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ESG-642 4.2 LITER - Pitt Auto Electric Company

1. 9H486 SS SECUS NF j L 1 5 NES 1 ELEC y E ES CA Sess a 02 15 ESG 642 ENGINE REPAIR Continued 2 Tighten the upper intake manifold retaining bolts in three stages in the sequence shown using the applicable illustration e Stage 1 6 Nm 53 Ib in e Stage 2 8 11 5 Nm 6 8 Ib ft e Stage 3 Rotate 85 95 Intake Manifold Lower Removal 1 Remove the upper intake manifold Refer to the procedure in this section 2 Drain radiator and remove the radiator upper hose from the lower intake manifold DAO206 A 02 16 ENGINE REPAIR Continued ESG 642 3 4 DA0207 B 02 17 Disconnect the coolant bypass hose and the heater hose ARS WARNING DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COM PONENTS HIGHLY FLAMMABLE MIX TURES ARE ALWAYS PRESENT AND CAN BE IGNITED RESULTING IN POSSIBLE PERSONAL INJURY Disconnect the fuel line Refer to Section 04 Disconnect the following electrical connectors 1 42 pin connector 2 Camshaft Position Sensor CMP 3 Cylinder head temp sensor 4 Crankshaft position sensor CKP 5 Oil pressure switch 6 Heated oxygen HO2S sensor LH 7 Manifold absolute pressure sensor MAP 8 Idle air control motor IAC 9 Intake air temperature IAT 10 Throttle position sensor TPS ESG
2. a Hames M h Protective intermittent Seal Unlocked Terminal Hidden by Intermittent Check for unlocked terminals by Wire Seal Contact pulling each wire at the cord of the Grounding Foil connector TERMINAL NOT PROPERLY SEATED ELECTRICAL SHORT INSIDE THE HARNESS Remove the tape and flex feel each circuit for reduction in diameter at break Displaced Female Lock may be displaced into an unlocked position pull on the connector to verify the lock Circuit Insulation Intermittent S amp BM Contact A EO tran Contact BENE Broken Strands Intermittent Signal intermittent Wiring Harness Tape Type A Type B BROKEN WIRE STRANDS IN HARNESS PARTIALLY MATED CONNECTORS 03 6 Electrical Symbols a ae Pee uem V 1 Auxiliary Systems Ignition INTRODUCTION Continued SHIELD WIRES COVERED BY A SHIELD FIELD COIL MOTOR HEATING ELEMENT THERMISTOR RHEOSTAT OR POTENTIOMETER SOLENOID SWITCH GANGED SWITCHES CONTACTS MOVE AT THE SAME TIME 03 7 DIODES CURRENT FLOWS IN DIRECTION OF ARROW ONLY CAPACITOR 9 c R 9 TRANSISTOR GAUGE LIGHT EMITTING DIODE LED LIGHT BULB DUAL FILAMENT LIGHT BULB RELAY CONTACTS CHANGE POSITION WITH CURRENT THROUGH COIL Auxiliary Systems Ignition DESCRIPTION AND OPERATION ECM
3. 09 4 Other Types 22 09 5 English Metric Conversion 09 6 Decimal and Metric Equivalent 09 7 Torque Conversion 09 8 41930 Terminology List 09 9 Response axes eines tuc reo auccm ee csse 09 19 09 1 Auxiliary Systems Metrics 09 2 Auxiliary Systems Metrics 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 fasterners 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 ot ensure that the proper replacement fastenres 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 n
4. HEN 05 36 Auxiliary Systems Charging CHARGING INDEX SUBJECT PAGE 06 3 Generator Diagnosis And Testing 06 4 Voltage Regulator and Back of Generator 06 4 Visual 5 06 4 Generator Output 222221 06 5 Symptom Chart 2 2 06 6 miis solio TESIS T 06 7 Generator Removal And Installation 06 13 Regulator Removal 06 13 Battery Mounting And Cables 06 15 Removal and Installation 06 15 Battery Removal and Installation 06 15 Service Procedures 4 422222 06 16 Battery 06 16 Maintenance Free and Low Maintenance Batteries M 06 16 Cleaning and Inspection 06 17 Clamp PUNET 06 18 Battery Clamp Spreader 06 18 Terminal Cleaning Brush 06 18 rm 06 18 Wiring SCliemali6 nein pae peii co erreur den eue 06 19 SSG ING QUI OUNS ene e c c 06 20 06 1
5. 05 11 Cylinder Head Temperature Sensor 05 12 COO IMAG FAN NR Emm 05 13 Fan Drive tes ae uestes pass 05 13 Removal And Installation 05 14 Belt Tensioner RO TRA 05 14 Belt Idler Pulley eee 05 15 Block im 5 BEER m 05 16 Water A CIMA rH 05 18 05 1 SUBJECT PAGE Cooling System Diagnosing And Testing 05 19 General Test Procedures 05 19 Cooling System Pressure Test 05 20 Engine 05 22 Visual Inspection 2 2 05 22 Inspection and Verification 05 22 Symptom Chart 05 22 FT Cm 05 23 Component Tests 4 0 4 2 1 05 29 Pressure Test Rc E 05 29 Cap Pressure Relief 05 30 05 30 Thermostat Test Thermostat Removed 05 30 Radiator Leak Test Removed From Vehicle 05 31 Engine Cylinder Head Temperature CHT 1 18 19 BINNEN EE E ene ener eee 05 31 Diagnostic Trouble Code DTC 43 Engine Cylinder Head Temperature Low Voltage and DTC 33 for High Voltage
6. 01 22 PUSH ROOS T 01 22 Positive Rotator and Valve Spring Retainer Keys 01 22 Valves and Cylinder Head 01 22 Camshaft Lobe Lift esses 01 22 OHV ENGINES 01 22 Typical Engine With Push Rods 01 22 Hydraulic Valve 01 23 Leakdown Testing 01 23 General Service Procedures 01 25 oy 9 2 91 i c M 01 25 Cie 01 26 Camshaft Journal 01 26 Camshaft Journal Clearance OHV Engines 01 27 Camshaft Lobe Surface 01 27 Camshaft Lobe ttes 01 28 Camshaft 01 28 Crankshaft Main Bearing Journal Diameter 01 29 Crankshaft Main Bearing Journal Taper 01 29 Crankshaft Main Bearing Journal Clearance 01 30 Bearing Inspection 01 31 Crankcase End Play 01 31 Cylinder Bore Taper 01 33 Cylinder Bore Out of Round 01 33 Piston In
7. Fuel Pump Relay ricotta eran pma oo pite seco 04 3 General Information Fuel Pressure Regulator 04 4 TTD Fuel Return NG RPM TON 04 4 Damper Assembly 04 4 04 4 Pa OUI ONG gii P c HO 04 4 Surging Above Idle 22 2 Throttle TO D 04 4 Poor Acceleration Option Electronic Governors 04 4 Inconsistant Idle Speed Fuel Pressure Relief Valve 04 4 Reduced Power Output GENERAL PROCEDURES ACTUATOR Pressure 22 2222 04 5 Barber Coleman Governor Actuator Coupling Spring Lock 2 2 2 04 6 Precision Governor Actuator Fittings Push 11111 04 9 Electronic Variable Speed Governing Drive By Fittings R Clip sees 04 11 Wire Electronic Throttle Control EFI 04 21 REMOVAL AND INSTALLATION LIQUEFIED PETROLEUM GAS LPG amp NATURAL GAS 5 2 PE 04 14 Supply Manifold Fuel
8. 399856 44 39 276959 49 Ls s mess 45 958 888 3794 309 2423 262 6 10 13 8 ve 387 6t 125 104 25 0 260 98 22 18 275 89 _ 388 389 15 a 1 lt 15 150 302 563 Voltage values calculated for VREF 5 volts may vary 15 due to sensor and VREF variations 04 24 Fuel Flow Diagram for LPG Auxiliary Systems Fuel FUEL SYSTEM DESCRIPTION AND OPERATION A Air Intake Mixer C Fuel Line VAPORIZER REGULATOR 2 stage Max inlet pressure Primary outlet pressure Secondary outlet pressure Fuel inlet connection Fuel outlet connection Coolant connections Fuel outlet hose Coolant hose THROTTLE BODY FORD Type Angle of operation Bore Throttle linkage connection Retaining studs spacing E Engine Outlet G Inlet D Vaporizer Regulator H Coolant Hoses 2150 kPa 10 3 kPa 0 37 kPa 1 4 NPTF 1 NPTF 3 8 NPTF 19 1 mm inside dia 15 8 mm inside dia POWER PRODUCTS Butterfly plate 75 total movement 27 0 mm dia 6 35 mm dia ball 76 2 mm 04 25 Battery 2 Ignition Switch L Shut Off Valve P LPG MIXER Type Air i
9. Nm Lb in O Block Heater Cylinder Head Temperature Sensor 9 11 Fan Assembly and Fan Clutch To Water Pump 4 Fan Shroud Screws Fan Assembly To Fan Clutch Bolts 1 9 9 1 3 5 1 Premium Long Life Grease XG 1 C ESA M1C75 B Radiator Support Bracket P Stop Leak Powder 3 22 6 7 19558 ESE M99B170 Transmission Fluid Cooler Fittings 2 15 Includes radiator coolant recovery reservoir fluid level Water Inlet and Outlet between the COOLANT FILL LEVEL lines Connection Ford Premium Engine Coolant green in color E2FZ Water Pump Bolts 20 30 15 22 19549 AA or B Canada Motorcraft CXC 8 B Oregon Water Pump Pulley Bolts 20 30 15 22 F5FZ 19549 Recycled Coolant or equivalent meeting 4 Ae Ford specification ESE M97B44 A UJ o o WATER PUMP AND FRONT COVER FASTENERS F C PART NO PART NAME DESCRIPTION HEX SIZE N805112 Stud Bolt 8 X 1 25 X 98 15mm Hex N805112 Stud Bold M8 X 1 25 X 98 15mm Hex N805757 M8 x 1 25 X 137 N A N804853 8 X 1 25 X 156 N A N805757 M8 X 1 25 X 137 N A N A N A HOLE NO 055 NS082 NeO4882 M8X125X1603 15mmHex NEO4853 W7O1885 x Neo 125 38 x 0598 MBX125X38 10mmHex 804745 8 1 25 15mm Hex NOTE Bolt information on installation page this section
10. 03 35 Auxiliary Systems Ignition SUBJECT PAGE MST amp IAT Sensor Data 03 41 Engine Cranks But Doesn t Start 03 42 Circuit Description 1 03 42 DIAGNOSTIC AlGS m 03 42 Test Description 04 4 000000 03 42 Circuit Test 22 03 42 Wiring Schematic 4 2L amp 2 5L Alternator Gauges Ignition and Discrete Governing 03 48 Wiring Assembly 4 2L DLX ICM 03 49 Wiring Assembly 90930 03 50 Wiring Assembly To 14324 03 50 Wiring Assembly To 03 51 Pedal Switch Drive By Wire 03 52 First Version Foot Pedal Assembly 03 52 Drive By Wire Food Pedal Wiring Harness 03 53 Second Version Foot Pedal Assembly 03 53 Wiring Schematic 4 2L amp 2 5L Alternator Gauges Ignition and Drive By Wire 03 54 Removal and Installation of ICM 03 55 Spark Plug Wire Routing 2 222 03 56 General Specifications 03 56 Torque Specifications 2 03 56 03 2 Auxiliar
11. Circuit 361 gt Splice 1 K Off OV KOEO 12V Fuse or wiring 12V Fuse Fuel Lockout Connector Closed Loop 18 lt O N LO 361E R 9 TO FUEL LOCKOUT NOTE Fuel Lockout solenoid is supplied by customer Circuit 570J gt Fuel Lockout Relay K Off OV KOEO Ground Bad relay ECM Wiring KOER Ground Circuit 361E Splice 1 04 22 Auxiliary Systems Fuel Liquid Petroleum Gas and Natural Gas LPG amp NG Dry Fuel Modulator Connector DRY FUEL MODULATOR NOTE For future application controls alternate fuel closed loop system Circuit 77 gt R 2 K Off 2 OV KOEO N A KOER N A Circuit 361F Splice 1 K Off OV KOEO N A KOER N A Manifold Skin Temp Connector 225 BK Y 20 x gt Q LO Co MANIFOLD SKIN TEMP Manifold skin temperature reads manifold surface SKIN temperature Circuit 359D gt Splice 5 gt ECM Pin B2 K Off OV KOEO 5V KOER 5V Circuit 225 gt ECM Pin 03 K Off OV KOED Use chart on Page 04 24 KOER for volt reading NOTE Check for Ohm reading across the two pins of DFT sensor unplugged per chart on Page 04 24 04 23 Auxiliary Systems Fuel MST CHT ECT amp IAT SENSOR DATA Temperature Sensor Characteristics TEMPERATURE OHMS VOLTS 3s 450 80 2 49508 446
12. Circuit Description 2 22 22 Conditions for Setting the DTC Actions Taken When the DTC Sets Conditions for Clearing the DTC Resetting the 05 32 Diagnostic FIGS c 05 32 Temperature Sensor Characteristics 05 33 V Ribbed Serpentine Drive Belt 05 34 Visual Inspection Tuoi eos cin 05 34 Symptom Chart 05 34 4 2L Belt Drive Tensioner Belt Length Indicator 05 35 Drive Belt 05 35 i es c 05 36 Auxiliary Systems Cooling 05 2 Auxiliary Systems Cooling COOLING SYSTEM DESCRIPTION AND OPERATION ENGINE COOLANT CIRCULATION UPPER RADIATOR INLET HOSE WATER OUTLET i CYLINDER HEAD WATER PUMP ASSEMBLY COOLANT OVERFLOW RESERYOIR LOWER MADIATOR OUTLET HOSE Engine Cooling Water temperature indicator sender unit 10884 Walter C Avrea the owner of patents 3 601 181 Water thermostat and gasket assembly and RE27 965 has granted Ford Motor Company rights with respect to cooling systems covered by Upper radiator hose 88275 these patents Lower radiator hose 8B273 The cooling system components are Bypass hose and heater hose system
13. 02 56 Installation of Oil 2222 2 02 57 ANIM eT T 02 58 02 59 Installation of Oil 122 21 201 02 61 Oil Pump Screen Cover and Tube 02 62 Installation of Oil Pump Screen Cover amp Tube 02 63 Crankshaft Main Piston Rod Bearings 02 63 Installation of Crankshaft Main Piston Rod Bearings 02 65 Engine Front Cover eese 02 66 Installation of Engine Front Cover 02 71 Timing Chain Balance Shaft 02 77 TN T Pm 02 83 Removal of Engine 02 87 02 1 ESG 642 02 2 SPECIAL TOOLS ESG 642 Special Service Tools called for by the procedures can be obtained by calling 1 800 ROTUNDA 1 800 768 8632 Special Tool s ST1385 A ST1378 A ST1327 A Purchased From Local Tool Dealer Seal Remover T92C 6700 CH Vibration Damper Remover Adapter T82L 6316 B Impact Slide Hammer T50T 100 A Rear Crankshaft Seal Remover T95P 6701 EH Rear Main Seal Replacer T82L 6701 A Front Crankcase Seal Installer Cover Aligner T88T 6701 A Front Crankcase Seal Replacer T94P 6701 AH Pound Inch Torque Wrench 02 3 Special Tool s ST1276 A Syncro Positioning Tool T89P 12200 A Valve Spring Compressor T81P 6
14. 08 58 Trouble Code 33 0 08 60 Trouble Code TR 08 62 Trouble Code Banca 08 64 Trouble Code 4i 08 66 Trouble Code 42 08 68 Trouble Code 08 70 Trouble Code 45 enne 08 72 Trouble Code 47 cm 08 74 Trouble Code 51 00 0 0 0 08 76 08 1 Auxiliary Systems EFI amp Ignition Electronics 08 2 Auxiliary Systems EFI amp Ignition Electronics IDLE AIR CONTROL IAC VALVE Part Description The Engine Control Module ECM modulates the position of the IAC solenoid to regulate the air flow which controls engine RPM at idle AIR FLOW n DIAPHRAGM B 14 nu S VALVE BODY VALER is 1 E EE 2 ST rm w m M W SOLENOID j AIR FLOW TROUBLESHOOTING RESISTANCE SUPPLY amp CONTROL EGA PCM DISCONNECTED 7 130 NORMAL ECM PIN K 1 361J G R IDLE AIR CONTROL PINS LOCATED ON ALL HARNESS CONNECTORS SOLENOID HARNESS VIEWED INTO MATING SURFACE CONNECTOR 08 3 Auxiliary Systems EFI amp Ignition Electronics CAMSHAFT POSITION SENSOR CMP HALL EFFECT Part Description This device provides cylinder identification information to the Engine Control Module ECM for fuel synchronization The sensor contains a Hall effect device an integrated circuit and a magnet An air
15. A2 CHECK THE PRESSURE RELIEF CAP Perform the Pressure Relief Cap Test For additional information refer to Component Tests Cap Pressure Relief in this section 5 pressure relief cap OK Yes GO to A3 gt No INSTALL a new pressure relief cap TEST the system for normal operation CHECK THE ENGINE COOLANT FOR INTERNAL LEAK Inspect the engine coolant in degas bottle for signs of transmission fluid or engine oil oil or transmission fluid evident in coolant Yes If engine oil or transmission fluid is evident REPAIR or INSTALL a new radiator as necessary No GO to A4 Continued 05 23 Auxiliary Systems Cooling COOLING SYSTEM DIAGNOSING AND TESTING Continued PINPOINT TEST A LOSS OF COOLANT Continued Remove the oil level dipsticks 6750 from the engine and the transmission e s coolant evident in oil or transmission fluid p Yes If coolant is in engine GO to Section 01 If coolant is in transmission 7003 INSTALL a new radiator or REPAIR as necessary GO to Transmission Service Manual to repair the automatic transmission No GO to 5 A6 CHECK THE COOLANT RECOVERY SYSTEM warnine 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 AVOID HAVING SCALDING HOT COOLANT OR STEAM BLOW OUT OF THE DEGAS BOTTLE WHEN REMO
16. Before this step is started both cylinder heads must be removed to prevent lower block from distorting Remove the oil pan baffle DA0629 A 02 101 ESG 642 DISASSEMBLY Continued 22 Remove the water pump 8501 20 8 i rins 23 Remove the engine front cover Discard the gasket 24 Remove the following 1 Synchronizer drive gear 2 Camshaft sprocket 3 Crankshaft sprocket 4 Timing chain 5 Balance shaft drive gear 25 Remove the timing chain vibration damper DA0625 A 02 102 ESG 642 DISASSEMBLY Continued 26 Remove the balance shaft DA0624 A 27 Remove the camshaft DA0623 A 28 NOTE Mark the location of each piston connecting rod bearing 6211 and connecting rod cap When the engine is assembled each component should be installed in its original position Discard all bolts and replace with now bolts Inspect the top of each cylinder bore and if necessary remove the ridge or carbon deposits Remove the pistons gt 0622 02 103 ESG 642 DISASSEMBLY Continued 29 Remove the crankshaft and main bearings Discard the crankshaft rear oil seal 6701 and all bolts and replace with new bolts and oil seal DA0621 A DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES Cylinder Blocks Special Tool s Camshaft Bearing Set T65L 6250 A Special Service Tools called for by the procedures can be obtained by calling 1
17. 03 17 Distributorless Ignition System Description And e S 03 18 Service Adjustments And Checks 03 18 Diagnosis Equipment 03 18 PINGS ING S 03 18 Preliminary Checks Seen 03 19 Visual Physical Check 03 19 Intermittent Problems 03 19 Hard Start SymplODi 03 20 03 1 SUBJECT PAGE Engine Surges Symptom 03 22 Lack of Power or Sluggish Symptom 03 24 Detonation Spark Knock Symptom 03 25 Rough Unstable or Incorrect Idle Stalling SYMPTOM etuer eu Excessive Fuel Consumption Symptom Dieseling Run on Symptom Backfire Symptom esee Hesitation Sag Stumble Symptom Cuts Out Misses Symptom Ignition System Diagnosing And Testing NOTE Defective Trouble Codes DTC how to retrieve and remove see Section 08 26 Ignition Secondary System Resistance Checks Diagnostic Trouble Code DTC 42 For High Voltage And DT
18. 07 3 Sequence Of Operation 07 3 Starter Lockout Relay 07 3 Road Service 07 4 dump Starting 07 4 Negative Grounded Battery 07 4 Starter Permanent Magnet Diagnosis And E 07 5 Starter Load 07 5 Bench TESIS MNT 07 5 Starter No Load 07 6 Starter Lock Out Relay 07 6 System Inspection 07 7 Symptom Char M 07 7 Evaluation Procedure T 3 n o 07 8 Evaluation Procedure 2 07 8 Diagnosis And Testing 07 9 General Procedures 07 9 Starter Permanent Magnet Removal 2 2 07 10 Switch Relay Solenoid 07 11 Starter Motor 07 11 Ini EMIO NN mem 07 12 Starter Permanent Magnet Specifications 07 16 Starter System Special Tools 07 16 07 1 Auxiliary Systems Starter 07 2 Auxiliary Systems Starter STARTER PERMANENT MAGNET DESCRI
19. Block heater 6A051 Degas bottle e Engine coolant temperature sensor ECT sensor 12 648 e Radiator degas bottle 8A080 Fan blade 8600 Holds surplus coolant when hot Fan clutch 8A616 De aerates the system reducing engine hot spots e Fan shroud 8146 Location for service fill e Radiator 8005 Allows coolant expansion and system Radiator cap 8100 pressurization 110 kPa 16 psi e Radiator degas bottle 8A080 s l Air separation during operation e Radiator draincock 8115 Replenishes coolant to system 05 3 Auxiliary Systems Cooling COOLING SYSTEM DESCRIPTION AND OPERATION Continued The Coolant Fan The fan blade can either draw or push air through the radiator to help cool the system coolant The fan clutch is a thermostatic controlled clutch that controls the fan drive Coolant flow is as follows The water pump 8501 circulates the coolant From the water pump to the engine block and the cylinder heads 6049 to the thermostat Thermostat closed the coolant returns to the water pump through bypass hose Thermostat open the coolant flows back to the radiator To the radiator for heat rejection then back to the lower radiator hose From the lower radiator hose 8286 to the water pump The Radiator The radiator allows excess heat to be transferred to the air The radiator can
20. 20 Install a new O ring on the synchronizer and make sure the oil pump intermediate shaft is installed with the lock ring into the synchronizer Lubricate O ring with WSE M2C908 A oil prior to installation DA0670 A 02 118 ASSEMBLY Continued DA0671 B 0 0992 ESG 642 22 02 119 21 NOTE The arrow on the alignment tool must point as shown in the illustration Make sure piston number one is at top dead center on intake stroke Install the synchronizer remove the alignment tool and install the camshaft position sensor Install the coolant water heater outlet tube assembly refer to cooling system Section 05 of auxiliary system section e Use a new O ring Lubricate O ring with WSE M2C908 A oil prior to installation ESG 642 ASSEMBLY Continued 23 Install the valve tappets and tappet guides 10 14 Nm 88 124 Ib in Lubricate the tappet bore and tappet roller with Engine Assembly Lubricant D9AZ 19579 D or equivalent meeting Ford specification ESR M88C80 A 24 Install the cylinder heads 1 Use new gaskets and cylinder head bolts 2 Tighten the cylinder head bolts in three stages in the sequence shown e Stage 1 20 Nm 14 lb ft e Stage 2 40 Nm 29 lb ft e Stage 3 50 Nm 36 lb ft 3 The bolts must be loosen and retighten Following procedure in Step 25 next page 0646 02 120 ESG 642 ASSEMBLY Continued
21. 5 voltage at test point equal to battery voltage CHECK FOR LOOSE A CIRCUIT FUSE e Start engine REPAIR loose fuse Check the generator fuse loose connection by wiggling connection the fuse with the engine running Does indicator lamp flicker GO to C4 CHECK A CIRCUIT CONNECTIONS e With engine running connect test point on the REPLACE voltage voltage regulator to the positive battery post using regulator If problem still a jumper wire exists REPLACE generator Does indicator lamp flicker GO to C4 CHECK BRUSH HOLDER SCREWS Remove generator from unit GO to C6 Check the brush holder screws located on the voltage TIGHTEN screws to regulator test points F and A specification 2 8 4 0 Nm Are the brush holder screws tight 25 35 In Lb 06 9 Auxiliary Systems Charging GENERATOR DIAGNOSIS AND TESTING Continued PINPOINT TEST C INDICATOR LAMP FLICKERS INTERMITTENT Continued STEP RESULT ACTION TO TAKE ce CHECK FOR GROUNDED SLIP RING FOR GROUNDED SLIP RING Remove voltage regulator If grease or dirt has Measure resistance from each generator slip ring to accumulated near the slip the generator housing rings CLEAN the slip rings s resistance from either slip ring to housing less and RECHECK resistance than 200 ohms If still less than 200 ohms REPLACE generator REPLACE voltage regulator PINPOINT TEST D CHARGING VOLTAGE HIGH TEST
22. Gs ome o o gt N O O pond N O 22 6 Auxiliary Systems Metrics METRICS Continued Decimal and Metric Equivalents 164 0165 397 L 132 03125 794 364 046875 1191 i 3 64 764 109375 278 397 794 __732__ 0895 556 1 2 12 7 FRACTIONS DECIMAL INCH METRIC 8 43 21 32 65625 16 669 671875 17 066 11 16 6875 17 463 7 8 7 8 875 22225 59 64 921875 23 416 09 7 METRICS Continued Torque Conversion Auxiliary Systems Metrics 09 8 POUND FEET NEWTON METRES LB Nem 68 7 95 10 15 839 35 45 55 0 7 75 101 7 108 5 122 0 100 135 6 120 162 7 110 1627 130 140 150 160 170 180 Auxiliary Systems Metrics J1930 TERMINOLOGY LIST NOTE 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 New Term New Acronym Old Terms Acronyms Accelerator Pedal Air Cleaner Thermac Air Cleaner A 1 U Air Cleaner Element ACL Element Air Cleaner Element ACL Element Air Cleaner Housing ACL Housing Air Cleaner Housing ACH Air Cleaner Housing Cover ACL Housing Cover A
23. P _ 59 G Y R 264 W LB S03 S05 361G 359 GY R 351 BR W _ ____ C1 R1 K1 Signal t T 7 MAP ee PWM Power 1 Engine Return Sensor Throttle Feed Control Signal Reference Control Module 1 DIAGNOSTIC TROUBLE CODE DTC 12 THROTTLE POSITION TP SENSOR LOW VOLTAGE Circuit Description The throttle position TP sensor is a potentiometer which is attached to the throttle plate shaft inside the electronic governor The ECM provides a 5V reference voltage to the TP sensor between terminal A Grey Red circuit 359F and terminal C Brown White circuit 351D of the electronic governor A TP signal is returned to the ECM from terminal B Grey White circuit 355 of the electronic governor The TP signal varies from about 1 0V at idle to 4 8V at WOT The TP signal is an important input used by the ECM for fuel control and other engine control functions Conditions for Setting the DTC e KOEO or TP signal is 0 3V or less e Above conditions are present for at least 2 consecutive seconds 08 30 Auxiliary Systems EFI amp Ignition Electronics Diagnostic Trouble Code 12 Actions Taken When the DTC Sets The ECM illuminates the malfunction indicator lamp MIL e The ECM forces the throttle to a default position of 6 open e The ECM will shut down engine when using DBW Engine be restarted after recycling ignition switch NOTE Drive By Wire When code
24. Yes GO to B3 gt No FLUSH the engine cooling system For additional information refer to Flushing Engine and Radiator in this section TEST the system for normal operation CHECK FOR AIRFLOW OBSTRUCTION gt Inspect the radiator B3 CHECK OW OBSTRUCTION obstructions such as leaves or dirt there an obstruction P Yes REMOVE the obstruction CLEAN the radiator TEST the system for normal operation No GO to B4 B4 CHECK THE HEATER CORE OPERATION AND OR LPG EVAPORATOR Install the pressure relief cap Bie 27 Q4194 B Continued 05 26 Auxiliary Systems Cooling COOLING SYSTEM DIAGNOSING AND TESTING Continued PINPOINT TEST B THE ENGINE OVERHEATS Continued TEST CONDITIONS TEST DETAILS RESULTS ACTIONS B4 CHECK THE HEATER CORE OPERATION AND OR LPG EVAPORATOR Continued As the engine starts to heat up feel the inlet and outlet heater water hoses 18472 They should feel approximately the same after three or four minutes Is the outlet heater water and or LPG evaporation hose approximately the same temperature as the inlet heater water hose Yes GO to B5 gt No TURN the engine off REPAIR or INSTALL a new heater core or clear the LPG evaporation coolant passage way TEST the system for normal operation B5 CHECK THE WATER THERMOSTAT OPERATION Start the engine and allow the engin
25. 01 60 ESG 642 DESCRIPTION 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 The ESG 642 engine incorporates a closed type crankcase ventilation system To maintain the required performance level the fuel system ignition system and engine must be kept in good operating condition and meet recommended adjustment specifications Before replacing damaged or worn engine components such as the crankshaft cylinder head valve guide valves camshaft or cylinder block make sure part s is not serviceable OF PERSONAL INJURY OR DAMAGE DO NOT OPERATE THE ENGINE UNTIL THE FAN BLADE HAS FIRST BEEN EXAMINED FOR POSSIBLE CRACKS OR SEPARATION WARNING TO AVOID THE POSSIBILITY 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 CAUTION Use of abrasive grinding Ford Power Products does not recommend using abrasive grinding discs to remove engine gasket material Use manual gasket scrapers for removing gasket material from t
26. 2 Install push rods 3 Install rocker arms and bolts 4 Install valve cover and gasket 5 Install upper and lower intake manifolds 30 40 Nm 22 29 Ib ft DA0895 A Exhaust Manifold LH Removal 1 Remove the oil level indicator tube 6754 1 Remove the oil level indicator tube bracket nut 2 Remove the oil level indicator tube 3 Remove and discard the oil level indicator tube O ring 02 45 ESG 642 ENGINE REPAIR Continued 2 Disconnect the LH heated oxygen sensor HO2S electrical connector if so equipped 3 Remove the LH exhaust manifold and the LH exhaust manifold gasket 9448 1 Remove the three LH exhaust manifold stud bolts 2 Remove the three LH exhaust manifold bolts 3 Remove the LH exhaust manifold 4 Remove and discard the LH exhaust manifold gasket 1 NOTE Tighten in the sequence shown Follow the removal procedure in reverse order 02 46 ESG 642 ENGINE REPAIR Continued Exhaust Manifold RH Removal 1 Disconnect the RH heated oxygen sensor HO2S electrical connector if so equipped 2 Hemove the RH exhaust manifold and the RH exhaust manifold gasket 1 Remove the two RH exhaust manifold stud bolts 2 Remove the four RH exhaust manifold bolts 3 Remove the RH exhaust manifold 4 Remove and discard the RH exhaust manifold gasket 1 NOTE Tighten in the sequence shown Follow the
27. Conditions for Clearing the DTC Resetting the MIL e The DTC can be cleared from memory by disconnecting the battery for 5 minutes f a personal computer PC is connected to the engine the DTC can be cleared from memory by hitting the C key while in the View Sensor Data Screen Diagnostic Aids The IAT sensor shares the same ground with the Manifold Absolute Pressure MAP sensor and the CHTS Check the ground circuit 359 Gray Red if these DTCs are also set Inspect the harness connectors for backed out terminals improper mating broken locks improperly formed or damaged terminals and poor terminal to wire connections Inspect the wiring harness for damage If the harness appears to be OK backprobe the IAT sensor connector with a paper clip and DVOM and observe the voltage while moving connectors and wiring harnesses related to the IAT sensor A change in the voltmeter display will indicate the location of the fault INTAKE AIR TEMPERATURE IAT SENSOR A Low Air High Air Temperature Temperature IAT sensor is a type of thermistor that converts air temperature to a voltage signal Output is a variable voltage signal which typically ranges from 0 3 volt to 4 5 volts As air temperature increases the IAT resistance decreases e At 40 F CHT resistance is 269K ohms e At 77 F CHT resistance is 29K ohms e At 248 F CHT resistance is 1 2K ohms 03 38 Auxiliary System
28. Inspect and test the secondary ignition spark plug wires Check for the following conditions Verify that the resistance of all ignition wires is less than the specified value Verify that ignition wires are correctly routed to eliminate cross firing Verify that ignition wires are not arcing to ground Verify repair Spraying the secondary ignition wires with a light Go to MIL DTC mist of water may help locate an intermittent retrieval problem key ON engine running Refer to procedure if Was a problem found Page 03 35 required Go to Step 35 1 Check the ignition coil primary resistance Verify repair 2 Replace the coil if it is not within the specified Go to MIL DTC 35 range of resistance retrieval Did the coil require replacement Refer to procedure if Page 03 35 required Go to Step 36 1 Check the ignition coil secondary resistance Verify repair 2 Replace the coil if it is not within the secondary Go to MIL DTC 36 range of resistance retrieval Did the coil require replacement Refer to procedure if Page 03 35 required Go to Step 37 1 Remove the spark plugs and check for gas or oil fouling cracks wear improper gap burned electrodes or heavy deposits Verify repair 37 2 If spark plugs are fouled the cause of fouling Go to MIL DTC must be determined before replacing the spark retrieval plugs procedure if Was a problem found required Go to Step 38 the TPS function Was a problem found Check the
29. KOEO or Action Taken When the DTC Sets ECM will illuminate the malfunction indicator lamp MIL Diagnostic Aids Inspect the harness connectors for backed out terminals improper mating broken locks improperly formed or damaged terminals and poor terminal to wire connections Inspect the wiring harness for damage DTC 57 ECM Fault Computer COP Failure Step ales Are you using a personal computer PC to perform this diagnosis Stem to Diagnostic Check before continuing at Step 2 Go to gn 2 Check the MIL or the PC engine data screen Are any other DTC s set to applicable DTC Go to Goto steps 3 Install replacement ECM Remove replacement Is system operation normal with replacement ECM installed ECM and install original ECM Go at Step 4 Is the repair complete system operation normal with original ECM Remove original reinstalled ECM and reinstall Keep original ECM replacement ECM installed Re test Go to Step 5 Is the repair complete system operation normal with replacement ECM Leave replacement ECM reinstalled installed Re test 08 85 Auxiliary Systems EFI amp Ignition Electronics Diagnostic Trouble Code 61 DIAGNOSTIC TROUBLE CODE DTC 61 SYSTEM VOLTAGE LOW Circuit Description The ECM monitors the system voltage through circuit 361 Red terminal K1 power feed and circuit 37 Yellow terminal F2 battery feed DTC 61 will
30. Throttle Position TP Sensor Connector Electronic Governor Connector o 9 359C GY R 361 507 513 1 355 351B BR W 359G GY R 2641 W LB 511 506 361L R 359F GY R 351 BR W B2 C1 2 H1 K rr Signal ne o Num TP RERO 3 RA m Return Sensor j Engine 1 Contro Module Throttie Control Signal 1 ECM DIAGNOSTIC TROUBLE CODE DTC 37 DRIVE BY WIRE DECAY FAILURE Circuit Description The throttle position TP sensor is a potentiometer which is attached to the throttle plate shaft inside the electronic governor The ECM provides a 5V reference voltage to the TP sensor between terminal A Grey Red circuit 359C and terminal C Brown White circuit 351B of the electronic governor ATP signal is returned to the ECM from terminal B Grey White circuit 355 of the electronic governor The TP signal varies from about 1 0V at idle to 4 8V at WOT The TP signal is an important input used by the ECM for fuel control and other engine control functions Conditions for Setting the DTC KOER Throttle plate stuck open Normalized TPS gt TPS set point 0 5V for atleast 1 second when not at idle Above conditions are present for at least 1 second Actions Taken When the DTC Sets ECM illuminates the malfunction indicator lamp MIL e
31. 359C GY R 18 H PIN J 1 HHH VOLTAGE SIGNAL e IGNGND 0 0 4 WINE sg 1 2 B KOER 08 5 Auxiliary Systems EFI amp Ignition Electronics MANIFOLD ABSOLUTE PRESSURE SENSOR MAP Part Description The MAP 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 FOR498 035 MAP sensor Specifications Range of Measurement 12 105 kPa Measurement Accuracy 1 7 kPa e Sensor Response Time 3 to 15 msec Resolution 0 1 kPa max 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 frequency is proportional to the pressure input 08 6 Auxiliary Systems EFI amp Ignition Electronics MANIFOLD ABSOLUTE PRESSURE SENSOR MAP Continued SENSOR OPERATION TRANSFER FUNCTION PRESSURE MANIFOLD VACUUM SENSING ELEMENT REFERENCE OSCILLATOR VARIABLE FREQUENCY 25 07 5 OSCIELATOR HARMONIC y GENERATOR _ Fey SQUARE WAVE 15 10 154 GENE
32. 4 Remove the mounting bolts and the coil pack Ignition Coil Pack Removal 1 Reverse removal procedures Tighten the mounting nuts to 5 6 Nm 44 53 Ib in 2 A N CAUTION Spark plug wires must be connected to the proper ignition coil terminal Engine Idle Speed To control engine idle speed some engines utilize an idle air control valve This valve is attached to the intake manifold and controls airflow when engine is idling and throttle plate is closed With the intake mounted valve air enters the intake through the valve behind the throttle plate The ECM controls idle speed by controlling the amount of bypassed air this is done by changing the valve opening Idle speed will be increased during cold engine warm up IAC Motor AIR FLOW DIAPHRAGM VALVE BODY aT r lt SOLENOID AIR FLOW IAC DIAGNOSTICS Action Idle Air Control IAC Circuit e CHECK IAC circuit Malfunction AC circuit open e IAC circuit short to PWR e AC circuit short to GND Damaged IAC valve e Vacuum leak e REPLACE IAC CHECK engine for vacuum leaks Refer to Section 01 e CLEAN or REPLACE as needed IAC valve stuck e AC circuit short to GND e CHECK IAC circuit Damaged IAC valve Idle Air Control IAC Overspeed CHECK IAC circuit Idle Air Control IAC Underspeed IAC circuit open e AC circuit short to PWR Air in
33. 5751 LR UR RS h 7 Me LCOS DAO0636 A 02 96 ESG 642 DISASSEMBLY Continued 12 Remove the cylinder heads and head gaskets left side shown right side similar Discard the head gaskets and bolts Ont 4 LULA 2 m di m x SA SEC 9 c ed MIT n uM 22 0 0730 13 NOTE Identify the location of each valve tappet When the engine is assembled make sure each valve tappet is installed in its original position Remove the tappet guides and valve tappets DA0637 A 02 97 ESG 642 DISASSEMBLY Continued 14 Remove the heater outlet water tube 15 Remove the crankshaft synchronizer 02 98 ESG 642 DISASSEMBLY Continued 16 NOTE The crankshaft pulley 6312 and damper are a balanced assembly Mark the components for alignment before removal Remove the crankshaft pulley DA0726 A 17 Remove the retaining bolt and the crankshaft damper A puller will be needed to remove the damper from the crankshaft DA0729 A 02 99 ESG 642 DISASSEMBLY Continued 18 Remove the oil bypass filter and the engine oil cooler 6A642 if so equipped 19 Remove the oil pan 6675 and the oil pan rear seal 0631 02 100 ESG 642 DISASSEMBLY Continued 20 Remove the oil pump screen cover and tube 6622 Discard the oil pan gasket 6710 A ee m 21 N
34. 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 01 17 ESG 642 DIAGNOSIS AND TESTING Continued The following are potential gauge readings Some are normal others should be investigated further A26227 A NORMAL READING Needle between 51 74 kPa 15 22 in Hg and holding steady NORMAL READING DURING RAPID ACCELERATION AND DEACCELERATION When the engine is rapidly accelerated dotted needle the needle will drop to a low reading not to zero When the throttle is suddenly released the needle will snap back up to a higher than normal figure 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 O kPa in Hg Upon deceleration the needle runs slightly above 74 kPa 22 in Hg 01 18 10 11 12 13 14 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 WAR
35. Check that all connections are secure starter solenoid battery feed or ground circuit Ring gear runout excessive Defective starter Starter remains engaged and runs with engine Shorted ignition switch Battery cable touching solenoid S Replace ring gear Replace starter See removal and installation procedure this section Replace ignition switch Replace or relocate cable terminal defective or mispositioned cable Defective starter Starter clicks and engages but engine will not crank Seized main or rod bearing Hydrolocked cylinder Replace starter See removal and installation procedure this section Remove all plugs one at a time while checking for fluid in cylinders Repair as needed Refer to Section 01 Auxiliary Systems Starter STARTER PERMANENT MAGNET DIAGNOSIS AND TESTING Continued Evaluation Procedure 1 NOTE Remove plastic safety cap on starter solenoid 5 terminal as described under solenoid and disconnect hardshell connector at Removal and Installation in this section CHECK STARTER MOTOR TEST TEST STEP RESULT ACTION TO TAKE ron VOLTAGE STARTER Key OFF Transmission in Neutral PTO disengaged Go to A2 Check for voltage between starter B terminal and CHECK wire connections Starter drive housing between battery and starter 5 voltage OK 12 12 45V solenoid and th
36. Switch the tester to the voltmeter function Connect the positive lead to the generator A terminal connector and the negative lead to ground Turn off all electrical accessories With the engine running at 2000 rpm check the generator voltage Voltage should be between 13 0 15 5 volts NOTE If voltage is not within specifications refer to symptom chart in this Section Auxiliary Systems Charging GENERATOR DIAGNOSIS AND TESTING SYMPTOM CHART CONDITION POSSIBLE SOURCE ACTION Dead battery Battery will not stay Key off battery drain Go to Pinpoint Test A charged Slow crank Low battery Open voltage drop in B Circuit 38 voltage No generator output BK O 290 and 37 Open voltage drop in A Circuit 36 Y W Open high resistance I Circuit 904 LG R Voltage regulator Generator Indicator lamp on with engine running Open A Circuit 36 Y W Go to Pinpoint Test B e Shorted Circuit 904 LG R Open high resistance in S Circuit 4 W BK Voltage regulator Generator Indicator lamp flickers or intermittent Loose connection to generator voltage Go to Pinpoint Test C regulator battery Loose fuse or poor connection in Circuit 36 Loose brush holder screw Voltage regulator Generator Battery overcharging Battery voltage Voltage drop in A Circuit 36 Y W Go to Pinpoint Test D greater than 15 5 volts Voltage drop in Circuit
37. The ECM will react to a limp home mode allowing the machine to be driven at a very low speed 08 38 Auxiliary Systems EFI amp Ignition Electronics Diagnostic Trouble Code 16 DBW Trouble shooting APP out of set range while IVS off is damaged or misadjusted The IVS malfunction has damaged wiring encounters an electrical or mechanical failure DTC 16 Idle Verification Switch Are you using a personal computer PC to perform this diagnosis to Check before continuing at Step 2 Go to Step 2 E 2 Is voltage within specification pem B Go to um 4 Go to Step 3 Repair wire on circuit 361 R Is repair complete Reet oo Go to Step 5 1 KOEO Check voltage at circuit 307 BK Y mem 2 Is voltage within specification Re test 1 Step on AP Check voltage again Circuit 307 BK Y Replace APP 2 Is the voltage within specification VPWR B Go to Step 6 Re test_ heck for a shut or open circuit 30 at ECM pin 2 for 12 volts VPWR B Go to Step 7 307 Re test 7 Check APP sensor follow steps from DTC 13 Does APP check OK Re test 8 Replace ECM Retst test NEM Nm replacemen ECM and install original 5 system operation normal with replacement ECM installation g ECM Go to Sfep 10 Remove original Is the repair complete system operation normal with original ECM ECM and reinstall Meus 4
38. C 1 175 185 20 30 Nm 15 22100 40 50 Nm 30 36 V DA0913 A 30 40 Nm 22 30 Ib ft 0762 02 121 26 27 25 A CAUTION Do not loosen all of the cylinder head bolts at one time Each cylinder head bolt must be loosened and the final tightening completed prior to working on the next bolt in the sequence In the sequence shown loosen the cylinder head bolt three turns then tighten the A short cylinder head bolt or B long cylinder head bolt to the specification indicated and then further tighten the cylinder head bolt to the C degrees indicated Install the rocker arms rocker arm seats and push rods in the following positions 1 Lubricate the ends of the push rods and rocker arm seats with Engine Assembly Lubricant D9AZ 19579 D or equivalent meeting Ford specification ESR M88C80 A e Number 1 intake and exhaust Number 2 exhaust Number intake e Number 4 exhaust Number 6 intake Rotate the crankshaft 180 degrees ESG 642 ASSEMBLY Continued 30 40 Nm 22 30 Ib ft ad 28 Install the remaining push rods rocker arms and rocker arm seats e Number 2 intake Number exhaust e Number 4 intake Number 5 intake and exhaust WEVA e Number 6 exhaust a HUS sr AN AAS SS 29 Install the valve covers NOTE Install the ignition coil pack if necessa
39. C l 175 185 20 30 Nm 15 22 Ib ft 2 0894 DA0913 A ESG 642 02 28 NOTE Make sure to tighten the cylinder head bolts in three steps using two operations The head bolts are to be tighten following the next 3 steps When this operation is complete the 3 steps in sequence 4 must be followed Tighten the cylinder head bolts in three stages in the sequence shown e Stage 1 20 Nm 14 lb ft e Stage 2 40 Nm 29 lb ft e Stage 3 50 Nm 36 lb ft 4 CAUTION Do not loosen all of the cylinder head bolts at one time Each cylinder head bolt must be loosened and the final tightening completed prior to working on the next bolt in the sequence In the sequence shown loosen the cylinder head bolt three turns then tighten the A short cylinder head bolt or B long cylinder head bolt to the specification indicated and then further tighten the cylinder head bolt to the C degrees indicated ESG 642 ENGINE REPAIR Continued NOTE Refer to location note made during removal and make sure components are installed in the correct location 5 NOTE Lubricate the push rods with engine oil prior to installation Install the six push rods A25443 A 02 29 ESG 642 ENGINE REPAIR Continued 6 Install the six rocker arms 1 Position the six rocker arms 2 Install the six bolts 30 40 Nm 22 29 Ib ft DA0895 A 7 If valve train components have been replaced inspect the v
40. Check for plugged oil in the rocker arms or cylinder head Check for proper overhead valve train lubrication If insufficient oiling is suspected accelerate the engine to 1200 rpm 100 rpm with the transmission in NEUTRAL or load removed and the engine at normal operating temperature Oil should spurt from the rocker arm oil holes such that valve tips and rocker arms are well oiled or with the valve covers off oil splash may overshoot the rocker arms If oiling is insufficient for this to occur check oil passages for blockage Push Rods eCheck for bent push rods and restriction in oil passage Positive Rotator and Valve Spring Retainer Keys Check for proper operation of positive rotator Valves and Cylinder Head 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 rom with the transmission in NEUTRAL or load removed and the engine at normal operating temperature Oil should spurt from the rocker arm oil holes such that valve tips and camshaft roller followers are well oiled With the valve covers off some oil splash may overshoot camshaft roller followers Camshaft Lobe Lift OHV Engines 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
41. ESG 642 4 2 LITER Power Products The Source for Power Worldwide INDUSTRIAL ENGINE SERVICE MANUAL FPP 194 309 up pril 2001 Power Products The Source for Power Worldwide 7 Ford Power Products 28333 Telegraph Rd Suite 300 Southfield MI 48034 248 945 4500 Fax 248 945 4501 Ford Power Products LTD 20 586 Arisdale Avenue South Ockendon Essex RM 15 5TJ England 44 1708 672 415 Fax 44 1708 672 815 Ford Power Products GmbH Stolberger Str 313 D 50933 K ln Germany 49 221 94700 551 Fax 49 221 94700 560 223 Y 9 6 Registered 74 4 2 KPMG 6 Quality Registra Ld REN ae FIRM ISO 9001 1994 Tbe Quality Advantage HEALTH amp SAFETY AN WARNING THE FOLLOWING HEALTH AND SAFETY RECOMMENDATIONS SHOULD BE CAREFULLY OBSERVED CARRYING OUT CERTAIN OPERATIONS AND HANDLING SOME SUBSTANCES CAN BE DAN GEROUS OR HARMFUL TO THE OPERATOR IF THE CORRECT SAFETY PRECAUTIONS ARE NOT OBSERVED SOME SUCH PRECAUTIONS ARE RECOMMENDED AT THE APPROPRIATE POINTS IN THIS BOOK WHILE IT IS IMPORTANT THAT THESE RECOMMENDED SAFETY PRECAUTIONS ARE OB SERVED CARE NEAR MACHINERY IS ALWAYS NECESSARY AND NO LIST CAN BE EXHAUS TIVE 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 clothin
42. NOTE If the plunger of the pump is depressed too fast an erroneous pressure reading will result Slowly depress the plunger of the pressure test pump until the pressure gauge reading stops increasing and note the highest pressure reading obtained If the pressure relief cap does not hold pressure remove and wash the pressure relief cap in clean water to dislodge all foreign particles from the gaskets Check the sealing surface in the filler neck If 48 kPa 7 psi cannot be reached install a new pressure relief cap If more than 83 kPa 12 psi shows on gauge install a new pressure relief cap NOTE If the pressure drops check for leaks at the engine to heater core hoses engine to LPG evaporator hose engine to radiator hoses water valve hose if applicable oil cooler return tube gasket 6N789 radiator and heater core or other system components and connections Any leaks which are found must be corrected and the system rechecked Pressurize the engine cooling system as described in Step 4 using a pressure relief cap that operates within the specified upper and lower pressure limits Observe the gauge reading for approximately two minutes For additional information refer to Specifications in this section Pressure should not drop during this time Release the system pressure by loosening the pressure relief cap Check the engine coolant level and replenish if necessary with the correct engine coolant mixture
43. Positioned so their tips direct fuel just ahead of the engine intake valves e Atomize the fuel as the fuel is delivered e Are deposit resistance Do not clean NOTE Cannot be serviced must be replaced when plugged or inoperative J Fuel rail e Attaches to the lower intake manifold Receives fuel from the fuel supply line Delivers fuel to the 6 injectors Must be replaced as a complete unit if it fails Holds the pressure test relief Schrader valve The fuel charging and controls system consist of the Throttle body 9E926 Fuel charging wiring Fuel pressure relief valve 9H321 Fuel injectors The fuel charging and controls system is e A sequential multiport fuel injection SFI system Pulse width modulated The Actuator throttle body Controls air supply to the upper intake manifold 9424 by positioning the throttle plate at different angles from wide open throttle to partially opened at idle NCAUTION Do not force the throttle plate open This may cause permanent damage to the actuator e s not adjustable e Cannot be cleaned NOTE These two types of governors are controlled by pre determined setting electronically set in the ECM These settings are not adjustable They can only be programmed by authorized personnel only Contact your local FPP Distributor listed in the back of this manual for information The fuel pressure relief valve 15 a Schrad
44. Sensor Sensor Ground Sensor Sensor Engine Return Signal Signal Retum Control j Module se NE NM M E MN E EE M 20 M M M MOM MN NM E DIAGNOSTIC TROUBLE CODE DTC 53 CAMSHAFT POSITION SENSOR ILLEGAL PATTERN Circuit Description The camshaft position CMP sensor signal is produced by the CMP sensor pulses when the engine is running and CKP sync pulses are also being received The ECM uses the CMP signal pulses to initiate sequential fuel injection The ECM constantly monitors the number of pulses on the CMP signal circuit and compares the number of CMP pulses to the number of CKP reference pulses received If the ECM receives an incorrect number of pulses on the CMP reference circuit DTC 53 will set The engine will perform with little or no degradation in perceived performance Conditions for Setting the DTC The correct number of crankshaft pulses 70 not detected between each CKP pulse Actions Taken When the DTC Sets ECM illuminates the malfunction indicator lamp MIL The ECM will default to the previously established injection sequence 08 80 Auxiliary Systems EFI amp Ignition Electronics Diagnostic Trouble Code 53 Diagnostic Aids Inspect the harness connectors for backed out terminals improper mating broken locks improperly formed or damaged terminals and poor terminal to wi
45. Starter DIAGNOSIS AND TESTING Pinion and Ring Gear Wear Patterns 0045 NORMAL WEAR PATTERN 2 SMALL WEAR PATTERN MILLED GEARS Armature Gear Armature Gear Flywheel Gear Flywheel Gear Armature Gear Flywheel Gear Milled Condition Excessive Wear on 3 or 3 Teeth Milled Tooth Metal Build up Will Not Permit Engagement 00000 General Procedures Starter Drive and Flywheel Ring Gear Inspection 1 Check the wear patterns on the A starter drive 11350 and the B flywheel ring gear If the wear pattern is normal install the starter motor refer to Starter Motor in this section 2 Ifthe A starter drive gear and the flywheel ring gear are not fully meshing or the gears are B milled or damaged replace the starter motor refer to Starter Motor in this section Replace the flywheel ring gear 07 9 Auxiliary Systems Starter STARTER PERMANENT MAGNET REMOVAL AND INSTALLATION PPD0043 Solenoid Blade Terminal or Post Nut Connection caution A jumper wire must not be installed between the large round electrical terminal and the solenoid blade terminal at the starter If done voltage is generated to the solenoid by the spinning starter after release of the start key or button causing the starter to remain engaged resulting in failure Nut Starter Relay Starter Cable Battery Positive Cable 12 Gauge Wire Red E9SF 11A004 AB S 2 9 Perman
46. Thermostat The water thermostat should be replaced only after the following test has been performed Thermostat Test Thermostat Removed A WARNING USE CAUTION WORKING WITH HOT BOILING WATER AND WEAR APPROPRIATE PROTECTIVE GEAR MAY CAUSE BODILY HARM Remove the thermostat and immerse it in boiling water Replace the thermostat if it does not open at least 0 230 after one minute at 212 F If the problem being investigated is the inability of the cooling system to reach normal operating temperature the thermostat should be checked for leakage This may be done by holding the thermostat up to a lighted background Leakage of light all around the thermostat valve thermostat at room temperature indicates that the thermostat is unacceptable and should be replaced It is possible on some thermostats that a slight leakage of light at one or two locations on the perimeter of the valve may be detected This should be considered normal 05 30 Auxiliary Systems Cooling COOLING SYSTEM DIAGNOSING AND TESTING Continued Radiator Leak Test Removed From Vehicle CAUTION Never leak test an aluminum radiator in the same water that copper brass radiators are tested in Flux and caustic cleaners may be present in the cleaning tank and they will damage aluminum radiators 1 Always install plugs in the oil cooler fittings before leak testing or cleaning any radiator 2 Clean the radiator before leak testing to avoid
