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TSG416 Service Manual Rev0 - EDI Ford Industrial Engine

1. ____ _ _____ ____ Cylinder Bore _ 6_ 0__ _____ __ ie PISTON TNR ER UT TET TTL Piston to Cylinder Bore ClearariCe uu cetus rte 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 TSG 416 GENERAL INFORMATION INDEX CONT Subject Piston Pin Diameter TM Connecting Rod Buhne Connecting Rod Bend Connecting Rod Twist Connecting Rod Piston Pin Side Clearance Connecting Rod Journal Bearing Inspection Roller Follower Hydraulic Lash Adjuster ineoection Mika dacs Puss tise OA scare Valve Stem Diameter Valve Stem to Valve Guide Clearances SRP RN VERE RIES Valve Inspection cim Valve Guide Inner Diameter Valve Guide Reaming Valve Spring Installed Len es Valve Spring Free HOC tect ee ete Valve Spring OUL O1 SGU ____ Valve Spring Compression PEesSUFG Valve and Seat Refacing Measurements eese eene nennen ener eene nennen cece
2. nennen nnne nnne Spring Lock Coupling Type 5 nennen Spring Lock Coupling Type 11 eene nennen nnn nonni Quick Connect Coupling Type Disconnect eese Quick Connect Coupling Type cesessseceecessseceecescsseaeeecescessseaeeeesessaees Quick Connect Coupling Type 11 Quick Connect Coupling Type 11 Removal and Installation Fuel Rail amp Injectors Replacement esee ener nenne ernannt nnne Actugtor Re tmoWVval scien ACTUATOR Installatiofi ui err ee DR OR EU Mixer Mixer IAS EAU AU OM Specifications ocio die avi DHL 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 TSG 416 FUEL SYSTEM CAUTIONS amp WARNINGS AN WARNING DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR
3. ve a ma Me een ure Cylinder Head Oil Pump Removal Oil Pump fastallation M Crankshaft Rear Oil Crankshaft Rear Oil Seal maihin Camshaft Follower Hydraulic Lash Adjuster Removal Camshaft Follower Hydraulic Lash Adjuster Oil Pan Removal Oil Pan installations Pickup tube daflector Pickup tube deflector nnns Crankshaft main bearings Removal eese eene eene enne nennen Crankshaft main bearings Installation eese Connecting Rod Bearings Remowval eese eene eene enne nnne n Connecting Rod Bearings Installation eese eene Piston REMIOV _____ __ dated M Piston sten Flywheel Removal Flywheel TE Timing Chain and Sprockets Removal Timing Chain and Sprockets e alla On Tr E Oil Level Indicator iua not n vh ai Oil Eevel Indicator nstallati ed eto ota a le ee ved eva Fee ci Oil Level Filter and Adapter Oil Level Filter and Adapter Installation seen 02 1 02 10
4. T m Tightening Sequence 4 Carefully install sprocket into timing chain aligning timing mark with 2 copper links Copper Links _ 42 O clock Timing Mark TSG 416 ENGINE 5 Using tool 15 030A install camshaft sprocket 6 bolt Tighten to 92 Ib ft 125 Nm Lecking Tool Uo 15 0304 Install hydraulic tensioner and tighten to 30 Ib ft 40 Nm Hydraulic Tensioner Install oil level indicator bolt Tighten to 15 Ib ft 20 Nm Install exhaust manifold and nuts Tighten nuts to 11 Ib ft 15 Nm Install bolts and nuts holding intake manifold to cylinder head Tighten to nuts and bolts to 13 Ib ft 18 Nm 02 20 10 11 12 13 14 15 Install the coolant flow control module refer to Section 05 Coolant Flow Control Module Pa Install spark plugs and wires refer to Section 03 Install valve cover Refer to Valve Cover Removal on 10 Install and route any wiring and vacuum hoses removed Fill engine with correct type and quantity of coolant refer to Section 05 Fill engine with correct type and quantity of engine oil refer to Operator Handbook TSG 416 ENGINE Oil Pump Removal CAUTION The oil pump pulley and sealer are provided as an assembly kept together by a clip no BF9A 6606 AA Do not remove clip until oil pump is installed If pulley is pushed out of the oil pump prior to oil pump installa
5. E d Crank Angle Sensor Data Link Connector DLC Assembly Line Communicaton Link ALCL in a bie ta Connie Dia Dagens Tle Differential Pressure Feedback Gas Recirculation Differential Pressure Diferential Pressure Feedback EGR System System lt Direct Fuel injection Dre 0 Drectrjecton 0 Ignition CDI Bowi Distributor eerie I with Distributor Electronic Contr EAC ta Remote Mount TFI Thick Film Ignition RN Distributor ignition Control Module 5 Module SO a ee 1 e Electronic Continuous Fuel 5 Electronic CFI System sonore yp om M Electronic Ignition ore Coi C31 5 ane Ignition 101 Electronic ignition System 09 8 TSG 416 METRICS new A X RT Engine Coolant Temperature Sensor ECT Sensor Coolant Temperature Sensor CTS aa emporium Engine Coolant Temperature Switch ECT Switch Coolant Temperature Switch CTS i Crankshaft Rue Erasable Programmable Read Only Memory ee Esporte Emission EVAP Evaporative Emission Canister EVAP Canister Canister Evaporative Emission Canister Purge EVAP Canister Purge EVAP Canister Purge Evaporative Emission Canister Purge Valve Vacuum Solenoid Valve EVAP VSV
6. 01 3 Battery Handling and 2 Engine Identification Parts and Service Description and Diagnosis and Testing Special Tools ui Inspection and Symptom PEV System EOD DER Compression MEINT LU UU UI CvInder Leakage Dod itake Manifold Vacuum eub eren e abd bea Ce aon Excessive Engine Oi ConsumptlODs nd iia Qu deca etu rb eoo Qo tuc mt COIS Valve Traim ANdlysi s Sti C Valve Train Analysis Camshaft Love Lift T m Hydraulic Valve pu General Service Procedures Our al ione bet dise Camshaftt Journal eiie taie bios scs Sod Camshatt Lobe S TI CO tici om se eis e ceu CARS at ODE MEE ours cies D epu DERE Camshaft Runout Camshaft End Play pisa Crankshaft Main Bearing Journal Diameter Crankshaft Main Bearing Journal Crankshaft Bearing Journal Bearne Crankshatt End PLAY _____4__8_ ROUDOU
7. Valve Seat Runout Flywheel I eec Oil Pump Gear Radial Clearance Oil Pump Rotor OIL Pump side CIO AI ANC Oe Cylinder Bore Cynder Bore Cylinder Bore Core Plug Replacement eese eene Cylinder Bore Repair Cast Iron Porosity Cylinder Block Distortion Spark suaviter ae mH bt d NEUE Exhaust Manifold Straightness essere eren ennt nnne nennen nenne General Service Procedures Page cisco ra cla Piston PING End 7 Piston Ring to Groove we aes Crankshaft Connecting Rod Journal Crankshaft Connection Rod Journal eene Connecting Rod Connecting Rod Larger End Bofe sd awh anes 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 01 35 01 36 01 36 01 36 01 38 01 39
8. Removal Ignition Coil Replacement e EPM High Tension Wires 5 Spark Plug Remove and or disconnect components to allow access and removal of the ignition coil pack Label if necessary to allow for correct reinstallation Disconnect electrical connector from the engine harness then disconnect the high tension wires that go to each spark plug Remove four bolts Remove the ignition coil pack 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_ E 8 Ls 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 06 1 16 mm 0 042 0 046 in Install spark plugs to original locations and tighten to 11 lb ft 15 Install coil Refer to Ignition Coil Replacement on page 6 of this section TSG 416 IGNITION SYSTEM SPECIFICATIONS GENERAL SPECIFICATIONS Firing Order 1 3 4 2 Spark Plug Type 5G5E 12405 AA Gap 1 06 1 16 mm 0 042
9. Removal NOTE Remove oil pan Refer to Oil Pan Removal on page 25 Hemove pick up tube and deflector Refer to Pickup Tube Deflector Removal on page 26 Remove spark plug for cylinder being serviced Rotate crankshaft until connecting rod and bearing to be serviced is placed at the bottom of its stroke Remove two connecting rod nuts Remove connecting rod cap with lower bearing Lower Bearing Push piston and connecting assembly up into bore Remove upper bearing from connecting rod For bearing service refer to Section 01 02 28 Connecting Rod Bearings Installation NOTE Make sure bearing bore of connecting rod and cap and bearing journal are clean Lubricate wear surfaces with clean engine oil 1 Insert upper bearing into connecting rod 2 Insert lower bearing into cap CAUTION Do not scratch journal with connecting rod bolts Install cap and bolts Tighten bolts in 2 steps e Step 1 9 12 5 Nm e Step 2 22 Ib ft 30 Nm 41 94 4 Install deflector and pick up tube Refer to Pick up Tube Deflector Installation on page 26 5 Install oil pan Refer to Oil Pan Installation on page 25 TSG 416 ENGINE Piston Removal 6 Remove 2 bolts connecting rod cap and lower bearing 1 Remove oil pan Refer to Oil Pan Removal on page 25 2 Remove pick up tube and deflector Refer to Pickup Tube
10. Spark kill is only available on gasoline NOT on gaseous fuels hese 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 button 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 Nomal v njector kill Nomal v DBW test Of ww Extemal power Automatic VW 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
11. 19 9 91 1 9 QM 7 ki En m d e o HP d QM 95 049 049 99 08 21 TSG 416 Engine Controls Engine Controls Actuator Data Link Connector DLC ool yo sed suam OF 1 81 vv 8 _ ______ dt NYO 1 Od 2 30 290U0 5 2 2541 bSdi Sy ee SS EE a i l T s eo Te n 8i yo sed suam 0 AL HAVNS 8 QM AO 85 k b GH ADE 81 43M e AS 94 97 8 HwaJdMS Hwa9 85 OO ____ 9 Li oye 5v emori yosog 08 22 TSG 416 Engine Controls Engine Controls Dry Fuel DEPR r mE lps 1 eS 10A 10A L mmi dl af 14 RD TAN 16 RD LB 6 3 Relayed Power 18 BK WH me Ground DEPR 4 12 BK WH 4 CAN CAN Front of Connector 73 gt View 18 BDG VT 181 OG LG Twist 10 tums per foot min Grounding Ring 18 OG LG Twist 10 tums per foot min 18 14 15 n CAN1 1 L m ee J 08 23 TSG 416 Engine Controls DIAGNOSIS AND TESTING Diagnostic Approach Use the
12. 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 Y112 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 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 Runthe 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
13. Idler Pulley Replacement 1 Remove drive belt Refer to Drive Belt Removal of this section 2 Remove belt idler pulley assembly 3 Reverse procedure to install e Tighten to 47 Nm 35 lb ft 05 9 TSG 416 COOLING SYSTEM Radiator Hose Removal A 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 Loosen 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 TSG 416 COOLING SYSTEM Thermostat amp Housing Replacement AN WARNING REFER TO CAUTIONS AND 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
14. Improper valve to valve seat contact Replace valve or valve seat Damaged cylinder head gasket Replace cylinder head gasket Malfunctioning ar damaged fuel system Refer to Section 04 of this manual Malfunctioning ar damaged ignition system Refer to Section 03 of this manual spark plugs gapped incorrectly Check plug gap Malfunctioning or damaged IAC motor or system Refer to Section 03 af this manual Abnormal combustion Damaged hydraulic lash adjuster hydraulic lash Replace hydraulic lash adjuster or hydraulic lash adjuster adjuster Damaged hydraulic lash adjuster quide or hydraulic lash Replace hydraulic lash adjuster guide or hydraulic lash adjuster adjuster Burnt or sticking valve Repair ar replace Weak or broken valve spring Replace valve spring Carbon accumulation in combustion chamber Eliminate carbon buildup Malfunctioning damaged fuel system Refer to Section 04 of this manual Malfunctioning ar damaged ignition system Refer to Section 03 of this manual 01 7 TSG 416 GENERAL INFORMATION Excessive Worn peston ring groove Replace piston and pin Consumptban Sticking piston rings Repair or replace rings Worn or cylinders Repair or replace piston or cylinder blocks Worm piston rings Replace piston rings Plugged PCV system Service system Wom valve stem or valve guide Replace valve stem and guide 01 8 TSG 416 GENERAL INFORMATION
15. 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 driver will stay disabled for 5 seconds and then re set Record the change in rpm or closed loop multiplier while each driver is disabled TSG 416 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 34 RAW VOLTS Screen The RAW VOLTS screen shows actual voltage readings from various circuits Use the k
16. 0 046 in TORQUE SPECIFICATIONS Spark Plugs Coil bots 8 03 7 TSG 416 FUEL SYSTEM INDEX Subject Cautions Se 5 General Information Gasoline ccccccsccccccecseccscssceeccccsnssescccccccccosccsccscosccsesscosecses RC T Operation F elkSystem Regemente WV PIT SD ACU oues UNUS General Information Dry eere eene eerte toten ten tontos DES CAP PE E D EDU Operation Fuel System Winne B Is Ide RR EE EET TTE P Diagnosis Testing un ene bu eee SV UNDE OM C ___ _______ __ m Diagnosis and Testing GASOLINE cccccccsccecsecescescescescescencescescescessensescescessesseseesee Visual InSDecto puto uds Q NAPON CNC Fuel Pressure Checa teda FueL Pup tesa emet lerem NT TT D o General Service Procedures Spring Lock Coupling Type Disconnect eese nennen Spring Lock Coupling Type
17. Note that many types of English and Metric fasteners carry no special identification if they are otherwise unique Tapping thread forming and certain other case hardened screws CLASS 10 9 CLASS 9 8 CLASS 8 8 09 4 TSG 416 METRICS umm ENGLISH METRIC CONVERSION 8 F 32 0 556 i inl ili J ili JHJE 5 inihi iii ili 09 5 TSG 416 METRICS DECIMAL AND METRIC EQUIVALENTS TORQUE CONVERSION 09 6 TSG 416 METRICS J1930 TERMINOLOGY LIST Certain Ford Component names have been changed in this Service Manual to conform to Society of Automotive Engineers SAE directive J1930 SAE J1930 standardizes automotive component names for all vehicle manufacturers e _ _______ t Camshaft Position Sensor CPS nemo LLL NENNEN LL RN Pedal Position CPP Pedal Position CPP _ _ Pedal Position Switch Engage Switch CES Cons Ds ny ay 09 7 TSG 416 METRICS Continuous Injection System CIS Continuous Inj System Electronic inaction System E CIS E K Jetronic Garros eon Sym Continuous Trap Oxidizer CTOX pun Trap pou CT Trap Ox Continuous TOC Crankshaft Position
18. Radiator Cap Pressure Thermostdt Operational COCK General Service Procedures Draiming the Flushing the euer _ Filing the oollng SYS COI c peat ______ __ dedu Removal and Installation Drive Bet Removal ess denti Drive Belt InstallatlOTi aurou qti Belt Tensioner REplaceMent sccsssssscsecsescresssstesessonsonestecesessostonstestssuensessussuoatents essere Idler Pulley reset uds Radiator Hose Removal Radiator Hose installation Thermostat amp Housing Rep oceneni E He Coolant Pump Coolant Bypass Replacement 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 TSG 416 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 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
19. SHELL BORE ELECTRODES POSIT BUILD CAUSED BY EXCESSIVE ee GAP BETWEEN ENTERING COMBUSTION CHAMBER 5 THROUGH WORN RINGS CAUSED BY OR CARBON PISTONS EXCESSIVE CLEARANCE FOULING REPLACE PLUG OR BETWEEN VALVE GUIDES AND IF DEPOSITS ARE NOT EXCESSIVE STEMS OR WORN OR LOOSE THE PLUG CAN BE CLEANED BEARINGS CORRECT OIL PROBLEM REPLACE THE PLUG IDENTIFIED BLACK DRY FLUFFY IDENTIFIED BY ELECTRODES CARBON DEPOSITS ON INSULATOR AND POSSIBLY BLISTERED mes 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 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 HOT 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 WITK SMALL WITH T S IDENTIFIED BY MELTED OR SPOTTY BLISTE CAUSED BY ENGINE OVER s 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 TSG 416 IGNITION SYSTEM REMOVAL AND INSTALLATION Spark Plug
20. 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 The 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 TSG 416 FUEL SYSTEM a Y To Sensor 4 Fuel Injectors dg Fuel Pump 3 Fuel Filter 49 4 52 Return to 5 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 u
21. ee r Exhaust Gas Recirculation Vacuum Regulator EGR Vacuum EGR Vacuum Regulator Solenoid EVR Solenoid Regulator Solenoid Solenoid Exhaust Gas Recirculaton Vacuum Regulator Valve EGR Vacuum EGR Vacuum Regulator Valve EVRV Regulator Valve Exhaust Gas Recrculaton Valve EGR Valve EGR EGRV EGR Valve Control EGR Control EGRVC EGR Valve Position EGR Valve Position Sensor EVP Sensor Electro Drive Fan Control EDF Control Engine Coolant Fan Control Exhaust Gas Recirculation Valve Control Exhaust Gas Recirculation Valve Position Sensor Fan Control igh Electro Drive Fan Control HEDF Control Rae Pan i Fan Control Module Fan Control Module TSG 416 METRICS ee Fan Control Relay FC Relay Fan Motor Control Relay Radiator Fan Relay Feedback Pressure Exhaust Gas Recirculation x Pressure Pressure Feedback Exhaust Gas Recirculation Feedback Pressure Exhaust Gas Recirculation Feedback Pressure Pressure Feedback Exhaust Gas Recirculation Sensor EGR Sensor PFE Sensor Flash Electrically Erasable Programmable Read Flash EEPROM Sinema reu a O O C em em Fuel Pres R Fuel Pressu Fuel Regulator e nan Hoh Speed FC Switch idle Air Control Idle Air idle S Control Bypass air ISC BPA idle Air Control Thermal Vave si Fa
22. 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 Refer to Equipment Setup for information about using a personal computer to assist with unit diagnosis TSG 416 Engine Controls DTC s can be retrieved by shorting the Self Test Input STI 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 123 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 DTC 123 the MIL bulb will blink If the MIL bulb does not illuminate when b
23. 01 40 TSG 416 GENERAL INFORMATION GENERAL INFORMATION Introduction This section covers various engine tests adjustments service procedures and cleaning inspection procedures Engine assembly and service specifications appear at the end of the Section 02 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 15 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 material Use manual gasket scrapers for removing
