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MSG425 Service Manual - Rev 1 - Small

1. Page 03 2 03 3 03 3 03 4 03 5 03 6 03 6 03 6 03 7 MSG 425 IGNITION SYSTEM GENERAL INFORMATION Camshaft Position CMP Sensor Ignition Coil Description The MSG 425 engine is equipped with an individual coil on plug electronic ignition system The brain of this system is the Electronic Engine Control GCP Module which receives inputs from the following e Crankshaft Position CKP Sensor e Camshaft Position CMP Sensor e Engine Temperature Sensor From these inputs the GCP module computes spark strategy spark advance to obtain optimum engine performance for correct input conditions through the following outputs 03 2 Crankshaft Position Sensor Engine Coolant Temp ECT Sensor Ignition Coils e Spark Plugs WARNING HIGH TENSION VOLTAGE PRODUCED BY A DISTRIBUTORLESS IGNITION SYSTEM IS HIGHER THAN FOR A CONVENTIONAL IGNITION SYSTEM WHEN CARRYING OUT SERVICE OPERATIONS ON AN ENGINE EQUIPPED WITH DISTRIBUTORLESS IGNITION IT IS IMPORTANT TO BE AWARE OF THE ABOVE POINT AS WELL AS ALL THE USUAL SAFETY MEASURES TO PREVENT THE POSSIBILITY OF ELECTRIC SHOCKS MSG 425 IGNITION SYSTEM Compression Stroke Operation With this system the GCP monitors the engine speed and operating temperature and decides what degree of spark advance is correct for all of the operating conditions Because timing is set for life inherently in the design of
2. 02 2 Page 02 24 02 25 02 25 02 26 02 27 02 27 02 27 02 33 02 33 02 34 02 35 02 43 02 44 MSG 425 ENGINE GENERAL INFORMATION gt hi Tun 4 B 1 5 E An tS V ATS RON OY iip D SEL em we 2 m f iL 2 2 TT T Engine The MSG425 is a 4 valve per cylinder dual overhead cam engine The engine block is cast aluminum with iron cylinder liners Connecting rods are made of sintered metal the crankshaft is nodular iron with five main bearings The cam cover oil pan and front cover are also made of aluminum The dual camshafts are chain driven with an automatic tensioning system The valve train components are alternate fuel ready Spark is delivered by an individual coil on plug ignition system A broadband knock sensor is calibrated for individual cylinder use 02 3 All fuels are controlled in closed loop Gasoline is delivered by sequential port fuel injection The electronic engine management system has built in engine protection against Detonation High coolant temperature Low oil pressure Engine over speed Starter engagement while engine is running NOTE A set of metric wrenches are required to service the MSG425 engine AN WARNING TO
3. 08 25 08 25 08 25 08 25 08 26 08 27 08 27 08 36 08 36 08 37 08 40 08 41 08 41 08 42 08 43 08 43 08 44 08 44 08 45 MSG 425 Engine Controls GENERAL INFORMATION GCP and Sensors CMP Sensor CKP Sensor TMAP Sensor HO25 Sensor KS Sensor ECT Sensor AL A T 0 wi tS x EA ae cs irr ex N F uam br dur Na gt Actuator Fuel Injector DEPR Ignition Coil Engine Control Module GCP The Engine Control Module GCP has the following features e Programmable four speed electronic governing throttle by wire or variable speed control governing e Programmable emergency warning shut down feature for high water temperature low oil pressure etc Starter lockout Auto crank Programmable overspeed protection Automatic altitude compensation Sequential port fuel injection gasoline with pressure regulator to precisely control fuel delivery e Dry fuel lockout controlled by the GCP produces a reliable transition when switching fuels e Certified closed loop dry fuel control e Configurable inputs available based on customer requirements e Configurable outputs available based on ECT RPM or MAP signals and customer requirements 08 2 Diagnostic software allows viewing of histo
4. Oil Level Indicator amp Tube Replacement Oll Pan _______________ __ Oil Pati Installat lobis adio _____ INSTA ATION cia ______ Flvwnheel Replacemelnl 02 1 Page 02 3 02 3 02 3 02 4 02 4 02 4 02 4 02 5 02 6 02 5 02 6 02 7 02 8 02 9 02 9 02 9 02 11 02 13 02 13 02 15 02 16 02 17 02 17 02 17 02 18 02 18 02 19 02 19 02 19 02 20 02 20 02 21 02 22 02 22 02 23 02 23 02 23 02 24 02 25 02 25 02 26 MSG 425 ENGINE INDEX CONT Subject Removal and Installation Oil Pickup TUDE Replacement GE OM Crankshaft Rear Seal Retainer Crankshaft Rear Seal Retainer Installation esee Disassembly amp Assembly EDgineDisdssembly sete um d enti da Cylinder Head TE Cylinder Head 5 Engine Ru MM d Ud Adjustments Malve Cledramnce
5. Crankshaft Pulley Installation eese eee nnn nnn nnne ne Crankshaft Front Seal Crankshaft Front Seal Installation essent Engine Front met Engine Front Cover Fan Drive Disassembly Fan Drive Assembly To Timing Drive Removal Timing Drive Components ran Valve SOHNE REMOVA dutem tina Valve Spring Irstallatlohsusecesntediete du n iiiv Valve seal REMON __ Seal Stal lat OM Valve Tappete Replacemiebibe a ioo attin vetro CIS ATES REMOVA _______ 8 utn InstallatiOPuese Exhaust Manifold Removal Exnaust Manifold Cylinder Head EINIOV Cylinder MEAG MAST Oil Eilter Adapter tetas du e aec i Oil Filter Adapter Installation siete hb c eoe Oil Pressure Sender Replacement oi
6. UL JRL BELA peus puna LOR Dum NC 08 12 1 MSG 425 Engine Controls GCP Power Distribution Box Part of 5210120 Engine Wiring Harness starter Relay Starter 20 AMP EMPTY EMPTY Battery Voltage out of Power Relay 08 13 MSG 425 Engine Controls Wire Colors Revision Level The following wiring schematics are taken from the wiring diagram labeled below e EDI FORD 2 5L W GCP Number EE 7 Date 11 1 2011 Drawn By J SUTTON 08 14 56 425 Engine Controls Power Distribution dao my _ IEA _ _ _ p 91 9 __ _ 0 NOY 91 p LAA Vous kund fi E md 1 pus dni 98 E au dum PH 9 d PH 9 oan or 341 ror EET 9 100 1 eun eru 08 15 56 425 Engine Controls Ignition System mds mds peds HdiHM OSA 1 81 7 zl 7 2 4 puol lt Wo
7. Thermostat amp Housing Gasket 05 11 eee eee MSG 425 COOLING SYSTEM Coolant Pump Replacement WARNING REFER TO CAUTIONS AND WARNINGS AT THE BEGINNING OF THIS SECTION 1 Drain the cooling system Refer to Draining the Cooling System of this section 2 Remove or disconnect components as necessary to gain access to the coolant pump 3 Remove the drive belt Refer to Drive Belt Installation of this section 4 Remove 3 bolts and coolant pump pulley 5 Remove 3 bolts and coolant pump 6 Reverse procedure to install e Lubricate coolant pump o ring with clean coolant e Tighten coolant pump bolts to 10 Nm 89 Ib in e Tighten pulley bolts to 25 Nm 18 10 Coolant PUmp 05 12 Pulley MSG 425 COOLING SYSTEM Outlet fo d 1 WARNING REFER CAUTIONS WARNINGS AT THE BEGINNING OF THIS SECTION 1 Drain the cooling system Refer to Draining the Cooling System of this section 2 Remove or disconnect components as necessary to gain access to the outlet pipe 3 Disconnect hoses from outlet pipe 4 Disconnect electrical connector at ECT Sensor 5 Remove bolts and outlet pipe 6 Reverse procedure to install e Clean gasket mating surfaces e Install new gasket Tighten bolts to 10 Nm 89 05 13 MSG 425 COOLING SYSTEM Coolant Bypass Replacement 1 Drain the cooling system Refer to
8. Uoc RF Bolts lt 4 Voltage Regulator Insertion Hole Drive Belt Screws 3 Reverse procedure to install e Insert a wire into the insertion hole to hold the brushes during assembly Hemove wire when done Tighten screws to Nm 27 lb in 1 Disconnect battery negative cable Refer to Battery Cleaning and Inspection on page 9 of this section 2 Remove or disconnect any component to allow access and removal of generator 3 Remove drive belt refer to cooling system section 4 Remove 2 bolts and position the generator aside Disconnect electrical connector Remove generator Reverse procedure to install e Tighten generator bolts to 25 Nm 18 Ib ft Tighten B terminal to 8 Nm 71 NO 06 11 MSG 425 CHARGING SYSTEM Generator Pulley Replacement 1 Remove generator assembly Refer to Generator Replacement of this section 2 Remove nut Uy a No 2222 Hut 3 Remove pulley 4 Reverse procedure to install e Tighten nut to 109 Nm 80 lb ft 06 12 MSG 425 CHARGING SYSTEM Battery Removal WARNING WHEN LIFTING PLASTIC CASED BATTERY EXCESSIVE PRESSURE ON THE END WALLS COULD CAUSE ACID TO SPEW THROUGH THE VENT CAPS RESULTING IN PERSONAL INJURY DAMAGE TO THE EQUIPMENT OR BATTERY LIFT WITH A BATTERY CARRIER OR WITH YOUR HANDS ON OPPOSITE CORNERS WARNING KEEP OUT OF REA
9. Camshaft End Play e Move camshaft to the rear e Zero dial indicator e Move camshaft to the front e Compare end play with specifications MSG 425 GENERAL INFORMATION Crankshaft Main Bearing Journal Diameter Crankshaft Main Bearing Journal Taper e Measure each of the crankshaft main bearing e Measure each of the crankshaft main bearing journal diameters in at least two directions journal diameters in at least two directions at If it is out of specification replace as necessary each end of the main bearing journal If itis out of specifications replace as necessary 01 22 MSG 425 GENERAL INFORMATION Crankshaft Main Bearing Journal Clearance 4 Verify the crankshaft journal clearance If it is out of specification replace as necessary Special Tool s Pha or Equivalent Special Service Toots cated for me procedures can o RCO ROTUNDA 1 500 765 8632 NOTE Crankshaft main bearing journals must be within specifications before checking journal clearance 1 Remove the crankshaft main bearing caps and Bearing Inspection bearings 2 Lay apiece of Plastigage across the face of each crankshaft main surface Inspect bearings for the following defects Possible causes are shown e Cratering fatigue failure A Spot polishing improper seating B Scratching dirty C Base exposed poor lubrication D Both edges worn journal damaged E One edg
10. 2 Reface the valve seat 3 Clean the sharp edges left by reaming 01 32 MSG 425 GENERAL INFORMATION Valve Spring Compression Pressure Valve Seat Width Special Tool s e Measure the valve seat width If necessary Valve uten Spring Tester rind the valve seat to specification TOOL 51 00 or Equivalent 9 change cag 1 500 768 5632 Use the Valve Clutch Spring Tester to check the valve springs for proper strength at the specified valve spring length Valve Seat Runout Usethe Valve Seat Runout Gauge to check valve seat runout Valve and Seat Refacing Measurements NOTE After grinding valves or valve seats check valve clearance Check the valve seat and valve angles 01 33 MSG 425 GENERAL INFORMATION Flywheel Inspection Oil Pump Rotor Inspection e Inspect the oil pump rotor tips for damage or Special Tool s Weal Dial Indicator with Bracketry TOOL 4201 C or Equivalent Special Service Tools called for procedures can be 1 600 ROTUNDA 1 800 768 8632 1 Inspect the flywheel for e Cracks e Worn ring gear teeth B Oil Pump Side Clearance e Chipped or cracked ring gear teeth C 2 Inspect the flywheel ring gear runout Special Tool s specu Senior Tools called the pr ROTUNDA 1 800 788 5831 Oil Pump Gear Radial Clearance e Place the Straight Edge across the top of the oil p
11. ___ thermostat bolts 10 89 Coolant pump bolts 10 89 Coolant outlet connector bols 25 18 __ Grankease ventilation coverbots 10 89 Cylinder head bolts a Crankshaft pulley bolts a Camshaft bearing caps a Crankshaft position sensor 7 62 Crankshaft oil seal retainer E head stud bolt liii ia inlet pipe nuts Engine to transbots 48 35 Engine front cover bolts a Enginelifting eye bolts 45 33 PWwstmanioenderheadsu 17 18 54 40 Flywheel bolts a Generator bolts 25 18 Intake manifold bolts 18 1 ______ 20 15 Oil pressure switch 15 11 02 45 MSG 425 IGNITION SYSTEM INDEX Subject General Information Diagnosis and Testing Spark Plug Removal and Installation SPIK PUE REMOVA lenan Spare Plus InstalldtiOr sto ea taie tassi detur Specifications m 03 1 Mr T OM nana ace Winne
12. ae a SEC in NEGY ie X E 62 Install A C compressor if equipped and bolts Tighten to 25 Nm 18 lb ft 63 Install oil level indicator tube e Tighten to 10 Nm 89 Ib in 2131608 pass 02 42 MSG 425 ENGINE 64 Install accessory drive belt Larger Grooved Fa Idler gt 4 Smooth Alternator C 07 E A 4 Pm NOTE Measure each valve s clearance at base circle d a with lobe pointed away from the tappet before removing Yenroner camshafts Failure to measure all clearances prior to removing camshafts will necessitate repeated removal Grooved and installation and wasted labor time idler 3 Select tappets and mark location using the following formula Tappet thickness measured clearance plus base tappet thickness minus most desirable thickness 65 Install any tubes hoses or components removed or disconnected 66 Remove engine from engine stand and install flywheel or flexplate 67 Using special tool tighten bolts in the sequence NOTE If any tappets do not measure within shown in 3 stages specifications install new tappets in those locations Refer to Valve Tappet Replacement on page 18 of this section Stage 1 Tighten to 50 Nm 37 Ib ft Stage 2 Tighten to 80 Nm 59 lb ft Stage 3 Tighten to 112 Nm 8
13. 06 8 General Service Procedures Battery Cleaning and rods Ob 9 WOO 1069 Batre hy Chae _______ _ _ __ ____ _____ _ Removal and Installation Generator REO ACSI OMT 06 11 Voltage Regulator 06 11 Generator Pulley 12 battery REMOV 1 Battery rbv a 06 06 1 MSG 425 CHARGING SYSTEM Cautions amp Warnings DANGER POISON e Typical Battery Labeling 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 labeling 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 aM GOA FALLET sent in pe _ d Gooey Cee CAUTION Observe all manufacturers instructions when using charging equipment WARNING BATTERIES NORMALLY PRODUCE EXPLOSIVE GASES WHICH CAN CAUSE PERSONAL INJ
14. An example of charging by friction is a person sliding across a seat Charge by induction occurs when a person with well insulated shoes stands near a highly charged object and momentarily touches ground Charges of the same polarity are drained off leaving the person highly charged with the opposite polarity Static charges can cause damage therefore it is important to use care when handling and testing electronic components CAUTION To prevent possible electrostatic discharge damage follow these guidelines e Donottouch the GCP connector pins or soldered components on the GCP board Do open the replacement part package until the part is ready to be installed e Before removing the part from the package ground the package to a known good ground on the equipment part has been handled while sliding across a seat while sitting down from a standing position or while walking a distance touch a known good ground before installing the part MSG 425 Engine Controls Diagrams and Schematics Symbols doo Enpooo no urea s SES e juo Cun cw peur dun ge ipo aco c 7 pure naudrbe Pett cy Laeuodub jusupDduro E p n pt er D
15. Check the positive crankcase ventilation PCV system Make sure the system is not plugged Check for plugged oil drain back holes in the cylinder heads and cylinder blocks If the condition still exists after performing the above steps proceed to next step Perform a cylinder compression test Refer to Compression Tests on page 12 or perform a cylinder leak detection test with Engine Cylinder Leak Detection Air Pressurization Kit Refer to Cylinder Leakage Detection on page 13 This can help determine the source of oil consumption such as valves piston rings or other areas NOTE After determining if worn parts should be replaced make sure correct replacement parts are used Check valve guides for excessive guide clearances REPLACE all valve stem seals after verifying valve guide clearance 01 16 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 e 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
16. LIA 2 pu De m SS nw Ae 2 e 1 Install fuel rail refer to Section 4 Install exhaust manifold Refer to Exhaust Manifold Installation on page 19 of this section Install camshafts Refer to Camshafts Installation on page 18 of this section Install camshaft cover Refer to Camshaft Cover Installation on page 7 of this section Install or reconnect any other component that was removed or disconnected Reconnect negative battery cable refer to Section 6 Oil Filter Adapter Removal 1 2 6 7 8 Oil Filter Adapter Bolts Disconnect negative battery cable refer to Section 6 Remove and or disconnect components to allow access and removal of the oil filter adapter Label if necessary to allow for correct reinstallation Drain the engine oil Disconnect the oil pressure sender connector Remove the oil pressure sender Refer to Oil Pressure Sender Replacement on page 23 of this section Oil Pressure Sender Filter Remove and discard the oil filter Remove 4 bolts and oil filter adapter Remove and discard the gasket Installation CAUTION Do not use metal scrapers wire brushes power abrasive discs or other abrasive means to clean the sealing surfaces These tools cause scratches and gouges which make leak paths Use a plastic scraping tool to remove all traces of old sealant 1 Clean
17. Oil Pressure Test 1 Disconnect and remove the oil pressure sensor from the engine 2 Connect the Engine Oil Pressure Gauge and Transmission Test Adapter to the oil pressure sender oil gallery port Run the engine until normal operating temperature is reached 4 Run engine at 3000 rpm and record the gauge reading 5 The oil pressure should be within specifications 6 Ifthe pressure is not within specification check the following possible sources e insufficient oil oil leakage worn or damaged oil pump oil pump screen cover and tube excessive main bearing clearance excessive connecting rod bearing clearance MSG 425 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 in 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 e Check the bolts on the intake manifold Push Rods if equipped e Check for bent push rods and restricted oil passage Valve Springs e Check for bro
18. Refer to Engine Front Cover Removal on page 11 of this section 3 Remove oil pan Refer to Oil Pan Removal on page 24 of this section 4 Remove oil pickup tube Refer to Oil Pickup Tube Replacement on page 25 of this section 5 Helease the tension on the tensioner spring and remove the bolt and tensioner P I SE d s t aS Sprocket gt Tensioner Pt gt Pump Chain Guide 6 Remove 2 bolts and oil pump chain guide 7 Remove oil pump chain 8 Remove bolt and oil pump sprocket 9 Remove 4 bolts and oil pump Oil Pump Installation 1 Clean the oil pump and block mating surface with metal surface prep WARNING OBSERVE ALL WARNINGS AND CAUTIONS AND FOLLOW ALL APPLICATION DIRECTIONS CONTAINED ON THE PACKAGING OF THE SILICONE GASKET REMOVER AND METAL SURFACE PREP MSG 425 ENGINE 2 Install oil pump and 4 bolts in sequence shown 2 stages e Stage 1 Tighten to 10 Nm 89 1 Stage 2 Tighten to 20 Nm 15 lb ft NAM 4 1 3 i Tightening Sequence Install sprocket and bolt e Tighten to 25 Nm 18 lb ft 4 Install the chain onto the sprockets 5 Install guide and 2 bolts e Tighten to 10 Nm 89 6 Install tensioner and bolt e Hook tensioner spring around the shoulder bolt e Tighten to 10 Nm 89 16 JJ d DO i o PLA 7
19. de 09 vomuby _ uogpub j 91 81 91 94 QM 91 qu 9t 81 quet 91 penes T imoa pakea FaR En L 08 16 56 425 Engine Controls Starting System 9 2 Starter Lt Blue Pink Start Command 7 42 Pin 08 17 MSG 425 Engine Controls Charging System B attory Ring Red Red Red 1 Fu a 17 Fo Alt Fuse Panel J 10A 1 Red 5 00ohm resistor Fi White Gene rator Stator Plommarinr Red Red ptr Power 08 18 MSG 425 Engine Controls Engine Controls Sensors 1 of 2 109080 5 Ld ALL aine 01 L um am pd qu eur MER m em ere wp 02 cz T or awasi oi HANAJ 8 Anat BL 08 19 MSG 425 Engine Controls Engine Controls Sensors 2 of 2 z a m umm a SE HAVOO HAVO 81 08 20 MSG 425 Engine Controls Fuel Injectors 16 16 RD 1 gen 16 BN YE 16 RD 5 21 Injector 115 18 RD 16 RD 2o o A 16 08 2
20. 1 Disconnect battery ground cable refer to section 6 08 45 MSG 425 METRICS INDEX Subject Page 09 2 Nomenclature for codd dat NL oa aca 09 2 Bolt Strength Identification oe er etd Ao eee 09 3 Hex Nut Strength Identification ae 09 3 MEM ML ED eI 09 4 English Metric conversion 09 5 Decimal and Metric EQuivalents sssscssccscsscssccssssssssscsessccssscesseeceeceecescescusccsscssecesesenseecsecescess 09 6 Torque COD VerstODus 09 6 11930 Terminology essa eden as o Doe 09 7 09 1 MSG 425 METRICS INTRODUCTION Most threaded fasteners are covered by specifications that define required mechanical properties such as tensile strength yield strength proof load and hardness These specifications are carefully considered in initial selection of fasteners for a given application To ensure continued satisfactory vehicle performance replacement fasteners used should be of the correct strength as well as the correct nominal diameter thread pitch length and finish Most original equipment fasten
21. AN WARNING REFER TO WARNINGS AT THE BEGINNING OF THIS SECTION 1 Connectto the GCP display 2 Putthe key in the on position 3 faults page check the fuel pressure by cycling the keyswitch 4 Fuel pressure should be as follows a Keyon Engine off first 50 seconds 60psia b Engine running 60psia Note Refer to the engine controls section for GCP display setup and installation To check the actual fuel pressure a gauge will have to be installed in line of the fuel system close the fuel rail Fuel pressure should be as follows o Key on Engine off first 50 seconds 45psig o Engine running 45psig If fuel pressure is insufficient check for a clogged pump filter screen or fuel filter Also check for a break or restriction in the fuel lines If fuel pump is inoperative check for damaged or loose ground or improper wiring Make sure fuel lines connections area tight and not leaking Note The GCP is reading fuel pressure at the fuel block located after the fuel pump Fuel Pump Check The fuel pump is modulated with a PWM signal from the GCP to precisely control the fuel pressure to the injectors The positive side of the fuel pump will always have 12 volts with the engine running which is supplied from the fuel pump relay e PWM signal from the GCP is Pin 90 lf 12 volts is present ensure the wirings to the GCP for the PWM signal If wiring is ok possible faulty GCP MSG 425 FUEL SYSTEM Fuel
22. It uses a pre programmed routine to calculate the air fuel ratio based on inputs from the TP ECT TMAP amp CKP sensors The system remains in open loop until the following conditions are met The ECT has reached 75 F 24 C 50 seconds has elapsed since starting the engine After these conditions are met the engine is said to be operating in closed loop In closed loop the GCP continuously adjusts the air fuel ratio by responding to signals from the HO2S except at wide open throttle When the 25 reports a lean condition low sensor signal voltage the GCP responds by increasing the on time of the fuel injectors thus enriching the mixture When the HO2S reports a rich condition high sensor signal voltage the GCP responds by reducing the time of the fuel injectors thus leaning out the mixture Adaptive Learn Adaptive Learn is a fuel correction coefficient that is derived from the closed loop correction and is stored in the GCP s memory The normal purpose of the Adaptive Learn is to compensate fuel flow for the following e Fuel composition variance e Engine wear e Component variation e Component degradation The GCP system will operate in closed loop plus adaptive learn when the ECT reaches 165 F NOTE The adaptive learn coefficient will get erased if battery power falls below 9 5 volts GCP Service Precautions The GCP is designed to withstand normal current draws associa
23. MSG 425 2 5 LITER 2 ENGINE INDUSTRIAL ENGINE SERVICE MANUAL Powertrain Assemblies amp Components Provided By Ford Component Sales Power Products EDI 1020050 Revision O October 2012 Section Index Reproduction in any manner in whole or in part is prohibited without the express permission in writing from Engine Distributors Inc EDI EDI policy is one of continuous improvement and while every effort is made to ensure that this publication is up to date and correct in all respects the right to change prices specifications and equipment at any time without notice is reserved Accordingly this publication is not to be regarded as a final description of any individual engine Section O1 Section 02 Section 03 Section 04 Section 05 Section 06 Section 07 Section 08 Section 09 Section 10 GENERAL INFO IGNITION FUEL COOLING CHARGING STARTER ENG CONTROLS METRICS DISTRIBUTORS HEALTH amp SAFETY A WARNING THE FOLLOWING HEALTH AND SAFETY RECOMMENDATIONS SHOULD BE CAREFULLY OBSERVED WARNING CARRYING OUT CERTAIN OPERATIONS AND HANDLING SOME SUBSTANCES CAN BE DANGEROUS OR HARMFUL TO THE OPERATOR IF THE CORRECT SAFETY PRECAUTIONS ARE NOT OBSERVED SUCH PRECAUTIONS ARE RECOMMENDED AT THE APPROPRIATE POINTS IN THIS BOOK WARNING WHILE IT IS IMPORTANT THAT THESE RECOMMENDED SAFETY PRECAUTIONS ARE OBSERVED CARE NEAR MACHINERY IS ALWAYS NECESSARY A
24. converter with the engine e With the engine at idle running indicates the e Check for ice or frost build up on the converter Poss Ole coolant SUPP problem Check Coolant level casing and outlet port and the coolant system for leaks Check for proper Is ice present coolant type Go to step 2 2 Check the vapor regulator operation Regulator is functioning Engine OFF e Install pressure gauge on the Primary Pressure Test port e Start and idle the engine Did you measure 3 5psi Go to step 3 3 Check the carburetor air valve for binding Replace the mixer e With the air cleaner removed pull the air valve piston upwards to ensure free movement of the carburetor air valve Refer to section 5 for E cooling system Is the air valve binding troubleshooting Diagnostic Aids Regulator Assembly Converter amp FCV Overheating is typically related to a cooling or coolant problem There is a possibility of a gasket leak inside the regulator which would allow coolant to pass through to the fuel supply This may affect the emissions if large enough In this situation the coolant level should consistently drop as coolant is lost through the fuel path If no other problems have been identified replace the fuel management assembly with a known good part of the same pressure range Retest 04 19 MSG 425 FUEL SYSTEM The pinpoint tests below should be performed after the preliminary te
25. m Periods Trap Oxickzer Trap Oxidizer Periode TOP Crankcase Ventiabon Positve Crankcase Ventiaton PCY single Board rone Contre BEL AM CURE RED Pressure Transducer Exhaust Gas Recrculation Pressure Transducer RM 09 12 MSG 425 METRICS om S mem Ari Rector AIR C pm mmm RE p je eme e m Three Way Catalysc Converter TWC eta nen ee ede m Fuel injection FT Monotromc Single Point injection SP1 09 13 MSG 425 METRICS Air Flow Control AFC 09 14 EDI Ford Industrial Engine Distributor List AUSTRALIA 10 Wilmette Place Mona Vale All Marine Spares 61 2 99972788 N S W Australia 2103 EUROPE FRANCE Fornaut S A 45 Rue Charles Nodier 93310 133 148 450 394 33 Pre St Gervais France 148 457 504 GERMANY Sauer amp Sohn Sauer Gross Zimmerner Strasse 51 D 49 6071 206 330 Motive Systems 64807 Dieburg Germany 49 6071 206 219 School Lane Chandlers Ford CREAT BRITAIN Industrial Estate 44 2380 579 800 Eastleigh Hampshire 5053 406 44 2380 271 471 England Power Torque Herald Way Binly Conventry 44 2476 635 757 Engineering Warwichshire CV3 2RQ England 44 2476 635 878 Compagnia mo s Via Magellano 1 1 20090 39 02 450 581 39 S
26. 2 Drain engine oil crankcase and refill with recommended oil premixed with Diesel Engine Oil Dye 164 R3705 meeting Ford specification ESEM9C103 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 01 10 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 f necessary pressurize the main oil gallery system to locate leaks due to improperly sealed loose or cocked plugs 5 Hepair 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 air supply and air hose e pressure gauge that registers pressure in 4 kPa 1 psi increments e airline shutoff valve e appropriate fittings to attach the above parts to oil fill PCV grommet hole and crankcase ventilation tube e appropriate plugs to seal any openings leading to the crankcase 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 airline shutoff valve and the appropria
27. 26 Compress the timing chain tensioner and insert 31 Remove the bolt and the VCT solenoid a paper clip into the hole Aj 59 gv 230 7 Y 139154 ODL vA 32 Remove the plug and the VCT system oi filter from the intake camshaft thrust 2 Remove 2 bolts and tensioner t 2 m 28 Remove right timing chain guide lt gt Sl ih S iV p o lt CAUTION Do not rely on camshaft alignment plate to prevent camshaft rotation Damage to the tool or the camshaft can occur 33 Using a wrench on the camshaft flats remove bolts washers and sprockets 4 SM 02 31 MSG 425 ENGINE 35 Remove the bolt and tensioner e Ts Pump 36 Remove bolts and guide 37 Holding oil pump sprocket in place remove bolt chain sprockets and diamond washers 38 Remove special tool 303 465 CAUTION Failure to follow the camshaft loosening procedure can result in damage to the camshafts NOTE Note the position of the lobes on the number one cylinder before removing the camshafts for assembly reference 39 Remove the camshaft bearing caps as follows a Loosen the camshaft bearing cap bolts the sequence shown one turn time b Repeat until all the tension i
28. Coolant mixture Open thermostat Temperature gauge or cold light 05 6 Inspect wash gasket test Replace only if cap will not hold pressure to specification Pressure test system Inspect hose hose connection radiator edges of cooling system gaskets core plugs and drain plugs transmission oil cooler lines water pump heater system components Repair or replace as required Disassembly engine as necessary check for cracked intake manifold blown head gaskets warped head or block gasket surfaces cracked cylinder head or engine block Fill as required Check for coolant loss Adjust Test Replace if necessary Remove bugs leaves etc Test Replace if necessary Test replace if necessary Check timing and advance Adjust as required Check electrical circuits and repair as required Check water pump block for blockage 1 2 water and 1 2 permanent anti freeze mixture Test replace if necessary Check electrical circuits and repair as required MSG 425 COOLING SYSTEM Cooling System Pressure Test gt xz Pressure Tester 1 9 uL vum zr Io ARTE i AR 11 i WARNING REFER TO CAUTIONS AND WARNINGS AT THE BEGINNING OF THIS SECTION 1 Remove the radiator cap from the radiator filler neck CAUTION Do not pressurize the cooling system beyond 138 kPa 20 psi 2
29. Fill the radiator as needed 3 Fit the pressure tester to the radiator neck 4 Pump the cooling system to a maximum of 138 kPa 20 psi and hold for 2 minutes 5 Ifthe pressure drops within this time inspect for leaks and repair as necessary Radiator Cap Pressure Test A WARNING REFER TO CAUTIONS AND WARNINGS AT THE BEGINNING OF THIS SECTION 1 Inspect radiator cap and seals for damage or deterioration replace as necessary 2 Fitthe radiator cap to the pressure tester using an adapter 05 7 Pressure Tester Adapt er Cap NOTE If the plunger of the pressure tester is depressed too fast an incorrect pressure reading will result 3 Slowly pump the pressure tester until the gauge stops increasing and note the highest pressure reading Release the pressure and repeat the test Install a new radiator cap if the pressure is not 124 kPa 18 psi Thermostat Operational Check Hold thermostat up to the light Visually check the valve to be sure it is air tight e Leakage of light all around the valve at room temperature indicates a bad thermostat Aslight leakage of light at one or two locations on the perimeter of the valve is normal Place the thermostat and a thermometer in water Gradually increase the water temperature Replace thermostat if it does not open at the specified temperatures e Starts to open 82 C 180 F Fully open 97 C 206 6 F MSG 425
30. Install pickup tube Refer to Oil Pickup Tube Replacement on page 25 of this section 8 Install oil pan Refer to Oil Pan Installation on page 25 of this section 9 Install engine front cover Refer to Engine Front Cover Installation on page 12 of this section 10 Install or reconnect any other component that was removed or disconnected 02 26 1 O J i 3 E T Bolt similar gt CAUTION Special bolts are used for installation Do SN not use standard bolts Flywheel Flexplate Replacement Remove any components necessary to gain access to the flywheel flexplate Remove the transmission or PTO Remove the pressure plate and clutch if equipped Remove bolts using tool 303 103 e m 1 Ll E Flywheel 6 Reverse procedure to install Tighten bolts in sequence shown in three stages Stage 1 Tighten to 50 Nm 37 lb ft Stage 2 Tighten to 80 Nm 59 lb ft Stage 3 Tighten to 112 Nm 83 lb ft gt j lt gt OZ NS C LSS 2 4 5 Y j Pn i 303 103 MSG 425 ENGINE Crankshaft Rear Seal Retainer Removal 1 Remove and or disconnect components to allow access and removal of the rear seal Label if necessary to allow for correct reinst
31. Oil Filter Restriction 08 39 MSG 425 Engine Controls Engine Control Module GCP Diagnostic Trouble Codes CAUTION When checking codes with the diagnostic software the DTC terminal can NOT be grounded CAUTION Removing battery power before accessing diagnostic program will erase all codes recorded This section contains circuit description information and troubleshooting charts on all the DTC s obtained by diagnostic software or a Malfunction Indicator Lamp MIL When diagnostic trouble codes are obtained by a Malfunction Indicator Lamp MIL the following sequence will be flashed e 1654 will flash 3 times to indicate the beginning of the flash code display sequence Any active DTC s will flash 3 times each e 1654 will flash 3 times indicating the end of the code display sequence If code 1654 is the only code present the system does not have any active codes all systems are working fine If an active DTC is present refer to the GCP diagnostic manual for code description and troubleshooting NOTE If you have a symptom of the pedal not working and no DTC is set go to the voltage screen and check pedal voltage If pedal voltage is 75 1 25 volts and idle validation switch says yourre at idle replace the pedal 08 40 MSG 425 Engine Controls REMOVAL AND INSTALLATION Camshaft Position CMP Sensor Replacement CMP Sensor 1 Disconnect battery ground cable refer
32. This will display the contents of the CD as shown ECOM Drives inetall with USB Varien of BOM Cable File 1 E GCP 7 M 2 BP Fou l si Pug Fe BREAD THES DOCUMENT ARSTE Ti Test Dicoremet Cor uerretti 310 Double click Display folder USB to Serial Driver P GCP PASSWORD and Instructions Double click the Display folder DistFile E instmsi amp jl instmsiw setup setup Double click the GCP_Display icon 08 You will now see a welcome screen Welcome to the FPP Display LES Wea copag and ema Da ilia fe eee ied ae ee Click next A screen will pop up telling you the name of the destination folder Click next You will now see a screen telling you it is ready to install the software Click next 29 MSG 425 Engine Controls You will see an Installation Success screen Follow those install instructions Once when the software 15 finished installing successfully installed reboot your sy
