before replacing damaged or worn engine components such as the crankshaft cylinder head valve guide valves camshaft or cylinder block make sure part s is not serviceable WARNING TO AVOID THE POSSIBILITY OF PERSONAL INJURY OR DAMAGE DO OPERATE THE ENGINE UNTIL THE FAN BLADE HAS FIRST BEEN EXAMINED FOR POSSIBLE CRACKS OR SEPARATION CAUTION Use of abrasive grinding discs to remove gasket material from the engine sealing surfaces dur ing repair procedures can contribute to engine damage and wear Airborne debris and abrasive grit from the grinding disc may enter the engine through exposed cavities causing premature wear and eventual en gine damage Ford Power Products does not recommend using abrasive grinding discs to remove engine gasket material Use manual gasket scrapers for removing gasket material from the engine sealing surfaces Take added care to prevent scratching or gouging aluminum sealing surfaces PRELIMINARY 01 3 TSG 416 GENERAL INFORMATION Safety Notice There are numerous variations in procedures techniques tools and parts for servicing equipment as well as in the skill of the individual doing the work This manu
42. ON Cylinder Leakage Detection When a cylinder produces a low reading use of the Engine Cylinder Leak Detection Air Pressurization Kit will be helpful in pinpointing the exact cause The leakage detector is inserted in the spark plug hole the piston is brought up to dead center on the compression stroke and compressed air is admitted Once the combustion chamber is pressurized a special gauge included in the kit will read the percentage of leakage Leakage exceeding 20 percent is excessive While the air pressure is retained in the cylinder listen for the hiss of escaping air A leak atthe intake valve will be heard in the throttle body A leak at the exhaust valve can be heard at the tail pipe Leakage past the piston rings will be audible at the positive crankcase ventilation PCV connection If air is passing through a blown head gasket to an adjacent cylinder the noise will be evident at the spark plug hole of the cylinder into which the air is leaking Cracks in the cylinder blocks or gasket leakage into the cooling system may be detected by a stream of bubbles in the radiator Oil Leak and Valve Stem Seal Test The cylinder leakage detector 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 Detection Air Pressurization Kit to a crankcase opening an oil level indicator tube is
43. TSG 416 1 6 LITER Power Products INDUSTRIAL ENGINE SERVICE MANUAL PRELIMINARY FPP 194 355 TSG 416 GENERAL INFORMATION INDEX Subject Page General Information Introduetlon WEE 01 3 SAN 01 4 Notes Cautions and Warnings 01 4 Battery Handling and R aenean 01 5 RE 01 6 notos mure oer 01 7 Parts ard ServiGe iina RR THERE cece suas E ele PRA IRR DURER 01 8 Diagnosis and Testing Special ers C 01 9 Inspection and Verification nosira ae iie eaei a ae eaa Eea 01 10 Symptom Ohan i ce RE GG RE LH RUE Up rud 01 11 IDEE c nee nes ae ni unse ee ner nn 01 13 Coripressloti REN 01 14 Cylinder Leakage Detection 2222242 0 1 11 00 esee tn dnas nnn nnd 01 15 Intake Manifold Vacuum Test 01 15 Excessive Engine Oil Consumption 01 17 cuu TEE 01 18 Valve Train Analysis 01 19 Valve Train Analysis 0 00000 nennen nennen 01 19 Camshaft Lobe Litt EE 01 20 Hydraulic Valve Lash Adjuster 01 21 General Service Procedures Camshaft Journal 22 1 00000 E
44. Tighten oil pan bolts in 3 steps in the sequence shown 44 Lubricate bolt threads with clean engine oil and enough for gasket settlement tighten to 49 Ib ft 67 Nm 5 lb ft 7 Nm 45 Check flywheel runout at clutch disc surface 7 lb ft 10 Nm maximum runout 0 005 in 0 13 mm Dial Indicator Tightening Sequence PRELIMINARY 02 54 TSG 416 ENGINE 46 Check flywheel runout at gear surface 50 Install oil filter support with new filter Tighten bolts to 15 Ib ft 20 Nm maximum runout 0 024 in 0 6 mm Cil Filter Indicator FPP04152 47 Install valve cover and gasket Tighten bolts to 7 Ib ft 9 Nm 04092 Gensor CKP Sensor Valve Cover 48 Apply grease WSD M13P8 A1 kluberpaste HEL46 450 anti seize or equivalent to spark plug threads 49 Install spark plugs and tighten to 10 13 Ib ft 13 17 Nm 52 Install crankshaft position sensor and tighten to 3 Ib ft 4 Nm PRELIMINARY 02 55 TSG 416 ENGINE 53 Install intake manifold and gasket Tighten bolts and nuts to 6 Ib ft 8 Nm Intake Manifold Assembly Ves e ele 54 Install coolant flow control module and gasket Tighten bolts to 7 Ib ft 10 Nm Coolant Flow Control Module 55 Apply sealer WSK M2G 349 4 Loctite 648 to lower end of oil level indicator tube Install immediately and tighten bolt to 15 Ib ft 20 Nm Oi
45. When diagnosing engine oil leaks the source and location of the leak must be positively identified prior to service Prior to performing this procedure clean the cylinder block cylinder heads valve covers oil pan and flywheel with a suitable solvent to remove all traces of oil Fluorescent Oil Additive Method Use the 12 Volt Master UV Diagnostic Inspection Kit to perform the following procedure for oil leak diagnosis 1 Clean the engine with a suitable solvent to remove all traces of oil 2 Drain engine oil crankcase and refill with recommended oil premixed with Diesel Engine Oil Dye 164 R3705 meeting Ford specification ESE M9C103 B1 or equivalent Use a minimum 14 8 ml 0 5 ounce to a maximum 29 6 ml 1 ounce of fluorescent additive to all engines If the oil is not premixed fluorescent 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 Kit A clear bright yellow or orange area will identify the leak For extremely small leaks several hours may be required for the leak to appear 4 If necessary pressurize the main oil gallery system to locate leaks due to improperly sealed loose or cocked plugs 5 Repair all leaks as required Pressure Method The crankcase can be pressurized to locate oil leaks The following materials are required to fabricate the tool to be used e
46. able to diesel engines only 11 This box is provided for Equipment Manufacturers use when extra equipment is fitted outside of the Ford Motor Company Reference should be made to the Equipment Manufacturer for any information or parts required Parts and Service Replacement parts can be obtained through your local Ford Power Products Distributors listed in the back portion of this manual They also may be found in the yellow pages under Engines or contact Ford Power Products Ford Power Products Distributors are equipped to perform major and minor repairs They are anxious to see that all of your maintenance and service needs are quickly and courteously completed PRELIMINARY 01 8 TSG 416 GENERAL INFORMATION DIAGNOSIS AND TESTING Special Tools FPP10023 Commercially Available Leakdown Tester d 10024 Compression Tester 014 00707 or Equivalent Cup Shaped Adapter TOOL 6565 AB or Equivalent NEA Ox M O FPP10026 Dial Indicator with Bracketry TOOL 4201 C or Equivalent Engine Cylinder Leak Detection Air Pressurization Kit 014 00705 or Equivalent 10028 Engine Pressure Gauge T73L 6600 A FPP10029 12 Volt Master UV Diagnostic Inspection Kit 164 R0756 or Equivalent iG ho FPP10030 Vacuum Pressure Tester 164 R0253 or Equivalent Special Service Tools called for by the procedures can be obtaine
47. al cannot possibly anticipate all such variations and provide advice or cautions as to each Accordingly anyone who departs from the instructions provided in this Manual must first establish that neither personal 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 WARNINGS Each one is there for a specific purpose NOTES gives you added information that will help you to complete a particular procedure CAUTIONS are given to prevent you from making an error that could damage the equipment WARNINGS remind you to be especially careful in those areas where carelessness can cause personal injury The following list contains some general WARNINGS that you should follow when you work on the equipment GENERAL WARNINGS TO HELP AVOID INJURY e ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION USE SAFETY STANDS WHENEVER A PROCEDURE REQUIRES YOU TO BE UNDER THE EQUIPMENT BESURE THAT THE IGNITION SWITCH IS ALWAYS IN THE OFF POSITION UNLESS OTHERWISE REQUIRED BY THE PROCEDURE SET THE PARKING BRAKE IF EQUIPPED WHEN WORKING ON THE EQUIPMENT IF YOU HAVE AN AUTOMATIC TRANSMISSION SET IT IN PARK ENGINE OFF OR NEUTRAL ENGINE ON UNLESS INSTRUCTED OTHERWISE FOR A SPECIFIC OPERATION PLACE WOOD BLOCKS 4 X 4 OR LARGER TO THE FRONT AND REAR SURFACES OF THE TIRES TO PROVIDE FURTHER RESTRAINT FROM INADVERTENT