24. 02 10 02 11 02 12 02 13 02 14 02 15 02 15 02 16 02 16 02 17 02 19 02 21 02 22 02 23 02 23 02 24 02 24 02 25 02 25 02 26 02 26 02 27 02 27 02 28 02 28 02 29 02 30 02 31 02 31 02 32 02 33 02 35 02 35 02 36 02 36 TSG 416 ENGINE INDEX CONT Subject Page Disassembly o doe ad RUN ERE tu NN a 02 37 Subassemblies Cylinder BIO Ci b vm Emu Used PISTON DISASSEIN DIY O2 A5 Piston Assembly E 02 45 Cylinder Head Disassembly 702 46 CylinderHead Assembly ntc dei ri eee 0247 ASSemDIV xoc 02 48 Note For engine diagnosis refer to Section 01 02 2 TSG 416 ENGINE GENERAL INFORMATION Special Tools Valve Spring Compressor T81P 6513 A or Equivalent Piston Ring Compressor D81L 6002 C or Equivalent Camshaft Bearing Set T65L 5250 A or Equivalent Connecting Rod Guide Tool T93P 6136 A or Equivalent Crankshaft Damper Remover T58P 6316 D or Equivalent 02 3 Seal Remover T92C 6700 CH or Equivalent Dial Indicator with Bracketry TOOL 4201 C or Equivalent Cylinder Ridge Reamer T64L 6071 EA or Equivalent Vibration Damper Remover Adapter Feeler Gauge 0811 4201 or Equivalent TSG 4
25. 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 driving 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 lite
26. Generator Open A circuit Shorted I circuit Open high resistance in 5 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 B Voltage regulator Generator Accessory drive belt Accessory brackets Bent generator pulley Generator Other components Lamp circuit shorted to B Improper lamp circuit wiring 06 6 Repair as necessary Repair as necessary Repair as necessary Repair as necessary Repair as necessary Repair as necessary Repair as necessary TSG 416 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
27. 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 e Check the fuel lockoff connection and fuel check necessary valve connection No e Check the vacuum hoses for any damage or leakage Go to step 4 Is there any damaged or loose wires and hoses Check for fuel system leaks e Key ON Yes Repair the leak e Check the fuel system for leaks e 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 TSG 416 FUEL SYSTEM Diagnostic Charts Perform the preliminary test before proceeding Engine Cranking but Will Not Start Resut ActiontoTake _ 1 Check fuel tank Yes Fill or replace the fuel tank Do not exceed 80 of liquid Is fuel tank empty capacity No Go to Step 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 t
28. Various types of flushing equipment are available Follow manufacturer s operating instructions Filling the Cooling System WARNING REFER TO CAUTIONS AND WARNINGS AT THE BEGINNING OF THIS SECTION 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 Veri
29. f necessary pressurize the main oil gallery system to locate leaks due to improperly sealed loose or cocked plugs 5 Repair all leaks as required Pressure Method The crankcase can be pressurized to locate oil leaks The following materials are required to fabricate the tool to be used e air supply and air hose e air 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 a solution 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 appropriate 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 TSG 416 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
30. satisfactory 01 12 Compression Pressure Limit Chart MAX MIN MAX MIN MAX MIN MAX MIN kPa psi kPa psi kPa psi kPa psi 924 696 1131 848 1338 1000 1154 1158 134 101 164 123 194 146 224 168 938 703 1145 855 1351 1014 1558 1165 136 102 166 124 196 147 226 169 952 717 1158 869 1365 1020 1572 1179 138 104 168 126 198 148 228 171 1172 876 1379 1034 1586 1186 170 127 200 150 230 172 979 738 1186 889 1303 1041 1600 1200 142 107 172 129 202 151 232 174 933 745 1200 903 1407 1055 1055 1207 144 109 174 131 204 153 153 175 1007 758 1214 910 1420 1062 1627 1220 146 110 176 132 206 154 154 177 1641 1227 238 178 1241 931 1034 779 1448 1083 1655 1241 150 113 180 135 210 157 240 180 1048 786 1225 936 1462 1089 1669 1248 152 114 182 136 212 158 242 181 1062 793 1269 952 1476 1103 1682 1262 154 115 184 138 214 160 244 183 1076 807 1282 965 1489 1117 1696 1269 156 117 216 162 246 184 965 724 140 106 1020 765 1227 917 1434 1075 148 111 178 133 208 156 186 140 1089 814 1296 972 1503 1124 1710 1202 158 118 188 141 218 163 248 186 1103 872 1310 979 1517 1138 1724 1289 160 120 190 142 220 165 250 187 1110
31. 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 TSG 416 GENERAL INFORMATION Interpreting Vacuum Gauge Readings A careful study of the vacuum gauge reading while the engine is idling will help pinpoint trouble areas Always conduct other appropriate tests before arriving at a final diagnostic decision Vacuum gauge readings although helpful must 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 fig
32. Condition Possible Source Action Excessive main bearing ail clearance Adjust clearance or replace main bearing Seized heat damaged main bearing Replace main bearing Engine Noise Excessive crankshaft and play Excessive connecting bearing oil clearance Heat damaged connecting rod bearing Damaged connecting rod bushing Mense Wom piston or pistan pin Damaged piston rings Bent connecting rod Malfuncboning hydraulic lash adjuster or hydraulic lash adjuster Excessive hydraulic lash adjuster or hydraulic lash adjuster clearance Broken valve spring Excessive valve quide clearance Malfuncboning or damaged cooling system Malfunchoning damaged fuel system Leaking exhaust system Improper drive belt tension Malfunchening generator bearing Loose timing Damaged timang bell bensiner Malfuncboning water pump bearing insufficient Power Malfunctioning hydraulic lash adjuster or hydraulic lash adjuster Damaged hydraulic lash adjuster quide or hydraulic lash adjuster Compression leakage at valve seat Seized valve stem Weak or broken valve spring Damaged cylinder head gasket Cracked or distorted cylinder head Damaged worn or sticking piston 5 Wom damaged piston Malfuncboning or damaged fuel system Malfunctianing damaged ignition system Damaged or plugged exhaust system 01 9 Replace crankshaft thr
33. Cover Removal on page 10 TSG 416 ENGINE Oil Pan Removal 1 Remove bolts 2 Remove oil pan Gasket Oil Pan 3 Remove all gasket material from pan CAUTION Be careful not to contact surfaces Oil Pan Installation CAUTION The contact surfaces of oil pan gasket and block must be free of oil Do not wait more than 5 minutes to install the oil pan gasket after sealer has been applied 1 Apply WSEM A4 sealer Loctite 5910 to the 4 positions as shown EP 32 10 15mm 2 Install the oil pan and bolts finger tight 02 25 3 Align oil pan with rear portion of engine block Straight Edge 4 Tighten oil pan bolts in 3 steps in the sequence shown e enough for gasket settlement e 5 b ft 7 Nm e 7 10 Nm 4 Front of Engine Tightening Sequence Pick up Tube Deflector Removal 1 Remove oil pan Refer to Oil Pump Removal on page 21 Remove 4 nuts 1 bolt Remove pick up tube Remove oil deflector TSG 416 ENGINE 02 26 Fick up Tube F __ Deflector Pick up Tube Deflector Installation 1 2 3 Install oil deflector Install pick up tube Install 4 nuts and tighten to 14 Ib ft 19 Nm Install bolt and tighten to 7 Ib ft 9 5 Nm Install oil pan Refer to Oil Pump Installation on page 22 TSG 416 ENGINE Crankshaft Main Bearings Removal NOTE To check bearing clearances or to sele
34. 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 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 barsa S b v Ter Lee v j TSG 416 Engine Controls Ignition System Test Diagnostic Modes Spark kill Injector kill v DBW test Off Extemal power Automatic VW 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
35. MAY RESULT IN PERSONAL INJURY CAUTION To prevent damage to the meter do not crank engine or operate accessories that draw more than 104 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 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 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 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 TH
36. 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 Action to Take 1 Check for clogged or restricted air filter Yes This would indicate e Remove air filter clogged air cleaner as e Start the engine 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 TSG 416 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 A
37. Sensor Response Time 300 1500 msec Heater Current Draw 1 A steady state Voltage Output 0 450 mV lean exhaust gas 450 1000 mV rich exhaust gas TSG 416 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 Is used to determine the following e Engine vacuum level for engine control purposes e Barometric pressure 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 Silicon Capacitive Absolute Pressure SCAP sensor with a maximum operating temperature of 100 C The output is a 50 duty cycle wave form whose
38. approximately one half turn counterclockwise and remove 01 39 TSG 416 GENERAL INFORMATION SPECIFICATIONS GENERAL SPECIFICATIONS Epoxy Sealer M3D35 A E Threadiock 262 WSK M2G351 A6 2 2 19554 Super Premium SAE5W20 WSS M2C930 A 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 TSG 416 ENGINE INDEX Subject General Information Special Tools ins TET Positive Ventilation COMPONENT LOCION Engine Repair Valve Cover REIMOV _____ ___ _ Valve Cover InstallatlOpis a ____ __ ious Camshan Stall A OM Su ______ ___ _6_6__ __ Valve Stem Seal Remova p i ott ib ito bet bets antes Valve Stem Sal Installations seite eap eu eed Ree Uo oa eene Eu e Hostal cett eus Intake Manifold Intake Manifold Exhaust Manifold Removal eese eene nennen ne ernannt nenne Exhaust Manifold Installation eese eene nnns Cylinder Head
39. 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 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 a 22 7 kg 50 Ib load Test the lash adjusters as follows Leak down Testing NOTE Do not mix parts from different hydraulic lash adjuste
40. been trained in their use and are adequately supervised DANGERIPOISON Eye protection must be WORN No smoking or naked flames Corrosive acid Flush eyes immediately when contacted with acid Caution important notice NOTE Observe all manufacturers instructions when using charging equipment CAUTION Batteries should not be charged in the vehicle or equipment May damage electrical components 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 Read relevant instructions Keep away from children Do not dispose of as household waste Recycle via recognized disposal system RECYCLE Electrical current may cause injury to personnel TSG 416 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 is correctly operated We consider it to be in your 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 av
41. consecutive seconds may set DTC 222 If any TP DTC is set the GCP will shut down the engine immediately Specifications e Range of Measurement 0 85 angular e Measurement Accuracy 2 of VREF e Resolution 0 5 max TSG 416 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 provide 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
42. 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 Tool s Dial Indicator with Bracketry TOOL 4201 C or Equivalent Special Service Tools called for by the 5 can be obtained Dy calling 1 8 OTUNDA 1 800 768 8632 NOTE Camshaft journals must be within specifications before checking runout 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 DAT VI 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 TSG 416 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 TSG 416 GENERAL INFORMATION Crankshaft Main Bearing Journal Clearance 4 Veri
43. e Starts to open 82 C 180 F e Fully open 97 C 206 6 F TSG 416 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 a 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 B 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
44. engine oil e Torque 30 Nm Engins Coolant i ECT z Caolant Flew Contre Assembly Installation 1 To install reverse the removal procedure 08 41 Heated Oxygen Sensor 25 Replacement 3 ED ae 2 A d S D RR we dc due a HO2S Sensor _ A ci S 4 he V NY PW MN 2 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 303 476 6 Reverse procedure to install e Apply a light coat of anti seize lubricant to the threads of the sensor e Tighten sensor to 40 Nm 30 Ib ft TSG 416 Engine Controls Knock Sensor KS Replacement 1 Disconnect battery ground cable refer to section 6 2 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 a new KS sensor e Tighten bolt to 20 Nm 15 Ib ft 08 42 Temperature Manifold Absolute Pressure TMAP Sensor Replacement 1 Disconnect battery groun
45. 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 3 Ifa diagnostic trouble code DTC is stored follow the designated DTC chart exactly to make an effective repair 4 DTC is stored select the symptom 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
46. 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 SURE THAT THE IGNITION SWITCH IS ALWAYS IN THE OFF POSITION UNLESS OTHERWISE REQUIRED BY THE PROCEDURE SET THE PAR
47. 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 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 TSG 416 FUEL SYSTEM The pinpoint tests below should be performed after the preliminary tests and Emission failure
48. od ste tier ms LEE o eI D ED dE NUI e Ma 09 6 Terminology 09 7 09 1 TSG 416 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 fasteners 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 Grade Marking strength Length inches Thread Pitch thread inch Nominal Diamete
49. 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 All 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 before 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
50. 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 steps 5 through 9 If 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 the engine for three minutes 10 minutes if cold and allow the oil to drain back for at least five minutes with the engine vehicle on a level surface 7 Remove oil level dipstick and wipe clean CAUTION Do not wipe with anything contaminated with silicone compounds 8 Reinstall the oil level dipstick being sure to seat it firmly in the oil level indicator tube Remove the oil level dipstick and draw a mark on the back unmarked surface at the indicated oil level This level should be about the same as the ADD mark on the face of the oil level dipstick 9 Add one quart of oil Restart the engine and allow to idle for 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 TSG 416 GENERAL INFORMATION Record the v
51. 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 converter with the engine e With the engine at idle running indicates the e Check for ice or frost build up on the converter pos omy Coon Suppy 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 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 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 su
52. power required when the equipment load requirements exceed the supply from the charging system 06 3 To 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 terminal of the generator 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 TSG 416 CHARGING SYSTEM Wiring Diagram Revision Level The following wiring schematics are taken from t
53. 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 e Lubricate new o rings with clean engine oil e Tighten fuel rail bolts to 25 Nm 18 Ib ft Bolts Fuel Rail 5 L ed ri we he Te s e f e r O ring Seals 1 04 25 TSG 416 FUEL SYSTEM Actuator Removal 1 Qiu 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 oo Inspect gasket and install a new one if necessary Position actuator onto studs Install nuts e Tighten to 8 ft lb Heconnect electrical connectors Heconnect accelerator cable Reconnect air cleaner components to actuator Install or connect any other component removed or disconnected 04 26 Mixer Removal 1 R
54. 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 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 bee
55. timing mark between 2 NOTE All components must be clean and dried with coppered links on drive chain compressed air or a lint free cloth Lubricate with clean engine oil Coppered Links 12 O clock Position ri 1 Install the if removed chain guide and the tensioner arm from the top of the engine Install bolts finger tight ne Chain Guide i Timing Mark 5 Install camshaft sprocket bolt and hydraulic tensioner finger tight 02 33 TSG 416 ENGINE 6 Tighten guide and tensioner arm bolts to 18 21 8 Tighten hydraulic tensioner to 27 32 lb ft 36 44 Ib ft 24 28 Nm Tensioner Arm Chain Guide Hydraulic Tensioner 7 Using locking tool tighten camshaft sprocket 9 Install valve cover Refer to Valve Cover bolt to 52 59 Ib ft 70 80 Nm Installation on page 10 10 Install oil pump assembly Refer to Oil Pump Installation on page 22 02 34 TSG 416 ENGINE Level Indicator Oil Level Indicator Removal Oil Level Indicator Installation 1 Remove bolt 1 Apply sealer WSK M2G 349 A4 Loctite 648 to lower end of oil level indicator tube 2 Hemove oil level indicator amp tube 2 Install tube immediately into bore Install bolt and tighten to 15 Ib ft 20 Nm 02 35 TSG 416 ENGINE Oil Filter and Adapter Removal NOTE Place oil drain pan under oil filter to catch oil drainage 1 Remove oil filter 2 Remove 3 bolts
56. vic e c o 48 49 53 po A TEN EEE 1 ed E dim uus J A x 2 e Start Command 42 Pin Conn 08 17 TSG 416 Engine Controls Charging System Battery Ring Red Red Red 1 1 r _ __ F3 GCP FO Alt Fuse Panel 10A p 10A L fou m Rad um xa Red Tan 500 resistor Generator Connector Red gs Power Lg Relay 08 18 TSG 416 Engine Controls Engine Controls Sensors 1 of 2 459 NUM AS 8i 8 HANS St 498 A9 St 24981 208005 d VEL anjesedw eo 08 19 TSG 416 Engine Controls Engine Controls Sensors 2 of 2 429 DINSSA d HOSS 093 AS 0 X20Uuy bow lr cd c e cr E c T ES fiz 33333 t Ek OWAODE SL 1 3 HM 9g 81 QN A9881 uuo2 Ze SWUM OF SIAL IN 8 2 81 QH A9881 973998 8 1 1 3 ___ SX v 9 8 Josueg 20805 Qnsseid yoouy 2 28 20105 SZOH 08 20 TSG 416 Engine Controls Fuel Injectors 71 te Siw 10 90 fu fu