33. antifreeze battery acid etc do NOT encourage vomiting and OBTAIN QUALIFIED MEDICAL ASSISTANCE IMMEDIATELY Wear protective goggles when handling liquids which are harmful to the eyes these include ammonia and battery acid If any of these substances are splashed in the eyes wash out thoroughly with clean water and OBTAIN QUALIFIED MEDICAL ASSISTANCE IMMEDIATELY WARNING WARNING ENGINE EXHAUST SOME OF ITS CONSTITUENTS AND CERTAIN VEHICLE COMPONENTS CONTAIN OR EMIT CHEMICALS KNOWN TO THE STATE OF CALIFORNIA TO CAUSE CANCER AND BIRTH DEFECTS OR OTHER REPRODUCTIVE HARM IN ADDITION CERTAIN FLUIDS CONTAINED IN VEHICLES AND CERTAIN PRODUCTS OF COMPONENT WEAR CONTAIN OR EMIT CHEMICALS KNOWN TO THE STATE OF CALIFORNIA TO CAUSE CANCER AND BIRTH DEFECTS OR OTHER REPRODUCTIVE HARM IMPORTANT SAFETY NOTICE Appropriate service methods and proper repair procedures are essential for the safe reliable operation of all industrial engines as well as the personal safety of the individual doing the work This Service Manual provides general directions for accomplishing service and repair work with tested effective techniques Following them will help assure reliability MSG 425 GENERAL INFORMATION INDEX Subject General Information Page Introduction Safety Notice Notes Caution and armies Battery Handling FOWA
34. bolts in the sequence shown in 2 stages Stage 1 Tighten to 10 Nm 89 lb in Stage 2 Tighten to 20 Nm 15 lb ft 1 4 gt wt 2 Cu uu y j n 1 1 1 1 3 OW WA M 7 4 2 pak I o 4 OM o Position a new oil pump pickup tube gasket and the pickup tube and tighten 4 bolts in the sequence shown Tighten to 10 Nm 89 Ib in 3 Ss A f I 21 1 D 4 1044 m T 71 11 t 43 a te 2 Py eee L p 4 6 Using special tool 303 328 install a new crankshaft rear seal and retainer plate assembly Tighten bolts in the sequence shown Tighten to 10 Nm 89 AAS j Pa LAM y 1 Y gt 2 d gt 4 6 NOTE If oil pan is not secured within 4 minutes the sealant must be removed and the sealing area re cleaned Refer to Engine Cleaning on page 34 of this section pm 11 b 14 B MSG 425 ENGINE 7 Apply a 2 5 mm 0 1 in bead of silicone gasket and sealant to the oil pan Install the oil pan and bolts Tighten in the sequence shown e Tighten to
35. 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 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 manual 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 ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION e USE SAFETY STANDS WHENEVER A PROCEDURE REQUIRES YOU TO BE UNDER THE EQUIPMENT e BE SURE THAT THE IGNITION SWITCH IS ALWAYS IN THE OFF POSITION UNLESS OT
36. pa E s p if 4 d xt x dr 1 Disconnect battery ground cable refer to section 6 Remove or disconnect any component to allow access and removal of the Knock sensor 3 Disconnect KS sensor electrical connector NOTE The KS sensor is a one time use item and a new KS sensor must be installed 4 Remove bolt and KS sensor and discard sensor 5 Reverse procedure to install e Install anew KS sensor Tighten bolt to 20 Nm 15 lb ft 08 44 Temperature Manifold Absolute Pressure TMAP Sensor Replacement Sensor J 1 Disconnect battery ground cable refer to section 6 Remove or disconnect any component to allow access and removal of the TMAP sensor Disconnect TMAP electrical connector Remove bolt and TMAP Sensor Reverse procedure to install a Use a new o ring seal b Tighten bolt to 3 Nm 2 2 lb ft MSG 425 Engine Controls Actuator Throttle Position TP 2 Disconnect the connector from the men throttle PESO 3 Remove the bolts from the throttle to the plate 4 Remove the bolts from the plate to the intake manifold 5 NOTE The gasket is to be reused unless damaged Installation 1 To install reverse the removal procedure e Torque bolts to 10 Nm 2 The gasket between the throttle and plate is to be reused unless damaged Removal NOTE Removal steps in this procedure may contain installation details
37. terminal which causes the motor s shaft to rotate When the starter switch is released a spring returns the solenoid to the released position The starter relay is grounded through the GCP and the power to trigger the starter is from the OEMs keyswitch When both conditions are present the relay closes and engages the starter Be Terminal i E a ow 3 EN m f n T A T F 5 Terminal 3 2 3 r x lt um F F n T nu 2 139 E j i E Starter Motor p x i gt s a E T p E L 1 F Ce ue cm A b i e Ens n H j P 5 MSG 425 STARTER SYSTEM Wiring Diagram Revision Level The following wiring schematics are taken from the wiring diagram labeled below EDI FORD 2 5L W GCP Size Number Rev Date 11 1 2811 Drawn By J SUTTON Starting System Starter B Ring is e fare B eoa Lt Blue Pink 3 oe 21 3 Lt Blue Pink Green Purple f es gu 18 32 MSG 425 STARTER SYSTEM DIAGNOSIS AND TESTING A WARNING REFER TO CAUTIONS amp WARNINGS AT THE BEGINNING THIS
38. the GCP relearns its adaptive strategy The engine may need to run to relearn its strategy Preliminary Checks Before beginning test procedures check battery cables and generator wiring especially grounds for clean tight connections Wires and connectors should not be damaged or corroded Perform the following checks before any testing Loose or corroded connections at battery grounded starter motor cutout relay or engine e Inspect all connectors for loose or damaged pins wires etc sure the batteries are at 75 state of charge SOC or higher This represents an open circuit voltage OCV of 12 4 volts Batteries with an OCV of 12 volts or less are either completely discharged or have a dead cell e Check the generator drive belt tension This will cause low generator output e Check any light or indicator lamp filaments that are suspected of being open burned out This is done to avoid unnecessary extensive circuit checks fuse is blown locate the cause of the overload condition and repair it The common procedure is as follows isolate sections of the circuit by disconnecting connectors and measure the resistance to ground to find the circuit that is shorted to ground Then locate the damaged spot in the wire or connector and repair Excessive battery drain due to lamps left on damaged or misadjusted switch accessories left on etc 06 5 Warning Indicator Check Check the opera
39. 25 Nm 18 d 2 P P ex 4 6 3 lt 7 12 10 F TECA 5 FS n V Y BY e a 6 471 JEP F E 4 Oo 8 Install cylinder head alignment dowels until fully seated in block NOTE If cylinder head is not secured within 4 minutes the sealant must be removed and the sealing area Refer to Engine Cleaning on page 34 of this section 9 Apply silicone gasket and sealant to the locations shown A j JJ ff 4 i il 4 rs N F K NON C 2 c 57 gt lt rT y 4 att 10 Install a new gasket and position cylinder head CAUTION Do not reuse cylinder head bolts 11 Lubricate new bolts and install in the sequence shown in 5 stages Stage 1 Tighten to 5 Nm 44 Stage 2 Tighten to 15 Nm 11 lb ft Stage 3 Tighten to 45 Nm 33 lb ft e Stage 4 Tighten an additional 90 degrees 1 4 turn e Stage 5 Tighten an additional 90 degrees 1 4 turn CAUTION Install the camshafts with alignment slots in the camshaft lined up so the camshaft alignment plate can be installed without rotating the camshafts Make sure the lobes on the No 1 cylinder are in the same position as noted in the d
40. 6mm bolt 40 Install the plug bolt Tighten to 20 Nm 15 lb ft 4 amp YN gt SEY yf o P n T SE fil 4 dit 02 40 41 Position a new crankshaft position sensor and loosely install 2 bolts 42 Using alignment tool that came with new sensor adjust CKP alignment The tool must engage a tooth of the damper then tighten bolts Tighten to 7 Nm 62 NOTE If camshaft cover is not secured within 4 minutes the sealant must be removed and the sealing area re cleaned Refer to Engine Cleaning on page 33 of this section 43 Apply silicone gasket and sealant to the locations shown 44 Install camshaft cover and tighten bolts in sequence show Tighten to 10 Nm 89 Ib in MSG 425 ENGINE Tightening Sequence CAUTION The knock sensor KS must not touch 45 Install camshaft position CMP sensor and bolt the engine vent cover Tighten to 7 Nm 62 50 Install Knock sensor 46 Install spark plugs Tighten to 20 Nm 15 Tighten to 15 Nm 11 lb ft MN 47 Lubricate a new coolant pump o ring seal with clean engine coolant and install coolant pump and 3 bolts Tighten to 10 Nm 89 51 Install engine vent cover and bolts Tighten to 10 Nm 89 48 Install coolant pump
41. 730 15 307 12 574 3579 608 1 NJ oO M gt 51 20 01 11 472 9 514 C un e 145 599 MSG 425 Engine Controls Heated Oxygen Sensor HO2S The Heated Oxygen Sensor HO2S is mounted in the exhaust stream where it can monitor the oxygen content of the exhaust gas The oxygen present in the exhaust gas reacts with the sensor to produce a voltage output This voltage should constantly fluctuate from approximately 100mV to 900 mV when the engine is running in closed loop fuel control The Heated Oxygen Sensor HO2S voltage can be monitored on an IBM PC compatible computer with diagnostic software By monitoring the voltage output of the oxygen sensor the GCP calculates the pulse width command for the injectors to produce the proper combustion chamber mixture The 4 wire HO2S indicates whether the air fuel ratio is rich or lean with respect to stoichiometry The signal from this sensor contains valid air fuel ratio information only when the sensor element has reached its normal operating temperature The 4 wire HO2S also has an isolated case ground which goes to Signal Return SIGRTN either in the processor as a dedicated HO2S ground or as a jumper to SIGRTN in the wiring harness Low HO2S voltage indicates a lean mixture which will result in a rich command to compensate High HO2S voltage indicates a rich mixture which will resu
42. A WARNING REFER TO CAUTIONS amp WARNINGS AT THE BEGINNING OF THIS SECTION The charging system consists of a generator voltage regulator and battery A serpentine belt drives the generator from the crankshaft pulley refer to Section 5 for information on the drive belt The generator produces alternating current which is subsequently converted to direct current The charging rate is adjusted automatically by the built in regulator to provide sufficient electric current to keep the battery fully charged under normal operating conditions 06 3 Battery power The battery is a 12 volt DC source connected in a negative ground system There are three main functions of the battery supply power to the starter and ignition system so the engine can be cranked and started supply extra power required when the equipment load requirements exceed the supply from the charging system e actas a voltage stabilizer by smoothing out or reducing temporary high voltages within the electrical system Operation With the ignition on voltage is applied to the voltage regulator This turns the regulator on allowing current to flow from the battery to the generator field coil When the engine is started the generator begins to generate alternating current AC which is internally converted to direct current DC This current is then supplied to the equipment electrical system through the B terminal of the genera
43. Block Check The fuel block monitors the fuel pressure and fuel temperature which is what the GCP display is reading e Check wiring from the fuel block to the main engine harness e f damaged replace the fuel block jumper harness e Bad or diesel fuel can damage this component Replace if known fuel contamination e Grounding out the fuel pump can cause the fuel pump to output 120psia If this is done and the GCP display does not read the higher pressure then the sensor is possibly bad Check the wiring and if that is ok replace the fuel block lfagaugeis installed in line of the fuel rail this reading can be checked against the fuel pressure read in the GCP display If these do not match then a possible faulty fuel block sensor 04 22 MSG 425 FUEL SYSTEM Quick Connect Coupling Type Quick Connect Coupling Type Il Disconnect Disconnect A A WARNING REFER TO WARNINGS AT THE WARNING REFER TO WARNINGS AT THE BEGINNING OF THIS SECTION BEGINNING OF THIS SECTION CAUTION Do not use any tools Use of tools CAUTION Do not use any tools Use of tools may cause a deformity in the coupling may cause a deformity in the coupling components which can cause fuel leaks components which can cause fuel leaks 1 Relieve the fuel system pressure 1 Relieve the fuel system pressure Refer to Fuel Pressure Relief on page 31 of this section 2 Press the fuel tube quick connect 2 coupling button and pull
44. Bolt ignition 1 Remove and or disconnect components to allow access and removal of the ignition coil Label if necessary to allow for correct reinstallation 2 Disconnect electrical connector 3 Remove bolt 4 Remove ignition coil 5 Reverse procedure to install e Inspect for cracks carbon tracking or dirt e Apply silicone dielectric compound to the inside of coil 03 6 Spark Plug Removal Spark 1 Spark Plug_ a a Remove ignition coil Refer to Ignition Coil Replacement on page 6 of this section Loosen spark plugs and remove any dirt or foreign material from spark plug areas of cylinder head with compressed air Remove spark plugs and mark location using a piece of masking tape Inspect condition of spark plug Refer to Spark Plug Inspection on page 7 of this section Plug Installation Apply a few drops of engine oil to spark plug threads near tip Adjust spark plug gap to 1 25 1 35 mm 0 049 0 053 in Install spark plugs to original locations and tighten to 11 15 Nm Install coil Refer to Ignition Coil Replacement on page 6 of this section MSG 425 IGNITION SYSTEM SPECIFICATIONS GENERAL SPECIFICATIONS Firing Order 1 3 4 2 Spark Plug Type AYFS 32Y R Gap 1 25 1 35 mm 0 049 0 053 in TORQUE SPECIFICATIONS Spark Plugs Coil bolts 8 6 71 03 7 MSG 425 FUEL SYSTEM INDEX Subject Caution
45. Draining the Cooling System of this section 2 Remove or disconnect components as necessary to gain access to the bypass hose 3 Detach coolant bypass hose from the routing clip 4 Disconnect the coolant bypass hose from the tubes 5 Reverse procedure to install Retainer Clip Bypass Hose 05 14 MSG 425 COOLING SYSTEM SPECIFICATIONS GENERAL SPECIFICATIONS 472270771 Coolant Water Mixture 50 50 Pressure Relief Cap 89 124 kPa 13 18 psi Opening Pressure kPa psi Radiator Pressure Test 138 kPa 20 psi temperature temperature WSS M97B51 A1 Engine Coolant TORQUE SPECIFICATIONS Description Nm Coolant pump pulley bolts Coolant pump to block bolts Drancok 2 Thermostat housing bolts 05 15 MSG 425 CHARGING SYSTEM INDEX Subject General Information Page manson eel H 06 3 OC SF ALI 06 3 Wiring 06 3 Diagnosis and Testing Preliminary Warning INGICALOF Chet Kasten O05 SV MOCO MC MONE TELE Battery Drain POS 06 7 Battery mI 2 _ gt Generator Output 06 8 Generator Voltage
46. E T ERIC MNS A S DESCrIDUION anda OP Diagnosis and Testing Special Tools Inspection and Verifications Symptom PEV System Malfunction ive gt Ense IU ATE TU UI Cylinder Leakage Detectlorisssssudni Intake Manifold Vacuum Excessive Engine nnn nnne nnn TES Valve Traim A alysis ______________ Valve Train Analysis Camshaft Love Lift T E Hydraulic Valve ach Wester General Service Procedures Journal DI aM ClO Camshalt cioe dites GANS ATE LODE SUICO 2 s esheets Ee tires M e QUOS Lm CAMS ate obe Camshaft Runout Camshaft End Play m Crankshaft Main Bearing Crankshaft Bearing Journal Crankshaft Main Bearing Journal INSPECT Oli OO
47. Go to Step 2 2 lt Check operation Possible wiring issue e With the engine at idle Yes faulty ECU or faulty DEPR view page 9 of this section for wiring e Disconnect the electrical connector Is there a change in engine running with this No unplugged Go to Step 3 3 Check DEPR supply voltage ves 12 volt DEPR circuit is Key OFF open shorted to gnd or Disconnect DEPR electrical connector the GCP module is Key ON faulty Check wiring Check pins 3 and 6 for 12 volt supply in the harness connectors and fuses for possible causes View page 9 of this section for wiring Is the voltage less than 11 5 volts No Go to step 4 4 Check the vapor regulator operation 5 Regulator is e Engine OFF malfunctioning replace Install a pressure gauge on the Primary Pressure the regulator Test port e Start and idle the engine No Did you NOT measure 3 5psi Go to step 5 5 Check fuel lock supply voltage Yes 2 fuelock activation Key Off circuit is open shorted to ground or the GCP module is Disconnect fuellock connector from harness faulty Check wiring Key On connectors and fuses for Using a high impedance DVOM check for 12 volt supply at the harness connector Is the voltage less than 11 5 volts No Go to step 6 6 Check the carburetor air valve for binding Replace the mixer e With the air cleaner removed pull the air valve piston upwards to ensure
48. NE 68106 1 800 562 8049 877 877 3311 602 269 3581 1 800 562 8049 1 559 264 1776 1 800 891 1776 1 559 264 2933 1 714 635 1774 1 800 678 3673 1 714 635 1771 402 558 8700 1 800 220 2700 1 800 220 2700 1 800 220 2700 1 800 220 2700 1 800 220 2700 877 877 3311 877 877 3311 877 876 3732 1 800 589 9025 402 558 8700 1 800 562 8049 402 558 8700 NORTH AMERICA UNITED STATES LOUISIANA MAINE MARYLAND MASSACHUSETTS MICHIGAN MINNESOTA MISSISSIPPI MISSOURI MONTANA NEBRASKA NEVADA NEW HAMPSHIRE NEW JERSERY NEW YORK NEW MEXICO NORTH DAKOTA NORTH CAROLINA OHIO OKLAHOMA OREGON Been ue 5400 C W Post Road 5 ua Jonesboro AR 72401 Engine Distributors 41 Pope Road Inc Holliston MA 01746 Engine Distributors 400 University Court Inc Blackwood NJ 08012 Engine Distributors 41 Pope Road Inc Holliston MA 01746 McDonald Eaui 1217 East Grand River oe Portland MI 48875 Diesel Power 13619 Industrial Rd Equipment Omaha NE 68137 doe 5400 C W Post Road Jonesboro AR 72401 Diesel Power 13619 Industrial Rd Equipment Omaha NE 68137 Perkins Pacific 2024 Ridgefield 98642 Anderson Industrial 5532 Center Street Engines Co Ohmaha NE 68106 5143 W Roosevelt Phoenix Products AX 85043 Inc Holliston MA 01746 Inc Blackwood NJ 08012 Inc Blackwood NJ 08012 5143 W Roosevelt Phoenix Products AX 85043 Equipme
49. OF CHILDREN BATTERIES CONTAIN SULFURIC ACID AVOID CONTACT WITH SKIN EYES OR CLOTHING ALSO SHIELD YOUR EYES WHEN WORKING NEAR THE BATTERY TO PROTECT AGAINST POSSIBLE SPLASHING OF THE ACID SOLUTION IN CASE OF ACID CONTACT WITH SKIN EYES OR CLOTHING FLUSH IMMEDIATELY WITH WATER FOR A MINIMUM OF 15 MINUTES IF ACID IS SWALLOWED DRINK LARGE QUANTITIES OF MILK OR WATER FOLLOWED BY MILK OF MAGNESIA A BEATEN EGG OR VEGETABLE OIL CALL A PHYSICIAN IMMEDIATELY A WARNING TO AVOID INJURY USE PARTICULAR CARE WHEN CONNECTING A BOOSTER BATTERY TO A DISCHARGED BATTERY MSG 425 STARTER SYSTEM GENERAL INFORMATION Description The starter motor provides the rotation of the engine crankshaft through the flywheel that is needed to start the engine The starter system consists of e starter motor e starter solenoid e starter relay e battery The starter motor is a permanent magnet gear reduction type It runs on 12 volts DC current The starter solenoid is integral to the motor and a relay is also used Refer to the charging section for information on the battery M Terminal Operation When the ignition is turned to the start position the starter relay switches power to the starter solenoid causing the starter motor to engage transmission must be in PARK or NEUTRAL Battery power is always present at the starter motor B terminal The starter motor relay when energized sends current to the starter motor S
50. OTT CNK Ra ENG __ Crankshaft Runout Cylinder Bore Tapers Cylinder Bore Out ot Round Piston Inspection Piston Diameter Piston to Bore 01 3 01 3 01 3 01 4 01 5 01 5 01 5 01 5 01 6 01 7 01 7 01 10 01 10 01 12 01 13 01 13 01 15 01 16 01 17 01 17 01 18 01 19 01 20 01 20 01 20 01 21 01 21 01 21 01 22 01 22 01 23 01 23 01 24 01 24 01 24 01 25 01 25 01 25 01 25 MSG 425 GENERAL INFORMATION INDEX CONT Subject Piston Pin Diameter TR Connecting Rod Bushing Diameters Connecting Rod Bend Connecting Rod Twist Connecting Rod Piston Pin Side Clearance Connecting Rod Journal Bearing Inspection Roller Follower inspection Hydraulic Lash Adjuster inspection __ Valve Stem Diameter Valve Stem to Valve Guide T TTD sees Valve Inspection Valve Guide Inner Diemer Valve Guide Reaming Valve Spring Installed nu C Valve Spring Free POP Valve Spring Out oF Sqaldl6 eet _ _____ Valve Spring Compression PreSSUFO iud Valve and Seat Refacing Measurements eese eene nnne enn nennen nnns Seat de ei Mato but serie dua t Valve Seat Runout Flywheel ipe cions Oil Pu
51. Open fuse Low Battery Defective remote relay Open circuit or high resistance in external feed circuit to starter solenoid Defective starter Defective neutral park switch Starter note mounted flush cocked Noise from other components Ring gear tooth damage or excessive ring gear runout Defective starter Starter note mounted flush cocked Ring gear tooth damage Problem in fuel system Engine related problem Low Battery High resistance or loose connections in starter solenoid battery feed or ground circuit Ring gear runout excessive Defective Starter Shorted ignition switch Battery cable touching solenoid S terminal Defective starter Hydrolocked cylinder Seized main or rod bearing 07 6 ACTION Check fuse continually Refer to battery diagnosis in charging section Check relay Check starter wiring Rplace starter motor Replace switch Realign starter or transmission bell housing or SAE housing Investigate other powertrain accessory noise Replace flywheel ring gear Replace Starter motor Realign starter or transmission bell housing or SAE housing Replace flywheel ring gear Refer to fuel system section Refer to section 01 diagnosis and testing Charge or replace battery Check that all connections are secure Replace ring gear Replace starter motor Replace ignition switch Replace or relocate cable Replace starter motor Remove all plugs one at a time wh
52. S mam wed zd 4 i ABS us 7 E 5 2 4 02 19 2 Install timing chain and sprockets Refer to Timing Drive Components Installation on page 15 of this section 3 Install or reconnect any other components removed or disconnected Exhaust Manifold Removal 1 Disconnect negative battery cable refer to Section 6 2 Remove and or disconnect components to allow access and removal of the exhaust manifold Label if necessary to allow for correct reinstallation 3 Remove accessory drive belt refer to Section 6 4 Drain the engine cooling system refer to Section 5 5 Disconnect exhaust pipe from manifold 6 Remove oil level indicator Refer to Oil Level Indicator amp Tube Replacement on page 24 of this section 7 Remove generator support bracket refer to Section 6 8 Remove nuts exhaust manifold and gasket discard nuts and gasket Gasket Exhaust 2 Manifold 9 Remove discard exhaust manifold studs 10 Inspect manifold for flatness refer to Section 1 MSG 425 ENGINE CAUTION Do not use metal scrapers wire brushes power abrasive discs or other abrasive means to clean the sealing surfaces These tools cause scratches and gouges which make leak paths Use a plastic scraping tool to remove all traces of old sealant 11 Clean the sealing surface with silicone gasket remover and metal surface prep WARNING OB
53. Starter Motor Ground Circuit Check A slow cranking condition can be caused by resistance in the ground or return portion of the cranking circuit Check the voltage drop in the ground circuit as follows 1 Connect a remote starter switch between the starter solenoid S terminal and the battery positive post Remote Start Switch bi F B 5 id 4 mx ui AT Voltmeter Connect a digital multimeter positive lead to the starter motor housing the connection must be clean and free of rust or grease Connect the negative lead of the voltmeter to the negative battery terminal Engage the remote starter switch and crank the engine Read and record the voltage reading a Areading of 0 2 volt or less indicates a good ground connection b reading is more than 0 2 volts clean all ground connections and retest If still too high replace battery negative cable NOTE If the voltage reading is less than 0 2 volt and the engine still cranks slowly install a new starter motor MSG 425 STARTER SYSTEM GENERAL SERVICE PROCEDURES WARNING REFER TO CAUTIONS 4 WARNINGS AT THE BEGINNING OF THIS SECTION Jump Starting For cases of a starter that cranks the engine very slowly connect a 12 volt booster battery to the system To avoid damage to the equipment and battery or the possibility of personal injury follow these instructions and precautions AN
54. 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 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 Head Thickness MSG 425 GENERAL INFORMATION Valve Guide Inner Diameter Valve Spring Installed Length 1 Measure the inner diameter of the valve guides e Measure the installed length of each valve in two directions where indicated spring 2 Ifthe 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 Valve Spring Free Length e Measure the free length of each valve spring Valve Guide Reaming 1 Use kit to ream the valve guide Valve Spring Out of Square Measure the out of square on each valve spring Turn the valve spring and observe the space between the top of the valve spring and the square Replace the valve spring if it is out of specification
55. Tighten to 25 Nm 18 lb ft 17 Install oil pump chain guide and shoulder bolt Tighten to 10 Nm 89 Ib in 18 Install oil pump chain tensioner Hook spring around shoulder bolt and tighten Tighten to 10 Nm 89 10 1 f 4 Oi 0 lt PIC NOTE Sprockets must turn freely the camshafts 19 Position camshaft sprockets and loosely install bolts di CAUTION Do not compress the ratchet assembly This will damage the ratchet assembly 20 Using the edge of a vise compress the timing chain tensioner plunger 02 37 MSG 425 ENGINE e Tighten to 10 Nm 89 d X 4 j lt j rm f j D m A ur i i y A 1540 777 4 ASSA Ia 21 Using a small pick push back and hold the Ss ratchet mechanism ERN 26 Install timing chain tensioner and 2 bolts Remove the paper clip to apply tension to chain x hms L 7 8 22 While holding the ratchet mechanism push the ratchet arm back into the tensioner housing CAUTION The special tool 303 465 is for camshaft alignment only Using this tool to prevent engine rotation can result in engine damage 27 Install special tool 303 465 in the timing slots on rear of both camshafts Timing
56. WARNING HYDROGEN AND OXYGEN GASES ARE PRODUCED DURING NORMAL BATTERY OPERATION THIS GAS MIXTURE CAN EXPLODE IF FLAMES SPARKS OR LIGHTED TOBACCO ARE BROUGHT NEAR THE BATTERY WHEN CHARGING OR USING A BATTERY IN AN ENCLOSED SPACE ALWAYS PROVIDE VENTILATION AND SHIELD YOUR EYES WARNING KEEP OUT OF REACH OF CHILDREN BATTERIES CONTAIN SULFURIC ACID AVOID CONTACT WITH SKIN EYES OR CLOTHING ALSO SHIELD YOUR EYES WHEN WORKING NEAR THE BATTERY TO PROTECT AGAINST POSSIBLE SPLASHING OF THE ACID SOLUTION IN CASE OF ACID CONTACT WITH SKIN EYES OR CLOTHING FLUSH IMMEDIATELY WITH WATER FOR A MINIMUM OF 15 MINUTES IF ACID IS SWALLOWED DRINK LARGE QUANTITIES OF MILK OR WATER FOLLOWED BY MILK OF MAGNESIA A BEATEN EGG OR VEGETABLE OIL CALL A PHYSICIAN IMMEDIATELY A CAUTION Do not disconnect the battery of the engine to be started Disconnecting the battery could damage the equipment s electronic system A WARNING MAKING THE FINAL CABLE CONNECTION COULD CAUSE AN ELECTRICAL SPARK NEAR THE BATTERY AND COULD CAUSE AN EXPLOSION REFER TO WARNING AT THE BEGINNING OF THE JUMP STARTING PROCEDURE A WARNING WHEN SERVICING STARTER OR PERFORMING OTHER UNDERHOOD WORK IN THE VICINITY OF THE STARTER BE AWARE THAT THE HEAVY GAUGE BATTERY INPUT LEAD AT THE STARTER SOLENOID IS ELECTRICALLY HOT AT ALL TIMES A WARNING TO AVOID INJURY USE PARTICULAR CARE WHEN CONNECTING A BOOSTER BATTERY TO A DISCHARGED BATTERY 1
57. and radiator The thermostat and housing are serviced as a unit The radiator degas bottle holds a surplus coolant when the engine is hot It also replenishes coolant back to the system as it cools The degas bottle allows air separation during operation which reduces engine hot spots 05 3 e The coolant pump circulates the coolant through the engine block and cylinder heads to the thermostat If th thermostat is closed the coolant returns to the coolant pump through a bypass hose Once the coolant reaches a specified temperature the thermostat will open allowing the coolant to flow to the radiator for heat transfer and back to the coolant pump inlet Engine coolant provides freeze and boil protection to the engine and cooling components In order to obtain these protections the engine coolant must be maintained at the correct concentration and fluid level in the degas bottle or coolant expansion tank Coolant is made up of a 50 50 mix of ethylene glycol permanent antifreeze and water This mixture is to be used year round with temperatures above 34 4 30 F If recycled coolant is used it must meet Ford specification ESE M97B44 A or WSSM97B44 D CAUTION Not all coolant recycling processes produce coolant which meets Ford specification ESEM97B44 A or WSS M97B44 D Use of coolant that does not meet specifications may harm engine and cooling system components CAUTION Do not use alcohol type antifreeze alk
58. be held in the ON position for up to three minutes After releasing switch and with charger still on measure battery voltage If it shows 12 volts or higher the battery is accepting a charge and is capable of being recharged However it may require up to two hours of charging with batteries colder than 5 C 41 F before charging rate is high enough to show on the charger ammeter It has been found that all non damaged batteries can be charged by this procedure If a battery cannot be charged by this procedure it should be replaced 06 10 A rapid recharge procedure has been developed for recharging batteries that only need a quick recharge This can be due to battery in service no start battery failures engine will not crank due to low battery state of charge or battery discharged due to key off loads The battery can be rapidly recharged by using either of the following methods Perform two hour charge using 20A constant current manual setting on charger Perform a two hour charge using a constant potential automatic setting on charger MSG 425 CHARGING SYSTEM REMOVAL AND INSTALLATION Voltage Regulator Replacement Generator Replacement 1 Remove the generator Refer to Generator Replacement in this section 2 Remove 4 screws and voltage regulator includes brush and holder Generator D 54 m LJ y XN h n if E gt S i
59. button You will see the progress bar moving from 0 to 100 When the logging is complete you can close the Edis Log box or start another log file If you start another log file you must change the Log File name or the first log file will be overwritten To view the contents of a saved log file you can use Notepad or Excel The following are examples showing the Edis Log box before starting a log file when running the log file the progress bar will move py 4 mo D bas sl MSG 425 Engine Controls Ignition System Test Diagnostic Modes injector Noma 7 DBW test OF Exemalpower _ Automatic 77 Cylinder numbering Firing Order The Spark Kill diagnostic mode allows the technician to disable the ignition on individual cylinders If the Spark Kill diagnostic mode is selected with the engine running below 1000 RPM the minimum throttle command will lock into the position it was in when the test mode was entered If the Spark System Test mode is selected with the engine running above 1000 RPM the throttle will continue to operate normally opark kill is only available on gasoline NOT on gaseous fuels These diagnostic modes found on the faults page Disabling Ignition Ouputs To disable the ignition system for an individual cylinder use the mouse to highlight the Spark Kill butt
60. corner or the page command to toggle the three main screens GAUGES FAULTS AND RAW VOLTS NOTE F9 key will toggle to the last screen you were on NOTE If a for a sensor is current the engineering value for that sensor may be a default limp home value and the voltage value will be the actual sensor voltage Use the voltage value when performing diagnostics unless directed to do otherwise by the diagnostic trouble tree MSG 425 Engine Controls Plotting and Data Logging Recording the values and voltages be a very useful tool while diagnosing engine problems The GCP diagnostic software includes real time plotting and real time logging capabilities These features enhance the ability to diagnose and repair possible problems with the GCP system Both plotting and logging allows the user to record in real time any variable that can be seen in the GCP_Dis software In order to record variables the GCP_ Dis software must be Connected to the GCP Plotting To plot a variable you must first TAG the variable To do this use the mouse to right click on the variable The variable will highlight in green to let you know it is TAGGED Next press the P key or click the Plot Log button and then click the Plot Tags button to invoke the plotting feature This begins the plot function and you can observe the plotted variables The plot sweeps from right to left To stop the plotting feat
61. fuel tube to disconnect 7 Quick Connect Coupling Connect 1 Inspect for damage and clean fittings CAUTION Make sure the fuel tube clicks into place when installing the tube To make sure that the fuel tube is fully seated pull on the tube 2 Lubricate the o ring seals with clean engine oil 3 Install the quick connect coupling onto the tube until it is fully seated 4 Pull on the fitting to make sure it is fully engaged 04 23 3 Refer to Fuel Pressure Relief on page 31 of this section Release the locking tab on the quick connect coupling 24 Separate the quick connect coupling from the fitting Sed C C f MSG 425 FUEL SYSTEM Quick Connect Coupling Type Connect 1 Inspect for damage and clean fittings CAUTION Make sure the fuel tube clicks into place when installing the tube To make sure that the fuel tube is fully seated pull on the tube 2 Lubricate the o ring seals with clean engine oil 3 Helease the locking tab and install the quick connect coupling onto the fitting C 4 Position the locking tab into the latched position lt lt E 5 Pullon the fitting to make sure it is fully engaged 04 24 MSG 425 FUEL SYSTEM REMOVAL AND INSTALLATION Fuel Rail amp Injectors Replacement A WARNING DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAM
62. gassing or electrolyte spewing occurs during the charge discontinue charging The battery has reached serviceable charge If the battery will not accept at least 5A after 20 minutes of charging replace the battery WARNING WEAR SAFETY GLASSES BATTERY CHARGING CAN BE DANGEROUS WHILE BEING CHARGED THE BATTERY PRODUCES A POTENTIALLY EXPLOSIVE MIXTURE OF HYDROGEN AND OXYGEN GASSES KEEP SPARKS FLAMES AND LIGHTED CIGARETTES AWAY FROM BATTERIES IN CASE OF ACID CONTACT WITH SKIN EYES OR CLOTHING FLUSH IMMEDIATELY WITH LARGE AMOUNTS OF WATER GET MEDICAL ATTENTION Inspect and service any of the following pre existing conditions before recharging a discharged battery Refer to Preliminary Checks on page 5 of this section Cold batteries will not readily accept a charge Therefore batteries should be allowed to warm up to approximately 5 C 41 F before charging This may require four to eight hours at room temperature depending on the initial temperature and battery size A battery which has been completely discharged may be slow to accept a charge initially and in some cases may not accept charge at the normal charger setting When batteries are in this condition charging can be started by use of the dead battery switch on chargers so equipped To determine whether a battery is accepting a charge follow charger manufacturer s instructions for use of dead battery switch If switch is the spring loaded type it should
63. gouges which make leak paths Use a plastic scraping tool to remove all traces of old sealant 5 Clean the sealing surface of the cylinder head with silicone gasket remover and metal surface prep WARNING OBSERVE ALL WARNINGS AND CAUTIONS AND FOLLOW ALL APPLICATION DIRECTIONS CONTAINED ON THE PACKAGING OF THE SILICONE GASKET REMOVER AND META SURFACE PREP 6 Remove and discard intake manifold gaskets 02 5 Intake Manifold Installation 1 Install new intake gaskets 2 Position intake manifold and install 5 bolts Tighten to 18 Nm 13 lb ft 3 Reconnect fuel supply connections refer to Section 4 4 Reinstall or connect any components that were removed or disconnected 5 Fill and bleed the engine cooling system refer to Section 5 Camshaft Cover Removal 1 Disconnect negative battery cable refer to Section 6 2 Remove intake manifold Refer to Intake Manifold Removal on page 6 of this section 3 Remove and or disconnect components to allow access and removal of the camshaft cover Label if necessary to allow for correct reinstallation CMP Sensor __ Bolt Vent Tube _ 1 O Ring 37 WT Rs j X EN Bw x Yo 4 Disconnect VVT connector 5 Disconnect ignition coil connectors 6 Disconnect Camshaft Position CMP Sensor connector 7 Remove CMP Sensor 8 Disconnect crankcase ventilation tube quick connec
64. incorrectly Check plug gap Damaged hydraulic tappet or hydraulic lash adjuster Replace tappet or lash adjuster Damaged hydraulic lash adjuster or hydraulic lash Replace hydraulic lash adjuster or hydraulic lash Poor Idling adjuster adjuster Replace hydraulic lash adjuster guide or hydraulic lash Damaged hydraulic lash adjuster guide or hydraulic lash adjuster adjuster Improper valve to valve seat contaci Replace valve or valve seat Damaged cylinder head gasket Malfunctioning or damaged ignition system Abnormal combustion Damaged hydraulic lash adjuster or hydraulic lash Replace hydraulic lash adjuster or hydraulic lash adjuster adjuster Replace cylinder head gasket Refer to Section 04 of this manual Refer to Section 03 of this manual Damaged hydraulic lash adjuster guide or hydrauliclash Replace hydraulic lash adjuster quide or hydraulic fash adjuster adjuster Burnt or sticking valve Repair or replace valve Weak or broken valve spring Replace valve spring Carbon accumulation in combustion chamber Malfunctioning or damaged fuel system Refer to Section 04 of this manual Malfunctioning or damaged ignition system Refer Section 03 of this manual 01 7 Eliminate carbon buildup MSG 425 GENERAL INFORMATION Condition Possible Source Action Tine Oil Warn piston ring groove piston and pin Consumption Stic
65. jaws gripping the underside of the cable clamp pull the clamp up by means of pressure exerted against the top of the battery terminal Proper use of this tool avoids the damaging lateral or twisting forces that result when using a pry bar or pliers Battery Clamp Spreader The spreader is used to expand the cable clamp after it has been removed from the terminal and the clamp bolt has been loosened The cable clamp can then be easily placed in its correct position completely on the terminal Terminal Cleaning Brush The terminal cleaning brush is designed with units to clean both tapered battery terminal and the mating surface of the cable clamp 06 9 WARNING GRIPPING THE END WALLS ON THE PLASTIC CASED BATTERY COULD CAUSE ELECTROLYTE TO SPEW FROM SOME OF THE CELLS RESULTING IN PERSONAL INJURY AND POSSIBLY CAUSE DAMAGE TO SOME OF THE INTERNAL COMPONENTS Use a suitable battery carrier for lifting and transporting the battery The illustration shows a clamp type carrier used to grip the sidewalls of the container just below the lip of the cover The carrier is used on the sidewalls rather than the end walls since the sidewalls have additional strength from the inner cell partitions This is particularly important with the plastic cased battery which has end walls that are flexible MSG 425 CHARGING SYSTEM Battery Charging WARNING REFER TO CAUTIONS amp WARNINGS AT THE BEGINNING OF THIS SECTION NOTE If excessive
66. next oversize MSG 425 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 within the wear limit and bore the cylinder to the next oversize limit Piston Inspection Special Tool s Piston Ring Groowe Cleaner D amp 1L 5002 D or Equi ures can CAUTION Do not use a caustic cleaning solution or a wire brush to clean the pistons or possible damage can occur 1 Clean and inspect the ring lands skirts pin bosses and the tops of the pistons If wear marks or polishing is found on the piston skirt check for a bent or twisted connecting rod Ring Lands 2 Use the Piston Ring Groove Cleaner to clean the piston ring grooves 01 25 e Make sure the oil ring holes are clean Piston Diameter e Measure the piston skirt diameter Piston to Cylinder Bore Clearance Subtract the piston diameter from the cylinder bore diameter to find the piston to cylinder bore clearance MSG 425 GENERAL INFORMATION Piston Selection CAUTION Use care when fitting piston rings to avoid possible damage to the piston ring or the NOTE The cylinder bore must be within the cylinder bore specifications for taper and out of round before fitting a piston CAUTION Piston rings should not be transferred 1 Select a piston size based on the cylinder bore from one piston to another to prevent damage to cylinder w
67. outside the active area Active Area Camshaft Journal Clearance NOTE The camshaft journals must meet specifications before checking camshaft journal clearance e Measure each camshaft bearing in two directions e Subtract the camshaft journal diameter from the camshaft bearing diameter 01 20 MSG 425 GENERAL INFORMATION Camshaft Lobe Lift Special Ola Brackesry TOOL 4201 C of Equivalent pee Service Toots cated for by cal STUN 1 800 763 8832 1 Use the Dial Indicator with Bracketry to measure camshaft intake lobe lift 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 01 21 Camshaft Runout Special Dial Indicator with Bracketry TOOL 820 1 or Equivalent Spec Service Coed the procedures can be 1 800 765 5632 NOTE Camshaft journals must 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 Loon
68. 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 01 13 Intake Manifold Vacuum Test Bring the engine to normal operating temperature Connect a Vacuum Pressure Tester such as Rotunda Vacuum Pressure Tester 059 00008 or equivalent to the intake manifold Run the engine at the specified idle speed Vacuum Pressure Tester 059 00008 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 5 5 kPa 1 in Hg from the specified reading for every 500 meters 1 000 feet of elevation above sea level The reading should be quite 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 MSG 425 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
69. tappets prior to removal 4 Remove 16 valve tappets 5 Using special tools 303 350 303 300 amp 303 472 compress valve spring and remove valve spring retainer keys retainers and springs 02 33 6 Remove all special tools CAUTION Note location of valves if they are to be reused 7 Remove valves 8 Using special tools 303 005 and 303 468 remove and discard valve stem seals 9 Inspect valve valve springs retainers and keys refer to Section 1 Engine Cleaning During engine repair procedures cleanliness is extremely important Any foreign material including any material created while cleaning gasket surfaces can enter the oil passages coolant passages or the oil pan and cause engine failure Place clean shop towels over exposed engine cavities Carefully remove the towels so foreign material is not dropped into the engine CAUTION Do not use metal scrapers wire brushes power abrasive discs or other abrasive means to clean the sealing surfaces These tools cause scratches and gouges that make leak paths Use a plastic scraping tool to remove all traces of the gasket material and sealant CAUTION Aluminum surfaces are soft and can be scratched easily Never place the cylinder head gasket surface unprotected on a bench surface To clean residual sealant oil coolant and gasket material from sealing area use silicone gasket remover and metal surface prep A second application may be requ
70. the engine and there are no moving parts in the ignition system itself no maintenance 15 required except for periodic spark plug checks The system provides for fixed spark advance at start up for cold weather starting and for average value default attention has been given to spark optimization for excellent fuel economy in the warm up mode The spark plugs are paired so that one plug fires during the compression stroke and its companion plug fires during the exhaust stroke The next time that coil is fired the plug that was on exhaust will be on compression and the one that was on compression will be on exhaust The spark in the exhaust cylinder is wasted referred to as the waste spark but little of the coil energy is lost Engine Speed and Crankshaft Position The crankshaft position and speed information comes to the GCP from the Crankshaft Position CKP Sensor mounted near the crankshaft pulley The CKP Sensor is triggered by teeth on a trigger wheel located on the crankshaft pulley The pulse frequency indicates crankshaft speed and a missing tooth indicates crankshaft position 03 3 Exhaust Stroke Engine Temperature The Engine Coolant Temperature ECT Sensor sends engine temperature information to the GCP It is located in the rear coolant outlet pipe Fuel Octane Level Adjustment In the event that the engine is operated on dry fuels such as natural gas compressed natural gas CNG or liquefi
71. the hole Remove the 2 bolts and the timing chain tensioner 4 Remove the right timing chain guide a T 5 oh Y 5 02 15 6 Remove the 2 bolts and left timing chain guide CAUTION Do not rely on the Camshaft Alignment Plate to prevent camshaft rotation Damage to the tool or the camshaft can occur 7 f necessary remove the bolts and the camshaft sprockets ay A y 2 7 75 f 7 4 Fi NOTE Use the flats on the camshaft to prevent camshaft rotation MSG 425 ENGINE imi 4 Install the right timing chain guide Timing Drive Components 9 9 f Installation olo i SAN Ji D CAUTION Do not rotate the camshafts Damage to the valves and pistons can occur 4 NC gt MS WN CAUTION Do not rely on the Camshaft Alignment NS Plate to prevent camshaft rotation Damage to the tool or the camshaft can occur Pos Leys Sy 5 Position the timing chain tensioner and install NOTE If the camshaft sprockets were not removed the 2 bolts use the flats on the camshafts to prevent camshaft Tighten to 10 Nm 89 Ib in rotation and loosen the sprocket bolts e Remove the paper clip to release the piston gt emm li S ON 1 If removed install the camshaft sprockets and NO the bolts finger tight 6 Instal
72. the mating surface of adapter and block with silicone gasket remover and metal surface prep WARNING OBSERVE ALL WARNINGS AND CAUTIONS AND FOLLOW ALL APPLICATION DIRECTIONS CONTAINED ON THE PACKAGING OFTHE SILICONE GASKET REMOVER AND METAL SURFACE PREP 2 02 22 Using new gasket install the oil filter adapter and 4 bolts Tighten to 25 Nm 18 lb ft Install a new oil filter Apply thread sealant with PTFE to the oil pressure sender threads and install the sender MSG 425 ENGINE 5 Tighten to 15 Nm 11 lb ft 6 Connect oil pressure sender connector 7 Fil the engine with clean engine oil 8 Run the engine and check for leaks 9 Install or reconnect any other component that was removed or disconnected Oil Pressure Sender Replacement 1 Disconnect negative battery cable refer to Section 6 2 Remove and or disconnect components to allow access and removal of the oil pressure sender Label if necessary to allow for correct reinstallation 3 Disconnect the oil pressure sender connector 4 Remove the oil pressure sender 1 5 Apply thread sealant with PTFE to the oil pressure sender threads and install the sender 6 Tighten to 15 Nm 11 Ib ft 7 Connect oil pressure sender connector 02 23 Oil Level Indicator amp Tube HEPA emeni 131608 Remove and or disconnect components to allow access and removal of the oil level indicator amp tube Label i
73. 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 at least 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 11 12 13 14 15 16 17 18 MSG 425 GENERAL INFORMATION Record the vehicle mileage or hours Instruct the customer to run engine as usual and perform the following e Check the oil level regularly at intervals of 3 to 3 1 2 hours e Return to the service point when the oil level drops below the lower ADD mark on the oil level dipstick e Add only full quarts of the same oil in an emergency Note the mileage at which the oil is added Check the oil level under the same conditions and at the same location as in Steps 7 9 e Measure the distance from the oil level to the UPPER mark on the oil level dipstick and record e Measure the distance between the two scribe marks and record e Divide the first measurement by the second e Divide the hours run during the oil test by the result This quantity is the approximate oil consumption rate in hours per quart If the oil consumption is unacceptable proceed to next step
74. 01 35 01 36 01 36 01 36 01 38 01 39 01 40 MSG 425 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 For engine disassembly assembly installation adjustment procedures and specifications refer to Section 02 This engine incorporates a closed type crankcase ventilation system 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 A WARNING TO AVOID THE POSSIBILITY OF PERSONAL INJURY OR DAMAGE DO NOT 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 during 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 engine damage Engine Distributors Inc EDI does not recommend using abrasive grinding discs to remove engine gasket
75. 014 00705 or equivalent will be helpful in pinpointing the exact cause Rotunda Pressurization Kit 014 00705 The leakage detector is inserted in the spark 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 15 excessive While the air pressure is retained in the cylinder listen for the hiss of escaping air A leak at the 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 convenient Adjust the air pressure to approximately 34 kPa 5
76. 1 MSG 425 Engine Controls Engine Controls Actuator Data Link Connector DLC UO Gm gt unu sed sum oi p SL TL 08 22 MSG 425 Engine Controls Engine Controls Dry Fuel DEPR 1 Relayed Power Twist 10 tums per foot min 1 1 08 23 Front of Connector View MSG 425 Engine Controls Engine Component Locator View TMAP Sensor CMP Sensor Actuator with Throttle gt Position ES TP 2 N Sensor HO2S Sensor 08 24 MSG 425 Engine Controls DIAGNOSIS AND TESTING Diagnostic Approach Use the following step by step approach when diagnosing an engine performance problem 1 Verify the concern and determine if it is a deviation from normal operation 2 Once the concern has been verified preliminary checks can be done Conduct a thorough visual inspection be alert for unusual sounds or odors and gather diagnostic trouble code DTC information diagnostic trouble code DTC is stored follow the designated DTC chart exactly to make an effective repair 4 DTC is stored select the sym
77. 110 F 1 Wrap a thick cloth around the pressure relief and turn it slowly one half turn counterclockwise Stepping back while the pressure is released from the cooling system 2 When you are sure all the pressure has been released still with a cloth turn counterclockwise and remove the pressure relief WARNING ANTIFREEZE CONTAINS MONO ETHYLENE GLYCOL AND OTHER CONSTITUENTS WHICH ARE TOXIC IF TAKEN INTERNALLY AND CAN BE ABSORBED IN TOXIC AMOUNTS ON REPEATED OR PROLONGED SKIN CONTACT PERSONS USING ANTIFREEZE ARE RECOMMENDED TO ADHERE TO THE FOLLOWING PRECAUTIONS ANTIFREEZE MUST NEVER BE TAKEN INTERNALLY IF ANTIFREEZE IS SWALLOWED ACCIDENTALLY MEDICAL ADVICE SHOULD BE SOUGHT IMMEDIATELY e PRECAUTIONS SHOULD BE TAKEN TO AVOID SKIN CONTACT WITH ANTIFREEZE IN THE EVENT OF ACCIDENTAL SPILLAGE ONTO THE SKIN ANTIFREEZE SHOULD BE WASHED OFF AS SOON AS PRACTICABLE IF CLOTHING IS SPLASHED WITH ANTIFREEZE IT SHOULD BE REMOVED AND WASHED BEFORE BEING WORN AGAIN TO AVOID PROLONGED SKIN CONTACT e FOR REGULAR AND FREQUENT HANDLING OF ANTIFREEZE PROTECTIVE CLOTHING PLASTIC OR RUBBER GLOVES BOOTS AND IMPERVIOUS OVERALLS OR APRONS MUST BE USED TO MINIMIZE SKIN CONTACT 05 2 CAUTION Under no circumstances should the engine be started without liquid in the cooling system This may cause permanent damage to the engine CAUTION The use of straight water as a coolant will cause permanent damag
78. 1324 993 192 144 1462 1089 212 158 1476 1103 214 160 1489 1117 216 162 1503 1124 218 163 1517 1138 220 165 1631 1145 222 165 MAX MIN 1669 1248 242 181 1682 1262 244 183 1696 1269 246 184 1710 1202 248 186 1724 1289 250 187 If after checking the compression pressures in all cylinders it was found that the highest reading obtained was 1351 kPa 196 psi and the lowest pressure Interpreting Compression Readings reading was 1069 kPa 155 psi the engine is within 1 If compression improves considerably with the specification and the compression is considered addition of oil piston rings are faulty satisfactory 2 lf compression does not improve with oil valves are sticking or seating improperly 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 01 12 MSG 425 GENERAL INFORMATION Cylinder Leakage Detection When a cylinder produces a low reading use of the Engine Cylinder Leak Detection Air Pressurization Kit such as the Rotunda Pressurization Kit
79. 3 lb ft F r 303 103 4 i gt a 68 Lubricate transmission input shaft pilot bearing with grease ADJUSTMENTS Valve Clearance Check 1 Remove camshaft cover Refer to Camshaft Cover Removal on page 6 of this section CAUTION Turn the engine clockwise only and use the crankshaft bolt only 2 Use feeler gauge to measure each 5 clearance and record its location A mid range clearance is most desirable Intake 0 22 0 28 mm 0 008 0 011 inch Exhaust 0 27 0 33 mm 0 010 0 013 inch 02 43 MSG 425 ENGINE General Specifications Valve J ecification 34 85 35 15 mm 29 85 30 15 mm 5 470 5 485 mm Valve stem diameter exhaust 5 465 5 480 mm Silicone Gasket Remover ZC 30 Motorcraft Metal Surface Prep ZC 31 pm Silicone Gasket and Sealant TA WSE M4G323 A4 30 Valve stem to guide clearance 0 0027 mm Intake Valve stem to guide clearance 0 0029 mm Exhaust Valve face runout 0 05 mm Valve face angle 45 degrees Valve Spring Compression Pressure Motorcraft SAE 5W 20 Premium WSS M2C930 A Synthetic Blend Motor Oil XO 5W 20 QSP in Canada Motorcraft SAE 5W 20 Super Premium Motor Oil CXO 5W20 LSP12 or equivalent 2 Engine WSS M97B51 A Intake and exhaust installed 17 5kg ze P E Intake valve open 8 9 mm of lift 44kg Exhaust valve open 7 4
80. 38 7 No ferent 39 0 USA Vaporized gr 4 propane is introduced into the engine with a Vapor Carburetor Pressure is regulated by an Direct Electronic Pressure Regulator DEPR which is controlled by the GCP Coolant is circulated through the DEPR FUEL VALVE Operation The dry fuel vapor carburetor is a device by which fuel can be added to passing air flow The based on a differential pressure across the amount of fuel added is related to the amount of diaphragm The more air the engine demands air passing through the carburetor the lower the pressure in the throat and hence on the top of the diaphragm When the pressure on the top of the diaphragm is low enough the diaphragm overcomes the spring force holding it down and lifts and allows fuel to be drawn from the fuel port into the air flow into the engine The variable venturi carburetor controls fuel flow Mixer 04 7 MSG 425 FUEL SYSTEM Cite certis in pressure on each side of Osei cones the spring DIAPHRAGM PART THROTTLE force and lifts the valve 23 y NE wir r FUEL INLET 14 The greater the airflow into the engine the greater the pressure drop across the diaphragm and the more lift occurs on the fuel valve This allows more fuel to be drawn into the engine DIAPHRAGM WIDE OPEN THROTTLE J AIR INLE
81. AVOID THE POSSIBILITY OF PERSONAL INJURY OR DAMAGE DO NOT OPERATE THE ENGINE UNTIL THE FAN BLADE HAS BEEN FIRST EXAMINED FOR POSSIBLE CRACKS OR SEPARATION Positive Crankcase Ventilation System This engine is equipped with a positive closed type crankcase ventilation system which recycles crankcase vapors to the intake manifold Engine Cooling System The 2 5L engine is liquid cooled using an engine mounted coolant pump and external radiator This is a full flow system regulated by a thermostat located behind the water outlet connection The thermostat controls and maintains engine temperature Refer to Section 05 of this manual for more information on the cooling system Valves and Seats The engines for petrol operation and LPG CNG operation are basically identical Because LPG CNG is a dry fuel and combusts at a higher temperature the valve train is under higher stress The adaptations described below are therefore necessary Because of the higher stress involved in LPG CNG operation e The inlet valves are made of a harder material e The inlet and exhaust valve seats are made of a harder material MSG 425 ENGINE Lubrication System The engine lubrication system consists of Oil pan e Oil pump screen cover and tube e Oil pump e Oil filter Passageways in the cylinder block crankshaft camshaft and cylinder head The oil pan is pressure cast aluminum and serves as both an oil reservoir and en
82. CH OF CHILDREN BATTERIES CONTAIN SULFURIC ACID AVOID CONTACT WITH SKIN EYES OR CLOTHING ALSO SHIELD YOUR EYES WHEN WORKING NEAR THE BATTERY TO PROTECT AGAINST POSSIBLE SPLASHING OF THE ACID SOLUTION IN CASE OF ACID CONTACT WITH SKIN OR EYES FLUSH IMMEDIATELY WITH WATER FOR MINIMUM OF 15 MINUTES AND GET PROMPT MEDICAL ATTENTION IF ACID IS SWALLOWED DRINK LARGE QUANTITIES OF MILK OR WATER FOLLOWED BY MILK OF MAGNESIA A BEATEN EGG OR VEGETABLE OIL CALL A PHYSICIAN IMMEDIATELY CAUTION Care should be taken when removing or replacing the cable clamp bolts so that the battery terminal is not subjected to any excessive lateral or twisting forces Such forces could cause major damage to the internal components of the battery and leakage at the terminals 1 Remove battery cables from battery terminals battery ground cable first 2 Remove battery hold down components CAUTION When lifting a plastic cased battery excessive pressure on the end walls could cause acid to spew through the vent caps resulting in personal injury damage to the equipment or battery Lift with a battery carrier or with your hands on opposite corners 3 Remove battery from equipment 06 13 Battery Installation 1 Clean cable terminals and battery hold down clamp with a wire brush Replace all cables or parts that are worn or frayed Clean battery tray with a wire brush and scraper Place battery in battery tray with positive and neg
83. COOLING SYSTEM GENERAL SERVICE PROCEDURES Draining the Cooling System WARNING REFER TO CAUTIONS AND WARNINGS AT THE BEGINNING OF THIS SECTION 1 Remove radiator cap CAUTION The coolant must be recovered in suitable clean container for reuse If the coolant is contaminated it must be recycled or disposed of correctly 2 Open drain cock at radiator and drain old coolant from engine into a suitable container Close the drain cock when finished Radiator Drain Cock If necessary remove the lower radiator hose to completely drain the system Reinstall when finished 4 If rust sludge or other foreign material are present in the old coolant system should be flushed Refer to Flushing the Cooling System instructions in this section 05 8 Flushing the Cooling System To remove rust sludge and other foreign material from the cooling system use Rotunda Cooling System Cleanser Removal of such material restores cooling efficiency and avoids overheating Always remove the thermostat prior to pressure flushing A pulsating or reversed direction of flushing water flow will loosen sediment more quickly than a steady flow in the normal direction of coolant flow In severe cases where cleaning solvents will not properly clean the cooling system for efficient operation it will be necessary to use the pressure flushing method Various types of flushing equipment are available Follow manufacturer s operatin
84. Capacitor Failure Improper PCV Routing Valve Timing Low Cylinder Compression Excessive Engine Load Hydraulic Pump Failing Binding Ancillary Drive Components Low Battery Voltage Incorrect Battery Specifications Incorrect Battery Cable Size Starter Relay Starter Failure Excessive Drain Engine Cranks But No Start Engine Runs Poorly Engine Cranks Slowly Dead Battery Ground Loss Ancillary Components Binding or Seized OEM Shutdown Oil Level Safety Starter Lockout Relay Failure Ignition Switch Failure Bad Starter Crank Control Wire Failure Loose Connection or Corrosion Engine Does Not Crank 08 37 MSG 425 Engine Controls Engine Performance While Under Load SYMPTOM POSSIBLE CAUSE Engine Stalls Quits e Faulty OEM Drivers Safety Shut off Seat Switch Low Battery Voltage Low Fuel Pressure e OEM Safety Shutdowns Sensor Restriction e Coil Failure Fuel Mixer Binding Dry Fuel e Ground Loss Misrouted Spark Plug Wires Fuel System Failure Vacuum Leak e Wiring Failure Low Fuel Pressure Spark Plugs Fouled Incorrect Valve Timing Fuel System Failure Misrouted Spark Plug Wires Spark Plug Gap Too High Spark Plugs Fouled Cracked Spark Plug Insulator Runs Rough Compression Loss Spark Plugs Fouled MAP Sensor Vacuum Signal Loss Low Fuel Pressure e Sensor Fai
85. E OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENT HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED RESULTING IN POSSIBLE PERSONAL INJURY WARNING FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING BEFORE WORKING ON OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS THE FUEL SYSTEM PRESSURE MUST BE RELIEVED FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY 1 Disconnect the battery ground cable 2 Remove and or disconnect components to allow access and removal of the fuel rail amp injectors Label if necessary to allow for correct reinstallation CAUTION After disconnecting fuel lines plug the ends to prevent fuel leakage 3 Disconnect fuel lines Refer to General Service Procedures on page 310f this section 4 Disconnect injector electrical connectors 5 Remove bolts 6 Carefully remove the fuel rail and injector assembly 7 If necessary remove the retaining clips and separate the fuel injectors from the fuel rail discard the o rings CAUTION Use o ring seals that are made of special fuel resistance material The use of ordinary o rintg seals can cause the fuel system to leak Do not reuse the o ring seals 8 Reverse procedure to install Lubricate new o rings with clean engine oil Tighten fuel rail bolts to 25 Nm 18 lb ft Bolts Fuel Rail Retainer Clips X od E i Electrical
86. ECTRODES POSIT BUILD CAUSED BY EXCESSIVE OIL UP CLOSING GAP BETWEEN ENTERING COMBUSTION CHAMBER ELECTROOES THROUGH WORN RINGS ANO CAUSED OR CARBON PISTONS EXCESSIVE CLEARANCE FOULING REPLACE PLUG OR BETWEEN VALVE GUIDES AND DEPOSITS ARE NOT EXCESSIVE STEMS OR WORN OR LOOSE THE PLUG CAN BE CLEANED BEARINGS CORRECT OIL PROBLEM REPLACE THE PLUG IDENTIFIED BY BLACK DRY FLUFFY IDENTIFIEO BY MELTED ELECTRODES CARBON DEPOSITS ON INSULATOR AND POSSIBLY BLISTERED 5 EXPOSED SHELL SURFACES AND INSULATOR CTRODES IDENTIFIED BY LIGHT TAN OR GRAY METALLIC DEPOSITS ON INSULATOR CAUSED BY TOO COLD A PLUG DEPOSITS ON THE FIRING TIP INDICATE ENGINE DAMAGE DIRTY AIR CLEANER DEFECTIVE FUEL CAUSED BY WRONG TYPE OF FUEL PUMP TOO RICH A FUEL MIXTURE INCORRECT IGNITION TIMING OR IMPROPERLY OPERATING MEAT RISER ADVANCE TOO A PLUG BURNT OR EXCESSIVE IDLING CAN BE VALVES OR ENGINE OVERHEATING CLEANED REPLACE THE PLUG OVERHEATING FUSED SPOT DEPOSIT IDENTIFIED BY A WHITE OR LIGHT GRAY INSULATOR WITH SMALL AND SPOTS IDENTIFIED BY MELTED OR SPOTTY BLISTERS CAUSED BY ENGINE OVER CAUSED BY SUDDEN ACCELERATION CAN BE CLEANED IF NOT EXCESSIVE OTHERWISE REPLACE PLUG HEATING WRONG TYPE OF FUEL LOOSE SPARK PLUGS TOO HOT A PLUG LOW FUEL PUMP PRESSURE OR INCORRECT IGNITION TIMING REPLACE THE PLUG 03 5 MSG 425 IGNITION SYSTEM REMOVAL AND INSTALLATION Ignition Coil Replacement
87. Engine Controls Engine Coolant Temperature ECT Sensor The Engine Coolant Temperature ECT Sensor is a thermistor a resistor which changes value based on temperature mounted in the engine coolant stream Low coolant temperature produces a high resistance of 100 000 ohms at 40 C 40 F High temperature causes a low resistance of 70 ohms at 130 C 266 F The GCP supplies a 5 volt signal to the ECT sensor through resistors in the GCP and measures the voltage The signal voltage will be high when the engine is cold and low when the engine is hot By measuring the voltage the GCP calculates the engine coolant temperature Engine coolant temperature affects most of the systems that the GCP controls CM 4 ECT FN Sensor y VN E s Y P 24 Jo 2 2 E e ay 1 4 VEM F 1 After engine start up the temperature should rise steadily to about 85 C 185 F It then stabilizes when the thermostat opens If the engine has not been run for several hours overnight the engine coolant temperature and intake air temperature displays should be close to each other A fault in the engine coolant sensor circuit will set a DTC 117 or DTC 118 Low High Voltage 08 5 OHMS Rt OHMS 32 265 158 529 129 659 100 644 78 660 44 55 28 500 gt 2
88. FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY CAUTION Under no circumstances should the drive belt tensioner or pulleys be lubricated as potential damage to the belt material and tensioner dampening mechanism will occur Do not apply any fluids or belt dressing to the drive belt or pulleys MSG 425 COOLING SYSTEM GENERAL INFORMATION Radiator Upper Hose Fan Assembly Lower Hose Description The cooling system consists of the following e Engine Coolant Temperature ECT Sensor Fan Assembly Radiator and Cap Thermostat and Housing Degas Bottle Engine Block Heater Coolant pump Coolant Walter C Avrea the owner of patents 3 601 181 and RE27 965 has granted Ford Motor Company rights with respect to cooling systems covered by these patents The ECT Sensor is used by the GCP to obtain coolant temperature information Refer to Section 8 for further information on this sensor The coolant fan blade can either draw or push air through the radiator to help cool the system coolant The radiator allows excess heat to be transferred to the air The radiator tanks cannot be repaired The radiator maintains system pressure This pressure raises the boiling point of the coolant and helps prevent vapor locks in the engine block and cooling system The thermostat prevents coolant flow until it reaches a specified temperature At this temperature it will open and allow coolant flow through the engine
89. HERWISE 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 EQUIPMENT MOVEMENT OPERATE THE ENGINE ONLY IN A WELL VENTILATED AREA TO AVOID THE DANGER OF CARBON MONOXIDE KEEP YOURSELF AND YOUR CLOTHING AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING ESPECIALLY THE FAN BELTS TO PREVENT SERIOUS BURNS AVOID CONTACT WITH HOT METAL PARTS SUCH AS THE RADIATOR EXHAUST MANIFOLD TAIL PIPE CATALYTIC CONVERTER AND MUFFLER 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 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 MSG 425 GENERAL INFORMATION Battery Handling and Charging The handling and correct use of lead acid batteries 15 not It is important that all la
90. ING 1 Apply 2 5 mm 0 1 in bead of silicone gasket and sealant to the oil pan Install the oil pan and bolts in sequence shown Tighten to 25 Nm 18 lb ft f a F O gt PET 1 3 Al f w 7 2 10 D F 9 3 s AS od gt 8 i t had m y 2 Install oil level indicator and tube Refer to Oil Level Indicator amp Tube Replacement on page 24 of this section 3 Install drain plug e Tighten to 28 Nm 21 lb ft 4 Fill engine with clean engine oil 5 Install or reconnect any other component that was removed or disconnected Oil Pickup Tube Replacement 1 Remove the oil pan Refer to Oil Pan Removal on page 24 of this section 2 Remove bolts and oil pickup tube n a Gasket Pickup Tube 02 24 MSG 425 ENGINE 3 Remove gasket and discard 4 Clean the sealing surface with metal surface prep AN WARNING OBSERVE ALL WARNINGS AND CAUTIONS AND FOLLOW ALL APPLICATION DIRECTIONS CONTAINED ON THE PACKAGING OF THE SILICONE GASKET REMOVER AND METAL SURFACE PREP 5 Reverse procedure to install e Use anew gasket Tighten bolts to 10 Nm 89 Ib in 02 25 Oil Pump Removal 1 Remove and or disconnect components to allow access and removal of the oil pump Label if necessary to allow for correct reinstallation 2 Remove engine front cover
91. ND NO LIST CAN BE EXHAUSTIVE ALWAYS BE CAUTIOUS TO AVIOD POTENTIAL SAFETY RISKS The following recommendations are for general guidance 1 Always wear correctly fitting protective clothing which should be laundered regularly Loose or baggy clothing can be extremely dangerous when working on running engines or machinery Clothing which becomes impregnated with oil or other substances can constitute a health hazard due to prolonged contact with the skin even through underclothing 2 So far as practicable work on or close to engines or machinery only when they are stopped If this is not practicable remember to keep tools test equipment and all parts of the body well away from the moving parts of the engine or equipment fans drive belts and pulleys are particularly dangerous The electric cooling fan used on some installations is actuated automatically when the coolant reaches a specified temperature For this reason care should be taken to ensure that the ignition isolating switch is OFF when working in the vicinity of the fan as an increase in coolant temperature may cause the fan suddenly to operate 3 Avoid contact with exhaust pipes exhaust manifolds and silencers when an engine 15 or has recently been running these can be very hot and can cause severe burns 4 Many liquids used in engines or vehicles are harmful if taken internally or splashed into the eyes In the event of accidentally swallowing gasoline petrol oil diesel fuel