47. fatigue failure A e Spot polishing improper seating B e Scratching dirty C Base exposed poor lubrication D Both edges worn journal damaged E e One edge worn journal tapered or bearing not seated F 01 42 ESG 642 GENERAL SERVICE PROCEDURES Continued Roller Follower Inspection OHC Engines y 1 Inspectthe roller for flat spots or scoring If any damage is found inspect the camshaft lobes and hydraulic lash adjusters for damage A26461 A Hydraulic Valve Tappet Inspection OHV Engines y 1 Inspect the hydraulic valve tappet and roller for damage If any damage is found inspect the camshaft lobes and valves for damage A26461 A Hydraulic Valve Tappet Leakdown Test OHV Engines 1 NOTE The leakdown test will not be accurate if itis done with engine oil in the hydraulic valve tappet Use testing fluid New hydraulic valve tappets are already filled with testing fluid Compress the hydraulic valve tappet to remove the engine oil if necessary 2 Place A hydraulic valve tappet in a B commercially available hydraulic tappet leakdown tester Position the C steel ball provided in the plunger cap Add testing fluid to cover the hydraulic tappet and compress Hydraulic Tappet Leakdown Tester until the hydraulic valve tappet is filled with testing fluid 01 43 ESG 642 GENERAL SERVICE PROCEDURES Continued 3 Adjust the length of the A ram so that
48. t Engine Signal Return Control Module DIAGNOSTIC TROUBLE CODE DTC 42 HO2S SENSOR HIGH VOLTAGE STUCK RICH Circuit Description The ECM supplies a voltage of about 0 45 volts to the heated exhaust gas oxygen sensor This may read as low as 0 10 volts with a 10 megohm digital voltmeter The oxygen sensor varies the voltage within a range of about 1 volt if the exhaust is rich down through about 0 10 volts if the exhaust is lean A cold sensor causes an open loop operation If the sensor pigtail wiring connector or terminal is damaged the entire oxygen sensor assembly must be replaced Do not attempt to repair the wiring connector or terminals In order for the sensor to function properly it must have a clean air reference provided to it This clean air reference is obtained by way of the signal return wire Any attempt to repair the wires connector or terminals could result in the obstruction of the air reference and degrade the sensor performance There must be no crimp connectors in the wiring Conditions for Setting the DTC and in closed loop HO2S sensor voltage is greater than or equal to 0 65 volts for 20 consecutive seconds Actions Taken When the DTC Sets ECM will illuminate the malfunction indicator lamp MIL The ECM will switch to open fuel control 08 68 Auxiliary Systems EFI amp Ignition Electronics Diagnostic Trouble Code 42 Diagnostic Aids A
49. 3 If a problem is found repair as necessary Technical Was a problem found Verify repair Support Hotline 1 800 521 0370 03 32 Auxiliary Systems Ignition CUTS OUT MISSES SYMPTOM Step Action Yes No DEFINITION Steady pulsation or jerking that follows engine speed usually more pronounced as engine load increases Check for incorrect idle speed Ensure that the following conditions are present Engine fully warm Accessories are OFF Does engine cut out or miss Go to Step 2 Perform a visual physical check including ignition coil and secondary ignition wire connections Was a problem found Verify repair Go to Step 3 Hefer to DTC chart perform Perform MIL DTC retrieval procedure Ignition ON engine not running short STI connector to ground Do any fault codes flash and display component and circuit test as equired Go to Step 4 Check the heated oxygen sensor HO2S operation The HO2S should respond quickly to different throttle positions If it doesn t check for silicone or other contaminants from fuel or use of improper RTV sealant The sensor may have a white powdery coating which is silicone contamination Silicone contamination sends a rich exhaust signal which causes the ECM to command an excessively lean air fuel mixture Replace HO2S Was oblem found Verify repair Go to Step 5 as a problem found Check the ECM grounds to verify that they are c
50. AN WARNING WHEN CARRYING OUT SERVICE OPERATIONS ON AN ENGINE EQUIPPED WITH DISTRIBUTORLESS IGNITION FOLLOW ALL THE USUAL SAFETY MEASURES TO PREVENT THE POSSIBILITY OF ELECTRIC SHOCKS SHOULD BE FOLLOWED NOTE High tension voltage produced by a distributorless ignition system is higher than for a conventional ignition system It is in excess of 55 000 Volts Description The ESG 642 engine uses a Distributorless Ignition System DIS to ignite the fuel air mixture at the correct time and sequence based upon the input it receives The brain of this system is an Engine Control Module ECM The ECM has the capability at the OEM option to protect the engine from over heating and low oil pressure Inputs are sensors or switches that feed the ECM information The ECM is used on EFI engines and the ICM is used on carbureated engines e Engine Cylinder Head Temperature Sensor Input Camshaft Position Sensor CMP Input Crankshaft Position Sensor CKP Input Intake Air Temperature Sensor IAT Input Heated Oxygen Sensor 025 Input e Manifold Absolute Pressure Sensor MAP Input e Throttle Position Sensor TP Sensor Input Fuel Select Switch Manifold Skin Temperature MST sensor From these inputs the ECM computes spark strategy Spark advance and fuel mixture air fuel to obtain optimum engine performance for correct load conditions Operation The engine control module needs the fo
51. B for 3 seconds VPWR Crank VPWR B Ground 04 20 42 Pin Connector Pin 5 Auxiliary Systems Fuel Actuator Two types of actuators are available as options for electronic variable speed governing EFI Either a Barber Coleman or Precision Governor Actuator are available Barber Coleman Phase Governor Actuator The ECM can within the operating parameters be programmed to accept up to four engine speeds The speedi is selected by means of a remote toggle switch ALL ACTUATORS DRY FUEL MODULATOR 264 W LB 361H VPWR K1 04 21 Precision Governor Actuator Auxiliary Systems Fuel Liquid Petroleum Gas and Natural Gas LPG amp NG Fuel Lockout Relay 5708 5700 30 87 242 361C 86 85 FUEL LOCKOUT 570 BK W 16 L 361C R 16 _ _570 BK W 16 NOTE Alternate fuel select switch is supplied by customer All test must be completed with fuel select switch in the alternate fuel position NOTE Make all following checks with connector connected to relay and back probe wire circuits with paper clip Circuit 242 gt ECM Connector Pin 2 K Off OV KOEO B Ground KOER Ground Circuit 570J gt To Fuel Lockout Relay K Off OV KOEO Same voltage if unit has fuel KOER lockout solenoid Circuit 570 gt Splice 10 gt 42 Pin Connector Pin 34 or 42 K Off B
52. DTG A Shuts off engine B NO ACTION e The following DTC s are SOFTWARE SELECTABLE DTC 43 Over maximum coolant temperature or cylinder head temperature DTC 51 Low oil pressure DTC 62 Over maximum voltage e DTC s may be extracted using either the MIL or a computer DTC s can only be retrieved with key on engine off KOEO e When extracting DTC s via the MIL the following apply When the Self Test Input STI circuit is grounded to begin flashing the DTCs there is a 5 second delay before the DTC s begin flashing The STI circuit is a white wire with a purple stripe exiting pin H3 from the ECM It branches off to terminal A of the 6 pin diagnostic connector Flashing MIL is on for 0 4 second an off for 0 4 second 1 2 seconds MIL off time between digits of two digit DTC s 2 4 seconds MIL off time between DTC s Each DTC repeated 3 times before flashing next stored DTC Up to 6 DTC s can be stored Once all stored DTC s are flashed process repeats with first stored DTC DTC s are flashed in the order in which they were set f is stored a DTC 11 is flashed indicating all systems are OK stored except DTC 11 will illuminate the MIL during engine operation 08 26 Auxiliary Systems EFI amp Ignition Electronics 08 27 Auxiliary Systems EFI amp Ignition Electronics Other Descriptions MALFUNCTION PROCESS DESCR
53. Electronic Governor ir p M Mn Throttle Position TP Sensor Connector ees Connector 359C GY R 361JAR S07 S13 1 E 355 GY W 351B BR W 359G GY R 264 W LB 511 506 361L R 359F GY R 351 BR W 2 482 __ A2 Rt K L7 7 Signal 777 Power 71 Engine Return Sensor TP Throttie Feed 1 Control l Signal 5V Reference Control 1 Module 1 DIAGNOSTIC TROUBLE CODE DTC 47 DRIVE BY WIRE RISE FAILURE Circuit Description The throttle position TP sensor is a potentiometer which is attached to the throttle plate shaft inside the electronic governor The ECM provides a 5V reference voltage to the TP sensor between terminal A Grey Red circuit 359C and terminal C Brown White circuit 351B of the electronic governor ATP signal is returned to the ECM from terminal B Grey White circuit 355 of the electronic governor The TP signal varies from about 1 0V at idle to 4 8V at WOT The TP signal is an important input used by the ECM for fuel control and other engine control functions Conditions for Setting the DTC Actuator is lower than the commanded position by the ECM TPS set point gt normalized TPS 0 5V for at least 2 consecutive seconds when not at idle Actions Taken When the DTC Sets ECM illuminates the malfunction indicator lamp MIL e The ECM shuts down the engine The engine can be rest
54. Hot circuits can cause equipment damage and false readings 03 4 Figure 4 Switch Circuit Check and Voltage Check In an inoperative circuit with a switch in series with the load jumper the terminals of the switch to power the load If jumpering the terminals powers the circuit the switch is inoperative Figure 4 Continuity Check Locating open circuits Connect one lead of test lamp to a Known good ground or the negative battery terminal Test for voltage by touching the other lead to the test point The bulb goes on when the test point has voltage Figure 4 Auxiliary Systems Ignition INTRODUCTION Continued example in Figure 5 with a ground at X the bulb goes out when C1 or C2 is disconnected but not after disconnecting C3 This means the short is between C2 and C3 A SELF SE VOLTAGE BATTERY MOTOR POWERED CHECK uy DISCONNECTED TEST e 2 4 POETS Figure 5 Short Check Figure 6 Ground Check A fuse that repeatedly blows is usually caused by a short to ground It s important to be able to locate such a short quickly Figure 5 Turn on power to the circuit Perform a Voltage Check between the suspected inoperative ground and the frame Any indicated voltage means that 1 Turn off everything powered through the fuse the ground is inoperative Figure 6 Turn off power to the circuit Connect one lead of a Self Powered Test Lamp or Ohmmete
55. LB BK S 3 BR W 307 BK Y B2 A1 A2 K2 I oes DIAGNOSTIC TROUBLE CODE DTC 13 ACCELERATOR PEDAL POSITION APP SENSOR LOW VOLTAGE Circuit Description The Accelerator Pedal Position APP sensor is a potentiometer which is attached to the accelerator pedal pivot shaft The ECM provides a 5V reference voltage to the APP sensor between terminal A Grey Red circuit 359A and terminal C Brown White circuit 351B APP An APP sensor signal is returned to the ECM from terminal B Grey White circuit 355 of the electronic governor The APP sensor signal varies from about 1 0V at idle to 4 8V at WOT The APP signal is an important input used by the ECM for fuel control and engine RPM Conditions for Setting the DTC e KOEO or APP signal is 0 3V or less Actions Taken When the DTC Sets The ECM illuminates the malfunction indicator lamp MIL e The ECM forces the APP internally to a default position of 0 235V limp home mode 08 32 Auxiliary Systems EFI amp Ignition Electronics Diagnostic Trouble Code 13 Trouble Shooting e Potentiometer in APP sensor is bad bad DBW harness or connectors electrical failure APP sensor signal is 0 3V or less DTC 13 Accelerator Pedal Position Sensor Low Voltage Step tion 7 Vaws No 1 Are you using a personal computer PC to perform this diagnosis Go to Dia
56. M Pedal Assembly Switch Return Signal H Power Feed From Ignition Switch J 42 Pin Connector L Connector for A Idle Validation Switch Circuit 359 Circuit 355 Circuit 351 Circuit 307 K Off OV K Off OV K Off OV K Off OV KOEO Ground KOEO 0 70V KOEO 5V KOEO OV w foot pedal at rest KOER Ground KOER 0 70V KOER 5V 9 w foot pedal at rest to 4 8V 12V w foot pedal depressed 03 52 Auxiliary Systems Ignition Drive By Wire Foot Pedal Wiring Harness F8JL 12B476 AA TN Circuit 22427 iT Number Circuit Description Color 355 111 1 VPWR 4 12 20 Drive Input GYw 20 _ 351 VREFG 361 20 4774 x Second Version Foot Pedal A Enlarged View 1 Signal Return 2 PP Sensor Signal 3 PP 5V Reference Pedal Assembly Switch Return Signal Ground 5 Power Feed From Ignition Switch NOTE All wires connect to the 42 Pin Connector as previous pedal on Page 03 52 Circuit 359 Circuit 355 Circuit 351 Circuit 307 K Off OV K Off OV K Off OV K Off OV KOEO Ground KOEO 0 70V KOEO 5V KOEO 12V w foot pedal at rest KOER Ground KOER 0 70V KOER 5V 12V w foot pedal at rest to 4 8V _ OV pedal depressed 03 53 Auxiliary Systems Ignition Wiring Schematic 4 2L amp 2 5L Alternator Gauges Ignition Drive By Wire HARNESS 100307
57. Non serviceable e Must be replaced as needed 04 3 Auxiliary Systems Fuel FUEL SYSTEM DESCRIPTION AND OPERATION Continued F Fuel pressure regulator and filter Fuel enters through 7 9mm 5 16 in inlet tube located at center of the end of the regulator with return outlet tube Controls the fuel pressure at a constant 441 or 10 kPa 64 psi or 1 5 psi to the fuel rail Directs excess fuel through the return outlet tube 9 5mm 3 8 in located off center of end with inlet tube Contains a fuel filter filter media PMS 120 high capacity pleated phenolic treated paper that cannot be serviced Must replace complete unit to service Directs fuel out the single outlet tube 9 5mm 3 8 in located at center of opposite end of regulator NOTE Cannot be serviced must be replaced when plugged or inoperative G Fuel return line Fuel returning to tank is under pressure and may be as high as 689 kPa 100 psi if the line is blocked Excess fuel supplied by the fuel pump but not needed by the engine is returned to the fuel tank H Damper assembly e Absorbs high pressure spikes caused by shut downs from high RPM and high demand of fuel under a sudden full load Must be mounted within 100mm from fuel rail Fuel injectors 6 injectors e Sequential multiport fuel injectors Batch fired during crank at start up e Solenoid operated electrically controlled by the ECM
58. Pin D output 2 open drain Pin E ICM supply voltage Operational range is 6 24v Ignition supply voltage is monitored and a correction factor is applied to assure proper dwell period Power Ground Main ground circuit Main Pin H Indicates crankshaft position and engine RPM Controls switching of coils The OCT1 input is used to select one of three timing maps and can be globally modified using OCT2 The following inputs are used for fuel selection Open Gasoline Grounded LPG 12V NG The OCT2 input selects a constant to be added or subtracted from entire ignition timing map The following inputs are used for ignition map modification Open no action Grounded subtract 3 degrees from table 12V add 5 degrees to table Used to indicate an overheated condition ICM responds with engine protection function stalls engine Also used to modify timing when higher than normal coolant temperatures are experienced Used to indicate a low oil pressure condition ICM responds with engine protection function stalls engine The oil pressure switch is normally open when engine is off or the oil pressure is low 6 psi 1 5 Undefined Possible use could be an application select if ICM is to contain multiple calibrations example 1 3L 2 0L 2 5L 4 2L Defined as Intake Air Temperature IAT input To control ignition timing based on intake temperature Need to determine location of sensor in intake air stre
59. THE ENGINE OVERHEATS TEST CONDITIONS TEST DETAILS RESULTS ACTIONS B1 CHECK THE ENGINE COOLANT LEVEL NOTE If the engine is hot allow the engine to cool before proceeding 1 NwanNING 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 AVOID 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 110 F Wrap a thick cloth around the pressure relief cap and turn it slowly one half turn counterclockwise Stepping back while the pressure is released from the cooling system When you are sure all the pressure has been released still with a cloth turn counterclockwise and remove the pressure relief cap Check the engine coolant level at the degas bottle 5 the engine coolant OK P Yes GO to B2 p No REFILL the engine coolant at the degas bottle GO to Pinpoint Test A Continued 05 25 Auxiliary Systems Cooling COOLING SYSTEM DIAGNOSING AND TESTING Continued PINPOINT TEST B THE ENGINE OVERHEATS Continued B2 CHECKTHE COOLANT CONDITION E AIEBIBESULTSIACTIONS CONDITIONS TESTDETAILS RESULTS ACTIONS B2 CHECK THE COOLANT CONDITION eee Check the coolant for contaminants such as rust corrosion or discoloration the coolant condition OK
60. and observe the voltage while moving connectors 4 02 and wiring harnesses related to the CHT sensor 4 25 22 446 925 021 4 54 Voltage values calculated for VREF 5 volts may vary 15 due to sensor and VREF variations A change in the CHT display will indicate the location of the fault DTC 33 4 2L Engine Cylinder Head Temperature High Voltage Step tion Ses Yes S No Are you using a personal computer PC to perform this diagnosis s to Diagnostic System Check before continuing at Step 2 Go to Step 2 1 Ignition OFF 2 Disconnect the CHT sensor electrical connector 3 Check ohm value across the two pins of the CHT Is it within specs of above chart Go to Step 3 Go to Step 7 1 KOEO 2 With aDVOM measure the voltage on circuit 359G Grey Yellow cavity 1 Is the voltage greater then the specified value Go to gr 4 Go to perg 5 Check for a short to voltage on circuit 359G Grey Yellow Grey Red and repair as necessary Was a repair necessary test Go to 6 1 Reconnect the CHT sensor electrical connector 2 With a suitable backprobing technique measure the voltage between cavity 2 circuit 1102 Y LG and ground Is the voltage greater than the specified value Go to uu 7 Go to penam 6 eck for a short to voltage on circuit 1102 Y LG and repair as necessary Was a repair necessary 25 test Go to gua 0 Replace the CHT sensor Is fhe repair complete tet eese d nstall replacem
61. contamination of the tank 3 Leak test the radiator in clean water with 138 kPa 20 psi air pressure ENGINE CYLINDER HEAD TEMPERATURE CHT SENSOR GI Low High Coolant Temperature Temperature e Engine cylinder head temperature CHT sensor is a type of thermistor that converts engine temperature to an electrical voltage signal e The electrical resistance of the CHT sensor changes with temperature As engine coolant temperature increases the CHT resistance decreases Output is a variable voltage signal which typically ranges from 0 3 volt to 4 5 volts e At 40 F CHT resistance is approximately 269K ohms At 77 F CHT resistance is approximately 29K ohms e At 248 F CHT resistance is approximately 1 2K ohms NOTE Complete list of temperature sensor characteristics can be found on page 05 34 of this section DIAGNOSTIC TROUBLE CODE DTC 43 ENGINE CYLINDER HEAD TEMPERATURE LOW VOLTAGE AND DTC 33 FOR HIGH VOLTAGE Engine Cylinder Head Temperature Sensor D Sensor Ground Connector Ground B Engine Control Module ECM Circuit Description E Sensor Signal The engine cylinder head temperature CHT sensor is a termistor which measures the temperature of the engine cylinder head The ECM supplies a ground circuit 359 Gray Red from the sensor and monitors voltage signal circuit to 1102 Yellow Lt Green to the sensor When the engine
62. for more than 1 second Normalized TPS gt 0 1V for more than 0 1 second when engine has been idling for at least 1 second Actions Taken When the DTC Sets ECM illuminates the malfunction indicator lamp MIL e The ECM shuts down the engine The engine can be restarted by recycling the ignition switch 08 54 Auxiliary Systems EFI amp Ignition Electronics Diagnostic Trouble Code 27 DTC 27 Drive By Wire Idle Failure No 1 Are you using a personal computer PC to perform this diagnosis Go to Diagnostic NOTE This test cannot be made without a PC or a very high tech DVOM System Check before continuing at Step 2 Go to Step 2 Visually check for dirt or carbon in the throat of the actuator or on the 2 throttle plate Clean with carb Is there any dirt or carbon cleaner Re test Go to Step 3 3 Is the normalized TPS gt 0 1V above ECM set point for more than 0 1 second Go to Step 4 Re start when engine has been at idle for at least 1 second 4 Does the ECM have correct program for this application The program can be checked by using the monitoring screen on your PC Download correct Go to Step 5 program amp re test Go to Sfep 6 Repair wire Reconnect battery and re test Go to Step 7 Repair or replace terminals Reconnect battery Re test Go to Step 8 Remove amp replace electronic governor Using EEMS SERV program read graph for throttle body position TPS
63. installed Re testthe replacement ECM Go to Step 9 Is the repair complete system operation normal with replacement eave replacement ECM ECM reinstalled installed Re test 08 81 Auxiliary Systems EFI amp Ignition Electronics Diagnostic Trouble Code 54 DIAGNOSTIC TROUBLE CODE DTC 54 ECM FAULT ILLEGAL OPERATION Circuit Description The ECM continuously monitors electrical signals form the engine If for some reason the ECM receives an illegal instruction it then executes an exception handling code the ECM will then go to a default program and return to normal operation but it will set DTC 54 and will need to be replaced Conditions for Setting the DTC e KOEO or Action Taken When the DTC Sets ECM will illuminate the malfunction indicator lamp MIL Diagnostic Aids Inspect the harness connectors for backed out terminals improper mating broken locks improperly formed or damaged terminals and poor terminal to wire connections Inspect the wiring harness for damage Check for shorts or open in the spark plug wires DTC 54 ECM Fault Illegal Operation Step Action alr Are you using a personal computer PC to perform this diagnosis to Diagnostic Check before continuing at Step 2 Go to 2 Check the MIL or the PC engine data screen Are any other DTC s set e to applicable DTC Go to Goto steps 3 Install replacement ECM Remove replacement Is
64. 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 engine size operator driving habits ambient temperature quality and viscosity of the oil Operating under varying conditions can frequently be misleading An engine that has been run for short hours or in below freezing ambient temperatures may have consumed a normal amount of oil However when checking engine oil level it may measure up to the full mark on the oil level dipstick 6750 due to dilution condensation and fuel in the engine crankcase The engine might then be run at high speeds where the condensation and fuel boil off The next time the engine oil is checked it may appear that a liter quart of oil was used in about 3 to 3 1 2 hours This perceived 3 to 3 1 2 hours per liter quart oil consumption rate causes customer concern even though the actual overall oil consumption rate is about 50 hours per liter quart Make sure the selected engine oil meets Ford specification WSS M2C153 F and the recommended API performance category SJ or higher and SAE viscosity grade as shown in the equipment Owner s or Operators Engine handbook It is also important that the engine oil is changed at the intervals specified Refer to the Vehicle Owner s Guide or E
65. it must be replaced as an assembly 06 14 Auxiliary Systems Charging BATTERY MOUNTING AND CABLES 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 VEHICLE OR BATTERY LIFT WITH A BATTERY CARRIER OR WITH YOUR HANDS ON OPPOSITE CORNERS 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 Removal and Installation Environmental Protection Ford Motor Company strongly recommends that lead acid batteries 10655 be returned to an authorized recycling facility for disposal RECYCLE J4961 A Battery Removal 1 Remove battery cables from battery terminals battery ground cable 14301 first 2 Remove battery hold down clamp 10718 3 caution When lifting a plastic cased battery 10655 excessive pressure on the end walls could cause acid to spew through the vent caps resulting in personal injury damage to the vehi
66. wm oo Valve Cover to Cyl LH amp RH wl EN 71 102 Water Outlet Tube to 10 Front Water Pump Bolt 15 2 Water Pump Stud Bot 8 12 71 106 Water Pump Nuts 20 30 15 22 Water Pump Pulley Bolts 22 28 16 21 Water Temperature 14 19 10 14 indeator Sender Unt 742 Pin Connector Bot 10 89 42 Pin Connector Bracket 4 5 6 35 50 Hold Down Bolt 1 Refer to the procedure for torque specification and sequence 0 Valve Cover to Cyl Head 0 Stud Bolt LH amp RH 2 Refer to the procedure for the tightening sequence 02 135 Auxiliary Systems Ignition IGNITION INDEX SUBJECT PAGE lrrigecs P eire m 03 3 How to Find Electrical Concerns 03 3 Troubleshooting 00 00 03 3 03 4 Self Powered Test Lamp 03 4 Continuity Check Locating open circuits 03 4 Troubleshooting Wiring harness and Connector Hidden Concerns 03 6 Electrical Symbols 03 7 Description And Operation ECM 03 8 JBC uo Pe Ha 03 8 Run Mode Transient Mode Overspeed Mode 03 9 Electronic Engine Controls 03 9 Inputs to the ECM Effecting the Ignition 03
67. 2 Replace the coil if it is not within the specified value Refer to Did the coil require replacement Page 03 35 Verify repair Go to Step 12 1 Remove the spark plugs and check for gas or oil fouling cracks wear improper gap burned electrodes heavy deposits or improper heat 12 range 2 If spark plugs are fouled the cause of fouling must be determined before replacing the spark plugs Was a problem found Verify repair Go to Step 13 1 Check the injector connectors 2 If any of the connectors are connected at an improper cylinder correct as necessary Was a problem found n repair Go to mum 14 Visually physically check vacuum hoses for splits kinks and proper connections and routing Was a problem found Go to 15 Check the exhaust system for a possible restriction Damaged or collapsed pipe Internal muffler failure Was a problem found Verify repair Go to Step 16 1 Review all diagnostic procedures within this table 2 If all procedures have been completed and no malfunctions have been found review inspect the following 16 Visual physical inspection including fuel quality Contact Ford check Power Products All electrical connections within a suspected Customer circuit and or system Service Center 3 If a problem is found repair as necessary Technical Was a problem found Verify repair Support Hotline 1 800 521 0370 03 23 Auxiliary Systems Ignition LACK OF POWER O
68. 3 Vent Pin 1 Coolant Outlet Connection 2 Thermostat 2 Install thermostat 2 into coolant outlet connection 1 rotating in a clockwise or counter clockwise direction to engage cam on thermostat securely Thermostat vent pin 3 should be located at the 1 o clock C or 11 o clock D position ua FRONT OF ENGINE ap Sub Assembly 5 Thermostat Housing Gasket 6 Hold Down Bolt 7 Thermostat Housing Sub Assembly 8 Lower Intake Manifold Front 3 Install water outlet connection thermostat sub assembly 7 and gasket 5 to lower intake manifold 8 4 Install two hold down bolts and washers 6 and rundown to specified torque 8 Nm then rotate 55 65 degrees 5 Connect upper radiator hose and clamp to coolant connector 6 Fill cooling system with a 50 50 mixture of Ethylene Glycol green or green yellow in color not red and water 05 10 Auxiliary Systems Cooling COOLING SYSTEM REMOVAL AND INSTALLATION Continued With or Without Heater or Dry Fuel Evaporator Plumbing Installation of Heater Water Inlet Tube 18696 1 Install new ring E on portion of tube that fits into intake manifold Lubricate O ring E with ESE M99B144 B Surfactant or other approved lubricant Insert tube into hole located at the left rear of lower intake manifold A Hold Down Bolt Outlet Tube Indicates direction of coolant flow D Lower Intake Manifold Rear E O Ring Star
69. 3 BR W 307 BK Y B2 A1 A2 K2 cr e cum eee A A m m ECM EE DIAGNOSTIC TROUBLE CODE DTC 23 APP SENSOR HIGH VOLTAGE Circuit Description APP The Accelerator Pedal Position APP sensor is a potentiometer which is attached to the accelerator pedal pivot shaft The ECM provides a 5V reference voltage to the APP sensor between terminal A Grey Red circuit 359A and terminal C Brown White circuit 351B APP An APP sensor signal is returned to the ECM from terminal B Grey White circuit 355 of the electronic governor The APP sensor signal varies from about 1 0V at idle to 4 8V at WOT The APP signal is an important input used by the ECM for fuel control and engine RPM Conditions for Setting the DTC e KOEO or APP signal is 4 9V or more Above conditions are present for at least 2 consecutive seconds 08 46 Auxiliary Systems EFI amp Ignition Electronics Diagnostic Trouble Code 23 Actions Taken When the DTC Sets The ECM illuminates the malfunction indicator lamp MIL ECM forces the PPS internally to 0 235V The ECM will shutdown engine Engine can be restarted after cycling ignition switch DTC 23 Accelerator Pedal Position Sensor Low Voltage Step 1 7 Values No 1 Are you using a personal computer PC to perform this diagnosis Go to Diagnostic System Check before continu
70. 4 Keep original ECM replacement installed Re test Go to Step 1 Leave Is the repair complete system operation normal with replacement ECM 08 39 Auxiliary Systems EFI amp Ignition Electronics Diagnostic Trouble Code 17 DBW NOTES Electronic J Governor TP Sensor 35986 359C GY H 361Hi R S01 3590 BR W 355 GY W 359 GY R 264 W LB 03 05 3616 359F GY R 351 BR W _ B2 C1 A2 R1 K1 T Signal cg Engine Return Sensor s d Control Signal 5V Reference VPWR 1 Module ECM DIAGNOSTIC TROUBLE CODE DTC 17 ACTUATOR UNSTABLE Circuit Description The electronic governor consists of a throttle body an electronically actuated throttle plate and a built in throttle position TP sensor There are two pigtails that exist the governor body The 3 wire pigtail connects the TP sensor to the ECM Refer to Throttle Position TP Sensor for more information The 2 wire pigtail carries the throttle signal from the ECM to the governor Desired engine speeds are stored in the configuration program for each specific application and can be changed with the ECM calibration software When the accelerator pedal is depressed a signal is sent from the APP sensor to the ECM the ECM responds by sending the appropriate signal to the g
71. 4 minutes and connecting bolts must be torqued within 15 minutes after applying sealant Failure to follow this procedure can cause future oil leakage e Use silicone gasket and sealant FGAZ 19562 AA or equivalent meeting Ford specification WSE M4G323 A6 NOTE Sealant must be removed and area cleaned with solvant if above instructions are not followed Use metal surface cleaner F4AZ 19A536 RA or equivalent meeting Ford specification WSE M5B292 A 1 Clean mating surfaces on the oil pan and the cylinder block 2 Apply a bead of Silicone Gasket and Sealant as shown in the illustration 3 Follow removal procedure in reverse order 0755 4 Tighten the oil pan retaining bolt in two stages in the sequence shown e Stage 1 4 5 Nm 35 44 Ib in e Stage 2 9 12 Nm 79 106 Ib in 0757 02 61 ESG 642 ENGINE REPAIR Continued Oil Pump Screen Cover and Tube Removal 1 Remove the oil pan Refer to the procedure in this Section 2 Remove the retaining bolts and the oil pump screen cover and tube Discard the gasket 0 0991 02 62 ESG 642 ENGINE REPAIR Continued Installation of Oil Pump Screen Cover and Tube 1 Install the oil pump screen cover and tube Use a new gasket 2 Install the oil pan Refer to the procedure in this section 20 30 Nm 15 22 10 0 DA0987 A Crankshaft Main Piston Rod Bearings Removal JU CAUTION The cylinder heads must be remo
72. 55 40 0 Maximum mm Inch 0 36 max 0 014 max Camshait Position ME Sensor Bolts PSION Camshaft Position 40 50 30 36 Piston Diameter Sensor Drive Gear Bolt Standard mm Inch 96 795 3 81 Camshaft Synchronizer 18 to Front Cover Bolt Piston to Bore 0 018 0 044 Camshaft Synchronizer 33 Clearance mm Inch 0 000709 0 00173 Drive Gear to Camshaft Piston Ring to Land 0 030 0 080 Camshaft Thrust Plate Bod 71 124 Clearnace mm Inch 0 00122 0 00315 Bolts Compression Ring 1 54 1 52 top ee mm Inch 0 060 0 059 154 152 b Reservoir to Bracket Bolts 22 eo Coolant recover reservoir Se bracket to GOP bolts Ring Gap Crankshaft Damper Bolt 140 180 103 132 Compression Ring 0 25 0 41 Crankshaft Pulley Bolts 26 38 19 28 mm Inch 0 00098 0 00161 Cylinder Head Bolts Page 02 119 0 38 0 64 Drive Belt Tensioner Bolts 25 0 00149 0 0025 Engine Coolant By Pass 8 11 5 NEU 71 102 Oil Ring mm Inch 0 15 165 0 0059 0 0064 Hose 6 5 Engine Exhaust Gas 36 46 27 34 Lubrication System Specifications Oxygen HO2S Sensor Head m Temperature ECHT Oil Pump Gear Radial 0 125 0 050 Sensor Cal had 20 30 14 22 8 Clearance Idler and 0 0055 0 002 Engine Dynamic Balance 10 PIU AE Shaft Thrust Plate Bolts Oil Pump Gear End Height 0 085 0 010 Engine Front Cover Bolt 20 30 14 22 Extends Below Housing 0 0033 0 0004 Engine Fr
73. 9 Crankshaft Position Sensor Sensor 03 9 Cranking 03 10 Fuel Select Switch 03 10 Throttle Position Sensor TP Sensor 03 10 Camshaft Position Sensor CMP Sensor 03 11 Cylinder Head Temperature Sensor CHT SCNSOR Pc 03 11 Heated Oxygen Sensor 25 03 11 Intake Air Temperature Sensor IAT Sensor 03 12 Electronic Control Module ECM Outputs 03 12 ignition Goll PACK E o S 03 12 Engine Idle Speed 03 13 Idle Air Control IAC Motor 03 13 OP CATIONS c 03 13 IAC DIAGMOS ICS EE 03 13 Description And Operation ICM 03 14 Starting Mode 03 14 EOT ENGCIS 03 14 IAT Effects 03 14 Overspeed Protection 03 14 Engine Protection sauisceecsvaccccnutecoustcnuncadmetanxtdesteatdineneas 03 14 otaner LOCKOUT m T RM 03 14 Tachometer 03 14 Table 1 Input Output Function 03 15 Harness Connector Pinout Description 03 16 Octane Select Operation
74. Auxiliary Systems Charging 06 2 Auxiliary Systems Charging GENERATOR INTEGRAL REAR MOUNT REGULATOR INTERNAL FAN TYPE DESCRIPTION AND OPERATION Generator With the key in the RUN position voltage is applied through the charge indicator lamp 1 circuit to the voltage regulator This turns the voltage regulator on allowing current to flow from the battery sense circuit to the generator field coil When the engine 6007 is started the generator 10346 begins to generate alternating AC current which is converted to direct DC current by the rectifier internal to the generator This current is then supplied to the electrical system through the Battery Positive voltage B terminal located on the rear of the generator Once the generator begins generating current a voltage signal is taken from the stator and fed back to the voltage regulator S circuit turning off the charge indicator lamp With the system functioning normally the generator output current is determined by the voltage at the circuit This voltage is compared to a set voltage internal to the voltage regulator and the voltage regulator controls the generator field current to maintain proper generator output The set voltage will vary with temperature and is typically higher in the winter than in the summer allowing for better battery recharge J5683 A 1 Generator Regulator 10316 2 Generator 10346 3 Generator Pull
75. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY 1 Disconnect the battery ground cable 2 Relieve fuel pressure For additional information refer to this section 3 Remove the upper intake manifold 9424 For additional information refer to Section 02 4 A CAUTION After disconnecting plug the fuel lines to prevent leakage Disconnect the fuel lines For additional Information refer to this section 5 NOTE One fuel injector is shown all are similar Disconnect the six fuel injector electrical connectors 6 Remove the fuel injection supply manifold 9F792 1 Remove the bolts 2 Remove the fuel injection supply manifold V9618 A 04 15 Auxiliary Systems Fuel REMOVAL AND INSTALLATION Continued 7 Inspect the two O rings from each fuel injector Install new O rings as needed 1418 Installation 1 NOTE Lubricate new O rings with clean engine oil XO 5W20 QSP or DSP or equivalent meeting Ford specification WSS M2C153 G to aid installation To install reverse the removal procedure The injectors are pushed into lower intake manifold Use care aligning all injectors into each hole before applying downward pressure on the supply manifold until each of the injectors are completely seated 2 Connect the battery ground cable 04 16 Auxiliary Systems Fuel REMOVAL AND INSTALLATION Continued Pressure Relief Valve AS WARNING DO NOT SMOK
76. GENERAL PROCEDURES Continued 6 When the coolant is drained make sure drain plugs are installed and tight 7 Close the radiator draincock when finished TE ee 1 ANNAM JJ ew Filling 1 Add the proper engine coolant mixture to the degas bottle or radiator 2 Move the temperature blend selector to the full warm position when equipped 3 Run the engine until it reaches operating temperature 05 7 Auxiliary Systems Cooling GENERAL PROCEDURES Continued 4 Add the proper engine coolant mixture to the degas bottle or radiator until the coolant level is er Tm between the COOLANT FILL LEVEL marks MANSIS TH 5 i KU Wi iL NOTE Systems without degas bottle fill radiator ip up to 1 inch below the filler neck 5 Turn off the engine and allow the cooling system to cool 6 Repeat Steps 1 through 5 until the degas bottle radiator level is OK Flushing Engine and Radiator Special Tool s Coolant System Drain Flush Fill 164 R3673 Flush Kit Hardware Package 164 R3658 or equivalent Special Service Tools called for by the procedures can be obtained by calling 1 800 ROTUNDA 1 800 768 8632 ST1167 A Drain Kit 164 R3662 or equivalent 05 8 Auxiliary Systems Cooling GENERAL PROCEDURES Continued Flushing Heater Core Q4187 A 05 9 AX wanna DO NOT OPEN THE COOLING SYSTEM WHILE IT
77. If it doesn t check for silicone or other contaminants from fuel or use of improper RTV sealant The sensor may have a white powdery coating which is silicone contamination Silicone contamination sends a rich exhaust signal which causes the ECM to command an excessively lean air fuel mixture Replace HO2S Was a problem found Verify repair Go to Step 4 ee MIL DTC retrieval procedure Ignition engine not running short STI connector to ground Do any fault codes flash and display Inspect the fuel delivery system to determine if there is a problem with fuel delivery Fuel Pressure Was problem found BEEN 2 items that can cause engine to run rich cs a problem found Verify repair Go to Step 7 Check electronic governor operation including throttle position sensor function Refer to Fuel Section of this Manual Check items that can cause the engine to run lean Refer to DTC 32 cs a problem found Check for proper ignition voltage output with a suitable spark tester Was a problem found Inspect the secondary ignition wires Check for the following conditions Verify that the resistance of all ignition wires is less than the specified value Verify that ignition wires are correctly routed to 9 eliminate cross firing Verify that ignition wires are not arcing to ground Spraying the secondary ignition wires with a light mist of water may help locate an intermittent problem key ON engin
78. Injection 04 15 Fuel Lockout Relay 2 2 04 22 Pressure Relief Valve 04 17 Fuel Lockout Connector 04 22 Dry Fuel Modulator uictis hau series mecs 04 23 Manifold Skin Temp Connector 04 23 DFT CHT ECT amp IAT Sensor Data 04 24 Fuel Flow Diagram for LPG 04 25 System Operation LPG 04 26 Fuel Systems Field Calibrations General 04 26 Fuel Flow Diagram for Natural Gas 04 27 System Operation Natural Gas 04 28 Specifications 04 29 04 1 Auxiliary Systems Fuel 04 2 Auxiliary Systems Fuel FUEL SYSTEM DESCRIPTION AND OPERATION The fuel system is designed to deliver fuel safely prevent lines from working loose The delivery and an adequate supply as demanded All system consists of a fuel tank filter pump pressure connections are designed to prevent leaks and to regulator damper assembly fuel rail and injectors Fuel Flow Diagram for Gasoline Petrol EFI A Fuel Tank E Fuel Pump Relay Damper Assembly Gasoline F Fuel Pressure Regulator amp Fuel Injectors Fuel Filter Fuel Filter G Return Fuel Line to Fuel Tank Fuel Rail Fue
79. Install the water pump refer to the procedure in this section DAO774 A 02 76 ESG 642 ENGINE REPAIR Continued Timing Chain Balance Shaft Removal 1 Remove the front cover Refer to the procedure in this section 2 Remove the synchronizer drive gear DA0773 A 02 77 ESG 642 ENGINE REPAIR Continued 3 Remove the crankshaft sprocket camshaft sprocket and timing chain as an assembly DA0734 A 4 A CAUTION Use care when removing balance shaft as not to bump or score balance shaft bearings May cause balance shaft failure Remove the balance shaft drive gear DA0735 A 02 78 ESG 642 ENGINE REPAIR Continued 5 Remove the timing chain vibration damper 6 Remove the thrust plate retaining screws and the balance shaft DA0737 A 02 79 ESG 642 ENGINE REPAIR Continued Installation 1 caution Use care when removing balance shaft as not to bump or score balance shaft bearings May cause balance shaft failure Lubricate the balance shaft bearings with Engine Assembly Lubricant D9AZ 19579 D or equivalent meeting Ford specification ESR 88 80 and install the balance shaft 02 80 ESG 642 ENGINE REPAIR Continued 2 Install the timing chain vibration damper 3 Install the balance shaft drive gear e The timing marks on the drive and driven gear must align 02 81 ESG 642 ENGINE REPAIR Continued 4 Install the crankshaft sprocket
80. KOEO or IAT sensor signal 1 gt 4 96 e Above conditions are present for at least 3 consecutive seconds Actions Taken When the DTC Sets The ECM will illuminate the malfunction indicator lamp MIL e The ECM will force the IAT sensor to a 50 F default value 08 62 Auxiliary Systems EFI amp Ignition Electronics Diagnostic Trouble Code 35 Diagnostic Aids ECT CHT IAT amp MST Sensors The IAT sensor shares the same ground with the Temperature vs Ohm or Volts Values approx Manifold Absolute Pressure MAP sensor and the E PE Cylinder Head Temperature ECT sensor Check 100 A7 the ground circuit 359 Grey Red Grey Yellow if 79 these are also set 140 1 34 Inspect the harness connectors for backed out pu terminals improper mating broken locks improperly 2 39 formed or damaged terminals and poor terminal to 2 86 wire connections Inspect the wiring harness for 3 32 damage If the harness appears to be 371 backprobe the IAT sensor connector with a digital voltmeter and observe the voltage while moving 4 02 connectors and wiring harnesses related to the IAT 4 25 22 4 46 925 021 4 54 Voltage values calculated for VREF 5 volts may vary 15 due to sensor and VREF variations A change in the voltage reading will indicate the location of the fault DTC 35 Intake Air Temperature High Voltage Sep 1 Are you using a personal computer PC to perfo
81. Nene est LES GAZ EXPLOSES ETINCELLES PEUT CAUSER LA SE RINCER LES YEUX A PEUVENT BLESSER OU ET LES FLAMMES CECITE OU DES L EAU IMMEDIATEMENT RENDRE AVEUGLE DFENSE DE FUMER BRULURES GRAVES CONSULTER UN MEDECIN RECYCLE RAPIDEMENT KEEP OUT OF REACH OF CHILDREN TENIR HORS DE LA PORTEE DES ENFANTS RECYCLE Fig 1 Typical Battery Labelling 1 Explosive gases 7 Read relevant instructions 2 Eye protection must be WORN 8 Keep away from children 3 No smoking or naked flames 9 Do not dispose of as household waste 4 Corrosive acid 10 Recycle via recognized disposal 9 Flush eyes immediately when contacted system with acid 11 Electrical current may cause injury to 6 CAUTION IMPORTANT notice personnel NOTE Observe all manufacturers instructions when using charging equipment CAUTION Batteries should not be charged in the vehicle or equipment May damage electrical components 01 6 ESG 642 FOREWORD This book contains operating and maintenance instructions for the engine s listed on the title page The life of your engine unit and the delivery of the high performance built into it will depend on the care it receives throughout its life It is the operator s responsibility to ensure that the engine is correctly operated and that the maintenance operations outlined in this book are carried out regularly after the specified hours of operation have been reached We consider it to be in your interests to enlist the aid of an authori
82. STEP RESULT gt ACTION TO TAKE m DROP NAGROUT __ Turn key to ON position GO to D2 Measure voltage between test point A on the voltage regulator and the positive battery post s voltage drop less than 0 25 volt REPAIR excess voltage drop in Circuit 36 Y W CHECK fuse or fuse link and connections in Circuit 36 and SERVICE as required 02 CHECK VOLTAGE DROP IN I CIRCUIT Measure voltage at wiring harness terminal Circuit GO to D3 904 LG R REPAIR high resistance in NOTE Voltage regulator must be connected to wiring Circuit 904 LG R harness for this test s voltage greater than 1 volt CHECK FOR POOR GROUND Check for poor ground connections between voltage GO to D4 regulator and generator generator and engine or engine and battery Are all ground connections clean and tight CLEAN or REPAIR grounds as required D4 CHECK FOR FIELD CIRCUIT DRAIN Turn key to OFF position Generator is OK RE Measure voltage at test point F on the voltage PLACE voltage regulator regulator CLEAN or REPAIR grounds 5 voltage at test point equal to battery voltage as required D5 CHECK FOR GROUNDED SLIP RING Remove generator from vehicle If grease or dirt has Remove voltage regulator accumulated near the slip Measure resistance from each generator slip ring to rings CLEAN the slip rings the generator housing and RECHECK resistance s r
83. Sensor Coolant Temperature Sensor CTS Engine Coolant Temperature Sende ECT Sender ECT Switch Coolant Temperature Switch CTS RPM Crankshaft Speed Revolutions Per Minute RPM RPM Sensor Crankshaft Speed Sensor EPROM Erasable Programmable Read Onl Memory EPROM Evaporative Emission EVAP Canister Charcoal Canister Electronic Ignition System Evaporative Emission Canister EVAP Canister Purge Valve Purge Valve El System Engine Control Engine Control Module Engine Coolant Level Engine Coolant Level Indicator Engine Coolant Temperature Engine Coolant Temperature Sensor ECM Engine Coolant Temperature Switch Engine Speed Engine Speed Sensor Erasable Programmable Read Only Memory Evaporative Emission Evaporative Emission Canister VAP EVAP Canister EVAP Canister Purge EVAP Canister Purge CANP Canister Purge Valve Canister Purge Vacuum Switching Valve Canister Purge VSV Duty Solenoid for Purge Valve Evaporative Emission Canister Purge m m m Evaporative Emission Purge Valve EVAP Purge Valve Vacuum Solenoid Valve Canister VSV Vacuum Solenoid Valve EVAP VSV Evaporative Emission System EVAP System Evaporation Emission Control System EECS Exhaust Gas HRecirculation EGHR Digital Exhaust Gas Recirculation Digital EGR 09 11 Auxiliary Systems Metrics J1930 TERMIN
84. Step 7 Check circuits 351D and 359F for poor terminal connections at the ECM Repair the terminal Replace the electronic governor Is the repair complete and engine Remove amp replace operating to specifications electronic governor Is system operation normal with replacement ECM installation ECM and install original ECM Go to Step 10 Remove original Is the repair complete system operation normal with original ECM ECM and reinstall Repair the wiring Re test Go to Step 5 Repair the terminal Re test Go to Step 9 5 reinstalled Keep original ECM replacement ECM installed Re test Go to Step 11 Is the repair complete system operation normal with replacement ECM Leave replacement ECM reinstalled installed Re test 08 31 Auxiliary Systems EFI amp Ignition Electronics Diagnostic Trouble Code 13 DBW NOTES Connector for PP Sensor N Idle Validation Switch Pedal Position PP Sensor Connector Connector for Idle Validation Switch 359A GY R 355 GY W 351 BR W Power Feed From oe Ignition Switch 359A GY R 151 LB BK 351 33 31 Signal PP Sensor PP 5V Pedal Assembly Switch t Return Signal Reference Return Signal 42 Pin Connector m e um GER GER GER mb o m S wem am d um rm wm S 5 GY R 151
85. The ECM shuts down the engine The engine can be restarted by recycling the ignition switch 08 64 Auxiliary Systems EFI amp Ignition Electronics Diagnostic Trouble Code 37 DTC 37 Drive By Wire Decay Failure Step 202 Yes No 1 Are you using a personal computer PC to perform this diagnosis Go to Diagnostic NOTE This test cannot be made without a PC or a very high tech DVOM System Check before continuing at Step 2 Go to Step 2 Visually check for dirt or carbon in the throat of the actuator or on the 2 throttle plate Clean with a carb cleaner Re test Go to Step 3 Is there any dirt or carbon 3 Is the normalized TPS within specification of the TPS set point Normalized TP lt TPS set point Re test Does the ECM have the correct program for this application If needed contact FPP or OEM for Download correct correct program Go to Step 5 program amp re test Using EEMS SERV program read graph for throttle body position TPS in ce em relation to the ECM set point Are graph lines close together but not even Go to Step 6 Re test 1 Disconnect battery ground 2 Disconnect ECM connector L Y 3 Check for a short or open on circuit 264 W LB circuit 361H R and 361G R Repair wire Reconnect Where any shorts or opens found battery and re test Go to Step 6 Check circuits 264 W LB and 361G R for poor terminal connectors Repair or replace at ECM terminals Reconnect Do any of
86. VOLTAGE Circuit Description When the ignition switch is first turned on the ECM energizes the fuel pump relay which applies power to the fuel pump The fuel pump relay will remain active as long as the engine is running or cranking If the fuel pump is not active the ECM will receive no signal This condition may indicate a problem with the relay or the wiring Conditions for Setting the DTC e KOER or KOEO e Fuel pump voltage is gt 4 9V below ignition voltage for at least 2 consecutive seconds Actions Taken When the DTC Sets ECM illuminates the malfunction indicator lamp MIL 08 56 Auxiliary Systems EFI amp Ignition Electronics Diagnostic Trouble Code 31 Diagnostic Aids Inspect the harness connectors for backed out terminals improper mating broken locks improperly formed or damaged terminals and poor terminal to wire connections Inspect the wiring harness for damage If the harness appears to be OK backprobe the fuel pump relay connector with a digital voltmeter and observe the voltage while moving connectors and wiring harnesses related to the fuel pump relay A change in the fuel pump voltage display will indicate the location of the fault DTC 31 Fuel Pump Low Voltage Are you using a personal computer PC to perform this diagnosis Yes No Go to Domus System Check before continuing at Step 2 Go to Step 2 1 Ignition OFF 2 Remove the fuel pump relay 3 KOEO 4 Conne