57. 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 38 7 UK 39 0 USA Vaporized 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 Operation The dry fuel vapor carburetor is a device by which fuel can be added to passing air flow The amount of fuel added is related to the amount of air passing through the carburetor The variable venturi carburetor controls fuel flow based on a differential pressure across the diaphragm The more air the engine demands the lower the pressure in the throat and hence on the top of the diaphragm When the pressure A SN on the top of the diaphragm is low enough the Mixer Y SAA diaphragm overcomes the spring force holding it ve lt lt down and lifts and allows fuel to be drawn from Assembly Ps NS A 1i the fuel port into the air flow into the engine 4 A 35 yh 04 7 TSG 416 FUEL SYSTEM Cite certis in pressure on each side of the gem cones the spring DIAPHRAGM PART THROTTLE force and lifts the valve NES ns AR INLET 14 psi FUEL INLET 14 1 The greater the airflow into the engine the greater the pressure drop acr
58. 16 ENGINE Special Tools Impact Side Hammer Valve Seal Tool 21 024 or T50T 100 A or Equivalent Equivalent Pound Inch Torque Wrench Purchase from Local Tool Dealer Spring Tester 303 006 or TOOL 6513 DD or Equivalent Valve Clearance Measuring Tool 100 002 or TOOL 6505 E or Equivalent Spring Testing Fixture Extra space 21 024 or Equivalent 02 4 TSG 416 ENGINE Description The 1 6L 4 cylinder Zetec Rocam engine has been developed with the highest technology Its main characteristics are e electronic controlled multipoint sequential injection roller finger follower camshaft intake manifold made of aluminum high resistance aluminum cylinder hea steel oil pan Fuel System The electronic fuel injection EFI system is electronically controlled by an ECM module which carefully controls fuel air mixture along with spark timing depending on information received from various sensors Intake Manifold The intake manifold is made of aluminum It consists of two pieces 02 5 Cylinder Head The Zetec Rocam engine cylinder head is entirely made of aluminum which improves the thermal characteristics and reduces weight The assembly is attached using a multi layer steel gasket and 12 bolts Oil Pan The Zetec Rocam engine oil pan is made of steel The gasket must always be replaced whenever the oil pan is removed Engine Identification Number The engine ide
59. 3 4 S Vacuum Hose Install bolts Tighten to 7 Ib ft 9 Nm Install DIS coil refer to Section 03 2 Remove DIS coil and set aside refer to Section Reconnect any wiring and vacuum hoses 03 removed 3 Remove bolts a CAM Sensor PCV etc 4 Remove valve cover and gasket 02 10 TSG 416 ENGINE Camshaft Removal 5 Remove camshaft lower bearings roller NOTE Store components to ensure assembly in the followers and lash adjusters same order as they were removed 1 Remove valve cover Refer to Valve Cover Removal on page 10 2 Using tool 15 030A to lock camshaft sprocket remove bolt Bearing Caps Roller Follower Camshaft Locking Tool T 15 030A Refer to Section 01 for camshaft and bearing service CAUTION During camshaft removal the camshaft sprocket and chain must remain engaged and the chain tensioned in order to keep timing links aligned If chain is allowed to slacken or disengage with sprocket the oil pump will have to be removed and the timing chain realigned refer to timing chain assembly xxx 3 Separate camshaft sprocket and chain from camshaft while maintaining tension on the chain 4 Remove bolts and camshaft bearing caps evenly in the sequence shown 02 11 TSG 416 ENGINE Camshaft Installation 15 i bol igh 2 NOTE All components must be clean and assembled in p ED pod install bolt and tighten to 5 the same positi
60. 3 Remove adapter and gasket Oil Filter Oil Filter and Adapter Installation 1 Install a new gasket 2 Lubricate oil seal on a new filter and install to adapter Tighten 1 1 2 to 1 3 4 turns after first contact 3 Install filter adapter to block 4 Install 3 bolts and tighten to 15 Ib ft 20 Nm 02 36 TSG 416 ENGINE DISASSEMBLY 3 Loosen the tensioner pulley and remove the drive belt 1 Install engine on an engine stand 2 Drain the engine oil NOTE Record drive belt routing and direction of travel for use during assembly 4 Disconnect wiring at generator 5 Remove the generator 6 Remove the generator support 02 37 TSG 416 ENGINE 7 Remove oil level indicator tube 10 Remove the coolant flow control module 8 Remove the return connector Coolant Flow Oil Level Indicator Control Module Coolant Return Connector bs NOTE Record routing of wiring harnesses and vacuum tubes so they may be returned to their original positions during assembly 9 Remove any vacuum hoses and wiring Wiring Harness Vacuum Hose 02 38 TSG 416 ENGINE 12 Remove the oil filter and support assembly 16 Remove the valve cover assembly PCY Valve om 13 Remove oil pressure switch 14 Remove crankshaft position CKP sensor Sensor 02 39 TSG 416 ENGINE 18 Remove 3 bolts and the water pump pulley E 22 Remove 4 nuts 1 bolt oil pick
61. 4201 A or equivalent Special Service Tools called for by the procedures can be obtained b ry 1 800 ROTUNDA 1 800 768 8632 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 4 ugs I H E Feeler Gauge Straight Edge FPPO4065 TSG 416 GENERAL INFORMATION Cylinder Block Core Plug Cup Type CAUTION Do not contact the flange when installing a cup type cylinder block core plug as this could damage the sealing edge and result in leakage NOTE When installed the flanged edge must be below the chamfered edge of the bore to effectively seal the bore e Use 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 TSG 416 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 3 rt Installation Kit 10720021 or Equivalent cutting oil FFPTOOCM Feeler Gauge D81L 4201 A or Equivalent Special Service T
62. 47 TSG 416 ENGINE ASSEMBLY NOTE All components must be clean and dried with compressed air or a lint free cloth For information on bearings amp piston inspection and selection Refer to Section 01 1 Install upper main bearings and thrust washers to cylinder block Lubricate the wear surfaces with clean engine oil Make sure oil holes align Upper Main Bearings 2 Carefully install the crankshaft onto the upper bearings 3 Assemble the lower main bearings into caps Lubricate the wear surfaces and the bolt threads with clean engine oil 02 48 NOTE The main bearing caps are numbered and must be assembled to corresponding numbers The arrow on the main bearing caps must point to the front of the engine CAUTION Use new main bearing cap bolts 4 Install main bearing caps in the same positions as removed NOTE Check the position of studs as shown 5 Tighten main bearing cap bolts studs in sequence shown and in three steps to 70 Ib ft 95 Nm Front of Engine Mme NOTE Check crankshaft end play as outlined in Section 01 TSG 416 ENGINE 6 Set piston ring gaps as follows e lower oil ring gap aligned with piston pin e center ring gap at 90 from the oil ring gap e top ring gap at 180 from the oil ring gap 7 Lubricate piston bearing wear surface crankshaft journal and cylinder wall with clean engine oil 8 Carefully install pis
63. 800 220 2700 SORORE mE 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 dd 972 623 4300 Grand Prairie TX 75051 6100 S 6th Way WASHINGTON Perk Pacif 877 877 3311 WASHINGTON erkins WA 98642 6100 S eth Way UTAH Perkins Pacifi 877 877 3311 UE Ridgefield WA 98642 Engine Distributors 400 University Court WEST VIRGINIA 1 800 220 2700 6100 S 6th Way WYOMING Perkins Pacif 877 877 3311 LLLA LM Ridgefield WA 98642 Engine Distributors 400 University Court VERMONT 1 800 220 2700 Diesel Power 13619 Industrial Rd WISCONSIN 800 999 5689 Equipment Omaha NE 68137 n Engine Distributors 303 Interstate Dr VIRGINIA 1 800 220 2700 NORTH AMERICA CANADA ALBERTA 5 Edmonton Alberta Canada 780 484 6213 T5L 288 ALBERTA 8750 58th A Edmonton AB Simson Maxwell ea SASKATCHEWAN Canada T6E 6G6 ALBERTA 5711 80 SE Cal AB Simson Maxwell Md 1 800 374 6766 SASKATCHEWAN Canada T2C 4S6 1605 Kebet Way Port C BC BRITISH COLUMBIA Si 1 800 374 6766 12 4131 Mostar Road Simson Maxwell BC Canada V9T 5P8 1846 Quinn Street Pri simson Maxwell ME 1 800 374 6766 George BC Canada V2L 3H4 8550 Delmeade MONTREAL MARINDUST
64. 834 1324 993 1631 1145 161 121 222 166 192 144 Interpreting Compression Readings 1 If compression improves considerably with the addition of oil piston rings are faulty 2 If compression does not improve with oil valves are sticking or seating improperly Iftwo 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 TSG 416 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 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 plug hole the piston is brought up to dead center on the compression stroke and compressed air is admitted Once the combustion chamber is pressurized a special gauge included in the kit will read the percentage of leakage Leakage exceeding 20 percent is excessive While the air pressure is retained in the cylinder listen for the hiss of escaping air A leak at the intake valve will be heard in the t
65. 9972788 arine Spares NSW Australia 2103 EUROPE FRANCE SA 45 Rue Charles Nodier 93310 Le133 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 Y Eastleigh Hampshire SO53 4DG 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 mu s M Via Magellano 1 1 20090 39 02 450 581 39 S 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 Neue Col 52 55 5341 9066 Ind Popotla 11400 Mexico D F NORTH AMERICA UNITED STATES ALABAMA 5400 C W Post Road diio 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 Fresno 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 Jack
66. A 2724 16827 02 31 TSG 416 ENGINE Timing Chain and Sprockets Removal 1 Remove oil pump assembly Refer to Oil Pump Removal on page 21 2 Remove valve cover Refer to Valve Cover Removal on page 10 3 Check to see if coppered links on the timing chain are still visible not identify them as follows e Turn engine until timing mark on camshaft sprocket is at 12 o clock Mark the two chain links left and right of that timing mark e Mark the single chain link that is positioned on the crankshaft sprocket timing mark s c liming Mark Copper Link 02 32 5 Remove the hydraulic tensioner Hydraulic Tensioner Using tool 15 030A to lock camshaft sprocket remove bolt and camshaft sprocket _ Locking Tool 7 15 030 TSG 416 ENGINE 6 Remove timing chain and crankshaft sprocket 2 Install crankshaft sprocket with key at 12 o clock 7 Remove tensioner arm and chain guide if position necessary 3 Assemble drive chain through chain housing cavity from top of engine and onto crankshaft sprocket Align timing mark with coppered link on drive chain Crankshaft Sprocket Timing Chain E E 12 O clock Position Timing Mark Coppered Link Chain Guide Camshaft Sprocket Timing Chain and Sprockets Installation 4 Insert camshaft sprocket into chain and assemble to camshaft Position camshaft key at 12 o clock and align
67. 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 alkaline brine solutions or 100 000 mile red in color antifreeze This may cause serious engine cooling system damage TSG 416 COOLING SYSTEM DIAGNOSIS AND TESTING A WARNING REFER TO CAUTIONS AND 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 e 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 antifr
68. AGE 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 If it is out of specification replace as necessary Camshaft Lobe Surface e Inspect camshaft lobes for pitting or damage in the active area Minor pitting is acceptable outside the active area Active Area V 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 TSG 416 GENERAL INFORMATION Camshaft Lobe Lift Special Tool s Dia Indicator with Bracketry TOOL 4201 C or Equivalent Special Service Tools called for 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
69. ARE NEAR MACHINERY IS ALWAYS NECESSARY AND 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 is 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 swal
70. 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 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 24 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 log
71. D Laptop Requirements USB port 800 x 600 screen Windows 95 or newer operating system No speed minimum 32 MB of RAM TSG 416 Engine Controls Interface Hook Up For a connection to a laptop use the below ECOM cable 5080050 ECOM Cable Fey Software CD 08 27 TSG 416 Engine Controls GCP Software Installation Insert CD into CD ROM drive Double click My Computer Icon Double Click CD ROM drive letter This will display the contents of the CD as shown COM Dover Grated Tha oth USO Verwon of COM Cable fowler h TREAD THE DOCUMENT PESTI Test Dec urnere Double click GCP_Display folder USB to Serial Driver GCP PASSWORD and Instructions Double click the PC Display folder DistFile amp l instmsi Fl instmsiw 5 setup amp setup Double click the GCP_Display icon 08 You will now see a welcome screen Welcome to the FPP Display Installation Wizard V is thet you edi eoo tetas setup posi Gack Corcel h Qai the rogo fen ce yy Phy uiro Ned cor n ue the n d The popa protected br ia and 0 fet a any wd Click next A screen will pop up telling you the name of the destination folder Foster Sabet wuse the abon nd b
72. Deflector Removal on page 26 3 Remove cylinder head assembly Refer to Cylinder Head Removal on page 17 CAUTION Never cut into the ring travel area in excess of 0 8mm 1 32 inch when removing ridges 4 crankshaft until piston to be removed is at Dem Oe MN the bottom of its travel and place a cloth on the Ww piston head to collect the cuttings tal 5 Remove any ridge and or deposits from the upper end of the cylinder bores using a ridge cutter Follow the instructions furnished by the tool manufacturer oe CAUTION Avoid damage to the crankshaft journal or the cylinder wall when removing the piston and rod 7 Push piston assembly out the top of the cylinder with the handle end of a hammer Piston Assembly NOTE Make sure all caps are marked so that they can be installed in their original positions 8 Remove upper bearing from connecting rod NOTE For piston and bearing service refer to Section 01 02 29 TSG 416 ENGINE Piston Installation NOTE Crankshaft journal should be at its lowest point 4 Install connecting rod caps with bearings All components should be clean and dried with lubricate wear surface and tighten bolts in 2 compressed air or a lint free cloth steps e Step 1 9 Ib ft 12 5 Nm 1 Set piston ring gaps as follows e Step 2 22 Ib ft 30 Nm e lower oil ring gap aligned with piston pin e center ring at 90 from the oil
73. E 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 f 12 4 volts or more go to step 4 e fless than 12 4 volts recharge then repeat step Apply a test load equal to 5096 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 temperature If measured voltage does not meet or exceed the value shown in the following table replace the battery es ar e ar oe D p e 6 Clean all cable ends and terminals of the battery with a wire brush terminal connector and the negative lead to ground 3 Turn off all electrical accessories Switch the tester to the voltmeter function 2 Connect the positive lead to the generator A generator voltage 5 Voltage should be between 13 0 15 5 volts 4 With the engine running at 2000 rpm check the 1 WARNING REFER TO CAUTIONS amp WARNINGS AT THE BEGINNING OF THIS SECTION Generator Voltage Test A TSG 416 CHARGING SYSTEM GENERATOR AMPS VS RPM CHART VAT 40 or equivalent load bank to dete
74. F e DIC 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 TSG 416 Engine Controls Power Derate 2 The actuator is limited to a maximum opening of 20 Power Derate 2 is active it will remain active until the active DTC goes away and the ignition input to the GCP usually the ignition Switch is cycled 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 DTC 1171 MegaJector delivery pressure higher than expected e DIC 1172 MegaJector delivery pressure lower than expected e 1173 MegaJector communication lost e DIC 1176 MegaJector internal actuator fault detection e 1177 MegaJector internal circuitry fault detection e DIC 1178 MegaJector internal communication fault detection e DIC 606 COP failure Internal GCP failure e DTC 1612 RTI 1 loss internal GCP failure e DTC 1613 RTI 2 loss internal GCP failure e DIC 1614 RTI 3 loss internal GCP failure e DIC 1615 A D loss internal GCP failure e DTC 1616 Invalid interrupt internal GCP failure e 601 Flash checksum invalid internal GCP f
75. Harness Starter 20 AMP Circuits protected Battery Voltage to EPR pet MN Battery Voltage out of Power Relay 08 13 TSG 416 Engine Controls Wire Colors pea eu Revision Level The following wiring schematics are taken from the wiring diagram labeled below EDI FORD 1 6L W GCP 2010 DEPR Number Rev 2122200 B Date 7 1 2818 Grown By J SUTTON Filename 91299006 sch Sheet 1 ol 1 08 14 TSG 416 Engine Controls Power Distribution SZOH 9 voqiub eC 9 8204290 e 9 joued e s 91 339 994 xn y 29 duing jong NLOY 91 9b Ova 8 Joy 204230099 9109 81 punog 91 jou 1 08 15 Ignition System TSG 416 Engine Controls r F5 Fuse Panel 15 Relayed Power METER Sika 16RD 16RD 16RD 16RD o o 16 16 ignition 7 ignition 2 Coil Cylinder 3 Cylinder LI oe ae 18 YE BK 18 YE RD r lu Xe um ume wd wie cm ame mu mE 4 m il 2A L 08 16 TSG 416 Engine Controls Starting System c 5 Lt Blue Pink DUBS r 420 ____