92. NFORMATION DIAGNOSIS AND TESTING Special Tools Commercially Available Compression Tester Leakdown Tester P 014 00707 or Equivalent Cup Shaped Adapter Dial Indicator with Bracketry TOOL 6565 AB or Equivalent TOOL 4201 C or Equivalent Engine Cylinder Leak Engine Oil Pressure Gauge Detection Air Pressurization Kit T7 3L 6600 A 014 00705 or Equivalent 12 Volt Master UV Diagnostic Vacuum Pressure Tester 164 Inspection Kit 164 0756 or R0253 Equivalent Equivalent Special Service Tools called by the procedures can be obtained by calling 1 800 ROTUNDA 1 800 768 8632 01 6 MSG 425 GENERAL INFORMATION Inspection and Verification 1 Verify the customer concern by operating the 3 Ifthe inspection reveals obvious concerns that engine to duplicate the condition can be readily identified repair as required 2 Visually inspect for obvious signs of mechanical 4 concerns remain after the inspection and electrical damage determine the symptoms and go to the symptom e Engine coolant leaks chart e Engine oil leaks e Fuel leaks Damaged or severely worn pads e Loose mounting bolts studs and nuts Symptom Chart piston rings 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 Spark plugs gapped
93. No 04 16 The presence of ice on the converter with the engine running indicates the possibility of a coolant supply problem Check coolant level and the coolant system for leaks Check for proper coolant type Go to Step 2 Possible wiring issue faulty ECU or faulty DEPR View page 9 of this section for wiring Go to Step 3 12 volt DEPR circuit is open shorted to gnd or the GCP module is faulty Check wiring connectors and fuses for possible causes View page 9 of this section for wiring Go to step 4 Regulator is malfunctioning replace the regulator Go to Step 5 This would indicate the fuel lock is not closing and allowing fuel to pass in the OFF position Replace the fuel lock May be electronic check that the CAM and crank sensor are not damaged and as well as all wiring Ensure all coils are firing Check if faults are present with the GCP diagnostic software Refer to section 8 engine controls MSG 425 FUEL SYSTEM The pinpoint tests below should be performed after the preliminary tests and Emission failure Rick Mixture chart Steps 1 3 Any electrical diagnostics should have been performed to eliminate any sensor GCP or solenoid valve problems before proceeding Emission Failure Rich Mixture TestStep 7 Action to Take 1 Check for clogged or restricted air Yes This would indicate e Remove air filter clogged air cleaner as e Start the eng
94. Position equipment so jumper cables will reach being careful that equipment does not touch each other Discharged Battery NOTE Be sure to disconnect battery negative cable before servicing starter 2 Connect one end of positive red jumper cable 1 to positive terminal of discharged battery and other end to positive terminal of booster battery 3 Connect one end of negative black jumper cable 3 to negative terminal of booster battery Connect other end to an engine bolthead or good metallic contact spot on engine of equipment to be started NOT TO NEGATIVE BATTERY TERMINAL 4 Make sure jumper cables are not in way of moving engine parts 5 Start engine with good battery Run engine at a moderate speed 6 Start engine with discharged battery Follow starting instructions in the Operator handbook 7 Completely discharged batteries may require an electrical load to initialize charging 8 Remove cables in exact REVERSE sequence Begin by removing negative cable from engine that had discharged battery If the starter does not turn the engine over even with the booster battery attached refer to Diagnosis MSG 425 STARTER SYSTEM REMOVAL AND INSTALLATION WARNING REFER TO CAUTIONS 4 WARNING REFER TO CAUTIONS amp WARNINGS AT THE BEGINNING OF THIS WARNINGS AT THE BEGINNING OF THIS SECTION SECTION Disconnect negative battery cable 2 Remove any component to allow access and removal of
95. RTA 5711 80 A SE Calgarv AB Simeon Mawel 1 800 374 6766 SASKATCHEWAN Canada T2C 4S6 1605 Kebet Way Port C BC BRITISH COLUMBIA Mandell 1 800 374 6766 Canada 5W9 12 4131 Mostar Road Nanaimo 1 800 374 6766 1846 Quinn Street Pri Simson Maxwell Ge 1 800 374 6766 George BC Canada V2L 3H4 8550 Delmeade MONTREAL MARINDUSTRIAL Montreal QUEBEC Canada 514 342 2748 117 NEW BRUNSWICK DAC Industrial 10 Akerley Blvd Unit 61 902 468 3765 SCOTIA NEWFOUNDLAND Engines Inc Dartmouth NS 1 4 877 468 3765 2320 Bristol Circle Unit 8 NTARI MARINDUSTRIAL 1 800 866 3831 EDI Worldwide Service Engine Distributors Inc 400 University Court Blackwood NJ 08012 Service Warranty 1 800 220 2700 1 856 228 7298 1 856 228 5657 fax parts amp service 1 856 228 5531 fax sales
96. RY A WARNING FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING BEFORE REPAIRING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS THE FUEL SYSTEM PRESSURE MUST BE RELIEVED PREVENT ACCIDENTAL SPRAYING OF FUEL CAUSING A FIRE HAZARD FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY A WARNING DO NOT CARRY PERSONAL ELECTRONIC DEVICES SUCH AS CELL PHONES PAGERS OR AUDIO EQUIPMENT OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENTS HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND CAN BE IGNITED FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY A WARNING THESE PROCEDURES INVOLVE FUEL HANDLING BE PREPARED FOR FUEL SPILLAGE AT ALL TIMES AND ALWAYS OBSERVE FUEL HANDLING PRECAUTIONS FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY CAUTION If the liquid or vapor tube is damaged torn holes or delaminated a new tube assembly must be installed Do not use aftermarket sleeving Do not re adhere loose sleeving material CAUTION Fuel injection equipment is manufactured to very precise tolerances and fine clearances It is therefore essential that absolute cleanliness is observed when working with these components Always cap off any open orifices or tubes CAUTION When reusing liquid or vapor tube connectors make sure to use compressed air to remove any foreign material from the connector retaining clip area b
97. Remove camshaft cover Refer to Camshaft Cove Removal on page 6 of this section 4 Remove the camshafts Refer to Camshafts Removal on page 18 of this section 5 Remove exhaust manifold Refer to Exhaust Manifold Removal on page 19 of this section 6 Remove fuel rail refer to Section 4 MSG 425 ENGINE 7 Remove and discard cylinder head bolts a Bolt mt m eic E s Coolant Pipes Gasket 4 oH NER EU LN 1 he F Block a i n i la H 0 P ES 8 and discard gasket 9 Inspect mating surfaces refer to Section 1 Cylinder Head Installation CAUTION Do not use metal scrapers wire brushes power abrasive discs or other abrasive means to clean the sealing surfaces These tools cause scratches and gouges which make leak paths Use a plastic scraping tool to remove all traces of old head gasket 1 Clean the mating surface of cylinder head and block with silicone gasket remover and metal surface prep Remove all traces of gasket sealant oil and coolant WARNING OBSERVE ALL WARNINGS AND CAUTIONS AND FOLLOW ALL APPLICATION DIRECTIONS CONTAINED ON THE PACKAGING OF THE SILICONE GASKET REMOVER AND METAL SURFACE PREP CAUTION Failure to follow this procedure can cause future oil leakage NOTE Do not attempt to make the metal shiny Some st
98. Rods if equipped e Check for bent push rods and restriction in oil passage Positive Rotator and Valve Spring Retainer Keys e Check for proper operation of positive rotator Valves and Cylinder Head e Check for plugged oil drain back holes e 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 solash may overshoot camshaft roller followers MSG 425 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 Remove the rocker arm seat bolts rocker arm seat and rocker arms if equipped Dial indicator p SNK um Shaped lt Adapter Typical Engine with Push Rods 3 Make sure the lash adjuster is seated against camshaft Install the dial Indicator with Bracketry so the ball socket adapter of the indicator is on top of the hydraulic lash adjuster or the Cup Shaped Adapter is on top of the push rod and in the same plane as the lash adjuster push rod movement 4 Onengines with overhead cam install the dial Indicator with Bracketry so t
99. SECTION NOTE When testing with a meter always make connections with the component terminal rather than at the wiring end connector Making connection with the wiring end connector can result in a false reading because the meter will not pick up any high resistance between the wiring connector and the component Visual Inspection CAUTION Be sure to disconnect battery negative cable before servicing starter e Verify the concern by operating the starting system to duplicate the conditions e Inspect starting system for loose connections e Check the wear patterns on the starter drive and the flywheel ring gear If the starter drive gear and the flywheel ring gear are not fully meshing or the gears are milled or damaged replace the starter motor and if necessary replace flywheel ring gear Fiywheel Ring Gear Starter Teeth If the inspection reveals an obvious concern that can be readily identified repair as necessary If the concern remains after the inspection note condition and continue diagnosis using the symptom chart 07 5 Symptom Chart CONDITION Starter does not crank audible click may or may not be heard Unusual starter noise Starter spins but the engine does not crank Starter cranks but engine does not start Starter cranks slowly Starter remains engaged and runs with engine Starter clicks and engages but engine will not crank MSG 425 STARTER SYSTEM POSSIBLE SOURCE
100. SERVE ALL WARNINGS AND CAUTIONS AND FOLLOW ALL APPLICATION DIRECTIONS CONTAINED ON THE PACKAGING OF THE SILICONE GASKET REMOVER AND METAL SURFACE PREP Exhaust Manifold Installation 1 Install new studs Tighten to 17 Nm 13 lb ft 2 Install new gasket 3 Position exhaust manifold and install nuts Tighten to 54 Nm 40 lb ft Nuts a 1 j P Lal E Gasket e Exhaust Manifold 4 Install generator support bracket refer to Section 6 5 Install oil level indicator Refer to Oil Level Indicator amp Tube Replacement on page 24 of this section 02 20 6 Install exhaust pipe to manifold 7 Install accessory drive belt refer to Section 6 8 Connect battery negative cable refer to Section 6 9 Install or reconnect any other components removed or disconnected Cylinder Head Removal CAUTION The crankshaft the crankshaft sprocket and the pulley are fitted together by friction with diamond washers between the flange faces on each part For that reason the crankshaft sprocket is also unfastened if you loosen the pulley Therefore the engine must be retimed each time the damper is removed Otherwise severe damage can occur 1 Disconnect negative battery cable refer to Section 6 2 Remove and or disconnect components to allow access and removal of the cylinder head Label if necessary to allow for correct reinstallation 3
101. System L Grade 8 PPOOS72 Grade 5 Metric System Metric mm bolts Identification class numbers correspond to bolt strength increasing numbers represent increasing strength Common metric fastener bolt strength properties are 9 8 and 10 9 with the class identification embossed on the bolt head HEX NUT STRENGTH IDENTIFICATION English System Grade Identification Metric System Class Identification HEX NUT HEX NUT Property Class 3 Property Class 10 PPO Increatung dots represent mcreasing strength May also have blue finish or paint daub on hex flat Increasing numbers represent increasing strength 09 3 MSG 425 METRICS OTHER TYPES OF PARTS Metric identification schemes vary by type of part most often a variation of that used of bolts and nuts Note that many types of English and Metric fasteners carry no special identification if they are otherwise unique Tappeng thread forming and certain Studs s Lup mere er ri dass number 2maller studs use geometnc code on the end CLASS 10 9 CLASS98 CLASS 88 09 4 MSG 425 METRICS ENGLISH METRIC CONVERSION ot MH E 09 5 MSG 425 METRICS DECIMAL AND METRIC EQUIVALENTS TORQUE CONVERSIO mom om 09 6 MSG 425 METRICS J1930 TERMINOLOGY LIST Certain Ford Component names have been changed in this Service Manual to conform to Society o
102. T 14 3psi Gre 0495549 ferential meant 3m a valve m FUEL INLET 13 13 99 While the carburetor is designed to mix the fuel and air and adjust fuel to match the speed and load of the engine it has only ballpark accuracy This accuracy is not fine enough to achieve emissions targets To achieve accurate fueling the air inlet pressure to the carburetor is controlled by a Direct Electronic Pressure Regulator DEPR 04 8 The DEPR serves to control the vapor pressure to the mixer After the propane is vaporized vapor regulator the DEPR monitors and controls the vapor pressure to the mixer in reference to the inlet air pressure to the carburetor mixer 2 The DEPR receives a pressure command from the GCP called Delta P which is the difference between fuel vapor pressure and the air inlet pressure This has been calibrated for all soeeds and loads There is a sensor internal to the DEPR that measures the actual Delta P of the delivered fuel Y gt yt 59 2 gt gt AE gt 1 egulator The actuator of the DEPR will then adjust the fuel pressure to the carburetor so that the actual Delta P matches the Delta P command from the GCP This provides an extremely accurate open loop type of fuel control After a preset time has passed the engine will go into closed loop cont
103. URY THEREFORE DO NOT ALLOW FLAMES SPARKS OR ANY IGNITED OBJECT TO COME NEAR THE BATTERY WHEN CHARGING OR WORKING NEAR A BATTERY ALWAYS SHIELDYOUR EYES ALWAYS PROVIDE VENTILATION WARNING WHEN LIFTING A BATTERY ALWAYS LIFT WITH A BATTERY CARRIER OR WITH YOUR HANDS ON OPPOSITE CORNERS EXCESSIVE PRESSURE ON THE END WALLS COULD CAUSE ACID TO SPEW THROUGH THE VENT CAPS RESULTING IN PERSONAL INJURY WARNING IT IS ESSENTIAL THAT THE WIRING CONNECTIONS TO THE GENERATOR ARE NOT REMOVED WHILE THE ENGINE IS RUNNING AS THIS WILL RESULT IN DAMAGE TO THE REGULATOR OR PERSONAL INJURY WARNING KEEP BATTERIES OUT OF THE REACH OF CHILDREN BATTERIES CONTAIN SULFURIC ACID AVOID CONTACT WITH SKIN EYES OR CLOTHING ALSO SHIELD YOUR EYES WHEN WORKING NEAR THE BATTERY TO PROTECT AGAINST POSSIBLE SPLASHING OF THE ACID SOLUTION IN CASE OF ACID CONTACT WITH THE SKIN OR EYES FLUSH IMMEDIATELY WITH WATER FOR A MINIMUM OF 15 MINUTES AND GET PROMPT MEDICAL ATTENTION IF ACID IS SWALLOWED CALL A PHYSICIAN IMMEDIATELY FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY NOTE Battery posts and cable clamps must be clean and tight for accurate meter indications CAUTION Always remove the negative cable first to prevent possible arcing possibly damaging other electrical components MSG 425 CHARGING SYSTEM GENERAL INFORMATION Bracket Generator gt d Drive Belt Voltage Regulator Description
104. aft Pulley Removal on page 8 of this section 4 Disconnect Crankshaft Position CKP Sensor connector 4 AAT diim Connector EM Sensor Bolt CAUTION A new CKP Sensor must be installed whenever the old sensor is removed 5 Remove the CKP Sensor and discard 6 Remove bolt and accessory drive tensioner MSG 425 ENGINE Tensioner Coolant Pump Pulley 7 Remove the three bolts and the coolant pump pulley 8 Remove three bolts and power steering pump upper idler pulley and set aside CAUTION There is one bolt behind the cooling fan drive pulley This bolt can be accessed by lining up one of the holes in the pulley with the bolt NOTE The next step is only necessary if a new front cover is being installed 02 10 9 Using a 3 jaw puller remove the fan drive pulley E a iN Front Cover CAUTION Do not use metal scrapers wire brushes power abrasive discs or other abrasive means to clean the sealing surfaces These tools cause scratches and gouges which make leak paths Use a plastic scraping tool to remove all traces of old sealant 11 Clean the sealing surface with silicone gasket remover and metal surface prep WARNING OBSERVE ALL WARNINGS AND CAUTIONS AND FOLLOW ALL APPLICATION DIRECTIONS CONTAINED ON THE PACKAGING OF THE SILICONE GASKET REMOVER AND METAL SURFACE PREP MSG 425 ENGINE Engine Front Cover Installat
105. agnostic Trouble Code DTC is set and the Malfunction Indicator MIL lamp will be illuminated refer to MIL DTC Retrieval Procedure for process description Refer to Diagnosis Using a Personal Computer on page 26 or Palm Pilot Diagnosis for information regarding performing GCP and engine control system diagnosis Engine Control Module GCP Limp Home Mode Strategy The GCP has four settings for limp home mode Depending on what Diagnostic Trouble Code DTC is set one or more of the limp home modes will be in effect The four limp home modes are as follows Power Derate 1 The actuator is limited to a maximum opening of 50 If Power Derate 1 is active it will remain active until the active DTC goes away The following DTC s will cause Power Derate 1 to take affect DTC 1521 CHT ECT higher than expected 1 CHT ECT is greater than 240 F DTC 111 IAT higher than expected 1 IAT is greater than 200 F e DTC 327 Knock sensor open 1 6L and 4 2L only e DTC 326 Excessive knock signal 1 6L and 4 2L only DTC 2122 FPP1 high voltage DTC 2123 FPP1 low voltage DTC 2128 FPP2 high voltage DTC 2127 FPP2 low voltage DTC 1531 IVS Brake interlock failure MSG 425 Engine Controls Power Derate 2 The actuator is limited to a maximum opening of 20 Power Derate 2 15 active it will remain active until the active DTC goes away and the ignition input to the GCP usually the ignition switch is cy
106. aining of the metal surfaces is normal 02 21 2 Apply silicone gasket and sealant to the locations shown 1 ov 6 4 Cw gt 1 _ f lt K 1 4 Y 1 NC 1 PN 4 _ u lt lt 7 j gt C It NOTE If not secured within 4 minutes the sealant must be removed and the sealing area recleaned as before Refer to previous CAUTION WARNING 3 Install a new cylinder head gasket 4 Lubricate new cylinder head bolts with clean engine oil CAUTION Cylinder head bolts are torque to yield and must not be reused New bolts must be installed 5 Install cylinder head carefully Bolt 4 e m g abo rm i z 1 pF i y b 1 IL is LT Ei Coolant Pipes 2 Gasket E P Bes Block 6 MSG 425 ENGINE Tighten bolts in sequence shown in 5 stages Stage 1 Tighten to 5 Nm 44 Stage 2 Tighten to 15 Nm 11 lb ft Stage 3 Tighten to 45 Nm 33 lb ft e Stage 4 Tighten an additional 90 degrees e Stage 5 Tighten an additional 90 degrees 8 4 1 5 9 h 26 UEN 2f ol G 5 f a amp py D A ipe lt MC
107. aline brine solutions or 100 000 mile red in color antifreeze This may cause serious engine cooling system damage MSG 425 COOLING SYSTEM DIAGNOSIS AND TESTING WARNING REFER TO CAUTIONS WARNINGS AT THE BEGINNING OF THIS SECTION Begin diagnosis by verifying the customer s concern by operating the engine to duplicate the condition The most frequent cooling system complaints are leakage and overheating Either of these problems will soon render the engine inoperable Perform a visual inspection If the inspection reveals an obvious concern that can be readily identified repair as necessary If the concern remains after the inspection determine the symptom s and go to the Symptom Chart The Symptom Chart lists cooling system problems their possible cause and recommended correction Visual Inspection Check for leaks or damage at all hoses connections and hose clamps radiator seams core and drain petcock all block core plugs and drain plugs edges of all cooling system gaskets transmission oil cooler if equipped coolant pump shaft and bushing thermostat head and intake manifold gaskets coolant pump degas bottle heater core if equipped fan and fan clutch engine coolant temperature sensor and wiring drive belt NOTE A small amount of antifreeze coming out the coolant pump weep hole may be considered normal Examine oil dipstick for evidence of coolant contaminated engine oil white milky appearanc
108. allation 2 Remove flywheel or flexplate Refer to Flywheel Flexplate Replacement on page 27 of this section 3 Remove oil pan Refer to Oil Pan Removal on page 24 of this section 4 Remove bolts and retainer plate N SD ANY gt M v Crankshaft Rear Seal Retainer Installation 1 Using special tool 303 328 position rear oil seal with retainer plate onto crankshaft 2 Install 6 bolts in the sequence shown Tighten to 10 Nm 89 us 43 4 gt 4 gt E lt 4 5 BENZ sO v 9s AAA 4 Af iV cum E E Wi fo 1 oe 2 wilt tO O i ll 41 XN 552 ww J A 4 i T i 1 A aL em bie pp J QS e 1 6 M tw 2 02 27 3 Install oil pan Refer to Oil Installation on page 25 of this section Install flywheel or flexplate Refer to Flywheel Flexplate Replacement on page 27 of this section 5 Install or connect any other component removed or disconnected DISASSEMBLY amp ASSEMBLY Engine Disa
109. alve clearance 0 22 0 28 mm intake 5 Descripion Nm Lb ft Oil level indicator tube bot 10 8 Ollpumpsproketbot 25 18 Tappet to valve clearance 0 27 0 33 mm Oil pump pickup tube and 10 exhaust screen bolts Oil drain plug M MC Tappet to bore clearance 0 02 0 06 mm Oil filter adapter bolts 25 18 Camshaft Oil pan bolts a bolts m bolts 0 09 0 24 mm Oil pump chain guide bolts 10 89 Power steering pump bolts 25 18 Journal diameter 24 96 24 96 mm Power steering pressure tube nut 0 035 0 080 mm Connecting Rod Starter motor bolts 25 18 Timingpegplug 20 15 Transmission access cover 10 bolt Pin bore diameter with bushing 20 010 20 021 mm inserted Torque Specifications Torque converter to flywheel 35 26 nuts Transmission lines bracket bolt Timing chain guide bolts 10 89 Timing chain tensionerbolts 10 89 89 Valve cover bolts Fan Bracket to Front Cover 58 425 Fran drive bracket with 28 5 21 bearing to bracket Fan Spacer to bearing bracket 12 9 Fan to fan spacer ew a Refer to the procedure in this section Description __ Nm Lb ft Lb in Camshaftsprocketbot 65 48 Coolant outlet pipe bolts 10 89 Coolant pump pulley bolts 25 18
110. ame rail not on the engine It must also be mounted in packed foam CAUTION The electric fuel pump MUST NOT be mounted directly on the engine assembly as engine vibration will shorten the life of the pump MSG 425 FUEL SYSTEM Wiring Diagrams Revision Level The following wiring schematics are taken from the wiring diagram listed below e EDI FORD 2 5L W GCP Size Number ES 2487000 Date 11 1 281 Drawn Drawn By J SUTON J SUTTON Filename 24872024 Sheet 1 of Fuel Injectors 16 RD r 168 RD 04 5 MSG 425 FUEL SYSTEM Actuator Data Link Connector DLC XH 2d 2641 L Sdi cun conn ee de ee kB E 7 777777777779 o 865 2d Jd CHASE 1 5 3 e e e e eee e ee e e e me e e pom 42809 04 MSG 425 FUEL SYSTEM GENERAL INFORMATION GCP Propane Line Vapor Propane Line imam Vapor Reg DRY FUEL Description This engine with the proper fuel equipment can also operate on dry fuel such as LPG Grade HD5 and natural gas 1050 BTU ft3 Natural Gas fuel specification must meet or exceed
111. aper Verify measurement is within the wear limit 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 Measure the crankshaft connecting rod journal Mark and separate the parts and clean with diameters in at least two directions solvent Clean the oil passages perpendicular to one another The difference between the measurements is the out of round Verify the journal is within the wear limit specification 01 27 MSG 425 GENERAL INFORMATION Connecting Rod Larger End Bore Connecting Rod Bushing Diameter Measure the inner diameter of the connecting CAUTION The connecting rod bolts are torque to rod bushing Verify the diameter IS within yield and must be discarded and replaced after this specification 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 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 Piston Pin Diameter e Measure the piston pin diameter in two directions at the points shown Verify the diameter is within specifi
112. are already filled with testing fluid Hydraulic Valve Lash Adjuster Hydraulic lash adjuster noise can be caused by any of the following e excessively collaosed lash adjuster ga iid 2 Place the lash adjuster in the tester with the e sticking lash adjuster plunger e lash adjuster check valve not functioning properly air in lubrication system e leak down rate too rapid e 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 out 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
113. arping with a feeler gauge NOTE The exhaust manifold shown is a typical exhaust manifold 7 Turn the mandrel body approximately one half turn counterclockwise and remove 01 39 MSG 425 GENERAL INFORMATION SPECIFICATIONS GENERAL SPECIFICATIONS Threadiock 262 WSK M2G351 AG E2FZ 19554 B vuper Premium Wass 20030 NOTE Ford engines are designed to perform with engine oils that are licensed by the American Petroleum Institute API and oils carrying the most current Classification SJ or greater must be used 01 40 MSG 425 ENGINE INDEX Subject General Information Engine Ventilation _ ____ Drive Belt SV SCSI gt SUM Removal and Installation Intake Manifold Removal Intake Manifold Installation eese nnnm nennen Camishalt Cover oet ua cet ieu rupes cuu tutt Camishaft Cover Installation ed Crankshaft Pulley RemoVal svisacesidtesucsisse seis
114. ative cables in same position as when removed Assemble and tighten battery hold down clamp so battery is secure Do not tighten excessively Secure cables to proper terminals Tighten to 6 Nm 53 Ib in Apply petroleum jelly to terminals Ford Motor Company strongly recommends that lead acid batteries be returned to an authorized recycling facility for disposal gt 2 RECYCLE MSG 425 CHARGING SYSTEM SPECIFICATIONS GENERAL SPECIFICATIONS Generator Output 65 110 max amps 1800 6000 generator rom approx 500 2000 engine rpm Battery Motorcraft 12 volt 750 CCA Battery charging voltage 13 15 5 volts TORQUE SPECIFICATIONS Description Lb ft Generator bolts Regulator attachment Screws a cable nuts Generator ya 9 71 wiring nuts SPECIAL TOOLS VAT 40 Starting charging 06 14 MSG 425 STARTER SYSTEM INDEX Subject Cautions amp Warnings General Information __ _ HX Diagnosis and Testing te Symptom Motor Feed Circuit Voltage Drop a Starter Motor Ground Circuit dv ba General Service Procedure
115. ay a 10 second graph of critical engine data from 8 seconds before the fault occurred to two seconds after With many OEMs using control modules to control their machinery the GCP has the ability to communicate engine data to and receive commands from other control modules through a Controller Area Network CAN link with messages written in the J1939 protocol This allows large amounts of data to move throughout the machine through only two wires and can be used to run some module based gauge packages The GCP also carries auxiliary features that can be programmed to control OEM devices allowing the OEM to eliminate components from their machinery The GCP is also equipped with multiple safety and protection devices that protect the user and engine from hazards such as over speed over temperature over voltage low oil pressure unauthorized tampering over cranking starter motor 08 3 The GCP controls the following e Fuel metering system Ignition timing e On board diagnostics for engine functions The GCP constantly observes the information from various sensors The GCP controls the systems that affect engine performance The GCP performs the diagnostic function of the system It can recognize operational problems alert the operator through the Malfunction Indicator Lamp MIL and store diagnostic trouble codes DTC s DTC s identify the problem areas to aid the technician in making repairs The GCP s
116. beling on the battery is carefully as hazardous provided that sensible precautions are read understood and complied with The format of the observed and that operatives have been trained in their following symbols and labels is common to most brands use and are adequately supervised of lead acid battery DANGERIPOISON i TESTE ij 7 ALIN 55 OF SEVERE j SULFURIOUE ETINCELLES i DSL ET Explosive gases Eye protection must be WORN No smoking or naked flames Corrosive acid Flush eyes immediately when contacted with acid T Caution important noice NOTE Observe all manufacturers instructions when using charging equipment CAUTION Batteries should not be charged in the vehicle or equipment May damage electrical components Read relevant instructions Keep away from children Do not dispose of as household waste Recycle via recognized disposal system Electrical current may cause injury to personnel MSG 425 GENERAL INFORMATION Forward This book contains service information 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 that the engine 15 correctly operated We consider it to be in you
117. cations Connecting Rod Twist e Measure the connecting rod twist on a suitable alignment fixture Follow the instructions of the fixture manufacturer Verify the measurement is within specification 01 28 MSG 425 GENERAL INFORMATION Connecting Rod Piston Pin Side Clearance 4 Install and torque to specifications then remove e Measure the clearance between the connecting the connecting rod bearing cap rod and the piston Verify the measurement is within specification 5 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 Connecting Rod Journal Clearance Special Tool s 02 5 or Equivalent Special Service Tools called tor ow procedures can pe ined Oy 1600 90 1 800 768 8532 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 3 bearing surface NOTE Do not turn the crankshaft during this step 01 29 MSG 425 GENERAL INFORMATION Bearing Inspection Roller Follower Inspection Inspect bearings for the following defects Possible In
118. cled DTC 2115 FPP1 higher than IVS limit DTC 2139 FPP1 lower than IVS limit DTC 2116 FPP2 higher than IVS limit DTC 2140 FPP2 lower than IVS limit DTC 2126 FPP1 higher than FPP2 DTC 2121 FPP1 lower than FPP2 1171 MegaJector delivery pressure higher than expected DIC 1172 MegaJector delivery pressure lower than expected 1173 MegaJector communication lost 1176 MegaJector internal actuator fault detection DTC 1177 MegaJector internal circuitry fault detection DTC 1178 MegaJector internal communication fault detection DIC 606 COP failure Internal GCP failure DTC 1612 RTI 1 loss internal GCP failure e DTC 1613 RTI 2 loss internal GCP failure DIC 1614 RTI 3 loss internal GCP failure DIC 1615 A D loss internal GCP failure e DTC 1616 Invalid interrupt internal GCP failure 601 Flash checksum invalid internal GCP failure DIC 604 RAM failure internal GCP failure Fault Low Rev Limit The engine RPM will be limited to a maximum of 1600 RPM If the Fault Low Rev Limit 15 active it will remain active until the active goes away and the ignition input to the GCP usually the ignition switch is cycled DTC 2122 FPP1 high voltage DTC 2123 FPP1 low voltage DTC 2115 FPP1 higher than IVS limit DTC 2139 FPP1 lower than IVS limit DTC 2116 FPP2 higher than IVS limit DTC 2140 FPP2 lowe
119. components that Install intake manifold Refer to Intake Manifold MSG 425 ENGINE Crankshaft Pulley Removal CAUTION The crankshaft the crankshaft sprocket and the pulley are fitted together by friction with diamond washers between the flange faces on each part For that reason the crankshaft sprocket is also unfastened if you loosen the pulley Therefore the engine must be retimed each time the damper is removed Otherwise severe damage can occur 1 Remove and or disconnect components to allow access and removal of the crankshaft pulley Label if necessary to allow for correct reinstallation 2 Remove the drive belt refer to Section 6 3 Remove the camshaft cover Refer to Camshaft Cover Removal on page 6 of this section CAUTION Failure to position the No 1 piston at top dead center TDC can result in damage to the engine Turn the engine in the normal direction of rotation only 4 Using the crankshaft pulley bolt turn the crankshaft clockwise to position the No 1 piston at TDC CAUTION The special tool 303 465 is for camshaft alignment only Using this tool to prevent engine rotation can result in engine damage 5 Install special tool 303 465 in the slots on the rear of both camshafts nmm OR Cat jk 4 i ed C HC T _ men pe NOTE Camshaft timing slots are offset special tool canno
120. cuit wiring 06 6 MSG 425 CHARGING SYSTEM Repair as necessary Repair as necessary Repair as necessary Repair as necessary Repair as necessary Repair as necessary Repair as necessary MSG 425 CHARGING SYSTEM Battery Drain Test WARNING REFER TO CAUTIONS amp WARNINGS AT THE BEGINNING OF THIS SECTION A defective component or wiring defect may be causing a small current drain that is less than the fuse rating for the circuit so the fuse does not open Perform the following to determine if an excessive drain is occurring NOTE Batteries should be fully charged for the following test WARNING DO NOT ATTEMPT THIS TEST ON A LEAD ACID BATTERY THAT HAS RECENTLY BEEN RECHARGED EXPLOSIVE GASES MAY CAUSE PERSONAL INJURY FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY CAUTION To prevent damage to the meter do not crank engine or operate accessories that draw more than 10A 1 Allow the engine to sit with the ignition off for at least 40 minutes to allow the GCP to power down 2 Connect a fused 10A jumper wire between the negative battery cable and post to prevent the GCP from resetting and to catch capacitive drains 3 Disconnect the negative battery cable without breaking the connection of the jumper wire NOTE It is very important that continuity between the negative battery cable and post is not broken If it is the entire procedure must be repeated so the GCP can power
121. de fuel at a pressure above the pressure needed by the injectors A fuel pressure regulator in the fuel filter assembly keeps fuel available to the fuel injectors at a constant pressure of 45psig A return line delivers unused fuel back to the tank The main control sensor is the heated oxygen sensor HO2S located in the exhaust system The HO2S tells the GCP how much oxygen is in the exhaust gas The GCP changes the air fuel ratio to the engine by controlling the amount of time that the fuel injector is ON The best mixture to minimize exhaust emissions is 14 7 parts of air to 1 part of gasoline by weight which provides the most efficient combustion Because of the constant measuring and adjusting of the air fuel ratio the fuel injection system is called a closed loop system The GCP monitors signals from several sensors in order to determine the fuel needs of the engine Fuel is delivered under one of several conditions called modes modes controlled by the GCP Refer to Open Loop and Closed Loop Operation for more information Fuel Injector The Electronic Fuel Injection EFI fuel injector is a solenoid operated device controlled by the GCP The GCP energizes the solenoid which opens a valve to allow fuel delivery The fuel is injected under pressure in a conical spray pattern at the opening of the intake valve Excess fuel not used by the injectors passes through the fuel pressure regulator befo