48. asure the free length of each valve spring FPP03547 Valve Guide Reaming 1 Use a hand reaming kit to ream the valve guide 03550 Valve Spring Out of Square Measure the out of square on each valve spring Turn the valve spring and observe the space FPPO3548 between the top of the valve spring and the square Replace the valve spring if out of specification 2 Reface the valve seat 3 Clean the sharp edges left by reaming 03551 PRELIMINARY 01 34 TSG 416 GENERAL INFORMATION Valve Spring Compression Pressure Special Tool s Valve Clutch Spring Tester TOOL 6513 DD or Equivalent Special Service Tools called for by the procedures can be obtained by calling 1 800 ROTUNDA 1 800 768 8632 FPP10035 e Use the Valve Clutch Spring Tester to check the valve springs for proper strength at the specified valve spring length FPP03552 Valve and Seat Refacing Measurements NOTE After grinding valves or valve seats check valve clearance e Check the valve seat and valve angles Valve Seat Width e Measure the valve seat width If necessary grind the valve seat to specification 03554 Valve Seat Runout Usethe Valve Seat Runout Gauge to check valve seat runout 03555 03553 PRELIMINARY 01 35 TSG 416 GENERAL INFORMATION Flywhee
49. ation SER No DATE 2 Engine capacity e 3 Serial No This identifies the engine as supplied by Power Products Engineering sten SPECIAL EQUIPMENT Date The two letters following the serial No indicate the year month in which the specified build components were assembled refer to the chart below NOTE These markings should not be confused with any that may be stamped or etched into the crankcase of the basic engine YEAR JAN FEB MAR APRIL MAY JUNE JULY AUG SEP OCT NOV DEC gt m CH zE U ozx UuUoz i 41 ull m a v O mie lt lt z U o lt m u Qimi H u o m m lt lt lt lt VI Q Mm 00 00 lt 0 lt 2 lt lt 2 lt lt gt o o lt Z gt lt gt oO NOTE The letters I O and Q are not used in the year column The letter representing the month repeats every five years 4 Selective Build Number indicates the complete specification The digit to the extreme right hand side is the build chart issue number Engine operating rpm An asterisk denotes speed set by customer Not applicable Not applicable Applicable to diesel engines only 9 Applicable to diesel engines only 10 Applic
50. causes are shown Cratering fatigue failure A Spot polishing improper seating B Scratching dirty C Base exposed poor lubrication D Both edges worn journal damaged E One edge worn journal tapered or bearing not seated F 03517 Roller Follower Inspection Inspect the roller for flat spots or scoring If any damage is found inspect the camshaft lobes and hydraulic lash adjusters for damage d 03541 Hydraulic Lash Adjuster Inspection Inspect the hydraulic lash adjuster and roller for damage If any damage is found inspect the camshaft lobes and valves for damage d 03541 PRELIMINARY 01 32 TSG 416 GENERAL INFORMATION Valve Stem Diameter Measure the diameter of each intake and exhaust valve stem at the points shown Verify the diameter is within specification tit FPP03544 Valve Stem to Valve Guide Clearance Special Tool s Dial Indicator with Bracketry TOOL 4201 C or Equivalent FPP10026 Valve Stem Clearance Tool TOOL 6505 E or Equivalent Special Service Tools called for by the procedures can be obtained by calling 1 800 ROTUNDA per ose 1 800 768 8632 NOTE Valve stem diameter must be within specifications before checking valve stem to valve guide clearance NOTE If necessary use a magnetic base 1 Install the Valve Stem Clearance Tool on th
51. cylinder to the next oversize 4 d i i H i N l l amp FPP03520 Dial Indicator with Bracketry TOOL 4201 C or Equivalent Special Service Tools called for by the procedures can be obtained by calling 1 800 ROTUNDA 1 800 768 8632 FPP10026 NOTE Crankshaft main bearing journals must be within specifications before checking runout PRELIMINARY 01 26 TSG 416 GENERAL INFORMATION Cylinder Bore Out of Round Measure the cylinder bore in two directions The difference is the out of round Verify the out of round is within the wear limit and bore the cylinder to the next oversize limit ze e SO V N A co UL or 03521 Piston Inspection Special Tool s Piston Ring Groove Cleaner D81L 6002 D or Equivalent Special Service Tools called for by the procedures can be obtained by calling 1 800 ROTUNDA 1 800 768 8632 FPP10032 Make sure the oil ring holes are clean FPP03523 Piston Diameter Measure the piston skirt diameter 03524 CAUTION Do not use caustic cleaning solution or a wire brush to clean the pistons or possible dam age 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 twisted
52. d 1 Remove valve cover Refer to Valve Cover Removal on page 10 2 Rotate the camshaft so the roller follower for the valve to be serviced is on the heel of the cam 3 Using a suitable valve spring compressor tool compress and hold down the valve spring Slide out the roller follower over the lash adjuster Roller Follower Lash Adjuster FPP04076 4 Replace spark plug for cylinder being serviced with an air line adapter Mark location so spark plug 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 cylinder Air pressure may rotate the crankshaft until the piston reaches the bottom of the stroke Rotunda Pressurization Kit 014 00705 6 Using a suitable valve spring compressor compress the valve spring and remove the keys and retainer Remove and discard the stem seal Bee Retainer Spring Valve Seal FPPO4073 7 If air pressure has forced the piston to the bottom of the cylinder any removal of air pressure will allow the valve s to drop into the cylinder Wrap a rubber band tape or string around the end of the valve stem in such a way to prevent the valve from falling in and to allow enough travel to check the valve for binds 8 Inspect the valve stem for damage Rotate the valve and check the stem tip for eccentric movement Mo
53. d Larger End 2 1 entente nnne nnde E nan Penne nnde 01 30 Piston Pin tiefen etta tipa ba dieat tu bet Lbs 01 30 Connecting Rod Bushing 31111 nter ne nennen nennen nn 01 30 Gonnecting Rod Bernd 01 30 Connecting Rod T 01 30 Connecting Rod Piston Pin Side Clearance 01 31 PRELIMINARY 01 1 TSG 416 GENERAL INFORMATION INDEX CONT Subject Page General Service Procedures Connecting Rod Journal Clearance nennen enne 01 31 Bearing Inspecti n E rent en 01 32 Roller Follower 01 32 Hydraulic Lash Adjuster JInspechon 0000 01 32 Valve Stem RTE EE 01 33 Valve Stem to Valve Guide Cearance 01 33 Valve Inspection 01 33 ab ete ie Dite d e ede 01 34 D 01 34 Valve Spring Installed Eernigth 2 inccr id teet iot ettet ink al seem AE 01 34 Valve Spring Free Lengtli 2 2 ELDER RELIER sas LO RE VR Dex 01 34 Valve S
54. d by calling 1 800 ROTUNDA 1 800 768 8632 PRELIMINARY 01 9 TSG 416 GENERAL INFORMATION Inspection and Verification 1 Verify the customer concern by operating the engine to duplicate the condition Visually inspect for obvious 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 If the inspection reveals obvious concerns that can be readily identified repair as required If the concerns remain after the inspection determine the symptoms and go to the symptom chart PRELIMINARY 01 10 Symptom Chart TSG 416 GENERAL INFORMATION Condition Possible Source Action Difficult Starting Damaged starting system Refer to Section 07 Damaged charging system battery Refer to Section 06 Burnt valve Replace valve Worn piston Replace piston and pin Worn piston rings or worn cylinder Repair or replace cylinder blocks Damaged cylinder head gasket Replace cylinder head gasket Damaged fuel system Refer to Section 04 Damaged ignition system Refer to Section 03 Damaged hydraulic tappet or hydraulic lash adjuster Replace tappet or lash adjuster Poor Idling Damaged hydraulic lash adjuster or hydraulic lash Replace hydraulic lash adjuster or hydraulic lash adjuster adjuster Damaged hydraulic lash adjuster guide or hydraulic lash adjuster