76. If pedal voltage is 75 1 25 volts and idle validation switch says you re at idle replace the pedal 08 39 TSG 416 Engine Controls REMOVAL AND INSTALLATION Camshaft Position CMP Sensor Replacement CMP Sensor 1 Disconnect battery ground cable refer to section 6 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 e Use anew o ring seal e Lubricate o ring with clean engine oil prior to installation e Tighten bolt to 7 Nm 62 16 ol Crankshaft Position CKP Sensor Removal 1 Disconnect battery ground cable refer to section 6 Remove or disconnect any component to allow access and removal of the CKP Sensor 2 3 Disconnect electrical connector 08 40 4 Remove plug Crankshaft Position CKP Sensor Installation 1 Position sensor and loosely install the bolt 2 Adjust the CKP sensor with the alignment tool and tighten 2 bolts e Tighten to 7 Nm 62 Ib in 3 Connect CKP sensor electrical connector TSG 416 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
77. KING 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 e 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 e DO NOT 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 TSG 416 GENERAL INFORMATION Battery Handling and Charging The handling and correct use of lead acid batteries is not as hazardous provided that sensible precautions are observed and that operatives have
78. NE 15 Install new bolts using the sequence shown in the following 3 steps e Step tighten M11 bolts to 29 5 40 Nm e Step 2 tighten M8 bolts to 11 Ib ft 15 Nm 45 e Step 3 tighten M11 bolts additional 120 Tightening Sequence 16 Install the chain guide and the tensioner arm from the top of the engine Install bolts finger tight M MEE Chain Guide F 02 50 17 Install crankshaft sprocket with key at 12 o clock position 18 Assemble drive chain through chain housing 19 cavity from top of engine and onto crankshaft sprocket Align timing mark with coppered link on drive chain T m O clock Position Timing Coppered Link Insert camshaft sprocket into chain and assemble to camshaft Position camshaft key at 12 o clock and align timing mark between 2 coppered links on drive chain Coppered Links 12 O clock Position i Timing Mark 20 Install camshaft sprocket bolt and hydraulic tensioner finger tight TSG 416 ENGINE 21 Tighten guide and tensioner arm bolts to 18 21 23 Tighten hydraulic tensioner to 27 32 lb ft 36 44 Ib ft 24 28 Nm Tensioner Arm Chain Guide Hydraulic i Tensioner 22 Using locking tool tighten camshaft sprocket bolt to 59 70 80 Nm CAUTION The oil pump pulley and sealer are provided as an assembly kept together by a clip no BF9A 6606 AA Do not remove clip until oil pump is installed If
79. 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 C 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 AN 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 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 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
80. ON SYSTEM 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 the engine and there are no moving parts in the ignition system itself no maintenance is 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 Exhaust Stroke Compression Stroke spark in the exhaust cylinder is wasted referred to as the waste spark but little of the coil energy 15 1051 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 Engine Temperature The Engine Coolant Temp
81. OPEN FLAME OF ANY TYPE 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 INJURY AN 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 TO 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 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 compone
82. 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 De iL SAB Equivaient Special Service Tools called for procedures can be tained by calling 1 OTUNDA 1 800 768 8632 NOTE The crankshaft connecting rod journals must be within specifications to check the connecting rod bearing journal clearances CAUTION The connecting rod bolts are torque to yield and must be discarded and replaced after this diagnostic test 1 Remove the connecting rod bearing cap 2 Position a piece of Plastigage across the 3 bearing surface NOTE Do not turn the crankshaft during this step 01 29 TSG 416 GENERAL INFORMATION Bearing Inspection Roller Follower Inspection Inspect bearings for the following defects Possible e Inspect the roller for flat spots or scoring If any causes are shown damage is found inspect the camshaft lobes e Cratering fatigue failure A and hydraulic lash adjusters for damage Spot polishing improper seating B Scratching dirty C B
83. RIAL Montreal QUEBEC Canada 514 342 2748 HAT 117 NEW BRUNSWICK NOVA DAC Industrial 10 Akerley Blvd Unit 61 902 468 3765 SCOTIA NEWFOUNDLAND Engines Inc Dartmouth NS B3B 1J4 877 468 3765 2320 Bristol Circle Unit 8 NTARI 1 1 O O MARINDUSTRIAL Oakville ON L6H 553 800 866 383 ENGINE DISTRIBUTORS INC 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
84. Replacerelits Spark Plug ROM Spark CUS AVION eeen Specification S 03 1 Wiring Lm Page 03 2 03 3 03 3 03 4 03 5 03 6 03 6 03 6 03 7 TSG 416 IGNITION SYSTEM GENERAL INFORMATION Camshaft Position CMP Sensor tue Spark Plug Description The TSG 416 engine is equipped with an coil pack electronic ignition system The brain of this system is the Electronic Engine Control GCP Module which receives inputs from the following e Crankshaft Position 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 e Ignition Coil pack e Spark Plugs 03 2 Crankshaft Position CKP Sensor T Engine Coolant Temp ECT Sensor AN 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 TSG 416 IGNITI
85. Sensor VAC Sensor Manifold Surface Temperature Manifold Surface Temperature MST ________ ______ Man Vas one Vacum Zane Sich Air Flow Control AFC Air Flow Meter Mass Air Flow Sensor Air Flow Meter Air Flow Sensor AFS Hot Wire Anemometer u Mixture Control M C Mixture Control Solenoid Mixture Control Solenoid MCS 09 11 TSG 416 METRICS 7 NEL _ tal Fuel EFI Digtal Fu Layens iniection EFI Fue ug econ r HEN Park Neutral Position Switch PNP Switch Neutral Drive Switch Nos Neutral Gear Switch REN 7707771777777 0 NN Power Steering Pressure Switch PSP Switch Pressure Switch Ose Pressure Switch PSPS Powertrain Control Module ic Control Ass Electronic Engi Processor Microproces Control Unit MCU Single Module Engine Control SMEC 7 Pulsed Secondary Air Injection Air Injection Reactor Air Injection Valve Thermactor 70 Peasy een OM 09 12 TSG 416 METRICS o Terms en SS EE B AIR Bypass gode m S e Bypass Vaive AIR Bypass Valve Secondary Bypass Valve SABV Secondary Injection Check Valve Secondary Air Check Valve Secondary Ar Contr
86. TSG 416 1 6 LITER ENGINE DISTRIBUTORS INC INDUSTRIAL ENGINE SERVICE MANUAL Powertrain Assemblies amp Components Provided By Ford Component Sales 1 EDI 1020120 Revision O December 2012 EDI 1020120 Revision O December 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 C
87. TTERY 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 TSG 416 CHARGING SYSTEM GENERAL INFORMATION a 0 Description 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 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 e supply extra
88. 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 f 7 7 gt 4 Fuel Injector 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 Falter TSG 416 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 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 A DEPR Direct Electronic Pressure Reg
89. Voltage Throttle Position Electronic Actuator Fuel Pump Voltage Intake Air Temperature Camshaft Position TSG 416 Engine Controls GCP Outputs systems controlled e Fuel control Injectors DEPHR e Electronic Throttle Control e Electric Fuel Pump gasoline e Diagnostics Malfunction Indicator Lamp check engine lamp e Diagnostics Data Link Connector DLC e Variable 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 si
90. ailable 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 function to identify the part number ENGINE smi INC Model No TSG 416 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
91. ailure e 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 is 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 lower 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 e 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
92. all any wiring and vacuum hoses that were removed Connect and route as they were removed ea 02 16 TSG 416 ENGINE Cylinder Head Removal 1 Drain engine oil refer to Operator Handbook 2 Drain engine coolant refer to Section 05 3 Remove any necessary wiring and vacuum hoses Mark connections and routing as necessary to assure they are returned as they were removed Remove valve cover Refer to Valve Cover Removal on page 10 Remove spark plugs and wires Remove the coolant flow control module refer to Section 05 Coolant Flow Control Module Remove bolts and nuts holding intake manifold to cylinder head Move aside Remove nuts at exhaust manifold Move aside Remove oil level indicator tube bolt at cylinder head 10 Remove timing chain hydraulic tensioner Hydraulic Tensioner 02 17 11 Rotate camshaft sprocket using tool 15 030A until the 2 copper links on timing chain are at 12 o clock Copper Links Timing Mark 12 Using tool 15 0304 to lock camshaft sprocket remove bolt CAUTION During cylinder head removal the timing chain must be held up with a wire with constant tension in order to keep timing links aligned at crankshaft If chain is allowed to slacken or disengage with sprocket the oil pump will have to be removed and the timing chain realigned refer to timing chain assembly xxx 13 Remove camshaft sprocket from chain while maintaining tension
93. 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 TSG 416 engine The TSG 416 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 Operator s Handbook or contact your nearest EDI distributor listed in the back of this manual TSG 416 GENERAL INFORMATION DIAGNOSIS AND TESTING Special Tools Commercially Available Compression Tester Leakdown Tester 014 00707 Equivalent FPP 1002s Cup Shaped Adapter Dial Indicator with TOOL 6565 AB or Equivalent TOOL 4201 C o
94. amps are tightly fastened to the battery posts If 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 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
95. ase 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 TSG 416 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 Dial indicator with Bracketry TOOL 4201 C or Equivalent Valve Stem Clearance Too TOOL 6505 E or Equivalent Special Service Tools called for 1 800 768 8632 NOTE Valve stem diameter must be within specifications before checking valve stem to valve guide clearance NOTE If necessary use a magnetic base 1 Install the Valve Stem Clearance Tool on 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 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
96. ast 10 megohms e Donot employ any non standard practices such as charging the battery with an arc welder e Take 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 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 there
97. ated it must be recycled or disposed of correctly AN WARNING DO NOT STAND INLINE WITH OR NEAR THE ENGINE COOLING FAN BLADE WHEN REVVING THE ENGINE FAILURE TO 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 TSG 416 COOLING SYSTEM GENERAL INFORMATION __ Upper Hose Radiator 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 Th
98. be installed Small scatted deposits of rubber material Known as piling are not a concern Small zu e Longer deposits building up to 50 of the rib height is also not a concern except it can result in excessive noise Medium Piling f 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 TSG 416 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 Leaka
99. ck 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 Oil Filter Restriction 08 38 TSG 416 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 123 will flash 3 times to indicate the beginning of the flash code display sequence Any active DTC s will flash 3 times each 123 will flash 3 times indicating the end of the code display sequence If code 123 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
100. 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 Top of Piston Ring Lands Pin Bosses 2 Usethe Piston Ring Groove Cleaner to clean the piston ring grooves 01 25 e 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 TSG 416 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 worn 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
101. comes 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 e if the fault still exists e alist of essential engine data from the time of the fault It can also display 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 e over speed e over temperature e over voltage 08 3 e low oil pressure e unauthorized tampering e over cranking starter motor The GCP controls the following e Fuel metering system e Ignition timing e On board diagnostics for engine functions The GCP constantly observes the i
102. ct new bearings refer to Section 01 1 Remove oil pan Refer to Oil Pan Removal on page 25 2 Remove pick up tube amp deflector Refer to Pick up Tube Deflector Removal on page 26 NOTE Replace one bearing at a time leaving the other bearings securely fastened Note location of studs for deflector installation Remove first main bearing cap bolts Remove cap and lower bearing Press on end of upper bearing without tang to start it out 6 Rotate bearing out from between crankshaft and cylinder block a Stud amp Nut Crankshaft Main Bearings Installation NOTE All components must be clean and dried with compressed air or a lint free cloth Lubricate bearing to crankshaft contact surfaces with clean engine oil 1 Place upper bearing on crankshaft and rotate into place Oil holes must align 2 Place lower bearing into cap NOTE Main bearing cap arrow must point to the front of the engine Install bearing cap CAUTION Use new main bearing cap bolts 4 Lightly oil new main bearing bolts or studs and install in same positions as removed Alternately tighten in steps to 70 Ib ft 95 Nm 5 Check crankshaft end play as outlined in Section 01 6 Install pick up tube and deflector Refer to Pick up Tube Deflector Installation on page 26 7 Install oil pan Refer to Oil Pan Installation on page 25 02 27 TSG 416 ENGINE Connecting Rod Bearings
103. ction 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 volt 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 TSG 416 FUEL SYSTEM The
104. d 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 Assembly 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 TSG 416 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 tan
105. d cable refer to section 6 2 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 Usea new o ring seal b Tighten bolt to 3 Nm 2 2 lb ft TSG 416 Engine Controls Actuator Throttle Position TP Sensor Replacement Removal NOTE Removal steps in this procedure may contain installation details 1 Disconnect battery ground cable refer to section 6 08 43 2 Disconnect the connector from the throttle 3 Remove the bolts from the throttle to the intake manifold 4 NOTE The gasket is to be reused unless damaged Installation 1 To install reverse the removal procedure e Torque bolts to 10 Nm 2 The gasket between the throttle and intake manifold is to be reused unless damaged TSG 416 METRICS INDEX Subject Page OCLC TION es 09 2 Nomenclature for 09 2 Bolt Strength Identification i 09 3 Hex Nut Strength Identification e e I GI IR eset esd hie eee 09 3 Other Types of diuisa er isi L ic MEME ML ED SIE 09 4 English Metric conversion cccccecceceeceeceeceeceecenceacencuneeueeueacenuesueaueaueaceaseaneaseuseaseass 09 5 Decimal and Metric EQuivalents ssssssscsscescscccscesssssssscssesssscesseeceeceecescesscecsesesseccsecescescescescees 09 6 WOR que CONV Cl
106. d install the quick connect coupling onto the fitting i A C d 4 Position the locking tab into the latched position P gt lt 4 4 ub 5 Pull on the fitting to make sure it is fully engaged 04 24 TSG 416 FUEL SYSTEM REMOVAL AND INSTALLATION Fuel Rail amp Injectors Replacement AG WARNING DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME 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 Retainer Clips Electrical Connector Fuel Injectors 4 e gt hs ine gt lt i h wo ed AIL 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
107. e abet Click next You will now see a screen telling you it is ready to install the software Click next 28 TSG 416 Engine Controls You will see an Installation Success screen Follow those install instructions Once when the software 15 finished installing successfully installed reboot your system i FPP Setup 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 Section Cock the testonto exit the 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 M Installer 1 MES Type in the Password which can found in the text file on the CD in the GCP Display folder Click No Go back to the main CD folder me D d EAD THE DOCUMEN PRSTI d CP Connecting 1 hon6ng OCP Morus GCP Place the ignition key 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 Driver Setup V31 015 Double click the Driver Setup ic
108. e thermostat prevents coolant flow until it reaches a specified temperature At this temperature it will open and allow coolant flow through the engine 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 Caclant Pump m 1 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
109. eeze coming out the coolant pump weep hole may be considered normal Examine oil dipstick for evidence of coolant contaminated engine oil white milky appearance 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 e iridescent sheen on top of the coolant could indicate a trace of oil is entering the system e Amilky 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 If 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 co