87. a wire broken inside the insulation Check for the following items Poor connection or damaged harness Inspect the ECM harness and connectors for improper mating broken locks improperly formed or damaged terminals poor terminal to wire connections or a damaged harness Coil pack with crack or split at bottom of one or more coils may be caused by broken secondary wire or inoperative spark plug Engine Cranks But Doesn t Start Circuit Test NOTE Check fuel pressure and confirm within 60 to 68 PSI before proceeding with test If unacceptable pressure start Circuit Test at Step 28 Also check for spark and air before proceeding Stp Value s Perform Visual Physical check Verify that all accessories are OFF Was a Visual Physical check performed Perform MIL DTC retrieval procedure If any DTC s are present repair before proceeding Is action complete MIL circuit operation normal and DTC s if present repaired Attempt to start the engine Does the engine start Check the ECM power relay for proper connection If no problem is found replace the relay with a known good relay Does engine run Does engine run with original relay reinstalled Ye No Perform Visual Physical Go to Step Check 2 Go to Step 3 Verify repair and test engine for proper operation at all temperatures Refer to MIL Circuit Diagnosis Before going to Step 4 go to Step 26 27 amp 28 I
88. a short to ground and repair if necessary Was a repair necessary Replace HO2S Remove Is system working to specification mE replacement HO2S and install original Re test Go to Step 5 Install replacement ECM Remove EN Is system operation normal with replacement ECM installed Remove original ECM and install EN ECM Go to Step 6 Is the repair complete system operation normal with original ECM and reinstall reinstalled Keep original ECM replacement ECM installed Re test Go to Step 7 Is the repair complete system operation normal with replacement ECM Leave replacement ECM reinstalled installed Re test 08 59 Auxiliary Systems EFI amp Ignition Electronics Diagnostic Trouble Code 33 NOTES DG MAP and IAT Sensors Engine Cylinder Head Temperature CHT 33 42 Pin Connector B2 O0 6 Sensor Engine Signal Ground Control Module I DIAGNOSTIC TROUBLE CODE DTC 33 ENGINE CYLINDER HEAD TEMPERATURE HIGH VOLTAGE NOTE This is a software serviceable DTC Circuit Description The cylinder head temperature CHT sensor is a thermistor which measures the temperature of the cylinder head in the engine The ECM supplies a ground circuit 359G Grey Red Grey Yellow to the sensor and supplies a 5V signal circuit 1102 Yellow Lt Green to the sensor When the engine coolant is cold the sensor resistance is high and the ECM will monitor a high signal volta
89. across from each other as shown in illustration The C engine balance shaft driven gear 6A304 and D engine balance shaft drive gear 6A303 must be positioned as illustrated 01 24 ESG 642 GENERAL SERVICE PROCEDURES Sprockets DA0878 A AN WARNING TO AVOID THE POSSIBILITY OF PERSONAL INJURY OR DAMAGE THE VEHICLE DO NOT OPERATE THE ENGINE WITH THE HOOD OPEN UNTIL THE FAN BLADE HAS BEEN EXAMINED FOR POSSIBLE CRACKS AND SEPARATION NOTE Specifications show the expected minimum or maximum condition NOTE If a component fails to meet the specifications it is necessary to replace or refinish If the component can be refinished wear limits are provided as an aid to making a decision Any component that fails to meet specifications and cannot be refinished must be replaced 1 Inspect the A chain and the B sprockets e Replace as necessary 01 25 ESG 642 GENERAL SERVICE PROCEDURES Continued Gears 1 Inspect the A thrust plate the B cam gear and the C crank gear Replace as necessary A26373 A Camshaft Journal Diameter 1 Measure each camshaft journal diameter in two directions e f it is out of specification replace as necessary DA0344 A 01 26 ESG 642 GENERAL SERVICE PROCEDURES Continued Camshaft Journal Clearance OHV Engines 1 NOTE The camshaft journals must meet specifications before checking camshaft journal clearance Measure each camsh
90. and Flywheel Removed 01 15 Compression Tests 2 2 1 01 15 WS Te SNS A pm 01 16 Compression Pressure Limit Chart 01 16 Interpreting Compression Readings 01 16 Cylinder Leakage Detection 01 17 Oil Leak and Valve Stem Seal Test 01 17 Intake Manifold Vacuum Test 01 17 Interpreting Vacuum Gauge Readings 01 17 Excessive Engine Oil Consumption 01 19 Oil Consumption 2 2 01 19 Oil Pressure 2 2 01 21 Valve Train Analysis Static Engine Off 01 21 Valve Cover Removed 01 21 ROCKOT ATTN 01 21 Camshaft Roller Followers amp Hydraulic Lash Adjusters Overhead Camshaft 01 21 Camshaft Overhead Camshaft Engines 01 21 PU MAOS Ree tr TEM 01 21 Valve Springs 2 01 21 Valve Spring Retainer and Valve Spring Retainer Keys said itd 01 1 SUBJECT Diagnosis And Testing Continued Valves and Cylinder Head 01 22 Valve Train Analysis Dynamic 01 22
91. and engine ground Also check the connection at the load distribution point starter relay 3 Auxiliary Systems Charging GENERATOR DIAGNOSIS AND TESTING Continued Check the fuses fuse links and wiring to the generator to ensure that they are not burned or damaged This condition resulting in an open circuit or high resistance can cause erratic or intermittent charging system concerns Check the battery voltage If the voltage is less than 12 3 volts with the engine and all accessories off charge battery before proceeding In order to check the generator the use of Rotunda Starting and Charging System Tester 078 00005 VAT 40 Rotunda Tools 1 800 578 7375 or equivalent is recommended Generator Output Test NOTE Refer to the test equipment user s manual for complete directions on examining the charging system 1 2 Switch the tester to ammeter function Connect the positive and negative leads of the tester to the battery Connect current probe to generator output lead Circuit 38 BK O to measure generator output With the engine running at 2000 rpm adjust the VAT 40 or equivalent load bank to determine the output of the generator Generator output should be greater than values given in graph below If not refer to symptom chart in this Section 95 AMP GENERATOR 76 AMPS MIN 2000 RPM 1000 1500 2000 2500 ENGINE SPEED 00058 06 5 Generator Voltage Test 1 2
92. be caused by a broken check valve spring Air bubbles in the lubrication system will prevent the valve tappet from supporting the valve spring load This can be caused by too high or too low an oil level in the oil pan or by air being drawn into the system through a hole crack or leaking gasket on the oil pump screen cover and tube If the leakdown time is below the specified time for used valve tappets noisy operation can result If no other cause for noisy valve tappets can be found the leakdown rate should be checked and any valve tappets outside the specification should be replaced Assembled valve tappets can be tested with Hydraulic tappet Leakdown Tester to check the leakdown rate The leakdown rate specification is the time in seconds for the plunger to move a specified distance while under a 22 7 kg 50 Ib load Test the valve tappets as follows 01 23 DIAGNOSIS AND TESTING Continued ESG 642 Leakdown Testing 1 NOTE Do not mix parts from different hydraulic lash adjusters HLA Parts are select fit and are not interchangeable Clean the valve tappet to remove all traces of engine oil NOTE Valve tappets cannot be checked with engine oil in them Use only testing fluid Place the valve tappet in the tester with the plunger facing upward Pour hydraulic tester fluid into a cup to a level that will cover the valve tappet The fluid can be purchased from the tester s manufacturer Using kerosene or an
93. control spark advance and air fuel ratio The MAP signal is also used at KOEO to indicate barometric pressure This information is used for altitude compensation when establishing spark advance and air fuel ratio Conditions for Setting the DTC KOEO or MAP signal is significantly lower than estimated by the ECM e Above conditions are present for at least 2 consecutive seconds Actions Taken When the DTC Sets ECM illuminates the malfunction indicator lamp MIL e The ECM uses an estimated MAP value based on throttle position and engine rpm 08 34 Auxiliary Systems EFI amp Ignition Electronics Diagnostic Trouble Code 14 DTC 14 Manifold Absolute Pressure MAP Sensor Low Voltage Values Yes Are you using a personal computer PC to perform this diagnosis Go to Diagnostic System Check before continuing at Step 2 Go to Step 2 1 KOEO Check the 5V reference signal from the ECM 2 Disconnect the MAP sensor electrical connector 3 Check the voltage between terminals A and C on the MAP sensor electrical connector Is the voltage within the specified values 4 9 5 1V Go to Step 3 Go to Step 6 Check the MAP signal to the ECM 1 Reconnect the MAP sensor electrical connector 2 No load on engine 3 KOER 4 Using a suitable backprobing technique measure the voltage between terminals A and B at the MAP sensor NOTE If a PC is available you can observe TP voltage on the engine data screen
94. disc closes the circuit between the battery and the motor terminals 07 3 6 The current flows to the motor and the drive pinion gear drives the flywheel and the engine crankshaft 7 current flows to the motor the solenoid pull in coil is bypassed 8 The hold in coil keeps the drive pinion gear engaged with the flywheel 9 The gear remains engaged until the ignition switch is released from the START position SOLENOID PULL IN STARTER HOLD IN COIL STARTER RELAY NEUTRAL START SWITCH OR LOCK OUT SWITCH START SWITCH 2 00037 NOTE When the is programmed to lock starter out when the engine is over 400 rpm 600 rpm for ICM the following sequence takes place Starter Lockout Relay See page 07 6 for further details 1 During start up with key in the on position 12V B is applied to relay through circuit 16A R LG 16G 2 With ignition switch turned to the crank position current flows from ignition switch to relay circuit 32A R LB 16G through relay and out circuit 32 R LB 16G to starter solenoid 3 he starter than should respond as in steps 2 through 9 in sequence of operation circuit 113 4 LB 18G is connected to the ECM L3 terminal The ECM keeps circuit 113 open until it reads 400 engine rpm Over 400 rpm the ECM grounds circuit 113 causing the relay to open circuits 32A and 32 This will prevent starter engagement while engine is running NOTE An overrun
95. disconnected component e fthe Test Lamp goes on the short is in the wiring You must find the short by disconnecting the circuit connectors one at a time until the Test Lamp goes out For 03 5 Auxiliary Systems Ignition INTRODUCTION Continued Troubleshooting Wiring Harness and Connector Hidden Concerns Any probe entering the The following illustrations are known examples of j T terminal may enlarge the wiring harness splices and connectors that will reg ero create intermittent electrical concerns The ser mating terminal Location concerns are hidden and can only be discovered M from the service kit and feel for a loose fit by a physical evaluation as shown in each illustration NOTE When servicing gold plated terminals in a Enlarged Normal connector only replace with gold plated terminals designed for that connector DEFORMED ENLARGED FEMALE TERMINALS Intermittent Short Operate the system and flex the harness at splice intermittent Signals Through Wire Strand Pierced Insulation Splice Tape Proper Insulation Wire gt Crimp Not Strands Removed Missing Splice Covered DEFECTIVE INSULATION STRIPPING ELECTRICAL SHORT WITHIN THE HARNESS Locked Male Female Half Solder coated wire pierced through Terminai the insulation of another circuit Solder Coated Wire to Ground aM j we N
96. electronic governor operation including Verify repair Go to MIL DTC retrieval procedure if required Go to Step 39 Check for the following engine mechanical problems e Camshaft timing chain or gear slipped or stripped Low compression eaking cylinder head gasket Worn camshaft Leaking or sticky valves or rings Verify repair Excessive valve deposits Go to MIL DTC Weak valve springs retrieval Damaged plugged or restricted exhaust system procedure if Is the action complete required Go to Step 40 1 Check injectors wire circuit 2 Check ECM ground and wire circuit Was problem found 1 Replace ECM with known good one Verify repair Go to Step 41 Does the noid light blink at each injector while cranking Go to Step 42 Go to Step 43 1 Replace new ECM with old one Check ECM Does the noid light blink at each injector while connector pins cranking and wire harness Goto Step 43 03 46 Auxiliary Systems Ignition ENGINE CRANKS BUT DOESN T START CIRCUIT TEST Continued Se Ye MW 1 Review all diagnostic procedures within this table 2 If all procedures have been completed and no malfunctions have been found review inspect the following Contact Ford Visual Physical inspection including fuel quality Power Products check Verify repair Customer All electrical connections within a suspected Go to MIL DTC Service Center circuit and or system retrieval Technical 3 If
97. gap between the magnet and the Hall device allows the tooth and space mounted on a rotating vane to pass between them This results in a change in the flux density reaching the Hall device As a tooth nears the centerline of the sensor a threshold Firepoint is reached where the output voltage changes state from low to high When the trailing edge of the tooth nears the centerline of the sensor the output reaches a second threshold operate point and returns to a low state This sensor as shown was designed to be installed in the bore originally provided for the distributor on the 3 8L engine other mountings are used on the 4 2L 5 4L and 6 8L engines A single tooth vane is used on all applications Cylinder Identification CID This input provides camshaft position information for determining the position of cylinder 1 which is required for phasing fuel injection and ignition coil synchronization 08 4 Auxiliary Systems EFI amp Ignition Electronics CAMSHAFT POSITION SENSOR CMP HALL EFFECT Continued TRANSFER FUNCTION SENSOR OPERATION 0 deb dm cac du DEGREES OF CAMSHAFT ROTATION FROUBLESHOOTING 6 CYLINDER 18r ECM CHE ROTATION EQUAL SENSOR blab haha CID HALL EFFEZT PIN B 2 SIGNAL LINE DEWKE 359C GY R Sn IN GAP OUTPUT HIGH WIMAN deli ea 282 DB O ECM SPLICE 5 PIN B 2 359 GY R e
98. in relation to the ECM set point Are graph lines close together but not even 1 Disconnect battery ground 2 Disconnect ECM connector L Y 3 Check for a short or open on circuit 264 W LB circuit 361H and 361G Where any shorts or opens found Check circuits 264 W LB and 361G and 361H R for poor terminal connectors at ECM Do any of the terminals need to be repaired or replaced Replace the electronic governor Is the repair complete and engine operating to specifications N with original Go to Step 9 Install replacement ECM Remove replacement ECM Go to Step 10 Is the repair complete system operation normal with original ECM reinstalled Remove original ECM and reinstall Keep original ECM replacement ECM installed Re test Go to Step 11 C Is the repair complete system operation normal with replacement ECM reinstalled 08 55 NOTES Auxiliary Systems EFI amp Ignition Electronics Diagnostic Trouble Code 31 Fuel Pump Relay Connector 787A PK BK 37CiY Power R Relay 787 PK BK sil S08 7 Fuel 42 p e Injectors 5 Pin g Connector Pin Connector 926A LB O pue 498 DG Y 37 Y Pump DUST Starter 361G R BK Relay 2 eel P3 F3 K1 7 7 5 5 544777 Power 777 Engine Pump Pump Feed Control Relay Manitor 1 Module Control DIAGNOSTIC TROUBLE CODE DTC 31 FUEL PUMP LOW
99. instead of using a DVOM Approx 1V at 5 While observing the voltage reading increase the engine speed from idle Idle to approx to WOT Does the voltage vary between the specified values 4 0V WOT Go to Step 4 Go to Step 8 1 Ignition OFF 2 Disconnect ECM connector A thru K 3 Disconnect the MAP sensor connector 4 Check for shorts or opens on circuit 358 Lt Green Black between the MAP sensor connector and the ECM connector Repair the wiring Were any shorts or opens found Re test Check circuit 358 for a poor terminal connection at the ECM 1 Disconnect ECM connector A thru 2 Check for a short or open on circuits 351C Brown White and 359B Grey Red Were any shorts or opens found Check circuits 351C and 359B for poor terminal connections at the ECM Does either terminal need to be replaced Replace the MAP sensor Is the repair complete nstall replacement ECM Is the system operation normal wi Remove replacement m Go to Step 5 Repair the terminal Re test Go to Step 9 Repair the wiring Re test Go to Step 7 7 Repair the terminal Go to Step 9 Re test replacement ECM ECM and install original ECM Go to Step 10 u Keep original ECM Remove original s repair complete SyS reinstalled installed Re test ECM and reinstall replacement ECM Go to Step 11 Is the repair complete system operation normal with replacement ECM Leave replace
100. is high and the ECM will monitor a high signal voltage at the CHT signal circuit If the engine cylinder head is warm the sensor resistance is lower causing the ECM to monitor a lower voltage DTC 43 will set when the ECM detects an excessively high signal voltage on the engine cylinder head temperature sensor signal circuit Conditions for Setting the DTC e KOEO or e ECT sensor signal is lt 0 32V Above conditions are present for at least 3 consecutive seconds Actions Taken When the DTC Sets The ECM will illuminate the malfunction indicator lamp MIL The ECM will set code 43 and go into open loop 08 70 Auxiliary Systems EFI amp Ignition Electronics Diagnostic Trouble Code 43 ECT CHT IAT amp MST Sensors Diagnostic Aids bs 2 2 the Me Temperature vs Ohm or Volts Values approx anifold Absolute Pressure sensor and the Intake Air Temperature IAT sensor Check the 2 080 47 ground circuit 359 Grey Red Grey Yellow if these AY DTC s are also set 140 1 34 n Inspect the harness connectors for backed out 5 terminals improper mating broken locks improperly formed or damaged terminals and poor 2 86 terminal to wire connections Inspect the wiring 3 32 harness for damage If the harness appears to be 3 71 OK backprobe the CHT sensor connector with a 4 02 digital voltmeter and observe the voltage while moving connectors and wiring harnesses related 4 25
101. less than 100 mA or test lamp with the key switch in the off Off position CHECK FOR OPEN CIRCUIT Measure voltage at B terminal on the back of the generator Circuit 38 BK O Is voltage at B terminal equal to battery voltage GO to A3 Check fuse link in Circuit 38 290 and 37 and HEPLACE if required If OK REPAIR open in Circuits 38 290 and 37 EN CHECK FOR OPEN A CIRCUIT Measure voltage at test point A on the voltage regulator Yes GO to 4 s voltage at test point A equal to battery voltage No Check fuse link in Circuit 38 290 and 37 and REPLACE if required If OK REPAIR open in Circuits 38 290 and 37 CHECK FOR OPEN FIELD CIRCUIT Measure voltage at test point F on the voltage regulator Yes GO to A5 s voltage at test point F equal to battery voltage No GO to A11 CHECK FOR OPEN I CIRCUIT Turn key to ON position Yes GO to A6 Measure voltage at wiring harness terminal Circuit No REPAIR open or high 904 LG R resistance in Circuit 904 NOTE Voltage regulator must be connected to wiring LG R harness for this test s voltage greater than 1 volt CHECK VOLTAGE DROP IN CIRCUIT Measure voltage drop between test point A on the voltage regulator and the positive battery post s voltage drop less than 0 25 volts GO to 7 REPAIR excess voltage drop in Circuit 36 Y W CHECK fuses or fuse link a
102. light to ground probe the harness connector ignition feed terminal Is the light ON Check the ignition feed wire from the CKP sensor to the ECM for a short to ground or open circuit and repair as required Is the action complete 1 Ignition ON 2 At the CKP harness connector connect a test light between the ignition and ground terminals Is the light ON Check the CKP sensor ground circuit for an open or short to voltage Was a problem found Check the signal circuit between the CKP sensor and the ECM for a short to ground short to voltage or an open Was a problem found Replace the CKP sensor Is the action complete Verify repair Go to MIL DTC retrieval procedure if required Verify repair Go to MIL DTC retrieval procedure if required Hemove replacement ECM and install original ECM Keep original ECM installed Verify repair and Go to MIL DTC retrieval procedure if required Leave replacement ECM installed Verify repair and Go to MIL DTC retrieval procedure if required Go to Step 22 Verify repair Go to MIL DTC retrieval procedure if required Go to Step 24 Verify repair Go to MIL DTC retrieval procedure if required Verify repair Go to MIL DTC retrieval procedure if required Verify repair Go to MIL DTC retrieval procedure if required 2 Vau s Ye No 00 Go to Step 16 Go to Step 17 Go to Step 18 Hemove original ECM and rei
103. outside of the Ford Motor Company Reference should be made to the Equipment Manufacturer for any information or parts required ERE E EI Industrial Power Products CAPACITY FUEL SYS RPM HD BLOCK EE SPECIAL EQUIPMENT 11 Fig 3 Build Date Chart NOTES The letters and are not Fig 2 Service Identification Plate used in the year column The letter representing the month repeats every five years SER DATE BUILD No 3 01 8 ESG 642 U S A ENGINE IDENTIFICATION DECAL An identification Decal is affixed to the valve cover of the engine The decal contains the engine serial number which identifies this unit from all others Use all numbers when seeking information or ordering replacement parts for this engine 01 Serial Number Has a total of 10 numbers 02 Model Number For a handy reference this information is recorded on your Ford Power Products Operations Engine Registration copy Form 194 103 0 PARTS AND SERVICE Replacement parts can be obtained through your local Ford Power Products Distributors or Dealers listed in the back portion of this handbook They also may be found in the yellow pages under Engines or contact Ford Power Products 1 800 833 4773 U S A 49221 94700551 Europe or 441708 858415 Great Britain Ford Power Products Distributors and Dealers are equipped to perf
104. removal procedure in reverse order 02 47 ESG 642 ENGINE REPAIR Continued Special Tool s Crankshaft Damper Remover T58P 6316 D Special Service Tools called for by the procedures can be obtained by calling Vibration Damper Remover 1 800 ROTUNDA 1 800 768 8632 Adapter T82L 6316 B i ST1378 A Removal of Crankcase Damper 1 Remove the drive belt if necessary 2 Remove the fan and shroud 3 Raise and support the vehicle when applicable 02 48 ESG 642 ENGINE REPAIR Continued 4 NOTE Markthe crankshaft pulley and damper position Remove the crankshaft pulley 5 Remove the crankshaft damper A puller will be needed DA0729 A 02 49 ESG 642 ENGINE REPAIR Continued Installation A CAUTION Mating parts must make contact to each other within 4 minutes and connecting bolts must be torqued within 15 minutes after applying sealant Failure to follow this procedure can cause future oil leakage Use silicone gasket and sealant FGAZ 19562 AA or equivalent meeting Ford specification WSE M4G323 A6 NOTE Sealant must be removed and area cleaned with solvant if above instructions are not followed Use metal surface cleaner F4AZ 19A536 RA or equivalent meeting Ford specification WSE M5B292 A 1 Apply a bead of sealant to the keyway in the crankshaft damper and use Vibration Damper Installer Adapter to install the crankshaft damper Use Silicone Gasket and Se
105. section 8 Fill cooling system with approved type and mixture of antifreeze For additonal information refer to Filling in this section 05 18 Auxiliary Systems Cooling COOLING SYSTEM DIAGNOSING AND TESTING Diagnosis Refer to the following Diagnosis Chart for cooling system problems their possible cause and recommended correction Refer to the pertinent part for testing and repair The most frequent cooling system complaints are leakage and overheating Either of these problems will soon render the vehicle inoperable CONDITION Loss of coolant Pressure cap and gasket eakage Internal leakage Low coolant level Loose fan belt Pressure cap e Radiator obstruction Closed thermostat Fan drive clutch gnition Temp gauge Engine Coolant mixture Engine overheats Open thermostat Temperature gauge Engine fails to reach normal operating temperature General Test Procedures Visual Inspection Check for leakage at 1 All hoses and hose connections 2 petcock 3 All block core plugs and drain plugs 4 Edges of all cooling system gaskets 5 Transmission oil cooler 6 Water pump shaft and bushing Radiator seams radiator core and radiator drain Most vehiles 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 le
106. sensor electrical connector 2 KOER with no load on engine 3 Using a suitable backprobing technique measure the voltage between terminals A and B at the MAP sensor 4 While observing the voltage reading increase the engine speed from idle to WOT Does the voltage vary between the specified values 1 Ignition OFF 2 Disconnect ECM connector A thru 3 Disconnect the MAP sensor connector 4 Check for an open or short to ground on circuit 358 Lt Green Black between the MAP sensor connector and the ECM connector and repair as necessary Was repair necessary Check circuit 358 Lt Green Black for a poor terminal connection at the ECM and repair if necessary Was a repair necessary 1 Disconnect ECM connector A thru 2 Check for a and open or short to ground on circuits 351C Brown White and 359B Grey Red between the MAP sensor connector and the ECM connector and repair as necessary Was a repair necessary Check circuits 351C Brown White and 359B Grey Red for a poor 7 terminal connection at the ECM and repair if necessary Was a repair necessary Replace the MAP sensor Is the repair complete Re test Install replacement ECM Is system operation normal with replacement Remove replacement ECM installed ECM and install original ECM Go to Step 10 Is the repair complete system operation normal with original ECM Keep original ECM Remove original reinstalled installed Re test ECM and reinstall
107. set whenever the ECM detects a voltage that is below a calibrated value Conditions for Setting the DTC e Engine RPM is greater than 700 e System voltage is less than or equal to 8 0V for at least 2 consecutive seconds Action Taken When the DTC Sets The ECM will illuminate the malfunction indicator lamp MIL Diagnostic Aids The DTC sets when an accessory is operated check for a poor connection or excessive current draw Excessive current draw can be a result of a short circuit or partial short circuit due to corrosion moisture or chafed insulation DTC 61 System Voltage Low Values Yes No Are you using a personal computer PC to perform this diagnosis Go to Diagnostic System Check before continuing at Step 2 Go to Step 2 Using a DVOM measure the battery voltage at the battery Lm Change the battery Is the battery voltage less than the specified value 8 0V Go to Step 3 the go to Step 3 1 Ignition OFF 2 Disconnect the ECM connector A thru K 3 With a DVOM measure the battery voltage at the ECM connector Go to terminal F2 Is it approximately equal to the battery voltage VPWR B Diagnostic Aids Go to Step 4 Was a repair necessary mE Re test Install replacement ECM Remove replacement Is system operation normal with replacement ECM installed ECM and install original NEN ECM Go to Step 7 _ Check for an open battery feed circuit 37 Yellow to the ECM and repai
108. signal is generated which increases with engine rpm and provides engine speed and crankshaft position information to the ECM By monitoring the pulse wheel the CKP sensor signal indicates crankshaft position and speed information to the ECM The CKP sensor is also able to identify piston travel in order to synchronize the ignition system and provide a way of tracking the angular position of the crankshaft relative to a fixed reference for the CKP sensor configuration A23996 A Pulse Wheel Part Crankshaft Pulley Crankshaft Damper Face Down 6312 Gap in Teeth Provides position reference for number one piston Crankshaft Position Sensor CKP Sensor Auxiliary Systems Ignition DESCRIPTION AND OPERATION ECM Continued Cranking Mode Cranking mode is the area of engine operating speed within which the ignition timing is at a static position The static spark advance is fixed at 10 degrees BTDC up to 250 RPM Ul AMHR 0266 CKP Sensor TDC 2 and6 Missing Tooth 60 BTDC Spark E 10 BTDC Coil 1 G Coil 2 H Coil 3 1 IDM 2 Sensor L Missing Tooth M 60 BTDC N TDC 1 and 5 0 TDC 3 and 4 P 1 and 5 Crankshaft Wheel R Note This diagram does not correlate to any timing marks that may be on the engine front cover or damp
109. system operation normal with replacement ECM installed ECM and install original ECM Go at Step 4 Is the repair complete system operation normal with original ECM Remove original reinstalled ECM and reinstall Keep original ECM replacement ECM installed Re test Go to Step 5 Is the repair complete system operation normal with replacement ECM Leave replacement ECM reinstalled installed Re test 08 82 Auxiliary Systems EFI amp Ignition Electronics Diagnostic Trouble Code 55 DIAGNOSTIC TROUBLE CODE DTC 55 ECM FAULT ILLEGAL INTERRUPTION Circuit Description The ECM continuously monitors electrical signals form the engine If for some reason the ECM receives an illegal interruption from one of those signals it then executes an exception handling code the ECM will then go to a default program and return to normal operation but it will set DTC 55 and will need to be replaced Conditions for Setting the DTC KOEO or Action Taken When the DTC Sets The ECM will illuminate the malfunction indicator lamp MIL Diagnostic Aids Inspect the harness connectors for backed out terminals improper mating broken locks improperly formed or damaged terminals and poor terminal to wire connections Inspect the wiring harness for damage DTC 55 ECM Fault Illegal Interruption Step amp Are you using a personal computer PC to perform this diagnosis to D
110. table 2 If all procedures have been completed and no malfunctions have been found review inspect the following Visual physical inspection including fuel quality Contact Ford check Power Products All electrical connections within a suspected Customer circuit and or system Service Center 3 If a problem is found repair as necessary Technical Was a problem found Verify repair support Hotline 1 800 521 0370 03 21 Auxiliary Systems Ignition ENGINE SURGES SYMPTOM Step Yes No DEFINITION Engine power variation under steady throttle setting Feels like the engine speeds up and slows down with no change in the governor switch or throttle position Was a visual physical check performed Perform MIL DTC retrieval procedure Ignition ON engine not running short STI connector to ground Do any fault codes flash and display Go to Visual Physical Go to Step 2 Check Hefer to DTC chart perform component and circuit test as Go to Step 3 2 a required NOTE Make sure engine is closed loop before proceeding Check the heated oxygen sensor 025 operation The 025 should respond quickly to different throttle positions If it doesn t check for silicone or other contaminants from fuel or use of improper RTV sealant The sensor may have a white powdery coating Silicone contamination sends a rich exhaust signal which causes the ECM to command an excessively lean air fuel mixture W
111. test light between feed and ground 5 Ignition OFF Was voltage equal to the specified value or is test light ON Locate and repair open or short in coil ignition feed circuit Was a problem found Perform spark test Ignition OFF Connect coil harness connector Connect the end of one of the secondary spark plug wires to a suitable spark tester Ignition ON Observe the spark tester while the engine is cranking Ignition OFF Was a crisp blue spark observed Only one or two sparks followed by no result is considered the same as No Spark Test the other 5 spark plug wires by using the test in Step 29 at each spark plug wire When the engine is cranked was a crisp blue spark observed Only one or two sparks followed by no 62 64 PSI Verify repair Go to MIL DTC retrieval procedure if required Go to Step 29 Go to Fuel System 2 Vauw s Ye No 00 Go to Step 27 Go to UE System Electrical test Go to Step 30 Go to Step 32 Verify repair Go to MIL DTC retrieval procedure if required Verify repair Go to MIL DTC retrieval procedure if required Diagnostic test Go to Step 40 Go to Step 31 Go to Step 32 Go to Step 33 result is the same as No Spark 03 45 Go to Step 35 Go to Step 34 Auxiliary Systems Ignition ENGINE CRANKS BUT DOESN T START CIRCUIT TEST Continued Step Ye No
112. the recommended amount b Run the engine for three minutes 10 minutes if cold and allow the oil to drain back for at least five minutes with the vehicle on a level surface c Remove oil level dipstick and wipe clean NOTE Do not wipe with anything contaminated with silicone compounds 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 01 20 d Add one liter 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 e Record the vehicle mileage or hours f Instruct the customer to run engine as usual and perform the following Check the oil level regularly at intervals of 3 to 3 1 2 hours Return to the service point when the oil level drops below the lower ADD mark on the oil level dipstick Add only full liters quarts of the same oil in an emergency Note the mileage at which the oil is added g Check the oil level under the same conditions and at the same location as in Steps 5c and 5d
113. the terminals need to be repaired or replaced battery Re test Go to Step 8 Replace the electronic governor Is the repair complete and engine Remove amp replace operating to specifications electronic governor with original Go to Step 9 Remove replacement ECM and install original ECM Go to Step 10 Is the repair complete system operation normal with original ECM Remove original reinstalled ECM and reinstall Keep original ECM replacement ECM installed Re test Go to Step 11 Is the repair complete system operation normal with replacement ECM Leave replacement ECM reinstalled installed Re test 08 65 Auxiliary Systems EFI amp Ignition Electronics Diagnostic Trouble Code 41 Fuel Pump Relay Connector NOTES 787A PK Bk 37 Hrs 361AN Relay 787 2 508 7 901 Fuel ETT injectors 926A LB O Fuel dd Pump r ISwitch 1 I 361G R l PEE P3 K1 a i ni Power Engine Pump Pump Feed 1 Control ela Cantal EOM ECM DIAGNOSTIC TROUBLE CODE DTC 41 FUEL PUMP HIGH VOLTAGE Circuit Description When the ignition switch is first turned on the ECM energizes the fuel pump relay which applies power to the fuel pump The fuel pump relay will remain active as long as the engine is running or cranking If the fuel pump is active when the ECM is not commanding it then
114. to corrosion moisture or chafed insulation DTC 62 System Voltage High Yes EE Go to System Check before continuing at Step 2 Go to Step 2 Using aDVOM measure the battery voltage at the battery Is the battery voltage greater than the specified value 1 Charge the battery and clean the battery terminals nto een ncn 2 Clean the battery ground cable connection if corrosion is indicated 5 the battery voltage less than the specified value VPWR B Replace batter Go to Step 4 1 Turn off all electrical accessories if applicable Verify that the 2 Start the engine alternator is functioning Is the ignition voltage more than 8 volts correctly Go to Step 5 Install replacement ECM Remove replacement 9 5 system operation normal with replacement ECM installed ECM and install original ECM Go to Step 5 the repair complete system operation normal with original ECM Remove original reinstalled ECM and reinstall Keep original ECM replacement ECM installed Re test Go to Step 7 Is the repair complete system operation normal with replacement ECM Leave replacement ECM reinstalled installed Re test 08 87 Auxiliary Systems EFI amp Ignition Electronics Diagnostic Trouble Code 65 NOTES Installation of Upper Intake Manifold MUSTANG DIAGNOSTIC TROUBLE CODE DTC 65 INTAKE MANIFOLD LEAK Circuit Description The ESG 642 intake manifold is in two parts upper and lower
115. will not allow engine to start Trouble shooting Check for ice or foreign object in actuator Check actuator for tampering DTC 26 Throttle Position Sensor High Voltage At Start Up No O Go to Diagnostic System Check before continuing at Step 2 Go to Step 2 Key off Check actuator for ice build up or foreign objects stuck in throttle plate Check for bent throttle plate Check ECM ground Were any problems found Repair as needed NOTE Ice can build up even at 45 F with the right conditions Re test amp start engine Go to Step 3 3 KOEO Check the 5V reference signal from the ECM on circuit 351D 351 Repair the wiring and Where any shorts or opens found OV retest Go to Step 4 4 KOEO Check the signal return circuit 355 from TPS to ECM pin C 1 Pu Clear DTC Restart for signal valve 1V to 1 1V engine Retest Go to Step 5 Step Replace the electronic governor Is the repair complete and engine 5 Are you using a personal computer PC to perform this diagnosis operating to specification NOTE Do not attempt to disassemble the actuator This will void the warranty Remove amp replace electronic governor Re test Go to Step Install replacement ECM Remove replacement ECM Go to Step 7 5 the repair complete system operation normal with original ECM Remove original reinstalled ECM and reinstall Keep original ECM replacement ECM installed Re test Go to Step 8 Is the repair c
116. 0 8 4 4 386 _ 28 5 a rm 05 33 Auxiliary Systems Cooling COOLING SYSTEM DIAGNOSING AND TESTING Continued V Ribbed Serpentine Drive Belt Cracks Across Ribs Chunks of Rib Missing Symptom Chart Drive belt cracking e Worn out e REPLACE the drive belt Drive belt chunking Overheated Refer to Belt in this section Chemical or oil spilled on belt Drive belt noise or squeal Pulley misalignment DETERMINE from which Excessive pulley groove runout pulley the noise originates CHECK that area with a straightedge and LOOK for for accessory pulley to be out of position in the fore aft direction or at an angle to the straightedge REPLACE the pulley or the component Damaged drive belt tensioner Replace belt tensioner 6B209 e Fluid or contamination on the e CLEAN or REPLACE the drive belt drive belt Refer to Belt this e Excessive A C head pressure section 05 34 Auxiliary Systems Cooling COOLING SYSTEM DIAGNOSING AND TESTING Continued 4 2L Belt Drive Tensioner Belt Length Indicator Part Number Description 0 Oai ee Belt Length Pom Acceptable Belt Installation and Wear Range 983 Belt Replacement Range Belt Tension Relief Point Use 1 2 Inch Ratchet Automatic tensioners are calibrated at the factory to provide the correct amount of tension to the belt Unless a spring within th
117. 03 Balance Shaft Drive 6375 Flywheel Gear 6A372 Engine Rear Plate 6A304 Engine Balance Shaft Driven 6701 Crankshaft Rear Oil Seal Gear 31 6333 Crankshaft Main Bearing 3 6C341 Balance Shaft Thrust Plate Req d 6A31 1 Engine Dynamic Balance 32 6337 Crankshaft Thrust Main Shaft Bearing 6A333 Balance Shaft Front and Rear 6626 Oil Pump Inlet Tube Gasket Bearing 2 Req d 6327 Main Bearing Cap 6 564 Eu and 6235 Rear Main Bearing Cap 36 6675 M 6K564 Tappet Guide Plate and 36 6675 Retainer LH 6622 ERE Screen Cover and 6500 Valve Tappet 16 Req d 38 6A835 Oil Pan Baffle Ass 6A335 Balance Shaft Cover Plug 38 64835 y 39 6723 Oil Pan Rear Seal Piston Ring 6 Req d 6261 Camshaft Front Bearing 9 6306 Crankshaft Sprocket ning 6 acl 6256 Camshaft Sprocket AO EH 43 6161 Piston Ring 6 Reqd 6269 Camshaft Thrust Plate Piston 6 d 99 6265 Camshaft Sprocket Spacer 6262 Gamehatt 6135 Piston Pin 6 Req d 46 6200 Connecting Rod 6 Req d 19 6250 Camshaft Center Bearing 2 46 6200__ 9 l Req d Connecting Rod Bearing Upper 6 Req d 6263 Camshaft Rear Bearing 21 6333 Crankshaft Main Bearing 3 Lower 6 Req d Heq d Connecting Rod Cap 6 22 6284 Timing Chain Vibration Req d ng P Damper 50 6200 Connecting Rod Assy 6 388907 Woodruff Key Edidi d ng 6329 Main Bearing Cap Piston and Connecting Rod 6334 Ma
118. 164 R3202 or equivalent Coupling Spring Lock Special Tool s opring Lock Coupler Tool 310 D004 D87L 9280 A or equivalent Disconnect Tool 1 2 inch 310 D005 D87L 9280 B or equivalent ST1147 A 04 6 Special Service Tools called for by the procedures can be obtained by calling 1 800 ROTUNDA 1 800 768 8632 Disconnect spring lock Special Service Tools called for by the procedures can be obtained by calling 1 800 ROTUNDA 1 800 768 8632 AS 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 LN WARNING FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING BEFORE SERVICING 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 PERSONAL INJURY OR A FIRE HAZARD 1 Disconnect the battery ground cable 2 Helieve the fuel pressure For additional information refer to Pressure Relief in this section Auxiliary Systems Fuel GENERAL PROCEDURES Continued 3 Remove the fuel tube clip 4 Install the Disconnect Tool 5 Close and push the Disconnect Tool into the open side of the cage 6 Separate the fitting 04 7 Auxiliary Systems Fuel GENERAL PROCEDURES Co
119. 2 Go to Step 11 m Does engine run with original relay reinstalled Hemove original relay and reinstall replacement relay Go to Step 9 Go to Step 10 Repair open in ECM relay or Fuel Pump relay feed Verify repair Go to MIL DTC retrieval procedure if required Go to Step 12 circuit Go to Step 13 Go to Step 15 connector with a test light to ground Is action complete engine operation normal Is the test light ON Go to Step 14 Go to Step 16 1 Check for a faulty ECM ground or a poor ground Verify repair connection at the ECM Go to MIL DTC 2 If a problem is found repair as necessary retrieval 1 Ignition OFF 2 Disconnect the ECM connectors 3 Ignition ON 4 Probe the ignition feed circuit at the ECM harness connector with a test light to ground Is the test light Probe the battery feed circuit at the ECM harness Was a problem found procedure if required Go to Step 13 03 43 Auxiliary Systems Ignition ENGINE CRANKS BUT DOESN T START CIRCUIT TEST Continued Locate and repair open or short to ground in ECM ignition feed circuit Was a problem found Locate and repair open or short to ground in ECM battery feed circuit Was a problem found Install replacement ECM Does engine start and run Does engine start and run Does engine start and run with replacement ECM installed 1 Ignition OFF 2 Disconnect CKP Sensor connector 3 With a test
120. 355 GY W 35168 BR W Power Feed From Ignition Switch 33 31 pom mc omo c c nh nc c gc A em dm m a oh 4 X Ran m 4 Signal PP Sensor PP5V Pedal Assembly Switch 42 Pin Connector t Return zumal Reference Return Signal 2 4 5 GY R 151 LB BK 5 3 BR W 307 BK Y B2 A1 A2 K2 pm wae e umo um eee eee A m DIAGNOSTIC TROUBLE CODE DTC 16 IDLE VERIFICATION SWITCH FAILURE Circuit Description The idle validation switch IVS is an off on switch normally open with 12V as a power supply from the ignition switch on circuit 361 R When the accelerator pedal is depressed the switch the switch is closed sending a 12V signal to the ECM on circuit 307 BK Y through the 42 pin connector pin 25 From the 42 pin connector to the ECM pin K2 The IVS signal is very important input used by the ECM to aid in the control of the engine RPM Conditions for Setting the DTC KOEO or The accelerator pedal position APP sensor is lt 0 8V with the IVS closed APP sensor 1 gt 1 54V with the IVS opened e Above conditions are present for at least gt 0 032 consecutive seconds Actions Taken When the DTC Sets ECM will illuminate the malfunction indicator lamp MIL The APP sensor internally is forced to 0 235V
121. 513 A Piston Ring Compressor D81L 6002 C or Equivalent Camshaft Bearing Set T65L 6250 A Connecting Rod Guide Tool T93P 6136 A Crankshaft Damper Remover T58P 6316 D Cylinder Ridge Reamer T64L 6011 EA DESCRIPTION AND OPERATION Engine The 4 2L engine has V block with six cylinders and splayed crankpins A distributorless ignition system multiport sequential fuel injection SFI system e Overhead valves ESG 642 Hydraulic tappets for automatic lash adjustment Connecting rod parting faces that are unique with an interference fit A balance shaft 02 4 ESG 642 DESCRIPTION AND OPERATION Continued Engine Disassembled View DA0614 B 02 5 ESG 642 DESCRIPTION AND OPERATION Continued number Description Number Description ___ Number Description Number Description Idle Air Control Gasket 12 12A648 Engine Coolant Temperature 2 9728 _ Accelerator Cable Bracket Sensor 3 13 Intake Manifold Lower 4 9E926 Throttle Body 14 9439 Intake Manifold Gasket RH 5 9E936 Throttle Body Gasket 15 9439 Intake Manifold Gasket LH 7 9H486 Intake Manifold Upper Gasket 17 9A424 Intake Manifold Seal Rear 9736 Accelerator Cable Routing 18 6010 Cylinder Block Clip 19 9B339 Oil Pressure Sender Fitting 8594 Water Outlet Connection 20 9278 Oil Pressure Sensor 10 8575 Water Thermostat a 11 10884 Water Temperatu
122. 563 Voltage values calculated for VREF 5 volts may vary 1596 due to sensor and VREF variations 2 135 y TEMPERATURE NOM R NOM Eo C F OHMS VOLTS E 6958 43 2096 425 4 138 415 128485 402 991 888 _ 4 7494 35 _ 58 358 332 68 3734 309 3000 2 24253 22 i oe 1 Le sm 18 9 9 0 8 4 4 386 _ 28 5 a rm 03 41 Auxiliary Systems Ignition ENGINE CRANKS BUT DOESN T START Circuit Description The electronic distributorless ignition system uses a six tower coil pack to provide spark distribution In the coil pack two adjacent coil towers share a common coil and are called a matched pair The matched pairs in this application are cylinders 1 and 5 2 and 6 and 4 and 3 cylinders During crank the ECM monitors the Crankshaft Position Signal CKP signal The CKP signals is used to determine which cylinder will fire first After the CKP signal has been processed by the ECM it will command all six injectors to allow a shot of fuel for all the cylinders This is known as batch fire and occurs anytime while in open loop Diagnostic Aids An intermittent problem may be caused by a poor connection rubber through wire insulation or
123. 614A R 16 37C Y 16 787 16 0 r zu e lt D u Fuel Pump Relay Circuit 926A gt ECM Pin P3 K Off OV KOEO B KOER B Crank B Circuit 787A gt Splice 11 gt ECM 238 DG Y 18g Pin F3 Also 42 Pin Conn Pin 05 K Off OV KOEO B 8 seconds KOER B Crank B Circuit 37C gt Splice 01 gt 42 Pin Conn Pin 09 B all times Circuit 361A gt Splice 1 gt Power Relay Circuit 361A K Off OV KOEO B KOER B Crank B 4 Once you have established the integrity of the power supply and ground to the pump if it still will not operate replace the pump assembly Fuel Supply and Pressure If a problem with fuel supply or delivery is suspected first ensure that there is fuel in the tank Next ensure that the in line filter between the fuel tank and the pump is clean Once these items have been checked and verified proceed as follows 1 Connect a pressure gauge onto the pressure relief valve at the fuel rail 2 Turn on the ignition switch but do not start the engine 3 The pump should click rapidly for 3 seconds and pressure should built to and level off at 64 PSI NOTE Ignition switch may have to be cycled twice to build pressure to 64 psi 4 f pressure fails to come up check for an obstruction in the supply line from the tank to the pump and between the pump and fuel rail 5 f pressure starts to drop off block return line to fue
124. 642 ENGINE REPAIR Continued P dei 6 NOTE Lower intake manifold bolts are torque to yield They must be discarded and replaced with new bolts NOTE The fuel charging components and engine wiring harness are removed with the lower intake manifold Remove the fourteen lower intake manifold bolts A and B and discard 7 Remove and discard the lower intake manifold sealing components Part Number Description 9439 Intake Manifold Gasket LH 9439 Intake Manifold Gasket RH 3 Intake Manifold Rear End Seal Part of 9439 4 Intake Manifold Front End Seal Part of 9439 02 18 ESG 642 ENGINE REPAIR Continued Installation of Lower Intake Manifold A CAUTION Mating parts must make contact to each other within 4 minutes and connecting bolts must be torqued within 15 minutes after applying sealant Failure to follow this procedure can cause future oil leakage Use silicone gasket and sealant FGAZ 19562 AA or equivalent meeting Ford specification WSE M4G323 A6 NOTE Sealant must be removed and area cleaned with solvant if above instructions are not followed e Use metal surface cleaner F4AZ 19A536 RA or equivalent meeting Ford specification WSE M5B292 A 1 Install the lower intake manifold front and rear end seals 1 Apply a bead of sealant to the intake manifold front and rear end seal mounting points as indicated 2 Install the lower intake manifold front and rear e
125. 68 8632 Adapter T82L 6316 B Rear Main Seal Replacer T82L 6701 A Assembly of Engine 1 Install the upper crankshaft main bearings 6333 in the cylinder block The third bearing from the front of the engine is the thrust bearing DA0661 A 02 109 ASSEMBLY Continued ESG 642 2 Install the lower crankshaft main bearings in the bearing caps The third bearing from the front of the engine is the thrust bearing 0662 Install the crankshaft e Lubricate the main bearings and crankshaft journals with Engine Assembly Lubricant D9AZ 19579 D or equivalent meeting Ford specification ESR M88C80 A e Make sure the Woodruff key is installed in the end of the crankshaft 02 110 ASSEMBLY Continued ESG 642 CAUTION Mating parts must make contact to each other within 4 minutes and connecting bolts must be torqued within 15 minutes after applying sealant Failure to follow this procedure can cause future oil leakage e Use silicone gasket and sealant FGAZ 19562 AA or equivalent meeting Ford specification WSE M4G323 A6 NOTE Sealant must be removed and area cleaned with solvant if above instructions are not followed Use metal surface cleaner F4AZ 19A536 RA or equivalent meeting Ford specification WSE M5B292 A 4 Clean the mating surfaces on the rear main bearing cap and the cylinder block Apply a small amount of Silicone Gasket and Sealant in the location sh