55. d link on drive chain 12 O clock Position Timing Mark FPPO4084 Coppered Link 19 Insert camshaft sprocket into chain and assemble to camshaft Position camshaft key at 12 o clock and align timing mark between 2 coppered links on drive chain Coppered Links 12 O clock Position Timing Mark 20 Install camshaft sprocket bolt and hydraulic tensioner finger tight PRELIMINARY 02 50 TSG 416 ENGINE 21 Tighten guide and tensioner arm bolts to 18 21 Ib ft 23 Tighten hydraulic tensioner to 27 32 Ib ft 36 44 24 28 Nm Tensioner Arm 22 Using locking tool tighten camshaft sprocket bolt to 52 59 Ib ft 70 80 Nm Nm Hydraulic Tensioner Chain Guide FPP04135 CAUTION The oil pump pulley and sealer are provided as an assembly kept together by a clip no n BF9A 6606 AA Do not remove clip until oil pump is installed If pulley is pushed out of the oil pump prior to oil pump installation it will have to be repaired or replaced can this pump be rebuilt Locking Tool 15 030A FPPO4132 FPP04166 Do Not Remove Clip Until Installed PRELIMINARY 02 51 TSG 416 ENGINE 24 Assemble gasket onto oil pump housing guiding it with 2 outer bolts FPP04139 CAUTION Do not apply oil to shaft or seal Sealing lip along with all contact surfaces must be free of oil 25 Place oil pump and gasket onto crankshaft 26 Install pulley bolt and tighten to 92 Ib ft 125 Nm Pulley
56. e camshaft so the roller follower for the valve to be serviced is on the heel of the cam 3 Using a suitable valve spring compressor tool compress and hold down the valve spring Slide out the roller follower over the lash adjuster Roller Follower Special Tool 21 024 Lash Adjuster FPP04076 1 Rotate the camshaft so the roller follower for the valve to be serviced is on the heel of the cam 2 Install the hydraulic lash adjuster FPPO4134 3 Using a suitable valve spring compressor tool compress and hold down the valve spring Slide in the roller follower over the lash adjuster 4 Lift outthe hydraulic lash adjuster 4 Install valve cover Refer to Valve Cover Removal on page 10 PRELIMINARY 02 24 TSG 416 ENGINE Oil Pan Removal 2 Install the oil pan and bolts finger tight 4 Remove bolts 3 Align oil pan with rear portion of engine block 2 Remove oil pan Straight Edge Oil Pan Oil Pan 04088 3 Remove all gasket material from pan CAUTION Be careful not to contact surfaces Oil Pan Installation 4 Tighten oil pan bolts in 3 steps in the sequence CAUTION The contact surfaces of oil pan gasket shown and block must be free of oil Do not wait more than 5 minutes to install the oil pan gasket after sealer enough for gasket settlement has been applied 5Ib ft 7 Nm 7 b ft 10 Nm 1 Apply WSEM A4 sealer Loctite 5910 to the 4 position
57. e valve stem and install the Dial Indicator with Bracketry Lower the valve until the Valve 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 from the Dial Indicator and note the reading The reading will be double the valve stem to valve guide clearance Valves with oversize stems will need to be installed if out of specification FPP03545 Valve Inspection Inspect the following valve areas The end of the stem for grooves or scoring The valve face and the edge for pits grooves or scores The valve head for signs of burning erosion warpage and cracking Minor pits grooves and other abrasions may be removed The valve head thickness for wear Valve Stem Valve Head Thickness d Valve Face 03546 PRELIMINARY 01 33 TSG 416 GENERAL INFORMATION Valve Guide Inner Diameter Valve Spring Installed Length 1 Measure the inner diameter of the valve guides in Measure the installed length of each valve spring two directions where indicated 2 If the valve guide is not within specifications ream the valve guide and install a valve with an oversize stem or remove the valve guide and install a new valve guide 03549 C n Valve Spring Free Length Me
58. er Crankshaft Main Bearing Journal Taper Measure each of the crankshaft main bearing journal Measure each ofthe crankshaft main bearing journal diameters in at least two directions diameters in at least two directions at each end of in T the main bearing journal e Ifitis out of specification replace as necessary e Ifitis out of specifications replace as necessary T FPP03513 FPP03514 PRELIMINARY 01 24 TSG 416 GENERAL INFORMATION Crankshaft Main Bearing Journal Clearance Special Tool s Plastigage amp D81L 6002 B or Equivalent Special Service Tools called for by the procedures can be obtained by calling 1 800 ROTUNDA 1 800 768 8632 FPP10031 NOTE Crankshaft main bearing journals must be within specifications before checking journal clearance 1 Remove the crankshaft main bearing caps and bearings 2 Lay a piece of Plastigage across the face of each crankshaft main surface FPP03515 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 fitis out of specification replace as necessary 03516 Bearing Inspection Inspect bearings for the following defects Possible causes are shown Cratering fatigue failure A Spot polishing improper seating B Scratching dirty C
59. etainer key on the valve stem and in valve spring retainer Valve Spring Retainer Keys Check for proper seating on the valve stem Valves and Cylinder Head e Check the head gasket for proper installation e Check for plugged oil drain back holes e Check for worn or damaged valve tips e Check for missing or damaged guide mounted valve stem seal e Check collapsed lash adjuster gap e Check installed valve spring height e Check for missing or worn valve spring seats 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 Start the engine and while idling check for proper operation of all parts Check the following Rocker Arm e Check for plugged oil in the rocker arms or cylinder head e Check for proper overhead valve train lubrication If insufficient oiling is suspected accelerate the engine to 1200 rpm 100 rpm with the PTO in NEUTRAL or load removed and the engine at normal operating temperature Oil should spurt from the rocker arm oil holes such that valve tips and rocker arms are well oiled or with the valve covers off oil splash may overshoot the rocker arms If oiling is insufficient for this to occur check oil passages for blockage Positive Rotator and Valve Spring Retainer Keys Check for proper operation of positive rotator Valves and
60. he engine CAUTION Use new main bearing cap bolts 4 Install main bearing caps in the same positions as removed NOTE Check the position of studs as shown Stud Positions 04145 5 Tighten main bearing cap bolts studs in sequence shown and in three steps to 70 Ib ft 95 Nm Front of Engine NOTE Check crankshaft end play as outlined in Section 01 PRELIMINARY 02 48 TSG 416 ENGINE 6 Set piston ring gaps as follows lower oil ring gap aligned with piston pin center ring gap at 90 from the oil ring gap top ring gap at 180 from the oil ring gap 7 Lubricate piston bearing wear surface crankshaft journal and cylinder wall with clean engine oil 8 Carefully install pistons with bearings into cylinder bores using a piston 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 identified in the base Hammer Handle Piston Ring Compressor Tool CAUTION Use new connecting rod cap bolts and lubricate threads with clean engine oil 9 Install connecting rod caps with bearings lubricate wear surface and tighten bolts in 2 steps Step 1 9 Ib ft 12 5 Nm Step 2 22 Ib ft 30 Nm 41 94 10 Install a new rear seal and retainer using tool