122. down again 4 Connect an ammeter between the negative battery cable and post The meter should have a 10 amp capability NOTE If after this next step the meter settings need to be switched or the test leads need to be moved to another jack the jumper wire must be reinstalled to avoid breaking continuity 06 7 5 Remove the jumper wire and note the amperage draw e There should not be any more than 50 mA 0 050 amp draw excessive remove fuses one at a time until the circuit with the excessive draw is located e Use the wiring diagram to locate any circuits that do not pass through the fuse box e Disconnect the generator connections to check for an internal short causing an excessive draw Battery Load Test WARNING REFER TO CAUTIONS amp WARNINGS AT THE BEGINNING OF THIS SECTION 1 Disconnect both battery terminal cables Check the battery visually 2 Examine the hydrometer eye if no eye go to next step e Eye shows green go to step 4 e Eye shows dark recharge then go to step 4 e Eye shows yellow replace battery 3 Apply a 300 amp load for 15 seconds Turn off load and wait one minute lf 12 4 volts or more go to step 4 Ifless than 12 4 volts recharge then repeat step Apply a test load equal to 50 of the battery CCA rating at 17 8 C 0 F After 15 seconds with the load still applied measure and record terminal voltage Turn the load OFF 5 Estimate the battery temp
123. e Check radiator for evidences of oil in coolant leakage at transmission oil cooler if equipped Some engines use an ethylene glycol base antifreeze solution to which the manufacturers have added a dye color The dye color makes the antifreeze solution an excellent leak detector If this type of solution is not being used in the cooling system a vegetable dye may be added to aid in locating external leakage 05 4 Coolant Inspection A WARNING REFER TO CAUTIONS AND WARNINGS AT THE BEGINNING OF THIS SECTION Check level and condition of coolant A dark brown color could indicate a stop leak was used A light or reddish brown color indicates that rust may be present in the cooling system Flush the system and refill with the correct mixture of distilled water and premium engine coolant An iridescent sheen on top of the coolant could indicate a trace of oil is entering the system milky brown color may indicate that either engine oil or transmission fluid is entering the cooling system If transmission fluid is suspected it may be entering through the transmission cooler in the radiator engine oil is Suspected the cause may an internal leak in the engine Coolant Range Check If the engine coolant appearance is acceptable test the engine coolant freezing point and concentration level The antifreeze concentration in a cooling system can be determined by using a suitable hydrometer or a battery a
124. e TP sensor 5 volt reference or signal circuits for greater than 2 consecutive seconds will set a DTC 123 or DTC 223 A hard failure with the TP sensor ground circuit for more than two consecutive seconds may set DTC 222 If any TP DTC is set the GCP will shut down the engine immediately Specifications Range of Measurement 0 85 angular Measurement Accuracy 2 of VREF Resolution 0 5 max MSG 425 Engine Controls Fuel System Components Gasoline The fuel metering system is made up of the following parts e The fuel injectors gasoline The fuel rail gasoline The fuel filter gasoline The GCP The Crankshaft Position CKP Sensor The Camshaft Position CMP Sensor The fuel pump gasoline The fuel pump relay gasoline The Direct Electronic Pressure Regulator Gaseous Fuels The Fuel Lock Off Solenoid Gaseous Fuels The Mixer Gaseous Fuels The Vapor Regulator LPG CNG Heated Oxygen HO2S Sensor Temp Manifold Absolute Pressure TMAP Sensor The basic function of the air fuel metering system is to control the air fuel delivery to the engine Fuel is delivered to the engine by individual fuel injectors mounted in the intake manifold near each intake valve The fuel metering system starts with the fuel in the fuel tank The fuel is drawn up to the fuel pump through a pre filter The electric fuel pump then delivers the fuel to the fuel rail through an in line fuel filter The pump is designed to provi
125. e all special tools and 6 mm bolt CAUTION Only turn the engine in the normal direction of rotation 4 Turn the engine 2 complete revolutions and then continue to turn until piston is at TDC 5 Install special tool 303 507 02 8 CAUTION Only hand tighten the bolt in the next step or damage to the front cover can occur 6 Using the 6mm x 70 mm bolt check the position of the crankshaft pulley If it is not possible to install this bolt correct the engine timing 7 Using special tool 303 465 check the position of the camshaft If it is not possible to install the special tool correct the engine timing J 8 Remove all special tools and 6m 9 Install the plug bolt Tighten to 20 Nm 15 lb ft 10 Install camshaft cover Refer to Camshaft Cover Installation on page 7 of this section AK YN 11 Install accessory drive belt refer to Section 6 12 Install or reconnect any other components that were removed or disconnected MSG 425 ENGINE Crankshaft Front Seal Removal CAUTION The crankshaft the crankshaft sprocket and the pulley are fitted together by friction with diamond washers between the flange faces on each part For that reason the crankshaft sprocket is also unfastened if you loosen the pulley Therefore the engine must be retimed each time the damper is removed Otherwise severe damage can occur 1 Remove and or disconnect com
126. e to the engine CAUTION Never use a cold coolant mixture to topup the radiator or degas tank of a hot engine if the coolant level is very low this could cause serious engine damage CAUTION In territories where freezing conditions may occur the coolant should consist of a mixture of 50 plain water and 50 Motorcraft Premium Gold coolant or equivalent This antifreeze contains additional corrosion inhibitors designed to provide lasting protection for the engine CAUTION Only this antifreeze or proprietary antifreeze meeting Ford specification WSS M97B51 A1 should be used when topping up or re filling the cooling system Do not mix coolant types CAUTION Do not add or mix an orange colored extended life coolant such as Motorcraft Specialty Orange engine coolant with factory filled coolant WSS M97B44 D Mixing Motorcraft Specialty Orange engine coolant or any orange colored extended life product with factory filled coolant can result in degraded corrosion protection CAUTION If there is engine coolant in the engine oil or transmission fluid the cause must be corrected and oil fluid changed or major component damage can occur CAUTION When removing coolant the coolant must be recovered in a suitable clean container for reuse If the coolant is contaminated it must be recycled or disposed of correctly WARNING DO NOT STAND INLINE WITH OR NEAR THE ENGINE COOLING FAN BLADE WHEN REVVING THE ENGINE FAILURE TO
127. e worn journal tapered or bearing not seated F NOTE Do not turn the crankshaft while doing this procedure FPES 3 Install and remove the crankshaft main bearing cap 01 23 MSG 425 GENERAL INFORMATION Crankshaft End Play Special Tool s TOOL 4201 C Equivalent service 1 800 763 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 4 Move the crankshaft to the front of the cylinder block Note and record the camshaft end play lf camshaft end play exceeds specifications replace the crankshaft thrust washers or thrust bearing Crankshaft Runout Special Tool s Indicator with Bracketry TOOL 4201 C or Equivalent 1 800 748 8432 NOTE Crankshaft main bearing journals must be within specifications before checking runout 01 24 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 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 cylinder to the
128. eck 08 36 Intermittent Problems NOTE An intermittent problem may or may not turn on the MIL or store a DTC Do not use the DTC charts for intermittent problems The fault must be present to locate the problem NOTE Most intermittent problems are caused by faulty electrical connections or wiring Perform a careful visual inspection for the following conditions e Poor mating of the connector halves or a terminal not fully seated in the connector backed out e Improperly formed or damaged terminals e Improper contact tension connector terminals in the problem circuit should be carefully checked e Poor terminal to wire connections This requires removing the terminal from the connector body to check e Improperly installed aftermarket equipment or accessories Operate the engine with accessories OFF and a suitable multimeter connected to the suspected circuit An abnormal voltage when the malfunction occurs is a good indication that there is a fault in the circuit being monitored To check GCP for loss of diagnostic code memory disconnect the MAP sensor connector and idle the engine until the MIL illuminates Perform MIL DTC retrieval procedure DTC should be stored and kept in memory when the ignition is turned OFF If not the GCP is faulty When this test is completed make sure that you clear the DTC from memory An intermittent MIL with no stored DTC may be caused by the following e Ignit
129. ed 260 C 500 F areas exposed to engine coolant or oil These areas will not repair and could cause future failure 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 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 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 Sand or grind the repaired area to blend with the general contour of the surface Paint the surface to match the rest of the cylinder block 2 Cylinder Block Core Plug Replacement Special Tool s impact Site Hammer T50T 100 A Specal Sence Tools caled for by the procedures can be obtained by call 1 800 ROTUNDA 1 500 706 0032 1 Use a slide hammer tools suitable to remove the cylinder block core plug 01 36 2 Inspect the cylinder block plug bore for any damage that 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 cylinder block core plug and bore lightly with Threadlock 262 E2FZ 19554 B equivalent mee
130. ed petroleum gas LGP timing can be modified by GCP Fuel Ignition Coil Driver The GCP switches 4 individual ignition coils on and off at the correct times to give the desired spark advance Ignition timing is adjusted constantly by the GCP Many factors including all the sensor inputs affect the final ignition setting Run Mode The GCP interprets engine speed above 200 rom as Run Mode The Base Spark advance BSA is calculated by the GCP processing the engine speed input Transient Mode This function is to provide detonation protection when the engine load 15 increased rapidly by fast opening of the throttle plate MSG 425 IGNITION SYSTEM Wiring Diagram 8 30 Bb WE noo 82109 N92 weds weds 5 de i al ake sa el nc one a D lcs m 4 Wd HAA 81 gi LA S 01 dl 71 T T 1 RENS d pwl ie uomubi TH 91 91 5 9i 9 91 Quer TN Mod kr 3 03 MSG 425 IGNITION SYSTEM DIAGNOSIS AND TESTING Spark Plug Inspection Inspect the spark plug tip as in the chart below GAP BRIDGED FOULED IDENTIFIED WET BLACK DEPOSITS ON THE INSULATOR a SHELL BORE EL
131. efore performing any diagnostic procedure Perform all necessary repairs before proceeding with additional diagnosis this can often lead to repairing a problem without performing unnecessary steps Use the following guidelines when performing a visual physical inspection check Inspect engine for modifications or aftermarket equipment that can contribute to the symptom verify that all electrical and mechanical loads or accessory equipment is OFF or disconnected before performing diagnosis Inspect engine fluids for correct levels and evidence of leaks Inspect vacuum hoses for damage leaks cracks kinks and improper routing inspect intake manifold sealing surface for a possible vacuum leak Inspect PCV valve for proper installation and operation Inspect all wires and harnesses for proper connections and routing bent or broken connector pins burned chafed or pinched wires and corrosion Verify that harness grounds are clean and tight Inspect GCP sensors and actuators for physical damage Inspect GCP grounds for cleanliness tightness and proper location Inspect fuel system for adequate fuel level and fuel quality concerns such as proper octane contamination winter summer blend Inspect intake air system and air filter for restrictions Inspect battery condition and starter current draw If no evidence of a problem is found after visual inspection has been performed proceed to Diagnostic System Ch
132. efore separating from the tube Apply clean engine oil to the end of the tube before inserting the tube into the connector CAUTION To ensure absolute cleanliness is observed when working with fuel system components always cap off any open orifices or tubes 04 2 MSG 425 FUEL SYSTEM GENERAL INFORMATION GASOLINE Camshaft Position CMP Sensor Actuator Description The fuel system delivers fuel by an electronic fuel pump A fuel pressure regulator controls fuel pressure and also contains a fuel filter The Electronic Control Module GCP uses information from various sensors and controls fuel delivery to the cylinders by individual fuel injectors mounted in the cylinder head near each intake valve Air delivery is controlled by an actuator Fuel Rail The fuel rail is mounted to the top of the engine and distributes fuel to the individual injectors Fuel is delivered to the fuel inlet tube of the fuel rail by the fuel lines and hoses Fuel Injector The fuel injector is a solenoid operated device mounted to the cylinder head The GCP energizes the solenoid which opens a valve to allow fuel delivery into the cylinder 04 3 Engine Coolant Temperature ECT Sensor Fuel Rail Injectors Camshaft Position CMP Sensor The Camshaft Position CMP Sensor is mounted in the camshaft cover This signal is sent to the GCP which uses it to indicate the position of the 1 piston during its power stroke T
133. emoval and Installation Drive tu Drive Belt InstalldtlODs Belt Tensioner REplaceEMent ssccsssssscsecsescsssssstesessonsonestecesessestonssestssuensessessonstensscensets Idler Pulley Replacement t Radiator Hose Removal Radiator Hose esu Thermostat amp Housing Replacements Coolant Pump Outlet E e 05 1 Page 05 3 05 4 05 4 05 4 05 5 05 6 05 7 05 7 05 7 05 8 05 8 05 8 05 9 05 9 05 9 05 9 05 10 05 10 05 11 05 12 05 13 05 14 05 15 MSG 425 COOLING SYSTEM CAUTIONS amp WARNINGS WARNING THE RADIATOR OR DEGAS TANK IS EQUIPPED WITH A PRESSURE CAP IT IS DANGEROUS TO REMOVE THIS WHEN THE SYSTEM IS VERY HOT AN WARNING NEVER REMOVE THE PRESSURE RELIEF CAP WHILE THE ENGINE IS OPERATING OR WHEN THE COOLING SYSTEM IS HOT MAY CAUSE PERSONAL INJURY OR DAMAGE TO COOLING SYSTEM OR ENGINE TO REDUCE THE RISK OF HAVING SCALDING HOT COOLANT OR STEAM BLOW OUT OF THE DEGAS BOTTLE WHEN REMOVING THE PRESSURE RELIEF CAP WAIT UNTIL THE ENGINE HAS COOLED DOWN TO AT LEAST 40
134. en contains a listing of all of the Historic and Active DTC s set within the GCP system If a DTC is stored in memory the screen will display that fault in the Historic Faults column If the fault condition currently exists the DTC will also show up in the Active Faults column Opening Diagnostic Trouble Codes To open a DTC click on the DTC in the Historic Faults column A DTC Dialog Box will pop up on the screen The DTC Dialog Box contains the following useful information e If the fault occurred during the current key cycle fthe fault caused current engine shutdown e How many key cycles since the fault was active e Snapshot Data explained later e Flight Data Recorder explained later The DTC Dialogue Box also allows you to clear a single fault by clicking on the Clear This Fault button and it allows you to clear all faults by clicking on the Click All Faults button NOTE Record faults before clearing them This will aid in diagnosis Below is an example of a DTC Dialogue Box Snap Shot Data The Snap Shot Data is a listing of specific engine system variables These variables are recorded by the GCP at the instant the DTC sets By clicking on the View Snap Shot Data button a new window will pop up and you will be able to view these variables Here is an example of a Snap Shot Data window MSG 425 Engine Controls Flight Data Recorder The Flight Data Recorder is also a list
135. er to Equipment Setup for information about using a personal computer to assist with unit diagnosis MSG 425 Engine Controls DTC s can be retrieved by shorting the Self Test Input 511 connector to ground The STI circuit is a white purple wire exiting pin 3 of the 42 pin connector The STI white purple wire branches off to terminal A of the 4 pin diagnostic connector If no DTC is stored with key on engine off KOEO a DTC 1654 is flashed indicating that all systems are OK During key on engine running KOER operation with no DTCs stored the MIL is not illuminated If during KOER operation a DTC is stored the MIL will illuminate and remain on steady if the code is active MIL Bulb Test The MIL bulb test occurs KOEO with the STI connector not grounded The MIL bulb will stay on and remain on if no DTCs are present If DTCs are present except 1654 the MIL bulb will blink If the MIL bulb does not illuminate when bulb test is performed access diagnostic software and view the fault indicator on screen If the screen fault indicator is illuminated and the MIL light is not inspect the bulb and replace it if damaged If bulb is OK or does not illuminate after replacement refer to MIL circuit test procedure Once MIL bulb illumination has been verified or established DTCs can be extracted from the MIL as follows DTC Extraction KOEO short the STI circuit to a known good ground There will be a 5 seco
136. erature If measured voltage does not meet or exceed the value shown in the following table replace the battery a 6 Clean all cable ends and terminals of the battery with a wire brush MSG 425 CHARGING SYSTEM Generator Output Test WARNING REFER TO CAUTIONS amp WARNINGS THE BEGINNING OF THIS SECTION CAUTION To prevent damage to the generator do not make jumper wire connections except as directed CAUTION Do not allow any metal object to come in contact with the housing and the internal diode cooling fins with the ignition on or off A short circuit may result and burn out the diodes In order to check the generator the use of rotunda Starting and charging System Tester 078 00005 VAT 40 or equivalent is recommended NOTE Refer to the test equipment user s manual for complete directions on examining the charging system NOTE Turn off all lamps and accessories 1 Switch the tester to ammeter function 2 Connect the positive and negative leads of the tester to the battery 3 Connect current probe to generator B terminal to measure generator output 4 With the engine running at 2000 rpm adjust the VAT 40 or equivalent load bank to determine the output of the generator Generator output should be greater than values given in the graph below 06 8 Generator Voltage Test A WARNING REFER TO CAUTIONS amp WARNINGS AT THE BEGINNING OF THIS SECTION 1 Switch the
137. ern except it can result in excessive noise Medium Piling If heavy deposits are apparent resulting in noise and belt instability install a new belt Heavy Piling Drive belt squeal that is short and intermittent is expected and considered normal Constant or reoccurring drive belt squeal can occur with a damaged pulley bearing fluid contamination or a loose belt Also check for belt misalignment which can cause a chirping noise If misalignment is found check the tensioner for damage especially the mounting pad surface Check for a damaged pulley that wobbles Check mounting brackets for tightness and for any interference Check tensioner with a suitable release tool that it moves without sticking or binding With belt off check that all pulleys rotate freely without binding CAUTION Incorrect drive belt installation will cause excessive drive belt wear and can cause the belt to come off the pulleys MSG 425 COOLING SYSTEM Symptom Chart Refer to the following Diagnosis chart for cooling system problems their possible cause and recommend correction CONDITION POSSIBLE SOURCE ACTION Loss of coolant Engine Overheats Engine fails to reach normal operating temperature Pressure cap and gasket Leakage External leakage Internal leakage Low coolant level Loose fan belt Pressure cap Radiator obstruction Closed thermostat Fan drive clutch Ignition Temp gauge or cold light Engine
138. ers English or Metric system are identified with markings or numbers indicating the strength of the fastener These markings are described in the pages that follow Attention to these markings is important to ensure that the proper replacement fasteners are used Further some metric fasteners especially nuts are colored blue This metric blue identification is in most cases a temporary aid for production start up and color will generally revert to normal black or bright after Start up English or Metric system fasteners are available through your Ford Parts and Service operation NOMENCLATURE FOR BOLTS English System Bolt 1 2 13 x 1 Metric System Bolt M12 1 75 x 25 CM P ELI ALIIS 1 Grade Marking bot strength Property Class strength L Length inches L Length milimeters T Thread Pitch T z Thread Pitch thread width crest to crest mm D Nominal Diameter inches D Nominal Diameter mdlmeters The Property class is an Arabic numeral distinguishable from the slash SAE English grade system The length of all bolts is measured from the underside of the head to the end 09 2 MSG 425 METRICS BOLT STRENGTH IDENTIFICATION e 1 or 2 English inch bolts Identification marks correspond to bolt strength increasing number of slashes represent increasing strength English
139. ey can only be programmed by authorized personnel only Contact your local EDI Distributor listed in the back of this manual for further information CAUTION Do not force the throttle plate open This may cause permanent damage to the actuator A pressure relief valve is located on the fuel rail This is used to read fuel pressure and also to relieve fuel pressure prior to component replacement Fuel Pressure Sensor Return to Tank 04 4 QU Ta Fuel injectors The GCP controls the amount of fuel air delivery refer to the Electronic Engine Control section for further information Fuel System Requirements Fuel Tanks The DOEM or OEM supplies the tanks There must be a fuel outlet and a fuel inlet The gas cap must also be vented per the emission installation instructions Wet Fuels The following fuels must all be unleaded and clean Gasoline petrol This engine is designed to operate on unleaded 87 or 89 octane gasolines Gasohol Ethanol A mixture of gasoline and ethanol grain alcohol containing up to 10 ethanol by volume with properly formulated cosolvents and other necessary additives Blends index of 87 or 89 Gasohol Methanol A mixture of gasoline and alcohol wood alcohol etc containing up to 5 methanol by volume with properly formulated cosolvents and other necessary additives Blends index of 87 or 89 Fuel Pump The fuel pump must be mounted on the fr
140. f Automotive Engineers SAE directive J1930 SAE J1930 standardizes automotive component names for all vehicle manufacturers Ae Gare wg Cove AG Hg Cove RN 08 O Feed Back Carturar FBC Central Multport Fuel Central Fuel Inpecton Fuel Insection FI Alter Cooler Inter Cooler Come ese ci 1 L oson CO _ Clutch Pedal Position Switch CPP Switch Clutch Engage Switch CES Clutch Start Clutch Switch E T 09 7 MSG 425 METRICS MSG 425 METRICS EVAP Canister Purge EVAP CANP Canister Purge EVAP Canister Purge Canister Purge Valve Vale Canister Purge Vacuum Switching Valve Exhaust Gas Recrculaton Valve EGR Valve EGRV 09 9 MSG 425 METRICS ave Fasi Thermo Valve Idle Air Control Valve Opener Vacuum Switching Valve 09 10 MSG 425 METRICS Indirect Fuel Indirect Diesel Inpecbon Mo Laam Block Laan Malin BLM Low Speed Fan Control Switch Speed FC Switch Low eed Fan Control Switch FC Switch 09 11 MSG 425 METRICS 38 TRAN EN F UR eroris injection Port Fuel injecton PF roun
141. f necessary to allow for correct reinstallation Remove the oil level indicator 3 Remove the 2 bolts and tube 4 Remove and discard the o ring 5 Reverse procedure to install e Install a new o ring e Apply clean engine oil to o ring Tighten bolts to 10 Nm 89 Oil Pan Removal CAUTION Failure to follow this procedure can cause future oil leakage 1 Remove and or disconnect components to allow access and removal of the oil pan Label if necessary to allow for correct reinstallation Drain the engine oil Remove oil level indicator amp tube Refer to Oil Level Indicator amp Tube Replacement on page 24 of this section MSG 425 ENGINE 4 PURUS oil pan ano bolts mt Drain Plug CAUTION Do not use metal scrapers wire brushes power abrasive discs or other abrasive means to clean the sealing surfaces These tools cause scratches and gouges which make leak paths Use a plastic scraping tool to remove all traces of old sealant 5 Clean the mating surface of oil pan and block with silicone gasket remover and metal surface prep WARNING OBSERVE ALL WARNINGS AND CAUTIONS AND FOLLOW ALL APPLICATION DIRECTIONS CONTAINED ON THE PACKAGING OF THE SILICONE GASKET REMOVER AND METAL SURFACE PREP Oil Pan Installation NOTE If not secured within 4 minutes the sealant must be removed and the sealing area re cleaned as before Refer to previous CAUTION amp WARN
142. free movement of the carburetor air valve Pressing on the diaphragm will move the valve Yes May be electronic check that the CAM and crank sensor are not damaged and as well as all wiring Ensure all coils are firing Check if faults are present with the GCP Is the air valve binding No diagnostic software Refer to section 8 engine controls 04 14 MSG 425 FUEL SYSTEM Diagnostic Aids Fuel Lock Solenoid The fuel lock is an electronic solenoid that is opened to allow fuel flow when the key is turned ON High temperatures may cause the solenoid to become intermittent not opening to supply sufficient fuel pressure Fuel Filter There is a filter element located in the inlet of the fuel lock which may become clogged and limit fuel flow especially at low tank pressures Check the filter and replace as necessary 04 15 Mixer Assembly Carburetor It is possible that a backfire may have caused the fuel valve to partially come off of its retainer and restrict fuel check the mixer fuel valves see section 475 1 for disassembly Fuel Line Restrictions The vehicle specifications table specifies the fuel line to be a certain size If the fuel line from the tank to the fuel lock is not the proper size or any valves or fittings with flow restrictive characteristics are used the fuel flow will not be sufficient to the converter with low tank pressure Correct any fuel line or fitting restrictions Requlator Assembl
143. g e Tighten to 10 Nm 89 7 Reconnect or install any other component that was removed 8 Reconnect battery cable refer to section 6 MSG 425 Engine Controls Engine Coolant Temperature ECT Sensor Replacement NOTE Removal steps in this procedure may contain installation details 1 Disconnect battery ground cable refer to section 6 NOTE The sensor is located at the rear of the cylinder head 1 NOTE Lubricate the O ring seal with clean engine oil e Torque 30 Nm El 6 PGE 6131793 Installation 1 To install reverse the removal procedure Heated Oxygen Sensor HO2S Replacement i HE fai j 2 Disconnect battery ground cable refer to section 6 3 Remove or disconnect any component to allow access and removal of the HO2S Sensor 4 Disconnect HO2S electrical connector NOTE Use penetrating oil to assist in removal 5 Remove HO2S sensor 6 Reverse procedure to install Apply a light coat of anti seize lubricant to the threads of the Sensor Tighten sensor to 40 Nm 30 Ib ft 08 43 MSG 425 Engine Controls Knock Sensor KS Replacement TP Le E i F mg 4 Knock gt Sensor 7 4 ii A 1 eun i grum Pu NI DEM ES ptm i eu 0 Pd Oe P
144. g instructions Filling the Cooling System WARNING REFER TO CAUTIONS AND WARNINGS AT THE BEGINNING OF THIS SECTION Coolant is made up of a 50 50 mix of ethylene glycol permanent antifreeze and distilled water This mixture is to be used year round with temperatures above 34 4 C 30 F If recycled coolant is used it must meet Ford specification ESE M97B44 A or WSS M97B44 D CAUTION Not all coolant recycling processes produce coolant which meets Ford specification ESEM97B44 A or WSS M97B44 D Use of coolant that does not meet specifications may harm engine and cooling system components The engine cooling system is filled with Motorcraft Premium Gold Engine Coolant Always refill the cooling system with the same coolant that was drained from the system Do not mix coolant types CAUTION Do not use alcohol type antifreeze alkaline brine solutions or 100 000 mile red in color antifreeze This may cause serious engine cooling system damage NOTE The use of stop leak may change the color of the coolant 1 Make sure the radiator drain cock is completely closed 2 Fill the system with the proper coolant mix 3 Start engine and hold at high idle engine speed for approximately 8 minutes until thermostat opens 4 Maintain high idle for an additional 3 minutes Add coolant as necessary 5 Stop the engine and check for leaks 6 Verify correct fluid level after engine cools for 20 minutes Top off the degas bottle
145. gine bottom cover The oil pan has reinforcing ribs which strengthen the reduce engine noise transmission and aid in oil cooling The oil pump is mounted to the engine block and is driven by chain from the crankshaft Oil cooling jets spray to the underside of the piston skirt Oil Pump Variable camshaft timing VCT This system is an electronically controlled camshaft adjuster that allows variable timing for the inlet camshaft 1 The valves are driven by timing chain which drives the inlet camshaft timing control unit This unit drives the associated camshafts The timing chain is tensioned using a conventional timing chain tensioner Advantages of variable camshaft timing e Lower fuel consumption due to improved volumetric efficiency e Enhanced engine power and torque 02 4 Drive Belt System Engine accessories such as the generator and water pump are driven by a single serpentine belt Tension is automatically adjusted by a tensioner Larger Grooved ral idler Smooth Alternator 4 Tensioner idler The fan is remotely mounted in front of the primary FEAD and is driven by a crank pulley extension with a separate belt Ignition System The ignition used on the 2 5L engine is an Electronic Distributorless Ignition System EDIS Individual ignition coils are located directly above each spark plug and are used to igni
146. he GCP uses the CMP signal as a sync pulse to trigger the injectors in the proper sequence This allows the GCP to calculate true sequential fuel injection SFI mode of operation Engine Coolant Temperature ECT Sensor The Engine Coolant Temperature ECT Sensor is a thermistor mounted in the engine coolant stream in the rear coolant outlet pipe The GCP uses this information to calculate the correct air fuel mixture which varies with engine temperature Actuator The actuator controls air delivery into the cylinders An integral Throttle Position TP Sensor sends a signal to the GCP indicating throttle position The GCP calculates fuel delivery based on throttle valve angle operator demand MSG 425 FUEL SYSTEM Fuel Fuel Filter 4 aye nt zm From Tank Operation The fuel delivery system starts with the fuel in the tank Fuel is drawn up to the fuel pump through a pre filter The electric fuel pump then delivers the fuel to the fuel rail and injectors The GCP controls the fuel pump to deliver fuel pressure required by the injectors The GCP monitors system pressure through a fuel pressure sensor Fuel is injected under pressure in a conical spray pattern at the opening of the intake valve There is a return line to the tank with a small orifice to prevent vapor lock in the pump An actuator controls air supply to the intake manifold Governor settings are not adjustable Th
147. he plunger is on top of the camshaft lobe and in the same plane as the camshaft lobe movement 01 18 5 6 Remove the spark plugs 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 is measuring on the base circle of the camshaft lobe in its lowest position If checking during engine assembly turn the crankshaft using socket or ratchet 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 lift on any lobe is below specified service limits the camshaft and any component operating on 8 10 11 worn lobes must replaced Compare the total lift recorded on the dial indicator with specifications To check the accuracy of the original dial indicator reading continue to rotate the crankshaft until the indicator reads zero Remove the dial indicator adapter and auxiliary starter switch Reinstall components as necessary CAUTION Do not rotate 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 MSG 425 GENERAL INFORMATION NOTE Lash adjusters cannot be checked with engine oil in them Use only testing fluid New hydraulic lash adjusters
148. heck for 12 ped and fused volt supply at the harness connector or possible cause Is the voltage less than 11 5 volts Go to step 5 Fuel filter element may be that 120 180 psi is going to the regulator clogged inspect and or Check downstream of the lock off replace the fuel filter Lockoff valve may be faulty replace e Key ON the lockoff valve Go to Step 6 The presence of ice on the converter without the engine Key ON cranking indicated the possibility of a fuel leak past the primary Check for ice or frost build up on the converter 2 casing and outlet port May be electronic check that the Key OFF CAM and crank sensor are not damaged and as well as all wiring Check if faults are present with the GCP diagnostic software Refer to Is ice present section 8 engine controls Is the pressure not in the above range 04 12 MSG 425 FUEL SYSTEM Diagnostic Aids Fuel Lock Solenoid The fuel lock is an electronic solenoid that is opened to allow fuel flow when the key is turned ON High temperatures may cause the solenoid to become intermittent not opening to supply sufficient fuel pressure Fuel Filter There may be a filter element located in the inlet of the fuel lockoff valve which may become clogged and limit fuel flow especially at low tank pressures Check the filter and replace or clean as necessary Fuel Line Restrictions The vehicle specifications table specifies the fue
149. iable valve timing VVT Crankshaft Position CKP Sensor The Crankshaft Position CKP Sensor provides a signal used by the Engine Control Module GCP to calculate the ignition sequence The sensor initiates the reference pulses which the GCP uses to calculate RPM and crankshaft position Camshaft Position CMP Sensor The Camshaft Position CMP Sensor uses a variable reluctor sensor to detect camshaft position The CMP signal is created as piston 1 is a pre determined number of degrees after top dead center on the power stroke The Camshaft Position CMP Sensor sends a CMP signal to the GCP The GCP uses this signal as a sync pulse to trigger the injectors in the proper sequence The GCP uses the CMP signal to indicate the position of the 1 piston during its power stroke The CMP uses a Hall Effect sensor to measure piston position This allows the GCP to calculate true sequential fuel injection SFI mode of operation If the GCP detects an incorrect CMP signal while the engine is running DTC 341 will set CAM sync noice If the CMP signal is lost while the engine is running the fuel injection system will shift to a calculated sequential fuel injection mode based on the last fuel injection pulse and the engine will continue to run As long as the fault DTC 08 4 342 CAM loss is present the engine can be restarted It will run in the previously established injection sequence CMP Sensor 56 425