126. 7 850 Y BK 18 234 W LB 18 25 BK Y 20 253 DG W 20 235 LG W 18 242 DG 16 251 Y 18 GY LB 20 03 51 Auxiliary Systems Ignition Drive By Wire Foot Pedal Switch AA1841 A Typical Foot Pedal Switch First Version Foot Pedal 359A Gy 355 GY W 3516 BR W Circuit Description The Pedal Position PP sensor is a potentiometer which is attached to the pedal assembly pivot shaft The ECM provides a 5V reference voltage to the PP sensor between terminal A Grey Red circuit 359 and terminal C Brown White circuit 351B of the pedal assembly A PP signal is returned to the ECM from terminal B Grey White circuit 355 of the pedal assembly The PP signal varies from about 7 or 8V at idle to 4 8V at WOT The PP signal is an important input used by the ECM for RPM control DTC 13 will set when the ECM detects low voltage and DTC 23 for excessively high voltage DTC 16 The Idle Validation Switch IVS is an off on switch normally opened with 12V as a power supply from the ignition switch on Circuit 361 When the IVS fails or is out of adjustment it will set DTC 16 This code will be set when the Pedal Position PP sensor is out of set range while IVS off damaged misadjusted IVS malfunction damaged wiring electrical failure or mechanical failure A Pedal Position PP Sensor Connector Signal Return PP Sensor Signal D PP 5V Reference E Pedal Assembly Connector for Idle Validation Switch
127. 7 eliminate cross firing Verify that ignition wires are not arcing to ground Spraying the secondary ignition wires with a light mist of water may help locate an intermittent 2 If spark plugs are fouled the cause of fouling must be determined before replacing the spark plugs Was a problem found Verify repair Go to Step 10 Check the ECM grounds to verify that they are clean and tight Refer to the ECM wiring diagram Was a problem found Verify repair Go to Step 11 03 20 Auxiliary Systems Ignition HARD START SYMPTOM Continued step Acin 7 Vaw Ys No 1 Check the ignition coil secondary resistance 2 Replace the coil if it is not within the specified range of resistance Refer to Did the coil require replacement Page 03 35 Verify repair Go to Step 12 Check the electronic governor operation including i the TPS function Refer to Fuel Section Verify repair Go to Step 13 i S for water alcohol contaminated fuel ul a uaa found repair Go to Step 14 Inspect the fuel delivery system to determined if there is a problem with fuel delivery Was a problem found Verify repair Go to Step 15 Check for the following engine mechanical problems refer to Section 01 of this Manual ow compression Leaking cylinder head gasket Worn camshaft Camshaft drive belt slipped or stripped Was a problem found Verify repair Go to Step 16 1 Review all diagnostic procedures within this
128. 8 15 Engine Cylinder Head Temperature Sensor CHT 08 16 CHT Detail SINC Cl RETRO 08 17 Injector Assembly 08 18 Injector Detail Sheet 08 19 Crankshaft Position Sensor 08 20 VR Detail Sheet 08 21 Fuel Pump Relay FP 08 22 Fuel Pump Relay Detail Sheet 08 23 DCC IMO AON 08 24 Diagnostic Trouble Codes WERE RES 08 25 Chart NOTES 08 26 Other Descriptions 08 28 Trouble Code 11 00 000 0 08 29 Trouble Code RT 08 30 Trouble Code 13 EU 08 32 Trouble Code TA Mu 08 34 Trouble Code 15 08 36 Trouble Code T 08 38 Trouble Code 17 enn 08 40 Trouble Code 21 METRE Or 08 42 Trouble Code 22 000000 0 08 44 Trouble 08 46 Trouble Code 08 48 Trouble Code 25 m RUE 08 50 Trouble Code 26 08 52 Trouble Code 27 08 54 Trouble Code 3 1 oomen 08 56 Trouble Code nA nee ne ioe er
129. 800 ROTUNDA 1 800 768 8632 02 104 ESG 642 DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES Continued Disassembly 1 Use the Camshaft Bearing Set to remove the four camshaft bearings 2 Use the Camshaft Bearing Set to remove the two engine dynamic balance shaft bearings 3 If so equipped remove the block heater 4 NOTE For cleaning purposes plugs should be removed If necessary remove plugs and dowels Cylinder block dowels A Oil gallery plugs B e Water jacket plugs 02 105 ESG 642 DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES Continued Assembly NOTE Moving components must be lubricated with engine oil before assembly NOTE Components with oil holes must be properly aligned with oil feed holes 1 Ifnecessary install plugs and dowels 25 40 Nm 19 29 Ib ft a lt gt Water jacket plugs N 2 If so equipped install the block heater e Cylinder block dowels A ant Oil gallery plugs B A25611 A 3 Use the Camshaft Bearing Set to install the two dynamic balance shaft bearings 4 Use the Camshaft Bearing Set to install the four camshaft bearings 02 106 ESG 642 DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES Continued 5 Install the A engine dynamic balance shaft bearing cover and the B camshaft bearing cover Cylinder Head Special Tool s Valve Spring Compressor T81P 6513 A Special Service Tools called for b
130. 904 LG R e Poor ground Voltage regulator Generator Indicator lamp off key on engine not Open high resistance I Circuit 904 Go to Pinpoint Test E running LG R Burned out bulb e Poor ground S Circuit 4 W BK shorted to B Voltage regulator Generator Generator noisy Accessory drive belt Go to Pinpoint Test F Accessory brackets Bent generator pulley Generator Other components Indicator lamp on key off e Lamp circuit GY W shorted to B Go to Pinpoint Test Improper lamp circuit wiring 06 6 Auxiliary Systems Charging GENERATOR DIAGNOSIS AND TESTING Continued Pinpoint Tests All voltage measurements are referenced to the connections may damage the voltage regulator negative battery post unless otherwise specified or fuses fuse links AN CAUTION Do not make jumper All key ON measurements are made with the connections except as directed Improper engine not running unless directed to start engine PINPOINT TEST A DEAD BATTERY NO GENERATOR OUTPUT TEST STEP RESULT ACTION TO TAKE Turn key to OFF position Yes GO to 2 Turn off all accessories No pe Check to ensure that the Connect an ammeter or test lamp between the key switch is functioning negative battery cable and the negative battery properly and that all lights post and accessories are off Is current drain
131. A 3 Vapor management hose for PCV system 4 Wiring at the throttle position sensor 5 Electronic Governor if so equipped 02 12 ESG 642 ENGINE REPAIR Continued 6 Remove the accelerator cable bracket if so equipped DA0202 A 7 Remove the throttle cable speed control routing clip retaining screw 8 Disconnect the manifold vacuum connection 02 13 ESG 642 ENGINE REPAIR Continued 9 Remove the PCV valve 9 A27159 B 10 Remove the transmission dipstick tube routing bracket retaining nut and solenoid mounting bracket if so equipped 2 25434 11 NOTE Illustration shown is F TYPE Remove twelve bolts and the upper intake manifold 9424 12 NOTE Illustration shown is MUSTANG TYPE Remove twelve bolts and the upper intake manifold 9424 02 14 ESG 642 ENGINE REPAIR Continued 13 For both types of intake manifolds remove and discard the two upper gaskets 9H486 Save and reuse spacer plate 9N469 e EIL az ata mra TIER z 1 Follow the removal procedure in reverse order MUSTANG for both types of manifold 9424 NOTE Install two new intake manifold upper gaskets 9H486 for both types of manifold 2 Install first gasket to lower intake manifold 9J447 3 Install spacer plate 9N469 4 Install second upper intake manifold gasket 9H486 5 Install upper intake manifold 9424
132. AWAY FROM BATTERIES IN CASE OF ACID CONTACT WITH SKIN EYES OR CLOTHING FLUSH IMMEDIATELY WITH LARGE AMOUNTS OF WATER GET MEDICAL ATTENTION Inspect and service any of the following pre existing conditions before recharging a discharged battery Loose drive belt 8620 e Pinched or grounded generator voltage regulator wiring 14305 Loose connections of the generator voltage regulator wiring at the generator GEN 10346 or voltage regulator VR 10316 Loose or corroded connections at battery grounded starter motor cutout relay 11433 or engine 6007 Excessive battery drain due to any of the following conditions on some types of equipment Compartment lamp 15702 glove compartment and interior lamps 13776 remaining energized damaged or misadjusted switch glove compartment left open etc Lamp switch 13713 continuously on Maintenance Free and Low Maintenance Batteries 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 charg
133. B S03 S05 3616 359 GY R 351 BR W L XB2 ___ AO A2 H1 K Signal TP 777 4 777 Power Engine Return Sensor TP Throttie Feed 1 Control Signai 5 Reference Control Module DIAGNOSTIC TROUBLE CODE DTC 22 THROTTLE POSITION TP SENSOR HIGH VOLTAGE Circuit Description The throttle position TP sensor is a potentiometer which is attached to the throttle plate shaft inside the electronic governor The ECM provides a 5V reference voltage to the TP sensor between terminal A Grey Red circuit 359F and terminal C Brown White circuit 351D of the electronic governor A TP signal is returned to the ECM from terminal B Grey White circuit 355 of the electronic governor The TP signal varies from about 1 0V at idle to 4 8V at WOT The TP signal is an important input used by the ECM for fuel control and other engine control functions Conditions for Setting the DTC e KOEO TP signal is 4 9V or more e Above conditions are present for at least 2 consecutive seconds Actions Taken When the DTC Sets The ECM illuminates the malfunction indicator lamp MIL e When DBW the ECM will shut the engine down Engine can be restarted by recycling the ignition switch 08 44 Auxiliary Systems EFI amp Ignition Electronics Diagnostic Trouble Code 22 DTC 22 Throttle Position Sensor High Voltage 1 Are you using a personal computer PC to
134. C 32 For Low Voltage From IOZS SOS OI Circuit Description Conditions for Setting the DTC Conditions for Clearing the DTC Resetting the 120 42 022 Exhaust Gas Oxygen HO2S Sensor Diagnostic Trouble Code DTC 43 Engine Cylinder Head Temperature Low Voltage And 33 for High Voltage Circuit Description 1 Conditions for Setting the DTC Actions Taken When the DTC Sets Conditions for Clearing the DTC Resetting the amp C Intake Air Temperature Sensor Circuit Circuit Description Actions Taken When the Sets Conditions for Clearing the DTC Resetting the Diagnosuc AldS Intake Air Temperature IAT Sensor Throttle Position TP Sensor Manifold Absolute Pressure MAP Circuit Description Conditions for Setting the DTC Actions Taken When the DTC Sets Conditions for Clearing the DTC Resetting the
135. CHARGE 7 INDICATOR KEY SWITCH LAMP D9 A 11572 A CUSTOMER SUPPLIED STARTER MOTOR _ 4 FUEL SELECT F87U 11000 A1B q TOGGLE SWITCH Oe 1 semp i FOOT PEDAL SENSOR AND SWITCH harness 7 128476 m rr j r W j Mrr popp HARNESS 71 Fg Le d bene J i T 4 2L ONLY 4 To i 42 ONLY 8 12A690 4 21 124581 2 54 MIL i ELE E F8 1 10A979 AA L CUSTOMER NIU J Al Ge cmm e el me VOLTAGE PRESSURE SENDER i 2 5L ONLY TEMPERATURE SENDER 2 54 ONLY eee 03 54 Auxiliary Systems Ignition REMOVAL AND INSTALLATION INSTRUCTIONS OF ECM ICM NOTE Make sure correct program is installed before condeming ECM To download or upload program for validation use Interface Communication Cable Part Number F8JL 9A820 AA Call your nearest FPP Distributor listed in the back of this manual Removal 1 Remove the negative ground battery cable 2 Loosen the bolts 2 and remove the wire connectors 2 NOTE Remove the vacuum hose from the ICM 3 Remove the module hold down bolts 4 Installation A CAUTION The installation instruction for the ECM amp ICM must be followed or potential failure of component is likely NOTE If the ECM or ICM
136. COUNTRY AND LOCAL CODES speed to open the fuel shut off valve IN THE USAFOLLOW ALL REGULATIONS AND STANDARDS MANDATED BY THE NATIONAL FIRE PROTECTION The system is similar to the LPG system except ASSOCIATION INC INCLUDING NEPA 37 52 convertor vaporizer is not used and the coolant 58 PLUS ANY OTHER STANDARDS YOU CAN OBTAIN COPIES connections are also not needed A regulator is FROM YOUR LOCAL FIRE DEPARTMENT required and must be supplied by the OEM to suit FOR CANADIAN CODES SEE NATIONAL STANDARDS OF the mains gas supply pressure CANADA IN THE UNITED KINGDOM FOLLOW THE CODE OF PRACTICE ELEVEN PRODUCED BY THE LPG NG ASSOCIATION WARNING Natural gas passes through a vacuum operated fuel shut off valve into a regulator unit where it is converted into a low pressure gas This gas is then fed into the mixer where a vacuum operated gas metering valve ensures that the correct air to fuel ratio is maintained When the engine is switched off vacuum supply to the fuel shut off vacuum is disconnected and the valve closes cutting off the fuel supply to the regulator 04 28 Auxiliary Systems Fuel SPECIFICATIONS General Specifications Fluid Lubrication Specification Engine oil XO 10W30 QSP or DSP WSS M2C153 G Specifications Description Nm Lbh Her eT MP Electrical Connector Bolt 35 50 PUTET Bolts 8 11 5 71 102 Fuel Pressure Relief Valve Thr
137. Camshaft Position Sensor Canister Carburetor Central Multiport Fuel Injection L Clutch Pedal Position Switch 09 9 Auxiliary Systems Metrics J1930 TERMINOLOGY LIST New Term Continuous Fuel Injection New Acronym Old Terms Acronyms CFI Continuous Injection System CIS Continuous Injection System Electronic Continuous Injection System E CIS E Fuel Injection FI K Jetronic KE Jetronic KE Motronic CFI System Continuous Injection System CIS TOX Continuous Trap Oxidizer CTO Trap Oxidizer Continuous TOC Crankshaft Position CP Position Indicator Pulse PIP Continuous Fuel Injection system Continuous Trap Oxidizer A U Crankshaft Position Crankshaft Position Sensor CKP Sensor Crankshaft Position Sensor CPS Crank Angle Sensor Data Link Connector DLC Assembly Line Communications Link ALCL Assembly Line Diagnostic Link ALDL Self Test Connector Vehicle In Process Connector VIP Connector Diagnostic Test Mode Diagnostic Trouble Code Differential Pressure Feedback Gas Differential Pressure Differential Pressure Feedback Recirculation System Feedback EGR EGR System System DFI Og A Direct Fuel Injection Direct Injection DI Direct Injection Diesel DID Fuel Injection FI Capacitive Discharge Ignition CDI Closed Bowl Distributor Electronic Ig
138. D 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 Keeping the battery 10655 top clean and dry reduces the need for service and extends battery life Also make certain the cable clamps are tightly fastened to the battery posts 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 The battery cleaning operation shown in the following illustration is typical for all vehicles and equipment Tools Anyone working with a battery 10655 needs the proper tools Using the right tools will prevent damage to the battery battery cables and battery hold down clamp 10718 Tools and equipment manufactured for servicing batteries 10653 have parts insulated to help prevent arcing should the tool be dropped or placed accidentally between a terminal a
139. DTC 41 will set This condition indicates a problem with the relay or the wiring Conditions for Setting the DTC e KOEO Fuel pump voltage is active when the ECM is not commanding it e Above conditions must be met for at least 2 consecutive seconds Actions Taken When the DTC Sets ECM illuminates the malfunction indicator lamp MIL e The drive by wire engine will shut down and or will not start 08 66 Auxiliary Systems EFI amp Ignition Electronics Diagnostic Trouble Code 41 Diagnostic Aids Inspect the harness connectors for backed out terminals improper mating broken locks improperly formed or damaged terminals and poor terminal to wire connections Inspect the wiring harness for damage DTC 41 Fuel Pump High Voltage No Are you using a personal computer PC to perform this diagnosis Go to Diagnostic System pum Check before continuing at Step 2 Go to Step 2 1 KOEO 2 Connect a DVOM from the ECM connector back probe K1 to ground Does the DVOM show battery voltage B Go to Step 4 Go to Step 3 Step Repair the open or short to ground in circuit 361A amp 361G Red between B amp me o the ECM and the fuel pump relay Is the repair complete B Re test 4 Connect a DVOM from cavity 85 to ground Recycle ignition switch to KOEO Does the DVOM show battery voltage 3 sec Go to Step 6 Go to Step 5 Repair the open or short to ground in circuit 926A Lt Blue Or
140. Disconnect the battery ground cable 2 Relieve fuel pressure For additional information refer to this section 3 Remove the fuel injection supply manifold 9F792 For additional information refer to Supply Manifold Fuel Injection in this section 4 A CAUTION The fuel injectors 9F593 are deposit resistant Do not clean the fuel injectors Remove the fuel injector retaining clips and the C28 B s Bc fuel injectors Inpsect the fuel injector O rings SEM X30 725 and if necessary install new O rings AV1766 A Installation 1 CAUTION Install the injector clips in the uppermost groove of the fuel injectors NOTE Lubricate new O rings with clean engine oil XO 10W30 QSP or DSP or equivalent meeting Ford specification WSS M2C153 G to aid installation To install reverse the removal procedure 2 Connect the battery ground cable 04 14 Auxiliary Systems Fuel REMOVAL AND INSTALLATION Continued Supply Manifold Fuel Injection AS 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
141. E B Verify repair Verify repair 03 25 Verify repair Verify repair Go to Step 9 Verify repair Verify repair Go to Visual Physical Check Go to Step 3 Verify repair Go to Step 5 Go to Step 6 Go to Step 7 Go to Step 8 Verify repair Go to Step 10 Contact Ford Power Products Customer Service Center Technical Support Hotline 1 800 521 0370 Auxiliary Systems Ignition ROUGH UNSTABLE OR INCORRECT IDLE STALLING SYMPTOM Stp Action Ye DEFINITION Engine runs unevenly at idle If severe the engine may shake Engine idle speed may vary in RPM Either condition may be severe enough to stall the engine Check for rough unstable or incorrect idle or stalling condition Ensure that the following conditions are 1 present Engine fully warm Accessories are OFF Does engine run rough idle fluctuate or stall mum to Step 2 Perform a visual physical check including ignition 2 coil and secondary ignition wire connections Was a problem found repair to Step 3 Perform MIL DTC retrieval procedure Refer to DTC Ignition ON engine not running short STI chart perform 3 connector to ground component and Do any fault codes flash and display circuit test as required Go to Step 4 NOTE Make sure engine is closed loop before proceeding Check the heated oxygen sensor HO2S operation The 025 should respond quickly to different throt
142. E 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 Relieve fuel pressure For additional information refer to this Section 3 Remove the fuel pressure relief valve 9H321 with the fuel pressure relief valve cap 9H323 Installation 1 Toinstall reverse the removal procedure NOTE Use teflon tape on threads using caution not to allow tape particles to enter fuel system Do not use in excess 2 Connect the battery ground cable 7o 259 04 17 Auxiliary Systems Fuel FUEL SYSTEM DESCRIPTION AND TESTING Electrical 1 Connect the positive lead of a voltmeter to the pump power wire circuit 787 PK BK from pin 5 of 42 pin connector and the negative lead to a known good ground 2 Turnon the ignition switch 3 The voltmeter should read 12 volts for 3 seconds not check the power supply from the fuel pump relay to the pump and the ground wire between pump and engine cylinder block 3
143. EE If no page please describe YES NO Is the organization of the manual clear and easy to follow Please comment Are there any important procedures not covered in this manual that you would like to see included YES NO If yes please describe Please enclose a copy of each page marked with your suggestions Please tell us who you are Name Street Jp 5 gt 5 5 gt 5 5 5 5 gt 5 gt gt 55 gt gt Position Thank You for Your Help Ford Power Products Publications Department
144. ER CABLE 411 Block Heater Check resistance in circuits 1 2 and 3 of the block heater 5 the resistance in circuits 1 2 and less than 5 ohms Yes INSTALL a new block heater No INSTALL a new power cable TEST the system for normal operation 05 28 Auxiliary Systems Cooling COOLING SYSTEM DIAGNOSING AND TESTING Continued Component Tests Pressure Test 1 Turn the engine OFF 2 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 AVOID 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 43 110 F Wrap a thick cloth around the pressure relief cap and turn it slowly one half turn counterclockwise Stepping back while the pressure is released from the cooling system When you are sure all the pressure has been released still with a cloth turn counterclockwise and remove the pressure relief cap Check the engine coolant level For additional information refer to Cooling System Draining Filling and Flushing in this section AQO0245 A Connect Radiator Heater Core Pressure Tester to the degas bottle nipple and overflow hose Install a pressure test pump to the quick connect fitting of the test adapter 6 10 05 29
145. Edge ESG 642 GENERAL SERVICE PROCEDURES Continued Cylinder Bore Honing Special Tool s Engine Cylinder Hone Set T73L 6011 A ST1275 A Cylinder Bore Cleaning 1 Special Service Tools called for by the procedures can be obtained 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 Hone with the Engine Cylinder Hone Set at a speed of 300 500 rpm and a hone grit of 180 220 to provide the desired cylinder bore surface finish 1 CAUTION If these procedures are not 01 54 followed rusting of the cylinder bores may occur Clean the cylinder bores with soap or detergent and water 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 ESE M2C153 E ESG 642 GENERAL SERVICE PROCEDURES Continued Cylinder Block Repair Cast Iron Porosity Defects CAUTION Do not attempt to repair L cracks areas where temperature will exceed us 260 C 500 F or areas exposed to engine coolant or oil These areas will not repair and could cause future failur
146. F THE STARTER BE CAREFUL TO AVOID TOUCHING HOT EXHAUST COMPONENTS SYMPTOM CHART CONDITION POSSIBLE SOURCE ACTION Starter solenoid does not pull in and starter does not crank audible click may or may not be heard Open fuse ow battery Defective remote relay Open circuit or high resistance in Check fuse continuity Refer to appropriate battery service manual Go to Test B Page 07 8 0 to Test A Page 07 8 external feed circuit to starter solenoid Defective starter Defective neutural park switch Unusual starter noise during starter overrun Noise from other components Ring gear tooth damage or excessive ring gear runout Defective starter Starter cranks but engine does not start Starter cranks slowly Low battery High resistance or loose connections in e Starter not mounted flush cocked Problem in fuel system Problem in ignition system Engine related problem e Replace starter See removal and installation procedure this section Replace switch Realign starter on transmission bell housing or SAE housing Investigate other powertrain accessory noise contributors Replace flywheel ring gear Replace starter See removal and installation procedure this section e Refer to fuel system section Refer to ignition system section Refer to Section 01 Diagnosis and Testing Charge or replace battery
147. For additional information refer to Cooling System Draining Filling and Bleeding in this section Auxiliary Systems Cooling COOLING SYSTEM DIAGNOSING AND TESTING Continued Cap Pressure Relief 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 AVOID 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 110 F 2 Wrapa thick cloth around the pressure relief cap and turn it slowly one half turn counterclockwise Stepping back while the pressure is released from the cooling system 3 When you are sure all the pressure has been released still with a cloth turn counterclockwise and remove the pressure relief cap Inspect the pressure relief cap and seals for damage or deterioration Replace the pressure relief cap if necessary Q4216 A 4 Fit the pressure relief cap to Radiator Heater Core Pressure Tester Kit using the aftermarket adapter 5 NOTE If the plunger of the pressure tester is depressed too fast an incorrect pressure reading will result Slowly pump the pressure tester until the pressure gauge stops increasing and note the highest pressure reading Release pressure and repeat test Install a new pressure relief cap if the pressure is not 48 kPa 7 psi
148. Go to Step 4 Check that ECM has correct program to match application rax Install correct Is the correct program installed Varies per program manufacture Go to Step 5 Re test Is system operation normal with replacement ECM install Remove replacement ECM and install original ECM Go to Step 7 Remove original 5 the repair complete Does system operate normal with original ECM Keep original ECM ECM and re insall installed replacement ECM Re test Go to Step 8 Step Replace the electronic governor Is the repair complete and engine Remove amp operating to specifications replace electronic governor with original Re test Go to Step 6 Leave replacement ECM Is the repair complete installed Is the system operation normal with replacement ECM Re test 08 41 NOTES Auxiliary Systems EFI amp Ignition Electronics Diagnostic Trouble Code 21 Crankshaft Position Camshaft Position CMP Sensor Connector CKP Sensor Connector Sensor Sensor 265 Ground Sensor Sensor DS jEngine Return Signal Signal Return Control iModule DIAGNOSTIC TROUBLE CODE DTC 21 OVERSPEED Circuit Description The ECM monitors engine speed through the crankshaft position CKP sensor If the engine speed reaches 4000 RPM the fuel is immediately removed to shut off the engine DTC 21 will set at this time The engine may be restarted after the ignition switch is cycl
149. Go to Step 6 Approx 1V at idle to approx 4 8V WOT Go to Step 4 Go to Step 8 Re test Go to Step 5 Re test Go to Step 9 Re test Go to Step 7 Re test Go to Step 9 replacement ECM Go to Step 11 s the repair complete system operation normal with replacement ECIV Leave replacement ECM reinstalled installed Re test 08 49 NOTES Auxiliary Systems EFI amp Ignition Electronics Diagnostic Trouble Code 25 359E E n MAP and CHT Sensors Manifold Skin Temperature MST Sensor Connector Engine Control Modute 1 DIAGNOSTIC TROUBLE CODE DTC 25 MANIFOLD SKIN TEMPERATURE HIGH VOLTAGE Circuit Description The manifold skin temperature MST sensor is a thermistor which is used to calculate the temperature of the air entering the cylinder The ECM provides a ground circuit 359E Grey Red from the sensor and supplies 5V reference signal on circuit 255 BK Y When the intake air is cold the sensor resistance is high and the ECM will monitor a high signal voltage at the MST signal circuit If the intake air is warm the sensor resistance is lower causing the ECM to monitor a lower voltage DTC 35 will set when the ECM detects an excessively high signal voltage on the intake air temperature sensor signal circuit Conditions for Setting the DTC e KOEO or MST sensor signal is gt 4 96V e Above conditions are present for at least gt 2 64 consecut
150. HING FLUSH IMMEDIATELY WITH WATER FOR A MINIMUM OF FIFTEEN MINUTES IF ACID IS SWALLOWED DRINK LARGE QUANTITIES OF MILK OR WATER FOLLOWED BY MILK OF MAGNESIA BEATEN EGG OR VEGETABLE OIL CALL A PHYSICIAN IMMEDIATELY Generator Removal 1 Disconnect battery ground cable 14301 2 Remove snow ice shield 3 Disconnect the generator voltage regulator wiring 14305 to the voltage regulator 4 Remove wiring connector bracket 5 Loosen the drive belt tensioner 613209 and remove the drive belt 6 Remove the bolts holding the generator to the generator bracket 10A313 7 Remove the generator from the generator bracket Installation 1 2 6 8 Position the generator on the generator bracket Install the bolts and tighten to 40 55 Nm 30 AO ft lb Install the drive belt over the generator pulley Install the drive belt over tensioner as outlined in Section 05 Connect generator voltage regulator wiring to the voltage regulator Tighten generator Battery Positive Voltage B wire attaching nut to 9 12 Nm 6 5 9 ft lb Install wiring connector bracket Install snow ice shield Connect battery ground cable Regulator Removal 1 1 Slip Rings 10328 06 13 NOTE for ease or removal and installation of regulator remove the generator from engine as described above Remove the four screws T20 Torx type head attaching the voltage regulator to the generator housing
151. I amp Ignition Electronics Diagnostic Trouble Code 32 Heated N S Oxygen Qi Sensor HO2S amp eS Connector 34 LB O 89A 570N BK W 74 GY LB S01 S05 S10 3616 359 GY R 570 BK W AER _ 1 B2 sensor Heater Signal o ee Ground j Engine Signal Return 1 Control Module 1 DIAGNOSTIC TROUBLE CODE DTC 32 HO2S SENSOR LOW VOLTAGE STUCK LEAN Circuit Description The ECM supplies a voltage of about 0 45 volts to the heated exhaust gas oxygen sensor This may read as low as 0 32 volts with a 10 megohm digital voltmeter The oxygen sensor varies the voltage within a range of about 1 volt if the exhaust is rich down through about 0 10 volts if the exhaust is lean A cold sensor causes an open loop operation If the sensor pigtail wiring connector or terminal is damaged the entire oxygen sensor assembly must be replaced Do not attempt to repair the wiring connector or terminals In order for the sensor to function properly it must have a clean air reference provided to it This clean air reference is obtained by way of the signal return wire Any attempt to repair the wires connector or terminals could result in the obstruction of the air reference and degrade the sensor performance Conditions for Setting the DTC and in closed loop HO2S sensor voltage is less than or equal to 0 20 volts for 20 consecutive seconds Actions Taken When
152. IGNAL 0 247 E RETAN 45 M 1148 182 287 9m d TEMP F TROUBLESHOOTING VOLTAGE SIGNAL amp SIGNAL RETURN OMAL 0 242 SHORTED 24 535 OPEN RESISTANCE SIGNAL amp SIGNAL RETURN DISCONNECTED PIN 0 3 225 BK Y 20 PIN B 2 e 359 GY R 359D GY R 2 MST Detail Sheet 08 15 Auxiliary Systems EFI amp Ignition Electronics ENGINE CYLINDER HEAD TEMPERATURE SENSOR CHT Part Description The CHT sensor is a temperature sensitive resistor thermistor which interfaces with a resistor network internal to the Engine Module ECM to provide a ratio metric output voltage inversely proportional to engine coolant temperature The sensor is threaded into the rear of the right cylinder head of engine to read cylinder head temperature For engine control applications the signal is used to modify ignition timing and air fuel ratio The output is used to control a coolant temperature indicator The sensor element is a 0 095 inch diameter disc thermistor with soldered leads and a plastic protective coating The thermistor resistance varies non linearly and inversely with respect to temperature The element is packaged in a brass bulb housing or molded plastic housing with a two terminal integral brown nylon plastic connector THERMISTOR amp LEAD ASSEMBLY CHT sensor typical Specifications e Range of Measurement 40 C 40 F to 125 C 257 F Meas
153. INE SIGNAL RETURN 359 GY R lt lt 359F GY R TPSINPUT PIN C 1 355 GY W lt lt 355B GY W VREF 5V PIN 4 A 2 351 BR W lt lt 3510 BR W PINS LOCATED ON ALL HARNESS CONNECTORS VIEWED INTO MATING SURFACE 08 9 Auxiliary Systems EFI amp Ignition Electronics HEATED OXYGEN SENSOR HO2S Part Description 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 in formation 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 Housing Screw in Thread Ceramic Gasket protective Tube Protective Insulator Exhaust Gas Intake Slots 2 H E Lim A IA 4 L qal mm External Electrical Clamping Contact Ceramic Sensor Conductive Layer Contact m Bushing y Internal Electrical Conductive Layer Contact Spring Sleeve HO2S sensor typical Specifications e Accuracy of Measurement 1 5 Operating Temp Range 350 C to 850 sensor tip e Sensor Response Time 300 to 1500 msec Heater Current Draw 1 A steady state Voltage Output 500 to 300 mV lean exha
154. INT Smoke Puff Limiter SPL Smoke Puff Limiter SPL INT imiter SCB Supercharger Bypass Solenoid SCB Solenoid Supercharger Bypass Solenoid SBS gt 09 16 Auxiliary Systems Metrics J1930 TERMINOLOGY LIST New Acronym Old Terms Acronyms System Readiness Test SRT Thermal Vacuum Switch TVS Third Gear System Readiness Test Thermal Vacuum Valve Third Gear 27 lt gt lt 44 Three Way Catalytic Converter TWC Three Way Catalytic Converte TWC Three Way Oxidation Catalytic TWC 4 OC Converter Throttle Body Throttle Body Fuel Injection Dual Bed Fuel Charging Station Central Fuel Injection CFI Electronic Fuel Injection EFI TBI Fuel Injection FI Monotronic Single Point Injection SPI Throttle Position TP Throttle Position Sensor TP Sensor Throttle Position Sensor TP Throttle Potentiometer TP Switch Throttle Position Switch TPS Torque Converter Clutch TCC Converter Clutch Control CCC Converter Clutch Override CCO Viscous Converter Clutch VCC Torque Converter Clutch Relay TCC Relay Lock Up Relay Torque Converter Clutch Solenoid Valve TCC Solenoid Valve Lock Up Solenoid Valve LUS Transmission Control Module TCM Transmission Control Module Transmission Range Park Reverse Neutral Drive Low PRNDL Selection Lever Position SLP Transmis
155. ION Piston rings should not be transferred 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 DA0362 A 01 35 ESG 642 GENERAL SERVICE PROCEDURES Continued 2 Useafeeler gauge to measure the top piston ring end gap and the second piston ring end gap DA0363 A Piston Ring to Groove Clearance Special Tool s Feeler Gauge D81L 4201 A or Equivalent Special Service Tools called for by the procedures can be obtained by calling 1 800 ROTUNDA 1 800 768 8632 1 Inspect for a stop in the grooves 2 Measure the piston to groove clearance DA0365 A 01 36 ESG 642 GENERAL SERVICE PROCEDURES Continued Crankshaft Connecting Rod Journal Diameter 1 Measure the crankshaft connecting rod journal diameters in at least two directions perpendicular to one another The difference between the measurements is the out of round Verify the journal is within the wear limit specification DA0364 A Crankshaft Connecting Rod Journal Taper 1 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 measurement is within t
156. IPTION When a malfunction occurs for DTC s with the limp home mode feature a DTC will be set the MIL will illuminate and the corrective action limp home mode default values will be initiated This will continue as long as the engine runs without being shut off If the malfunction occurs and then corrects itself while the engine is continuously running the DTC will be stored the MIL will remain illuminated and the engine will continue to run in the limp home mode until shut off and restarted Once restarted the malfunction does not reoccur the engine will resume in a normal operating mode Below is a description of possible scenarios Scenario 1 Hard DTC malfunction occurs and stays Engine running malfunction occurs gt set DTC turn on MIL ECM corrective action limp home mode gt DTC MIL limp home mode continues until engine is shut off gt engine shut off then restarted gt malfunction continues gt DTC remains MIL remains on ECM corrective action continues Scenario 2 Intermittent DTC set malfunction occurs but corrects itself Engine running gt malfunction occurs gt set DTC turn on MIL ECM corrective action limp home mode gt malfunction corrects itself gt DTC MIL limp home mode continues until engine is shut off gt engine shut off then restarted gt no malfunction gt DTC MIL continue but engine returns to normal operation e Limp Home Mode When an input to the ECM is outside of an establ
157. IS AND TESTING Special Tool s Engine System 12 Volt Master UV Diagnostic Inspection Kit 164 R0756 or Equivalent Special Tool s Commercially Available Leakdown Tester Vacuum Pressure Tester 164 R0253 or Equivalent Compression Tester 014 00707 or Equivalent ST1297 A Inspection and Verification Cup Shaped Adapter 1 Verify the customer concern by operating the TOOL 6565 AB or Equivalent engine to duplicate the condition 2 Visually inspect for obvious signs of mechanical and electrical damage Refer to the following chart Visual Inspection Chart Dial Indicator with Bracketry TOOL 4201 C or Equivalent Mechanical e Engine coolant leaks Engine oil leaks e Fuel leaks e Damaged or severely worn pads Loose mounting bolts studs and nuts Engine Cylinder Leak 2 2 Kit 3 If the inspection reveals obvious concerns that be readily identified repair as required 4 If the concerns remain after the inspection determine the symptoms and go to the symptom chart Engine Oil Pressure Gauge T73L 6600 A Special Service Tools called for by the procedures can be obtained by calling 1 800 ROTUNDA 1 800 768 8632 01 11 ESG 642 DIAGNOSIS AND TESTING Symptom Chart Poor Idling e Abnormal Combustion ENGINE OPERATION Difficult Starting Damaged starting system Damaged charging system battery Burnt valve e Worn piston e Worn pi
158. IS HOT OR WHILE THE ENGINE IS RUNNING FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY Drain the cooling system For additional information refer to Draining in this section Remove the water thermostat 8575 Install the water hose connection 8592 without the water thermostat Use cooling system Flush All Flush Kit Hardware Package and Drain Kit to flush the engine and radiator When flushing operation is complete install the water thermostat Back flush the heater core 18476 if necessary For additional information refer to Flushing Engine and Radiator in this section Fill the cooling system For additional information refer to Filling in this section A WARNING DO NOT OPEN THE COOLING SYSTEM WHILE IT IS HOT OR WHILE THE ENGINE IS RUNNING FAILURE TO FOLLOW THIESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY Partially drain the cooling system For additional information refer to Draining in this section Use cooling system Flush All Flush Kit Hardware Package and Drain Kit to back flush the heater core Use Ford Premium Cooling System Flush F1AZ 19A503 A or equivalent meeting Ford specification ESR M14P7 A When flushing operation is complete fill the cooling system For additional information refer to Filling in this section Auxiliary Systems Cooling COOLING SYSTEM REMOVAL AND INSTALLATION Radiator Hose Removal Radiator hoses should be replaced whenever they be
159. Improper contact tension All connector terminals in the problem circuit should be carefully checked Poor terminal to wire connections This requires removing the terminal from the connector body to check 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 ECM for loss of diagnostic code memory disconnect the MAP sensor connector and idle the engine until the MIL illuminates Perform MIL DTC Retrieval Procedure DTC 14 should be stored and kept in memory when the ignition is turned OFF If not the ECM is faulty When this test is completed make sure that you clear DTC 14 from memory An intermittent MIL with no stored DTC s may be caused by the following DIS ignition coil shorted to ground and arcing at ignition wires or plugs MIL circuit to ECM shorted to ground Poor ECM grounds Keep alive memory wire doesn t have a constant 12V 03 19 Auxiliary Systems Ignition HARD START SYMPTOM Stp Yes DEFINITION Engine cranks but does not start for a long time Does eventually run or may start but immediately Go to Visual Physical Check 2 Perform MIL DTC retrieval procedure Refer to DTC Ignition ON engine not running short
160. Is the repair complete and engine operating to specifications electronic governor with original Re test Go to Step 9 Install replacement ECM mE Remove replacement Is system operation normal with replacement ECM installed ECM and install original ECM Go to Step 10 5 Check circuit 355 for a poor terminal connection at the ECM Repair the terminal Does the terminal need to be replaced Re test Go to Step 9 5 the repair complete system operation normal with original ECM reinstalled Remove original ECM and reinstall replacement ECM Go to Step 11 0 Keep original ECM installed Re test Is the repair complete system operation normal with replacement ECM Leave replacement ECM reinstalled installed Re test 08 45 Auxiliary Systems EFI amp Ignition Electronics Diagnostic Trouble Code 23 DBW N S Connector for PP Sensor Idle Validation Switch Pedal Position PP Sensor Connector Connector for Idle Validation Switch 359A GY R 355 GY W 3516 BR W Power Feed From Ignition Switch 33 31 Se m m RAN m ae oe ian ee Signal PP Sensor PP5V Pedal Assembly Switch 42 Pin Connector t Return Signal Reference Return Signal e gt gt ms M 5 GY R 151 LB BK 5
161. KSHAFT SENSOR RETURN gt ese DB O 26 1 CAMSHAFT SENSOR FEED 355 GY W eo Cl THROTTLE POSITION SENSOR INPUT 238 DG Y 18 37B Y 18 Fe ALIVE PWR BATIERY gt 37B 18 238108 S60LG D18 34920 6518 SS9T B 18 Y3_ FUEL INJECTOR 5 350 20 O9AC20 gt 355 T 18 2 ape 2 556 w 18 2 FUEL INJECTOR 2 7 2538 20 gt 7 BR Y 18 FUEL INJECTOR 3 3616418 674620 554 BR LB 18 UEL INJECTOR 4 307020 351 18 B 77 DB Y 18 RY FUEL MODULATOR 570 BK W 18 570 BK W 18 570 18 POWER GROUND POWER GROUND POWER GROUND lt P OIE NZ xxt P I POP coo r7 2 252 Y W 18 COIL C IGNITION MODULE Z 1074 eo MI DATA LINK o 7 d 151 LB BK 0 DRIVE BY VIRE LLI NOT USED 2 20 H3 SELF TEST INPUT CS 29608 226 T LB 55708 55518 227 BK Y 20 Ke TGUVERNOR SPEED SELECT 2 559808 658 PK LG 20 R3 MALFUNCTION INDICATOR LAMP 570HCX8 3708 72 Y BK 20 56018 914A T D 20 DATA LINK CONNECTOR gt 37008 70 18 915A PK LB eo Ne DATA LINK CONNECTOR lt gt 85018 926A LB O 16 VPWR BATTERY 4 0 t ji 12034400 A Ww C lt TO ro no Wm SIGNAL RETURN 7 NOT 058 _ __ _ _ _ 0 358 LG BK 20 B MAP SENSOR INPUT Y GR De CHT SENSOR 13 Y LB 18 LOCKOUT
162. M as an indication of engine load This information is used to control spark advance and air fuel ratio The MAP signal is also used at KOEO to indicate barometric pressure This information is used for altitude compensation when establishing spark advance and air fuel ratio Overspeed Protection Module contains an RPM limit that is set at 4000 RPM Reaction is the module will be shut off stalling the engine Key must cycle from run to off to start in order to restart engine Note this strategy must be compatible with governor controllers Engine Protection Reaction for overtemp based on ECT or CHT input and low oil pressure based on oil pressure switch input the module will be shut off stalling the engine Key must cycle from run to off to start in order to restart engine Engine protection becomes active after 240 crankshaft revolutions and when 800 rpm is exceeded The purpose of having to meet these conditions provides an opportunity for the engine to restart if the failure still exists which caused the engine to stall Over temperature reaction is experienced when temperature reaches 250 F Low oil pressure reaction is experienced when oil pressure drops below 6 psi 1 5 psi Oil pressure switch position is normally open when engine is off This is the same strategy that is in the ECM Starter Lockout Starter lockout relay control open drain switch to ground Activated once engine is in the run mode and has reac
163. Measure the inner diameter of the valve guides in two directions where indicated If the valve guide is not within specifications ream the valve guide and install a valve with an oversize stem or remove the valve guide and install a new valve guide ESG 642 GENERAL SERVICE PROCEDURES Continued Valve Guide Reaming 1 Useahand reaming kit to ream the valve guide 2 Reface the valve seat 3 Clean the sharp edges left by reaming A26464 A 1 Measure the installed length of each valve spring DA0378 A DA0380 A 01 48 ESG 642 GENERAL SERVICE PROCEDURES Continued Valve Spring Free Length 1 Measure the free length of each valve spring DA0379 A Valve Spring Out of Square 1 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 out of specification DA0382 A Special Tool s Valve Clutch Spring Tester TOOL 6513 DD or Equivalent Special Service Tools called for by the procedures can be obtained by calling 1 800 ROTUNDA 1 800 768 8632 ST1278 A 01 49 ESG 642 GENERAL SERVICE PROCEDURES Continued 1 Use the Valve Clutch Spring Tester to check the valve springs for proper strength at the specified valve spring length DA0381 A Valve and Seat Refacing Measurements NOTE After grinding valves or valve seats check valve clearance 1 Check th
164. 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 AVOID 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 43 3 C 110 F 1 Wrap a thick cloth around the pressure relief cap 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 cap Auxiliary Systems Cooling GENERAL PROCEDURES Continued NCAUTION The coolant must be recovered in a suitable clean container for reuse If the coolant is contaminated it must be recycled or disposed of properly NOTE About 80 of coolant capacity can be recovered with the engine in the vehicle Dirty rusty or contaminated coolant requires replacement 3 Place a suitable container below the radiator draincock 8115 If equipped disconnect the coolant return hose at the fluid cooler 4 Open the radiator draincock 5 Remove the cylinder drain plug if equipped to drain the coolant from the cylinder block 6010 1 Place a drain pan below the cylinder block 2 Remove the drain plugs JN VM e LY GQ0084 A 05 6 Auxiliary Systems Cooling
165. OLOGY LIST New Acronym Exhaust Gas Recirculation EGR Backpressure Backpressure Transducer Valve Exhaust Gas Recirculation System EGR System EGR System Exhaust Gas Recirculation Temperature EGRT EGR Temperatur Exhaust Gas Recirculation Temperature EGRT Sensor Recirculated Exhaust Gas Exhaust Gas Recirculation Thermal EGR TVV EGR Thermal Vacuum Valve Exhaust Gas Recirculation Vacuum EGR Vacuum EGR Vacuum Regulator Solenoid Regulator Solenoid solenoid EVR Solenoid Exhaust Gas Recirculation Vacuum EGR Vacuum EGR Vacuum Regulator Valve Regulator Valve Regulator Valve Valve EVRV EGR Valve Exhaust Gas Recirculation Valve EGR Valve Control EGR Valve Control EGRVC Exhaust Gas Recirculation Valve EGR Valve Position EGR Valve Position Sensor Control Engine Coolant Fan Control High Electro Drive Fan Control HEDF Control FC Module Fan Control Relay FC Relay Fan Motor Control Relay ERN Feedback Pressure Exhaust Gas Feedback Pressure Pressure Feedback Exhaust Gas Feedback Pressure Exhaust Gas Feedback Pressure Pressure Feedback Exhaust Gas EGR Sensor Recirculation PFE Sensor Flash Erasable Programmable Read FEPROM Flash EPROM Only Memory Flexible Fuel Sensor FF Sensor Alcohol Concntration Sensor Fan Control Electro Drive Fan Control EDF Radiator Fan Control Flash Electrically Erasable FEEPROM Flash EEPROM Programmable Rea
166. PED 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 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 rpm is increased weak valve springs are indicated The reading at idle could be relatively steady LATE VALVE TIMING A steady but low reading could be caused by late valve timing IGNITION TIMING RETARDING Retarded ignition timing will produce a steady but somewhat low reading INSUFFICIENT SPARK PLUG GAP When spark plugs are gapped too close a regular small pulsation of the needle can occur INTAKE LEAK A low steady reading can be caused by an intake manifold or throttle body gasket leak BLOWN HEAD GASKET Aregular drop of fair magnitude can be caused by a blown head gasket or warped cylinder head to cylinder block surface ESG 642 DIAGNOSIS AND TESTING Continued 15 RESTRICTED EXHAUST SYSTEM When the engine is first started and is idled the reading may be normal but as the engine rpm is
167. PTION AND OPERATION The function of the starting system is to crank the engine at a speed fast enough to permit the engine to start Heavy cables connectors and switches are used in the starting system because of the large current required by the starter while it is cranking the engine The amount of resistance in the starting circuit must be kept to an absolute minimum to provide maximum current for starter operation A discharged or damaged battery loose or corroded connections or partially broken cables will result in slower than normal cranking speeds and may even prevent the starter from cranking the engine The starting system includes the permanent magnet gear reduction starter motor with a solenoid actuated drive the battery a remote control starter switch part of the ignition switch the starter relay the heavy circuit wiring and may include starter lock out controlled by the ECM through a starter lockout relay PPD0036 Starter Motor Assy 11001 Sequence Of Operation 1 The ignition switch is turned to the START position A remote starter relay is energized which provides voltage to the starter solenoid The starter solenoid is energized creating a magnetic field in the solenoid coil The iron plunger core is drawn into the solenoid Coll A lever connected to the drive assembly engages the drive pinion gear to the flywheel ring rear When the iron plunger core is all the way into the coil its contact
168. R CLOTHING AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING ESPECIALLY THE FAN BELTS e TO PREVENT SERIOUS BURNS AVOID CONTACT WITH HOT METAL PARTS SUCH AS THE RADIATOR EXHAUST MANIFOLD TAIL PIPE CATALYTIC CONVERTER AND MUFFLER DO NOT SMOKE WHILE WORKING ON THE EQUIPMENT 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 01 5 ESG 642 Battery Handling and Charging The handling and correct use of lead acid batteries is not as hazardous provided that sensible precautions are observed and that operatives have been trained in their use and are adequately supervised It is important that all labelling on the battery is carefully read understood and complied with The format of the following symbols and labels is common to most brands of lead acid battery 9 9 OP OCA deo SHIELD EYES VEN DANGERIPOISON FLUSH EYES EXPLOSIVE SULPHURIC ACID CAN CAUSE IMMEDIATELY 2 BLINDNESS OR INJURY SMOKING L ACIDE GET MEDICAL SEPROTEEGER LES YEUX EVITER LES SULFURIQUE
169. R SLUGGISH SYMPTOM Value s DEFINITION Engine delivers less than expected power Little or no increase in speed when throttle position is increased Visual Physical Go to Step 2 Check 1 Remove and check air filter element for dirt or restrictions 2 Replace the air filter element if necessary Was a repair required Verify repair Go to Step 3 Perform MIL DTC retrieval procedure Refer to DTC Ignition ON engine not running short STI chart perform connector to ground Do any fault codes flash and display component and circuit test as Go to Step 4 required Verify repair Go to Step 5 Go to Step 6 7 Verify repair Go to Step 8 Verify repair Go to Step 9 Check for proper ignition voltage output with a suitable spark tester Was a problem found 1 Remove the spark plugs and check for gas or oil fouling cracks wear improper gap burned electrodes heavy deposits or improper heat range 2 If spark plugs are fouled the cause of fouling must be determined before replacing the spark plugs Was a problem found Inspect the fuel delivery system to determine if there is a problem with fuel delivery Was a problem found 7 Check for water or alcohol contaminated fuel Was a problem found Check the ECM grounds to verify that they are clean and tight Refer to the ECM wiring diagram Was a problem found Check the exhaust system for a possible restriction Damaged or collapsed