110. ehicle 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 rate is unacceptable proceed to next step 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 ri
111. emove top four bolts that hold the mixer to the mixer adapter 2 Remove the Mixer adapter unscrew the four bolts This will also unmount the actuator X RY 3 The DEPR can also be disconnected from the mixer via the four mounting bolts TSG 416 FUEL SYSTEM Mixer Installation 4 Mount DEPR to the mixer if 1 Reverse the removal procedure Ensure uninstalled Ensure the rubber gasket to install the two gaskets on the actuator on the DEPR is not damaged before installing the mixer adapter e Tighten to 35 Ib in 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 A Specifications GENERAL SPECIFICATIONS 414 448kPA 60 65psi 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 e Tighten to 6 6 lb ft 04 27 TSG 416 COOLING SYSTEM INDEX Subject General Information e Seiad arenes Diagnosis and Testing MIS Coolant RAN GSC Me Cis A _ Drive Belt Inspection Symptom Chart Cooling System Test
112. erator Reverse procedure to install e Tighten generator bolts to 25 Nm 18 Ib ft e Tighten B terminal to 8 Nm 71 lb in 06 11 TSG 416 CHARGING SYSTEM Generator Pulley Replacement 1 Remove generator assembly Refer to Generator Replacement of this section 2 Remove nut y lt 3 Sa j Pulley 3 Remove pulley 4 Reverse procedure to install e Tighten nut to 109 Nm 80 lb ft 06 12 TSG 416 CHARGING SYSTEM Battery Removal A 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 A 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 OR EYES FLUSH IMMEDIATELY WITH WATER FOR A 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
113. erature ECT Sensor sends engine temperature information to the It is located in the rear coolant outlet pipe 03 3 Fuel Octane Level Adjustment In the event that the engine is operated on dry fuels such as natural gas compressed natural gas CNG or liquefied petroleum gas LGP timing can be modified by GCP Fuel Type Ignition Coil Driver The GCP switches 2 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 is increased rapidly by fast opening of the throttle plate TSG 416 IGNITION SYSTEM Wiring Diagram 8L vt 1109 92102 Vi N02 weds weds yed 5 1N90 8 ATIA 81 I T 1 5 apuko HOD 1021 J von vomubi 95 91 91 qu 9i 099 099 E lued osny 03 4 TSG 416 IGNITION SYSTEM DIAGNOSIS AND TESTING Spark Plug Inspection Inspect the spark plug tip as in the chart below GAP BRIDGED FOULED IDENTIFIED BY WET BLACK DEPOSITS ON THE INSULATOR
114. ethanol 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 frame 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 TSG 416 FUEL SYSTEM Wiring Diagrams Revision Level The following wiring schematics are taken from the wiring diagram listed below Title EDI FORD 1 6L W GCP 2010 DEPR Sige Number D 2122200 B Date 7 1 2818 Drawn J SUTTON Filename 21222865 Sheet 1 ol 1 Fuel Injectors 16 RD 16 RD a 16 TN Injector 1LS 9 2 i ee 5 A 2 4 Actuat 2 Or Data Link 04 5 TSG 416 FUEL SYSTEM Connector DLC SS 4 95 99 7 gr ones s 8 wo sed sun OF AL OVOO ist 8i sed suam 0 1a 8 c dc fz GU ADE 8 we Od Od WY 210 ss 40398000 HM A9 81 04 6 TSG 416 FUEL SYSTEM GENERAL INFORMATION Liquid Propane Line Vapor Propane Content Trami Vapor Rex DRY FUEL Description This engine
115. excessive main bearing clearance excessive connecting rod bearing clearance TSG 416 GENERAL INFORMATION Valve Train Analysis Static With engine off and valve cover removed check for damaged or severely worn parts and correct assembly Make sure correct parts are used with the static engine analysis as follows Rocker Arm e Check for loose mounting bolts studs and nuts e Check for plugged oil feed 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 broken 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 s
116. eys 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 TSG 416 Engine Controls Visual Inspection Perform a careful visual and physical engine inspection before 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 e 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 e Inspect engine fluids for correct levels and evidence of leaks e Inspect vacuum hoses for damage leaks cracks kinks and improper routing inspect intake manifold sealing surface for a possible vacuum leak e Inspect PCV valve for proper installation and operation e 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 e Inspect GCP sensors and actuators for physical damage e Inspect GCP grounds for cleanliness tightness and proper location e Inspect fuel system for adequate fuel level and fuel quality c
117. fore 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 soldered components on the GCP board e Do not 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 e If the 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 TSG 416 Engine Controls Diagrams and Schematics Symbols doo JORON A ece6 eouengu eps no 29 90 Um Od ocu 0765920 Um Od 206 5 By amp pee iueuoduco e iueuoduco peupe ae SEULS UM 5 puno 6 wewonbe p yed mow ze eseo jueuoduo 0413 3 LI GLUO UOSDOUUCO Cup 23027 penanso 08 12 r TSG 416 Engine Controls GCP Power Distribution Box Part of 5210070 Engine Wiring
118. frequency 15 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 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 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 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 the TP sensor 5 volt reference or signal circuits for greater than 2 consecutive seconds will seta DTC 123 or DTC 223 A hard failure with the TP sensor ground circuit for more than two
119. fy correct fluid level after engine cools for 20 minutes Top off the degas bottle to max line TSG 416 COOLING SYSTEM Fan REMOVAL AND INSTALLATION NOTE If a major component of the cooling system is renewed such as the radiator water pump etc the system should be flushed and re filled with a 5096 solution of Motorcraft Premium Gold engine coolant or equivalent and clean water Refer to Flushing the Cooling System on the previous page Fan Belt Removal 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 Loosen the tensioner 2 Remove belt 3 Inspect belt and pulleys Refer to Visual Inspection of this section Drive Belt Installation 1 Route belt correctly and tighten the tensioner onto belt 2 Run engine for a minute and then turn off 3 Recheck belt routing and groove alignment FPPO1534 Fan Belt Installation 1 Place belt around the outer crank pulley 4 groove and fan pulley 2 Slide bearing bracket up to tension the belt while ensuring the bearing bracket is level 3 Tighten bearing bracket bolts 16Nm 12 lb ft Belt Tensioner Replacement 1 Remove drive belt Refer to Drive Belt Removal above 2 Remove bolt 3 Remove belt tensioner 4 Reverse procedure to install e lighten bolt to 47 Nm 85 Ib ft
120. fy the crankshaft journal clearance If itis out of specification replace as necessary Special Tool s Piast or Equivalent Special Service Tools called for by the procedures can be Ined by calling 200 ROTUNDA 1 800 768 8532 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 Laya piece 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 edge worn journal tapered or bearing not seated F NOTE Do not turn the crankshaft while doing this procedure FP 3 Install and remove the crankshaft main bearing cap 01 23 TSG 416 GENERAL INFORMATION Crankshaft End Play Special Tool s Dia Indicator with Bracketry TOOL 4201 C Equivalent Special Service Tools called for by the procedures can be obtained by calling 200 ROTUN A 1 800 768 8632 1 Measure the crankshaft end play Use the Dial Indicator with Bracketry to measure crankshaft end play 2 Position the crankshaft to the rear of the cylinder block 3 Zero the Dial Indicator with Bracketry 4 Move the crankshaf
121. g 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 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 TSG 416 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 wi
122. g adjustments e Increased available ignition coil saturation time T Spark 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 gt FEY GEKA N A b T gt J IN N on a E oL gt ul 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 TSG 416 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 is first started the system is in open loop operation In open loop the GCP ignores the signal from the Heated Oxygen Sensor HO2S 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 e The ECT has reached 75 F 24 50 seconds has elapsed since starting the engine After these conditions are met the en
123. ge 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 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 componenis 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 TSG 416 COOLING SYSTEM Cooling System Pressure Test Pressure Tester 4 1 iiy jns d m T f A WARNING REFER TO CAUTIONS AND WARNINGS AT THE BEGINNING OF THIS SECTION 1 Remove the radiator cap from the radiat
124. gine is at normal operating temperature Turn the ignition switch to the OFF position then remove all the spark plugs 2 Set the throttle plates in the wide open position 3 Install a Compression Tester such as Rotunda Compression Tester 059 R0009 or equivalent in the No 1 cylinder 4 Install an auxiliary starter switch in the starting circuit With the ignition switch in the OFF position and using the auxiliary starter switch crank the engine a minimum of five compression strokes and record the highest reading Note the approximate number of compression strokes required to obtain the highest reading 5 Repeat the test on each cylinder cranking the engine approximately the same number of compression strokes Test Results The indicated compression pressures are considered within specification if the lowest reading cylinder is within 75 percent of the highest reading Refer to the Compression Pressure Limit Chart If one or more cylinders reads low squirt approximately one tablespoon of clean engine oil meeting Ford specification ESE M2C153 E on top of the pistons in the low reading cylinders Repeat the compression pressure check on these cylinders Example Readings 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 reading was 1069 kPa 155 psi the engine is within specification and the compression is considered
125. gine 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 HO2S 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 on 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 associated with engine operation When servicing the GCP observe the following guidelines Do not overload any circuit 08 11 e When testing for opens and shorts do not 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 le
126. gnal 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 342 CAM loss is present the engine can be restarted It will run in the previously established injection sequence TSG 416 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 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 Vol
127. gnition 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 idling When vacuum leaks are indicated search out and correct the cause Excess air leaking into the system will upset the fuel mixture and cause concerns such as rough idle missing on acceleration or burned valves If the leak exists in an accessory unit such as the power brake booster the unit will not function correctly Always fix vacuum leaks TSG 416 GENERAL INFORMATION Excessive Engine Oil Consumption The amount of oil an engine uses will vary with the way the equipment is driven in addition to normal engine to engine variation This is especially true during the first
128. he wiring diagram labeled below Title EDI FORD 1 6L W GCP 2010 DEPR Size Humber D 2122200 Dote 7 1 2818 Filename 2122268b sch Sheet 1 of 1 Charging System B Ring Red Red Red r esce Fuse Panel 10 10 sonia Red Tan 500 resistor Gene rator Connector Red Red 06 4 TSG 416 CHARGING SYSTEM DIAGNOSIS AND TESTING AN WARNING REFER TO CAUTIONS amp WARNINGS AT THE BEGINNING OF THIS SECTION NOTE When the battery is disconnected and connected some abnormal symptoms may occur while 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 e 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 wil
129. hment 3 Screws Battery cable nuts Generator pulley nut Generator wiring nuts 06 14 TSG 416 Engine Controls INDEX Subject Page General Information 08 2 GOP AVG tian 08 2 Fuel System COMPONENTS 08 8 Coil on plug ignition sage ES 10 Open Loop and Closed 1667 Operation rr RR 08 11 6 GCP Service PrecautlOIn5 Meme Use of Circuit Testing TOO 08 11 Electrostatic Discharge Dama e etd Diagrams and UB T2 Engine COMP OREN locator VIeW 08 24 Diagnosis and Testing DIAS DO __ _____ GCP diagnostic overview On board diagnostics GCP Engine control module GCP time Horie Mode Intermittent MIL Malfunction indicator light MIL DTC Diagnosis and using a personal 08 25 08 25 08 25 08 25 08 26 08 27 08 27 08 36 Iritermittent proble S statute cst ____ _ 08 36 Symptom charts TC BE Engine Control Module GCP Diagnostic Trouble Codes np TR 08 40 Removal and Installation Cam
130. hrottle 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 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
131. iables 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 TSG 416 Engine Controls Flight Data Recorder The Flight Data Recorder is also a listing 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 followin
132. ical 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 Diagnostic 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 e 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
133. 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 Go to Step 2 2 Check DEPR operation Possible wiring issue 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 Checkthe vapor regulator operation Regulator is e Engine OFF malfunctioning replace e 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 fuelock activation Key Off circuit is open shorted to ground or the GCP module is Disconnect fuellock connector from harness faulty Check
134. icians and reduce oil pressure etc equipment downtime Starter lockout Auto crank 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 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 Each module can also be set up to run on a variety of electronic governing 08 2 TSG 416 Engine Controls 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 be an electronic replacement for a throttle cable with maximum speed governing throttle bywire e Oritcan 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 be
135. icient 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 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 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 TSG 416 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
136. ifies the fuel 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 Assembly If no other problems have been identified replace the fuel management assembly with a known good part of the same pressure range Retest TSG 416 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 ______________ Result 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 1 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 e Install a pressure
137. ing Ford specification M3D35 A E 1 Clean the surface to be repaired to a bright oil free metal surface 2 Chamfer or undercut the repair area to a greater depth than the rest of the cleaned surface Solid metal must surround the area to be repaired 3 Apply the epoxy sealer and heat cure with a 250 watt lamp placed 254 mm 10 inches from the repaired surface or air dry for 10 12 hours at a temperature above 10 C 50 F 4 Sand or grind the repaired area to blend with the general contour of the surface 5 Paint the surface to match the rest of the cylinder block Cylinder Block Core Plug Replacement Special Tool s Impact Slide Hammer T50T 100 A Special Service Tools called for by the procedures can be ned by calling 1 800 ROTUNDA 1 800 768 8632 1 Usea slide hammer or 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 cylinder block core plug and bore lightly with Threadlock amp 262 E2FZ 19554 B equivalent meeting Ford specification WSK M2G351 A6 and install the cylinder block core plug Cylinder Head Distortion Special Tool s Straightedge 303 0039 0831
138. into closed loop control using information from the pre and post oxygen sensors to allow further adjustment to meet emissions regulations TSG 416 FUEL SYSTEM Wiring Diagrams Revision Level The following wiring schematics are taken from the wiring diagram labeled below EDI FORD 1 6L W GCP 2010 DEPR oie Humber D 21222808 Cote 7 1 2818 Drown By J SUTTON Filenames 21222596095 Engine Controls Dry Fuel DEPR adii poo FS NEC 10A 10A 14 RD TAN 16 RD LB 12 BK WH CAN View 18 BDG VT 18 OG LG Twist 10 tums per foot min Grounding Ring 18 OG LG Twist 10 tums per foot min 18 DG VT 14 15 CAN1 TSG 416 FUEL SYSTEM DIAGNOSIS AND TESTING LPG Symptom Chart 04 10 TSG 416 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 e Check for leaks or damaged supply lines from the fuel tank to the fuel lock off valve No
139. ira Coaslant Plow Cema Madule ZFCM amp asamblg 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 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 e Tighten bolts to 10 Nm 89 16 05 13 TSG 416 COOLING SYSTEM Coolant Bypass Replacement 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 bypass hose 3 Disconnect the coolant bypass hose from the tubes 4 Reverse procedure to install Degas Return Hose Upp r Radiator Hose Water In Lower Radiator Hose SPECIFICATIONS 05 14 TSG 416 COOLING SYSTEM 02881 50 50 Pressure Relief 89 124 kPa 13 18 psi Opening Pressure kPa psi 138 kPa 20 psi temperature temperature Coolant Specification Motorcraft Premium Gold WSS M97B51 A1 Engine Coolant TORQUE SPECIFICATIONS Coolant 25 18 pump pulley bolts Coolant 10 a block bolts Draincock 2 Thermostat 10 housing bolts 05 15 TSG 416 CHARGING SYSTEM INDEX Subjec