150. icon Capacitive Absolute Pressure SCAP sensor with a maximum operating temperature of 100 C The output is a 50 duty cycle wave form whose frequency Is proportional to the pressure input 08 7 Throttle Position TP Sensor Electronic Actuator The Throttle Position TP Sensor is a dual track rotary potentiometer that uses a variable resistive element which is packaged inside a plastic housing The resistive element varies linearly and is directly proportional to the throttle plate angle The GCP applies reference voltage and ground to the sensor and monitors the sensor s ratio metric output voltage to determine precise throttle position The electronic actuator has two TP outputs that the GCP monitors 7 J 5 gt i The Electronic Actuator consists of a throttle body an electronically actuated throttle plate and a built in throttle position TP Sensor The Electronic Actuator also acts as an idle air control IAC valve Changes in engine load are detected by the GCP by comparing manifold absolute pressure TMAP with throttle position When the GCP detects a change in engine load it can adjust idle speed by changing the PWM signal to the actuator As the throttle valve opens the output increases so that at wide open throttle WOT the output voltage should be above 4 volts The GCP calculates fuel delivery based on throttle valve angle operator demand A hard failure in th
151. ile checking for fluid in cylinders Repair as needed refer to sections 01 MSG 425 STARTER SYSTEM Motor Feed Circuit Voltage Drop Test Slow cranking is often caused by high resistance in the battery cables or connections especially in cold weather After all batteries check good and terminals are clean and tight check the starter motor feed circuit 1 3 Connect remote starter switch between the starter S terminal and the battery positive terminal Connect a digital multimeter positive lead to the battery positive post Connect negative lead to the starter solenoid M terminal Remote Start Switch F B 4 amp L j Voltmeter Engage the remote starter switch Read and record the voltage The voltage reading should be 0 5 volt or less f 0 5 volt or less refer to starter motor ground circuit test If greater than 0 5 volt indicating excessive resistance move the negative lead to the terminal as shown and repeat the test If voltage reading at the B terminal is lower that 0 5 volt the concern is either in the connections at the starter solenoid or in the solenoid contacts By moving the lead toward the battery and checking each mechanical connection point the excessive voltage drop can be located When the high reading disappears the last mechanical point that was checked is the concern Clean or repair as necessary
152. ine and re check emission levels the cause Replace as No necessary Has the rich emission failure been eliminated Go to step 2 2 Check the carburetor air valve for binding Replace the mixer e With the air cleaner removed pull the air valve piston upwards to ensure free movement of the carburetor air valve Go to Step 3 Is the air valve binding 3 Check DEPR operation DEPR is likely not e With the engine at idle malfunctioning e Disconnect the electrical connector Possible wiring issue faulty ECU or faulty DEPR Check if faults are present with the Is there a change in engine running with this GCP diagnostic unplugged software Refer to section 8 engine controls 04 17 MSG 425 FUEL SYSTEM The pinpoint tests below should be performed after the preliminary tests and Emission failure Lean Mixture chart Steps 1 3 Any electrical diagnostics should have been performed to eliminate any sensor GCP or solenoid valve problems before proceeding Emission Failure Lean Mixture Test Step Result Action to Take 1 Check regulator fuel supply Yes e Install pressure gauge on the primary test port of the vapor regulator e Start the engine to induce the failure Is the primary pressure less than 3 5psi or fluctuating No 2 Check fuel lock supply voltage Yes Key Off Disconnect fuellock connector from harness Key On Using a high impedance DVOM check for 12 vol
153. ing 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 MSG 425 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 e severe loading applications e sustained high speed operation Engines need oil to lubricate the following internal components e cylinder block cylinder walls pistons piston pins and rings intake and exhaust valve stems intake and exhaust valve guides all internal 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 consumption rates e engine size e operator drivi
154. ing of specific engine system variables These variables are recorded by the GCP for an interval of 10 seconds The 10 second interval includes 8 seconds before the sets and 2 seconds after the DTC sets By clicking on the View Flight Data Recorder Data button a new window will pop up and you will be able to view these variables Below is an example of a flight Data Recorder Data window The FAULTS screen shows the following Fault Access System States DBW Variables Closed Loop Control Digital Input Voltages Diagnostic Modes Historic Faults Active Faults Use the keys at the upper left corner or the page command to toggle the three main screens GAUGES FAULTS AND RAW VOLTS NOTE F9 key will toggle to the last screen you were on Data Stream Reading Sensor amp Actuator Values Most applicable sensor and actuator values are displayed on the Gauges Screen The display shows the voltage the FORD system GCP is reading and for sensors the sensor value in engineering units This is one of three main screens GAUGES FAULTS AND RAW VOLTS The GAUGES screen shows the following Manifold Absolute Pressure MAP Engine Coolant Temperature ECT Intake Air Temperature IAT Throttle Position TP Foot Pedal Position FPP Battery Voltage Engine speed RPM Exhaust Gas Oxygen HO2S Hour meter Number of continuous starts Run mode power mode and fuel type Use the keys at the upper left
155. ion 2 Install the front cover and tighten the bolts in the sequence shown to the following specifications Tighten 8 mm bolts to 10 Nm 89 e Tighten 10 mm bolts to 25 Nm 18 lb ft e Tighten 13 mm bolts to 48 Nm 35 10 NOTE If not secured within 4 minutes the sealant must be removed and the sealing area re cleaned as before Refer to previous CAUTION amp WARNING 1 Apply a 3 mm 0 1 in bead of silicone gasket and sealant to the cylinder head and oil pan joint areas and also to front cover as shown below E131717 3 Position the power steering pump or upper idler pulley and install the bolts e Tighten to 25 Nm 18 lb ft TM A d P 1 Er a ate pi ge 4 2 i 4 b 4 gt We 5 m r f N W i 02 11 MSG 425 ENGINE 4 Position the coolant pump pulley and install the 3 bolts Tighten to 25 Nm 18 lb ft Tensioner M A5 Coolant Pump Pulley 5 Install the accessory drive belt tensioner and the bolt e Tighten to 50 Nm 37 lb ft CAUTION The crankshaft the crankshaft sprocket and the pulley are fitted together by friction with diamond washers between the flange faces on each part For that reason the crankshaft sprocket is also unfastened if you loosen the pulley Therefore the engine must be retimed each time the damper is removed Otherwise seve
156. ion coil shorted to ground and arcing at plugs e MIL circuit to GCP shorted to ground e Poor GCP grounds MSG 425 Engine Controls Symptom Charts NOTE Items listed in the possible cause column generally do not set a diagnostic trouble code NOTE If you have a symptom of the pedal not DTC or illuminate the MIL light working and no DTC is set go to the voltage screen and check pedal voltage If pedal voltage NOTE EDI engines are used in many different is 75 1 25 volts and idle validation switch says applications and equipment When performing you re at idle replace the pedal any system diagnosis be aware of any OEM inputs or equipment monitoring devices that may have an effect on the engine s performance or Engine Performance No Load any of the engine s operating systems SYMPTOM POSSIBLE CAUSE Engine Runs Briefly and Loss of Spark Shuts Down Frozen Fuel Regulator Dry Fuel Low Fuel Pressure Air Inlet Restriction Wiring Failure GCP Failure Faulty OEM Drivers Safety Shut Off Seat Switch Coil Power Loss GCP Ground Loss GCP Power Loss Severe Vacuum Leak Dry Fuel Air Inlet Restriction Air Inlet Leak Dry Fuel Fuel Lock Off Inoperative Dry Fuel Wiring Failure Low Fuel Pressure Ancillary Components Binding High Fuel Pressure Low Fuel Pressure Contaminated Fuel Incorrect Fuel Select Table Selected Wrong GCP Installed Actuator Air Blockage Map Sensor Leak Fuel Contaminated Noise Suppression
157. ion to identify the part number ENGINE DISTRIBUTORS INC MSG425 Model No 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 Parts and Service Replacement parts can be obtained through your local EDI Distributor listed in the back portion of this manual They also may be found in the yellow pages under Engines or contact EDI directly at 1 800 220 2700 EDI 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 Description and Operation Section 01 of this manual covers general procedures and diagnosis of the engine system including base engine repair procedures that would be common to most engines Refer to Section 02 for more specific service information on the MSG 425 engine The MSG 425 engine incorporates a closed positive crankcase ventilation system and an exhaust emission control system The engine s fuel ignition emissions system and exhaust system all affect exhaust emission levels and must be maintained according to the maintenance schedule Refer to the Maintenance and 5 Handbook or contact your nearest EDI distributor listed in the back of this manual MSG 425 GENERAL I
158. ir from the cylinder until the valve spring valve retainer and valve spring retainer keys are installed 1 Remove spark plug of the cylinder being serviced 2 Using special tools apply compressed air to the cylinder of the valve spring being removed 3 Using special tools 303 350 303 300 and 303 472 compress valve spring and remove the retainer keys using some grease and a small screwdriver me 4 Remove the valve spring retainer and valve spring NOTE Place all parts in order to one side CAUTION Keep air pressure in cylinder until valve spring is reinstalled 02 17 Valve Spring Installation CAUTION Check that there is no dirt or particles within the valve stem grooves Check the seating of the valve collets 1 Install the valve spring and retainer 2 Using special tools compress valve spring and install the valve retainer keys 3 Release spring and check that keys are seated properly 4 Remove air supply and all special tools 5 Install the valve tappets Refer to Valve Tappet Replacement on page 18 of this section 6 Install spark plug e Tighten to 15 Nm 11 lb ft Valve Seal Removal CAUTION During engine repair procedures cleanliness is extremely important Any foreign material including any material created while cleaning a gasket surface that enters the oil passages coolant passages or the oil pan can cause engine failure 1 Remove camshafts Refer to Camshaft
159. ired if traces of silicone or gasket material remain Allow to dry until there is no sign of wetness or 4 minutes whichever is longer Failure to follow this procedure can cause future oil leakage MSG 425 ENGINE WARNING OBSERVE ALL WARNINGS AND CAUTIONS AND FOLLOW ALL APPLICATION 7 Using a new gasket install coolant outlet pipe DIRECTIONS CONTAINED ON THE PACKAGING OF and 4 bolts THE SILICONE GASKET REMOVER AND METAL e Tighten to 10 Nm 89 Ib in SURFACE PREP 9 a gy NOTE Do not attempt to make metal shiny Some D IT fl staining of metal surfaces is normal are Dez iN Cylinder Head Assembly 1 EE CAUTION If installing original valves make sure WA they are installed in the same position as removed gt SN 1 Coat valve stems and guides with clean engine AV rT N oil and install into cylinder head 8 Install rear lifting eye and front lifting eye CAUTION Use protector provided with replacement bracket kit to prevent damage to the valve seals e Tighten to 45 Nm 33 Ib ft 2 Using special tool 303 470 install valve seals onto the guides Front Lifting Eye yond WEL 3 Position valve springs and retainers 4 Using special tools 303 350 303 300 and 303 472 compress valve spring and install retainer keys 303 350 NOTE Make sure keys are seated properly CAUTION Be sure to install tappets in the same locatio
160. isassembly procedure Rotating the camshafts or installing the camshafts 180 degrees out of position can cause severe damage to the valves and pistons 02 36 NOTE Lubricate camshaft journals and bearing caps with clean engine oil 12 Install the camshafts and bearing caps Tighten bolts in sequence shown in three stages e Stage 1 Tighten finger tight Stage 2 Tighten to 7 Nm 62 Stage 3 Tighten to 16 Nm 12 lb ft 5 3 1 2 4 222 2 4 CAUTION The crankshaft the crankshaft sprocket and the pulley are fitted together by friction with diamond washers between the flange faces on each part The diamond washers must be installed correctly or severe engine damage can result MSG 425 ENGINE 13 Install the variable camshaft timing VCT system oil filter and the plug in the intake camshaft thrust cap e Torque 12 5 lb ft 17Nm 14 Install the VCT solenoid and the bolt Torque 7 3 lb ft 10Nm 4 V g j Aa f f b Y gt gt 6 CS 4 2139154 LDP 25 15 Install washers and oil pump chain and sprockets Pump E 0 7 NOTE The crankshaft sprocket flange must facing away from the engine block 16 Holding the oil pump chain sprocket in place tighten oil pump sprocket bolt
161. ith diamond washers between the flange faces on each part For that reason the crankshaft sprocket is also unfastened if you loosen the pulley Therefore the engine must be retimed each time the damper is removed Otherwise severe damage can occur 21 Using the crankshaft pulley bolt turn the crankshaft clockwise to position the No 1 piston r AM SLA CAUTION The special tool 303 465 is for camshaft alignment only Using this tool to prevent engine rotation can result in engine damage NOTE The camshaft timing slots are offset If the special tool cannot be installed rotate the crankshaft one complete revolution clockwise to correctly position the camshafts 22 Install special tool 303 465 in the slots on the rear of both camshafts CAUTION Failure to hold the crankshaft pulley in place during bolt loosening can cause damage to the engine 23 Using the special tools remove bolt washer and crankshaft pulley Discard the bolt CAUTION There is one front cover bolt behind the cooling fan drive pulley 24 Remove bolt behind cooling fan drive pulley through one of access holes 25 Remove all front cover bolts and front cover 20 4 43 wm 777 27 iO F9 14 gq 87 12 j S 9 8 2 Uu 07 1 e g 3 67_ 1 S 4 8 Y 5 6 BMG lt 11 Qr 115 9 59 X9 19 1 18 16 MSG 425 ENGINE
162. ition and using the auxiliary starter switch 142 107 172 129 202 151 232 174 crank the engine a minimum of five compression 033 745 1200 203 1407 1055 1055 1207 strokes and record the highest reading Note the 144 109 174 131 204 153 153 175 approximate number of compression strokes TON un CUL LN I IG 1 5 Repeat test on each cylinder cranking the engine approximately the same number of 1020 765 1227 917 1434 1075 1641 1227 compression strokes 148 117 178 133 208 156 238 178 1034 779 1241 931 1448 1083 1655 1241 Test Results 150 113 180 135 210 157 240 180 The indicated compression pressures 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 2 153 on top of the pistons in the low reading cylinders Repeat the compression pressure check on these cylinders Example Readings Compression Pressure Limit Chart MIN MAX MIN 1048 786 152 114 1225 936 182 136 1062 793 154 115 1269 952 184 138 1076 807 156 117 1282 965 186 140 1089 814 158 118 1296 972 188 141 1103 872 160 120 1310 979 190 142 1110 834 161 121
163. k Coupling Type Disconnect essen Spring Lock Coupling Type 11 eren eren Quick Connect Coupling Type Quick Connect Coupling Type Quick Connect Coupling Type 00000000 nnns Quick Connect Coupling Type eene Removal and Installation Fuel amp Injectors ha ier tn T Actuator Removal eit tetti o e e b oi Pete RUE ss Actugtor InstallatiODi axi ccc chal ah isa da ee A eect Mixer Removal WIDMER CaN 2 5 04 1 Page 04 2 04 3 04 3 04 4 04 4 04 5 04 7 04 7 04 7 04 8 04 9 04 10 04 10 04 11 04 12 04 21 04 21 04 21 04 21 04 21 04 22 04 23 04 23 04 23 04 23 04 23 04 23 04 23 04 23 04 24 04 25 04 26 04 26 04 26 04 27 04 27 MSG 425 FUEL SYSTEM CAUTIONS amp WARNINGS WARNING DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENT HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJU
164. ken or damaged parts Valve Spring Retainer and Valve Spring Retainer Keys e Check for proper seating of the valve spring retainer key on the valve stem and in valve spring retainer Valve Spring Retainer Keys e Check for proper seating on the valve stem Valves and Cylinder Head e Check the head gasket for proper installation Check for plugged oil drain back holes Check for worn or damaged valve tips Check for missing or damaged guide mounted valve stem seal Check collapsed lash adjuster gap Check installed valve spring height 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 01 17 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 solash may overshoot the rocker arms If oiling is insufficient for this to occur check oil passages for blockage Push
165. king piston rings piston rings Repair ar replace piston rings Plugged PCV system service PCY system 01 8 MSG 425 GENERAL INFORMATION Engine Noise Excessive main bearing Clearance Adjust clearance or replace main bearing Seized or heat damaged main bearing Excessive crankshaft end play Replace crankshaft thrust main bearing ee oc Malfunchoning hydraulic lash adjuster or raulic lash Replace hydraulic lash adjuster or hydraulsz lagh adjuster nghy adjuster i Excessive hydraulic lash adjuster hydraulic lash Adjust clearance or replace hydraulic lash adjuster adjuster clearance guide or hydraulic tash adjuster or vane reres Malfunctioning generator bearing Refer to Section 06 diagnosis and testing of the generator Loose timing chain belt Adjust or replace timing be ese vater pup tero Maifunctoning hydraulic kash adjuster or hydraulic lash Replace hydraulic lash adjuster or lash adjuster adjuster Damaged hydraulic lash adjuster guide or hydraulic lash Replace hydraulic lash adjuster guide or hydraulic lash adjuster adjuster Compression leakage at valve seat Repair or replace
166. l if necessary to allow for correct reinstallation 2 Remove timing chain and sprockets Refer to Timing Drive Components Removal on page 14 of this section MSG 425 ENGINE CAUTION Failure to follow the camshaft loosening procedure can result in damage to the camshafts NOTE Note the position of the lobes on the No 1 cylinder before removing the camshafts for assembly reference 3 Loosen the camshaft bearing cap bolts in sequence shown one turn at a time 4 Repeat until all tension is released from the camshaft bearing caps 5 Remove bearing caps and camshafts Camshafts Installation CAUTION Install the camshafts with the alignment slots in the camshafts lined up so the camshaft alignment plate can be installed without rotating the camshafts Make sure the lobes on the No 1 cylinder are in the same position as noted in the removal procedure Rotating the camshafts when the timing chain is removed or installing the camshafts 180 degrees out of position can cause severe damage to the valves and pistons NOTE Lubricate the camshaft journals and bearing caps with clean engine oil prior to installation 1 Install the camshafts and bearing caps Tighten bolts in the sequence shown in 3 stages e Stage 1 Tighten one turn at a time until tight Stage 2 Tighten bolts to 7 Nm 62 e Stage 3 Tighten bolts to 16 Nm 12 ft 1 4 s ER air ha
167. l line to be a certain size If the fuel line from the tank to the fuel lock is not the proper size or any valves or fittings with flow restrictive characteristics are used the fuel flow will not be sufficient to the converter with low tank pressure Correct any fuel line or fitting restrictions Mixer Assembly Carburetor It is possible that a backfire may have caused the fuel valve to partially come off of its retainer and restrict fuel check the mixer fuel valves Regulator Assembly Converter If no other problems have been identified replace the fuel management assembly with a known good part of the same pressure range Retest 04 13 MSG 425 FUEL SYSTEM The pinpoint tests below should be performed after the preliminary tests and Engine Cranks but Will Not Start chart Steps 1 3 Any electrical diagnostics should have been performed to eliminate any sensor GCP or solenoid valve problems before proceeding Engine Idles With Rough Acceleration At Load Not Able to Reach Full Power or Misses Test Step Result Action to Take 1 Check for icing or freezing of the regulator Yes The presence of ice on the e With the engine at idle e Check for ice or frost build up on the converter casing and outlet port converter with the engine running indicates the possibility of a coolant supply problem Check coolant level and the coolant system for leaks Check for proper coolant type Is ice present No
168. l special tool 303 465 2 Install the left timing chain guide and 2 bolts OQ M KAZ lt i A cnt NE SETA NE CAUTION Do not rely on the Camshaft Alignment e Tighten to 10 Nm 89 Ib in Plate to prevent camshaft rotation Damage to the tool or the camshaft can occur Install the timing chain 7 Using the flats on the camshaft to prevent camshaft rotation tighten the sprocket bolts Tighten to 65 Nm 48 lb ft 2 lt lt 1 02 16 MSG 425 ENGINE 8 Install the front cover Refer to Engine Front Cover Installation on page 12 of this section 9 Install or reconnect any other component removed or disconnected Valve Spring Removal CAUTION The crankshaft the crankshaft sprocket and the pulley are fitted together by friction with diamond washers between the flange faces on each part For that reason the crankshaft sprocket is also unfastened if you loosen the pulley Therefore the engine must be retimed each time the damper is removed Otherwise severe damage can occur 1 Remove the valve tappets Refer to Valve Tappet Replacement on page 18 of this section WARNING ALWAYS WEAR PROTECTIVE GOGGLES WHEN WORKING WITH COMPRESSED AIR THIS CAN PREVENT INJURY FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN PERSONAL INJURY CAUTION Use compressed air at 7 10 bars 100 150 psi Do not disconnect the compressed a
169. ley and fan pulley Slide bearing bracket up to tension the belt while ensuring the bearing bracket is level Tighten bearing bracket bolts 16Nm 12 Ib ft Belt Tensioner Replacement Fan Belt Removal 1 1 Loosen two bolts holding fan bearing bracket in place 2 Slide the bearing bracket down to loosen belt 3 Remove belt Drive Belt Removal NOTE Note belt routing for installation purposes 1 Rotate tensioner counterclockwise to relieve belt 1 tension 2 Remove belt 2 3 Inspect belt and pulleys Refer to Visual 3 Inspection of this section Drive Belt Installation 1 Rotate tensioner counterclockwise to relieve tension 2 Route belt correctly and release tensioner onto belt 3 Run engine for a minute and then turn off 4 Recheck belt routing and groove alignment 05 9 Remove drive belt Refer to Drive Belt Removal above Remove bolt Remove belt tensioner Reverse procedure to install Tighten bolt to 47 Nm 35 lb ft Idler Pulley Replacement Remove drive belt Refer to Drive Belt Removal of this section Remove belt idler pulley assembly Reverse procedure to install e Tighten to 47 Nm 35 lb ft MSG 425 COOLING SYSTEM Radiator Hose Removal WARNING REFER TO CAUTIONS AND WARNINGS AT THE BEGINNING OF THIS SECTION 1 2 Drain the cooling system Refer to Draining the Cooling System of this section Loo
170. lly around valve cover bolts and crankshaft seals is not detrimental no repairs are required rear main bearing cap and seals e flywheel mounting bolt holes with flywheel installed e camshaft rear bearing covers or pipe plugs at the end of oil passages except for overhead cam Oil leaks at crimped seams in sheet metal parts and cracks in cast or stamped parts can be detected when pressurizing the crankcase 01 11 MSG 425 GENERAL INFORMATION Compression Tests Compression Gauge Check 1 Make sure the oil in the crankcase 15 of the kPa psi kPa psi kPa psi kPa psi correct viscosity and at the proper level and that 924 696 1131 848 1338 1000 1154 115 the battery is properly charged Operate until the 134 101 164 123 194 146 224 168 engine is at normal operating temperature Turn the ignition switch to the OFF position then 938 703 1145 855 1351 1014 1558 1165 2 Setthe throttle plates in the wide open position 952 717 1158 869 1365 1020 1572 1179 3 Install a Compression Tester such as Rotunda 138 104 168 126 198 148 228 171 Compression Tester 059 R0008 or equivalent in the No 1 cylinder 965 724 1172 876 1379 1034 1586 1186 mA A i MEM l 140 106 170 127 200 150 230 172 4 Install an auxiliary starter switch in the starting circuit With the ignition switch in the OFF 979 738 1186 889 1303 1041 1600 1200 pos
171. lt in a lean command to compensate 08 6 Specifications Accuracy of measurement 1 5 Operating Temp Range 350 C to 850 C sensor tip Sensor Response Time 300 1500 msec Heater Current Draw 1 A steady state Voltage Output o 0 450 mV lean exhaust gas 450 1000 mV rich exhaust gas MSG 425 Engine Controls Temperature Manifold Absolute Pressure TMAP Sensor The Temperature Manifold Absolute Pressure TMAP Sensor responds to changes in intake manifold pressure vacuum The TMAP sensor signal voltage to the GCP varies from below 2 volts at idle high vacuum to above 4 volts with the ignition ON engine not running or at wide open throttle low vacuum The TMAP sensor consists of a pressure sensing element capacitor and signal conditioning electronics The capacitor has a vacuum pressure reference which results in one surface diaphragm of the capacitor being partially deflected Further changes in pressure produce corresponding changes in the deflection of the diaphragm and therefore a change in capacitance This capacitance change is converted to a frequency by the conditioning electronics The TMAP sensor 15 used to determine the following e Engine vacuum level for engine control purposes e Barometric pressure BARO Specifications e Range of Measurement 1 7 15 2 psi e Measurement Accuracy 0 2 psi e Sensor Response Time 3 15 msec e Resolution 0 02 psi Present design Sil
172. lug ignition Open Loop and Closed L6GE Operation Use or CirculE Testing TOONS _ __ Electrostatic Discharee Engine component locator view Diagnosis and Testing GCP diagnostic overview On board diagnostics GCP Engine control module GCP inne Bom Mode Intermittent MIL Malfunction Indicator light MIL DTC Retrieval procedure Diagnosis and using a personal computer Symptom charts Engine Control Module Didenostic Trouble Codes Removal and Installation Camshaft Position CMP Sensor eee Crankshaft Position CKP Sensor Removal Crankshaft Position CKP Sensor Engine Coolant Temperature ECT Sensor Rapiscemeni UH REPERI Heat Oxygen Sensor 25 Replacement seen nnns Knock Sensor KS Replacement Temperature Manifold Absolute Sensor enu Actuator Throttle Position TP Sensor 08 1 SSC EON ies eee Iritermittent vete cst
173. lure e Application or Ancillary System Momentarily Binding During Load or Unload Backfires Faulty OEM Drivers Safety Shut off Seat Switch Fouled Spark Plugs Spark Plug Wire Broke Lack of Power GCP Momentary Ground Loss Excess Lean Condition Fuel Lock Off Leaking Dry Fuel Intake Manifold Leak Bad Intake Valve Ancillary Components Binding Intake Air Restriction Crossed Spark Plug Wires Spark Plugs Fouled Fuel System Failure Low Fuel Pressure Low Cylinder Compression Poor Quality or Contaminated Fuel Carbon Build up Wrong Spark Plugs Too High Heat Range Fuel Delivery System PCV System Fuel Selection Timing Cylinder Hot Spots 08 38 MSG 425 Engine Controls Engine Concerns SYMPTOM POSSIBLE CAUSE Oil System Concerns Positive Crankcase Ventilation PCV System High Cil Consumption Oil Viscosity External Leaks Improper Oil Dipstick Valve Seals Cylinder Wall Taper Excessive Worn Piston Rings Cooling System Concerns ert Worn Drive Belt Worn Water Pump Stuck Thermostat Plugged Radiator Internal amp External Dry Fuel System Running Rich Exhaust System Concerns visible smoke Ignition System Black Smoke Fuel Delivery System Sticking Fuel Injector High Fuel Pressure Blue Smoke PCV System Worn Piston Rings Worn valve guides Fuel System Concerns Leaky Lines Contaminated Fuel Excessive Alcohol in Fuel Incorrect Octane Rating Engine Noise Low Oil Pressure
174. ly Converter amp FCV If no other problems have been identified replace the fuel management assembly with a known good part of the same pressure range Retest 04 20 MSG 425 FUEL SYSTEM DIAGNOSIS AND TESTING GASOLINE NOTE For diagnosis of Electronic Engine Control refer to Section 08 Visual Inspection Check for dirt or water in the fuel tank Water and dirt that accumulate in the fuel tank can cause a restricted fuel line filter or a malfunction of the fuel pump Condensation which is the greatest source of water entering the fuel tank is formed by moisture in the air when it strikes the cold interior walls of the fuel tank Fuel Sample Water Falls to Bottom Check the fuel filter If the accumulation of dirt and water in the filter is excessive the fuel tank should be removed and flushed and the line from the fuel pump to the tank should be blown Out Check fuel lines for damage Air leakage in the fuel inlet line can cause low fuel pump pressure and volume Check fuel tank vent A restricted fuel tank vent can cause low fuel pump pressure and volume and can result in collapsed inlet hoses or a collapsed fuel tank High or low pressure are the two most likely fuel pump troubles that will affect engine performance Low pressure will cause a lean mixture and fuel starvation at high speeds and excessive pressure will cause high fuel consumption and possible flooding Fuel Pressure Check
175. mm of 42kg cate Free Length Multi Purpose Grease XG 4 ESB M1C93 B pice Fenn and or XL 5 Assembled height 3 9mm Thread Sealant with PTFE TA 24 WSK M2G350 A2 Displacement No of cylinders Cylinder head flatness 0 08 maximum overall Bore Stroke 89 100 He is Firing Order 1 3 4 2 Valve lift zero lash exhaust Oil Pressure hot 2000rpm 29 39psi Valve lift zero lash intake Oil Capacity 7 quarts including Valve guide diameter filter Valve seat width 0 99 1 84 mm intake exhaust Cylinder Block Valve seat angle Cylinder bore diameter 89 0 89 03 mm Valve seat runout Cylinder bore max out of round 0 008 mm Valve lash adjuster bore Main bearing bore diameter 57 018 57 040 mm diameter Head gasket surface flatness 0 1 mm general and Cam bore diameter 0 05 mm 200x200 Crankshaft Piston Diameter 2 Hing groove width top 1 203 1 205 mm Ring groove width 2 1 202 1 204 mm Ring groove width oil 2 501 2 503 mm Rings Piston skirt coating thickness 0 008 0 016 mm Wiath Top 1 17 1 185 mm Width 2 1 197 1 199 mm 19 995 20 0 mm Ring gap in bore top 0 19 0 26 mm Length 54 7 55 0 mm Ring gap in bore 2 0 31 0 46 mm Ring gap in bore oil 0 15 0 40 mm 02 44 MSG 425 ENGINE Valve Tappet Torque Specifications continued 30 97 30 98 mm Tappet to v
176. mp Gear Radial Clearances Oil PUMP Rotor IMS OILPurp side Cle ara NC R Cylinder Bore Honing Cylinder Bore Gleanings EEA S Cylinder Bore Core Plug Replacements To Cylinder Bore Repair Cast Iron Porosity Defects Cylinder Block Distortion eese enne Spar Plug ipt DE tiae Exhaust Manifold eene enne enne General Service Procedures Page Piston SelectlOn sed PISton Ring End eli cot Sette Ue Piston Ring to Groove Clearance eese eene ener nnns Crankshaft Connecting Rod Journal Crankshaft Connection Rod Journal esee eene nnne Connecting Rod ClO AN ING A eee Connecting Rod Larger End pU MEETS 01 26 01 26 01 27 01 27 01 27 01 27 01 28 01 28 01 28 01 28 01 28 01 29 01 29 01 30 01 30 01 30 01 31 01 31 01 31 01 32 01 32 01 32 01 32 01 32 01 33 01 33 01 33 01 33 01 34 01 34 01 34 01 34 01 35
177. n as removed 5 Install 16 valve tappets 6 Install 4 new spark plugs properly gapped Tighten to 15 Nm 11 Ib ft 02 34 MSG 425 ENGINE Engine Assembly CAUTION The crankshaft the crankshaft sprocket and the pulley are fitted together by friction with diamond washers between the flange faces on each part For that reason the crankshaft sprocket is also unfastened if you loosen the pulley Therefore the engine must be retimed each time the damper is removed Otherwise severe damage can occur CAUTION Failure to position the No 1 piston at top dead center TDC can result in damage to the engine Turn the engine in the normal direction of rotation only 1 Using the crankshaft pulley bolt turn the crankshaft clockwise to position the No 1 piston on TDC gt 2 Remove plug bolt A 24 NN EC 1 4 gt amp i Lie E 7 1 1 1 1 1 j 1 gt gt do _ ps 6 CAUTION Only turn the engine in the normal direction of rotation Installing the special tool in this next step will prevent the engine from being rotated in the clockwise direction However the engine can still be rotated in the counterclockwise direction 3 Install special tool 303 507 02 35 Position the oil pump assembly and tighten the
178. n one or more valves are not seating WORN VALVE GUIDES When the needle oscillates swings back and forth 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 WEAK VALVE SPRINGS When the needle oscillation becomes more violent as engine rom is increased weak valve springs are indicated The reading at idle could be relatively steady LATE VALVE TIMING A steady but low reading could be caused by late valve timing IGNITION TIMING RETARDING Retarded ignition timing will produce a steady but somewhat low reading INSUFFICIENT SPARK PLUG GAP When spark plugs are gapped too close a regular small pulsation of the needle can occur INTAKE LEAK A low steady reading can be caused by an intake manifold or throttle body gasket leak BLOWN HEAD GASKET A regular drop of approx 33 50 kPa 10 15 in Hg can be caused by a blown head gasket or warped cylinder head to cylinder block surface 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 is only idl