170. RAL PROCEDURES Continued 4 Install the Fuel Line Disconnect Set and push into the fitting AVOM 1 A 5 Separate the fittings Inspect for damage Clean the fittings Connect 1 Connect the fitting e Lubricate the tube end with clean engine oil meeting Ford specification WSS M2C153 F to easy assembly e Align the tube to the fitting and push until you hear a click 0312 2 First pull on the fitting to make sure it is fully engaged then install the safety clip 3 Connect the battery ground cable 04 10 Auxiliary Systems Fuel GENERAL PROCEDURES Continued Fittings R Clip AS 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 SERVICING 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 PERSONAL INJURY OR A FIRE HAZARD CAUTION Do not use any tools The use of tools may cause a deformity in the clip components which may cause fuel leaks 1 Disconnect the battery 2 Helieve the fuel pressure For additional information refer to Pressure Relief in this section 3 Remove the ship
171. RATION DIVIDE zu DOWN rmn 105 117 130 144 159 u FREQUENCY rt TROUBLESHOOTING SIGNAL 92 162Hz FHEGUENCY SIGNAL HEIUAN L ECM 08 7 Auxiliary Systems EFI amp Ignition Electronics THROTTLE POSITION SENSOR TP Part Description The TP sensor is a rotary potentiometer that uses a variable resistive element which is packaged inside a plastic housing with either a three terminal pigtail connector or integral connector The resistive element varies linearly and is directly proportional to the throttle plate angle The Engine Control Module ECM applies reference voltage and ground to the sensor and monitors the sensor s ratio metric output voltage to determine precise throttle position TP sensor typical Specifications Range of Measurement 0 to 85 angular e Measurement Accuracy 2 of VREF e Resolution 0 5 max 08 8 Auxiliary Systems EFI amp Ignition Electronics THROTTLE POSITION SENSOR TP Continued TRANSFER FUNCTION n Fog 3 4 E 7 2 428 1 820 Pu 0 13 54 jh 8 THROTTLE SHAFT ROTATION DEGREES TP ROTATIONAL ANGLE TROL BLESHOGCTING VOLTAGE SIGNAL amp SIGNA RETURN _ 08 45 OPERATIONAL 0 8 SHORTED 4 5 OFEN SENSOR RESISTANCE SIGNAL amp SIGNAL RETURN ECM DISCONNECTED m CLOSED THROTTLE 3 9 Kit WIDE OPEN THROTTLE SIGNAL L
172. RES Continued Valve Stem to Valve Guide Clearance Special Tool s Dial Indicator with Bracketry TOOL 4201 C or Equivalent Valve Stem Clearance Tool TOOL 6505 E or Equivalent ST1251 A A26460 A 1 01 46 Special Service Tools called for by the procedures can be obtained by calling 1 800 ROTUNDA 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 Install the Valve Stem Clearance Tool on the valve stem and install the Dial Indicator with Bracketery Lower the valve until the Valve Stem Clearance Tool contacts the upper surface of the valve guide 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 ESG 642 GENERAL SERVICE PROCEDURES Continued Valve Inspection DA0376 A DA0377 A 01 47 Inspect the following valve areas The end of the stem for grooves or scoring A e The valve face and the edge for pits grooves or scores B The valve head for signs of burning erosion warpage and cracking Minor pits grooves and other abrasions may be removed C The valve head thickness for wear D
173. Remove the voltage regulator with generator brush holder 10351 attached from the generator J5697 A 3 Screw 4 Req d Tighten to 2 3 3 4 Nm Regulator 10316 and Brush 20 30 In Lb Holder Assembly 10347 Auxiliary Systems Charging GENERATOR REMOVAL AND INSTALLATION Continued 2 Hold the voltage regulator in one hand and pry off the cap covering the A screw head with a screwdriver 3 Remove two screws T20 Torx type head attaching the regulator to the generator brush holder Separate the regulator from generator brush holder J5699 A Voltage Regulator 10316 2 Generator Brush Holder 10347 Screw 2 Req d Tighten to 2 8 4 0 Nm 25 35 In Lb Installation 1 Replace generator brush holder to voltage regulator and install attaching screws 2 Replace cap on the head of the A terminal screw 3 Depress the generator brushes in the generator brush holder e Hold the generator brushes in position by inserting a standard size paper clip or equivalent through both the location hole in the voltage regulator and through the holes in the generator brush holders 4 Install the voltage regulator and generator brush holder to the generator with attaching screws e Remove paper clip or equivalent from the regulator 5 Install generator following installation in this section NOTE Only the regulator brush holder and generator pulley are serviceable If the generator needs further service
174. S terminal on the back of the If lamp is on with one pin S generator connector removed Is voltage greater than 1 volt REPLACE generator REPLACE voltage regulator PINPOINT TEST F GENERATOR NOISY TEST STEP RESULT gt ACTION TO TAKE m eecronsccesomomwe Check the drive belt to make sure that it is installed Yes B GO to F2 properly and is not damaged No SERVICE accessory drive e Check the accessory mounting brackets for loose as required bolts or out of alignment condition e Check for a bent pulley e s accessory drive OK F2 SUBSTITUTE KNOWN GOOD GENERATOR e Remove generator and replace with a known good Yes gt Generator is OK INSTALL generator original part CHECK other 5 noise present with known good part accessories to find the cause of the noise REPLACE generator 06 11 Auxiliary Systems Charging GENERATOR DIAGNOSIS AND TESTING Continued PINPOINT TEST G RADIO FREQUENCY TEST STEP RESULT gt ACTION TO TAKE e vene moo FREQUENCY Start engine e Tune radio to a station where interference is present Remove three pin voltage regulator connector s accessory drive OK Generator is OK Interference is occurring elsewhere in the electrical system Go to G2 G2 SUBSTITUTE KNOWN GOOD GENERATOR Remove generator and replace with a known good Generator is OK generator Interference is occurring Is interference present with know
175. SENSING AND SWITCHING CIRCUITS TEST POINT F 06 3 Auxiliary Systems Charging GENERATOR DIAGNOSIS AND TESTING 5 51 153A 18 5 g STARTER RELAY Located after alternator harness at green red wire to ignition switch NOTE The generator main wiring diagram 14305 for the engine is found at the back of this section Before performing generator tests on the unit note conditions such as slow cranking dead battery charge indicator lamp stays on with engine running etc This information will aid in isolating the part of the system causing the symptom J5695 A 06 4 576 BK 18 mim 23 HAST 18 1 T Y T Y 19 219 Voltage Regulator and Back of Generator Item Part Number Mounting Screws Ground Connection 4 req d Tighten to 1 7 2 8 Nm 15 25 In Lb Part of 10316 Brush Holder Screw Test Point F Part of 10316 Brush Holder Screw Test Point A Part of 10316 Circuit 904 Part of 14305 S Circuit 4 Part of 14305 A Circuit 36 Part of 14305 Rotor Slip Ring Visual Inspection Preliminary checks to the charging system should be made regardless of the fault condition These checks include 1 Check battery posts and cable terminals for clean and tight connections Clean the posts and the cables to ensure good electrical contact Check for secure connections at the generator output regulator
176. STI chart perform connector to ground Purple and white wire component and Do any fault codes flash and display circuit test as required Go to Step 3 Check cylinder head temperature sensor CHT for shift in value Measure the engine temperature and note the value 2 Check the resistance of the engine CHTS temperature sensor 3 Refer to Temperature vs Resistance chart for resistance specifications Is the actual resistance near the resistance value in the chart for the temperature that was noted to Step 5 even to Step 4 ee d the CHT sensor Is the action repair to Step 5 Locate and repair high resistance or improper connection in the CHTS signal circuit or the ECM grounds Was a problem found Verify repair Go to Step 6 Check for a faulty plugged or incorrectly installed Was a problem found Verify repair Go to Step 7 Check for proper ignition voltage output with a Inspect the secondary ignition wires Check for the Refer to EE 03 35 repair to Step 8 suitable spark tester following conditions Was a problem found repair to Step 9 Verify that the resistance of all ignition wires is 1 Remove the spark plugs and check for gas or oil fouling cracks wear improper gap burned electrodes or heavy deposits problem key ON engine running problem found less than the specified value Verify that ignition wires are correctly routed to
177. Specifications Item Specification Item Specification Sealants O Ol J J M3D35 A E Engine Oil ESE M2C153 E Threadlock 262 WSK M2G351 A6 XO 5W20 QSP E2FZ 19554 B or DSP 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 01 60 ESG 642 Engine 4 2L SUBJECT PAGE SUBJECT PAGE TOONS fe 02 3 DISAS SCION e 02 90 C p 02 91 Description And Operation 02 4 zie jc 02 4 Disassembly and Assembly of Subassemblies 02 104 Cylinder BIOCKS t E 02 104 Diagnosis And Testing 02 12 PIS SS SOTTIDB quU Re adam ad dud 02 105 ASSeMmDIY cR 02 106 ENGING 02 12 Cylinder 02 107 Intake Manifold Upper Removal 02 12 Disassembly of Cylinder Head 02 107 Installation of Upper Intake Manifold 02 15 Assembly of Cylinder Head 02 108 Intake Manifold Lower Removal 02 16 Installation
178. TE If new oil filter is used fill filter with fresh oil before installation to help prevent oil starvation to bearings 1 Install oil filter using clean motor oil on mating gasket and tighten to specification 02 57 ESG 642 ENGINE REPAIR Continued Flywheel Removal 1 Remove the transmission or P T O 2 Remove the six flywheel bolts A26925 A 1 Position the flywheel on the crankshaft and install the retaining bolts 2 Install the transmission or P T O 74 87 Nm 54 64 Ib ft 02 58 ESG 642 ENGINE REPAIR Continued Oil Pan Removal 1 Disconnect the battery ground cable 2 Remove the fan shroud and fan 3 Remove the bolt retaining the dipstick tube support bracket to the transmission converter housing 4 Drain the oil pan DA0745 A 5 Remove the engine mount retaining nuts right side shown left side similar 02 59 ESG 642 ENGINE REPAIR Continued 6 Remove the bolt retaining the oil pan to the right side of the transmission converter housing or SAE housing 0752 ri Remove the bolts retaining the oil pan to the left side of the transmission converter housing n AN 1 DA0753 A 8 Remove the remaining retaining bolts and the oil pan Remove and discard the oil pan seal 02 60 ESG 642 ENGINE REPAIR Continued Installation of Oil Pan caution Mating parts must make contact to each other within
179. Taken When the DTC Sets The ECM will illuminate the malfunction indicator lamp MIL e The ECM will force the IAT sensor to a 50 F default value 08 72 Auxiliary Systems EFI amp Ignition Electronics Diagnostic Trouble Code 45 ECT CHT IAT amp MST Sensors The sensor shares the same ground with the Temperature vs Ohm or Volts Values approx Manifold Absolute Pressure MAP sensor and the 47 Cylinder Head Temperature CHT sensor Check 79 the ground circuit 359 Grey Red if these are 140 134 also set 13 236 1 93 Inspect the harness connectors for backed out 19 716 2 39 terminals improper mating broken locks improperly 30 000 2 86 formed or damaged terminals and poor terminal to 46 774 3 32 wire connections Inspect the wiring harness for i damage If the harness appears to be OK backprobe 14 914 3 71 the IAT sensor connector with a digital voltmeter and 123 485 4 02 observe the voltage while moving connectors and 209 816 4 25 wiring harnesses related to the IAT sensor ED 196 051 1 46 A change in the voltage reading will indicate the 925 021 4 54 location of the fault Voltage values calculated for VREF 5 volts may vary 15 due to sensor and VREF variations DTC 45 Intake Air Temperature Low Voltage Step i O Check ohm value across the two pins of the IAT Is within specs of above 1 Go to Step 2 Go to Step 7 2 1 KOEO Disconnect the IAT sensor c
180. Trouble Code 26 NOTES 359C a Electronic Governor Hn AO iz STEM 361H R 501 3510 BR W 355 QY W sel 359F GY R 2641 W LB S03 S05 361G H 359 GY H 351 BR W _ _ B2 ____ C1 NENNEN _ R1 K1 r Signal 7 77 Dower 7 1 Engine Return Sensor TP Throttle Feed Control Signal Reference Control 1 Module ECM DIAGNOSTIC TROUBLE CODE DTC 26 THROTTLE POSITION TP SENSOR HIGH VOLTAGE AT START UP Circuit Description The throttle position TP sensor is a potentiometer which is attached to the throttle plate shaft inside the electronic governor The ECM provides a 5V reference voltage to the TP sensor between terminal A Grey Red circuit 359F and terminal C Brown White circuit 351D of the electronic governor A TP signal is returned to the ECM from terminal B Grey White circuit 355 of the electronic governor The TP signal varies from about 1 0V at idle to 4 8V at WOT The TP signal is an important input used by the ECM for fuel control and other engine control functions Conditions for Setting the DTC e KOEO or signal at start up is gt 1 39V e Above conditions are present for at least 2 consecutive seconds 08 52 Auxiliary Systems EFI amp Ignition Electronics Diagnostic Trouble Code 26 Actions Taken When the DTC Sets ECM illuminates the malfunction indicator lamp MIL ECM
181. UBLE CODES METRICS DEALERS INDEX ESG 642 SUBJECT PAGE DESCHPUON ew 01 3 Mec 01 3 Engine Identification Nameplate 01 3 Safety NOCES mt 01 5 Notes Cautions and Warnings 01 5 General 01 5 Battery Handling And Charging 01 6 POPC WANG Ma 01 7 Engine Identification rennes 01 7 European Service Identification Plate 01 8 U S A Engine Identification Decal 01 9 Description And Operation 01 10 Engine System 01 10 Diagnosis And Testing ect 01 11 Engine domu 01 11 weise M 01 11 Inspection and Verification 01 11 Symptom 01 11 Component Tests 22 2 01 14 Engine Oil 01 14 Fluorescnt Oil Aditive Method 01 14 Pressure Method eere 01 15 Testing Procedure E 01 15 01 15 01 15 With Transmission
182. VING THE PRESSURE RELIEF CAP WAIT UNTIL THE ENGINE HAS COOLED DOWN AT LEAST 110 F Wrap a thick cloth around the pressure relief cap and turn it slowly one half turn counterclockwise Stepping back while the pressure is released from the cooling system When you are sure all the pressure has been released still with a cloth turn counterclockwise and remove the pressure relief cap Inspect the pressure relief cap for foreign material between the sealing gasket and the diaphragm Pressure test cap using tool ST1474 A e s 7 Ib pressure maintained 5 the pressure relief cap OK P Yes GO to 7 No CLEAN or INSTALL a new pressure relief cap TEST the system for normal operation GO to A1 be purchased separately 05 24 Auxiliary Systems Cooling COOLING SYSTEM DIAGNOSING AND TESTING Continued PINPOINT TEST A LOSS OF COOLANT Continued TEST CONDITIONS TEST DETAILS RESULTS ACTIONS A7 CHECK THE DEGAS BOTTLE NOTE The engine must be cool when coolant is added to the degas bottle Add coolant to the degas bottle until fluid is between the coolant fill level marks Does the degas bottle leak p Yes INSTALL a new degas bottle TEST the system for normal operation No PERFORM the cooling system pressure test For additional information refer to Component Tests Pressure Test in this section REPAIR as necessary TEST the system for normal operation PINPOINT TEST B
183. VNSIS ya 9 GNNOYD n uA o 268 O H 609 LANL uuo d zou TENURE u3MOd Gun g yey 3 u 193195 3Nv120 mua y 1 9 123155 1313 Na 4 29 1231585 1303 40102 Fi YOLOINNOD Nid 04 J 9 w u3MOd Avo LINDAI o wma H 4S GNNOYD w uU mit s8 y 058 pour a 669 INANE acts o grad g 96 LNdNI Ri wea 2 egz SS3NHVH _ DNE gr d en WALSAS X 22220 a zanoxovi4naino HOWL 40102 E YOLOANNOD Nid 6 01 OT Eu 3MIM LINDAI NOLLdIM2S3d TE T He r Hehi a E M Lede 9H Die Se 4 o 3 5 J HgS AT SES PFE LAE Tee q D I 9 8 are um m Us X8 A r 03 49 Auxiliary Systems Ignition 16 PIN CONNECTOR From Wire Harness XU1L 12A690 BA to 9D930 361B 14 99918 3558108 9959118 39620 361B R 14 6 VPWR BATTERY lt gt 39 R W 18 558 BR LB 18 557 BR Y 18 556 18 S555 T 18 560 LG U 18 559 T BK 18 11 FUEL INJECTOR 5 42 PIN CONNECTOR From Wire Harn
184. Yes No Are you using a personal computer PC to perform this diagnosis Go to Diagnostic System 1 Check before continuing at Step 2 Go to Step 2 2 Visually check For vacuum leaks Vacuum hoses e Intake manifold gaskets motor stuck open e PCV system Brake booster Make necessary repairs Are any of the above components causing a vacuum leak and re test Go to Step 3 Using a vacuum gage check engine vacuum at idle Find leak and repai and steady Go to Step 3 Re test Step 5 program Re test 4 Using a PC confirm correct program is downloaded into ECM Replace ECM Goto Download correct Is the program correct Is the repair complete system operation normal with original ECM reinstalled Remove original ECM and reinstall Keep original ECM replacement ECM installed Re test Go to Step 7 7 Is the repair complete system operation normal with replacement ECM Leave replacement ECM reinstalled installed Re test Install replacement ECM Is system operation normal with replacement Remove replacement 5 ECM installed ECM and install original ECM Go to Step 6 08 89 Auxiliary Systems Metrics METRICS INDEX SUBJECT PAGE m 09 3 Ib e TO Pee mot M n Cc 09 3 Nomenclature for Bolts 2222 09 3 Bolt Strength Identification 09 4 Hex Nut Strength Identification
185. a 1l L 211413 zT LE pt n 56801 71702 7 chua 7 1 amp 2 IESI a Zr 0990 1 0 Oe e 2esll Pet H 11 433 1 cha LL LI ie T MC 1 06 19 Auxiliary Systems Charging SPECIFICATIONS GENERATOR MOUNTING GENERATOR PARTS CROSS REFERENCE Lew me Lem mem 9A624 Engine Air Cleaner Intake Tube 10A313 Generator Bracket Alternator Mounting Parts SPECIFICATIONS TORQUE SPECIFICATIONS meson ue uen emet 65 Regulator Attachment Screw 4 1 7 2 8 EN 15 26 Battery Wire Attaching Nut 1 78 108 MM cic 10351 Generator Brush 14301 Battery Ground 14305 Generator Voltage Regulator Wiring EQUIPMENT 078 00005 VAT 40 Starting charging Tester BATTERY TORQUE Ts Battery Cable Bolts Battery Hold Down Bracket Bolt en Generator voltage Regulator Wiring Nut and Washer 44 97 Ranger with 2 3L Engine Relay Cable to Body Panel Screws Ranger and Explorer m 14 7 10 06 20 Auxiliary Systems Starter STARTER INDEX SUBJECT PAGE Starter Permanent Magnet Description And Operatloh iiie
186. a o Power Steering Pump 22 28 17 20 mos e EU Doo Power Steering Pump 20 15 pracketiowater Generator Bracket Short 20 30 15 22 EE Generator Bracket Long 40 55 30 41 Hoe e tL Power Steering Pump 20 15 Bracket to Generator S E Generator Bracket to 40 30 Cylinder Head Bolts Bracket Bos Power Steering Reservoir 12 80 106 bots LLL Generator Positive Cable Nit o co Head Bons 8 11 9 Radiator Fan Shroud to Radiator Bolts 3 Heater Water Outlet Tube Bolt Hocker Arm Bolts 22 29 Idler Bracket Bolt amp Nuts Rod Cap Bolts Spark Plugs 10 20 84 180 Idler Pulley 41 55 30 41 idler Pulley 421 Synchronizer Drive Gear 40 50 30 37 pote _ Synchronizer Hold 20 30 15 22 idler Pulley Bot 47 63 35 46 Ignition Coil Ios se aa Synchronizer Stator 2 5 3 5 20 4 pies Tappet Guide Plate Bots 10 14 75 10 Intake Manifold Lower Upper Timing Chain Tensioner 12 to Cyl Block Bolts Main Bearing Brace Nuts 40 55 30 40 Main Bearing Cap Bots so 9 Timing Chain Vibration 8 14 71 124 Damper Bolts Continued Continued 02 134 ESG 642 SPECIFICATIONS Continued Torque Specifications Nm Throttle Body Nuts 8 Bolts 10 89 Torque Converter to 36 27 _ Transmission to Engine 40 55 30 41 Retnng bots Valve Cover Bolts and 8 11 5
187. a problem is found repair as necessary procedure if Support Hotline Was a problem found required 1 800 521 0370 03 47 Auxiliary Systems Ignition Wiring Schematic 4 2L amp 2 5L Alternator Gauges Ignition and Discrete Governing T L O 12 LO 127 EB 3 05 eo wt pHs gb 1 7 214145 zr SS ms dn a In 1 0 6580 71702 E S2344vF 452 Boel E E ere ET chal 413 wll W q TMC L Cy Ja dame LG T OF h EL lc 1 pce 1 A 03 48 Auxiliary Systems Ignition Assembly 4 2L DLX ICM iring W v 96 OO 3NT HOVL OL g 96 ee 80102 pu MO123NNOO Nid 01 zl avo NOlLdIM2S3d TET NE EE veevL SS3NHuVH ug 2 IN31SAS L 3NION3 OL HOLO3NNOO dN MOld HOVL grid g 96 Z LNdNI ze _ 1noXnynoy901Y01YLS ora a xnv atu 3 ze 4001 201831 Y3LYY1S e YOSNAS atu 4 ve 4001 201831 1 15 up g 30133 T
188. acement ECM signal circuit 4 Grey Lt Blue and the return circuit 89 Orange NOTE If a PC is available you can observe HO2S voltage on the Is the HO2S voltage below the specified value Go to Diagnostic Aids Go to Step 3 1 Disconnect the HO2S sensor electrical connector to ground and repair if necessary Was a repair necessary system OK Go to Step 4 Install replacement ECM Remove cnra Is system operation normal with replacement ECM installed ECM and install original Remove original Is the repair complete system operation normal with original ECM ECM and reinstall installed Re test Go to Step 7 Is the repair complete system operation normal with replacement ECM Leave replacement ECM reinstalled installed Re test 08 69 Auxiliary Systems EFI amp Ignition Electronics Diagnostic Trouble Code 43 NOTES 3590 505 MAP and IAT Sensors Engine Cylinder Head Temperature CHT 33 42 Pin Connector B2 Sensor Engine Signal Ground Control Module I DIAGNOSTIC TROUBLE CODE DTC 43 ENGINE CYLINDER HEAD TEMPERATURE LOW VOLTAGE Circuit Description The engine cylinder head temperature sensor is a thermistor which measures the temperature of the cylinder head on the engine The ECM supplies a ground circuit 359G Grey Red Grey Yellow from the sensor and sends a 5V signal circuit 1102 Y LG to the sensor When the engine cylinder head is cold the sensor resistance
189. ading highest reading Refer to the Compression Pressure Limit Chart Compression Pressure Limit Chart 924 kPa 696 kPa 1131 kPa 848 kPa 1338 kPa 1000 kPa 1154 kPa 1158 kPa 134 psi 101 psi 164 psi 123 psi 194 psi 146 psi 224 psi 168 psi 938 kPa 703 kPa 1145 kPa 855 kPa 1351 kPa 1014 kPa 1558 kPa 1165 kPa 136 psi 102 psi 166 psi 124 psi 196 psi 147 psi 226 psi 169 psi 952 kPa 717 kPa 1158 kPa 869 kPa 1365 kPa 1020 kPa 1572 kPa 1179 kPa 138 psi 104 psi 168 psi 126 psi 198 psi 148 psi 228 psi 171 psi 965 kPa 724 kPa 1172 kPa 876 kPa 1379 kPa 1034 kPa 1586 kPa 1186 kPa 140 psi 106 psi 170 psi 127 psi 200 psi 150 psi 230 psi 172 psi 979 kPa 738 kPa 1186 kPa 889 kPa 1303 kPa 1041 kPa 1600 kPa 1200 kPa 142 psi 107 psi 172 psi 129 psi 202 psi 151 psi 232 psi 174 psi 933 ji 745 1200 x 903 pies 1407 kPa 1055 kPa 1055 kPa 1207 kPa 144 psi 109 psi 174 psi 131 psi 204 psi 153 psi 153 psi 175 psi 1007 kPa 758 kPa 1214 kPa 910 kPa 1420 kPa 1062 kPa 1627 kPa 1220 kPa 146 psi 110 psi 176 psi 132 psi 206 psi 154 psi 154 psi 177 psi 1020 kPa 765 kPa 1227 kPa 917 kPa 1434 kPa 1075 kPa 1641 kPa 1227 kPa 148 psi 111 psi 178 psi 133 psi 208 psi 156 psi 238 psi 178 psi 1034 kPa 779 kPa 1241 kPa 931 kPa 1448 kPa 1083 kPa 1655 kPa 1241 kPa 150 psi 113 psi 180 psi 135 psi 210 psi 157 psi 240 psi 180 psi 1048 kPa 786 kPa 1225 kPa 936
190. ads zero 9 Remove the dial indicator adapter and auxiliary starter switch 10 caution After installing rocker arms do not rotate the crankshaft until valve tappets have had sufficient time to bleed down To do otherwise may cause serious valve damage Manually bleeding down valve tappets will reduce waiting time Install the rocker arm seats rocker arms and rocker arm seat bolts 11 Install the valve covers 12 Install the spark plugs Hydraulic Valve Tappet Hydraulic valve tappet noise can be caused by any of the following excessive collapsed valve tappet gap e sticking valve tappet plunger valve tappet check valve not functioning properly air in lubrication system e leakdown rate too rapid excessive valve guide wear Excessive collapsed valve tappet gap can be caused by loose rocker arm seat bolts nuts incorrect initial adjustment or wear of valve tappet face or worn roller valve tappets push rod rocker arm rocker arm seat or valve tip With valve tappet 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 valve tappet plunger can be caused by dirt chips or varnish inside the valve tappet A valve tappet 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 valve tappet It may also
191. aft bearing in two directions e Subtract the camshaft journal diameter from the camshaft bearing diameter DA0345 A Camshaft Lobe Surface 4 lt 1 Inspect camshaft lobes for pitting or damage in the active area Minor pitting is acceptable outside the active area DA0350 A 01 27 ESG 642 GENERAL SERVICE PROCEDURES Continued Camshaft Lobe Lift 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 1 Use the Dial Indicator with Bracketry to measure camshaft intake lobe life Rotate the camshaft and subtract the lowest dial indicator reading from the highest dial indicator reading to figure the camshaft lobe lift DA0392 A i 2 Use the Dial Indicator with Bracketry to measure camshaft exhaust lobe life Rotate the camshaft and subtract the lowest dial indicator reading from the highest dial indicator reading to figure the camshaft lobe lift DA0392 A Camshaft 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 01 28 ESG 642 GENERAL SERVICE PROCEDURES Continued NOTE Camshaft journals must be within specifications before checking runout 1 Use the Dial Indicator with Bracketry to measure the camshaf
192. aintained When the engine is switched off the electrical supply to the fuel shut off solenoid is disconnected and the valve closes cutting off the high pressure fuel supply to the vaporizer regulator The electrical supply to fuel shut off valve passes through a vacuum operated safety switch Should the engine stall the vacuum switch opens and cuts off the electrical supply to the fuel shut off valve When starting the engine there is sufficient vacuum present even at cranking speed to close the safety switch FUEL SYSTEMS FIELD CALIBRATIONS GENERAL When performing field calibrations on LPG amp NG systems it should be noted that improper fuel calibrations and or improper hardware installation may result in decreased durability life of the cylinder head valve train Validation testing on the valve train was conducted in a controlled laboratory environment with proper air fuel distribution and proper air fuel ratios which fall within acceptable ranges Since your LPG amp NG units are not purchased through Ford Power Products they are not calibrated specifically to your application It is a requirement that each of these units are calibrated by the customer within the acceptable limits provided by Ford Power Products Engineering Development testing is underway to provide the customer with appropriate guidelines to successfully calibrate their LPG amp NG fuel systems Hecommendations may include but are not be li
193. ak 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 NOTE A small amount of antifreeze coming out the water pump weep hole may be normal POSSIBLE SOURCE ACTION Inspect washer gasket and test Replace only if cap will not hold pressure to specification Pressure test system Inspect hose hose connection radiator edges of cooling system gaskets core plugs and drain plugs transmission oil cooler lines water pump heater system components Repair or replace as required Disassembly engine as necessary check for cracked intake manifold blown head gaskets warped head or block gasket surfaces cracked cylinder head or cylinder block Fill as required Check for coolant loss Replace belt or tensioner as required Test replace if necessary Remove bugs leaves etc Test replace if necessary Test replace if necessary Check timing and timing advance Adjust as required Check electrical circuits and repair as required Check water pump and block for blockage 1 2 water and 1 2 permanent antifreeze mixture Test replace if necessary Check electrical circuits and repair as required 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 NOTE Asmall amount of antifreeze coming out the water
194. ak on inlet side of pump due to holes in fuel line or loose fittings Fuel pump leaks loose or dirty General Information Water and dirt that accumulate in the fuel tank can cause a restricted fuel line filter or 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 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 Air leakage in the fuel inlet line can cause low fuel pump pressure and volume A restricted fuel tank vent can cause low fuel pump pressure and volume and can result in collapsed inlet hoses or a collapsed fuel tank High or low pressure are the two most likely fuel pump troubles that will affect engine performance Low pressure will cause a lean mixture and fuel starvation at high speeds and excessive pressure will cause high fuel consumption and possible flooding If a problem seems to occur in one engine cylinder the ignition system or a fuel injector may be at fault If the problem seems to occur in all engine cylinders then the problem could be either fuel or ignition Check the fuel system first Dirt or water in the gas tank leaks in the fuel lines ECM or a defective fuel pump Observation pressure test and volume tests on the fuel system s
195. al connectors at ECM Do any of the terminals need to be repaired or replaced electronic governor with original Re test Go to Step 9 Remove replacement ECM and install original ECM Go to Step 10 Remove original ECM and reinstall Keep original ECM replacement ECM installed Re test Go to Step 11 Leave replacement ECM installed Re test operating to specifications Install replacement ECM Is system operation normal with replacement ECM installed Is the repair complete system operation normal with original ECM reinstalled Is the repair complete system operation normal with replacement ECM reinstalled Replace the electronic governor Is the repair complete and engine a Remove amp replace 08 75 Auxiliary Systems EFI amp Ignition Electronics Diagnostic Trouble Code 51 NOTES To Oil Pressure Switch 253 DG W J3 e Engine Pressure 1 Controi j Module i t DIAGNOSTIC TROUBLE CODE DTC 51 LOW OIL PRESSURE NOTE This is a software selectable DTC Circuit Description The ECM monitors the oil pressure through circuit 253 Dk Green White from the oil pressure switch If the oil pressure gets below an established pressure value the oil pressure switch will close to ground and the oil pressure light will come on This action will set DTC 51 Conditions for Setting the DTC e Engine must be above 850 RPM s and 250
196. alant F6AZ 19562 A or equivalent meeting Ford specification WSE M4G323 A6 02 50 ENGINE REPAIR Continued DA0774 A ESG 642 02 51 NOTE Crankshaft pulley position on the crankshaft damper was marked before removal Return it to the same position and install the crankshaft pulley Install the fan blade assembly ESG 642 ENGINE REPAIR Continued Crankcase Front Oil Seal Special Tool s Special Tool s Front Crankcase Seal Installer Seal Remover Cover Aligner T92C 6700 CH BOYD T88T 6701 A Front Crankcase Seal Replacer Vibration Damper Remover T94P 6701 AH Adapter T82L 6316 B Fh ST1378 A Special Service Tools called for by the procedures can be obtained by calling 1 800 ROTUNDA 1 800 768 8632 Removal of Front Crankshaft Oil Seal 1 Remove the crankshaft damper Refer to the E procedure in this Section 2 Use Seal Remover to remove the crankshaft front oil seal Discard the seal X 5 2 25480 Installation of Front Crankshaft Oil Seal 1 Inspectthe crankshaft damper and engine front cover for damage that might cause the front crankshaft oil seal to fail 02 52 ENGINE REPAIR Continued Crankshaft Rear Oil Seal Special Tool s C aa ST1327 A Impact Slide Hammer T50T 100 A Rear Crankshaft Seal Remover T95P 6701 EH Rear Main Seal Replacer T82L 6701 A ESG 642 02 53 NOTE Lubricate parts with engin
197. align 02 113 ESG 642 ASSEMBLY Continued 10 Install the crankshaft sprocket camshaft sprocket and timing chain as an assembly e Timing marks on gears and keyways on shafts must align a DA0650 A 11 Install the synchronizer drive gear Jemm ul DU 8 40 50 Nm 30 37 Iblft DA0649 A 02 114 ESG 642 ASSEMBLY Continued 12 Install the bearing in the piston connecting rod and rod cap e Lubricate the connecting rod bearings and crankshaft journals with Engine Assembly Lubricant D9AZ 19579 D or equivalent meeting Ford specification ESR M88C80 A Lubricate the cylinder walls with clean engine oil and install the pistons The arrow on the top of the piston must face the front of the engine and the notches in the bearing shells must align Install connecting rod caps NOTE Bolts are torque to yield Discard and replace with new e Refer to this Section for installation procedures 13 NOTE All timing marks must be aligned with the number one piston at TDC Turn the crankshaft to position the number one piston at top dead center TDC After setting at TDC the crankshaft must not be turned until camshaft synchronizer is installed 0667 02 115 ESG 642 ASSEMBLY Continued 14 Install the engine front cover 20 30 Nm 14 22 Ibift Use a new gasket 15 Install the water pump Use a new gasket DA0979 A 16 Ins
198. alve clearance 8 If installing the RH cylinder head install the generator bracket 1 Position the generator bracket 2 Install the two long bolts 3 Install the short bolt 02 30 ENGINE REPAIR Continued 8 11 5 Nm 71 102 Ib in A26854 A ESG 642 02 31 10 11 12 13 14 15 16 If installing the RH cylinder head install the idler pulley 1 Position the idler pulley 2 Install the bolt If installing the RH cylinder head install the generator Install the ignition coil pack if necessary Refer to procedures in Section 3 Torque bolts to 5 6 Nm 48 in Ibs If installing the LH cylinder head install idler pulley bracket 1 Position the idler pulley bracket 2 Start the bracket bolts 3 Install the three idler pulley bracket bolts Install idler pulley Refer to Section 02 72 Install the exhaust manifold Refer to the procedure in this section Inspect the LH valve cover gasket for damage Replace if necessary 1 Position the LH valve cover 2 Install the three bolts 3 Install the two stud bolts Install the lower intake manifold Refer to the procedure in this section ENGINE REPAIR Continued Valve Cover LH Removal 5 a OAD oN KI DAO899 A ESG 642 02 32 Disconnect the following 1 Oil filler extension tube if equipped 2 PCV breather tube Disenga
199. am Starter lockout relay control energizes relay which opens starter solenoid circuit once engine is in run mode and has reached 600 RPM This will also not allow a re start until ignition voltage to module is switched off and back on Same strategy as in ECM Tachometer signal on all application relay control Possible uses for output is tach signal relay control malfunction indicator lamp Could flash MIL to indicate source of problem O Input Output 03 15 Auxiliary Systems Ignition DESCRIPTION AND OPERATION ICM Continued TABLE 2 ICM Deluxe Pinout Main Connector 10 Pin Terminals I O Con 4 2L Deluxe Description Main A Crank signal input Main Crank ECT signal return Main C Coil 3 driver cyl gt gt x X gt lt Main ECT signal input Main E OCT2 select input Ground V or float Selects constant added or subtracted from timing Main F select input Ground V or float Selects from 3 fuel tables G Main Vigt V supply voltage Operational range 6 24V Main H Power ground Main J Coil 1 driver cyl gt gt Main K Coil 2 driver cyl gt gt 3 4 Auxiliary Connector 5 Pin Terminals Aux Aux input 1 digital Ground V or float X Undefined Aux Aux input 22 analog Defined as IAT To control X ignition timing based on intake temperature Aux C Oil pressure in
200. and made of aluminum The lower intake bolts down to the cylinder heads and is sealed with a gasket for each cylinder head The upper intake bolts to the lower with a gasket spacer and gasket to make the seal A throttle body is bolted to the intake mounted with a gasket to form a seal The throttle plate mounted inside the throttle body controls the amount of air entering into the intake manifold The two parts of the intake manifold are made of tubes or runners to control the air flow to each cylinder evenly With some application idle air control motor is mounted on either the throttle body or upper intake manifold This IAC is mated up to a gasket to form an air tight seal 08 88 Auxiliary Systems EFI amp Ignition Electronics Diagnostic Trouble Code 65 Conditions for Setting the DTC AC and actuator duty cycles are at their minimums start up gain phase in 1 and rpm gt set 300 Above conditions are present for at least 2 6 seconds e Driving machine and letting up on gas to gear down Actions Taken When the DTC Sets ECM illuminates the malfunction indicator lamp MIL The ECM shuts down the engine The engine can be restarted by recycling the ignition switch Trouble Shooting Check PCV system for leaks Check IAC motor stuck open Check booster brake system for leaks e Check intake manifold for gasket leaks DTC 65 Intake Manifold Leak Step Action Values
201. and remove stator assy 6B288 Index shaft by marking synchronizer housing to front cover Remove retaining bolt N808826 Remove chamshaft synchronizer assembly Remove the accessory drive belt idler pulley ESG 642 ENGINE REPAIR Continued 16 DA1009 A 17 2 0980 18 19 DA0780 A 02 70 Remove the accessory drive belt tensioner NOTE For ease of handling remove oil filter NOTE If new front cover is being installed remove oil filter and pump from cover Refer to this Section Remove the water pump mounting studs Discard the studs Remove the engine front cover 6019 and the engine front cover gasket 6020 discard the gasket NOTE When cleaning use care to prevent debris from falling into the oil pan Clean the mating surfaces on the oil pan and the cylinder block Use Metal parts Cleaner F4AZ 19A536 RA or equivalent meeting Ford specifications WSE M5B292 A ESG 642 ENGINE REPAIR Continued Installation of Engine Front Cover Mating parts must make contact to each other within 4 minutes and connecting bolts must be torqued within 15 minutes after applying sealant Failure to follow this procedure can cause future oil leakage e Use silicone gasket and sealant FGAZ 19562 AA or equivalent meeting Ford specification WSE M4G323 A6 NOTE Sealant must be removed and area cleaned DA0887 A with solvant if above instructions are not followed e Use meta
202. ange 9 between the ECM and the fuel pump relay Is the repair complete Bt Re test Connect a DVOM from circuit 37 at fuel pump relay to ground Does the DVOM show battery voltage Go to Step 8 Go to Step 7 7 Repair the open or short to ground in circuit 37 Yellow between the ECM and the ignition Is the repair complete Re test m Repair the open or short to ground in circuit 87 Pink Black and circuit 238 Dk Green Yellow between the ECM and the fuel pump relay Is the repair complete B 3 sec Re test Install replacement ECM Is system operation normal with replacement Remove replacement ECM installed ECM and install original ECM Go to Step 11 Is the repair complete system operation normal with original ECM Remove original reinstalled ECM and reinstall replacement ECM Keep original ECM Go to Step 12 Is the repair complete system operation normal with replacement ECM installed Re test reinstalled Leave replacement ECM installed Re test Connect the DVOM from F3 to ground Recycle ignition switch to KOEO Do you have battery for 3 seconds 3 sec Go to Sfep 10 Go to Step 9 08 67 NOTES Auxiliary Systems EFI amp Ignition Electronics Diagnostic Trouble Code 42 Heated Oxygen AN Sensor 25 o 9 Connector 341 89A 570N BK W 74 GY LB 505 510 361G 359 GY R 570 BK W _ B2 X2 Sensor Heater 7T Signal por Ground
203. ankshaft rear oil seal e rear main bearing cap partling line e rear main bearing cap and seals eflywheel mounting bolt holes with flywheel installed e camshaft rear bearing covers 6266 or pipe plugs at the end of oil passages Oil leaks at crimped seams in sheet metal parts and cracks in cast or stamped parts can be detected when pressurizing the crankcase 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 10655 is properly charged Operate the vehicle until the engine is at normal operating temperature Turn the ignition switch to the OFF position then remove all the spark plugs 12405 2 Set the throttle plates in the wide open position 01 15 ESG 642 DIAGNOSIS AND TESTING Continued 3 Install a Compression Tester in the No 1 cylinder 5 Repeat the test on each cylinder cranking the engine approximately the same number of 4 Install an auxiliary starter switch in the starting compression strokes circuit With the ignition switch 11572 in the OFF position and using the auxiliary starter Test Results switch crank the engine a minimum of five compression strokes and record the highest The indicated compression pressures are reading Note the approximate number of considered within specification if the lowest reading compression strokes required to obtain the cylinder is within 75 percent of the highest re
204. any fault codes flash and display component and circuit test as required Go to Step 3 Check for proper ignition voltage output with a suitable spark tester Was a problem found Verify repair Go to Step 4 1 Remove the spark plugs and check for gas or oil fouling cracks wear improper gap burned electrodes or heavy deposits 2 If spark plugs are fouled the cause of fouling must be determined before replacing the spark plugs Was a problem found Verify repair Go to Step 5 Inspect the secondary ignition wires Check for the following conditions Verify that the resistance of all ignition wires is less than the specified value Verify that ignition wires are correctly routed to eliminate cross firing Verify that ignition wires are not arcing to ground spraying the secondary ignition wires with a light mist of water may help locate an intermittent Refer to Was a problem found Page 03 35 Verify repair Go to Step 6 problem ignition ON engine running Check for an intermittent ignition system malfunction Intermittent crankshaft position sensor signal Intermittent ignition feed circuit or sensor ground circuit to the crankshaft position sensor Was a problem found num repair Go to mem 7 Inspect the fuel delivery system to determined if there is a problem with fuel delivery Was a problem found repair Go to n 8 Check for the following engine mechanical problems refer to Section 01 o
205. arted by recycling the ignition switch 08 74 Auxiliary Systems EFI amp Ignition Electronics Diagnostic Trouble Code 47 DTC 47 Drive By Wire Rise Failure 7 2 No 1 Are you using a personal computer PC to perform this diagnosis Go to Diagnostic NOTE This test cannot be made without a PC or a very high tech DVOM System Check before continuing at Step 2 Go to Step 2 Visually check for dirt or carbon in the throat of the actuator or on the throttle plate Clean with a carb Is there any dirt or carbon cleaner Re test Go to Step 3 3 Is the TPS set point gt normalized TPS 0 5V for at least 2 consecutive Go to Step 4 Re start seconds when not at idle Does the ECM have the correct program for this application If needed contact FPP or OEM for Download correct correct program Go to Step 5 program amp re test Using EEMS SERV program either view the monitor screen or read the kom Go to Step 6 Re test graph for throttle body position TPS in relation to the ECM set point Repair wire Reconnect battery and re test Go to Step 7 graph lines close together but not even Repair or replace terminals Reconnect battery Re test Go to Step 8 1 Disconnect battery ground 2 Disconnect ECM connector L Y 3 Check for a short or open on circuit 264 W LB circuit 361H R and 361G R Where any shorts or opens found Check circuits 264 W LB and 361G R for poor termin
206. as a problem found Verify repair Go to Step 4 Inspect the fuel delivery system to determine if there Go to Step 5 Was a problem found Check electronic governor operation including throttle position sensor function Refer to Fuel System in this Manual Was a problem found Check items that can cause an engine to run rich Refer to DTC 42 Was a problem found Check items that can cause the engine to run lean Refer to DTC 32 vi a problem found Check for proper ignition voltage output with a suitable spark tester Was a problem found Check the ECM grounds to verify that they are clean and tight Refer to the ECM wiring diagram Was a problem found Inspect the secondary ignition wires Check for the following conditions Verify that the resistance of all ignition wires is less than the specified value Verify that ignition wires are correctly routed to 10 eliminate cross firing Verify that ignition wires are not arcing to ground Spraying the secondary ignition wires with a light mist of water may help locate an intermittent problem key ON engine running Refer to Was a problem found Page 03 35 Verify repair Go to Step 11 is a problem with fuel delivery Go to Step 6 Go to Step 7 Go to Step 8 Go to Step 9 Go to Step 10 03 22 Auxiliary Systems Ignition ENGINE SURGES SYMPTOM Continued Step Yes No 1 Check the ignition coil secondary resistance
207. be serviced The Radiator Cap Maintains 16 lbs pressure Coolant under pressure Raises the boiling point of the coolant Helps prevent vapor locks in engine block and cooling system Coolant e Use a 50 50 mix of Ethylene Glycol Permanent Antifreeze and water This mixture is to be used year round with temperatures above 34 4 C 30 F 05 4 Recycled coolant e Use recycled engine coolant produced by Ford approved processes Not all coolant recycling processes produce coolant which meets Ford specification ESE M97B44 A or WSS M97B44 D and use of such a coolant may harm engine and cooling system components Unsatisfactory coolant materials Alcohol type antifreeze does not provide adequate water pump lubrication Has a lower boiling point Provides reduced antifreeze protection A CAUTION Alkaline brine solutions will cause serious engine cooling system damage CAUTION Do not nuse 100 000 mile red in color antifreeze it is not compatable with copper radiators The water temperature indicator sender unit Provides a signal to the temperature gauge The block heater 5 an optional electrical heating element installed in a core plug opening Uses a standard 110v electrical supply Keeps the engine coolant warm during cold weather Auxiliary Systems Cooling GENERAL PROCEDURES Cooling System Draining Filling and Flushing 05 5 Draining A WARNING
208. bolts rocker arm seat 6A528 and rocker arms Typical Engine With Push Rods 01 22 ESG 642 DIAGNOSIS AND TESTING Continued 3 Make sure the valve tappet is seated against camshaft 6250 Install the A dial Indicator with Bracketry so the ball socket adapter of the indicator is on top of the hydraulic lash adjuster or the B Cup Shaped Adapter is on top of the push rod and in the same plane as the valve tappet push rod movement 4 Remove the spark plugs 5 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 hydraulic lash adjuster is on the base circle of the camshaft lobe At this point the hydraulic lash adjuster will be in its lowest position If checking during engine assembly turn the crankshaft using a socket or ratchet 6 Zero the dial indicator Continue to rotate the crankshaft slowly until the valve tappet is in the fully raised position highest indicator reading 7 NOTE If the lift on any lobe is below specified service limits the camshaft and hydraulic lash adjuster operating on worn lobes must be replaced as well as any hydraulic lash adjuster showing roller wear or needle bearing damage Compare the total lift recorded on the dial indicator with specifications 8 To check the accuracy of the original dial indicator reading continue to rotate the crankshaft until the indicator re
209. bove conditions are present for at least 2 consecutive seconds Actions Taken When the DTC Sets ECM illuminates the MIL The ECM forces the throttle to default position of 6 open Conditions for Clearing the DTC Resetting the MIL DTC can be cleared from memory by disconnecting the battery for 5 minutes elf a personal computer PC is connect to the engine the DTC can be cleared from memory by hitting the C key while in the View Sensor Data screen 03 39 Auxiliary Systems Ignition IGNITION SYSTEM DIAGNOSING AND TESTING Continued MANIFOLD ABSOLUTE PRESSURE MAP SENSOR DIAGNOSTIC TROUBLE CODE DTC 14 24 Manifold Absolute Pressure Engine Control Sensor MAP Connector Module ECM Signal Return c Map Signal D 5V Map Reference Circuit 359 K Off OV KOEO Ground KOER Ground To CHT and IAT Sensors G To TP Sensor Circuit 358 K Off OV KOEO 4 8V KOER 1V at idle 4 8V at Wide Open Throttle Circuit 351 K Off OV KOEO 5V KOER 5V Circuit Description The manifold absolute pressure MAP sensor responds to changes in intake manifold pressure vacuum The ECM provides a 5V reference voltage to the MAP sensor between terminal A Grey Yellow circuit 359K and terminal C Brown White circuit 351C of the MAP sensor A MAP signal is returned to the ECM from terminal B Lt Green Black circuit 358 of the MAP sensor The MAP signal va
210. camshaft sprocket and timing chain as an assembly e Timing marks on the gears and keyways on the shafts must align DA0741 A 5 Install the synchronizer drive gear 6 Install the front cover Refer to the procedure in this section DA0742 A 02 82 ENGINE REPAIR Continued Camshaft Removal DA0735 A ESG 642 02 83 Remove the following components Refer to the procedures in this section Upper and lower intake manifolds e Valve covers Push rods tappet guides and tappets e Front cover Timing chain and sprockets Remove the balance shaft drive gear ESG 642 ENGINE REPAIR Continued 3 CAUTION Use care when removing cam as not to bump or score cam bearings May cause cam bearing failure Remove the thrust plate retaining screws and the camshaft 02 84 ESG 642 ENGINE REPAIR Continued Installation 1 2 40 50 Nm 30 37 Ib ft DA0740 A 02 85 A CAUTION Use care when removing cam as not to bump or score cam bearings May cause cam bearing failure Lubricate the camshaft bearings lobes and journals with Engine Assembly Lubrication D9AZ 19579 D or equivalent meeting Ford specification ESR M88C80 A Install the camshaft Install the timing chain vibration damper ENGINE REPAIR Continued DA0739 A ESG 642 02 86 Install the balance shaft drive gear The timing marks on the drive gear and driven gear must align Instal
211. ccess Memory NVRAM Keep Alive Memory KAM Nonvolatile Memory NVM Oxidation Catalytic Converter OC Continuous Oxidation Catalyst COC 25 Oxygen Sensor O Exhaust Gas Oxygen Sensor EGO Sensor EGOS Exhaust Gas Sensor EGS Exhaust Oxygen Sensor EOS Lambda Oxygen Sensor O2 Sensor OS Park Neutral Position Park Neutral P N Park Neutral Position Switch PNP Switch Neutral Drive Switch NDS Neutral Gear Switch NGS I Neutral Position Switch NPS Neutral Safety Switch Periodic Trap Oxidizer PTOX Trap Oxidizer Periodic TOP Positive Crankcase Ventilation Positive Crankcase Ventilation PCV PCV TET E PCV Positive Crankcase Ventilation Valve PCV Valve Positive Crankcase Ventilation PCV Valve Power Steering Pressure Power Steering Pressure PSP Power Steering Pressure Switch PSP Switch Power Steering Pressure Switch P S Pressure Switch PSPS Powertrain Control Module Electronic Control Assembly ECA Electronic Control Unit 4 ECU4 Electronic Engine Control Processor EEC Processor Microprocessor Control Unit MCU Single Board Engine Control SBEC Single Module Engine Control SMEC 09 15 Auxiliary Systems Metrics J1930 TERMINOLOGY LIST New Term New Acronym Pressure Transducer Exhaust Gas Pressure Transducer Pressure Transducer EGR System Recirculation Syst