140. k 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 A WARNING REFER TO WARNINGS AT THE BEGINNING OF THIS SECTION 1 Connect to the GCP display 2 Putthe key in the on position the 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 e Fuel pressure should be as follows o Key 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
141. l 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 e fa 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 e Excessive battery drain due to lamps left on damaged or misadjusted switch accessories left on etc 06 5 Warning Indicator Check Check the operation of the charging system warning indicator as follows e Ignition OFF Indicator should be OFF e Ignition ON Engine OFF Indicator should be ON e 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 TSG 416 CHARGING SYSTEM Key off battery drain Open voltage drop in B circuit Open voltage drop in A circuit Open high resistance in circuit Voltage regulator
142. l 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 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 36 TSG 416 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 e Bad Sensor e Restriction e Coil Failure Fuel Mixer Binding Dry Fuel e Ground Loss e Misrouted Spark Plug Wires e Fuel System Failure Vacuum Leak e Wiring Failure Low Fuel Pressure e e e e e e e e e e e e opark Plugs Fo
143. l intake manifold and gasket Tighten bolts 55 Apply sealer WSK M2G 349 A4 Loctite 648 to and nuts to 6 Ib ft 8 lower end of oil level indicator tube Install Intake Manifold immediately and tighten bolt to 15 20 Nm Assembly He ty E Levelindicmice Ud 8 4 E rs i gt 7 th QUI DM De Es EL i P 1 i z s iH AM S ua F T D a a ra E 4 ra E y qu n 54 Install coolant flow control module and gasket Tighten bolts to 7 10 56 Apply sealer WSK M2G 349 7 Loctite 243 to Coolant Flow Control Module threads of coolant return connector Install and tighten to 15 Ib ft 20 Nm 02 56 57 Install generator support Generator Support Electrical Connector TSG 416 ENGINE 59 Pry tensioner pulley as shown and install drive belt 60 Install engine wiring and vacuum hoses Wiring Harness EA Vacuum Hose 61 Fill engine with clean engine oil of the correct type and quantity NOTE Ford Power Products industrial engines are designed to perform with engine oils that are licensed by the American Petroleum Institute API and oils carrying the most current API classification should be used NOTE Drive belt must be installed in the same direction of rotation as when
144. 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 negative 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 7 RECYCLE TSG 416 CHARGING SYSTEM SPECIFICATIONS GENERAL SPECIFICATIONS 2 72 1 drive ratio CCA Battery charging voltage 13 15 5 volts TORQUE SPECIFICATIONS Description Lb ft Lb in Generator bolts Regulator attac
145. ll 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 feature 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 GCP Dis folder or the data can be viewed in Notepad or Excel 08 32 Below is a sample of a plot coc m UU 9 ette oem _ m TETTEST rry lt 4 ae ome 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
146. lowing gasoline petrol oil diesel fuel 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 TSG 416 GENERAL INFORMATION INDEX Subject General Information Page Oral dil ee RO 01 3 Safety Notice atts pue MEM MM A 01 3 Notes cautions and
147. m 7 Tighten remaining oil pump housing bolts to 15 Ib ft 20 Nm Remaining Bolts TSG 416 ENGINE Crankshaft Rear Oil Seal Removal Crankshaft Rear Oil Seal Installation 1 Install new rear seal and retainer using tool 21 1 Remove flywheel 046 Special Tool 2 Remove oil pan 3 Remove bolts and rear oil seal retainer Rear Seal Retainer Rear Oil Seal and Retainer m Install oil pan p Install flywheel 02 23 TSG 416 ENGINE Camshaft Follower Hydraulic Lash Adjuster Removal 1 2 Remove valve cover Refer to Valve Cover Removal on page 10 Rotate the camshaft so the roller follower for the valve to be serviced is on the heel of the cam Using a suitable valve spring compressor tool compress and hold down the valve spring Slide out the roller follower over the lash adjuster Special Tool 21 024 4 Lift out the hydraulic lash adjuster 02 24 Camshaft Follower Hydraulic Lash Adjuster Installation NOTE All components must be kept clean and lubricated with clean engine oil Roller Follower 1 Rotate the camshaft so the roller follower for the valve to be serviced is on the heel of the cam 2 Install the hydraulic lash adjuster 3 Using a suitable valve spring compressor tool compress and hold down the valve spring Slide in the roller follower over the lash adjuster 4 Install valve cover Refer to Valve
148. move the M11 cylinder head bolts in 3 phases in the sequence shown 32 Remove 2 M8 bolts cylinder head and gasket Cylinder Head 02 42 33 Remove crankshaft rear seal retainer Oil Seal Retainer NOTE Mark piston and cap so they may be returned to their original positions 34 Remove 2 bolts lower connecting rod bearing and cap Push piston assembly out of the engine block Repeat for other three cylinders Lower au Bearing TSG 416 ENGINE NOTE Keep caps and bearings in order so they may be returned to their original positions 36 Carefully remove the crankshaft and install it vertically on the flywheel to avoid warp running 35 Remove bolts caps and crankshaft lower main out bearings in the sequence shown _ Crankshaft 37 Remove the 5 upper main bearings and the 2 thrust washers Upper Main Bearings Front of Engine 02 43 TSG 416 ENGINE SUBASSEMBLIES Clean crankcase and all subassemblies of foreign 3 Check the engine block for warpage cracks or material Scrape or wire brush RTV sealant from mating any other damage surfaces Surfaces must be kept oil free for good adhesion of fresh RTV seal during reassembly NOTE For cleaning and service information on crankcase cylinder head camshaft crankshaft and bearings Refer to Section 01 Discard gaskets and O Rings and replace with new ones unless otherwise instructed Cylinder Block 1 Remove the core
149. mp housing 01 34 TSG 416 GENERAL INFORMATION Cylinder Bore Honing Special Tool s Engine Cylinder Hone Set Special Service Tools called for by the procedures can be med by calling 1 800 ROTUNDA 1 800 768 8632 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 e Hone with the Engine Cylinder Hone Set ata 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 a clean lint free cloth and lubricate the cylinder bores e Use Engine Oil XO 10W30 QSP or DSP or equivalent meeting Ford specification ESEM2C153 E 01 35 TSG 416 GENERAL INFORMATION Cylinder Block Repair Cast Porosity Defects CAUTION Do not attempt to repair cracks areas where temperature will exceed 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 meet
150. n 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 e Perform a two hour charge using 20A constant current manual setting on charger e Perform a two hour charge using a constant potential automatic setting on charger TSG 416 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 Sa DY Ri A Screws 3 Reverse procedure to install e Insert a wire into the insertion hole to hold the brushes during assembly Remove wire when done e Tighten screws to Nm 27 lb in Water Pump 108 mm diameter Crankshaft 132 mim diameter Tensioner Generator mm 54 diameter diameter 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 gen
151. nder 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 They 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 04 4 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 e Gasoline petrol This engine is designed to operate on unleaded 87 or 89 octane gasolines e 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 e Gasohol Methanol A mixture of gasoline and alcohol wood alcohol etc containing up to 5 m
152. nformation 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 supplies 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 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 HO2S GCP Inputs operating conditions read e Engine Coolant Temperature Crankshaft Position Exhaust Oxygen Content Manifold Absolute Pressure Battery
153. ng 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 TSG 416 GENERAL INFORMATION NOTE Lash adjusters cannot be checked with engine oil in them Use only testing fluid New hydraulic lash adjusters are already filled with testing fluid Hydraulic Valve Lash Adjuster Hydraulic lash adjuster noise can be caused by any of the following e excessively collapsed 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 e 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
154. ngs 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 e 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 e Check for excessive bearing clearance Repair as required 20 Perform the oil consumption test to confirm the oil consumption concern has been resolved 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 the 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
155. nt 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 e Mark and separate the parts and clean with solvent Clean the oil passages TSG 416 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 e 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 e 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 specifications 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 TSG 416 GENERAL INFORMATION Connecting Rod
156. ntification number is marked on the right side of the cylinder block as shown TSG 416 ENGINE Component Location Positive Crankcase Ventilation PCV Camshaft Position Oil Level Indicator CMP Sensor Cylinder Head Assembly Tensioner Arm Coolant Flow Control Module Oil Pressure Switch A US Mi t E Cylinder Block C rankshaft Position CKP Sensor Water Pump Chain Guide Piston Assembly 02 6 TSG 416 ENGINE Component Location PCV Hose Intake Manifold Exhaust Manifold 02 7 TSG 416 ENGINE Component Location Oil Pick up tube Oil Deflector Main Bearings Lower Main Bearing _ Rear Seal Retainer Crankshaft Sprocket Cylinder Block TSG 416 ENGINE Component Location Spark Plug Wires DIS Ignition Coil PCV Valve Valve Cover 2 PCV Hose 77 Camshaft _ Roller Follower Lash Adjuster Cylinder Head Gasket N Valve Assembly Timing Chain Hydraulic Tensioner TSG 416 ENGINE ENGINE REPAIR Valve Cover Installation 1 Contact surfaces must be clean and free of oil 2 Install anew gasket and valve cover Valve Cover Removal 1 Remove any necessary wiring and vacuum hoses Mark connections and routing as m m necessary to assure they returned as they S Sensor were removed M lt ___ Valve Wiring Harness Valve Cover
157. nts 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 before 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 TSG 416 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 Injectors Camshaft Position CMP Sensor
158. ol Valve AIR Control Valve Air Control Valve SUE SC Cheek Vaive Secondary Injection D verter Kem Sry Sg Ve A Sequential Multiport Fuel Injection Fuel injection F1 Sequential Electronic Fuel SEFI ne Mantenance S ___ fom emm 0 Throttle Body Fuel Injection Monotronic Single Point injection SP hte Postion TP rr Postion Poston Swish TES Torque Converter Clutch Converter Clutch Control CCC Converter Clutch Override CCO Viscous Converter Clutch VCC 09 13 TSG 416 METRICS wem Selection Lever Postion gt Transmission Range Selection TRS Range Sers Marval Lever Poston Sansor MLP Transmission Range Switch nea Switch MRPS Transmission Position Switch Transmission Range Selection Switch TRSS 70 Bd rtd crc AFC w War Tee wr Wide Open Throttle Switch Wide Open Throttle Switch WOTS 09 14 EDI Ford Industrial Engine Distributor List AUSTRALIA 10 Wilmette Place Mona Vale All Mari 61 2 9
159. olant freezing point and concentration level The antifreeze concentration in a cooling system can be determined by using a suitable hydrometer or a battery antifreeze tester The freezing point should be in the range 45 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 TSG 416 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 a rib over a distance of 100 mm 4 0 in can be considered acceptable uo x 2 Le 1 A ST 100 mm If cracks are beyond acceptable or any chunks are found to be missing from the ribs a new belt must
160. on 08 29 TSG 416 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 screen 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 e If the 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 DIC 315 heca 3 ja krg order ceat nap oen or ede to pound Snap Shot Data The Snap Shot Data is a listing of specific engine system variables These var
161. on the chain using a wire 14 Remove the M11 cylinder head bolts in 3 phases in the sequence shown TSG 416 ENGINE CAUTION Be careful to avoid the bolts falling into the timing chain compartment 15 Remove 2 M8 bolts cylinder head and gasket Cylinder Head 16 Carefully remove cylinder head and gasket while maintaining tension on timing chain Timing Chain 02 18 TSG 416 ENGINE Cylinder Head Installation NOTE The contact surface of the cylinder head and block must be clean and free of oil Use new cylinder head bolts and lubricate the threads 1 Rotate crankshaft so all pistons are below top dead center TDC CAUTION During cylinder head installation the timing chain must be held up with a wire with constant tension in order to keep timing links aligned at crankshaft If chain is allowed to slacken or disengage with sprocket the oil pump will have to be removed and the timing chain realigned 2 Carefully install dowels a new gasket and cylinder head to the engine block while maintaining tension on the timing chain Cylinder Head m Dowels g CAUTION Be careful to avoid the bolts falling into the timing chain compartment 02 19 3 Install new bolts using the sequence shown in the following 3 steps e Step 1 tighten M11 bolts to 29 5 Ib ft 40 Nm e Step 2 tighten M8 bolts to 11 Ib ft 15 Nm 4 45 e Step 3 tighten M11 bolts additional 120 0 2
162. oncerns such as proper octane contamination winter summer blend e Inspect intake air system and air filter for restrictions e 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 Check 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 All 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 Perf
163. ons as removed Lubricate contact i surfaces with clean engine oil 1 Install lash adjusters 2 Install roller followers Bearing Caps Roller Follower Camshaft _ 0 ed Lash COT 7 Adjuster Locking Tool 15 030A NOTE The chamfer on the camshaft bearing caps must be facing the chain housing Rotate camshaft so keyway will align with sprocket Carefully install camshaft bearings caps and bolts finger tight 4 Tighten bolts in the sequence shown in 3 steps to 6 7 Ib ft 8 10 Nm 5 Install camshaft sprocket with chain onto camshaft while maintaining tension on the chain CAUTION The camshaft sprocket and chain must remain engaged and the chain tensioned in order to keep timing links aligned If chain is allowed to slacken or disengage with sprocket the oil pump will have to be removed and the timing chain f realigned Install valve cover Refer to Valve Cover Installation on page 10 02 12 TSG 416 ENGINE Valve Stem Seal Removal NOTE If the valve or valve seat has not been damaged the valve spring seal retainer or keys may be replaced by holding the affected valve closed using compressed alr Use an appropriate air line tool installed in the spark plug hole A minimum of 965 kPa 140 psi line pressure is required air pressure does not hold the valve shut the valve is damaged or burned and the cylinder head must be removed and serviced 1 Remove valve co
164. ood NJ 08012 Engine Distributors 41 Pope Road Inc Holliston MA 01746 Micbonsld Eadi 1217 East Grand River SER Portland MI 48875 Diesel Power 13619 Industrial Rd Equipment Omaha NE 68137 Engine ip 5400 C W Post Road Jonesboro AR 72401 Diesel Power 13619 Industrial Rd Equipment Omaha NE 68137 Perkins Pacific 9190 Ot ay Ridgefield WA 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 Equipment 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 McD Id Equip 1 800 589 9025 WESTERN PENNSYLVANIA McDonald Equip Willoughby Ohio 44094 Engine Distri 41 P Road RHODE ISLAND pe EOE 1 800 220 2700 Inc Holliston MA 01746 Engine Distributors 259 Ellis Rd South TH CAROLINA 1
165. ools called for 1 00 ROTU NDA 1 800 768 8632 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 a 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 TSG 416 GENERAL INFORMATION Exhaust Manifold Straightness 6 Tighten the tapersert into the spark plug hole 9 P P pug Special Tool s Straightedge 502805295531 420 1 A aw Special Service Tools called for 5010 the procedures can be tained by 1 800 ROTUNDA 1 800 768 8632 e Place the Straightedge across the exhaust manifold flanges and check for warping with a feeler gauge NOTE The exhaust manifold shown is a typical exhaust manifold 7 Turn the mandrel body
166. or filler neck CAUTION Do not pressurize the cooling system beyond 138 kPa 20 psi 2 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 If the 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 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 Leakage of light all around the valve at room temperature indicates a bad thermostat slight 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
167. orm 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 Ignition coil shorted to ground and arcing at plugs e MIL circuit to GCP shorted to ground e Poor GCP grounds TSG 416 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 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 Fue