61. hoose the piston with the proper paint 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 Special Tool s Feeler Gauge D81L 4201 A or Equivalent Special Service Tools called for by the procedures can be obtained by calling 1 800 ROTUNDA FPP10033 1 800 768 8632 PRELIMINARY 01 28 TSG 416 GENERAL INFORMATION Piston Ring to Groove Clearance Special Tool s FPP10033 Feeler Gauge D81L 4201 A or Equivalent Special Service Tools called for by the procedures can be obtained by calling 1 800 ROTUNDA 1 800 768 8632 1 Inspect for a stop in the grooves 2 Measure the piston to groove clearance 03529 Crankshaft Connecting Rod Journal Diameter Measure the crankshaft connecting rod journal diameters in at least two directions perpendicular to one another The difference between the measurements is the out of round Verify the journal is within the wear limit specification E 03530 Crankshaft Connecting Rod Journal Taper e Measure the crankshaft rod journal diameters two directions perpendicular to one another at each end of the connecting rod journal The difference in the measurements from one end to the other is the taper Verify measurement is within the wear limit T FPP03531
62. ic Chain Guide Tensioner Camshaft Sprocket 4135 PRELIMINARY 02 41 TSG 416 ENGINE 33 Remove crankshaft rear seal retainer CAUTION Keep cylinder head in the vertical position during removal to avoid warping and damage to the sealing surfaces Oil Seal Retainer 31 Remove the M11 cylinder head bolts in 3 phases in the sequence shown FPP04078 NOTE Mark piston and cap so they may be returned to their original positions 34 Remove 2 bolts lower connecting rod bearing and cap Push piston assembly out of the engine block Repeat for other three cylinders 32 Remove 2 8 bolts cylinder head and gasket 8 Bolts Cylinder Head PRELIMINARY 02 42 TSG 416 ENGINE 36 Carefully remove the crankshaft and install it vertically on the flywheel to avoid warp running out NOTE Keep caps and bearings in order so they may be returned to their original positions 35 Remove bolts caps and crankshaft lower main bearings in the sequence shown Crankshaft FPPO4160 37 Remove the 5 upper main bearings and the 2 thrust washers Upper Main Bearings A USD Thrust Washers gut 5 6 t Front of Engine PRELIMINARY 02 43 TSG 416 ENGINE SUBASSEMBLIES 3 Check the engine block for warpage cracks or any other damage
63. ipstick and draw a mark on the back unmarked surface at the indicated oil level This level should be about the same as the ADD mark on the face of the oil level dipstick 9 Add one quart of oil Restart the engine and allow to idle for atleast two minutes Shut off the engine and allow the oil to drain back for at least five minutes Mark the oil level dipstick using the procedure above This level may range from slightly below the top of the cross hatched area to slightly below the letter F in FULL 10 Record the vehicle mileage or hours PRELIMINARY 01 17 TSG 416 GENERAL INFORMATION 11 Instruct the customer to run engine as usual and perform the following Checkthe oil level regularly at intervals of 3 to 3 1 2 hours Return to the service point when the oil level drops below the lower ADD mark on the oil level dipstick Add only full quarts of the same oil in an emer gency Note the mileage at which the oil is added 12 Check the oil level under the same conditions and at the same location as in Steps 7 9 Measure the distance from the oil level to the UP PER mark on the oil level dipstick and record Measure the distance between the two scribe marks and record Divide the first measurement by the second Divide the hours run during the oil test by the re sult This quantity is the approximate oil con sumption rate in hours per quart 13 If the oil consumption rate is unacceptable proceed to
64. is only idling When vacuum leaks are indicated search out and correct the cause Excess air leaking into the system will upset the fuel mixture and cause concerns such as rough idle missing on acceleration or burned valves If the leak exists in an accessory unit such as the power brake booster the unit will not function correctly Always fix vacuum leaks PRELIMINARY 01 16 TSG 416 GENERAL INFORMATION Excessive Engine Oil Consumption The amount of oil an engine uses will vary with the way the equipment is driven in addition to normal engine to engine variation This is especially true during the first 340 hours or 16 100 km 10 000 miles when a new engine is being broken in or until certain internal engine components become conditioned Engines used in heavy duty operation may use more oil The following are examples of heavy duty operation severe loading applications sustained high speed operation Engines need oil to lubricate the following internal components cylinder block cylinder walls pistons piston pins and rings intake and exhaust valve stems intake and exhaust valve guides allinternal engine components When the pistons move downward a thin film of oil is left on the cylinder walls As the engine is operated some oil is also drawn into the combustion chambers past the intake and exhaust valve stem seals and burned The following is a partial list of conditions that can affect oil consump
65. l 21 024 6 Install lash adjusters Roller Follower Lash Adjuster FPPO4134 4 Usinga suitable spring compressor tool install valve springs retainers and locks 7 Install roller followers NOTE The chamfer on the camshaft bearing caps must ptm be facing the chain housing Retainer 8 Carefully install camshaft bearings camshaft and bearing caps with bolts finger tight Spring NOTE Rotate camshaft so key is at 12 O clock position 9 Tighten bolts in the sequence shown in 3 steps to 6 Valve Seal 7 Ib ft 8 10 Nm aR 9 Br d ab Cylinder Head ay Tightening Sequence FPPO4133 PRELIMINARY 02 47 TSG 416 ENGINE ASSEMBLY NOTE components must be clean and dried with compressed air or a lint free cloth For information on bearings amp piston inspection and selection Refer to Section 01 1 Install upper main bearings and thrust washers to cylinder block Lubricate the wear surfaces with clean engine oil Make sure oil holes align Upper Main Bearings A USD Thrust Washers SD VI 1 1 gt 2 Carefully install the crankshaft onto the upper 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 corresponding numbers The arrow on the main bearing caps must point to the front of t
66. l Inspection Hone with the Engine Cylinder Hone Set at a speed of 300 500 rpm and a hone grit of 180 220 to provide Special Tool s the desired cylinder bore surface finish Dial Indicator with Bracketry NES TOOL 4201 C or Equivalent BUT Special Service Tools called for CSS 22 by the procedures be 7 E obtained by calling 1 800 ROTUNDA 1 800 768 8632 FPP10026 1 Inspect the flywheel for Cracks A FPP03560 Worn ring gear teeth B Chipped or cracked ring gear teeth C Cylinder Bore Cleaning 2 1 t the flywheel ri t NSPA ln u CAUTION If these procedures are not followed rusting of the cylinder bores may occur 1 Clean the cylinder bores with soap or detergent and water 2 Thoroughly rinse with clean water and wipe dry with a clean lint free cloth 3 Use a clean lint free cloth and lubricate the cylinder bores Use Engine Oil XO 10W30 QSP or DSP or equivalent meeting Ford specification ESE M2C153 E Cylinder Bore Honing Special Tool s Engine Cylinder Hone Set T73L 6011 A Special Service Tools called for by the procedures can be obtained by calling 1 800 ROTUNDA 1 800 768 8632 FPP10037 NOTE Before any cylinder bore is honed all main bearing caps must be installed so the crankshaft bearing bores will not become distorted NOTE To correct taper or out of round bore the cylinder block NOTE