212. ces are splashed in the eyes wash out thoroughly with clean water and OBTAIN QUALIFIED MEDICAL ASSISTANCE IMMEDIATELY WARNING The Engine Exhaust from this product contains chemicals known to the State of California to cause cancer 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 Section Index Reproduction in any manner in whole or in part is prohibited without the express permission in writing from Ford Power Products Marketing Department Ford Power Products 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 01 Section 02 Section 03 Section 04 Section 05 Section 06 Section 07 Section 08 Section 09 Section 10 ENGINE 4 2L IGNITION FUEL COOLING CHARGING STARTER ELECTRONICS amp DIAGNOSTIC TRO
213. cessary 04 19 Auxiliary Systems Fuel FUEL SYSTEM DESCRIPTION AND TESTING Continued Poor Acceleration or Load Response Time Poor acceleration may be caused by a mixture being too rich or too lean If a rich mixture is the cause of poor acceleration the fault may be fuel pressure faulty injector or injectors IAT CHTS fuel pump fuel pressure regulator Repair or replace as necessary If a lean mixture is the cause of poor acceleration the fault may be low fuel pressure faulty fuel pressure regulator fuel pump Air leaks are also responsible for a lean mixture causing poor acceleration Leaks may occur at the actuator to the intake manifold upper intake to lower intake or the lower intake manifold to the cylinder head Cracks in the assemblies or worn gaskets cause these air leaks Clean repair or replace as necessary Inconsistant Idle Speed Inconsistant idle speed is mostly a throttle related problem A sticking throttle shaft or a loose shaft in the actuator body or bore can cause inconsistent idle speed A faulty idle air control motor IAC will also cause the problem Repair replace or adjust as necessary Reduced Power Output Reduced power output may be caused by a throttle plate not opening fully or low fuel pressure Clean adjust repair or replace as necessary Fuel Pump F8JL 9A350 AA Harness Large Spade 5 16 B 12V Spade 1 4 Fuel Inlet VPWR K Off OV KOEO VPWR
214. change has occurred 3 05 20 Inspect the coolant in both the radiator and the degas bottle for coolant color Clear light green or blue indicates higher water content than required Dark brown indicates unauthorized stop leak may have been used Use cooling system Stop Leak Powder E6AZ 19558 A or equivalent meeting Ford specification ESE M99B170 A only A light or reddish brown color indicates rust in the cooling system Flush the system and refill with the correct mixture of water and Premium Engine Coolant green in color E2FZ 19549 AA or equivalent meeting Ford specification ESE M97B44 A An irridescent sheen on top of the coolant indicates a trace of oil is entering the cooling system A milky brown color indicates that oil is entering the cooling system The causes of the leak might be A blown head gasket 6051 Acracked or warped cylinder head 6049 A crack in the engine oil gallery and the cooling passageways If engine coolant is present in the engine oil the cause of the leak might be A blown head gasket A cracked or warped cylinder head crack in the engine oil gallery and cooling passageways If engine coolant is present in the transmission fluid the cause might be A leaking radiator A leaking auxiliary fluid cooler A reddish milky appearance indicates transmission fluid is entering the system The causes of the leak might be A l
215. cle or battery Lift with a battery carrier or with your hands on opposite corners Remove battery from vehicle or equipment Installation 1 NOTE The battery terminal cleaning operation shown in the following illustration is typical for all vehicles and equipment Clean cable terminals and battery hold down clamp with a wire brush Replace all cables or parts that are worn or frayed CLEANING CABLE WITH BATTERY CLEANING BRUSH 2 Clean battery tray 10732 with a wire brush and scraper 3 Place battery in battery tray with positive and negative terminals in same position as previous battery 10653 4 Assemble and tighten battery hold down clamp so battery is secure Do not tighten excessively 5 Secure cables battery to starter relay cable 14300 first to proper terminals Tighten to 7 10 Nm 5 7 lb ft Apply petroleum jelly to terminals 06 15 Auxiliary Systems Charging BATTERY MOUNTING AND CABLES Continued Service Procedures Battery Charging NOTE If excessive gassing or electrolyte spewing occurs during the charge discontinue charging The battery 10655 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
216. come cracked rotted or have a tendency to collapse Drain the radiator into appropriate container then 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 upper hose or the water pump connection lower hose Installation Position the clamps at least 1 8 inch from each end of the hose Coat the connection areas with an approved water resistant sealer and slide the hose on the connection Make sure the clamps are beyond the bead and placed in the center of the clamping surface of the connections Tighten the clamps Fill the radiator with the recommended permanent antifreeze and water mixture Operate the engine for several minutes then check the hoses and connections for leaks Thermostat Removal WARNING AVOID INJURY FROM HOT COOLANT WHEN ENGINE IS HOT 1 Allow the engine to cool down until the coolant has lowered in temperature to below 110 F 2 Drain the radiator so that the coolant level is below the thermostat 3 Disconnect upper radiator hose form the thermostat housing 4 Remove the coolant outlet housing retainer bolts and remove housing Remove the thermostat and gasket Installation Check the thermostate before installing it following the procedure under Thermostat Test Thermostat Removed 1 Clean the coolant outlet housing and manifold gasket surfaces Coat a new gasket with water resistant sealer
217. coolant is cold the sensor resistance is high and the ECM will monitor a high signal voltage at the CHT signal circuit If the engine cylinder head is warm the sensor resistance is lower causing the ECM to monitor a lower voltage DTC 43 will set when the ECM detects an excessively low signal voltage and DTC 33 when the ECM detects an excessively high signal voltage Conditions for Setting the DTC KOEO or CHT sensor signal is less than or equal to 0 22 volts or greater than 4 93 volts e Above conditions are present for a least 3 consecutive seconds 05 31 Auxiliary Systems Cooling COOLING SYSTEM DIAGNOSING AND TESTING Continued Actions Taken When the DTC Sets e The ECM will illuminate the malfunction indicator lamp MIL e The ECM will force the CHT sensor to a 50 F default value NOTE Complete list of temperature sensor characteristics found on page 05 34 of this section Conditions for Clearing the DTC Resetting the MIL e The DTC can be cleared from memory by disconnecting the battery ground cable for 5 to 20 minutes NOTE Touching the two disconnected battery cables will only clear the trouble codes from the PC not from the ECM personal computer PC is connected to the engine the DTC can be cleared from memory by hitting the C key while in the View Sensor Data screen Diagnostic Aids The CHT sensor shares the same ground with other sensors Check the gr
218. crankshaft rotations must have occurred e Oil switch must be closed to ground for at least 2 0 consecutive seconds Actions Taken When the DTC Sets ECM will illuminate the malfunction indicator lamp MIL e Software selectable The ECM will shut down the engine The engine can be restarted by recycling ignition switch 08 76 Auxiliary Systems EFI amp Ignition Electronics Diagnostic Trouble Code 51 Diagnostic Aids Check that the ECM has the correct governing program Inspect the harness connectors for backed out terminals improper mating broken locks improperly formed or damaged terminals and poor terminal to wire connections Inspect the wiring harness for damage If the harness appears to be OK go to diagnostic chart below DTC 51 Low Oil Pressure Stp Ye 1 Ignition OFF 2 Disconnect the circuit 253 Dk Green White oil pressure switch wire from the oil pressure switch 3 With a DVOM measure the continuity on circuit 253 Dk Green White Is there continuity Go at mum 2 Go to n 3 Locate and repair the short to ground in circuit 253 Dk Green White between the oil pressure switch and the ECM connector cavity J3 Is the repair complete test 2 Connect a DVOM to the oil pressure switch post and ground Is there continuity Go to m 4 Go to nM 5 Replace the oil pressure switch Install replacement ECM Remove NETTEN Is system operation normal wi
219. ct a DVOM from cavity 86 to ground Does the DVOM show battery voltage VPWR Go to Step 4 Go to Step 3 Repair the open or short to ground in circuit 361A Red between the and the fuel pump relay Is the repair complete Re test Connect a DVOM from cavity 85 to ground Does the DVOM show battery voltage Go to Step 6 Go to Step 5 Ki Repair the open or short to ground in circuit 926A Lt Blue Orange Ka between the ECM and the fuel pump relay Is the Connect a DVOM from cavity 87 to ground Repair the open or short to groundi in circuit 37 Yellow between the ECM and the ignition Is the repair complete Connect the DVOM ohms from cavity 30 to ground Do you have continuity Repair the open or short to ground in circuit 787 Pink Black and circuit 238A Dk Green Yellow between the ECM and the fuel pump relay Is the repair complete Connect a DVOM between cavity 87 to cavity 30 Does the DVOM show battery voltage Replace the fuel pump relay Is the repair complete Install replacement ECM Is system operation normal with replacement Remove ee ECM installed ECM and install original Remove original 5 the repair complete system operation normal with original ECM ECM and reinstall reinstalled Keep original replacement ECM installed Re test Go to Step 14 Is the repair complete system operation normal with replacement ECM reinstalled 08 57 Auxiliary Systems EF
220. ctor circuit located in the signal conditioning electronics is used to convert the A C signal into a digital pulse This sensor is used on all Electronic Ignition High Data Rate El applications 4 6L shown to provide basic spark timing data for the Engine Control Module ECM CKP Sensor typical 08 20 Auxiliary Systems EFI amp Ignition Electronics CRANKSHAFT POSITION SENSOR CKP VARIABLE RELUCTANCE Continued POLE PIECE LOW RESISTANCE POSITION OF VRS SENSOR POLE PIECE HIGH RESISTANCE POSITION OF VRS SENSOR VARIABLE RELUCTANCE 36 1 TOOTH SENSOR VRS TRIGGER WHEEL 10 PIN ICM CONNECTOR 4 B e 350 GY A 349 DB PTT TEILT MISSING TOOTH REGION VRS WAVEFORM sensor output voltage 18 150 millivolts peak to peak at a minum engine speed 0130 RPM sensor output voliag is 300 volts peak to peak at a maximum engine speed ar 000 RPM HARD SHELL CONNECTOR VARIABLE RELUCTANCE SENSOR VRS Auxiliary Systems EFI amp Ignition Electronics FUEL PUMP RELAY FP Part Description The Fuel Pump Relay is a Normally Open relay that supplies voltage to the electric fuel pump When the ignition key is turned to the START or RUN position the Engine Control Module ECM grounds the control pin which activates the relay closes the contacts and sends voltage to the fuel pump I
221. d Verify repair Go to Step 4 Remove and check the air filter element for dirt or Was a problem found Verify repair Go to Step 5 Remove the spark plugs and check for gas or oil fouling cracks wear improper gap burned electrodes or heavy deposits 9 If spark plugs are fouled the cause of fouling must be determined before replacing the spark plugs Was a problem found Verify repair Go to Step 6 verear Goto Step Was a problem found Verify repair Go to Step 7 very repair signs Refer to the Cooling Section of this Manual Verify repair Go to Step 8 Check for low engine compression Refer to Section 01 of this Manual Was a problem found Verify repair Go to Step 9 Check for excessive exhaust system back pressure Possible problems could be Damaged or collapsed pipe Internal muffler failure Was a problem found Verify repair Go to Step 10 Check the air intake system and the crankcase for air leaks Was a problem found Verify repair Go to Step 11 1 Review all the diagnostic procedures within this table 2 If all procedures have been completed and no malfunctions have been found review inspect the 11 following Contact Ford Visual physical inspection including fuel quality Power Products check Customer All connections within a suspected circuit and or Service Center system Technical Was a problem found Verify repair Support Hotline 1 800 521 0370 03 28 Auxiliar
222. d Only Memory Fuel Concentration Sensor Fuel Quality Sensor Percent Alcohol Sensor Variable Fuel Sensor Fourth Gear Fourth Gear 4GR Fuel Level Sensor Fuel Level Sensor Fuel Sensor Fuel Pressure Fuel Pressure Fuel Pressure B Ti JJ 09 12 Auxiliary Systems Metrics J1930 TERMINOLOGY LIST New Acronym Fuel Pressure Regulator Fuel Pressure Regulator Old Terms Acronyms Fuel Regulator Fuel Pump Fuel Pump Module Fuel Pump FP FP Module Fuel Module Fuel Sender Fuel Tank Unit Tank Module Fuel Pump Relay Adaptive Fuel Strategy Alternator ALT Es TI TI oJ 0 ez Governor Electronic Module GEM GND Ground GRD Heated Oxygen Sensor HO2S Heated Exhaust Gas Oxygen Sensor HEGO Sensor Heated Oxygen Sensor HOS High Speed Fan Control Switch High Speed FC High Speed Fan Control Switch Switch High Speed FC Switch IAC Idle Air Bypass Control Idle Speed Control ISC idle Speed Control Bypass Air ISC BPA Thermal Valve Idle Air Control Valve IAC Valve Air Valve Fast Idle Thermo Valve Idle Air Control Valve IACV Idle Speed Control ISC Throttle Opener Idle Speed Control Actuator ISC Actuator Idle Speed Control Actuator ISC Acutator Idle Speed Control Solenoid Vacuum ISC Solenoid Throttle Opener Vacuum Switching Vacuum Valve Valve Th
223. d bolts torque to yield Discard and replace The use of used bolts could cause engine failure ESG 642 ENGINE REPAIR Continued 3 Install the oil baffle assembly 4 Install oil pump screen cover and tube Refer to this Section 5 Install oil pan Refer to this Section NOTE Always use new cylinder head bolts 40 50 Nm 30 37 Ib ft 6 Install cylinder heads Refer to this Section 040884 Engine Front Cover Removal 1 Disconnect the battery ground cable Drain coolant from radiator 2 Remove the water pump Refer to this Section 3 Rotate the crankshaft until the damper timing mark aligns with the top dead center indicator K Tes em LL cI m OE Ce pum v ES DA0777 A 02 66 ESG 642 ENGINE REPAIR Continued 5 Mark the crankshaft damper and pulley for alignment reference Remove the crankshaft pulley 6 Remove the crankshaft damper A puller will be needed DA0729 A 02 67 ESG 642 ENGINE REPAIR Continued 7 Disconnect the wiring at the crankshaft position sensor 8 Remove crankshaft position sensor CKP 9 At the front of the oil pan remove a retaining bolt from the left and right side of the oil pan 0779 02 68 ENGINE REPAIR Continued ESG 642 02 69 10 11 12 13 14 15 Disconnect the wiring at the camshaft synchronizer Hemove the two screws 6B288 from stator assy
224. de CY 55 Programfaut ECM malfunction Secde o6 Programfaut ECM malfunction 1 Setode 7 Programfault malfunction Secode 7 8 Low system vollage AltemaiormafundiondbeKmissngfematrdeconnede _ Secos m amp Hghsystemvolage Alternator voltage exceeding TBvolis hom T 86 Intake manifold leak Vacuum leak IAC motor stuck causing engine rpm over foot pedal command Shutdown NOTE Bold Print denotes 4 2 Drive By Wire engine safety features Safety Concern Glossary Protects operator CHT Cylinder Head temperature sensor 1 software selectable Il Protects engine powertrain if enabled HO2S Heated exhaust gas oxygen sensor software selectable ECM Engine control module software selectable IAC Idle air control motor IVS Idle validation switch MST Manifold surface temp TPS Throttle Position Sensor 08 25 Auxiliary Systems EFI amp Ignition Electronics Chart Notes NO ACTION means DTC will be stored and MIL illuminated but engine performance will not be intentionally affected by calibration as a result of the stored DTC MIL Malfunction Indicator Lamp Diagnostic Trouble Code e HO2S Heated Oxygen sensor Closed loop fuel control is based on HEGO readings OPEN LOOP Fuel metering is not influenced by the HO2S sensor e SOFTWARE SELECTABLE means OEM has choice of action A or B as a result of a stored
225. der 2 Reconnect battery ground cable Nm 7 Starter Motor Removal WHEN CARRYING OUT MAINTENANCE ON THE STARTER SYSTEM BE AWARE THAT HEAVY GAUGE LEADS OR CONNECTED DIRECTLY TO THE BATTERY MAKE SURE PROTECTIVE CAPS ARE IN PLACE WHEN MAINTENANCE IS COMPLETE FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY 1 Disconnect the battery ground cable 14301 07 12 Auxiliary Systems Starter REMOVAL AND INSTALLATION Continued 2 Raise and support the vehicle or equipment 3 Remove the starter motor solenoid terminal cover 11N087 4 Disconnect the starter motor electrical connections 1 Remove the two nuts 2 Remove the battery cable 3 Remove the starter solenoid wire 5 Remove the nut and the starter motor ground cable when equipped 07 13 Auxiliary Systems Starter REMOVAL AND INSTALLATION Continued 6 Remove the starter 1 Remove the bolt and stub bolt 2 Remove the starter 7 Remove the stud bolt bolts and the starter Installation A warnine WHEN CARRYING OUT MAINTENANCE ON THE STARTER SYSTEM BE AWARE THAT HEAVY GAUGE LEADS ARE CONNECTED DIRECTLY TO THE BATTERY MAKE SURE PROTECTIVE CAPS ARE IN PLACE WHEN MAINTENANCE IS COMPLETE FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY NOTE It is recommended that wiring service kit F2PZ 11K162 A be used which includes a 70 inch long 12 gauge
226. e M 1 Repair porosity defects with an epoxy sealer meeting Ford specification M3D35 A E e Clean the surface to be repaired to a bright oil free metal surface e Chamfer undercut the repair area to greater depth than the rest of the cleaned surface Solid metal must surround the area to be repaired e 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 50 F e Sand or grind the repaired area to blend with the general contour of the surface e 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 obtained by calling 1 800 ROTUNDA 1 800 768 8632 01 55 ESG 642 GENERAL SERVICE PROCEDURES Continued DAO0451 A Cylinder Block Core Plug Cup Type Cylinder Block Core Plug Expansion Type 1 Useaslide hammer or tools suitable to remove the cylinder block core plug 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 3 NOTE Oversize plugs are identified by the OS stamped in the flat located on the cup side of the plug Coat the cyl
227. e battery could damage the vehicle s electronic system Negative Grounded Battery WARNING TO AVOID INJURY USE PARTICULAR CARE WHEN CONNECTING A BOOSTER BATTERY TO A DISCHARGED BATTERY 1 Position vehicles or equipment so jumper cables will reach being careful that vehicles do not touch wanNING MAKING THE FINAL CABLE CONNECTION COULD CAUSE ELECTRICIAL SPARK NEAR THE 07 4 BATTERY AND COULD CAUSE AN EXPLOSION REFER TO WARNING AT THE BEGINNING OF THE JUMP STARTING PROCEDURE N WARNING WHEN SERVICING STARTER OR PERFORMING OTHER UNDERHOOD WORK IN THE VICINITY OF THE STARTER BE AWARE THAT THE HEAVY GAUGE BATTERY INPUT LEAD AT THE STARTER SOLENOID IS ELECTRICALLY HOT AT ALL TIMES JUMP STARTING MAKE CONNECTIONS IN NUMERICAL ORDER DISCONNECT IN REVERSE ORDER 4 3 2 1 SECOND JUMPER 3 CABLE MAKE SURE VEHICLES DO NOT TOUCH PPD0038 BOOSTER BATTERY DISCHARGED BATTERY NOTE Be sure to disconnect battery negative cable before servicing starter 2 Make jumper cable connections a Connect one end of first jumper cable to positive 1 terminal of discharged battery and other end of positive 2 terminal of booster battery Connect one end of second jumper cable to negative 3 terminal of booster battery Connect other end to an engine bolthead or good metallic contact spot on engine 4 of equipment to be started NOT TO NEGATIVE BATTERY TERMINAL Make sure jum
228. e A block heater wiring from the B block heater 6A051 and remove 05 16 Auxiliary Systems Cooling REMOVAL AND INSTALLATION Continued 6 Remove the block heater 1 NOTE Do not loosen the block heater retaining screw more than necessary for removal Loosen the block heater retaining screw 2 Twist and slide the block heater to release the retainer clip and remove Discard the retainer clip AQ0128 A Installation 1 To install reverse the removal procedure NOTE Clean the inside diameter of the cylinder block hole machined surface and hole entrance NOTE To ease installation coat the block heater seal and the cylinder block hole with Premium Long Life Grease XG 1 C or equivalent meeting Ford specification ESA M1C75 B 2 Tighten retaining screw 1 6 1 8 Nm 14 16 Ib in 3 Refill engine cooling system 4 Connect battery ground cable 5 Start engine and check for leaks AQ0350 B 05 17 Auxiliary Systems Cooling REMOVAL AND INSTALLATION Continued Water Pump BIT 72 Torque Specs Bolt 1 2 6 7 8A 10 11 12 amp 13 20 30 Nm Stud 3 4 5 amp 9A 6 8 Nm 1 Install studs torque to 6 8 Nm 2 Install front cover gasket 6020 3 Install front cover amp oil pump assy 6 008 4 Install water pump gasket 8507 5 Install water pump assy 8501 6 Install remaining fasteners 7 Torque all bolts and nuts to 20 30 Nm ma
229. e Inspection c 01 47 Valve Guide Inner 01 47 Valve Guide Reaming 01 48 Valve Spring Installed Length 01 48 Valve Spring Free Length 2 2 01 49 Valve Spring Out of Square 01 49 Valve and Seat Refacing Measurements 01 50 Valve Seat 01 50 Valve Seat Runout 01 51 Flywheel Inspection 01 51 Oil Pump Gear Radial Clearance 01 52 Oil Pump Rotor Inspection 01 52 Oil Pump Side Clearance 01 53 Cylinder Bore Honing 01 53 Cylinder Bore Cleaning 01 54 Cylinder Block 01 55 Cast Porosity 01 55 Cylinder Block Core Plug Replacement 01 55 Cylinder Block Core Plug Cup Type 01 56 Cylinder Block Core Plug Expansion Type 01 56 Spark Plug Thread 01 57 Exhaust Manifold Straightness 01 58 SPDOCIICATIONS me
230. 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 Divide the first measurement by the second Divide the hours run during the oil test by the result This quantity is the approximate oil consumption rate in hours per liter or in hours per quart h If the oil consumption rate is unacceptable go to Step 6 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 go to Step 9 DIAGNOSIS AND TESTING Continued 9 10 11 12 Ci 1 ESG 642 Perform a cylinder compression test or perform a cylinder leak detection test with Engine Cylinder Leak Detection Air Pressurization Kit This can help determine the source of oil consumption such as valves piston rings or other areas NOTE After determining if worn parts should be replaced make sure correct replacement parts are used Check valve guides for excessive guide clearances REPLACE all valve stem seals after verifying valve guide clearance 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 proc
231. e ground circuit for open or short CHECK STARTER MOTOR Key OFF Transmission in Neutral PTO disengaged CHECK connections from Connect one end of a jumper wire to the starter B output of starter relay to S terminal and momentarily touch the other end to terminal for open or short solenoid S terminal Does starter crank Defective starter REPLACE starter Evaluation Procedure 2 CHECK RELAY TEST B TEST STEP RESULT ACTION TO TAKE e jecksmerenmev 0000000 Key in START Transmission in Neutral PTO disengaged Go to B2 s case ground OK REPAIR ground GO to B2 KL CHECK VOLTAGE AT STARTER RELAY START TERMINAL Key in START Transmission in Neutral PTO disengaged GO to B3 Check for voltage between relay start terminal and case Open circuit or high ground resistance exits in external s voltage OK 12 12 45 V circuit wiring or compo nents Check the following All circuit connections including plastic hard shell connector at solenoid S terminal to make sure it is not broken or distorted Ignition switch Neutral switch or manual lever position sensor B3 CHECK STARTER TERMINAL Key in START Transmission in Neutral PTO disengaged Yes gt REFER to Starter System Check for voltage at output terminal of remote relay Diagnosis in this section s voltage OK No gt Defective starter relay REMOVE and REPLACE relay 07 8 Auxiliary Systems
232. e no effect on cylinder head or spark plug life 1 Clean the spark plug seat and threads A26489 A 01 57 ESG 642 GENERAL SERVICE PROCEDURES Continued 2 Start the tap into the spark plug hole being B B careful to keep it properly aligned As the tap begins to cut new threads apply aluminum cutting oil 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 A26492 A 6 NOTE A properly installed tapersert will be either flush with or 1 0 mm 0 039 inch below the spark plug gasket seat Tighten the tapersert into the spark plug hole DA0391 A 01 58 ESG 642 GENERAL SERVICE PROCEDURES Continued 7 Turnthe mandrel body approximately one half turn counterclockwise and remove A26491 A Exhaust Manifold Straightness Special Tool s Straightedge D83L 4201 A Special Service Tools called for by the procedures can be obtained by calling 1 800 ROTUNDA 1 800 768 8632 NOTE The 4 6L engine exhaust manifold is shown the 4 2L engine exhaust manifold is similar 1 Place the Straightedge across the exhaust manifold flanges and check for warping with a feeler gauge A26498 B 01 59 ESG 642 SPECIFICATIONS General Specifications General
233. e oil before assembly Use the A Front Crankshaft Seal Replacer spacer B Front Crankshaft Seal Installer Cover Aligner and D Vibration Damper Hemover Adapter to install the C front crankshaft oil seal Install the crankshaft damper Refer to the procedure in this section Special Service Tools called for by the procedures can be obtained by calling 1 800 ROTUNDA 1 800 768 8632 ESG 642 ENGINE REPAIR Continued Removal of Rear Crankshaft Oil Seal 2 Remove the flywheel 6375 0978 3 Use Rear Crankshaft Seal Remover and Impact Slide hammer to remove the B crankshaft rear oil seal 02 54 ENGINE REPAIR Continued Installation of Rear Crankshaft Oil Seal DA0897 A ESG 642 2 02 55 NOTE Lubricate the crankshaft rear oil seal lips with engine oil prior to installation Use A Rear Main Seal Replacer to install the B crankshaft rear oil seal Install the flywheel ESG 642 ENGINE REPAIR Continued Oil Pump Removal 1 Remove the oil bypass filter 6714 2 Remove the six oil pump bolts 3 Remove the A oil pump drive gear B oil pump driven gear C oil pump O ring and D oil pump and filter body 6603 Discard the C oil pump O ring 02 56 ESG 642 ENGINE REPAIR Continued Installation of Oil Pump 1 NOTE Lubricate parts with engine oil before assembly 20 30 Nm 15 22 Ib ft Bond the removal procedure in reverse NO
234. e owner the part number It remains a distributor function to identify the part number The key to identifying the engine is the identification decal mounted on the engine rocker cover That decal provides not only the engine serial number but also the exact model or type options and S O Special Order The combination of that data permits you to isolate the precise engine build level and customer so you can determine the correct replacement parts ESG 642 EUROPEAN SERVICE IDENTIFICATION PLATE This plate Fig 2 is fixed to the engine in a prominent position Panels 1 to 11 on the plate refer to various engine details as listed here Detail Title 1 Engine model identification 2 Engine capacity 3 Serial No This identifies the engine as supplied by Power Products Engineering Date The two letters following the serial No indicate the year and month in which the specified build components were assembled refer to the chart Fig 3 NOTE These markings should not be confused with any that may be stamped or etched into the crankcase of the basic engine 4 Selective Build Number indicates the complete specification The digit to the extreme right hand side is the build chart issue number 5 Engine operating rpm An asterisk denotes speed set by customer 6 Not applicable 7 Not applicable Applicable to diesel engines only 4 11 This box is provided for Equipment Manufacturers use when extra equipment is fitted
235. e running Refer to Was a problem found Page 03 35 Verify repair Go to Step 10 Verify repair Go to Step 9 03 31 Auxiliary Systems Ignition HESITATION SAG STUMBLE SYMPTOM Continued Stp Action A 1 Check the ignition coil secondary resistance 2 Replace the coil if it is not within the specified value Refer to Did the coil require replacement Page 03 35 Verify repair Go to Step 11 1 Remove the spark plugs and check for gas or oil fouling cracks wear improper gap burned electrodes or heavy deposits 2 f spark plugs are fouled the cause of fouling must be determined before replacing the spark plugs Was a problem found NEN repair PEE to Step 12 Check the ECM grounds to verify that they are clean and tight Refer to the ECM wiring diagram Was a problem found men repair to Step 13 Visually physically check vacuum hoses for splits kinks and proper connections and routing Was a problem found Verify repair Go to Step 14 Check for a faulty plugged or incorrectly installed PCV valve Was a problem found Verify repair Go to Step 15 1 Review all diagnostic procedures within this table 2 If all procedures have been completed and no malfunctions have been found review inspect the following Visual physical inspection including fuel quality Contact Ford check Power Products All electrical connections within a suspected Customer circuit and or system Service Center
236. e tensioner assembly breaks or some other mechanical part of the tensioner fails there is no need to check tensioners for proper tension The only mechanical check that need be made if you have any doubt about the tensioner function would be to remove the belt in the area of the tensioner to avoid belt contact then using the proper tool rotate the tensioner from its relaxed position throught its full stroke and back to the relaxed position to assure that there is no stick grab bind and to assure that there is tension on the spring It is a normal condition for the tensioner to be moving under certain conditions when the engine is running If the tensioner meets this criteria it should be assumed to be a good tensioner Drive Belt Misalignment AN CAUTION Incorrect drive belt installation will cause excessive drive belt wear and may cause the drive belt to come off the drive pulleys Non standard replacement drive belts may track differently or improperly If a replacement drive belt tracks improperly replace it with an original equipment drive belt to avoid performance failure or loss of belt With the engine running check drive belt tracking If the A edge of the drive belt rides beyond the edge of the pulleys noise and premature wear may occur Make sure the B drive belt rides correctly on the pulley If a drive belt tracking condition exists proceed with the following Visually check the drive belt ten
237. e that has a minimum octane rating of 87 2 Re evaluate the engine performance Is detonation present Check for obvious overheating problems ow engine coolant Restricted air flow to radiator or restricted water flow through radiator Incorrect coolant solution It should be a 50 50 mix of approved antifreeze water If a problem is found repair as necessary Was a problem found Inspect the fuel delivery system to determine if there is a problem with fuel delivery Was a problem found Check items that can cause an engine to run lean Refer to DTC 32 Was a problem found Check spark plugs for proper heat range Refer to specification in the back of this section 1 Remove excessive carbon buildup with a top engine cleaner Refer to instructions on the top engine cleaner can 2 Re evaluate engine performance Is detonation still present Check for an engine mechanical problem Perform a cylinder compression check Refer to Section 01 of this Manual Was a problem found 1 Review all the diagnostic procedures within this table 2 If all procedures have been completed and no malfunctions have been found review inspect the following Visual physical inspection including fuel quality check All electrical connections within a suspected circuit and or system Was a problem found Go to Step 2 Hefer to DTC chart perform component and circuit test as required m
238. e to run for ten minutes Feel the inlet and outlet heater water hoses and the underside of the upper radiator hose 8260 e Are the upper radiator hose and the heater water hoses cold P Yes INSTALL a new water thermostat TEST the system for normal operation gt No Go to B6 B6 CHECK THE COOLING FAN OPERATION Perform the cooling fan component tests For additional information refer to the Component Tests in this section 5 the cooling fan operation OK Yes GO to Section 01 for diagnosis and testing of the engine gt No INSTALL a new component determined to be faulty For additional information refer to Fan Blade Clutch and Shroud in this section TEST the system for normal operation Continued 05 27 Auxiliary Systems Cooling COOLING SYSTEM DIAGNOSING AND TESTING Continued PINPOINT TEST C THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURE TEST CONDITIONS TEST DETAILS RESULTS ACTIONS C1 CHECK THE ENGINE TEMPERATURE otart the engine and allow the engine to idle for ten minutes Feel the inlet and heater water hoses and the underside of the upper radiator hose Are the upper radiator hose and the heater water hoses cold P Yes INSTALL a new water thermostat gt No Test and diagnose the engine coolant temperature gauge PINPOINT TEST C THE BLOCK HEATER DOES NOT OPERATE PROPERLY TEST CONDITIONS TEST DETAILS RESULTS ACTIONS D1 CHECK THE POW
239. e valve seat and valve angles DA0384 A Valve Seat Width 1 Measure the valve seat width If necessary grind the valve seat to specification DA0383 A 01 50 ESG 642 GENERAL SERVICE PROCEDURES Continued Valve Seat Runout 1 Use the Valve Seat Runout Gauge to check valve seat runout 0 0385 Flywheel Inspection 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 1 Inspect the flywheel for Cracks Worn ring gear teeth B Chipped or cracked ring gear teeth C 2 Inspect the flywheel ring gear runout 01 51 ESG 642 GENERAL SERVICE PROCEDURES Continued Oil Pump Gear Radial Clearance 1 Measure the clearance between the rotor and the pump housing DAQ387 A Oil Pump Rotor Inspection 1 Inspect the oil pump rotor tips for damage or wear A26479 A 01 52 ESG 642 GENERAL SERVICE PROCEDURES Continued Oil Pump Side Clearance Special Tool s Feeler Gauge D81L 4201 A or Equivalent Straight Edge D83L 4201 A or Equivalent DA0388 A Special Service Tools called for by the procedures can be obtained by calling 01 53 1 800 ROTUNDA 1 800 768 8632 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
240. e valve to keep it from dropping 7 Inspect the components replace if necessary Refer to Section 01 02 41 ESG 642 ENGINE REPAIR Continued Installation 1 NOTE Components removed should be marked for location Make sure components are installed in the correct location NOTE Lubricate parts with engine oil prior to assembly Follow the removal procedure in reverse order 30 40 Nm 22 2916 0 DA0895 A Valve Tappet Removal NOTE If removing more than one valve tappet 6500 mark components removed for proper location 1 Remove the upper and lower intake manifolds Refer to the procedure in this section 2 Remove the valve cover Refer to the procedure in this section 02 42 ESG 642 ENGINE REPAIR Continued 3 Remove the rocker arms 1 Remove the bolts 2 Remove the rocker arms Wi NE A25442 A 4 Remove the push rods A25443 A 02 43 ESG 642 ENGINE REPAIR Continued 5 Remove the valve tappet guide and valve tappet DAO0896 A Valve Tappet Installation 1 NOTE Components removed should be 10 14 Nm pom 5 10 Ib ft marked for location Make sure components US are installed in the correct location lt 7 N SGE NE A NOTE Lubricate the valve tappet with engine XN y oil before installing Ax P 0 0 Sos Follow the removal procedure in reverse hes 2 L7 order 02 44 ESG 642 ENGINE REPAIR Continued
241. eaking radiator leaking auxiliary fluid cooler Auxiliary Systems Cooling COOLING SYSTEM DIAGNOSING AND TESTING Continued 4 If the engine coolant appearance is good test the engine coolant range with the battery and antifreeze tester e Maximum ratio is 60 40 antifreeze water Minimum ratio is 45 55 antifreeze water Check the engine coolant system conditions If the engine cooling fluid is low add specified coolant mixture only If the engine coolant fluid tests weak add straight engine coolant until the readings are within acceptable levels If the engine coolant tests strong remove some of the engine coolant and add water until readings are within acceptable levels 05 21 Auxiliary Systems Cooling COOLING SYSTEM DIAGNOSING AND TESTING Continued Engine Cooling Visual Inspection Chart Special Tool s Radiator Heater Core Pressure Tester Leaks Damaged engine coolant 014 R1072 or equivalent Damaged hoses temperature sensor Loose damaged hose e Damaged wiring clamps Damaged water thermostat gasket Damaged head gaskets Rotunda 73 Digital Multimeter tapped 105 0051 or equivalent gasket Damaged water pump Damaged radiator Damaged degas bottle Damaged heater core Damaged fan fan clutch ST1137 A Special Service Tools called for by the procedures can be obtained by calling 1 800 ROTUNDA 1 800 768 8632 Inspect
242. ectrical failure 08 36 Auxiliary Systems EFI amp Ignition Electronics Diagnostic Trouble Code 15 Diagnostic Aids ECT CHT IAT amp MST Sensors The MST sensor shares the same ground with the OHMS Manifold Absolute Pressure MAP sensor and the Cylinder Head Temperature CHT sensor Check Temperature vs Ohm or Volts Values approx the ground circuit 359 Grey Red if this DTC is set 100 2 080 47 3 837 79 Inspect the harness connectors for backed out 140 7 548 1 34 terminals improper mating broken locks improperly formed or damaged terminals and poor terminal to S wire connections Inspect the wiring harness for 19 716 2 39 damage If the harness appears to be OK 30 000 2 86 backprobe the MST sensor connector with a digital 46 774 3 32 voltmeter and observe the voltage while moving 74 914 3 71 connectors and wiring harnesses related to the MST 193485 105 sensor 209 816 4 25 A change in the voltage reading will indicate the 22 496 051 4 46 location of the fault Unplug MST sensor and using 925 021 4 54 and OHM meter read resistance value It should be Voltage values calculated for VREF 5 volts may vary 15 due to sensor and VREF variations DTC 15 Manifold Skin Temperature Low Voltage _ Go to Res System Check before continuing at Step 2 Go to Step 2 Are you using a personal computer PC to perform this diagnosis mI Go to Step 3 Go t
243. ed or damaged terminals and poor terminal to wire connections Inspect the wiring harness for damage DTC 56 ECM Fault Computer COP Failure Step tion vs Are you using a personal computer PC to perform this diagnosis Go to Diagnostic Ses Check before continuing at Step 2 Go to gn 2 Check the MIL or the PC engine data screen Are any other DTC s set to applicable DTC Go to Goto steps 3 Install replacement ECM Remove replacement Is system operation normal with replacement ECM installed ECM and install original ECM Go at Step 4 Is the repair complete system operation normal with original ECM Remove original reinstalled ECM and reinstall Keep original ECM replacement ECM installed Re test Go to Step 5 Is the repair complete system operation normal with replacement ECM Leave replacement ECM reinstalled installed Re test 08 84 Auxiliary Systems EFI amp Ignition Electronics Diagnostic Trouble Code 57 DIAGNOSTIC TROUBLE CODE 56 ECM FAULT COMPUTER OPERATING PROPERLY COP FAILURE Circuit Description The ECM continuously monitors electrical signals form the engine Under normal operation the ECM will store numbers into memory If this does not happen the ECM will execute an exception handling routine and rest itself from the beginning This is a watch dog timer function If DTC 57 is set the ECM will have to be replaced Conditions for Setting the DTC
244. ed off and back on Conditions for Setting the DTC e KOER e Engine reaches a threshold at 4000 RPM Actions Taken When the DTC Sets ECM illuminates the malfunction indicator lamp MIL The engine will shut off 08 42 Auxiliary Systems EFI amp Ignition Electronics Diagnostic Trouble Code 21 DTC 21 Overspeed Stp Vauws Yes Are you using a personal computer PC to perform this diagnosis Go to Diagnostic System Check before continuing Goto Step 2 Check for obstructions in the throttle crack in the intake manifold or vacuum leak that would produce WOT and repair as necessary Was a repair necessary Re test Go to Step 3 Install replacement ECM Remove replacement Is system operation normal with replacement ECM installed ECM and install original ECM Go at Step 4 Is the repair complete system operation normal with original ECM Keep original ECM Remove original reinstalled installed Re test ECM and reinstall Leave replacement ECM replacement ECM installed Re test Go to Step 5 Is the repair complete system operation normal with replacement ECM Leave replacement ECM reinstalled installed Re test 08 43 Auxiliary Systems EFI amp Ignition Electronics Diagnostic Trouble Code 22 NOTES 359C Electronic Governor ml ia 361H R S01 BR 355 3010 BR W 359 GY R 264 W L
245. eed as follows a 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 6600 b Check piston ring clearance ring gap and ring orientation Repair as required c Check for excessive bearing clearance Repair as required Perform the oil consumption test to confirm the oil consumption concern has been resolved Pressure Test Disconnect and remove the oil pressure sensor from the engine 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 Run the engine at 3000 rpm and record the gauge reading The oil pressure should be within specifications 6 Ifthe pressure is not within specification check the following possible sources insufficient oil oil leakage worn or damaged oil pump oil pump screen cover and tube 6622 excessive main bearing clearance excessive connecting rod bearing clearance Valve Train Analysis Static Engine Off 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 Check for loose mounting bolts studs and nuts e Check for plugged oil feed in the rocker arms 6564 or cylinder head Camshaft Roller Followers and Hydraulic Lash Adjus
246. em EGR System ra PROM Pulsed Secondary Air Injection PAIR Air Injection Reactor AIR Air Injection Valve AIV Pulsair Thermactor II PAIR Valve Integrated Relay Module Secondary Air Injection Air Injection Al Air Injection Reactor AIR Thermac Thermactor Secondary Air Injection Bypass AIR Bypass Air Management 1 AM1 Secondary Air Injection Bypass AIRB Thermator Air Bypass TAB Secondary Air Injection Bypass Valve AIR Bypass Valve Secondary Air Bypass Valve SABV Secondary Air Injection Check Valve AIR Check Valve Secondary Air Check Valve Secondary Air Injection Control Valve AIR Control Valve Air Control Valve Secondary Air Check Valve SACV Secondary Air Injection Diverter AIR Diverter Air Management 2 AM2 Secondary Air Injection Diverter AIRD Thermactor Air Diverter TAD Secondary Air Injection Pump AIR Pump Air Injection Pump AIP Secondary Air Injection Switching AIR Switching Valve Secondary Air Switching Valve Valve SASV 22222 J Sequential Fuel Injection SFI Fuel Injection FI Sequential Electronic Fuel Injection SEFI Sequental fuel Injection SFI Service Reminer Indicator SRI Check Engine Engine Maintenance Reminder EMR Oxygen Sensor Indicator OXS Service Engine Soon Short term Fuel Trim Short Term FT Integrator
247. ener Transient Mode This function is to provide a limp in mode whenever certain components fail The engine will run but at a set timing and batch fuel delivery This mode will stay in effect until problem is corrected or ignition turned off and back on if an intermittent problem Overspeed Mode If the engine speed exceeds 4000 RPM the ignition and fuel are shut off Ignition key must be recycled to restart engine Electronic Engine Controls Refer to the Electronic Fuel Injection System Diagnostic Service Manual FPP 194 306 or Section 08 of this manual Throttle Position Sensor TP Sensor The throttle position TP sensor is a rotary potentiometer that provides a signal to the ECM that is linearly proportional to the throttle plate shaft position The sensor housing has a three blade electrical connector that may be gold plated The gold plating increases corrosion resistance on terminals and increases connector durability The TP sensor is mounted on the throttle body As the TP sensor is rotated by the throttle shaft four operating conditions are determined by the ECM from the TP sensor Those conditions are closed throttle includes idle or deceleration part throttle includes cruise or moderate acceleration wide open throttle includes maximum acceleration and throttle angle rate AA1841 A Typical TP Sensor ECM Replacement Make sure correct program is installed before replacing ECM To download or upl
248. energized An electrical signal from the Engine Control Module ECM activates the solenoid causing the pintle to move off its seat allowing the fuel to flow through the orifice Atomization of the fuel is obtained by contouring the needle to cause fuel separation MFI injector design prevents lean flow tendencies that are caused by injector tip deposit formations CAUTION Do not apply battery voltage to the injectors during any type of diagnostics MFI Fuel Injector typical 08 18 Auxiliary Systems EFI amp Ignition Electronics INJECTOR ASSEMBLY Continued ECM PIN K 1 PIN S 3 PIN 5 2 PIN 5 1 PIN W 2 PIN Y 3 PIN T 1 361G R ONE CYL 1 CYL 2 CYL 3 555 INJ 1 556 W I Mim INJ 3 INJECTOR VEHICLE HARNESS 560 LG O INJ 6 CONNECTOR SFI gt 558 BR LB TTE FRONT OF ENGINE CYL 4 CYL 5 CYL 6 Single Injector Resistance Specification Table ALL ENGINES 11 0 18 00 08 19 Auxiliary Systems EFI amp Ignition Electronics CRANKSHAFT POSITION SENSOR CKP VARIABLE RELUCTANCE Part Description The Variable Reluctance VR sensor reacts to variations in flux density created by a rotating 36 1 tooth wheel attached to the crankshaft The sensor contains a coil wire a magnet and a pole piece The changing flux field induces an A C voltage to the CKP sensor One A C cycle is generated for each tooth on the wheel Normally a zero dete
249. engine oil pan to the transmission retaining bolts on the right side Install the nuts retaining the exhaust pipe at the exhaust manifolds Install the engine oil pan to the transmission retaining bolts on the left side Install the C torque converter access cover and the B torque converter retaining nuts Turn the A crankshaft to access the retaining nuts studs Install the starter Connect the radiator lower hose INSTALLATION Continued DA0916 A ESG 642 17 18 19 02 131 14 15 16 Install the power steering pump if so equipped 1 Install the pump retaining bolts 2 Connect the low pressure line at the power steering pump 3 Fill pump with appropriate fluid Install the accessory drive belt Install the lower intake manifold Refer to Intake Manifold Lower Install the upper intake manifold Refer to Intake Manifold Upper Install the routing bracket retaining bolt and the engine oil dipstick tube Add the correct amount of oil to the engine and the transmission ESG 642 SPECIFICATIONS General Specifications Mem Specification Number of Cylinders 5 _ Bore mm Inch Stroke mm Inch Spark Plug Motorcraft Gas AGSF 42 FCM 1 12mm 044 in Dual Fuel AGSF 42 FCM 1 12mm 044 in LPG amp NG AGSF 42 FCM 1 12mm 044 in Firing Order 1 4 2 5 3 6 Compression Ratio 9 17 1 Oil Capacity with 5 7 6 0 Oil Filt
250. ensor resistance is lower causing the ECM to monitor a lower voltage DTC 43 will set when the ECM detects an excessively low signal voltage and DTC 33 when the ECM detects an excessively high signal voltage Conditions for Setting the DTC KOEO or CHT sensor signal is less than or equal to 0 22 volts or greater than 4 93 volts Above conditions are present for a least 3 consecutive seconds Actions Taken When the DTC Sets e The ECM will illuminate the malfunction indicator lamp MIL e The ECM will force the CHT sensor to a 50 F default value NOTE Complete list of temperature sensor characteristics found on page 03 30 of this section Conditions for Clearing the DTC Resetting the MIL e The DTC can be cleared from memory by disconnecting the battery for 5 minutes f a personal computer PC is connected to the engine the DTC can be cleared from memory by hitting the C key while in the View Sensor Data screen Diagnostic Aids The CHT sensor shares the same ground with other sensors Check the ground circuit 359 Gray Red if other DTCs are also set Inspect the harness connectors for backed out terminals improper mating broken locks improperly formed or damaged terminals and poor terminal to wire connections Inspect the wiring harness for damage If the harness appears to be OK back probe the CHT sensor connector with a digital voltmeter and observe the voltage while mov
251. ent ECM Is system operation normal with replacemen Remove replacement ECM installed ECM and install original ECM Go to Step 8 5 ete system operation normal with original ECIV 2 Remove original ECM and reinstall Keep original ECM replacement installed Re test Go to Step 9 s the repair complete system operation normal with replacement Leave replacement ECM reinstalled installed Re test 08 61 Auxiliary Systems EFI amp Ignition Electronics Diagnostic Trouble Code 35 NOTES 359E 505 Sensors Intake Air Temperature IAT Sensor Connector 33 42 Pin Connector F Sensor 0 7 Sensor 1 Engine Signal Ground Control Module I DIAGNOSTIC TROUBLE CODE DTC 35 INTAKE AIR TEMPERATURE HIGH VOLTAGE Circuit Description The intake air temperature IAT sensor is a thermistor which measure the temperature of the air entering the engine The ECM supplies a ground circuit 359 Grey Red from the sensor and sends a 5V signal circuit 743 Grey to the sensor When the intake air is cold the sensor resistance is high and the ECM will monitor a high signal voltage at the IAT signal circuit If the intake air is warm the sensor resistance is lower causing the ECM to monitor a lower voltage DTC 35 will set when the ECM detects an excessively high signal voltage on the intake air temperature sensor signal circuit Conditions for Setting the DTC
252. ent Magnet Starter Terminal Cover when relay is energized from ignition switch in crank position to 5 Terminal 12 Volt Battery Supply Terminal D SO Terminal Starter Motor Solenoid M M Terminal Positive Brush Connector 07 10 Auxiliary Systems Starter REMOVAL AND INSTALLATION Switch Relay Solenoid Removal 07 11 Bene WHEN CARRYING OUT MAINTENANCE ON THE STARTER SYSTEM BE AWARE THAT HEAVY GAUGE LEADS ARE CONNECTED DIRECTLY TO THE BATTERY MAKE SURE PROTECTIVE CAPS ARE IN PLACE WHEN MAINTENANCE IS COMPLETE FAILURE TO FOLLOW THIS PROCEDURE MAY RESULT IN PERSONAL INJURY 1 Disconnect the battery ground cable 14301 2 Remove the insulator 3 Disconnect the starter motor solenoid relay switch wires and cables Disconnect the engine control sensor wiring terminal e Remove the starter motor solenoid relay switch terminal nuts e Remove the wiring 4 Remove the starter motor solenoid relay switch 11450 e Remove the bolts e Remove the starter solenoid relay switch Auxiliary Systems Starter REMOVAL AND INSTALLATION Continued Installation AA WARNING WHEN CARRYING OUT MAINTENANCE ON THE STARTER SYSTEM BE AWARE THAT HEAVY GAUGE LEADS OR CONNECTED DIRECTLY TO THE BATTERY MAKE SURE PROTECTIVE CAPS ARE IN PLACE WHEN MAINTENANCE IS COMPLETE FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY 1 Follow the removal procedure in reverse or