168. oss the diaphragm and the more lift occurs on the fuel valve This allows more fuel to be drawn into the engine Gremet 0195549 DIAPHRAGM ferential groote diaphragm WIDE OPEN THROTTLE P d sc vaive V 7 AIR INLET 14 3psi FUEL INLET 13 9pct 13 9psi 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 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 speeds and loads There is a sensor internal to the DEPR that measures the actual Delta P of the delivered fuel 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
169. 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 oil filter oil pump if external oil level indicator tube connection oil pressure sensor Leakage Points Under Engine e oil pan gaskets e oil pan sealer e oil 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 equally around valve cover bolts and crankshaft seals is not detrimental no repairs are required e 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 TSG 416 GENERAL INFORMATION Compression Tests Compression Gauge Check 1 Make sure the oil in the crankcase Is of the correct viscosity and at the proper level and that the battery is properly charged Operate until the en
170. 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 e Red the lower third of the size range e Blue in the middle third of the size range e Yellow in the upper third of the size range Piston Ring End Gap Special Tool s Feeler Gauge D81L 4201 A or Equivalent Special Service Tools called for procedures can be obtained b 7 1 OTUN 1 800 768 8532 01 26 TSG 416 GENERAL INFORMATION Piston Ring to Groove Clearance Special Tool s Feeler Gauge D8 1L 4201 A Equivalent Special Service Tools called for by the procedures can be obtained by calling 1 800 ROTUNDA 1 800 768 8532 1 Inspect for a stop in the grooves 2 Measure the piston to groove clearance Crankshaft Connecting Rod Journal Diameter e Measure the crankshaft connecting rod journal diameters in at least two directions perpendicular to one another The difference between the measurements 15 the out of round Verify the journal is within the wear limit specification 01 27 Crankshaft Connecting Rod Journal Taper e Measure the crankshaft rod journal diameters in two directions perpendicular to one another at each end of the connecting rod journal The difference in the measurements from one end to the other is the taper Verify measureme
171. plugs if necessary 4 Coolant and oil galleries must be free of dirt and deposits 5 Refer to Section 01 for cleaning amp servicing cylinder block and core plug installation 2 Remove oil gallery plugs 6 Reinstall oil gallery plugs 02 44 TSG 416 ENGINE Piston Disassembly NOTE Store components to ensure assembly with the same rod and installation in the same cylinders from which they were removed Refer to Section 01 for piston inspection and servicing 1 Remove the connecting rod bearing from the connecting rod and cap 2 Remove the piston rings using a suitable piston ring expander Ring Expander Tool 3 Remove piston pin Piston Assembly NOTE Apply a light coat of clean engine oil contact surfaces 1 Assemble piston to connecting rod 2 Install piston rings using a suitable piston ring expander NOTE Check piston ring end gap and side clearance refer to Section 01 3 Install bearings into connecting rods and caps Make sure lock slots align CAUTION Make sure bearings and connecting rod bore are clean foreign material under the inserts will distort the bearing and cause a failure 02 45 TSG 416 ENGINE Cylinder Head Disassembly 6 Remove all valve components using a suitable NOTE Store components to ensure assembly in the valve spring compressor same order as they were removed 1 Remove bolts and camshaft bearing caps evenly in the sequence sho
172. pply 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 TSG 416 FUEL SYSTEM The pinpoint tests below should be performed after the preliminary tests 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 e 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
173. pring 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 rom 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 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
174. pulley is pushed out of the oil pump prior _ Locking Tool to oil pump installation Do Not Remove Clip Until Installed 02 51 TSG 416 ENGINE 24 Assemble gasket onto oil pump housing guiding it with 2 outer bolts CAUTION Do not apply oil to shaft or seal Sealing lip along with all contact surfaces must be free of oil 25 Place oil pump and gasket onto crankshaft 26 Install pulley bolt and tighten to 92 Ib ft 125 Nm 27 Remove clip 28 Install oil pump housing bolts finger tight CAUTION The oil pump housing must be positioned during tightening of the oil pump housing bolts so that the sealing flange of the oil pump housing is within x 0 008 in 0 20 mm of the block bottom sealing flanges 02 52 29 Tighten 2 outer oil pump housing bolts to 15 Ib ft 20 Nm 30 Tighten remaining oil pump housing bolts to 15 Ib ft 20 Nm Remaining Bolts TSG 416 ENGINE 31 Install water pump 35 Install oil deflector 32 Install bolts and tighten to 7 10 Nm 36 Install oil pick up tube Water Pump 33 Install water pump pulley 34 Install bolts and tighten to 9 12 Nm 37 Tighten nuts to 14 Ib ft 19 Nm Tighten bolt to 7 b ft 9 5 Nm 38 Apply WSEM A4 sealer Loctite 5910 to the 4 positions as shown 10 15mm CAUTION The contact surfaces of oil pan gasket and block must be free of oil Do not wait more than 5 min
175. quivalent Special Tool s Special Service Tools called for huren procedures can be tained by calling 1 OTUNDA 1 800 768 8632 e 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 e Check the valve seat and valve angles 01 33 TSG 416 GENERAL INFORMATION Flywheel Inspection Oil Pump Rotor Inspection e Inspect the oil pump rotor tips for damage or Special Tool s wear Dial Indicator with Bracketry TOOL 4201 C or Equivalent Special Service Tools called for by the procedures can be 1 800 768 8632 1 Inspect the flywheel for e Cracks A 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 Feeler Gauge D81L 4201 A or Equivalent Straight Edge D83L 4201 A or Equivalent Special Service Tools called for Ri the procedures can be tained by calling 1 800 ROTUNDA 1 800 768 8632 e Place the Straight Edge across the top of the oil pump and rotors and use the Feeler Gauge to measure the clearance between the rotors and the Straight Edge Oil Pump Gear Radial Clearance e Measure the clearance between the rotor and the pu
176. r 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 should get at least 31 7 hours per quart 900 miles per quart after 300 hours of service High speeds heavy loads high ambient temperature and other factors may result in greater oil use 1 Determine customer s engine load habits such as sustained high speed operation extended idle heavy work loads and other considerations 2 Verify that the engine has no external oil leak as described under Engine Oil Leaks in the Diagnosis and Testing portion of this section 3 Verify that the engine has the correct oil level dipstick 4 Verify that the engine is not being run in an
177. r inches Property Class strength Length millimeters Thread Pitch thread width crest to crest mm Nominal Diameter millimeters G L T D 0 The Property class is 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 TSG 416 METRICS BOLT STRENGTH IDENTIFICATION 2 V eade 1 or 2 English inch bolts Identification marks correspond to bolt strength increasing number of slashes represent increasing strength English System lt Grade 8 572 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 HEX NUT HEX NUT Grade 5 Grade 8 Property Class 9 Property Class 10 3 dots 6 dots Arabic 9 Arabic 10 Increasing dots represent increasing strength May also have blue finish or paint daub on hex flat Increasing numbers represent increasing strength 09 3 TSG 416 METRICS OTHER TYPES OF PARTS Metric identification schemes vary by type of part most often a variation of that used of bolts and nuts
178. r Equivalent Engine Cylinder Leak Eine Oil Pressure Gauge Detection Air Pressurization Kit T73L G600 A 014 00705 or Equivalent 12 Volt Master UV Diagnostic Vacuum Pressure Tester 164 Inspection Kit 164 0756 or R0253 or Equivalent Equivalent FOP Too Special Service Tools called by the procedures can be obtained by calling 1 800 ROTUNDA 1 800 768 8632 TSG 416 GENERAL INFORMATION Inspection and Verification 1 Verify the customer concern by operating the engine to duplicate the condition 3 Ifthe inspection reveals obvious concerns that can be readily identified repair as required 2 Visually inspect for obvious signs of mechanical and electrical damage 4 Ifthe concerns remain after the inspection e Engine coolant leaks determine the symptoms and go to the symptom e Engine oil leaks chart e Fuel leaks e Damaged or severely worn pads e Loose mounting bolts studs and nuts Symptom Chart Condition Possible Source Action Damaged charging system battery Refer to Section 06 Worn piston rings or worn cylinder Repair or replace cylinder blocks Damaged cylinder head gasket Replace cylinder head gasket Replace hydraulic lash adjuster hydraulic lash adjuster Poor Idling Damaged hydraulic lash adjuster or hydraulic lash adjuster Damaged hydraulic lash adjuster quide hydraulic lash Replace hydraulic lash adjuster quide or hydraulic lash adjuster adjuster
179. radiator so coolant level is below the thermostat Refer to Draining the Cooling System of this section Heated Flow Cul To Radiator of M Coolant Flow Control Module p E Thermostat O ring 05 11 Vater Out 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 e Clean and inspect gasket install a new gasket if necessary e Tighten bolts to 10 Nm 89 Heated Water Return Coolant Flow Control Module Assembly Flow in Fr m Radiator FPPD4113 TSG 416 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 Remove or disconnect components as necessary to gain access to the coolant pump Remove the drive belt Refer to Drive Belt Installation of this section Remove 3 bolts and coolant pump pulley Remove 3 bolts and coolant pump 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 Ib ft Coolant Pump 05 12 TSG 416 COOLING SYSTEM Thermostat Replacement eT O hma Mene LL J
180. removed 02 57 TSG 416 ENGINE SPECIFICATIONS GENERAL SPECIFICATIONS overhead camshaft operating the Polarity Negative to earth ground valves via roller cam followers _ ELECTRICAL SYSTEM ELECTRICAL SYSTEM Engine Type Overhead Valve OHV chain driven IGNITION Spark Plug Ford Part XS6F 12405 A1A NGK TR6B 10 Gap 0 95 1 05 mm Firing Order 1 3 4 2 Liter CID 1 6 97 5 82 070 mm 3 23in nk mm 75 480 mm 2 97in 5 4 cylinders Compression FUEL SYSTEM LPG Fuel Liquefied petroleum gas 5 NG Fuel Type 1050 btu ft 3 ITEM FT LB LB IN Gasoline Fuel Unleaded 87 or 89 Octane do not Nm me Drain Plug 25 18 221 3 P 13 diameter 56 980 57 000 mm Main journal undersize diameter 56 726 56 746 mm Spark Plugs 13 17 9 6 12 5 115 150 5 es 97 4 LUBRICATION SYSTEM Max Oil Hot 2500RPM 40 60 psi Oil Type SAE 5W30 API classification SJ Service oil fill 4 2 Liter 4 4quarts including filter Oil Filter Type X56E 6714 D1A COOLING SYSTEM Type Wax Element Thermostat Commences opening 180 F Fully Open 202 F 50 Motorcraft Super Plus 2000 plus 50 clear water 02 58 TSG 416 IGNITION SYSTEM INDEX Subject General Information Diagnosis and Testing Spark Plus InsDeclloDi nd _ a a Removal and Installation Ignition
181. ring top ring gap at 180 from the oil ring gap 2 Lubricate piston bearing wear surface crankshaft journal and cylinder wall with clean engine oil 3 Carefully install pistons with bearings into cylinder bores using a piston ring compressor and a hammer handle Avoid damage to the crankshaft bearing journals The arrow of the piston must point to the front of the engine The connecting rod has the cylinder number identified in the base 04072 Hammer Handle Piston Ring 7 5 Check connecting rod side clearance 6 Install cylinder head assembly Refer to Cylinder Head Installation on page 19 7 Install pick up tube and deflector Refer to Pick up Tube Deflector Installation on page 26 8 Install oil pan Refer to Oil Pan Installation on page 25 CAUTION Use new connecting rod cap bolts and lubricate threads with clean engine oil 02 30 TSG 416 ENGINE Flywheel Removal 1 Remove bolts 2 Remove flywheel 3 Check flywheel runout at clutch disc surface e maximum runout 0 005 in 0 13 mm Dial Indicator Flywheel 4 Check flywheel runout at gear surface e maximum runout 0 024 in 0 6 mm Flywheel Installation 1 Install flywheel using special locking tool 21 168 2 Lubricate bolt threads with clean engine oil and tighten to 49 Ib ft 67 Nm Indicator Flywheel Locking Tool TH4P 6375
182. ripped and closed Perform prelim Test No before proceeding to step 4 4 Check lockoff valve supply voltage M 12 volts to lockoff Key OFF 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 check for 12 jede 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 Verfiy 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 eae 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 TSG 416 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 suff
183. rmine the output of the generator Generator output should be greater than values given in the graph below Switch the tester to ammeter function 2 Connect the positive and negative leads of the to measure generator output 4 With the engine running at 2000 rpm adjust the tester to the battery 3 Connect current probe to generator B terminal 1 Starting and charging System Tester 078 00005 VAT 40 or equivalent is recommended NOTE Refer to the test equipment user s manual for 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 complete directions on examining the charging system circuit may result and burn out the diodes In order to check the generator the use of rotunda not make jumper wire connections except as directed NOTE Turn off all lamps and accessories Generator Output Test WARNING REFER TO CAUTIONS amp WARNINGS AT THE BEGINNING OF THIS SECTION CAUTION To prevent damage to the generator do 4 o o N D in M u 06 8 TSG 416 CHARGING SYSTEM GENERAL SERVICE PROCEDURES AN 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 cl
184. rs 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 Pointer A satisfactory 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 TSG 416 GENERAL INFORMATION GENERAL SERVICE PROCEDURES WARNING TO AVOID THE POSSIBILITY OF PERSONAL INJURY OR DAM
185. shaft Position CMP Sensor Replacement essen 08 41 Crankshaft Position CKP Sensor Removal Crankshaft Position Sensor installations Engine Coolant Temperature ECT Sensor Replacement ETC RR Heat Oxygen Sensor HO2S Replacement eese nnne Knock Sensor KS Replacement 08 1 Temperature Manifold Absolute Pressure TMAP Sensor Replacement Actuator Throttle Position TP Sensor 08 41 08 42 08 43 08 43 08 44 08 44 08 45 TSG 416 Engine Controls GENERAL INFORMATION GCP and Sensors CMP Sensor Sensor TMAP Sensor HO2S Sensor KS Sensor ECT Sensor RCR f 7 2 lt er e gt um GCP 7 M 45 gt S n 7 24 ho Py a f 7 C D ceret f 4 Actuator Fuel Injector DEPR High T slon rez Spark Engine Control Module GCP The Engine Control Module GCP has the following features e Configurable outputs available based on e Programmable four speed electronic ECT RPM or MAP signals and customer governing throttle by wire or variable speed requirements control governing e Diagnostic software allows viewing of down feature for high water temperature low diagnostics to assist techn
186. sonville FL 32254 Inc Lauderdale FL 33315 nc ille COLORADA HAWAII Perkins Pacific Ridgefield 98642 IDAHO Perkins Pacific Ridgefield 98642 Diesel 12111 ILLINOIS is OWer Pon Equipment Batavia IL 60510 37200 Vine St Willoughby Ohio 44094 GEORGIA Engine Distributors 259 Ellis Rd South Jacksonville FL 32254 INDIANA McDonald Equip Anderson 5532 Center Street IOWA Engines Co Ohmaha NE 68106 KENTUCKY Ine 5400 C W Post Road Jonesboro AR 72401 Anderson 5532 Center Street KANSAS Engines Co Ohmaha 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 5400 C W Post Road 5 TN Jonesboro AR 72401 Engine Distributors 41 Pope Road Inc Holliston MA 01746 Engine Distributors 400 University Court Inc Blackw
187. st idle Thermo Valve _______ Fast ide Th ermo Valve Idle Air Control Valve EE HE idle Speed Control Solenoid Vacuum ee Opener VE 9 Valve Throttle VSV 09 10 TSG 416 METRICS Meum m ignition Control Electronic Spark Advance ESA Electronic spark Timing EST ignition Control Module System Module Thick Film Ignition Module Module Indirect Fuel F gt Diesel menia IDI hena Fuel Shutot FS Inertia Fuel Shutoff Switch Inertia Switch Inertia Fuel Shutoff Switch e eni ILI Air Charge Temperature ACT Mandela Temperature Throtte Body Vane intake Air Temperature Sensor Sensor Air Temperature Sensor ATS Intake Air Temperature Genser IATS RAF TOME Sensor TS _ e omite Long Term Fuel Trim Long Term FT Block Leam Matrix BL is Block Leam Memory y GLM Block Lean BL Low Speed Fan Control Switch Low Speed FC Switch ya Fan Control Switch FC Switch emam a Manifold Absolute Pressure Absolute Pressure Manifold Absolute Pressure Sensor MAP Sensor Intake Manifold Absolute Pressure Sensor Manifold Absolute Pressure Sensor MAPS Pressure Sensor P Sensor Mania Pressure MOP Manifold Differential Pressure Sensor Vacuum