67. l Level Indicator Tube 56 sealer WSK M2G 349 A7 Loctite 243 to threads of coolant return connector Install and tighten to 15 Ib ft 20 Nm Coolant Return Connector PRELIMINARY 02 56 TSG 416 ENGINE 57 Install generator support Tighten bolts to Ib ft Nm Generator Support 04157 58 Install generator and electrical connectors Tighten bolts to Ib ft Nm FPP04167 Generator Electrical Connector NOTE Drive belt must be installed in the same direction of rotation as when removed 59 Pry tensioner pulley as shown and install drive belt Tension Pulley Of 4 PS RU FPPO4155 60 Install engine wiring and vacuum hoses Wiring Harness Vacuum Hose 61 Fill engine with clean engine oil of the correct type and quantity NOTE Ford Power Products industrial engines are designed to perform with engine oils that are licensed by the American Petroleum Institute and oils carrying the most current API classification should be used PRELIMINARY 02 57 TSG 416 ENGINE SPECIFICATIONS ELECTRICAL SYSTEM GENERAL SPECIFICATIONS Polarity Negative to earth ground Generator Drive Belt Tension 8K Poly Belt Tension is within specification if the tensioner is within the indicator markings Engine Type 4 cylinder 4 stroke spark ignition 90 Overhead Valve OHV chain driven overhead camshaft o
68. l in them Use only testing fluid New hydraulic lash adjusters are already filled with testing fluid Place the lash adjuster in the tester with the plunger facing upward Position the steel ball provided in the plunger cap Add testing fluid to cover the hydraulic lash adjuster and compress Leakdown Tester until the hydraulic lash adjuster is filled with testing fluid and all traces of air bubbles have disappeared The fluid can be purchased from the tester s manufacturer Using kerosene or any other fluid will not provide an accurate test Leakdown Tester Lash Adjuster 03542 Adjust the length of the ram so the pointer is just below the start timing mark when the ram contacts the hydraulic lash adjuster Start Timing as the pointer passes the start timing mark and end timing as the pointer reaches the center mark 03543 Pointer 4 A satisfactory lash adjuster must have a leakdown rate time in seconds within specified minimum and maximum limits Ifthe lash adjuster is not within specification replace it with a new lash adjuster Do not disassemble and clean new lash adjusters before testing because oil contained in the new lash adjuster is test fluid Remove the fluid from the cup and bleed the fluid from the lash adjuster by working the plunger up and down This step will aid in depressing the lash adjuster plungers when checking valve clearance PRELIMINARY 0
69. lation 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 oil 1 Place upper bearing on crankshaft and rotate into place Oil holes must align 2 Place lower bearing into cap NOTE Main bearing cap arrow must point to the front of the engine 3 Install bearing cap CAUTION Use new main bearing cap bolts 4 Lightly oil new main bearing bolts or studs and install in same positions as removed Alternately tighten in 3 steps to 70 Ib ft 95 Nm 5 Check crankshaft end play as outlined in Section 01 6 Install pick up tube and deflector Refer to Pick up Tube Deflector Installation on page 26 7 Install oil pan Refer to Oil Pan Installation on page 25 PRELIMINARY 02 27 TSG 416 ENGINE Connecting Rod Bearings Removal 1 Remove oil pan Refer to Oil Pan Removal on page 25 2 Remove pick up tube and deflector Refer to Pick up Tube Deflector Removal on page 26 3 Remove spark plug for cylinder being serviced 4 Rotate crankshaft until connecting rod and bearing to be serviced is placed at the bottom of its stroke 5 Remove two connecting rod nuts 6 Remove connecting rod cap with lower bearing Bearing FPP04072 7 Push piston and connecting rod assembly up into bore 8 Remove upper bearing from connecting rod NOTE For bearing service refer to Section 01
70. lift on any lobe is below specified service limits the camshaft and any component operating on worn lobes must be replaced 6 Compare the total lift recorded on the dial indicator with specifications 7 To check the accuracy of the original dial indicator reading continue to rotate the crankshaft until the indicator reads zero 8 Remove the dial indicator adapter and auxiliary starter switch CAUTION After installing rocker arms do not ro tate the crankshaft until lash adjusters have had sufficient time to bleed down To do otherwise may cause serious valve damage Manually bleeding down lash adjusters will reduce waiting time 9 Install the valve covers 10 Install the spark plugs PRELIMINARY 01 20 TSG 416 GENERAL INFORMATION Hydraulic Valve Lash Adjuster Hydraulic lash adjuster noise can be caused by any of the following excessively collapsed lash adjuster gap sticking lash adjuster plunger lash adjuster check valve not functioning properly airin lubrication system e leakdown rate too rapid excessive valve guide wear Excessive collapsed lash adjuster gap can be caused by loose rocker arm seat bolts nuts incorrect initial adjustment or wear of lash adjuster face or worn roller lash adjusters push rod rocker arm rocker arm seat or valve tip With lash adjuster collapsed check gap between the valve tip and the rocker arm to determine if any other valve train parts are damaged worn or ou
71. n type cylinder block core plug This could expand the plug before seating and result in leakage Use a fabricated tool to seat the expansion type cylinder block core plug PRELIMINARY 01 38 TSG 416 GENERAL INFORMATION Spark Plug Thread Repair Special Tool s 2 Startthe tap into the spark plug hole being careful to keep it properly aligned As the tap begins to cut new threads apply aluminum cutting oil Tapersert Installation Kit 107 R0921 or Equivalent 9 FPP10038 Feeler Gauge D81L 4201 A or Equivalent Special Service Tools called for by the procedures can be obtained by calling 1 800 ROTUNDA 10033 1 800 768 8632 CAUTION The cylinder head must removed from the engine before installing a tapersert If this pro cedure is done with the cylinder head on the engine the cylinder walls can be damaged by metal chips produced by the thread cutting process CAUTION Do not use power or air driven tools for finishing taperserts NOTE This repair is permanent and will have no effect on cylinder head or spark plug life 1 Clean the spark plug seat and threads FPP03564 geeaaee 03565 3 Continue cutting the threads and applying oil until the stop ring bottoms against the spark plug seat 4 Remove the tap and metal chips 5 Coat the threads of the mandrel with cutting oil Thread the tapersert onto the mandrel until one
72. ngines in normal service should get at least 31 7 hours per quart 900 miles per quart after 300 hours of service High speeds heavy loads high ambient temperature and other factors may result in greater oil use 1 Determine customer s engine load habits such as sustained high speed operation extended idle heavy work loads and other considerations 2 Verify that the engine has no external oil leak as described under Engine Oil Leaks in the Diagnosis and Testing portion of this section 3 Verify that the engine has the correct oil level dipstick 4 Verify that the engine is not being run in an overfilled condition Check the oil level at least five minutes after a hot shutdown with the engine vehicle parked on a level surface In no case should the level be above the top of the cross hatched area and the letter F in FULL If significantly overfilled perform steps 5 through 9 If not proceed to step 10 5 Drain the engine oil remove and replace the oil bypass filter and refill with one quart less than the recommended amount 6 Run the engine for three minutes 10 minutes if cold and allow the oil to drain back for at least five minutes with the engine vehicle on a level surface 7 Remove oil level dipstick and wipe clean CAUTION Do not wipe with anything contaminated with silicone compounds 8 Reinstall the oil level dipstick being sure to seat it firmly in the oil level indicator tube Remove the oil level d