253. er L Qt 5 qt Pan 1 qt Filter Oil Pressure Hot 2500 RPM Engine Oil XO 10W30 QSP or DSP 40 125 PSI ESE M2C153 E 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 General Specifications ltem Specification 8 682 8 662 0 3418 0 3410 Valve stem Diameter Exhaust mm Inch Valve Spring Installed 39 8 41 6 Length mm Inch 1 566 1 637 Valve Spring Free Length Intake mm Inch 50 5 1 99 Exhaust mm Inch 50 5 1 99 Valve Gap With Collapsed Tappet mm Inch 2 15 4 69 0 08465 0 18465 Camshaft Specifications Lobe Lift Intake mm Inch 6 22 0 245 6 57 0 259 0 127 0 005 0 127 0 005 Exhaust mm Inch Lobe Wear Limit Intake mm Inch Exhaust mm Inch General Specifications Specification Camshaft Specifications Continued End Play Wear Limit 0 025 0 150 mm Inch 0 001 0 006 0 025 0 015 0 001 0 0006 Runout mm Inch 0 05 0 002 52 108 52 082 2 0515 2 0505 0 025 0 001 Journal to Bearing Clearance mm Inch Journal Diameter mm Inch Out of Round Limit mm Inch Cylinder Block Specifications Head Gasket Surface 152 0 6 00 Flatness per 0 08 0 003 mm Inch Cylinder Bore Diameter Standard mm Inch 96 80 3 81 Out of Round 0 050 0 002 mm Inch Ta
254. er instructions NOTE When instructed to check point timing light on crankshaft pulley and note degree BTDC that pointer is in alignment with TIMING POINTER ROTATION CRANKSHAFT TIMING MARKS NCAUTION There should be no wires spliced to the main wire harness for source of power or RPM signal unless pre approved by Ford Power Products Altering of wire harness may cause lack of power no start or erratic running NOTE Do not use an incandescent test lamp to check CKPS or CKPS circuits The lamp will prevent the circuit from operating 03 18 Auxiliary Systems Ignition PRELIMINARY CHECKS Before using this section perform the MIL DTC Retrieval Procedure and verify all of the following items e The engine control module ECM and the malfunction indicator lamp are operating correctly e There are no DTC s stored Verify the customer complaint and refer to the appropriate symptom chart Perform the procedure included in the symptom chart Visual Physical Check Several of the symptom procedures call for a careful visual physical check This can often lead to repairing a problem without performing unnecessary steps Use the following guidelines when performing a visual physical check Inspect unit for modifications or aftermarket equipment that can contribute to symptom verify that all electrical and mechanical loads or accessory equipment is OFF or disconnected before performing diagno
255. er valve ocated on the fuel rail Used to inspect and relieve fuel pressure Can be replaced Auxiliary Systems Fuel GENERAL PROCEDURES Pressure Relief Special Tool s Fuel Pressure Gauge 310 012 T80L 9974 B _ ST1371 A Special Service Tools called for by the procedures can be obtained by calling 1 800 ROTUNDA 1 800 768 8632 SS 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 SERVICING 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 PERSONAL INJURY OR A FIRE HAZARD 1 Remove the Schrader valve cap and install the Fuel Pressure Gauge waRNING PLACE OR STORE ALL FUEL IN A SUITABLE CONTAINER THAT COMPLIES WITH OSHA REQUIREMENTS AND IS FM APPROVED TO HELP PREVENT FIRES OR EXPLOSION WHICH COULD RESULT IN PERSONAL INJURY 2 Open the manual valve slowly on the Fuel Pressure Gauge and relieve the fuel pressure This will drain some fuel out of the system Auxiliary Systems Fuel GENERAL PROCEDURES Continued Pressure Relief Continued Special Tool s Fuel Storage Tanker
256. erator output greater than the minimum REPLACE generator output specified CHECK FOR OPEN SHORTED FIELD Remove generator REPLACE generator Remove voltage regulator CHECK for worn brushes Measure resistance between the generator slip rings less than 8mm long or Is resistance greater than 10 ohms OR less than 1 open brush leads and ohm REPLACE if required If OK REPLACE voltage regulator PINPOINT TEST B INDICATOR LAMP ON ENGINE RUNNING TEST STEP RESULT gt ACTION TO TAKE m CHECK FOR ORENACIRCUT __ Measure voltage at test point A on the voltage GO to B2 regulator CHECK fuse or fuse link in Is voltage at test point A equal to battery voltage Circuit 36 and REPLACE if required If OK REPAIR EN CHECK FOR SHORTED CIRCUIT open in Circuit 36 Y W Remove three pin voltage regulator connector REPAIR short to ground in Turn key to ON position Circuit 904 LG R Is indicator lamp on GO to B3 CHECK CIRCUIT FUNCTION Install voltage regulator connector REMOVE jumper wire GO e Remove one pin S connector to B4 Connect wiring harness S terminal Circuit 4 W BK to REMOVE jumper wire GO the positive battery post using a jumper wire to B5 Is indicator lamp on 06 8 Auxiliary Systems Charging GENERATOR DIAGNOSIS AND TESTING Continued PINPOINT TEST B INDICATOR LAMP ON ENGINE RUNNING Continued TEST STEP RESULT gt ACTION TO TAKE L
257. ers 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 A rapid recharge procedure has been developed for recharging batteries that only need a quick recharge This can be due to battery in service no start battery failures vehicles will not crank due to low battery state of charge or battery discharged in vehicle 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 Perform a two hour charge using a constant potential automatic setting on charger 06 16 Auxiliary Systems Charging BATTERY MOUNTING AND CABLES Continued Cleaning and Inspection WARNING KEEP OUT OF REACH OF CHILDREN BATTERIES CONTAIN SULFURIC ACI
258. es air temperature information to the ECM The ECM uses the air temperature information as a correction factor in the calculation of fuel spark and mass air flow The IAT sensor provides a quicker temperature change response time than the CHT sensor Ignition Intake Air Temperature IAT Electronic Control Module ECM Outputs Ignition Coil Pack The coil is turned on i e coil charging then turned off by the ECM thus firing two spark plugs at once One is for the cylinder which is to be fired on compression stroke and the other goes to the mating cylinder which is on the exhaust stroke The next time the coil is fired the situation is reversed The next pair of spark plugs will fire according to the engine firing order etc Ignition timing is adjusted constantly by the ECM module Many factors including all the sensor inputs affect the final ignition setting C2 Coil Pack 2 Coil Power B Volts C1 Coil Pack 1 C3 Coil Pack 3 Firing Order 1 4 2 5 3 6 Mating or Companion Cylinder 1 amp 5 3 amp 4 and 2 amp 6 03 12 Auxiliary Systems Ignition DESCRIPTION AND OPERATION ECM Continued Ignition Coil Pack Removal 1 Disconnect the wire harness connector YU1L 12060 AA 2 N CAUTION Spark plug wires must be connected to the proper ignition coil terminal Mark plug wire locations before removing them Squeeze the locking tabs and remove each of the six ignition wires
259. esistance from either slip ring to housing less If still less than 200 ohms than 200 ohms REPLACE generator REPLACE voltage regulator 06 10 Auxiliary Systems Charging GENERATOR DIAGNOSIS AND TESTING Continued PINPOINT TEST E INDICATOR LAMP OFF KEY ON ENGINE NOT RUNNING TEST STEP RESULT ACTION TO TAKE Remove three pin voltage regulator connector Yes B GOtoE2 Turn key to ON position Measure voltage at wiring harness terminal Circuit No B REPAIR open in Circuit 904 904 LG R LG R s voltage greater than O volts EN CHECK FOR BURNED OUT BULB Connect wiring harness terminal Circuit 904 LG R Yes REMOVE jumper wire GO to ground with a jumper wire to E3 Is indicator lamp on No REPLACE bulb or REPAIR high resistance in bulb socket or Circuit 904 LG R CHECK FOR POOR GROUNDS Check for poor ground connections between voltage GO to E4 regulator and generator generator and engine or engine and battery Are all ground connections clean and tight CLEAN or REPAIR grounds as required CHECK S CIRCUIT WIRING Remove one pin S connector from generator SERVICE Circuit 4 W BK Measure voltage at wiring harness S terminal Circuit 4 Circuit should be hot only W BK when engine is running 15 voltage greater than 0 volts CHECK for swapped wires in voltage regulator connector GO to E5 EB CHECK FOR SHORTED RECTIFIER Measure voltage at the
260. ess XU1L 12A690 BA to 14324 570Ed2 sas 3eAd6 297 50 151 20 27809 32016 3518 20 gt 658202 78706 91420 15527 209 50 gt m 39 20 30620 10720 570 12 POWER KEY DN NOT USED 04 NOT USED i NOT USED NUT USED NOT USED NOT USED FUEL PUMP SPLICE 2 16 R LG m a 787 PK BK 16 37B Y 18 A m D lt m U td A m lt NOT USED NDT USED NOT USED 11 T Y 20 USED 8 NOT USED USED 570 BK W 12 570 BK W 12 VPWR BATTERY 109 37 Y 12 CUSTOMER WATER TEMP 16 139 R W 18 NUT USED 1 1 1 1 140 NOT USED 1 44 DATA 2e 107 P 20 DRIVE BY WIRE SIGNAL INPUT 14 151 LB BK 20 SELF TEST 18 209 20 306 T LB 20 307 BK Y 20 MALFUNCTION INDICATOR LAMP 06 658 PK LG 20 FUEL SELECT _________ 07 72 Y EK 20 914 20 DATA LINK CONNECTOR lt gt 915 PK LB 20 STARTER IN FROM SWITCH 32A R LB 16 p DRIVE BY WIRE SIGNAL RETURN 359A GY R 20 1 22222 22 T MEM MI p o 32 R LB 16 31 W R 20 03 50 Auxiliary Systems Ignition ECM CONNECTORS From Wire Harness XU1L 12A690 BA to ECM 12034398 151620 358020 35520 1102 18 SPLICE 17 743418 25 20 gt 7408 349 DB 20 CRANKSHAFT SENSOR RETURN 4 350 GY eo He CRAN
261. ession leakage at valve seat e Seized valve stem e Weak or broken valve spring Damaged cylinder head gasket Cracked or distorted cylinder head Damaged worn or sticking piston ring s e Worn or damaged piston Malfunctioning or damaged fuel system Malfunctioning or damaged ignition system e Damaged or plugged exhaust Action e REPLACE hydraulic valve tappet or hydraulic lash adjuster REPLACE hydraulic valve tappet guide or hydraulic lash adjuster e REPAIR or REPLACE valve valve seat or cylinder head e REPLACE valve stem e REPLACE valve spring e REPLACE cylinder head gasket e REPLACE cylinder head e REPAIR OR REPLACE piston ring s e REPLACE piston e Refer to Section 04 e Refer to Section 03 e REPAIR OR REPLACE system Component Tests 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 6582 oil pan 6675 and flywheel 6375 with a suitable solvent to remove all traces of oil Fluorescent Oil Additive Method Use the 12 Volt Master UV Diagnostic Inspection Kit to perform the following procedure for oil leak diagnosis 1 Clean the engine with a suitable solvent to remove all traces of oil exhaust system 2 Drain engine oil crankcase and refill with recomme
262. exhaust gas oxygen 25 Sensors NOTE There may only be one HO2S sensor depending upon application Install the engine mounts ESG 642 ASSEMBLY Continued 42 Remove the engine from the stand and install the rear oil seal A seal installer will be required DA0773 A 43 Install the rear cover plate and flywheel 73 87 Nm 54 64 Ib ft 0 0776 02 128 ESG 642 INSTALLATION Engine Special Tool s Engine Lifting Bracket 014 00730 or Equivalent Special Service Tools called for by the procedures can be obtained by calling 1 800 ROTUNDA 1 800 768 8632 Installation 1 Install the engine 2 Install the transmission or PTO to engine retaining bolts if so equipped 3 Install the transmission dipstick tube Use a new O ring Lubricate O ring with WSE M2C908 A oil prior to installation 4 Remove the engine lifting equipment DA0399 A 5 Raise the vehicle 6 Install the engine mount retaining nuts Left as shown 7 Install the shift cable routing bracket retaining bolt if so equipped 1 Position the wiring harness and engage the routing clips 2 Connect the wiring at the daytime running lamp module if so equipped DAO220 A 3 Connect the wiring at the horn if so equipped 4 Connect the wiring at the front air bag sensor if so equipped 02 129 INSTALLATION Continued ESG 642 02 130 10 11 Install the
263. ey 10344 Circuit Description Battery Positive Voltage B Output The generator output circuit 38 BK O is supplied through the battery positive voltage B output connection to the battery and electrical system The B circuit is hot at all times This circuit is protected by a 12 gage fuse link Circuit The I circuit or ignition switch 11572 circuit 904 LG R is used to turn on the voltage regulator This circuit is closed with the ignition switch in the RUN position This circuit is also used to turn the charge indicator lamp on if there is a fault in the charging system operation or associated wiring circuits A Circuit N CAUTION The A circuit is electrically hot at all times The A circuit or battery sense circuit circuit 36 YAN is used to sense the battery voltage This voltage is used by the voltage regulator to determine the output This circuit is also used to supply power to the field coil This circuit is protected by a 15 amp fuse in the power distribution box or a fuse link 6 Circuit The S circuit or stator circuit circuit 4 W BK is used to feed back a voltage signal from the generator to the voltage regulator This voltage typically 1 2 battery voltage when the generator is operating is used by the voltage regulator to turn off the charge indicator lamp INTEGRAL GENERATOR REGULATOR STATOR Mo GA m m VOLTAGE REGULATOR is
264. f OK come back to Step 4 Go to Step 4 Remove replacement relay and install original relay Go to Step 7 Remove replacement relay and install original relay Go to Step 5 Keep original power relay installed verify repair and Go to MIL DTC retrieval procedure if required Remove original relay and reinstall replacement relay Go to Step 6 03 42 Auxiliary Systems Ignition ENGINE CRANKS BUT DOESN T START CIRCUIT TEST Continued y 7 O Does engine run once again with replacement relay Leave installed replacement relay installed verify repair and Go to MIL DTC retrieval procedure if required Go to Step 7 Hemove replacement relay and install original relay Go to Step 8 Check the Fuel Pump relay for proper connection If no problem is found replace the relay with a known good relay Does engine run Hemove replacement relay and install original relay Keep original relay installed verify repair and Go to MIL DTC retrieval procedure if required Step mE Does engine run once again with replacement relay Leave installed replacement relay installed 9 Verify repair Go to MIL DTC retrieval procedure if required 1 Ignition ON 2 Remove ECM relay and Fuel Pump relay from connectors 10 3 Use a grounded test lamp to verify that B is available at the ECM relay and Fuel Pump relay connectors Was available at both connectors Go to Step 1
265. f the ECM does not receive a HPM signal indicating the engine is running within 1 second the ground on the control pin will be removed and the fuel pump will turn off The Fuel Pump Monitor FPM circuit is wired into the fuel pump circuit and allows the ECM to monitor failures in the secondary circuit Not Used 926A 37 961A 787A FP Relay typical Auxiliary Systems EFI amp Ignition Electronics FUEL PUMP RELAY Continued Hot In Nos at Hot Start or Run B ED in Start Resistor Wire Hot at All Times B 1 Fuel 4 Power Relay Relay 5 2 Self Test Fuel Connector Pump FPM 258 mE 1 Not Used 2 926A T Em 3 37C 4 361A 5 787A 42 PIN PIN 09 PIN 05 787 16 926A LB O 16 361A R 16 08 23 ECM SPECIFICATIONS Auxiliary Systems EFI amp Ignition Electronics Torque Specifications Description Nm Air Intake Sensor 840 Camshaft Position Sensor Bolts 2 2 3 3 5 Camshaft Synchronizer Bolt 1 20 30 15 22 Crankshaft Position Sensor Engine Control Module Mounting Bolts Engine Control Module Wire Connector 8 2 5 Non Ford Use OEM Foot Pedal Mounting Bolts Heated Oxygen Sensor Idle Air Control IAC Valve Ignition Coil Nuts and Stud Bolt Ignition Control Module Mounting Bolts 8 10 2 4 9 11 Cylinder Head Temperature Se
266. f this Manual Low compression Leaking cylinder head gasket Worn camshaft Incorrect valve timing Sticking or leaking valves Camshaft drive chain worn slipped or stripped Was a problem found Verify repair Go to Step 9 Check the intake and exhaust manifold s for casting flash Was a problem found Verify repair Go to Step 10 1 Review all the diagnostic procedures within this table 2 If all procedures have been completed and no malfunctions have been found review inspect the 10 following Contact Ford Visual physical inspection including fuel quality Power Products check Customer All electrical connections within a suspected Service Center circuit and or system Technical Was a problem found Verify repair Support Hotline 1 800 521 0370 03 30 Auxiliary Systems Ignition HESITATION SAG STUMBLE SYMPTOM Value s Yes DEFINITION Momentary lack of response as the throttle is opened Can occur at any engine speed Usually most pronounced when first trying to accelerate the engine May cause the engine to stall if severe enough Was a check performed Go to Visual Physical Go to Step 2 Check Refer to DTC chart perform component and circuit test as required Go to Step 3 NOTE Make sure engine is closed loop before proceeding Check the heated oxygen sensor HO2S operation page 03 26 of this section The HO2S should respond quickly to different throttle positions
267. g 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 swallowing 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 substan
268. ge at the CHT signal circuit If the cylinder head is warm the sensor resistance is lower causing the ECM to monitor a lower voltage DTC 33 will set when the ECM detects an excessively low signal voltage on the engine cylinder head temperature sensor signal circuit Conditions for Setting the DTC KOEO or CHT sensor signal is lt 0 22V Above conditions are present for a least 3 consecutive seconds Actions Taken When the DTC Sets MIL blinks at 230 F 36V The ECM will force the ECT sensor to a 50 F default value e The ECM illuminates the malfunction indicator lamp MIL when temperature reaches 240 F 0 32V and will shut engine down if software selected 08 60 Auxiliary Systems EFI amp Ignition Electronics Diagnostic Trouble Code 33 Diagnostic Aids ECT CHT IAT amp MST Sensors The CHT sensor shares the same ground with the T ture vs Ohm or Volts Values approx Manifold Absolute Pressure MAP sensor and the saa X aba Intake Air Temperature IAT sensor Check the 100 A7 ground circuit 359 Grey Red Green if these DTC s 79 are also set 140 1 34 Inspect the harness connectors for backed out Eus terminals improper mating broken locks improperly 2 39 formed or damaged terminals and poor terminal to 2 86 wire connections Inspect the wiring harness for 3 32 damage If the harness appears to be OK backprobe 3 71 the CHT sensor connector with a digital voltmeter i
269. ge the spark plug routing clips at the valve cover studs ESG 642 ENGINE REPAIR Continued 3 Remove the valve cover bolts and the valve cover 4 Inspect the valve cover gasket Replace if necessary 02 33 ESG 642 ENGINE REPAIR Continued Valve Cover LH Installation 1 Follow the removal procedure in reverse order DA0902 A 02 34 ESG 642 ENGINE REPAIR Continued Valve Cover RH Removal 1 Pull the PCV valve out of the valve cover DA0904 A 02 35 ESG 642 ENGINE REPAIR Continued 2 Disconnect the vacuum supply line at the intake manifold 3 Remove the transmission support bracket retaining nut and pull the bracket away from the stud if equipped DAOQ906 A 02 36 ESG 642 ENGINE REPAIR Continued 4 Remove the spark plug routing clips at the valve cover studs 5 Remove the ignition coil pack Refer to procedures in Section 3 02 37 ESG 642 ENGINE REPAIR Continued 6 Remove the retaining bolts and the valve cover The gasket is removed with the cover DA0911 A 02 38 ESG 642 ENGINE REPAIR Continued Valve Cover RH Installation 1 Install the valve cover Make sure the gasket is serviceable Replace if necessary Follow the removal procedure in reverse order Torque 8 12 Nm 71 106 Ib in 5 bolts 2 Install the ignition coil pack Refer to procedures in Section 3 Torque to 5 6 Nm 48 Ib in 3 bolts Valve Spri
270. gnostic System Check before continuing at Step 2 Go to Step 2 1 KOEO Check the 5V reference signal from the ECM 2 Check the voltage between terminals A and C on the APP sensor Is the voltage within the specified values 4 9 5 1V Go to Step 3 Go to Step 6 1 KOEO Check the APP sensor signal to the ECM 2 Start the engine 3 Using a DVOM to pins A and B of the three wire pigtail on the APP check voltage While observing the voltage reading step down on the AP and operate the engine throughout the widest available range of speeds ideally from idle to WOT NOTE If a PC is available you can observe AP voltage on the engine data screen instead of using a DVOM Approx 1V 4 Shutthe engine off at idle to 4 8V Does the voltage vary between the specified values Go to Step 8 Go to Step 4 1 Disconnect ECM connector A thru Repair the wiring Re test Go to Sfep 5 Repair the terminal Re test Go to Step 6 2 Disconnect the AP sensor connector 3 Check for shorts or opens on circuit 355 355B 351B 151 between the APP sensor connector and the ECM connector Were any shorts or opens found Check circuit 355 351B 151 and 359A 359 for a poor terminal connection at the ECM amp 42 Pin Connector Does the terminal need to be replaced Remove replacement ECM and install original ECM Go to Step 10 Install replacement ECM 7 5 system operation normal with replacement ECM installation Is the
271. haft from front of engine W70 POWER STEERING Pulley Rotation Installation 1 Toinstall reverse the removal procedure Refer to component locations for drive belt routing 05 13 Auxiliary Systems Cooling REMOVAL AND INSTALLATION Belt Tensioner Removal 1 Remove the drive belt 8620 For additional information refer to Belt in this section 2 Remove the belt tensioner 1 Remove the bolt 2 Remove the belt tensioner Installation 1 To install reverse the removal procedure 05 14 Auxiliary Systems Cooling REMOVAL AND INSTALLATION Continued Belt Idler Pulley Removal 1 Remove the drive belt 8620 off of the belt idler pulley 8678 For additional information refer to Belt in this section 2 NOTE The belt idler pulley shown is for a vehicle with air conitioning the belt idler pulley for a vehicle without air conditioning is ribbed Remove the bolt and the belt idler pulley Installation 1 To install reverse the removal procedure 47 83 Nm OM 48 Ib ft 05 15 Auxiliary Systems Cooling REMOVAL AND INSTALLATION Continued Block Heater Removal 1 Disconnect battery ground cable 2 Drain the cooling system For additional information refer to Draining in this section 3 Disconnect the A block heater wire extension 6B019 from the B block heater wiring 6B018 and remove 4 Raise and support the vehicle 5 Disconnect th
272. he engine sealing surfaces Take added care to prevent scratching or gouging aluminum sealing surfaces Serial Number 01234 1 05 98 Power Number ESG 642 6007 AA ase Engine Code uild Date 05 28 1998 istributor 5 FORD POWER PRODUCTS Prior 2001 Serial Number 37827 1 04 98 Prod i Model Number ESG 642 Base Engine Code Base Engine Build Date 6C 276 AA 01 02 2001 Distr utor S O Numb er a Engine Identification Nameplate For quick engine identification refer to the Engine Identification Nameplate The nameplates lists engine information required for proper servicing of the engine The Engine Identification Nameplate and identification label provide information pertaining to engine displacement serial number model number S O Options and model code ENGINE CODE ENGINE PLANT CODE SG612AB J MADE IN ESSEX CANADA 11 07 99 ESSEX Engine Code Decal An engine code decal is attached to the engine front cover The symbol code on the decal identifies each engine for determining parts usage 01 3 ESG 642 ESG 642 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
273. he wear limit DA0366 A 01 37 ESG 642 GENERAL SERVICE PROCEDURES Continued Connecting Rod Cleaning CAUTION Do not use a caustic cleaning solution or damage to connecting rods can occur 1 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 Mark and separate the parts and clean with solvent Clean the oil passages A25409 A 1 Measure the bore in two directions The difference is the connecting rod bore out of round Verify the out of round is within specification A CAUTION The connecting rod bolts are torque to yield and must be discarded and replaced after this diagnostic test 0368 01 38 ESG 642 GENERAL SERVICE PROCEDURES Continued Piston Pin Diameter 1 Measure the piston pin diameter in two directions at the points shown Verify the diameter is within specifications DA0367 A Connecting Rod Bushing Diameter 1 Measure the inner diameter of the connecting rod bushing Verify the diameter is within specification DA0370 A 01 39 Connecting Rod Bend ESG 642 GENERAL SERVICE PROCEDURES Continued DA0369 A 0371 01 40 Measure the connecting rod bend on a suitable alignment fixture Follow the instructions of the fixture manufacturer Verify the bend measurement is within specification Measure the connecting rod twist on a suitable al
274. hed 600 RPM Will not allow start until ignition voltage to module is switched off and back on Tachometer Output Tachometer output will be from auxiliary output 2 which is accessed through the five pin connector terminal E The pulses per revolution will be determined by the number of cylinders the ICM will control The four cylinder ICM will output 2 pulses per revolution the six cylinder ICM output 3 pulses per revolution the eight cylinder output 4 pulses per revolution and the ten cylinder 5 pulses per revolution The intention of this is to allow for use of a conventional tachometer from this output Ignition Control Module ICM 5 Pin Auxiliary Connector Round 10 Pin Main Connector Oblong Ignition Control Module Vacuum Port 5 32 1 0 MAP Sensor OOG 03 14 Auxiliary Systems Ignition DESCRIPTION AND OPERATION ICM Continued TABLE 1 Input Output Function Battery Power Vgt V Main Pin G Crankshaft position sensor Main Pins A B Coil Drivers main Pins C J K Octane select 1 analog States Open Ground or V Main Pin F Octane select 2 analog Stages Open Ground or V Main Pin E Engine Coolant Temperature or Cylinder Head Temperature Sensor analog Main Pin D Oil pressure input digital States open ground Aux Pin C Aux input 1 analog States Ground V or float Aux Pin A input 2 analog Pin B output 1 open drain
275. how whether the fuel system is the cause of the problem Fuel line fitting connections at pump are Repair or replace as needed Replace pump Inspect all monting or wiring Replace fuel pump relay Replace injector Replace pressure regulator Replace fuel line and tighten fittings apply a sealer if necessary Tighten and clean all connections at pump Flooding When flooding occurs disconnect power to fuel pump relay and start engine When engine stops re connect relay and re start engine Hard Starting Dripping fuel injectors blocked air intake passage low fuel volume or pressure Repair adjust or replace components as necessary Stalling Improper air fuel supply IAC malfunctioning or an idle speed set too low causes an engine to stall NOTE Idle speed is set by using a computer Refer to Diagnostic Manual Correct these systems as necessary The stalling problem may be due to a loose throttle shaft in the bore of the throttle body Repair as necessary Throttle body icing 7 2 C 45 F and lower is also a cause of stalling Rough Idle An improper air fuel supply can cause rough idle Adjust repair or replace Surging Above Idle Surging above idle may be caused by a fuel pressure too low due to faulty cylinder head temperature sensor CHTS or faulty fuel pressure regulator restricted fuel passages faulty fuel pump governors or ECM Adjust clean or replace as ne
276. iagnostic Check before continuing at Step 2 Go to pec 2 Check the MIL or the PC engine data screen Are any other DTC s set le to applicable DTC Go to Goto steps 3 Install replacement ECM Remove replacement Is system operation normal with replacement ECM installed ECM and install original ECM Go at Step 4 Is the repair complete system operation normal with original ECM Remove original reinstalled ECM and reinstall Keep original ECM replacement ECM installed Re test Go to Step 5 Is the repair complete system operation normal with replacement ECM Leave replacement ECM reinstalled installed Re test 08 83 Auxiliary Systems EFI amp Ignition Electronics Diagnostic Trouble Code 56 DIAGNOSTIC TROUBLE CODE 56 ECM FAULT COMPUTER OPERATING PROPERLY COP FAILURE Circuit Description The ECM continuously monitors electrical signals form the engine Under normal operation the ECM will store numbers into memory If this does not happen the ECM will execute an exception handling routine and rest itself from the beginning This is a watch dog timer function If DTC 56 is set the ECM will have to be replaced Conditions for Setting the DTC KOEO or Action Taken When the DTC Sets ECM will illuminate the malfunction indicator lamp MIL Diagnostic Aids Inspect the harness connectors for backed out terminals improper mating broken locks improperly form
277. ignment fixture Follow the instructions of the fixture manufacturer Verify the measurement is within specification ESG 642 GENERAL SERVICE PROCEDURES Continued Connecting Rod Piston Pin Side Clearance 1 Measure the clearance between the connecting rod and the piston Verify the measurement is within specification DA0372 A Connecting Rod Journal Clearance Special Tool s Plastigage 9 D81L 6002 B or Equivalent Special Service Tools called for by the procedures can be obtained by calling 1 800 ROTUNDA 1 800 768 8632 NOTE The crankshaft connecting rod journals must be within specifications to check the connecting rod bearing journal clearances 1 Remove the connecting rod bearing cap 2 Position a piece of Plastigag across the bearing surface A CAUTION The connecting rod bolts are A26377 A torque to yield and must be discarded and replaced after this diagnostic test 01 41 ESG 642 GENERAL SERVICE PROCEDURES Continued 3 NOTE Do not turn the crankshaft during this step Install and torque to specifications then remove the connecting rod bearing cap 4 Measure the Plastigage to get the connecting rod bearing journal clearance The Plastigage should be smooth and flat A change width indicates a tapered or damaged connecting rod bearing or connecting rod DA0373 A Bearing Inspection 1 Inspect bearings for the following defects Possible causes are shown Cratering
278. in Bearing Cap Assy 6 Req d 6337 Crankshaft Thrust Main Bearing 02 10 ESG 642 DESCRIPTION AND OPERATION Continued Engine Disassembled View Continued 0 0617 Part Number Description 1 6N867 Engine Oil Cooler Inlet Tube and Hose 2 6N866 Engine Oil Cooler Outlet Tube and Hose Part Number Description 9 18663 Heater Water Return Tube 6020 Engine Front Cover Gasket 11 6K342 Crankshaft Position Sensor Upper Shield 6010 Cylinder Block 8507 Water Pump Housing Gasket 6 12A112 Camshaft Position Sensor 12A362 Camshaft Synchronizer 8 6A618 Oil Pump Intermediate Shaft 02 11 ESG 642 DESCRIPTION AND OPERATION Continued The engine dynamic balance shaft 6A311 is driven by a camshaft gear and rotates in an opposite direction of the crankshaft 6303 to reduce vibration The large end of the connecting rod is mechanically split to produce a unique parting face This produces a locking joint Connecting rods 6200 and connecting rod caps are not interchangeable DIAGNOSIS AND TESTING Engine For basic engine mechanical concerns refer to Section 01 For driveability concerns refer to Ignition Section 03 ENGINE REPAIR Intake Manifold Upper Removal 1 Remove the air cleaner assembly 2 Remove the engine cover 3 Disconnect the following at the throttle body 1 Accelerator cable 2 Speed control cable if so equipped T
279. in a range of about 1 volt if the exhaust is rich down through about O 10 volts if the exhaust is lean A cold sensor causes an open loop operation If the senor pigtail wiring connector or terminal is damaged the entire oxygen sensor assembly must be replaced Do not attempt to repair the wiring connector or terminals In order for the sensor to function properly it must have a clean air reference provided to it This clean air reference is obtained by way of the signal return wire Any attempt to repair the wires connector or terminals could result in the obstruction of the air reference and degrade the sensor performance Conditions for Setting the DTC HO2S sensor voltage is greater than or equal to 0 65 volts or less than or equal to 0 20 volts for 20 consecutive seconds Action Taken When the DTC Sets e The ECM will illuminate the malfunction indicator lamp MIL The ECM will switch to open loop fuel control Conditions for Clearing the DTC Resetting the MIL e The DTC can be cleared from memory by disconnecting the battery for 5 minutes f a personal computer PC is connected to the engine the DTC can be cleared from memory by hitting the C key while in the View Sensor Data screen EXHAUST GAS OXYGEN HO2S SENSOR D A Lean Air Fuel Rich Air Fuel Mixture Mixture Stoichiometry Describe Heated exhaust gas oxygen HO2S sensor
280. 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 particuar 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 IN GENERAL WARNINGS TO HELP AVOID INJURY ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION USE SAFETY STANDS WHENEVER A PROCEDURE REQUIRES YOU TO BE UNDER THE EQUIPMENT SURE THAT THE IGNITION SWITCH IS ALWAYS IN THE OFF POSITION UNLESS OTHERWISE REQUIRED BY THE PROCEDURE SET THE PARKING BRAKE IF EQUIPPED WHEN WORKING ON THE EQUIPMENT IF YOU HAVE AN AUTOMATIC TRANSMISSION SET IT IN PARK ENGINE OFF OR NEUTRAL ENGINE ON UNLESS INSTRUCTED OTHERWISE FOR A SPECIFIC OPERATION PLACE WOOD BLOCKS 4 X 4 OR LARGER TO THE FRONT AND REAR SURFACES OF THE TIRES TO PROVIDE FURTHER RESTRAINT FROM INADVERTENT EQUIPMENT MOVEMENT OPERATE THE ENGINE ONLY IN A WELL VENTILATED AREA TO AVOID THE DANGER OF CARBON MONOXIDE KEEP YOURSELF AND YOU
281. increased the back pressure caused by a clogged muffler kinked tail pipe or other concerns will cause the needle to slowly drop to 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 2005 the unit will not function correctly Always fix vacuum leaks Excessive Engine Oil Consumption The amount of oil an engine uses will vary with the way the vehicle is driven in addition to normal engine to engine variation This is especially true during the first 340 hours or 16 100 km 10 000 miles when a new engine is being broken in or until certain internal engine components become conditioned Vehicles used in heavy duty operation may use more oil The following are examples of heavy duty operation severe loading applications sustained high speed operation Engines need oil to lubricate the following internal components e cylinder block cylinder walls pistons piston pins and rings 6102 e intake and exhaust valve stems e intake and exhaust valve guides all internal engine components When the pistons move downward a thin film of oil
282. inder block core plug and bore lightly with Threadlock 262 E2FZ 19554 B or equivalent meeting Ford specification WSK M2G351 A6 and install the cylinder block core plug 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 1 Use a fabricated tool to seat the cup type cylinder block core plug 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 1 Usea fabricated tool to seat the expansion type cylinder block core plug 01 56 ESG 642 GENERAL SERVICE PROCEDURES Continued Spark Plug Thread Repair Special Tool s e 4 571281 Tapersert Installation Kit 107 R0921 or Equivalent Special Service Tools called for by the procedures can be obtained by calling Feeler Gauge 1 800 ROTUNDA 1 800 768 8632 D81L 4201 A or Equivalent A 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 A CAUTION Do not use power or air driven tools for finishing taperserts NOTE This repair is permanent and will hav
283. ing at Step 2 Go to Step 2 1 KOEO Check the 5V reference signal from the ECM 2 Check the voltage between terminals A and C on the APP sensor Is the voltage within the specified values 4 9 5 1V Go to Step 3 Go to Step 6 1 KOEO Check the APP sensor signal to the ECM 2 Start the engine 3 Using a DVOM to pins A and B of the three wire pigtail on the APP check voltage While observing the voltage reading step down on the AP and operate the engine throughout the widest available range of speeds ideally from idle to WOT NOTE If a PC is available you can observe AP voltage on the engine data screen instead of using a DVOM Approx 1V 4 Shutthe engine off at idle to 4 8V Does the voltage vary between the specified values at WOT Go to Step 8 Go to Step 4 1 Disconnect ECM connector A thru Repair the wiring Re test Go to Step 5 2 Disconnect the AP sensor connector 3 Check for shorts or opens on circuit 355 355B 351B 151 between the mu Repair the terminal EMIT Replace the AP assembly 1 Clear code Install original AP 2 Retest Did code reset EM atthe ECM amp 42 Pin Connector Does the terminal need to be replaced APP sensor connector and the ECM connector Install replacement ECM Remove replacement 1 Is system operation normal with replacement ECM installation Were any shorts or opens found Check circuit 355 351B 151 and 359A 359 for a poor terminal connection ECM and insta
284. ing connectors and wiring harnesses related to the CHT sensor A change in the voltmeter display will indicate the location of the fault NOTE Refer to Section 08 03 37 Auxiliary Systems Ignition IGNITION SYSTEM DIAGNOSING AND TESTING Continued INTAKE AIR TEMPERATURE IAT SENSOR CIRCUIT AIR CHARGE DIAGNOSTIC TROUBLE CODE DTC 35 45 Intake Air Temperature Engine Control Sensor IAT Connector Module ECM MAP and ECT Sensors E Sensor Ground 42 Pin Connector F ze Sensor Signal Circuit Description The intake air temperature IAT sensor is a thermistor which measure the temperature of the air entering the engine The ECM supplies a ground circuit 359 Gray Red to the sensor and receives a voltage signal circuit 743 Gray from the sensor When the intake air is cold the sensor resistance is high and the ECM will monitor a high signal voltage at the IAT signal circuit If the intake air is warm the sensor resistance is lower causing the ECM to monitor a lower voltage DTC 35 will set when the ECM detects an excessively high signal voltage and DTC 45 for excessively low signal voltage on the intake air temperature sensor signal circuit Conditions for Setting the DTC e DIC 35 0 12V for 2 64 sec e DIC 45 4 96V for 2 64 sec Actions Taken When the DTC Sets e The ECM will illuminate the malfunction indicator lamp MIL e The ECM will force the ECT sensor to a 50 F default value
285. ing dots represent increasing May also have blue finish or paint daub on hex strength flat Increasing numbers represent increasing strength 09 4 Auxiliary Systems Metrics METRICS Continued Other Types of Parts Metric identification schemes vary by type of part most often a variation of that used of bolts and nuts Note that many types of English and Metric fasteners carry no special identification if they are otherwise Stamped U Nuts P 6 7 N f CLASS CLASS CLASS N N 10 9 9 8 8 8 Az Studs Large studs may carry the property class Tapping thread forming and certain number Smaller studs use a geometric code on other case hardened screws the end 09 5 Auxiliary Systems Metrics METRICS Continued English Metric Conversion Acceleration Us 03048 ms J iis 00254 me O t 1358 Nm Power hosepwr 0746 kW __ Pressure or Stress inchesofwatr 024931 kPa psi 685 o oo o y y y O psi 1 1 009 J br Energy or Work 10550 Joes b t 1358 Jodes or 3 6 x 10 liters kilometer L km Length inch 254 fot 5 08 J X oyad 1 09144 mie 10 kn J 7 mm susc square ft 2 Volume cubic inch in cm uart cubicyard 07646 m ton 978 _ 987 CE N
286. ion and Verification 3 If the inspection reveals an obvious concern that can be readily identified repair as 1 Verify the customer s concern by operating the necessary engine to duplicate the condition 4 f the concern remains after the inspection determine the symptom s and go to the Symptom Chart 2 Inspect to determine if any of the following mechanical or electrical concerns apply Symptom Chart Possible Source Loss of Coolant Radiator GO to Pinpoint Test A e Water pump seal Radiator hoses Heater hoses tubes Heater core e Engine gaskets Degas bottle e The Engine Overheats e Water thermostat GO to Pinpoint Test B e Water pump e Internal engine coolant leak Radiator e Heater core e Cooling fan e Pressure relief cap Normal Operating Temperature The Block Heater 6 051 Block heater power cable GO to Pinpoint Test D Does Not Operate Properly 05 22 Auxiliary Systems Cooling COOLING SYSTEM DIAGNOSING AND TESTING Continued Pinpoint Tests PINPOINT TEST A LOSS OF COOLANT TEST CONDITIONS TEST DETAILS RESULTS ACTIONS A1 CHECK THE ENGINE COOLANT LEVEL NOTE Allow the engine to cool before checking the engine coolant level Visually check the engine coolant level at the degas bottle 5 the engine coolant level within specification Yes GO to A2 No REFILL the engine coolant as necessary GO to A6
287. ion to the engine control module used to calculate fuel delivery The cylinder heat temperature CHT sensor 15 mounted into the back of the cylinder head and is not connected to any coolant passages e Sends a signal to the engine control module indicating the cylinder head temperature The manifold skin temperature sensor MST sensor e Sends the engine control module a signal indicating the temperature of the outer skin of the intake manifold e Resistance decreases as temperature increases Auxiliary Systems Ignition DESCRIPTION AND OPERATION ECM Continued The Fuel Select Switch In the event that the engine is operated on alternate fuels such as natural gas compressed natural gas CNG or liquefied petroleum gas LPG timing can be modified with a Fuel Select Switch NOTE Fuel select switch is supplied by customer e Sends a signal to the ECM to adjust base timing for alternate fuel 5 manually controlled With this system the ECM monitors the engine load speed operating temperature air intake temperature oxygen in exhaust for emissions and throttle position 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 s
288. ir Cleaner Housing Cover ACL Housing Cover Air Conditioning Air Conditioning AC Air Conditioning Clutch A C Clutch Air Conditioning Clutch ACC Air Conitioning Cycling Switch A C Cycling Switch Air Conditioning Cycling Switch ACCS Air Conditioning Sensor A C Sensor Air Conditioning Sensor A C Sensor Air Conditioning System SCS Air Conditioning System Automatic Transaxle Electronic Automatic Transaxle EATX Electronic Automatic Transmission Automatic Transmission EATX Barometric Pressure BARO Barometric Pressure BARO Barometric Pressure Sensor BARO Sensor Absolute Pressure Sensor APS Barometric Pressure Sensor BP Sensor Battery Positive Voltage Camshaft Position Battery Positive Voltage B CMP Snyc Pickup CMP Sensor Camshaft Position Sensor CPS Camshaft Sensor Cylinder Identification Sensor Cylinder ID Sensor CID Canister CARB Feed Back Carburetor FBC Central MFI Central Multiport Fuel Injection CMFI Fuel Injection FI Charge Air Cooler CAC After Cooler Closed Loop Closed Throttle Position CTP Closed Throttle Position Switch CTP Switch Clutch Pedal Position CPP CPP Switch Clutch Engage Switch CES Clutch Start Switch Clutch Switch Compact Disc Read Only Memory CDROM Compact Disc Read Only Memory CDROM gt
289. is a Zirconium dioxide type voltage generating sensor that converts oxygen levels in exhaust to a voltage signal eThe HO2S sensor switches between approximately 0 10 and one volt In lean conditions the HO2S sensor generates a low voltage signal of less than 0 4 volts In rich conditions the HO2S sensor generates a high voltage signal greater than 0 6 volts e The ECM uses this input to determine if the air fuel mixture is lean or rich e The HO2S sensor does not operate until it reaches an operating temperature between 300 850 C 572 1562 F e HO2S sensors are equipped with a heating element and begin operating at lower exhaust temperatures 03 36 Auxiliary Systems Ignition IGNITION SYSTEM DIAGNOSING AND TESTING Continued ENGINE CYLINDER HEAD TEMPERATURE SENSOR CHT DIAGNOSTIC TROUBLE CODE DTC 33 43 Engine Cylinder Head Temperature Sensor D Sensor Ground Connector Ground B Engine Control Module ECM Circuit Description E Sensor Signal The engine cylinder head temperature CHT sensor is a termistor which measures the temperature of the engine cylinder head The ECM supplies a ground circuit 359 Gray Red from the sensor and monitors a voltage signal circuit to 1102 Yellow Lt Green to the sensor When the engine coolant is cold the sensor resistance is high and the ECM will monitor a high signal voltage at the CHT signal circuit If the engine cylinder head is warm the s
290. is set the engine may shut down It can be restarted but will shut down again as long as the code is present DTC 12 Throttle Position Sensor Low Voltage Are you using a personal computer PC to perform this diagnosis Go to Diagnostic System Check before continuing at Step 2 Go to Step 2 1 KOEO Check the 5V reference signal from the ECM 2 Check the voltage between terminals A and C on the electronic governor Is the voltage within the specified values 4 9 5 1V Go to Step 3 Go to Step 6 1 KOEO Check the TP signal to the ECM Approx 1V atidle to 4 8V Go to Step 4 Go to Step 8 2 Using a DVOM to pins A and B of the three wire pigtail on the electronic governor While observing the voltage reading operate the engine throughout the widest available range of speeds ideally from idle to WOT NOTE If a PC is available you can observe TP voltage on the engine data screen instead of using a DVOM Does the voltage vary between the specified values Disconnect ECM connector A thru 2 Disconnect the TP sensor connector 3 Check for shorts or opens on circuit 355 between the TP sensor connector and the ECM connector Were any shorts or opens found heck circuit 355 for a poor terminal connection at the ECM Does the terminal need to be replaced 1 Disconnect ECM connector A thru 2 Check for a short or open on circuits 351D and 359F Repair the wiring Were any shorts or opens found Re test Go to
291. ished range the appropriate DTC sets The ECM will then ignore the errant input signal and carry on its functions as best it can via default calculated or estimated values An engine operating under these conditions is said to be in limp home mode e Engines are calibrated to run as smoothly as possible during limp home mode However engine performance during limp home mode varies according to which DTC is set Overspeed protection Hard coded for 4000 rpm There is a concern of the effect of high engine speeds on attached components example flywheels and fans If engine reaches this hard coded maximum rpm engine will be shut off and DTC 21 will be set HOW TO CLEAR CODES Conditions for Clearing the DTC Resetting the MIL DTC can be cleared from memory by disconnecting the battery for 20 minutes f a personal computer PC is connected to the engine the DTC be cleared from memory by hitting the C key while in the View Sensor Data screen 08 28 Auxiliary Systems EFI amp Ignition Electronics Diagnostic Trouble Code 11 This is an all clear trouble code It is a code to let the technician know all NOTES systems are OK 08 29 NOTES Auxiliary Systems EFI amp Ignition Electronics Diagnostic Trouble Code 12 Ul E D i 359C 5 Electronic Governor Throttle Position TP Sensor Connector 361H R S01 BR W 355
292. ive seconds Actions Taken When the DTC Sets ECM will illuminate the malfunction indicator lamp MIL e The ECM will force the MST sensor to a 50 F default value The fuel system will go into open loop Trouble shooting MST is malfunctioning bad wiring or connections electrical failure 08 50 Auxiliary Systems EFI amp Ignition Electronics Diagnostic Trouble Code 25 Diagnostic Aids ECT CHT IAT amp MST Sensors The sensor shares the same ground with the ae Manifold Absolute Pressure MAP sensor and the Temperature vs Ohm or Volts Values approx Engine Coolant Temperature ECT sensor Check 100 2 080 47 the ground circuit 359E 359 Grey Red Grey 3 837 79 Yellow if these DTC s are also set 140 7 548 1 34 Inspect the harness connectors for backed out 1 93 terminals improper mating broken locks improperly 2 39 formed or damaged terminals and poor terminal to 2 86 wire connections Inspect the wiring harness for 3 32 damage If the harness appears to be OK backprobe the sensor connector with a digital 3 71 voltmeter and observe the voltage while moving 4 02 connectors and wiring harnesses related to the MST 4 25 22 4 46 A change in the voltage reading will indicate the 925 021 4 54 location of the fault Voltage values calculated for VREF 5 volts may vary 15 due to sensor and VREF variations DTC 25 Manifold Skin Temperature High Voltage 0 8 tio
293. kPa 1462 kPa 1089 kPa 1669 kPa 1248 kPa 152 psi 114 psi 182 psi 136 psi 212 psi 158 psi 242 psi 181 psi 1062 kPa 793 kPa 1269 kPa 952 kPa 1476 kPa 1103 kPa 1682 kPa 1262 kPa 154 psi 115 psi 184 psi 138 psi 214 psi 160 psi 244 psi 183 psi 1076 kPa 807 kPa 1282 kPa 965 kPa 1489 kPa 1117 kPa 1696 kPa 1269 kPa 156 psi 117 psi 186 psi 140 psi 216 psi 162 psi 246 psi 184 psi 1089 kPa 814 kPa 1296 kPa 972 kPa 1503 kPa 1124 kPa 1710 kPa 1202 kPa 158 psi 118 psi 188 psi 141 psi 218 psi 163 psi 248 psi 186 psi 1103 kPa 872 kPa 1310 kPa 979 kPa 1517 kPa 1138 kPa 1724 kPa 1289 kPa 160 psi 120 psi 190 psi 142 psi 220 psi 165 psi 250 psi 187 psi 1110 kPa 834 kPa 1324 kPa 993 kPa 1631 kPa 1145 kPa 161 psi 121 psi 192 psi 144 psi 222 psi 166 psi If one more cylinders reads low squirt Interpreting Compression Readings approximately one tablespoon of clean engine oil meeting Ford specification ESE M2C153 E ontop If compression improves considerably piston of the pistons in the low reading cylinders Repeat rings are faulty the compression pressure check on these cylinders 2 If compression does not improve valves are sticking or seating improperly 01 16 ESG 642 DIAGNOSIS AND TESTING Continued 3 If two adjacent cylinders indicate low compression pressures and squirting oil on each piston does not increase compression the head gasket may be lea
294. king 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 Cylinder Leakage Detection When a cylinder produces a low reading use of the Engine Cylinder Leak Detection Air Pressurization Kit will be helpful in pinpointing the exact cause The leakage detector is inserted in the spark plug hole the piston is brought up to dead center on the compression stroke and compressed air is admitted Once the combustion chamber is pressurized a special gauge included in the kit will read the percentage of leakage Leakage exceeding 20 percent is excessive While the air pressure is retained in the cylinder listen for the hiss of escaping air Aleak at the intake valve 6507 will be heard in the throttle body 9E926 Aleak at the exhaust valve 6505 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 8005 Oil Leak and Valve Stem Seal Test The cylinder leakage detector tests for engi