188. stall valve cover Refer to Valve Cover Installation on page 10 TSG 416 ENGINE PCY Hose Gasket Intake Manifold Removal 1 Remove any necessary wiring and vacuum hoses Mark connections and routing as necessary to assure they are returned as they were removed Relieve fuel pressure Disconnect fuel lines from fuel rail Disconnect air intake tube Remove bolts nuts and intake manifold assembly 02 15 TMAP Sensor P Intake Manifold Installation NOTE contact surfaces must be clean and free from any old gasket material 1 pm SI Install a new gasket and intake manifold assembly Install bolts and nuts Tighten to 6 Ib ft 8 Nm Connect air intake tube Connect fuel lines to fuel rail Install any wiring and vacuum hoses that were removed Connect and route as they were removed TSG 416 ENGINE Exhaust Manifold Outlet Flange Exhaust Manifold Removal Exhaust Manifold Installation 1 Remove any necessary wiring and vacuum NOTE All contact surfaces must be clean and free from hoses Mark connections and routing as any old gasket material necessary to assure they are returned as they were removed 2 Disconnect exhaust at outlet flange 3 Remove nuts exhaust manifold and gasket Install a new gasket and exhaust manifold Install nuts Tighten to 11 Ib ft 15 Nm Connect exhaust at outlet flange Tighten flange nuts 35 Ib ft 47 5Nm Inst
189. started without liquid in the cooling system This may cause permanent damage to the engine CAUTION The use of straight water as a coolant will cause permanent damage 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 contamin
190. t General Information Page 06 3 OCD SF AU OM ES 06 3 Wiring PIT Ira E ee 06 3 Diagnosis and Testing Preliminary Chee peritis Ford _ _ _________ __ ______ ___ OOS Indicator CHECK ________________ 10615 O00 Battery Dial 06 7 Battery Lodd TESE occae O67 Generator OULDUCTGSE 06 8 Generator VOltdge NOSE goat 06 8 General Service Procedures Battery Cleaning and InSpectlon us uie ves etis tuc 6 9 Battery Ee Ban EV Removal and Installation Generator Replacement uico tatem utes tp pais ie ec rir Dec i i aee but uti dee Cueva 06 11 Voltage Regulator Replacement eese enne eene enne nennen 06 11 Generator Pulley Replacement eese 06 12 Battery isses nein nlii iia ted m dead aei JI Battery installa 06 1 TSG 416 CHARGING SYSTEM Cautions amp Warnings DANGER POISON M Typical Battery Labeling The handling and correct use of lead acid batteries is not as hazardous provided
191. t Move the valve up and down through normal travel in the valve guide and check the stem for any binding If the valve has been damaged it will be necessary to remove the cylinder head as outlined in this section TSG 416 ENGINE Valve Stem Seal Installation NOTE All components must be clean and assembled in the same positions as removed Lubricate contact surfaces with clean engine oil CAUTION Valve stem seal can be cut by grooves in valve stem A damaged seal will leak causing oil burning and valve fouling 1 Carefully slide oil seal over valve stem 2 Install new valve seal using special tool 21 024 optional T95P 6565A Special Tool 21 024 NOTE Apply a small amount of Ford Multi purpose Grease DOA2 19584 AA or equivalent meeting Ford specification ESR M1C159 A to valve spring retainer key to hold in place during installation 3 With cylinder pressurized and using a suitable spring compressor tool install valve spring retainer and locks __ mr _ Retainer _ Spring 02 14 Release air pressure and remove air adapter Install spark plug in proper cylinder Grease contact surfaces of roller follower with Ford Multi purpose Grease DOAZ 19584 AA or equivalent meeting Ford specification ESRM1C159 A Using spring compressor compress and hold down the valve and spring Slide the roller finger follower into place over valve and lash adjuster Release spring Roller Follower In
192. t to the front of the cylinder block Note and record the camshaft end play f camshaft end play exceeds specifications replace the crankshaft thrust washers or thrust bearing Crankshaft Runout Special Tool s Dial Indicator with Bracketry TOOL 4201 C or Equivalent Special Service Tools called for by the procedures can be obtained by calling 1 800 ROTUNDA 1 800 768 8632 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 next oversize TSG 416 GENERAL INFORMATION Cylinder Bore Out of Round Measure the cylinder bore in two directions The difference is the out of round Verify the out of round within the wear limit and bore the cylinder to the next oversize limit Piston Inspection Special Tool s asion Groove Cleaner 08 1L 6002 D or Equivalent Special Service Tools called for be procedures can be ined by Calling 1 OTUN 1 800 768 8532 CAUTION Do not use a caustic
193. t 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 fuel tube to disconnect 7 Quick Connect Coupling Type l 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 Pullon 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 A Ere Separate the quick connect coupling from the fitting Sed C C f TSG 416 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 an
194. tage 08 5 TSG 416 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 result in a lean command to compensate 67 08 6 Specifications Accuracy of measurement 1 5 Operating Temp Range 350 C to 850 C sensor tip
195. tapered battery terminal and the mating surface of the cable clamp 06 9 AN 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 TSG 416 CHARGING SYSTEM Battery Charging WARNING REFER TO CAUTIONS amp WARNINGS AT THE BEGINNING OF THIS SECTION NOTE If excessive 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
196. 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 7 AND BURN HAZARD Could i deot serous njury Chee contact conr couse aeneus burm or fre Alow Cotalyst fo cool CAUTION Observe all manufacturers instructions when using charging equipment WARNING BATTERIES NORMALLY PRODUCE EXPLOSIVE GASES WHICH CAN CAUSE PERSONAL INJURY 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 BA
197. that valve tips and camshaft roller followers are well oiled With the valve covers off some oil splash may overshoot camshaft roller followers TSG 416 GENERAL INFORMATION Camshaft Lobe Lift Check the lift of each lobe in consecutive order and make a note of the readings 1 Remove the valve covers 2 Remove the rocker arm seat bolts rocker arm seat and rocker arms if equipped Dial Indicator Cup Shaped 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 the plunger is on top of the camshaft lobe and in the same plane as the camshaft lobe movement 01 18 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 readi
198. 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 activation 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 use
199. the following valve areas The end of the stem for grooves or scoring The valve face and the edge for pits grooves or Scores The valve head for signs of burning erosion warpage and cracking Minor pits grooves and other abrasions may be removed The valve head thickness for wear Valve Stem Valve Head Thickness Valve Face Valve Head TSG 416 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 e 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 2 HReface the valve seat 3 Clean the sharp edges left by reaming 01 32 TSG 416 GENERAL INFORMATION Valve Spring Compression Pressure Valve Seat Width e Measure the valve seat width If necessary ValverCuton Spring Tester grind the valve seat to specification TOOL 6513 DD or E
200. tion 1 Remove drive belt 2 Remove water pump refer to Section 05 3 Insert retaining clip BF9A 6606 AA between crankshaft pulley and oil pump to prevent pulley axial movement Retaining Clip BF3A 55065 AA n Dil Pump 4 Remove crankshaft pulley bolt NOTE Identify oil pump bolts so they may be returned to their original positions 5 Remove 6 oil pump bolts oil pump and gasket 02 21 TSG 416 ENGINE Oil Pump Installation NOTE Contact surfaces of the oil pump and block must be clean and free of oil CAUTION The oil pump pulley and sealer are provided as an assembly kept together by a clip no BF9A 6606 AA Do not remove clip until oil pump is installed If pulley is pushed out of the oil pump prior to oil pump installation 1 Assemble gasket onto oil pump housing guiding it with 2 outer bolts Gasket CAUTION Do not apply oil to shaft or seal Sealing lip along with all contact surfaces must be free of oil 2 Place oil pump and gasket onto crankshaft 3 Install pulley bolt and tighten to 92 Ib ft 125 Nm 02 22 4 Remove clip 5 Install oil pump housing bolts finger tight CAUTION The oil pump housing must be positioned during tightening of the oil pump housing bolts so that the sealing flange of the oil pump housing is within x 0 008 in 0 20 mm of the block bottom sealing flanges 6 Tighten 2 outer oil pump housing bolts to 15 Ib ft 20 N
201. tons with bearings into cylinder bores using a piston ring compressor and a hammer handle Avoid damage to the crankshaft bearing journals The arrow of the piston must point to the front of the engine The connecting rod has the cylinder number identified in the base Hammer Handle Piston Ring ope Compressor Tool CAUTION Use new connecting rod cap bolts and lubricate threads with clean engine oil 9 Install connecting rod caps with bearings lubricate wear surface and tighten bolts in 2 steps e Step 1 9 Ib ft 12 5 Nm e Step 2 22 Ib ft 30 Nm Cap ij Bolts R j Lower m RS Bearing _ 02 49 10 Install a new rear seal and retainer using tool 21 046 Special Tool Rear Seal Retainer NOTE Rear seal retainer comes on a plastic sleeve Link plastic sleeve to crankshaft 22 34mm and push retainer to crankshaft Plastic pins at rear side of retainer must fit to corresponding block bores Remove plastic sleeve when done 11 Turn engine 180 to prepare for cylinder head installation NOTE The contact surface of the cylinder head and block must be clean and free of oil Use new cylinder head bolts and lubricate the threads 12 Rotate crankshaft so all pistons are below top dead center TDC 13 Install dowels and new cylinder head gasket to the engine block 14 Carefully install the cylinder head onto the gasket MS Bolts Cylinder Head TSG 416 ENGI
202. ulator 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 TSG 416 Engine Controls Distributor less Coil Pack The 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 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 Elimination of mechanical timin
203. ulb 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 second 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 e he MIL is off for 1 2 seconds between digits of three digit DTCs The 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 C
204. uled 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 Failure 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 37 TSG 416 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 ere 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 Bla
205. up tube and oil deflector 23 Insert retaining clip BF9A 6606 AA between crankshaft pulley and oil pump to prevent pulley axial movement NOTE When removing oil pan always keep the engine in its normal upright position to avoid contamination 24 Remove crankshaft pulley bolt NOTE Identify oil pump bolts so they may be returned 20 Remove bolts gasket and oil pan to their original positions 25 Remove 6 oil pump bolts and oil pump Gasket Retaining Clip BF34A 5606 AA 21 Turn the engine over 180 02 40 TSG 416 ENGINE 26 Check to see if coppered links on the timing 28 Using tool 15 030A to lock camshaft sprocket chain are still visible If not identify them as remove bolt and camshaft sprocket follows e Turn engine until timing mark on Locking Tool camshaft sprocket is at 12 o clock 16 0304 e Mark the two chain links left and right of p that timing mark e Mark the single chain link that is positioned on the crankshaft sprocket timing mark Copper Links a Timing Mark 29 Remove timing chain and crankshaft sprocket 30 Remove tensioner arm and chain guide Crankshaft Sprocket Copper Link 27 Remove the hydraulic tensioner Chain Guide Camshaft Sprocket Hydraulic Tensioner 02 41 TSG 416 ENGINE CAUTION Keep cylinder head in the vertical position during removal to avoid warping and damage to the sealing surfaces 31 Re
206. ure 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 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 mean 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 i
207. ust main beanmg Replace connecting rod Replace connecting rod bearing nnechng rod bushing Replace co Repair or replace cylinder blocks Replace piston or piston pin pum Replace connecting rod Replace hydraulic lash adjuster or hydraulic lash adjuster Adjust or replace hydraulic lash adjuster guide or hydraulic lash adjuster Replace valve spring clearance or replace valve guide stem Refer to Secbon 05 Refer to Secbon 04 exhaust leakage Refer to Secbon 05 Refer to Secbon O6 for diagnosis and testing of the generator Adjust or replace timing chain belt Replace timing belt tensioner Replace waler pump Replace hydraulic lash adjuster or hydraulic lash Replace hydraulic bash adjuster guide or hydraulic lash adjustar Repar or replace valve valve seat or cylinder head Replace valve stem Replace valve spring Replace cylinder nead gasket Replace cylinder head Repar or replace piston nng s Replace piston Refer to Saction 04 Refer to Secbon 03 Repair or replace exhaust system TSG 416 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
208. utes to install the oil pan gasket after sealer has been applied 02 53 TSG 416 ENGINE 39 Install the oil pan and bolts finger tight 40 Align oil pan with rear portion of engine block Straight Edge A 41 Tighten oil pan bolts in 3 steps in the sequence shown e enough for gasket settlement 5lb ft 7 Nm e 7 b ft 10 Nm i 1 1 lt a Front of Engine Tightening Sequence 02 54 42 Install the oil pan drain plug Tighten to 18 25 Nm 43 Install flywheel using special locking tool 21 168 Flywheel 44 Lubricate bolt threads with clean engine oil and tighten to 49 Ib ft 67 Nm 45 Check flywheel runout at clutch disc surface e maximum runout 0 005 in 0 13 mm Dial Indicator TSG 416 ENGINE 46 Check flywheel runout at gear surface 50 Install oil filter support with new filter Tighten e maximum runout 0 024 in 0 6 mm bolts to 15 Ib ft 20 Nm 47 Install valve cover and gasket Tighten bolts to 7 Ib ft 9 Nm 51 Install oil pressure switch and tighten to 15 Ib ft __ PCV Valve 20 Nm Sensor E E LI IE bl Valve Cover 48 Apply grease WSD M13P8 A1 or equivalent to 52 Install crankshaft position sensor and tighten to spark plug threads 3 4 Nm 49 Install spark plugs and tighten to 10 13 Ib ft 13 17 Nm 02 55 TSG 416 ENGINE 53 Instal
209. ver Refer to Valve Cover Removal on page 10 2 Rotate the camshaft so the roller follower for the valve to be serviced is on the heel of the cam 3 Using a suitable valve spring compressor tool compress and hold down the valve spring Slide out the roller follower over the lash adjuster Roller Follower 5 CURT de i 4 Replace spark plug for cylinder being serviced with an air line adapter Mark location so spark plug is returned to the same cylinder CAUTION The crankshaft may rotate when air pressure is applied Remove all objects from fan area such as lights extension cords etc 02 13 5 Turn on air supply and pressurize cylinder Air pressure may rotate the crankshaft until the piston reaches the bottom of the stroke Rotunda Pressurization Kit 014 00705 6 Using a suitable valve spring compressor compress the valve spring and remove the keys and retainer Remove and discard the stem seal Key _ Retainer Spring Seal 7 pressure has forced the piston to the bottom of the cylinder any removal of air pressure will allow the valve s to drop into the cylinder Wrap a rubber band tape or string around the end of the valve stem in such a way to prevent the valve from falling in and to allow enough travel to check the valve for binds 8 Inspect the valve stem for damage Rotate the valve and check the stem tip for eccentric movemen
210. wiring Key On connectors and fuses for Using a high impedance DVOM check for 12 volt CAUSE supply at the harness connector No Is the voltage less than 11 5 volts 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 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 TSG 416 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 spec
211. 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 1112 volts is present ensure the wirings to the GCP for the PWM signal If wiring is ok possible faulty GCP TSG 416 FUEL SYSTEM Fuel 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 If 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 e 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 TSG 416 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 no
212. wn _ Retainer Spring Valve Seal n Loosening Sequence is 2 Hemove camshaft 3 Remove roller followers 4 Remove lash adjusters 5 Remove spark plugs Refer to Section 01 for e Servicing valve components valve guide and valve seat Camshaft and bearing service ka Roller e Cylinder head cleaning and inspection i Follower Camshaft_ oe Lash ia BO 07 Adjuster p 02 46 TSG 416 ENGINE Cylinder Head Assembly 5 Check that spring installed height is 35 2 1mm NOTE All components must be clean and assembled in the same positions as removed Lubricate contact surfaces with clean engine oil Installed 1 Check that valves move freely in valve guides 2 Install intake and exhaust valves Install new valve seals using special tool 21 024 optional 95 6565 Special Tool 21 024 6 Follower JE Lash 7 Adjuster 4 Using a suitable spring compressor tool install valve springs retainers and locks NOTE The chamfer on the camshaft bearing caps must be facing the chain housing 8 Carefully install camshaft bearings camshaft and bearing caps with bolts finger tight _ Retainer gt NOTE Rotate camshaft so key is at 12 O clock position Seal 9 Tighten bolts in the sequence shown in 3 steps ET to 6 7 Ib ft 8 10 Nm 8 Tightening Sequence 02

TSG416 Service Manual Rev0 - EDI Ford Industrial Engine

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