73. nto connecting rods and caps Make sure lock slots align CAUTION Make sure bearings and connecting rod bore are clean foreign material under the inserts will distort the bearing and cause a failure PRELIMINARY 02 45 TSG 416 ENGINE Cylinder Head Disassembly 6 Remove all valve components using a suitable valve NOTE Store components to ensure assembly in the SS RE same order they were removed 1 Remove bolts and camshaft bearing caps evenly in the sequence shown Pe Retainer Spring Valve Seal al OR T CS n WC CI Ko G Ka p Ci my Loosening Sequence FPP04133 Cylinder Head Remove camshaft Remove roller followers Remove lash adjusters Remove spark plugs Refer to Section 01 for DF oh servicing valve components valve guide and valve seat y e camshaft and bearing service Bearing Caps i cylinder head cleaning and inspection CH c Follower PRELIMINARY 02 46 TSG 416 ENGINE Cylinder Head Assembly 5 Check that spring installed height is 35 2 1mm NOTE All components must be clean and assembled in the same positions as removed Lubricate contact surfaces with clean engine oil Spring 1 Check that valves move freely in valve guides Installed Height 2 Install intake and exhaust valves 3 Install new valve seals using special tool 21 024 optional T95P 65654 FPP04165 Special Too
74. o 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 92 Ib ft 125 Nm Pulley Bolt FPPO4140 4 Remove clip 5 Install oil pump housing bolts finger tight CAUTION The oil pump housing must be positioned during tightening of the oil pump housing bolts so that the sealing flange of the oil pump housing is within 0 008 in 0 20 mm of the block bottom sealing flanges 6 Tighten 2 outer oil pump housing bolts to 15 Ib ft 20 Nm Outer Bolts FPPO4141 7 Tighten remaining oil pump housing bolts to 15 Ib ft 20 Nm FPPO4142 Remaining Bolts PRELIMINARY 02 22 TSG 416 ENGINE Crankshaft Rear Oil Seal Removal Crankshaft Rear Oil Seal Installation 1 Remove flywheel refer to xx 1 Install new rear seal and retainer using tool 21 046 2 Remove oil pan refer to xx 3 Remove bolts and rear oil seal retainer Special Tool Rear Oil Seal gt and Retainer Rear Seal Retainer 2 Install oil pan refer to xx 3 Install flywheel refer to xx PRELIMINARY 02 23 TSG 416 ENGINE Camshaft Follower Hydraulic Lash Camshaft Follower Hydraulic Lash Adjuster Removal Adjuster Installation NOTE All components must be kept clean and 1 Remove valve cover Refer to Valve Cover lubricated with clean engine oil Removal on page 10 2 Rotate th
75. osition CKP Sensor Water Pump Chain Guide Piston Assembly 04128 PRELIMINARY 02 6 TSG 416 ENGINE Component Location Throttle Body o I gt Intake Manifold Exhaust Manifold PRELIMINARY 02 7 TSG 416 ENGINE Component Location Oil Pick up tube Oil Deflector Main Bearings Lower Main Bearing Cap Rear Seal Retainer Crankshaft Sprocket Crankshaft Main Bearings Upper Cylinder Block Timing Chair PRELIMINARY 02 8 TSG 416 ENGINE Component Location Spark Plug Wires DIS Ignition Coil PCV Valve Valve Cover PCV Hose Camshaft Sprocket 0 Bearing Caps Tension Arm Camshaft Roller Follower Lash Adjuster Cylinder Head Chain Guide Valve Assembl T ming Chain idc ee Hydraulic Tensioner PRELIMINARY 02 9 TSG 416 ENGINE ENGINE REPAIR Valve Cover Installation Valve Cover Removal 1 Contact surfaces must be clean and free of oil 2 Install a new gasket and valve cover 1 Remove any necessary wiring and vacuum hoses Mark connections and routing as necessary to assure they are returned as they were removed CMP Sensor PCV Valve Wiring Harness Valve Cover Vacuum Hose 3 Install bolts Tighten to 7 Ib ft 9 Nm any sequence Install DIS coil refer to Section 03 Remove DIS coil and set aside refer to Section 03 Remove bolts Reconnect any wi
76. overseas it is important that you as complete identification of the engine as possible in order to provide the correct replacement parts New engines being shipped include a standard parts listing describing the parts which does not tell the owner the part number It remains a distributor function to identify the part number The key to identifying the engine is the identification decal mounted on the engine rocker cover That decal provides not only the engine serial number but also the exact model or type options and S O Special Order The combination of that data permits you to isolate the precise engine build level and customer so you can determine the correct replacement parts U S A Engine Identification Decal An identification Decal is affixed to the valve cover of the engine The decal contains the engine serial number which identifies this unit from all others Use all numbers when seeking information or ordering replacement parts for this engine Serial Number 01 01 000123 Power 1259 Model Number TSG 416L 6005 BA Base Engine Code Build Date 2U1L 6005 BA 01 01 2003 Distributor S O Number 1 6L ENGINE For a handy reference this information is recorded on your Ford Power Products Operations Engine Registration copy Form 194 103 D U S A Emission Decal The emission decal is affixed to the valve cover on all certified engines over 25 horsepower distributed in the State of Califo
77. perating the valves via roller cam followers Liter CID 1 6 97 5 IGNITION Bore mm inch 82 070 mm 3 23 in Spark Ford Part Number XS6F 12405 A1A NGK TR6B 10 Plug Gap 0 95 1 05 mm Firing 1 3 4 2 Order Ratio Stroke mm 75 480 mm 2 97 in inch Number of 4 cylinders Compression 9 5 1 CRANKSHAFT Main journal standard diameter 2 243 2 244 56 980 57 000 mm FUEL SYSTEM Main journal undersize diameter 2 233 2 234 56 726 56 746 including filter Oil filter Type X56E 6714 D1A COOLING SYSTEM Thermostat Type Wax element Commences opening 82 2 C 180 F Fully open 94 5 C 202 F Coolant 50 Motorcraft Super Plus 2000 plus 50 clear water Ford Specification WSS M97B44 D or ESE 97 44 PRELIMINARY 02 58 LPG Liquefied Petroleum Gas n Width main journal bearing shell Fuel EN589 European USA Specification Pin Journal standard NG Natural Gas Type ITEM Nm FT LB LB IN Fuel 38 7 MJ m UK 39 0 MJ m USA ge nb Specification Oil Pan Drain 25 18 221 3 GAS Gasoline petrol Plug Type Electronic Fuel Injection Fuel Unleaded 87 or 89 Octane Gasoline blends Spark Plugs 13 17 9 6 12 5 115 150 5 Specification notto exceed 10 Ethanol by volume Octane Index of 87 or 89 Oil Filter 11 15 8 11 9
78. pring Bee ETC 01 34 Valve Spring Compression Pressure 9 8 01 35 Valve and Seat Refacing Measurement 01 35 45 IUIUS 01 35 Valve Seat Runout 5e eiim da d e 01 35 Elywheelinspection T ae aa Ala i 01 36 Oil Pump Gear Radial Clearance ii iei elec ba testo deu a 01 36 Oil Pump Rotor Inspection 1 2 2 2 2 4 800000 ennemi e sn nes a nnns nn 01 36 Oil Pump Tee Ee EE 01 36 Cylinder Bore FGM ee ees ooo oe RE I re Hie met ale ee M e 01 36 Cylinder Bore Cleaning ry i ure et e ege titer oe spend repeti RA dern indu 01 36 Cylinder Block Repair Cast Iron Porosity Deiects A 01 37 Cylinder Block Core Plug nn 01 37 Cylinder Head DIStOFtIOD o o eit i EN EE RE ERA 01 37 Spark Plug Thread Re paima ga a 01 39 Exhaust Manifold Straightness 01 40 lat Ell le Ne EE 01 40 PRELIMINARY 01 2 TSG 416 GENERAL INFORMATION GENERAL INFORMATION Introduction This section covers various engine tests adjustments service procedures and cleaning inspection procedures Engine assembly and service specifications appear at the end of the Section 02
79. ring and vacuum hoses removed o o RON Remove valve cover and gasket PRELIMINARY 02 10 TSG 416 ENGINE Camshaft Removal 5 Remove camshaft lower bearings roller followers NOTE Store components to ensure assembly in the same order they were removed 1 Remove valve cover Refer to Valve Cover Removal on page 10 Bearing Caps 2 Using tool 15 030A to lock camshaft sprocket Cm Roller remove bolt Follower Locking Tool 15 030A FPPO4132 6 7 Refer to Section 01 for camshaft and bearing service CAUTION During camshaft removal the camshaft sprocket and chain must remain 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 refer to timing chain assembly xxx 3 Separate camshaft sprocket and chain from camshaft while maintaining tension on the chain 4 Remove bolts and camshaft bearing caps evenly in the sequence shown Dog UV 2 C3 DON Po Ss 1772 FPPO4133 PRELIMINARY 02 11 TSG 416 ENGINE Camshaft Installation NOTE All components must be clean and assembled the same positions as removed Lubricate contact surfaces with clean engine oil 1 2 3 Install lash adjusters 4 Install roller followers Bearing Caps mA M NOTE