179. nd delay before DTCs begin flashing When extracting DTCs via the MIL the following apply flashing MIL is on for 0 4 second and off for 0 4 second he MIL is off for 1 2 seconds between digits of three digit DTCs e he MIL is off for 2 4 seconds between DTCs e Each DTC repeats 3 times before the next stored DTC begins flashing Upto 6 DTCs can be stored e Once all stored DTCs are flashed the process repeats with the first stored DTC e DTCs are flashed in the order in which they were set Once the DTC s is retrieved refer to the appropriate DTC chart for explanation of what caused the DTC to set Perform component and circuit test as required to conduct repair Diagnosis Using a Personal Computer Equipment Requirements You will need a laptop computer with a USB Port and CD drive e Kit for laptop part 5080050 Cable o Software CD The required software is included with the kit via a CD Laptop Requirements USB port 800 x 600 screen Windows 95 or newer operating system No speed minimum 32 MB of RAM MSG 425 Engine Controls Interface Hook Up For a connection to a laptop use the below ECOM cable 5080050 ECOM Cable gt PA Software CD dev GCP SOFTWARE 08 28 MSG 425 Engine Controls GCP Software Installation Insert CD into CD ROM drive Double click My Computer Icon Double Click CD ROM drive letter
180. ng engine repair procedures cleanliness is extremely important Any foreign material including any material created while cleaning a gasket surface that enters the oil passages coolant passages or the oil pan can cause engine failure NOTE Valve tappets are select fit and the valve clearance must be checked before removing the tappets Refer to Valve Clearance Check on page 45 of this section 1 Remove camshafts Refer to Camshafts Removal on page 18 of this section CAUTION If the camshafts and valve tappets are to be reused mark the location of the valve tappets to make sure they are assembled in their original positions NOTE The number on the valve tappets only reflects the digits that follow the decimal For example a tappet with the number 0 650 has the thickness of 3 650 mm 2 Remove and inspect valve tappets 3 Reverse procedure to install 4 AX ae NOTE Coat valve tappets with clean engine oil prior to installation Camshafts Removal CAUTION The crankshaft the crankshaft sprocket and the pulley are fitted together by friction with diamond washers between the flange faces on each part For that reason the crankshaft sprocket is also unfastened if you loosen the pulley Therefore the engine must be retimed each time the damper is removed Otherwise severe damage can occur 1 Remove and or disconnect components to allow access and removal of the timing drive components Labe
181. ng habits e ambient temperature e 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 It is also important that the engine oil is changed at the intervals specified Refer to the Engine Operator s handbook 01 15 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 Engines in normal service sho
182. nt Omaha NE 68137 Inc Archdale NC 27263 37200 Vine St Willoughby Ohio 44094 Grand Prairie TX 75051 Ridgefield WA 98642 1 800 562 8049 1 800 220 2700 1 800 220 2700 1 800 220 2701 1 800 445 5273 800 999 5689 1 800 562 8049 800 999 5689 877 877 3311 402 558 8700 602 269 3581 1 800 220 2700 1 800 220 2700 1 800 220 2700 602 269 3581 800 999 5689 1 800 220 2700 1 800 589 9025 972 623 4300 877 877 3311 NORTH AMERICA UNITED STATES Engine Distributors 400 University Court EASTERN PENNSYLVANIA 1 800 220 2700 37200 Vine St WESTERN PENNSYLVANIA Id Equip 1 800 589 9025 WESTERN PENNSYLVANIA MeDonald Equip _ Willoughby Ohio 44094 Engine Distri 41 P Road RHODE ISLAND 1 800 220 2700 Inc Holliston MA 01746 SOUTH CAROLINA Engine Distributors 259 Ellis Rd South 1 800 220 2700 Inc Jacksonville FL 32254 Diesel Power 13619 Industrial Rd SOUTH DAKOTA 800 999 5689 SOUTH DAKOTA Equipment Omaha NE 68137 5400 C W Post Road TENNESSEE Engi Inc 1 800 562 8049 1906 S Great S W Parkwa TEXAS M G Bryan Mind 972 623 4300 Grand Prairie TX 75051 Diesel P 13619 Rd Engine Distributors 303 Interstate Dr VIRGINIA 1 800 220 2700 NORTH AMERICA CANADA ALBERTA Industrial Engines i 5 Edmonton Alberta Canada 780 484 6213 SASKATCHEWAN Ltd 151 268 ALBERTA 8750 58th A Ed ton AB Simson Maxwell a SASKATCHEWAN Canada T6E 6G6 ALBE
183. ntifreeze tester The freezing point should be in the range 45 C to 23 C 50 F to 10 F If the equipment is run in cold climates colder than 36 34 F it may be necessary to increase the coolant concentration to get adequate freeze protection Maximum coolant concentration is 6096 coolant to 4096 distilled water If coolant tests too strong remove some of the coolant and ad distilled water until the readings are acceptable Minimum coolant concentration is 4096 coolant to 6096 distilled water If coolant tests too weak drain some coolant out and add straight coolant until readings are acceptable MSG 425 COOLING SYSTEM Drive Belt Inspection WARNING REFER TO CAUTIONS AND WARNINGS AT THE BEGINNING OF THIS SECTION With engine running observe the belt movement It should respond when engine 15 accelerated rapidly If tensioner moves excessively without rapid acceleration install a new belt If excessive movement still exists install a new tensioner Visually inspect the belt for obvious signs of damage Up to 15 cracks in over a distance of 100 mm 4 0 in can be considered acceptable A 100 mm cracks are beyond acceptable any chunks are found to be missing from the ribs a new belt must be installed Small scatted deposits of rubber material known as piling are not a concern Small Piling t Longer deposits building up to 5096 of the rib height is also not a conc
184. on circuit is open shorted to ground or the GCP module is faulty Check wiring connectors and fuses for possible cause Go to step 4 Replace the mixer May be electronic check that the CAM and crank sensor are not damaged and as well as all wiring Ensure all coils are firing Check if faults are present with the GCP diagnostic software Refer to section 8 engine controls Fuel Lock Solenoid The fuel lock is an electronic solenoid that is opened to allow fuel flow when the key is turned ON High temperatures may cause the solenoid to become intermittent not opening to supply sufficient fuel pressure Fuel Filter There is a filter element located in the inlet of the fuel lock which may become clogged and limit fuel flow especially at low tank pressures Check the filter and replace as necessary Fuel Line Restrictions The vehicle specifications table specifies the fuel line to be a certain size If the fuel line from the tank to the fuel lock is not the proper size or any valves or fittings with flow restrictive characteristics are used the fuel flow will not be sufficient to the converter with low tank pressure Correct any fuel line or fitting restrictions Mixer Assembly Carburetor It is possible that a backfire may have caused the fuel valve to partially come off of it s retainer and restrict fuel check the mixer fuel valves Also check the mixer adapter plates for leakage past the carburetor Regulator Assemb
185. on and select the desired coil The spark output can be re enabled by using the mouse to highlight the Spark Kill button and selecting Normal If the engine is running below 1000 RPM the spark output will stay disabled for 15 seconds and then re set If the engine is running above 1000 RPM the spark output will stay disabled for 5 seconds and then reset This test mode has a timeout of 10 seconds Record the rpm drop related to each spark output disabled The Spark outputs are arranged in the order which the engine fires not by cylinder number Injector Test Diagnostic Modes Spark kill Normal Extemal power Automatic Cylinder numbering Firing Order The Injector Kill mode is used to disable individual fuel injectors If the Injector Kill mode is selected with the engine running below 1000 RPM the minimum throttle command will lock into the position it was in when the test mode was entered If the Injector Kill mode is selected with the engine running above 1000 RPM the throttle will continue to operate normally Disabling Injectors To disable an injector use the mouse to select the desired injector The word Normal will change to the Injector you have selected The injector driver can be re enabled by selecting again If the engine is running below 1000 RPM the injector driver will stay disabled for 15 seconds and then re set If the engine is running above 1000 RPM the injector drive
186. orn or piston NOTE Cylinder bore must be within specification for taper and out of round to fit piston rings 1 Use a piston without rings to push a piston ring in a cylinder to the bottom of ring travel 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 new pistons indicates the position within the size range 2 Use feeler gauge to measure the top piston ring end gap and the second piston ring end gap 2 Choose the piston with the proper paint color Red the lower third of the size range Blue in the middle third of the size range Yellow the upper third of the size range Piston Ring End Gap Special Tool s Ferer Gauge Specin Denice Tools cated for by tne procedures can be obtained Dy calling 1 800 SOTUNDA 1 600 768 6632 01 26 MSG 425 GENERAL INFORMATION Piston Ring to Groove Clearance Crankshaft Connecting Rod Journal Taper Special Tool s 1 Crankshaft Connecting Rod Journal Diameter Inspect for a stop in the grooves 2 Measure the piston to groove clearance e Measure the crankshaft rod journal diameters in two directions perpendicular to one another at each end of the connecting rod journal The Gauge DA 1L 4201 A Equivalent difference in the measurements from one end to the other is the t
187. p A Cesano Boscone Milano Italy 02 450 582 60 62 Houtzaagmolen 41 MIJDRECHT NETHERLANDS My Power Product 03 129 758 1555 MEXICO Equipos y Motores Cuitlahuac 52 55 5341 9066 Ind Popotla 11400 Mexico D F NORTH AMERICA UNITED STATES ALABAMA 5400 C W Post Road didi Jonesboro AR 72401 ALASKA Perkins Pacific Ridgefield WA 98642 Southwest Power 5143 W Roosevelt Phoenix ARIZONA Products AX 85043 5400 C W Post Road Jonesboro AR 72401 ARKANSAS Engines Inc Powertech Engines 2933 E Hamilton Ave CALIFORNIA Inc Main Office CA 93721 1410 South Acacia Ave Suite B Fullerton CA 92831 Powertech Engines Inc Anderson Industrial 5532 Center Street Engines Co Ohmaha NE 68106 Inc Holliston MA 01746 Inc Blackwood NJ 08012 Inc Jacksonville FL 32254 Inc Lauderdale FL 33315 Er Uem nc ille COLORADA HAWAII Perkins Pacific Ridgefield 98642 IDAHO Perkins Pacific SUD Nay Ridgefield WA 98642 Diesel P 12111 ILLINOIS ower EXON Equipment Batavia IL 60510 37200 Vine St Willoughby Ohio 44094 GEORGIA ngine Distributors 259 Ellis Rd South Jacksonville FL 32254 INDIANA McDonald Equip Anderson Industrial 5532 Center Street IOWA Engines Co Ohmaha NE 68106 KENTUCKY Ensine Tne 5400 C W Post Road Jonesboro AR 72401 Anderson Industrial 5532 Center Street KANSAS Engines Co Ohmaha
188. ponents to allow access and removal of the crankshaft front seal Label if necessary to allow for correct reinstallation 2 Remove crankshaft pulley Refer to Crankshaft Pulley Removal on page 8 of this section CAUTION Use care not to damage the engine front cover or the crankshaft when removing the seal 3 Using special tool 303 409 remove the crankshaft front seal Crankshaft Front Seal Installation 1 Lubricate the new crankshaft front seal with clean engine oil prior to installation 2 Using special tool 303 096 install the crankshaft front seal 303 096 3 Install the crankshaft pulley Refer to Crankshaft Front Seal Installation on page 10 of this section 4 Install or reconnect any other components that were removed or disconnected Engine Front Cover Removal 1 Disconnect the negative battery cable refer to Section 6 CAUTION The crankshaft the crankshaft sprocket and the pulley are fitted together by friction with diamond washers between the flange faces on each part For that reason the crankshaft sprocket is also unfastened if you loosen the pulley Therefore the engine must be retimed each time the damper is removed Otherwise severe damage can occur 2 Remove and or disconnect components to allow access and removal of the engine front cover Label if necessary to allow for correct reinstallation 3 Remove the crankshaft pulley Refer to Cranksh
189. ptom from the symptom charts and follow the suggestions to complete the repair 5 If no matching symptom is available analyze the complaint and develop a plan for diagnostics utilizing the wiring diagrams technical assistance and repair history 6 Some diagnostic charts contain diagnostic aids which give additional information about a system Be sure to use all of the information that is available to you GCP Diagnostic Overview FORD Diagnostic Trouble Codes are set when the FORD system GCP runs a diagnostic self test and the test fails When a DTC is set the FORD system GCP will illuminate the Malfunction Indicator Lamp MIL on the instrument panel and save the code in memory The FORD system GCP will continue to run the self test unless the DTC is an oxygen sensor lean oxygen sensor rich or a GCP related DTC If the system continues to fail the test the lamp will stay illuminated and the DTC is current ACTIVE All DTC s are stored as historical faults until they are cleared All DTC s except the GCP related DTC s will automatically clear from memory if the DTC does not reset within 50 consecutive engine run cycles While a Diagnostic Trouble Code is current for a sensor the FORD system GCP may assign a default limp home value and use that value in its control algorithms All of the FORD system diagnostic self tests run continuously during normal engine operation The Diagnostic Trouble Codes can be read by using either
190. pulley and 3 bolts Tighten to 25 Nm 18 lb ft PEV Valve lt lt PCV Hose 52 Using a new gasket install thermostat housing iB iX and 3 bolts Tighten to 10 Nm 89 At PL gt 9 Coolant Pump a Pulley NOTE Lubricate new fuel injector o ring seals with clean engine oil prior to installation 49 Using new o ring seals install fuel rail assembly ccn RO PX AO and bolts LES ren e Tighten to 25 Nm 18 10 NOTE Apply silicone dielectric compound to inside of Spark plug boot area prior to installation of coils 02 41 e Tighten to 10 89 Ib in 54 Make any connections that will not be accessible after intake manifold is installed 55 Inspect and install new intake manifold gaskets if necessary 56 Install intake manifold and bolts Tighten to 18 Nm 13 lb ft Intake Manifold 57 Install power steering pump and bolts Tighten to 25 Nm 18 lb ft 58 Install 7 new exhaust manifold studs Tighten to 17 Nm 13 lb ft 59 Position a new gasket and install exhaust manifold and 7 new nuts Tighten to 54 Nm 40 lb ft MSG 425 ENGINE 53 Install coils over spark plugs and tighten bolts 60 Install generali and support bracket 61 Tighten bolts in the sequence shown in 2 stages e Stage 1 Tighten finger tight 2 Tighten to 47 Nm 935 Ib ft
191. r interests to enlist the aid of an authorized EDI Distributor not only when repairs are required but also for regular maintenance Distributors are listed at the back of this manual Engines manufactured by Ford Motor Company are available through EDI 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 EDI 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 service procedures outlined in this book still apply to your engine Engine Identification Because Ford Power Products markets such a wide range of industrial gasoline and diesel engines manufactured both in the U S and overseas it is important that you have as complete identification of the engine as possible in order to provide the correct replacement parts Review the list in the back of this book for an EDI distributor in your area You can obtain a standard parts listing describing the parts It remains a distributor funct
192. r than IVS limit DTC 2126 FPP1 higher than FPP2 DTC 2121 FPP1 lower than FPP2 DTC 1531 IVS Brake interlock failure Force to Idle The engine RPM will be limited to a maximum of 800 RPM If the Force to Idle is active it will remain active until the active DIC goes away DIC 2122 FPP1 high voltage DTC 2123 FPP1 low voltage DTC 2128 FPP2 high voltage DTC 2127 FPP2 low voltage DTC 2115 FPP1 higher than IVS limit DTC 2139 FPP1 lower than IVS limit DTC 2116 FPP2 higher than IVS limit DTC 2140 FPP2 lower than IVS limit DTC 2126 FPP1 higher than FPP2 DTC 2121 FPP1 lower than FPP2 Intermittent MIL Conditions that are only present from time to time are called intermittents To resolve intermittents perform the following steps 1 Evaluate the history of DTC s observed with this particular engine 2 Evaluate the symptoms and conditions described by the customer Use strategy based diagnosis especially where it relates to the elimination of bad connectors and wiring 4 When using a personal computer with Ford software data capturing capabilities are available that can assist in detecting intermittents Review the user manual pdf document that is included on the software CD Malfunction Indicator Lamp MIL DTC Retrieval Procedure NOTE DTC s can be retrieved from the engine control module GCP by using either the MIL or an IBM compatible personal computer with a USB port Ref
193. r will stay disabled for 5 seconds and then re set Record the change in rpm or closed loop multiplier while each driver is disabled MSG 425 Engine Controls Throttle Test Diagnostic Modes To select this test mode the engine must be off but the key must be in the ON position The DBW Test mode allows the technician to control the throttle directly without the engine running with the foot pedal or entering a number into the TPS Command box It is used during the diagnostic routines specified for FPP foot pedal position and TPS throttle position sensor related faults FP position displays the current position of the foot pedal as a percentage FPP volts display the voltage that the GCP is reading from the FPP sensor TPS Command displays the commanded throttle position expressed as a percentage which is being sent to the throttle TPS Position is the actual percent of throttle opening being sent to the GCP from the throttle TPS volts display the actual TPS signal voltage the GCP is receiving from the throttle 08 35 RAW VOLTS Screen The RAW VOLTS screen shows actual voltage readings from various circuits I Use the keys at the upper left corner or the page command to toggle the three main screens GAUGES FAULTS AND RAW VOLTS NOTE F9 key will toggle to the last screen you were on MSG 425 Engine Controls Visual Inspection Perform a careful visual and physical engine inspection b
194. re being returned to the fuel tank A fuel injector which is stuck partly open will cause a loss of fuel pressure after the engine is shut down causing long crank times Fuel Rail The fuel rail is mounted to the top of the engine and distributes fuel to the individual injectors Fuel is delivered to the fuel inlet tube of the fuel rail by the fuel lines lt gt i A M a i ze 1 e AS E Fuel Rail Fuel Injector P C cs Fuel Filter The fuel filter is an inline filter assembly Refer to Section 4 for information on relieving fuel pressure disconnecting fuel lines and fuel filter replacement Fuel Filter MSG 425 Engine Controls Fuel Pump Electrical Circuit When the key is first turned ON the GCP energizes the fuel pump relay for two seconds to build up the fuel pressure quickly If the engine is not started within two seconds the GCP shuts the fuel pump off and waits until the engine 15 cranked When the engine is cranked and crankshaft position signal has been detected by the GCP the GCP supplies 12 volts to the fuel pump relay to energize the electric fuel pump An inoperative fuel pump will cause a no start condition A fuel pump which does not provide enough pressure will result in poor performance Mixer Gaseous Fuels The Mixer allows air and fuel to mix together before entering the engine Based on pressure differentials the diaphragm in
195. re damage can occur 6 Install the crankshaft pulley Refer to Crankshaft Pulley Installation on page 8 of this section 7 Position a new Sensor and loosely install the 2 bolts 02 12 8 Adjust the CKP with the alignment tool supplied with the new sensor 303 1417 The tool must engage a tooth of the vibration damper Tighten 2 bolts e Tighten to 7 Nm 62 9 Connect Sensor connector 10 Connect battery negative cable refer to Section 6 11 Install or reconnect any other component removed or disconnected MSG 425 ENGINE Fan Drive Disassembly 1 Loosen bolts of fan bearing bracket so the bracket can slide down and the fan belt can be removed 2 Remove bracket to front cover bolts 1 zm 4 3 al l 3 a 3 The fan and brackets can then be removed from the engine and placed to the side Note To remove the bracket from the engine the fan may need to be taken off Fan Drive Assembly Note These instructions assume all components of the fan drive assembly are not assembled Note Some of the following steps may have to be done in an alternate order depending on the configuration of the cooling system 02 13 1 Boltthe bracket to the front cover of the engine e Torque bolts 42 lb ft 58 gt 2 7 1 B _ ee 2 Put the bea
196. readings although helpful must 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 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 01 14 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 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 POOR VALVE SEATING A small but regular downscale flicking can mea
197. res and hoses Check for fuel system leaks Key ON Yes Repair the leak Check the fuel system for leaks Key OFF No Go to step 5 Are there any leaks present Check carburetor air inlet for obstructions Remove the Yes obstruction re install the air cleaner and e Remove the air cleaner attempt to start Are there any obstructions in the air inlet of the carburetor No Proceed to appropriate troubleshooting section 04 11 MSG 425 FUEL SYSTEM Diagnostic Charts Perform the preliminary test before proceeding Engine Cranking but Will Not Start 2 ActiontoTake 1 Check fuel tank Fill or replace the fuel tank Do not exceed 80 of liquid Is fuel tank empty capacity Goto Step 2 2 Check fuel valve Yes Slowly open the fuel valve Is liquid fuel valve closed No Go to step 3 3 Check the excess flow valve Reset excess flow safety valve Close the main fuel valve Wait for a clicking sound from the excess flow valve indicating the valve has reset Slowly open the main fuel valve Is excess fuel valve tripped and closed Perform prelim Test No before proceeding to step 4 4 Check lockoff valve supply voltage activation circuit is Disconnect lock off valve connector from open shorted to gnd or harness the GCP module is Key ON faulty Check wiring Using a high impedance DVOM c
198. rical and active faults with on demand diagnostics to assist technicians and reduce equipment downtime The Engine Control Module GCP engine control system is a complete engine control system for Ford industrial engines running on gasoline propane or natural gas Each module can be set up to run an engine on any two of the three fuels in certified closed loop control with virtually transparent on the fly fuel switching Each module can also be set up to run on a variety of electronic governing be programmed to provide up to four specific speeds with use of a matching toggle switch e be programmed to provide an infinite variety of speeds with customer specified minimum and maximum based on a variable signal input MSG 425 Engine Controls be an electronic replacement for a throttle cable with maximum speed governing throttle bywire e Or it switch between throttle by wire and a second fixed or variable input based on a neutral parking brake signal With the GCP system a laptop and a communications cable diagnosis becomes simpler The technician can either view engine data with a real time graphing program or store that data into a numeric data file Every time a fault is set the laptop will give you detailed information about the fault including e when it happened if the fault still exists e alist of essential engine data from the time of the fault lt can also displ
199. ring bracket place and thread in the M8x1 5 bolts Do not tighten MSG 425 ENGINE 3 Line up the fan pulley and fan spacer with the four mounting points of the bearing bracket Insert the M6x1 0 bolts Torque bolts 9 16 6 12Nm 4 Install fan onto the end of the fan spacer Torque bolts 20 lb ft 28Nm 5 Place fan belt around fan pulley and crank extension pulley fan drive pulley 6 Evenly slide the bearing bracket up to tension the fan belt With the belt tensioned tighten the bearing bracket bolts 20 lb ft 28Nm Note The fan belt should have some deflection in it when pressure is applied from the side Using a belt tensioner gauge a reading of 50 60 lbs is recommended 02 14 MSG 425 ENGINE Timing Drive Components Removal CAUTION The crankshaft the crankshaft sprocket and the pulley are fitted together by friction with diamond washers between the flange faces on each part For that reason the crankshaft sprocket is also unfastened if you loosen the pulley Therefore the engine must be retimed each time the damper is removed Otherwise severe damage can occur 1 Remove and or disconnect components to allow access and removal of the timing drive components Label if necessary to allow for correct reinstallation 2 Remove the engine front cover Refer to Engine Front Cover Removal on page 11 of this section 3 Compress the timing chain tensioner and insert a paper clip into
200. rol using information from the pre and post oxygen sensors to allow further adjustment to meet emissions regulations MSG 425 FUEL SYSTEM Wiring Diagrams Revision Level The following wiring schematics are taken from the wiring diagram labeled below EDI FORD 2 5L W GCP D Number 2487000 Date 11 1 2011 Drawn Drawn By J SUTON J SUTTON Engine Controls Dry Fuel DEPR 04 9 MSG 425 FUEL SYSTEM DIAGNOSIS AND TESTING LPG Symptom Chart _________ Gt Engine stops running Dies 04 10 MSG 425 FUEL SYSTEM Preliminary Test This pinpoint test checklist is your guide to the most probably causes of an engine performance complaint when the malfunction is due to the fuel system Test Step Result Action to Take Inspect Installation e Check fuel hose for kinks e Check fuel hose lengths orientation and presence of Yes Go to Step 2 parts No Repair as necessary Is Everything OK ES Inspect Fuel system for supply leaks e Key OFF Yes Repair the leak Check for leaks or damaged supply lines from the fuel tank to the fuel lock off valve No Go to Step 3 Are there any leaks present Inspect the Fuel system for any loose wires or hoses e Key OFF Yes Repair or replace as Check the fuel lockoff connection and fuel check necessary valve connection No Check the vacuum hoses for any damage or leakage Go to step 4 Is there any damaged or loose wi
201. ry lash adjuster must have a leak down rate time in seconds within specified minimum and maximum limits If the 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 MSG 425 GENERAL INFORMATION GENERAL SERVICE PROCEDURES WARNING TO AVOID THE POSSIBILITY OF PERSONAL INJURY OR DAMAGE TO THE EQUIPMENT DO NOT OPERATE THE ENGINE UNTIL THE FAN BLADE HAS BEEN EXAMINED FOR POSSIBLE CRACKS AND SEPARATION NOTE Illustrations are typical and may not reflect your particular engine 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 e Measure each camshaft journal diameter in two directions lf itis out of specification replace as necessary Journal Camshaft Lobe Surface e Inspect camshaft lobes for pitting or damage in the active area Minor pitting is acceptable
202. s e Removal and Installation Starter Relay Replacement Starter Motor 1 said ae RR 07 1 Page 07 2 07 3 07 3 07 4 07 5 07 6 07 7 07 7 07 8 07 9 07 9 07 10 MSG 425 STARTER SYSTEM CAUTIONS amp WARNINGS WARNING WHEN SERVICING STARTER OR PERFORMING OTHER WORK IN THE VICINITY OF THE STARTER BE AWARE THAT THE HEAVY GAUGE BATTERY INPUT LEAD AT THE STARTER SOLENOID IS ELECTRICALLY HOT AT ALL TIMES FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY A WARNING WHEN WORKING IN THE AREA OF THE STARTER MOTOR BE CAREFUL TO AVOID TOUCHING HOT EXHAUST COMPONENTS FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY CAUTION A protective cap or boot is provided over the battery input terminal and must be reinstalled after removal CAUTION Be sure to disconnect the battery ground cable before repairing the starter motor WARNING HYDROGEN OXYGEN GASES ARE PRODUCED DURING NORMAL BATTERY OPERATION THIS GAS MIXTURE CAN EXPLODE IF FLAMES SPARKS OR LIGHTED TOBACCO ARE BROUGHT NEAR THE BATTERY WHEN CHARGING OR USING A BATTERY IN AN ENCLOSED SPACE ALWAYS PROVIDE VENTILATION AND SHIELD YOUR EYES WARNING KEEP OUT OF REACH
203. s Removal on page 18 of this section CAUTION If the camshafts and valve tappets are to be reused mark the location of the valve tappets to make sure they are assembled in their original positions NOTE The number on the valve tappets only reflects the digits that follow the decimal For example a tappet with the number 0 650 has the thickness of 3 650 mm 2 Remove the valve tappets Refer to Valve Tappet Replacement on page 18 of this section 3 Remove valve spring assembly Refer to Valve Spring Removal on page 16 of this section 4 Using special tools 307 005 and 303 468 remove and discard the valve seal EZ 7 005 AUIT FS 303 468 0 E a MSG 425 ENGINE Valve Seal Installation 1 Install the valve stem seal installation sleeve Installation Sleeve 2 Using special tool 303 470 install a new valve seal 4 1 j 2 E tpa 9 Install valve spring Refer to Valve Spring Installation on page 16 of this section 4 Install tappets Refer to Valve Tappet Replacement on page 18 of this section CAUTION If reusing tappets install in original locations 5 Install camshafts Refer to Camshafts Installation on page 18 of this section 6 Repeat for each cylinder being serviced 02 18 Valve Tappet Replacement CAUTION Duri
204. s S General Information Gasoline cccccccccccccecseccscssceeccccssceecccccesseccccccccscosccsesscosecess Operation Fuel System ReguUIremen eproma General Information Dry DSS Git Olt ever E at tee sa A Operation System Re guitemieblbs dst WAV IU LUE Diagnosis and Testing eee SVIDDEOD __ _ __ Preliminary TeS situa Diagnostic Diagnosis and Testing VISUAL INS DECO SVHIDEOI _ __________ __ L uel Pressure C ecl FueL Pump CRECE ono dora ba Lue Bloc CROCK General Service Spring Lock Coupling Type 2 1 1 1 Spring Lock Coupling Type Spring Loc
205. s released from the camshaft bearing caps c Remove the bearing caps 40 Remove the camshafts am IACTA _ _ i a ee cox orn ne E X CAUTION The cylinder head must cool before removing it from the engine Cylinder head warpage can result if a warm or hot cylinder head is removed 02 32 CAUTION The cylinder head bolts must be discarded and new bolts must be installed They are tighten to yield designed and cannot be reused 41 Remove and discard cylinder head bolts lt lt 8 42 Remove cylinder head 43 Remove and discard the gasket 44 Remove the cylinder head alignment dowels Sy HQ 45 Remove bolts and oil pan J 2 cs m Yj 9 is 46 Remove bolts and rear seal retainer plate MSG 425 ENGINE 47 Remove bolts oil pump pickup tube and discard gasket 48 Remove 4 bolts and oil pump SE u ZZ 49 Remove and discard oil pump gasket 4 s y F EC 4 gt 4 gt a 0 Cylinder Head Disassembly 1 Remove rear lifting eye and front bracket Front Lifting Eye 2 Remove coolant outlet pipe 3 Remove spark plugs and discard CAUTION Note location of the
206. s to 25 Nm 18 Ib ft e Stage 3 Tighten 13 mm bolts to 48 Nm 35 16 9 02 39 CAUTION Do not reuse crankshaft pulley bolt NOTE Apply clean engine oil to crankshaft front seal area prior to installing 31 Install crankshaft pulley and hand tighten bolt CAUTION Only hand tighten crankshaft pulley bolt or damage to front cover can occur NOTE This next step will correctly align crankshaft pulley to crankshaft 32 Install a standard 6 mm x 18 mm bolt through the crankshaft pulley and thread it into the front cover align the bolt holes CAUTION Failure to hold the crankshaft pulley in place during bolt tightening can cause damage to the engine front cover 34 Remove all special tools and 6mm bolt CAUTION Only turn engine in the normal direction of rotation 35 Turn the engine 2 complete revolutions then continue turning in same direction until the No 1 piston is at top dead center TDC MSG 425 ENGINE CAUTION Only hand tighten the bolt in this next step or damage to the front cover can occur 37 Using a 6mm x 18 mm bolt check the position of the crankshaft pulley If it is not possible to install the bolt correct the engine timing 38 Using special tool 303 465 check the position of the camshafts If it is not possible to install the special tool correct the engine timing J 1 39 Remove all special tools 803 507 303 465 and
207. sen the clamps at each end of the hose to be removed Slide the hose off the radiator connection and the engine water outlet connection 05 10 Radiator Hose Installation 1 Position the clamps at least 1 8 inch from each end of the hose 2 Coat the connection areas with an approved water resistant sealer and slide the hose on the connection NOTE Make sure the clamps are beyond the bead and placed in the center of the clamping surface of the connections 3 Tighten the clamps 4 Fill the system with coolant Refer to Filling the Cooling System of this section 5 Operate the engine for several minutes then check the hoses and connections for leaks Thermostat amp Housing Replacement WARNING REFER TO CAUTIONS WARNINGS AT THE BEGINNING OF THIS SECTION NOTE The thermostat and housing are serviced as an assembly 1 Allow the engine to cool down until the coolant has lowered in temperature to below 110 F 2 Drain the radiator so coolant level is below the thermostat Refer to Draining the Cooling System of this section Radiator Hose Bolt MSG 425 COOLING SYSTEM 3 Remove or disconnect components as necessary to gain access to the thermostat housing Disconnect the lower radiator hose Remove bolts and thermostat housing Reverse procedure to install Clean and inspect gasket install a new gasket if necessary Tighten bolts to 10 Nm 89 edu aa
208. slots are offset from the centerline of the camshaft 23 Install a paper clip into the hole in the tensioner housin hold the ratch sembly and the Bind ks 4 1 5 NOTE Use a wrench on the flats between cylinders No 1 2 to hold the camshafts in place 24 Install the timing chain Poy Ew LL AO hake a T ES fy gt 7 _ TENG EVI JN zx l im 2 ff if gt ie Y 28 Tighten camshaft sprocket bolts e Tighten to 65 Nm 48 lb ft Position timing chain guides and install guide bolts 25 02 38 MSG 425 ENGINE NOTE If front cover is not secured within 4 minutes the sealant must be removed and the sealing area re cleaned Refer to Engine Cleaning on page 34 of this section 29 Apply a 2 5 mm 0 1 in bead of silicone gasket and sealant to the front cover and to block as shown 7 1 on i AW J O 4 gt en eos 2 pu NU o yx WAC Ya A 5 A Rays w ts 2 4 d E 4 4 6 4 30 Install the front cover and bolts Tighten in the sequence shown in 3 stages e Stage 1 Tighten 8mm bolts to 10 nm 89 Ib in e Stage 2 Tighten 10 mm bolt