80. rnia IMPORTANT ENGINE INFORMATION with an engine build date after January 1st 2001 The decal H in H THIS ENGINE IS EQUIPPED WITH ELECTRONIC ENGINE CONTROL identifies that the engine is compliant with California s Air SYSTEMS ENGINE IDLE SPEED IDLE MIXTURE AND IGNITION Resources Board s ARB Large Spark Ignited LSI Engine TIMING ARE NOT ADJUSTABLE SEE GWINERS MANUAL FOR MORE Regulations Use all numbers when seeking information or AE NONE E CEEE o LENA ordering replacement parts for this engine REGULATIONS FOR OFF ROAD LARGE SPARK IGNITION ENGINES THIS ENGINE IS CERTIFIED TO OPERATE ON GASOLINE AND LIQUID PETROLEUM GAS 1FMXBO2 5GAA 1 6L TWC HO28 SFI CATALYST SPARK PLUG AWSF32EE GAP 042 046 Engine Build Identification Label The TSG 416 Engine Build Identification Label is located on the front side of the valve cover near the oil level indicator This label contains assembly information as shown below Sequential for the engine this day Assembly date dd mm y ID QD 2U1L 6005 BA Working Shift NOTE This engine was assembled on June 27 2000 PRELIMINARY 01 7 TSG 416 GENERAL INFORMATION European Service Identification plate This plate is fixed to the engine in a prominent position Panels 1 to 11 on the plate shown to the right refer to various engine details as listed below Industrial Power Products Lesen CAPACITY FUEL SYS RPM 1 Engine model identific
81. s as shown Sealer Rope an Tightening Sequence 10 15mm PRELIMINARY 02 25 TSG 416 ENGINE Pick up Tube Deflector Removal Remove oil pan Refer to Oil Pump Removal on page 21 4 Remove 4 nuts and1 bolt 5 Remove pick up tube Remove oil deflector Pick up Tube Oil Deflector 004087 Pick up Tube Deflector Installation ao A gt Install deflector Install pick up tube Install 4 nuts and tighten to 14 Ib ft 19 Nm Install bolt and tighten to 7 Ib ft 9 5 Nm Install oil pan Refer to Oil Pump Installation on page 22 PRELIMINARY 02 26 TSG 416 ENGINE Crankshaft Main Bearings Removal NOTE To check bearing clearances or to select new bearings refer to Section 01 1 Remove oil pan Refer to Oil Pan Removal on page 25 2 Remove pick up tube amp deflector Refer to Pick up Tube Deflector Removal on page 26 NOTE Replace one bearing at a time leaving the other bearings securely fastened Note location of studs for deflector installation Stud Positions FPPO4145 3 Remove first main bearing cap bolts 4 Remove cap and lower bearing 5 Press on end of upper bearing without tang to start it out 6 Rotate bearing out from between crankshaft and cylinder block Lower Bearing Stud amp Nut Crankshaft Main Bearings Instal
82. strokes and record the highest reading Note the approximate number of compression strokes required to obtain the highest reading 5 Repeat the test on each cylinder cranking the engine approximately the same number of compression strokes Test Results The indicated compression pressures are considered within specification if the lowest reading cylinder 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 specification ESE M2C153 E on top of the pistons in the low reading cylinders Repeat the compression pressure check on these cylinders Compression Pressure Limit Chart MAX MIN MAX MIN MAX MIN MAX MIN kPa psi kPa psi kPa psi kPa psi 924 696 1131 848 1338 1000 1154 1158 134 101 164 123 194 146 224 168 938 703 1145 855 1351 1014 1558 1165 136 102 166 124 196 147 226 169 952 717 1158 869 1365 1020 1572 1179 138 104 168 126 198 148 228 171 965 724 1172 876 1379 1034 1586 1186 140 106 170 127 200 150 230 172 979 738 1186 889 1303 1041 1600 1200 142 107 172 129 202 151 232 174 933 745 1200 903 1407 1055 1055 1207 144 109 174 131 204 153 153 175 1007 758 1214 910 1420 1062 162
83. t 12 5 Nm Step 2 22 Ib ft 30 Nm 41 94 222 FPP04072 5 Check connecting rod side clearance 6 Install cylinder head assembly Refer to Cylinder Head Installation on page 19 7 Install pick up tube and deflector Refer to Pick up Tube Deflector Installation on page 26 8 Install oil pan Refer to Oil Pan Installation on page 25 PRELIMINARY 02 30 TSG 416 ENGINE Flywheel Removal 3 Check flywheel runout at clutch disc surface 4 Remove bolts maximum runout 0 005 in 0 13 mm 2 Remove flywheel 3 Dial 4 Indicator Flywheel 4 Check flywheel runout at gear surface maximum runout 0 024 in 0 6 mm Flywheel Installation Indicator 1 Install flywheel using special locking tool 21 168 2 Lubricate bolt threads with clean engine oil and tighten to 49 Ib ft 67 Nm Flywheel Locking Tool T84P 6375 A 21 168 FPPO4150 PRELIMINARY 02 31 TSG 416 ENGINE Timing Chain and Sprockets Removal 8 Remove the hydraulic tensioner T 2 Hydraulic 3 Tensioner 4 Remove oil pump assembly Refer to Oil Pump Removal on page 21 5 Remove valve cover Refer to Valve Cover Removal on page 10 6 oil pan water pump 7 Check to see if coppered 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 e Mark the
84. t of adjustment A sticking lash adjuster plunger can be caused by dirt chips or varnish inside the lash adjuster A lash adjuster check valve that is not functioning can be caused by an obstruction such as dirt or chips that prevent it from closing when the camshaft lobe is lifting the lash adjuster It may also be caused by a broken check valve spring Air bubbles in the lubrication system will prevent the lash adjuster from supporting the valve spring load This can be caused by too high or too low an oil level in the oil pan or by air being drawn into the system through a hole crack or leaking gasket on the oil pump screen cover and tube If the leakdown time is below the specified time for used lash adjusters noisy operation can result If no other cause for noisy lash adjusters can be found the leakdown rate should be checked and any lash adjusters outside the specification should be replaced Assembled lash adjusters can be tested with Hydraulic lash adjuster Leakdown Tester to check the leakdown rate The leakdown rate specification is the time in seconds for the plunger to move a specified distance while under a 22 7 kg 50 Ib load Test the lash adjusters as follows Leakdown Testing NOTE Do not mix parts from different hydraulic lash adjusters Parts are select fit and are not interchangeable 1 Clean the lash adjuster to remove all traces of engine oil NOTE Lash adjusters cannot be checked with engine oi
85. t would interfered with the proper sealing of the plug If the cylinder block plug bore is damaged bore for the next oversize plug NOTE Oversize plugs are identified by the OS stamped in the flat located on the cup side of the plug 3 Coat the cylinder block core plug and bore lightly with Threadlock 262 E2FZ 19554 B or equivalent meeting Ford specification WSK M2G351 A6 and install the cylinder block core plug Cylinder Head Distortion Special Tool s Straightedge 303 D039 D83L 4201 A or equivalent di FPP10036 Special Service Tools called for by the procedures can be obtained by calling 1 800 ROTUNDA 1 800 768 8632 e Usea straight edge and a feeler gauge to inspect the cylinder head for flatness Compare with specifications If the cylinder head is distorted install a new oylinder head Straight Edge FPP04065 PRELIMINARY 01 37 TSG 416 GENERAL INFORMATION Cylinder Block Core Plug Cup Type CAUTION Do not contact the flange when installing a cup type cylinder block core plug as this could damage the sealing edge and result in leakage NOTE When installed the flanged edge must be below the chamfered edge of the bore to effectively seal the bore e Use fabricated tool to seat the cup type cylinder block core plug 03563 Cylinder Block Core Plug Expansion Type CAUTION Do not contact the crown when installing an expansio
86. ter Release spring Lash Adjuster FPP04076 7 Install valve cover Refer to Valve Cover Installation on page 10 PRELIMINARY 02 14 TSG 416 ENGINE TMAP Sensor Electronic Throttle Body Gasket Intake Manifold PCV Hose Gasket Intake Manifold Removal Intake Manifold Installation NOTE All contact surfaces must be clean and free from 1 Remove any necessary wiring and vacuum hoses any old gasket material Mark connections and routing as necessary to assure they are returned as they were removed Install a new gasket and intake manifold assembly Relieve fuel pressure Install bolts and nuts Tighten to 6 Ib ft 8 Nm Disconnect fuel lines from fuel rail Disconnect air intake tube Connect air intake tube Connect fuel lines to fuel rail NOOR WN Remove bolts nuts and intake manifold assembly NO a F WN gt Install any wiring and vacuum hoses that were removed Connect and route as they were removed PRELIMINARY 02 15 TSG 416 ENGINE Exhaust Manifold Outlet Flange Exhaust Manifold Removal 1 Remove any necessary wiring and vacuum hoses Mark connections and routing as necessary to assure they are returned as they were removed Disconnect exhaust at outlet flange Remove nuts exhaust manifold and gasket Exhaust Manifold Installation NOTE All contact surfaces must be clean and free from any old gasket material
87. that the engine is correctly operated and that the maintenance operations outlined in this book are carried out regularly after the specified hours of operation have been reached We consider it to be in your interests to enlist the aid of an authorized Ford Power Products Distributor not only when repairs are required but also for regular maintenance Distributors are listed at the back of this manual Regular maintenance will result in minimal operating costs Engines manufactured by Ford Motor Company are available through Ford Power Products Distributors When in need of parts or service contact your local Authorized Distributor In overseas territories in the event of difficulties communicate directly with the supervising Ford affiliated Company in your area whose address appears at the end of this book Where the terms Right or Left occur in this publication they refer to the respective sides of the engine when viewed from the rear or flywheel end Pistons and valves are numbered from the front or timing cover end of the engine commencing at No 1 You may find that your engine assembly includes optional equipment not specifically covered in the following text Nevertheless the maintenance procedures outlined in this book still apply to your engine PRELIMINARY 01 6 TSG 416 GENERAL INFORMATION Engine Identification Because Ford Power Products markets such a wide range of industrial engines manufactured both in the U S and
88. thread of the mandrel extends beyond the tapersert FPP03566 NOTE A properly installed tapersert will be either flush with or 1 0 mm 0 039 inch below the spark plug gasket seat PRELIMINARY 01 39 TSG 416 GENERAL INFORMATION 6 Tighten the tapersert into the spark plug hole 03567 7 Turn the mandrel body approximately one half turn counterclockwise and remove 03568 Exhaust Manifold Straightness Special Tool s n dai FPP10036 Straightedge 303 D039 D83L 4201 A or equivalent Special Service Tools called for by the procedures can be obtained by calling 1 800 ROTUNDA 1 800 768 8632 Placethe Straightedge across the exhaust manifold flanges and check for warping with a feeler gauge SPECIFICATIONS GENERAL SPECIFICATIONS Epoxy Sealer M3D35 A E Threadlock 262 E2FZ 19554 B WSK M2G351 A6 Engine Oil SAE 5W30 D9AZ 19579A NOTE Ford Power Products industrial engines are designed to perform with engine oils that are licensed by the American Petroleum Institute and oils carrying the most current API classification should be used PRELIMINARY 01 40 TSG 416 ENGINE INDEX Subject Page General Information opecial Ee EE 02 3 D SCHIPUON ET 02 5 Gomponerit ee te EE 02 6 Repair Valve ee E CET 02 10 Valve Cover Installation
89. tion rates engine size operator driving habits ambient temperature quality and viscosity of the oil Operating under varying conditions can frequently be misleading An engine that has been run for short hours or in below freezing ambient temperatures may have consumed a normal amount of oil However when checking engine oil level it may measure up to the full mark on the oil level dipstick due to dilution condensation and fuel in the engine crankcase The engine might then be run at high speeds where the condensation and fuel boil off The next time the engine oil is checked it may appear that a liter quart of oil was used in about 3 to 3 1 2 hours This perceived 3 to 3 1 2 hours per liter quart oil consumption rate causes customer concern even though the actual overall oil consumption rate is about 50 hours per liter quart Make sure the selected engine oil meets Ford specification WSS M2C153 F and the recommended API performance category SJ or higher and SAE viscosity grade as shown in the equipment Owner s or Operators Engine handbook Itis 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 determine the source of excessive internal oil consumption NOTE Oil use is normally greater during the first 300 hours of service As hours increase oil use generally decreases E
90. to the crankshaft journal or the cylinder wall when removing the piston and rod 7 Push piston assembly out the top of the cylinder with the handle end of a hammer Piston Assembly FPP10048 NOTE Make sure all caps are marked so that they can be installed in their original positions 8 Remove upper bearing from connecting rod NOTE For piston and bearing service refer to Section 01 PRELIMINARY 02 29 TSG 416 ENGINE Piston Installation NOTE Crankshaft journal should be at its lowest point All components should be clean and dried with compressed air or a lint free cloth 1 Set piston ring gaps as follows lower oil ring gap aligned with piston pin center ring gap at 90 from the oil ring gap top ring gap at 180 from the oil ring gap 2 Lubricate piston bearing wear surface crankshaft journal and cylinder wall with clean engine oil 3 Carefully install pistons with bearings into cylinder bores using a piston 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 identified in the base Hammer Handle Piston Ring Compressor Tool FPPO4149 CAUTION Use new connecting rod cap bolts and lubricate threads with clean engine oil 4 Install connecting rod caps with bearings lubricate wear surface and tighten bolts in 2 steps Step 1 9 Ib f
91. ve the valve up and down through normal travel in the valve guide and check the stem for any binding If the valve has been damaged it will be necessary to remove the cylinder head as outlined in this section PRELIMINARY 02 13 TSG 416 ENGINE Valve Stem Seal Installation NOTE All components must be clean and assembled in the same positions as removed Lubricate contact surfaces with clean engine oil CAUTION Valve stem seal can be cut by grooves in valve stem A damaged seal will leak causing oil burning and valve fouling 1 Carefully slide oil seal over valve stem 2 Install new valve seal using special tool 21 024 optional T95P 6565A protective cap Special Tool 21 024 FPPO4434 NOTE Apply a small amount of Ford Multi purpose Grease DOA2 19584 AA 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 valve spring retainer and locks gee E I Retainer Spring 4 Release air pressure and remove air adapter Install spark plug in proper cylinder 5 Grease contact surfaces of roller follower with Ford Multi purpose Grease DOAZ 19584 AA or equivalent meeting Ford specification ESR M1C159 A 6 Using spring compressor compress and hold down the valve and spring Slide the roller finger follower into place over valve and lash adjus

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