209. spark advance of the ignition system Coil on plug ignition has the following advantages over a mechanical distributor system No moving parts Less maintenance Remote mounting capability No mechanical load on the engine More coil cool down time between firing events e Elimination of mechanical timing adjustments e Increased available ignition coil saturation time e Elimination of high tension wires Ignition Coil coil on plug The coil on plug design has individual coils mounted directly over each spark plug Each cylinder is paired with its opposing cylinder in the firing order so that one cylinder on compression fires simultaneously with the opposing cylinder on exhaust The spark that occurs in the cylinder on the exhaust stroke is referred to as a waste spark waste spark 8 M d os 28 AT gt v Power Stroke Exhaust Stroke The primary coils in the coil pack are triggered by the ignition coil feed 1 and ignition coil feed 2 signals from the GCP 08 10 MSG 425 Engine Controls Open Loop and Closed Loop Operation NOTE No DTC will be set unless engine has operated in closed loop status for more than 6 seconds The GCP will operate in the following two modes e Open loop e Closed loop When the engine 15 first started the system is in open loop operation In open loop the GCP ignores the signal from the Heated Oxygen Sensor HO2S
210. spect the roller for flat spots or scoring If any causes shown damage is found inspect the camshaft lobes fatigue failure A and hydraulic lash adjusters for damage 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 Hydraulic Lash Adjuster Inspection e Inspect the hydraulic lash adjuster and roller for damage If any damage is found inspect the camshaft lobes and valves for damage 01 30 MSG 425 GENERAL INFORMATION Valve Stem Diameter e Measure the diameter of each intake and exhaust valve stem at the points shown Verify the diameter is within specification Valve Stem to Valve Guide Clearance Special Tool s Dix with Brack etry TOOL 4201 C Equivarert Vave 50m Claarance Tod TOOL 6505 E or Equivaient Service Toon caned for 22 procedures can De pr Called 1 50C R OTUNDA 1 200 752 8632 NOTE Valve stem diameter must be within specifications before checking valve stem to valve guide clearance NOTE necessary use a magnetic base 1 Install the Valve Stem Clearance Tool on the 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 01 31 2 Move the Valve
211. ssembly CAUTION During engine repair procedures cleanliness is extremely important Any foreign material including any material created while cleaning gasket surfaces can enter the oil passages coolant passages or the oil pan and cause engine failure CAUTION Due to the precision fit and timing of the balancer shaft assembly it cannot be removed from the engine block 1 Remove engine from equipment and mount on an engine stand Refer to Flywheel Flexplate Replacement on page 27 of this section 2 Remove the drive belt Remove all coolant pipes and hoses 5 Remove A C compressor if equipped MSG 425 ENGINE 6 Remove generator and bracket assembly nuts 8 Remove and discard exhaust manifold gasket and studs 9 Inspect exhaust manifold for flatness refer to Section 1 02 28 10 Remove 4 bolts and power steering pump or Power Steering Pump 11 Remove 5 bolts and intake manifold Intake Manifold 12 Remove ignition coils 13 Remove 3 bolts and thermostat housing MSG 425 ENGINE 14 Remove knock sensor 18 Remove 3 bolts and coolant pump Discard the Coolant Pump 02 29 MSG 425 ENGINE CAUTION Failure to position the No 1 piston at top dead center TDC can result in damage to the engine Turn the engine in the normal direction of rotation only CAUTION The crankshaft the crankshaft sprocket and the pulley are fitted together by friction w
212. stem Ope Sep O The software is now installed on your system in FPP Display has been a folder called GCP Display Refer now to successfully installed Using Technicians GCP Software in this L Section ss eee Using GCP Software Menu Functions You can begin using the technicians GCP software after installation by clicking Start Programs GCP Display GCP Display as shown Click Finish A screen will pop up asking if it is ok to reboot your system E bee Type in the Password which can be found in the text file on the CD in the GCP Display folder Click No Go back to the main CD folder FPP Dapry B Dagla Dur Liiris 1 Dus Tile dolce Hike Folia x E TES DOCUMENT ITE gy Lannesbng Trad Soke Scrat 1 Place the ignition key in the ON position The GCP system Gauge screen should now appear and a green banner in the upper left Double click the ECOM driver folder hand corner will read Connected Double click the Driver Setup icon 08 30 MSG 425 Engine Controls Diagnostic Trouble Codes The System Fault screen is used to view and clear DTC s which have been set E E Checking Diagnostic Trouble Codes The System Fault scre
213. sts and Engine stops running and dies chart Steps 1 3 Any electrical diagnostics should have been performed to eliminate any sensor GCP or solenoid valve problems before proceeding Engine Stops Running Dies Test Step Result Action to Take 1 Check for icing or freezing of the regulator Yes e With the engine at idle Check for ice or frost build up on the converter casing and outlet port i 2 Is ice present No 2 Check regulator fuel supply Yes Install pressure gauge on primary test port of vapor regulator e Start the engine to induce the failure Is the primary pressure less than 3 5 psi or fluctuating No 3 Check fuel lock supply voltage Yes Key Off Disconnect fuellock connector from harness Key On Using a high impedance DVOM check for 12 volt supply at the harness connector Is the voltage less than 11 5 volts No 4 Check the carburetor air valve for binding Yes With the air cleaner removed pull the air valve piston upwards to ensure free movement of the carburetor air valve Is the air valve binding Diagnostic Aids The presence of ice on the converter with the engine running indicates the possibility of a coolant supply problem Check Coolant level and the coolant system for leaks Check for proper coolant type Go to step 2 The fuel filter may be clogged or the fuel lock may be intermittent Go to step 3 Go to step 4 12 volt fuelock activati
214. t supply at the harness connector Is the voltage less than 11 5 volts No 3 CheckDEPR operation Yes e With the engine at idle e Disconnect the electrical connector Is there a change in engine running with this No unplugged 4 Check the carburetor air valve for binding Yes e With the air cleaner removed pull the air valve piston upwards to ensure free movement of the carburetor air valve Is the air valve binding 04 18 The fuel filter may be restricting flow or the fuel lock may be intermittent Go to step 2 Go to step 3 12 volt fuelock activation circuit is open shorted to ground or the GCP module is faulty Check wiring connectors and fuses for possible cause Go to step 3 Go to Step 4 Possible wiring issue faulty ECU or faulty DEPR Replace the mixer May be electronic check that the CAM and crank sensor are not damaged and as well as all wiring Ensure all coils are firing Check if faults are present with the GCP diagnostic software Refer to section 8 engine controls MSG 425 FUEL SYSTEM The pinpoint tests below should be performed after the preliminary tests and Engine Overheats chart Steps 1 3 Any electrical diagnostics should have been performed to eliminate any sensor GCP or solenoid valve problems before proceeding Engine Overheats Test Step Result Action to Take 1 Check for icing or freezing of the regulator Yes The presence of ice on the
215. t be installed rotate crankshaft one complete revolution clockwise to correctly position camshafts 6 Remove plug bolt Er CAUTION Installing special tool in this next step will prevent engine from being rotated in the clockwise direction However the engine can still be rotated in the counterclockwise direction Only turn the engine in the normal direction of rotation 7 Install special tool 303 507 5 2 w 8 Install special tools 205 126 205 072 02 CAUTION Failure to hold the crankshaft pulley in place during bolt loosening can cause damage to the engine 9 Remove bolt washer and pulleys Discard crankshaft pulley bolt Pulley Jd r 02 7 MSG 425 ENGINE Crankshaft Pulley Installation CAUTION Do not reuse the crankshaft pulley bolt 1 Apply clean engine oil on the crankshaft front seal and install crankshaft pulley washer and hand tighten new bolt CAUTION Only hand tighten the bolt or damage to the front cover can occur NOTE This next step will correctly align the crankshaft pulleys to the crankshaft 2 Install a standard 6mm x 70mm bolt as shown and thread it into the front cover NOTE Rotate the crankshaft pulley as necessary to align the bolt hole then align the fan drive pulleys bolt hole CAUTION Failure to hold the crankshaft pulley in place during bolt tightening can cause damage to the engine front cover E 3 Remov
216. t coupling MSG 425 ENGINE 9 Remove bolts and camshaft cover Camshaft Cover Installation 1 Install new gaskets 9 c Pd 2 Position camshaft cover and install bolts in i i d sequence shown AL TE Tighten to 10 Nm 89 Ib in gi Q 11 3 7 12 1 2 i 10 113 sy 14 t EM an Tightening Sequence Pu m P x ox d 4 iie mL AY 3 Reconnect crankcase ventilation tube GA Rar 4 NOTE Apply clean engine oil to CMP sensor o ring seal 10 Remove and discard gaskets ae 4 Install CMP sensor and bolt CAUTION Do not use metal scrapers wire brushes Tighten to 7 Nm 62 Ib in power abrasive discs or other abrasive means to clean the sealing surfaces These tools cause scratches and 5 Reconnect CMP sensor ignition coil and CHT gouges which make leak paths Use a plastic scraping Sensor connectors tool to remove all traces of old sealant 11 Clean the sealing surface of the cylinder head were removed or disconnected with silicone gasket remover and metal surface prep gt WARNING OBSERVE ALL WARNINGS AND Installation on page 6 of this section CAUTIONS AND FOLLOW ALL APPLICATION 8 Reconnect negative battery cable refer to DIRECTIONS CONTAINED ON THE PACKAGING OF THE Section 6 SILICONE GASKET REMOVER AND METAL SURFACE PREP 02 6 6 Reinstall or connect any other
217. te adapter to permit the air to 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 CAUTION Use extreme caution when pressurizing crankcase Applying air pressure above specified pressure risks damage to seals gaskets and core plugs Under no circumstances should pressure be allowed to exceed 27 kPa 4 psi MSG 425 GENERAL INFORMATION Testing Procedure e Open the air supply valve until the pressure gauge maintains 20 kPa 3 psi e 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 e valve cover gaskets intake manifold gaskets cylinder head gaskets filter pump if external oil level indicator tube connection oil pressure sensor Leakage Points Under Engine oil pan gaskets Oil pan sealer pan rear seal e engine front cover gasket crankshaft front seal e crankshaft rear oil seal 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 equa
218. te the fuel in the cylinders Refer to Section 03 of this manual for more information on the ignition system Fuel System The fuel system includes a remote mounted electric fuel pump The pump regulates and maintains fuel flow through an in line fuel filter to the electronic actuator mounted on the intake manifold The engine can be adapted for dry fuel use Refer to Section 04 of this manual for more information on the fuel system MSG 425 ENGINE REMOVAL amp INSTALLATION Intake Manifold Removal 1 Drain the engine cooling system Refer to Section 5 2 Remove and or disconnect components to allow access and removal of the intake manifold Label if necessary to allow for correct reinstallation CAUTION Relieve fuel system pressure before disconnecting fuel supply lines refer to Section 4 3 Remove fuel supply connections refer to Section 4 Intake Manifold 1 mlt LT am 71 gt n A m uw LOUP T 4 m Ew Pim zu gd EC bf gs wi iy amp f F bh t ar i d 4 LI Pj i i ig 4 KC woe px 1 i EN Gaskets Bolts 4 Remove 5 bolts and the intake manifold CAUTION Do not use metal scrapers wire brushes power abrasive discs or other abrasive means to clean the sealing surfaces These tools cause scratches and
219. ted with engine operation When servicing the GCP observe the following guidelines Do overload any circuit 08 11 When testing for opens and shorts ground or apply voltage to any of the GCP s circuits unless instructed to do so e When measuring voltages use only a digital voltmeter with an input impedance of at least 10 megohms Donot employ any non standard practices such as charging the battery with an arc welder e proper precautions to avoid static damage to the GCP Refer to electrostatic Discharge Damage for more information Use of Circuit Testing Tools Do not use a test light to diagnose the engine electrical systems unless specifically instructed by the diagnostic procedures A test light can put an excessive load on a GCP circuit and result in component damage For voltage measurements use only a digital voltmeter with an input impedance of at least 10 megohms Electrostatic Discharge Damage Electronic components used in the GCP are often designed to carry very low voltage Electronic components are susceptible to damage caused by electrostatic discharge Less than 100 volts of static electricity can cause damage to some electronic components By comparison it takes as much as 4000 volts for a person to feel the spark of a static discharge There are several ways for a person to become statically charged The most common methods of charging are by friction and induction
220. tester to the voltmeter function 2 Connect the positive lead to the generator A terminal connector and the negative lead to ground 3 Turn off all electrical accessories 4 With the engine running at 2000 rpm check the generator voltage 5 Voltage should be between 13 0 15 5 volts MSG 425 CHARGING SYSTEM GENERAL SERVICE PROCEDURES WARNING REFER TO CAUTIONS amp WARNINGS AT THE BEGINNING OF THIS SECTION Battery Cleaning and Inspection Keeping the battery top clean and dry reduces the need for service and extends battery life Also make certain the cable clamps are tightly fastened to the battery posts corrosion is found disconnect the cables and clean clamps and posts with a wire brush Neutralize the corrosion with a solution of baking soda and water After installing cables apply a small quantity of Premium Long Life Grease XG 1 C or K or equivalent grease meeting Ford specification ESA M1C75 B to each battery post to help prevent corrosion Battery Tools Anyone working with a battery needs the proper tools Using the right tools will prevent damage to the battery battery cables and battery hold down clamp Tools and equipment manufactured for servicing batteries have parts insulated to help prevent arcing should the tool be dropped or placed accidentally between a terminal and some other contact surface Clamp Puller Use a clamp puller to remove a cable clamp from the battery terminal With the
221. the Malfunction Indicator Lamp MIL or a Laptop computer Refer to Using a Laptop Computer to Diagnose the FORD System and Using a Diagnostic Jumper to Diagnose the FORD System located in this section Diagnostic Trouble Codes can be cleared from memory with a laptop computer or by turning the ignition key to the OFF position and removing the FORD system main power fuse F3 for 15 seconds If more than one DTC is detected begin with the lowest number DTC and diagnose each problem to correction unless directed to do otherwise by the fault tree The DTC s are numbered in order of importance Having DTC 112 and DTC 122 both concerning the oxygen sensor is possible 08 25 By repairing DTC 112 first the problem causing the DTC 122 may also be corrected On Board Diagnostics GCP The diagnostic tests and circuit charts are designed to assist the technician to locate a faulty circuit or component through a process of logical decisions The tests and charts are prepared with the requirement that the engine functioned correctly at the time of assembly and that there were not multiple faults present There is a continuous self diagnosis on certain control functions This diagnostic capability is complimented by the diagnostic procedures contained in this section The language for communicating the source of the malfunction is a system of diagnostic trouble codes When a malfunction is detected by the Engine Control Module GCP a Di
222. the leak down 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 leak down rate should be checked and any lash adjusters outside the specification should be replaced Assembled lash adjusters can be tested with Hydraulic lash adjuster Leak down Tester to check the leak down rate The leak down rate specification is the time in seconds for the plunger to move a specified distance while under 22 7 kg 50 Ib load Test the lash adjusters as follows Leak down 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 01 19 plunger facing upward Position the steel ball provided in the plunger cap Add testing fluid to cover the hydraulic lash adjuster and compress Leak down 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 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 Center Pointer A satisfacto
223. the mixer will actuate allowing the proper amount of air and fuel to mixer together This pressure differential is based on the vacuum in the intake manifold of the engine which is directly related to load DEPR Direct Electronic Pressure Regulator The DEPR controls the fuel trim to the engine on dry fuels based on inputs to the GCP HO2 sensor MAP sensor crank and cam sensors Nominal pressure input to the DEPR is 11 WC and outputs 4 5 WC It is mounted directly to the mixer 08 9 Vapor Regulator The vapor regulator is used with LPG and CNG fuels It converts LPG from a liquid state to a gaseous state Nominal pressure output is 11 of WC to the DEPR Coolant is run through the DEPR to prevent freezing of the regulator which could result ina lean fuel condition Fuel Lock Off Valve The fuel lock off valve is located before the DEPR and or the vapor regulator It is only open during cranking and running This prevents the intake manifold from filling with gaseous fuel which could result in a backfire The power is constant and supplied by the power relay The ground of the solenoid is controlled by the GCP MSG 425 Engine Controls Coil on plug Ignition The coil on plug ignition system controls fuel combustion by providing a spark to ignite the compressed air fuel mixture at the correct time To provide optimum engine performance fuel economy and control of exhaust emissions the GCP controls the
224. the starter motor Starter Motor Replacement B Terminal i fi 4 Ju an Ati E 7 lt 5 i 5 M Terminal ET l ad 3 5 5 Terminal ji x Starter Motor wA 144 ae 5 ag ee x 7 Solenoid 2 OF TT 1 SX r i X Pe UU 3 Remove terminal cover and nuts 4 Remove starter mount bolts WARNING WHEN SERVICING STARTER OR PERFORMING OTHER WORK IN THE RS 9 Ib ft VICINITY OF THE STARTER BE AWARE THAT THE HEAVY GAUGE BATTERY INPUT Tighten S nut to 5 Nm 44 Ib in e Tighten mount bolts to 25 Nm 18 lb ft LEAD AT THE STARTER SOLENOID IS ELECTRICALLY HOT AT ALL TIMES 07 9 MSG 425 STARTER SYSTEM SPECIFICATIONS GENERAL SPECIFICATIONS Current draw NO Load 60 80 Amps Current Draw Max 800 Amps Load Minimum Stall torque 14 7Nm 16lb ft 5 volts Cranking Speed 140 220 RPM TORQUE SPECIFICATIONS p bolts nuts studs nuts Solenoid 5 44 terminal B nut SPECIAL TOOLS VAT 40 Starting Charging 078 00005 Tester 07 10 MSG 425 Engine Controls INDEX Subject Page General Information 08 2 CEP Senso S ti Fuel System en on Coil on p
225. ting Ford specification WSK M2G351 A6 and install the cylinder block core plug Cylinder Head Distortion Special 5 Straxhtedge 303 0039 083 4201 equ valent Specal Semice Tools called tor by the procedures can be obtaned by 1 BDO R OTUNDA 1 800 768 5832 e Useastraight edge and a feeler gauge to inspect the cylinder head for flatness Compare with specifications If the cylinder head is distorted install a new cylinder head MSG 425 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 Use a fabricated tool to seat the cup type cylinder block core plug Cylinder Block Core Plug Expansion Type CAUTION Do not contact the crown when installing an expansion type cylinder block core plug This could expand the plug before seating and result in leakage e Use a fabricated tool to seat the expansion type cylinder block core plug 01 37 MSG 425 GENERAL INFORMATION Spark Plug Thread Repair 2 Start the tap into the spark plug hole being Special Tool s careful to keep it properly aligned As the tap begins to cut new threads apply aluminum Tapersen Installanon Kit 1070021 or Equivalent cut
226. ting oil Feeder Gauge D81L 4201 or Equivalent Spena Senyce Tools caled for by the procedures can be 1 800 ROTUNDA 1 600 766 8032 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 thread of the mandrel extends beyond the tapersert CAUTION The cylinder head must be removed from the engine before installing tapersert If this procedure 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 NOTE A properly installed tapersert will be either flush with or 1 0 mm 0 039 inch below the spark plug gasket seat 01 38 MSG 425 GENERAL INFORMATION Exhaust Manifold Straightness 6 Tighten the tapersert into the spark plug hole 9 dii Special Tool s Straightedge 303 038 0831 4201 or equivalent Special Service Tools called for procedures can be 44 1 B00 ROTUNDA 1 800 768 8437 e Place the Straightedge across the exhaust manifold flanges and check for w
227. tion of the charging system warning indicator as follows e lgnition OFF Indicator should be OFF e ignition ON Engine OFF Indicator should be ON ignition ON Engine ON Indicator should be OFF Symptom Chart CONDITION POSSIBLE SOURCE ACTION Dead battery Battery will not stay charged Slow crank Low battery voltage No generator output Indicator lamp on with engine running Indicator lamp flickers or intermittent Battery over charging battery voltage greater than 15 5 volts Indicator lamp off key on engine not running Generator noisy Indicator lamp on key off Key off battery drain Open voltage drop in B circuit Open voltage drop in A circuit Open high resistance in circuit Voltage regulator Generator Open A circuit Shorted I circuit Open high resistance in S circuit Voltage regulator Generator Loose connection to generator voltage regulator or battery Loose fuse or poor connection in A circuit Loose brush holder screw Voltage regulator Generator Voltage drop in A circuit Voltage drop in I circuit Poor ground Voltage regulator Generator Open high resistance in I circuit Burned out bulb Poor ground S circuit shorted to Voltage regulator Generator Accessory drive belt Accessory brackets Bent generator pulley Generator Other components Lamp circuit shorted to B Improper lamp cir
228. to max line MSG 425 COOLING SYSTEM Fan Bearing Bracket Tensioner REMOVAL AND INSTALLATION 1 NOTE If a major component of the cooling system is renewed such as the radiator water pump etc the 2 system should be flushed and re filled with a 50 solution of Motorcraft Premium Gold engine coolant or 3 equivalent and clean water Refer to Flushing the Cooling System on the previous page T 1 i 1 ri T ri FL p Luc X x d 55 11 Eu Ve 1 mz j ar F Li LI LM 1 k T as mus roy E ak i E kgs ET 0 f 1 a 1 E nmi i T E zia EL ar i 2 es Lm E r vd a AL i m La draco Tm Lu Fi Pa jl a LA E E a m E 8 F e 5 LS rot z Dis i AR E I 10 a pb m bo 24 E Fan Belt Installation Place belt around extended crank pul
229. to section 6 2 Remove or disconnect any component to allow access and removal of the CMP Sensor Disconnect CMP electrical connector Remove bolt and CMP Sensor Reverse procedure to install Use anew o ring seal e Lubricate o ring with clean engine oil prior to installation Tighten bolt to 7 Nm 62 Ib in ao Crankshaft Position CKP Sensor Removal 1 Disconnect battery ground cable refer to section 6 2 Remove or disconnect any component to allow access and removal of the CKP Sensor 3 Disconnect CKP electrical connector 4 Remove plug 5 Install special tool 303 507 and turn the crankshaft pulley bolt to position the No 1 cylinder at top dead center TDC Kol 6 Remove 2 bolts and sensor Sensor 4 7 Install M6 bolt in the position shown Jj A UU 5 gt C b D lt 33 J in EN e 4 gt gt 2 7 gt P 2 MSG 425 Engine Controls Crankshaft Position CKP Sensor Installation 1 Position sensor and loosely install the 2 bolts NOTE The CKP sensor alignment tool is supplied with the new sensor and is not available separately 2 Adjust the CKP sensor with the alignment tool and tighten 2 bolts e Tighten to 7 Nm 62 3 Connect sensor electrical connector 4 Remove the M6 bolt 08 42 6 Install the plu
230. tor Once the generator begins generating current a voltage signal is taken from the generator stator and fed back to the regulator This voltage feedback signal typically half the battery voltage is used to turn off the warning indicator With the system functioning normally the generator output current is determined and compared to a set voltage internal to the regulator and the regulator controls the generator field current to maintain the correct generator output The set voltage varies with temperature and typically is higher in cold temperatures and lower in warm temperatures This allows for better battery recharge in the winter and reduces the chance of overcharging in the summer MSG 425 CHARGING SYSTEM Wiring Diagram Revision Level The following wiring schematics are taken from the wiring diagram labeled below EDI FORD 2 5L W GCP Surber 2487000 Date 11 1 2811 Filename 24878884d sch Charging System Batter Ring Red Red Red T1 1 r PR ITE F3 FE Alt Fuse Panel 10 10 a E e Red Tan 500o0hm resistor Stator C White E Red F Red Power L wr J 06 4 MSG 425 CHARGING SYSTEM DIAGNOSIS AND TESTING WARNING REFER CAUTIONS amp WARNINGS THE BEGINNING OF THIS SECTION NOTE When the battery is disconnected and connected some abnormal symptoms may occur while
231. uld 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 not proceed to step 10 5 Drain the engine oil remove and replace the oil filter and refill with one quart less than the recommended amount 6 Run 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 dipstick and draw a mark on the back
232. ump and rotors and use the Feeler Gauge to measure the clearance between the rotors and the Straight Edge e Measure the clearance between the rotor and the pump housing 01 34 MSG 425 GENERAL INFORMATION Cylinder Bore Honing Special Tool s Engine Cylinder Hone Se T7320 Special Semice Tools called for by the procedures can be med 1 800 ROTUNDA 1 800 748 8432 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 Honing should be done when fitting new piston rings or to remove minor surface Hone with the Engine Cylinder Hone Set at a speed of 300 500 rom and a hone grit of 180 220 to provide the desired cylinder bore surface finish Cylinder Bore Cleaning 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 Use clean lint free cloth and lubricate the cylinder bores e Use Engine Oil XO 10W30 QSP DSP or equivalent meeting Ford specification ESEM2C153 E 01 35 MSG 425 GENERAL INFORMATION Cylinder Block Repair Cast Iron Porosity Defects CAUTION Do not attempt to repair cracks areas where temperature will exce
233. uninstalled Ensure the rubber gasket to install the two gaskets on the actuator on the DEPR is not damaged before installing the mixer adapter Tighten to 35 4Nm 2 Mount the actuator with the mixer adapter using the four 85mm long M6x1 0 bolts Ensure the gasket for the actuator is not damaged e Tighten to 6 6lb ft Specifications GENERAL SPECIFICATIONS Fuel Pressure Motorcraft SAE 5W20 WSS M2C930 A Super Premium Torque Specifications Lb ft ft Fuel Rail 25 18 Bolts 3 Mount the mixer to the mixer adapter using the four short M6x1 0 bolts Ensure the gasket on the mixer is not damaged Tighten to 6 6 lb ft 04 27 INDEX Subject MSG 425 COOLING SYSTEM General Information NOU a Diagnosis and Testing Visual un doo aiu iu fatu coolant Range CHOC Drive Belt Inspection Symptom Chart Cooling System Test Radiator Cap Pressure Thermo sta General Service Procedures Draiming the Cooling SV SLOT Flushing the Cooling System the COOITTg aa R
234. upplies either 5 or 12 volts to power various sensors or switches The power is supplied through resistances in the GCP which are so high in value that a test light will not light when connected to the circuit In some cases even an ordinary shop voltmeter will not give an accurate reading because its resistance is too low Therefore a digital voltmeter with at least 10 megohms input impedance is required to ensure accurate voltage readings The GCP controls output circuits such as the fuel injectors electronic governor etc by controlling the ground or the power feed circuit through transistors or other solid state devices The GCP is designed to maintain exhaust emission levels to government mandated standards while providing excellent operation and fuel efficiency The GCP monitors numerous engine functions via electronic sensors such as the throttle position TP sensor and the heated oxygen sensor 25 GCP Inputs operating conditions read Engine Coolant Temperature Crankshaft Position Exhaust Oxygen Content Manifold Absolute Pressure Battery Voltage Throttle Position Electronic Actuator Fuel Pump Voltage Intake Air Temperature Camshaft Position MSG 425 Engine Controls GCP Outputs systems controlled e Fuel control Injectors DEPR e Electronic Throttle Control e Electric Fuel Pump gasoline e Diagnostics Malfunction Indicator Lamp check engine lamp e Diagnostics Data Link Connector DLC e Var
235. ure simply click the Freeze To restart the plotter click on the Hesume button The maximum number of variables that can be plotted at one time is 10 The range of the selected variables will be shown on the Y axis and the time will be shown on the x axis You may change the desired time interval and sample interval for the plot by stopping the plot and typing in a new intervals The plot can be saved to the PC by stopping the plot and clicking File then SAVE When saving a plot you will have to type in a filename Plot files can later be viewed with the edis saplot software located in the Windows Start Programs folder or the data be viewed in Notepad or Excel 08 33 Below is a sample of a plot gun i I a pem mg 75 m T EL BE m E m Logging Logging variables means the variables are stored to the PC During logging there is no plot shown on the screen To log variables you must first TAG the variables by right clicking them same as plotting Next click on Plot Log and then Log Tags An Edis Log window will pop up You can type in a custom log File name or select a custom folder to save the log file to The default filename is edis log and the default folder is GCP_Dis The sample interval and time interval can also be changed from the default To start logging click on the START
236. uu E M 7 gt Y T 4 Fuel Injectors 7 F F ia al i 4 gt Oc ring Seals gt rmt zl lt lt 7 4 T 1 FEY E _ de gt n 2 L 04 25 MSG 425 FUEL SYSTEM Actuator Removal 1 Remove and or disconnect components to allow access and removal of the actuator Label if necessary to allow for correct reinstallation Disconnect air cleaner components from actuator Disconnect accelerator cable Disconnect electrical connectors Remove nuts Remove actuator and gasket Actuator Installation 1 2 3 Oa Inspect gasket and install a new one if necessary Position actuator onto studs Install nuts e Tighten to 8 ft lb Reconnect electrical connectors Reconnect accelerator cable Reconnect air cleaner components to actuator Install or connect any other component removed or disconnected 04 26 Mixer Removal 1 Remove top four bolts that hold the mixer to the mixer adapter m To Remove the Mixer adapter unscrew the four bolts This will also unmount the actuator 3 The DEPR can also be disconnected from the mixer via the four mounting bolts MSG 425 FUEL SYSTEM Mixer Installation 4 Mount the DEPR to the mixer if 1 Reverse the removal procedure Ensure
237. valve valve seat or cylinder head Weak or broken valve spring Replace valve spring Renace cyinder head Cracked or distorted cylinder head Replace cylinder head Roa eb pt a Malfunctioning or damaged fuel system Refer to Section 04 Malfunctioning or damaged ignition system Refer to Section 03 01 9 MSG 425 GENERAL INFORMATION PCV System Malfunction A malfunctioning Positive Crankcase Ventilation System closed type may be indicated by loping or rough engine idle Do not attempt to compensate for this idle condition by disconnecting the PCV system and making an air bypass or idle speed adjustment CAUTION The removal of the PCV system from the engine will adversely affect fuel economy and engine crankcase ventilation with resultant shortening of engine life Engine Oil Leaks NOTE 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 Oil Leak Detector 112 R0021 Fluorescent Oil Additive Method Use a 12 Volt Master UV Diagnostic Inspection Kit such as the Rotunda Oil Leak Detector Y112 R0021 or equivalent to perform the following procedure for oil leak diagnosis 1 Clean the engine with a suitable solvent to remove all traces of oil
238. y If no other problems have been identified replace the fuel management assembly with a known good part of the same pressure range Retest MSG 425 FUEL SYSTEM The pinpoint tests below should be performed after the preliminary tests and Engine Backfires chart Steps 1 3 Any electrical diagnostics should have been performed to eliminate any sensor GCP or solenoid valve problems before proceeding Engine Backfires 2 TestStp ActiontoTake __1 __ Check for icing or freezing of the regulator Yes e With the engine at idle e Check for ice or frost build up on the converter casing and outlet port Is ice present 2 Check DEPR operation With the engine at idle Yes e Disconnect the electrical connector No Is there a change in engine running with this No unplugged 3 Check DEPR supply voltage 7 Yes Key OFF Disconnect DEPR electrical connector Key ON Check pins 3 and 6 for 12 volt supply in the harness Is the voltage less than 11 5 volts No 4 Check the vapor regulator operation Yes e Engine OFF Install a pressure gauge on the Primary Pressure Test port e Start and idle the engine No Did you NOT measure 3 5psi EM During startup check for fuel lock leakage not closing Close the tanks main fuel valve Yes Install a pressure gauge on the primary test port of the vapor regulator Key Off Slowly open the main fuel valve Do you measure any fuel pressure

MSG425 Service Manual - Rev 1 - Small

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