295. king sure to follow the sequence as shown above NOTE Indicates the torque sequence order Cylinder Block Assy VEN Water Pump Assy 8501 AY Front Cover amp Oil Pump Assy 6 008 A Wire Retention Hole A Water Pump Gasket 8507 Removal NOTE A small amount of antifreeze coming out the water pump weep hole may be normal 1 Drain the cooling system For additional information refer to Draining in this section 2 Remove the drive belt For additional information refer to Belt in this section 3 Remove the cooling fan and pulley For additional information refer to Cooling Fan in this section 4 Remove the Water Heater Return Tube Assembly For additional information refer to Water Heater Outlet Tube in this section 5 Remove the bolts and nuts from water pump 6 Remove water pump Installation 1 Clean all gasket surface on the front cover Clean gasket surface on water pump if not replacing with a new one 2 Align water pump and water pump gasket to engine front cover 3 Install all water pump bolts and nuts finger tight 4 Torque all bolts and nuts to specification and in the sequence as illustrated 5 Replace Water Heater Return Tube Assembly For additional information refer to Water Heater Tube Assembly in this section 6 Replace Cooling Fan For additional information refer to Fan in this section 7 Replace Drive Belt For additional information refer to Belt in this
296. l Pump A Fuel tanks D Fuel pump e he DOEM or OEM supplies tanks Have a fuel outlet and return inlet A CAUTION The electric fuel pump MUST The gas cap must be vented NOT be mounted directly on the engine assembly as engine vibration will shorten the B Fuels The following fuels must all be life of the pump UNLEADED AND CLEAN Gasoline petrol This engine is designed to operate e Inlet tube 7 9mm 5 16 in on unleaded 87 or 89 octane gasoline s a high pressure fuel pump Gasohol Ethanol A mixture of gasoline and Mounted on the frame rail not on the engine ethanol grain alcohol containing up to 10976 Must be mounted in packed foam ethanol by volume with properly formulated 15 powered by B through a relay cosolvents and other necessary additives Blends Positive spade 5 16 in is larger in size compared index of 87 or 89 to negative spade 1 4 in Gasohol Methanol A mixture of gasoline and Outlet tube 7 9mm 5 16 in located at the alcohol wood alcohol etc containing up to 5 electrical connector end of pump methanol by volume with properly formulated cosolvents and other necessary additives Blends E Fuel pump relay index of 87 or 89 Powered by B from ECM Controlled by the ECM C Fuel filter Directs B to fuel pump e Low pressure Is identical and interchangable with the power In line type that has 20 micron filtration starter and alternate fuel relays
297. l clearance f it is out of specification replace as necessary 0354 01 30 ESG 642 GENERAL SERVICE PROCEDURES Continued Bearing Inspection 1 Inspect bearings for the following defects Possible causes are shown Cratering fatigue failure A e Spot polishing improper seating B e Scratching dirty C Base exposed poor lubrication D Both edges worn journal damaged E One edge worn journal tapered or bearing not seated F Crankcase End Play 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 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 01 31 ESG 642 GENERAL SERVICE PROCEDURES Continued 4 Move the crankshaft 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 DA0355 A 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 wi
298. l surface cleaner F4AZ 19A536 RA or equivalent meeting Ford specification WSE M5B292 A 1 kt 8 12 Nm 71 106 Ibfin NY I H DAO917 A 02 71 Apply a bead of Silicone Gasket and Sealant at the oil pan to block seam Install the engine front cover gasket Apply a second bead of sealant along the edge of the engine front cover gasket at the oil pan to block seam Apply a bead of sealant on the oil pan flange Install the front cover Position the lower edge of the cover on the oil pan and tip upward into position NOTE If new front cover was used reinstall oil pump and filter Refer to this Section Install the new water pump studs The correct stud will be supplied with pre applied Loctite NOTE Make sure the Loctite end of the stud is installed in the engine Refer to this Section ESG 642 ENGINE REPAIR Continued 3 Water Pump assembly Torque Specs Bolt 1 2 6 7 8A 10 11 12 amp 13 20 30 Nm 15 22 Ib ft Stud 3 4 5 amp 9A 6 8 Nm 1 Install studs torque to 6 8 Nm 2 Install front cover gasket 6020 3 Install front cover amp oil pump assy 6 008 4 Install water pump gasket 8507 5 Install water pump assy 8501 6 Install remaining fasteners 7 Torque all bolts and nuts to 20 30 Nm 15 22 Ib ft making sure to follow the sequence as shown above NOTE Indicates the torque sequence order Cylinder B
299. l tank Recycle ignition switch and recheck pressure If pressure continues to drop off check for leaks in line or a leaking injector s 6 Ensure that the fuel cap vent is operating properly The vent should allow air to enter the tanks as fuel is removed Correct any obstruction or restriction found NOTE If no obstruction is found and the electrical supply ground and fuel supply to the pump as described above are verified all right replace the pump assembly 7 Start the engine and allow it to come up to operating temerature 8 Fuel pressure should be maintained at 62 PSI 04 18 Auxiliary Systems Fuel FUEL SYSTEM DESCRIPTION AND TESTING Continued 9 Iffuel pressure cannot be maintained verify that all of the above checks have been carried out NOTE If all of the above checks have been carried out and fuel pressure cannot be maintained replace the fuel pump assembly SERVICE CHECK CHART CONDITION Insufficient fuel delivery pressure regulator or fuel filter A break or restriction in fuel lines POSSIBLE SOURCE ACTION Clogged pump filter plugged fuel tank vent Replace as needed Repair fuel line or remove restriction Clogged fuel pump pressure regulator or fuel tank vent cap Pump not operating Inoperative or damaged pump loose ground or improper wiring Faulty fuel pump relay Flooding Leaking injector Pressure regulator malfunction Air le
300. l the following components Refer to the procedures in this section e Timing chain e Front cover Tappets tappet guides and push rods e Valve covers e Lower and upper intake manifolds ESG 642 REMOVAL Engine Special Tool s Engine Lifting Bracket 014 00730 or Equivalent Special Service Tools called for by the procedures can be obtained by calling 1 800 ROTUNDA 1 800 768 8632 Removal of Engine 1 Disconnect the battery gound cable 2 Remove the retaining bolt and the lower core support 3 Remove the routing bracket retaining bolt and the engine oil dipstick tube 4 Remove the upper intake manifold Refer to Intake Manifold Upper this section 5 Remove the lower intake manifold Refer to Intake Manifold Lower this section 6 Remove the accessory drive belt 7 Setthe power steering pump aside if equipped 1 Disconnect the low pressure line at the power steering pump 2 Remove the pump retaining bolts 8 Setthe radiator lower hose aside 1 Cut the clamp DA0214 A 2 Disconnect the hose at the water pump 02 87 REMOVAL Continued DA0218 A ESG 642 10 02 88 11 12 13 14 15 Drain the engine oil A WARNING PROTECT ENVIRON MENT IT IS ILLEGAL TO POLLUTE DRAINS WATER COURSES OR SOIL USE AUTHORIZED FACILITY FOR DISPOSAL IF IN DOUBT CONTACT YOUR LOCAL AUTHORITY FOR ADVICE Remove the starter Remove the tor
301. leaking or malfunctioning fuel injector can cause the system to go rich A misfiring cylinder will result in unburned oxygen in the exhaust which can cause a lean condition An intermittent throttle position sensor output will cause the system to go rich due to a false indication of the engine accelerating Inspect the oxygen sensor for silicone contamination from fuel or the use of improper room temperature vulcanizing RTV sealant The sensor may have a white powdery coating which may result in a high but false voltage signal rich exhaust indication Inspect the harness connectors for backed out terminals improper mating broken locks improperly formed or damaged terminals and poor terminal to wire connections Inspect the wiring harness for damage If the harness appears to be OK go to diagnostic chart below DTC 42 HO2S Sensor High Voltage Stuck Rich Ye No Are you using a personal computer PC to perform this diagnosis Go to Diagnostic system Check before continuing at Step 2 Go to Step 2 1 Let the sensor cool 2 KOEO 3 With a suitable backprobing technique measure the voltage between the 5 Step engine data screen instead of using a DVOM 2 Check the sensor signal circuit 74 Grey Lt Blue for an open or a short mE Replace HO2S Remove Is system working to specification replacement HO2S and install original Re test Go to Step 5 Go to Step 6 reinstalled Keep original ECM repl
302. lean and tight Refer to the ECM wiring diagram Was a problem found Verify repair Go to Step 6 Check the items that can cause the engine to run rich Refer to DTC 42 Verify repair Go to Step 7 Check items that can cause the engine to run lean Refer to DTC 32 Was a problem found Verify repair Go to Step 8 N Was a problem found Inspect the fuel delivery system to determine if there PM Verify repair Go to Step 9 is a problem with fuel delivery Page 03 35 Verify repair Go to Step 10 Was a problem found Inspect the secondary ignition wires Check for the following conditions Verify the resistance of all ignition wires is less than the specified value Verify that ignition wires are correctly routed to eliminate cross firing Verify that ignition wires are not arcing to ground Spraying the secondary ignition wires with a light mist of water may help to locate an intermittent problem ignition ON engine running Was a problem found 1 Check ignition coil secondary resistance 10 2 Replace the coil if it is not within the specified range of resistance Refer to Was a problem found Page 03 35 Verify repair Go to Step 11 03 33 Auxiliary Systems Ignition CUTS OUT MISSES SYMPTOM Continued Acin 00 Check for proper ignition voltage output with un ems suitable spark tester Was a problem found Verify repair Go to Step 12 Check the injector connections If a
303. let is plugged Damaged IAC solenoid e Clean as needed e REPLACE IAC Diagnosis Aids The IAC solenoid resistance is from 6 to 13 ohms Disconnect IAC valve and look for no change in engine rpm as an indication of a stuck or damaged valve 03 13 Auxiliary Systems Ignition DESCRIPTION AND OPERATION IGNITION CONTROL MODULE ICM Starting Mode Module enters start mode at first application of power No spark is applied for first turn of crankshaft Timing is fixed at 10 degrees BTDC Dwell is fixed at 10 degrees of crankshaft rotation Start mode remains in effect until 10 turns of the crankshaft 500 rpm If drops below 500 rpm at any time turn counter is reset Once 10 turns are made 500 rpm or greater module is set to run mode In transitioning to run mode calculated timing values are ramped into system during approximately 3 5 revolutions to ensure transition Dwell is determined with a base value plus a correction factor based on system voltage ECT Effects Engine Coolant Temperature ECT is monitored and a correction factor is applied to engine timing based on one of three 1 X 8 tables OCT1 selects which timing table will be used for correction IAT Effects Intake Air Temperature IAT is monitored and a correction factor is applied to engine timing based on one of three 1 X 8 tables OCT1 selects which timing table will be used for correction MAP Sensor Effects The MAP signal is used by the EC
304. lete the ground when the proper conditions occur The 6 ohm heater design used by Ford Power Products is not interchangeable with new style 3 3 ohm new fast light off FLO HO2S heater 03 11 Auxiliary Systems DESCRIPTION AND OPERATION ECM Continued ma KF Heated Oxygen Sensor HO2S Positive Elec Term F Wire Terminals Insulator G Heating Element Graphite Seal amp Contact Exhaust Manifold D Housing Shield E Exhaust Gases 7 0 0 1 1 Volt Signal High Voltage Over 0 6 Rich Low Voltage Under 0 4 Lean Intake Air Temperature Sensor IAT Sensor The IAT sensors are thermistor devices in which resistance changes with temperature The electrical resistance of a thermistor decreases as the temperature increases and increases as the temperature decreases The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the ECM corresponding to temperature Thermistor type sensors are considered passive sensors passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the voltage signal at the ECM This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor The IAT sensor provid
305. ling must be determined before replacing the spark plugs Was a problem found Verify repair Go to Step 10 03 26 Auxiliary Systems Ignition ROUGH UNSTABLE OR INCORRECT IDLE STALING SYMPTOM RR Go to Step 11 Go to Step 12 Go to Step 13 Go to Step 14 Verify repair Go to Step 15 Go to Step 16 Verify repair Go to Step 17 Value s Check the ECM grounds to verify that they are clean 10 and tight Refer to the ECM wiring diagram Was a problem found Check the items that can cause the engine to run 11 rich Refer to DTC 42 Was a problem found Check items that can cause the engine to run lean 12 Refer to DTC 32 Was a problem found Check the injector connections If any of the injector connections are connected to an incorrect cylinder correct as necessary Was a problem found Visually physically check the vacuum hoses for splits kinks and proper connections and routing Was a problem found Check the exhaust system for a possible restriction Damaged or collapsed pipe Internal muffler failure Was a problem found Check for a faulty plugged or incorrectly installed PCV valve Was a problem found Check the following engine mechanical problems refer to Section 01 of this Manual Low compression Leaking cylinder head gasket Worn camshaft Sticking or leaking valves Valve timing Broken valve springs Camshaft drive chain worn s
306. lipped or stripped Ol N O Was a problem found Verify repair Go to Step 18 1 Check for faulty motor mounts Refer to 8 Section 01 of this Manual 2 If a problem is found repair as necessary Was a problem found Verify repair Go to Step 19 1 Review all diagnostic procedures within this table 2 If all procedures have been completed and no malfunctions have been found review inspect the following 19 Visual physical inspection including fuel quality Contact Ford check Power Products All electrical connections within a suspected Customer circuit and or system Service Center 3 If a problem is found repair as necessary Technical Was a problem found Verify repair Support Hotline 1 800 521 0370 03 27 Auxiliary Systems Ignition EXCESSIVE FUEL CONSUMPTION SYMPTOM Value s Ye DEFINITION Fuel economy is noticeably lower than expected Also economy is noticeably lower than it was at one time previously Was a visual physical check performed Go to 1 Visual Physical Go to Step 2 Check Perform MIL DTC retrieval procedure Refer to DTC Ignition ON engine not running short STI chart perform connector to ground component and Do any fault codes flash and display circuit test as required Go to Step 3 Visually physically check Vacuum hoses for splits kinks and improper connections and routing o mun Was a problem foun
307. ll original ECM Go to Step 10 Is the repair complete system operation normal with original ECM reinstalled Remove original ECM and reinstall Keep original ECM replacement ECM installed Re test Go to Step 9 Is the repair complete system operation normal with replacement ECM reinstalled Leave replacement ECM installed Re test 08 47 NOTES Auxiliary Systems EFI amp Ignition Electronics Diagnostic Trouble Code 24 Manifold Absolute Pressure se W Sensor Connector 0600 CHT IAT Sensors TP Sensor iocis CREE SWAT TT Engine Return Signal Reference Control 1 Module DIAGNOSTIC TROUBLE CODE DTC 24 MANIFOLD ABSOLUTE PRESSURE MAP SENSOR HIGH VOLTAGE Circuit Description The manifold absolute pressure MAP sensor responds to changes in intake manifold pressure vacuum The ECM provides a 5V reference voltage to the MAP sensor between terminal A Grey Red Circuit 359K and terminal C Brown White circuit 351C of the MAP sensor A MAP signal is returned to the ECM from terminal B Lt Green Black circuit 358 of the MAP sensor The MAP signal varies from about 1V at idle high vacuum to 4 8V with KOEO or at WOT low vacuum The MAP signal is used by the ECM as an indication of engine load This information is used to control spark advance and air fuel ratio The MAP signal is also used at KOEO to indicate barometric pres
308. llowing information to calibrate the engine properly Crankshaft position e Engine RPM Engine temperature e Air temperature Engine load and altitude Fuel select switch 03 8 The Manifold Absolute Pressure Sensor MAP sensor e Monitors atmospheric pressure at start up to adjust timing for altitude e During operation monitors engine vacuum which is proportional to its load and adjust timing accordingly The throttle position sensor TP sensor e Sends the engine control module a signal indicating the throttle plate angle 15 the main input to the engine control module from the driver The idle air control valve IAC Controls bypass air around the throttle plate at low speeds 5 controlled by the engine control module The camshaft position sensor CMP sensor e Sends the engine control module a signal indicating camshaft position used for fuel synchronization The crankshaft position sensor CKP sensor e Sends the engine control module a signal indicating crankshaft position 5 essential for calculating spark timing The intake air temperature sensor IAT sensor e Sends the engine control module a signal indicating the temperature of the air entering the engine e Resistance decreases as temperature increases The heated oxygen sensor HO2S e Has the ability to create a voltage signal dependent on exhaust oxygen content Provides feedback informat
309. lock Assy AA Water Pump Assy 8501 A Front Cover amp Oil Pump Assy 6F008 Wire Retention Hole A Water Pump Gasket 8507 wP Fic NB05112 Hex Hex Gomm Hex 10mm Hex 15mm Hex fmm Hex N605908 M8 X 1 25 X 38 10mm Hex N605908 M8 X 1 25 X 38 10mm Hex N804745 8 X 1 25 15mm Hex 02 72 ESG 642 ENGINE REPAIR Continued 4 Install the accessory drive belt tensioner 48 64 Nm 35 47 Ibift 5 Install the accessory drive belt idler pulley 02 73 ESG 642 ENGINE REPAIR Continued 6 Install a new O ring on the synchronizer and make sure the oil pump intermediate shaft is installed with the lock ring into the synchronizer 7 NOTE The arrow on the alignment tool must point as shown in the illustration Make sure piston number one is at top dead center on intake stroke Install the synchronizer remove the alignment tool and install the camshaft position sensor DA0671 B 02 74 ESG 642 ENGINE REPAIR Continued 8 Install the oil pan retaining bolts 0 0890 9 Install crankshaft position sensor CKP Torque hold down bolts to Ib in 10 Connect the wiring at the CKP DA0891 A 02 75 ESG 642 ENGINE REPAIR Continued 11 Install the crankshaft damper An installation tool will be required Refer to Special Tools at front of this section 12 Align the crankshaft pulley and install the retaining bolts 13
310. lute Pressure MAP Manifold Absolute Pressure MAP Manifold Absolute Pressure Sensor MAP Sensor Intake Manifold Absolute Pressure Sensor Manifold Absolute Pressure Sensor MAPS Pressure Sensor P Sensor Manifold Differential Pressure MDP Manifold Differential Pressure MDP Manifold Differential Pressure Sensor MDP Sensor Vacuum Sensor VAC Sensor Manifold Surface Temperature Manifold Surface Temperature MST Intake Air Temperature Sensor IAT Sensor Long Term FT Manifold Vacuum Zone Manifold Vacuum Zone MVZ Manifold Vacuum Zone Switch MVZ Switch Vacuum Switches Mass Air Flow Air Flow Control AFC Air Flow Meter Mass Air Flow Sensor Air Flow Meter Air Flow Sensor AFS MAF Sensor Hot Wire Anemometer Mixture Control MC Feed Back Control FBC Mixture Control M C Mixture Control Solenoid MC Solenoid Mixture Control Solenoid MCS gt OU TI a 09 14 Auxiliary Systems Metrics J1930 TERMINOLOGY LIST Old Terms Acronyms Multiport Fuel Injection MFI D Jetronic Digital Fuel Injection EFI Electronic Fuel Injection EFI Fuel Injection FI L Jetronic LH Jetronic Motronic Multipoint Injection MPI Multiport Injection MPI Port Fuel Injection PFI Programmed Fuel Injection PGM Fl Tuned Port Injection TPI Nonvolatile Random A
311. m creck ron crew Remove three pin S voltage regulator connector REPAIR open or excess Measure wiring resistance between the one pin S resistance in Circuit 4 connector and the S center pin of the voltage W BK regulator connector Is resistance greater than 1 ohm CHECK for loose or bent pin in voltage regulator or connector If OK RE PLACE voltage regulator BS CHECK STATOR OUTPUT VOLTAGE e Start engine GO to B6 Measure voltage at the S terminal on the back of the GO to Pinpoint Test A to generator find the cause of low s voltage at least 1 2 of battery voltage generator output B6 CHECK GENERATOR OUTPUT VOLTAGE Measure voltage at the B terminal on the back of the GO to Pinpoint Test D to generator with the engine running at 2000 RPM and all find the cause of high accessories turned off output voltage s voltage greater than 15 5 volts REPLACE voltage generator PINPOINT TEST C INDICATOR LAMP FLICKERS INTERMITTENT TEST STEP RESULT gt ACTION TO TAKE Check these connections for corrosion loose or bent GO to C2 pins or loose eyelets Three pin voltage regulator connector CLEAN or REPAIR One pin S connector connections as required Generator eyelet Battery cables Are all connections clean and tight CHECK FOR FIELD CIRCUIT DRAIN Turn key to OFF position GO to C3 Measure voltage at test point F on the voltage regulator GO to C5
312. m leak electrical failure Setcode openlop 25 Highmanifoldsurfacetemp MST sensor defective damaged wiring electrical failure 1 Setcodelopenlop 26 Initial TPS over Max Actuator foreign object in bore e g ice tampering nostat Actuator throttle plate moving whi in idle position e g unstable Shutdown Fuel pump no voltage wiring from harness bypassed ll TENES HO2S LOW Voltage HO2S sensor defective damaged wiring electrical failure Set code open loop 33 Highenginetemp CHTat240 F gt Z 35 Highintakeairtemp lATsensor wiring problem in wrong location bad ing engine overheats Setcode openloop ll 37 DBWdecayfalue Actuator Throttle platestuckopen High fuel pump voltage Fuel pump on when not requested Shutdownornostat Ba EP HO2S High Voltage HO2S sensor defective damaged wiring electrical failure Set code open loop CHTat230 F wiring problem ed iri Set code open loop Actuator Throttle plate not opening or stuck Shutdown 1I 51 LowOilPressure Oilpressure lw 5 CKP 90 539 Camshaftsensorerror CMP 900 Progamfaut ECM malfunction Seto
313. ment ECM reinstalled installed Re test BEEN 08 35 Auxiliary Systems EFI amp Ignition Electronics Diagnostic Trouble Code 15 359D 22 545 Sensors NOTES Manifold Skin Temperature MST Sensor Connector Sensor Engine Sensor Ground j Control Module 1 t DIAGNOSTIC TROUBLE CODE DTC 15 MANIFOLD SKIN TEMPERATURE LOW VOLTAGE Circuit Description The manifold skin temperature MST sensor is a thermistor which measures the temperature of the air next to the intake manifold of engine The ECM supplies a ground circuit 359 and 3590 Grey Red from the sensor When the skin temperature air is cold the sensor resistance is high and the ECM will monitor a high signal voltage at the MST signal circuit If the skin temperature air is warm the sensor resistance is lower causing the ECM to monitor a lower voltage DTC 15 will set when the ECM detects an excessively low signal voltage on the skin temperature sensor signal circuit Conditions for Setting the DTC e KOEO or MST sensor signal is lt 0 22V e Above conditions are present for at least gt 2 64 consecutive seconds Actions Taken When the DTC Sets ECM will illuminate the malfunction indicator lamp MIL e The ECM will force the MST sensor to a 50 F default value The fuel system will go into open loop Trouble Shooting MST is malfunctioning bad wiring or connectors or el
314. mited to air fuel ratios exhaust temperatures and mixer regulator orientation 04 26 Auxiliary Systems Fuel FUEL SYSTEM DESCRIPTION AND OPERATION Fuel Flow Diagram for Natural Gas D Engine E Regulator Vacuum Connector A Air Intake Mixer C Fuel Line REGULATOR 5 0 kPa Inlet 1 5 kPa Outlet This is to be supplied by the OEM to suit the operating conditions gas supply pressure THROTTLE BODY FORD POWER PRODUCTS Type Butterfly plate Angle of operation 75 total movement Bore 27 0 mm dia Throttle linkage connection 6 35 mm dia ball Retaining studs spacing 68 26 mm MIXER Type Air valve venturi Air inlet bore 77 8 mm diameter Fuel inlet connection 3 4 NPTF Mixture outlet bore 60 3 mm diameter Max inlet pressure 1 5 kPa Shut Off Valve Fuel Filter Fuel Tank 2 NG SHUT OFF VALVE Type Double poppet valve Max working pressure 2150 kPa Inlet connection 3 4 NPTF Outlet connection 3 4 NPTF Coil 12V 6W SAFETY SWITCH Type Vacuum operated FUEL Fuel Natural Gas Fuel Specifications 38 7 MJ m UK 39 0 MJ m USA 04 27 Auxiliary Systems Fuel FUEL SYSTEM DESCRIPTION AND OPERATION SYSTEM OPERATION NATURAL GAS Should the engine stall the loss of vacuum will close the fuel shut off valve When starting the engine WHEN INSTALLING ANY NATURAL GAS FUEL SYSTEMS there is sufficient vacuum present even at cranking FOLLOW ALL
315. n Malfunctioning generator bearing Loose timing chain belt Damaged timing belt tensioner Malfunctioning water pump bearing 01 13 Action e REPLACE piston and pin e REPAIR or REPLACE piston rings e REPAIR or REPLACE piston or cylinder blocks e REPLACE valve stem seal eREPLACE valve stem and uide REPAIR oil leakage e ADJUST clearance or REPLACE main bearing e REPLACE main bearing e REPLACE crankshaft thrust main bearing e REPLACE connecting rod REPLACE connecting rod bearing e REPLACE connecting rod bushing e REPAIR or REPLACE cylinder blocks e REPLACE piston or piston pin REPLACE piston rings e REPLACE connecting rod e REPLACE hydraulic valve tappet or hydraulic lash adjuster e ADJUST clearance or REPLACE hydraulic valve tappet guide or hydraulic lash adjuster e REPLACE valve spring REPAIR clearance or REPLACE valve guide stem e REFER to Section 05 e Refer to Section 04 e REPAIR exhaust leakage e REFER to Section 05 e REFER to Section 06 for diagnosis and testing of the generator e ADJUST or REPLACE timing chain belt e REPLACE timing belt tensioner Replace water pump ESG 642 DIAGNOSIS AND TESTING Continued e Insufficient Power ENGINE OPERATION Malfunctioning hydraulic valve tappet or hydraulic lash adjuster Damaged hydraulic valve tappet guide or hydraulic lash adjuster Compr
316. n 05 12 for cylinder head temperature sensor removal and installation if needed A25442 A 02 23 ESG 642 ENGINE REPAIR Continued 10 Remove the six push rods 6565 A25443 A 11 Remove and discard the eight cylinder head bolts 02 24 ESG 642 ENGINE REPAIR Continued 12 Remove the cylinder head and the head gasket 6051 Discard the head gasket and head e A naw LN Nes a 4 ae ps sey 4 PU EC LN SEC Swe i 1 A DA0730 A 02 25 ESG 642 ENGINE REPAIR Continued Cylinder Head A N WARNING DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENTS HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND CAN BE IGNITED RESULTING IN POSSIBLE PERSONAL INJURY Installation 1 Install a new head gasket on the cylinder blocks 6010 with the small hole to the front of the engine and position the cylinder head 0 0898 02 26 ENGINE REPAIR Continued A25447 A ESG 642 02 27 2 CAUTION Head bolts are torque to yield To obtain proper torque specification always use new cylinder head bolts otherwise may cause engine failure NOTE Lubricate the new cylinder head bolts with engine oil prior to installation Install the four new A short cylinder head bolts and the four new B long cylinder head bolts ENGINE REPAIR Continued
317. n 1 Ye No O Are you using a personal computer PC to perform this diagnosis Go to Diagnostic System Check before continuing at Step 2 Go to Step 2 Go to Step 3 Go to Step 7 Go to Step 4 Go to Step 2 Re test Go to Step 5 1 Ignition OFF 2 Disconnect the MST sensor electrical connector 3 Check Ohm value across the two pins of the MST Is it within specs of above chart 2 With DVOM check for ground on circuit 359E Grey Red cavity 1 Is there a ground Check for an open on circuit 359E Grey Red and repair as necessary Was a repair necessary Go to Step 6 Go to Step 7 Is the voltage greater than the specified value Check for a short to ground or open on circuit 255 BK Y and repair as necessary Was a repair necessary Replace the MST sensor Is the repair complete Install replacement ECM Is system operation normal with replacement ECM installed V reinstalled Re test Re test Remove replacement ECM and install original ECM Go to Step 9 Remove original ECM and reinstall Keep original replacement ECM installed Re test Go to Step 10 s the repair complete system operation normal with replacemen Leave reinstalled 1 Reconnect the MST sensor electrical connector 2 With a suitable backprobing technique measure the voltage between cavity 2 circuit 225 and ground EN 08 51 Auxiliary Systems EFI amp Ignition Electronics Diagnostic
318. n completed and no malfunctions have been found review inspect the following 19 Visual physical inspection including fuel quality Contact Ford check Power Products All electrical connections within a suspected Customer circuit and or system Service Center 3 If a problem is found repair as necessary Technical Was a problem found Verify repair Support Hotline 1 800 521 0370 03 34 Auxiliary Systems Ignition IGNITION SYSTEM DIAGNOSING AND TESTING 1 Check the following circuits with the volt ohmmeter per the following chart IGNITION SECONDARY SYSTEM RESISTANCE CHECKS Pin Nos Selection Ohms Coil Ohm 14 000 Coil Circuit Secondary Towers 1 5 2 Coil Ohm 14 000 Coil Secondary Circuit Secondary Towers 4 3 3 Coil Ohm 14 000 Coil Secondary Circuit Secondary Towers 2 6 4 Ends of Each Ohm 6 000 to 16 000 Spark Plug Wire Resistance Spark Plug approx 6 000 Ohms Wire per foot 03 35 Auxiliary Systems Ignition IGNITION SYSTEM DIAGNOSING AND TESTING Continued HEATED OXYGEN SENSOR HO2S DIAGNOSTIC TROUBLE CODE DTC 32 42 74 GY LB Heated Oxygen Sensor HO2S Connector B Engine Control Module ECM c VPWR Circuit Description D Signal Return E Sensor Signal F Power Ground The ECM supplies a voltage of about 0 45 volts to the heated oxygen sensor This may read as low as 0 32 volts with a 10 megohm digital voltmeter The oxygen sensor varies the voltage with
319. n good part elsewhere in the electrical system REPLACE generator PINPOINT TEST H INDICATOR LAMP ON KEY OFF TEST STEP RESULT gt ACTION TO TAKE m CHECK LAMP ORCUTT WANG O Turn key to OFF position Yes SERVICE Circuit 904 Remove three pin voltage regulator connector LG R Circuit should be Measure voltage at wiring harness terminal Circuit hot in RUN position only 904 LG R s voltage greater than O volts SERVICE instrumentation system Indicator lamp circuit is finding a path to ground at a point other than the generator 06 12 Auxiliary Systems Charging GENERATOR REMOVAL AND INSTALLATION WARNING BATTERIES NORMALLY PRODUCE EXPLOSIVE GASES WHICH CAN CAUSE PERSONAL INJURY THEREFORE DO NOT ALLOW FLAMES SPARKS OR LIGHTED SUBSTANCES TO COME NEAR THE BATTERY WHEN CHARGING OR WORKING NEAR A BATTERY ALWAYS SHIELD YOUR FACE AND PROTECT YOUR EYES ALWAYS PROVIDE VENTILATION 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 LIFT WITH A BATTERY CARRIER OR WITH YOUR HANDS ON OPPOSITE CORNERS WARNING KEEP BATTERIES 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 THE SKIN EYES OR CLOT
320. n the terminal The battery clamp spreading operation shown in the following illustration is typical for all vehicles and equipment A BATTERY CLAMP SPREADER LS gt LA 2926 Terminal Cleaning Brush The terminal cleaning brush is designed with units to clean both tapered battery terminal and the mating surface of the cable clamp Refer to illustration under Battery Installation Carrier 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 POSSIBLE 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 The battery removal operation shown in the following illustration is typical for all vehicles and equipment 06 18 Auxiliary Systems Charging Wiring Schematic 4 2L amp 2 5L Alternator Gauges Ignition and Discrete Governing 14 15 IH Tid i 12 Ld 122 TW Swett fat H
321. nd connectors in Circuit 36 and SERVICE as required CHECK FIELD TURN ON Measure voltage at test point F on the voltage regulator Yes GO to 8 s voltage at test point F less than 2 volts No GO to A11 06 7 Auxiliary Systems Charging GENERATOR DIAGNOSIS AND TESTING Continued PINPOINT TEST A DEAD BATTERY NO GENERATOR OUTPUT Continued TEST STEP RESULT gt ACTION TO TAKE aa REGTRER Remove one pin S connector from generator REPLACE generator Measure voltage between the S terminal on the back of GO to A9 the generator and ground Measure voltage between the positive battery terminal and the S terminal on the back of the generator s either voltage reading greater than 1 volt CHECK VOLTAGE DROP IN B CIRCUIT Install S connector GO to A10 Start engine HEPAIR excess voltage Turn on headlights or any accessory drop in Circuits 38 290 e With engine running at 2000 RPM measure voltage and 37 drop between the B terminal on the back of the CHECK fuse link in Circuits generator and the positive battery post 38 290 and 37 and the Is voltage drop less than 0 5 volt connections between the battery and under hood CHECK FOR OPEN STATOR PHASE fuse box Connect test point F on the voltage regulator to the REPLACE voltage negative batter post using a jumper wire regulator Repeat Generator Output Test Is gen
322. nd seals 2 Install the intake manifold gaskets 9439 02 19 ESG 642 ENGINE REPAIR Continued A CAUTION Mating parts must make contact to each other within 4 minutes and connecting bolts must be torqued within 15 minutes after applying sealant Failure to follow this procedure can cause future oil leakage Use silicone gasket and sealant FGAZ 19562 AA or equivalent meeting Ford specification WSE M4G323 A6 NOTE Sealant must be removed and area cleaned with solvant if above instructions are not followed Use metal surface cleaner F4AZ 19A536 RA or equivalent meeting Ford specification WSE M5B292 A 3 Apply a bead of sealant to the intake manifold front and rear end seal mounting at the points as indicated e Position the lower intake manifold A26859 A 4 NOTE Lower intake manifold bolts are torque to yield They must be discarded and replaced O Install six new A long lower intake manifold bolts and the eight new B short lower intake manifold bolts dei 5 Tighten the lower intake manifold bolts in two stages in the sequence shown e Stage 1 5 Nm 44 Ib in e Stage 2 8 11 5 Nm 71 101 Ib in 0893 02 20 ESG 642 ENGINE REPAIR Continued 6 Connect the water pump bypass hose 5 1 Position the water pump bypass hose o 2 Position the hose clamp C 7 Connect the fuel line Refer to Section 04 8 Install the upper radiato
323. nd some other contact surface Pliers CAUTION Always remove the negative cable first to prevent possible arcing possibly damaging other electrical components Battery pliers have jaws specifically designed for gripping cable clamp bolts securely Care should be taken when removing or replacing the cable clamp bolts so that the battery terminal is not subjected to any excessive lateral or twisting forces Such forces could cause major damage to the internal components of the battery and leakage at the terminals The battery terminal removal operation shown in the following illustration is typical for all vehicles and equipment BATTERY CLAMP PULLER 06 17 Auxiliary Systems Charging BATTERY MOUNTING AND CABLES Continued Clamp Puller CAUTION Always remove the negative cable first to prevent possible arcing possibly damaging other electrical components 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 o
324. nded oil premixed with Diesel Engine Oil Dye 164 R3705 meeting Ford specification ESE M9C103 B1 or equivalent Use a minimum 14 8 ml 0 5 ounce to a maximum 29 6 ml 1 ounce of fluorescent additive to all engines If the oil is not premixed fluorescent additive must first be added to crankcase 3 Run the engine for 15 minutes Stop the engine and inspect all seal and gasket areas for leaks using the 12 Volt Master UV diagnostic Inspection Kit A clear bright yellow or orange area will identify the leak For extremely small leaks several hours may be required for the leak to appear 01 14 ESG 642 DIAGNOSIS AND TESTING Continued 4 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 eair pressure gauge that registers pressure in 4 kPa 1 psi increments e air line shutoff valve e appropriate fittings to attach the above parts to oil fill PCV grommet hole and crankcase ventilation tube 6758 appropriate plugs to seal any openings leading to the crankcase ea 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 air line shutoff valve and
325. ne 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 6754 is convenient Adjust the air pressure to approximately 34 kPa 5psi Using a solution of liquid soap and water brush the solution along the gasket sealing surfaces and bearing seals Look for bubbles or foam 4 Remove the spark plugs and rotate the crankshaft slowly with a wrench Check for large amounts of air escaping into the cylinders as each intake valve and exhaust valve opens 5 The spark plugs on the leaking cylinders will probably show deposits of burned oil Intake Manifold Vacuum Test Bring the engine to normal operating temperature Connect the Vacuum Pressure Tester to the intake manifold 9424 Run the engine at the specified idle speed The vacuum gauge should read between 51 74 kPa 15 22 in Hg depending upon the engine condition and the altitude at which the test is performed Subtract 4 0193 kPa 1 in Hg from the specified reading for every 304 8 m 1 000 feet of elevation above sea level The reading should be steady If necessary adjust the gauge damper control where used if the needle is fluttering rapidly Adjust the damper until the needle moves easily without excessive flutter Interpreting Vacuum Gauge Readings
326. ng 1 800 ROTUNDA 1 800 768 8632 02 90 ESG 642 DISASSEMBLY Continued Gears 1 Remove the flywheel and rear cover plate and mount the engine 6007 on a suitable workstand DA0643 A 02 91 ESG 642 DISASSEMBLY Continued 2 Remove the water pump pulley 8509 3 Remove the drive belt idler pulley 8678 DA0728 A 02 92 ESG 642 DISASSEMBLY Continued 4 Remove the generator mounting bracket DA0727 A 02 93 ESG 642 DISASSEMBLY Continued Remove the engine mounts 5 lt lt e left side shown right side Remove the heated exhaust gas oxygen O ed 5 Lu 6 DA0761 A 02 94 ESG 642 DISASSEMBLY Continued 7 Remove the engine lifting eyes left side shown right side similar 8 Remove the oil level indicator tube 02 95 ESG 642 DISASSEMBLY Continued 9 Removethe exhaust manifolds left side shown right side similar Discard the gaskets Same procedure for optional center dump exhaust manifolds DAO0656 A 10 Remove the valve covers left side shown right side similar NOTE Remove the ignition coil pack if necessary Refer to Section 3 11 NOTE The location of each rocker arm seat rocker arm and pushrod should be identified When the engine is assembled each component should be installed in its original position Remove the rocker arms rocker arm seats and push rods
327. ng and Valve Spring Retainer Special Tool s Valve Spring Compressor T81P 6513 A Special Service Tools called for by the procedures can be obtained by calling 1 800 ROTUNDA 1 800 768 8632 Removal 1 Remove the valve cover Refer to the procedure in this section 02 39 ENGINE REPAIR Continued ESG 642 A25456 B A25442 A 02 40 2 Rotate the crankshaft 6303 until the piston 6108 for the valve being worked on is at the top of its stroke with both the A intake valve 6507 and the B exhaust valve 6505 closed 3 Hold the valve in the cylinder head Remove the spark plug if necessary Apply a minimum of 965 kPa 140 psi of compressed air to the cylinder to hold valve NOTE If the components are to be reinstalled they must be installed in the same position Mark the components for location A CAUTION If a valve drops into the cylinder remove the cylinder head Refer to the procedure in this section 4 Remove the rocker arms 1 Remove the bolts 2 Remove the rocker arms ESG 642 ENGINE REPAIR Continued 5 Use Valve Spring Compressor to compress the valve springs A26648 A 6 Remove the following 1 Remove the valve spring retainer key 6518 2 Remove the valve spring retainer 6514 3 Remove the valve spring 6513 4 Remove and discard the valve stem seal 6571 5 Remove the valve spring seat 6 Secure th
328. ngine Operator s handbook Oil Consumption Test The following diagnostic procedure is used to determine the source of excessive internal oil consumption 01 19 ESG 642 DIAGNOSIS AND TESTING Continued 1 NOTE Oil use is normally greater during the first 300 hours of service As hours increase oil use generally decreases Vehicles in normal service should get at least 30 hours per liter 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 Define excessive oil consumption such as the number of hours per liter quart of oil used Also determine customer s engine load habits such as sustained high speed operation extended idle heavy work loads and other considerations Verify that the engine has no external oil leak as described under Engine Oil Leaks in the Diagnosis and Testing portion of this section Verify that the engine has the correct oil level dipstick Verify that the engine is not being run in an overfilled condition Check the oil level at least five minutes after a hot shutdown with the vehicle parked on a level surface In no case should the level be above the top of the cross hatched area and the letter F in FULL If significantly overfilled perform steps 5a through 5d Perform an oil consumption test a Drain the engine oil remove the oil bypass filter and refill with one liter quart less than
329. ning clutch in the drive assembly protects the starter from the excessive speeds during the brief period before the driver releases the ignition switch from the START position as the engine starts Auxiliary Systems Starter STARTER PERMANENT MAGNET DESCRIPTION AND OPERATION Continued Field Service For cases of a starter that cranks the engine very slowly connect a 12 volt booster battery to the System Jump Starting To avoid damage to the vehicle or equipment and battery or the possibility of personal injury follow these instructions and precautions ANS WARNING HYDROGEN AND OXYGEN GASES ARE PRODUCED DURING NORMAL BATTERY OPERATION THIS GAS MIXTURE CAN EXPLODE IF FLAMES SPARKS OR LIGHTED TOBACCO ARE BROUGHT NEAR THE BATTERY WHEN CHARGING OR USING A BATTERY IN AN ENCLOSED SPACE ALWAYS PROVIDE VENTILATION AND SHIELD YOUR EYES WARNING KEEP OUT OF REACH OF CHILDREN BATTERIES CONTAIN SULFURIC ACID AVOID CONTACT WITH SKIN EYES OR CLOTHING ALSO SHIELD YOUR EYES WHEN WORKING NEAR THE BATTERY TO PROTECT AGAINST POSSIBLE SPLASHING OF THE ACID SOLUTION IN CASE OF ACID CONTACT WITH SKIN EYES OR CLOTHING FLUSH IMMEDIATELY WITH WATER FOR A MINIMUM OF 15 MINUTES IF ACID IS SWALLOWED DRINK LARGE QUANTITIES OF MILK OR WATER FOLLOWED BY MILK OF MAGNESIA A BEATEN EGG OR VEGETABLE OIL CALL A PHYSICIAN IMMEDIATELY AN CAUTION Do not disconnect the battery of the vehicle to be started Disconnecting th
330. nition El with Distributor Electronic Spark Advance Control ESAC High Energy Ignition Remote Mount Thick Film Ignition Remote Mount TFI Thick Film Ignition TFI Di Capacitor Condenser Distributor ICM Electronic Distributor Ignition System Module EDIS Module Distributor Ignition System DI System Electronic Distributor Ignition System EDIS Early Fuel Evaporation EFE Early Fuel Evaporation EFE Electrically Erasable Programmable EEPROM Electrically Erasable Programmable Read Only Memory Read Only Memory E2PROM Distributor Ignition 09 10 Auxiliary Systems Metrics J1930 TERMINOLOGY LIST New Acronym Old Terms Acronyms Electronic Continuous Fuel Injeciton Electrnic CFI Continuous Injection System System System Electronic Continuous Injection System E CIS E Electronic Engine Control Electronic EC Electronic Engine Control EEC Electronic Ignition Computer Controlled Coil Ignition C3l Distributorless Ignition Electronic Ignition El without Distributor Integrated Direct Ignition IDI Direct Ignition System DIS Distributorless Ignition System DIS Electronic Distributorless Ignition System EDIS Electronic Engine Control EEC Engine Control Module ECM ECL Engine Coolant Level ECL ECL Indicator Engine Coolant Level Indicator ECT Engine Coolant Temperature ECT ECT
331. nlet bore Fuel inlet connection Mixture outlet bore Vacuum pipe nipple SHUT OFF VALVE Type Max working pressure Inlet connection Outlet connection Coil SAFETY SWITCH Type FUEL Fuel Fuel Specifications Solenoid N Fuel Filter Fuel Tank Vacuum Operated On Off Switch R Vacuum Connector Air valve venturi 77 8 mm diameter 3 4 NPTF 60 3 mm diameter 6 35 mm outside diameter Double poppet valve 2150 kPa 1 4 NPTF 1 4 NPTF 12V 6W Vacuum operated Liquefied Petroleum Gas LPG EN 589 European HO 5 USA Auxiliary Systems Fuel SYSTEM OPERATION LPG WARNING WHEN INSTALLING ANY LIQUID PETROLEUM GAS FUEL SYSTEMS FOLLOW ALL COUNTRY AND LOCAL CODES IN THE USAFOLLOW ALL REGULATIONS AND STANDARDS MANDATED BY THE NATIONAL FIRE PROTECTION ASSOCIATION INC INCLUDING NEPA 37 NFPA 52 AND NFPA 58 PLUS ANY OTHER STANDARDS YOU CAN OBTAIN COPIES FROM YOUR LOCAL FIRE DEPARTMENT FOR CANADIAN CODES SEE NATIONAL STANDARDS OF CANADA IN THE UNITED KINGDOM FOLLOW THE CODE OF PRACTICE ELEVEN PRODUCED BY THE LPG NG ASSOCIATION High pressure liquefied Petroleum Gas passes through a solenoid operated fuel shut off valve into an engine coolant heated vaporizer regulator unit where it is converted into a low pressure gas This gas is then fed into the carburetor body mixer where a vacuum operated gas metering valve ensures that the correct air to fuel ratio is m
332. nsor Lb In 71 89 20 4 27 5 15 19 Specifications 08 24 Auxiliary Systems EFI amp Ignition Electronics ECM Diagnostic Trouble Codes The following table lists the Diagnostic Trouble Code DTC s supported by this application If any DTC s not listed here are flashed by the Malfunction Indicator Lamp MIL or displayed on a PC there may be a software error Notify Ford Power Products Customer Service Center if any DTC s are displayed that are not included in the following table All systems AlsystemsOK FP Eie wmm Sensor Voltage Low Accelerator Pedal Accelerator Pedal Position Sensor bad disconnected worn out Sensor Voltage wiring damaged Limp Home 4 Lowmanifold pressure MAP sensor bad bad wiring disconnected 1 Setcodeopnlop 15 Lowmanifoldtemp MST sensor disconnected sensor damaged wiring electrical failure Setcode openlop Pedal Switch Failure Pedal Position Sensor out of set range while IVS off damaged mis adjusted IVS malfunction damaged wiring electrical failure mechanical failure Limp Home DBW Actuator Unstable Actuator broken spring dirt in bore uneven operation ECM malfunction Lem TPS problem Engine over 4000 RPM Shutdown 2 HighThrottlePosition TPS faulty tampering iring electrical failure 24 High Manifold Pressure sensor defective vacuu
333. nstall replacement ECM Go to Step 19 Go to Step 20 or Go to Step 26 if Steps 20 25 have already been performed Go to Step 21 Go to Step 22 Go to Step 23 Go to Step 24 Go to Step 25 Go to Step 17 03 44 Auxiliary Systems Ignition ENGINE CRANKS BUT DOESN T START CIRCUIT TEST Continued 1 Test the fuel for water alcohol or other possible contamination 2 If a problem is found clean the fuel system and correct the contaminated fuel condition as necessary Replace the fuel filter and replace any injectors that are not delivering fuel Was a problem found 1 Ignition OFF install a suitable fuel pressure gauge at the fitting on the fuel rail 2 Ignition ON observe the fuel pressure Is the fuel pressure within the specified values and does it hold steady Is any fuel pressure indicated 1 Ignition OFF Install a test noid light at the injector harness connectors CAUTION Do not apply battery voltage B directly to the fuel injector electrical connector terminals The solenoids may be damaged internally in a matter of seconds 3 Ignition ON crank engine Does the light blink at each injector when the engine is cranked Check for B at coil connector Refer to Distributorless Ignition System Diagnosis 1 Ignition OFF 2 Disconnect coil harness connector 3 Ignition ON 4 Measure voltage at coil connector between B Coil feed and ground or use
334. nstalled in the aluminum cylinder head and measures the metal temperature The CHT sensor communicates an overheating condition to the ECM The ECM would then initiate a cooling strategy based on information from the CHT sensor A cooling system failure such as low coolant or coolant loss could cause an overheating condition As a result damage to major engine components could occur Using a CHT sensor and cooling strategy would prevent damage by allowing air cooling of the engine and limp home capability Cylinder Heat Temperature CHT Sensor Heated Oxygen Sensor HO2S The heated oxygen sensor HO2S detects the presence of oxygen in the exhaust and provides a variable voltage according to the amount of oxygen detected A high concentration of oxygen lean air fuel ratio in the exhaust provides a low voltage signal less than 0 4 volt A low concentration of oxygen rich air fuel ratio produces a high voltage signal greater than 0 6 volt The HO2S provides feedback to the ECM indicating air fuel ratio in order to achieve a near stoichiometric air fuel ratio of 14 7 1 during closed loop engine operation The HO2S generates a voltage between 0 0 and 1 1 volts Embedded with the sensing element is the HO2S heater The heating element heats the sensor to temperatures of 800 C 1400 F At approximately 300 C 600 F the engine can enter closed loop operation The VPWR circuit supplies voltage to the heater and the ECM will comp
335. ntinued Connect Spring Lock 7 Remove the Disconnect Tool 1 Connect the fitting Inspect and clean both the coupling ends Lubricate the O rings with clean engine oil meeting Ford specification WSS MN2C153 F Connect the fitting Pull on the fitting ot make sure it is fully engaged Install the safety clip 2 Connect the battery ground cable 04 8 Auxiliary Systems Fuel GENERAL PROCEDURES Continued Fittings Push Connect Disconnect Special Tool s Fuel Line Disconnect Tool 310 8039 T90T 9550 S 04 9 Special Service Tools called for by the procedures can be obtained by calling 1 800 ROTUNDA 1 800 768 8632 AS 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 SERVICING 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 PERSONAL INJURY OR A FIRE HAZARD 1 Disconnect the battery ground cable 2 Helieve the fuel pressure For additional information refer to Pressure Relief in this section 3 Disconnect the safety clip from the male hose Auxiliary Systems Fuel GENE
336. ny of the injector connections are connected to an incorrect cylinder correct as necessary Was a problem found Verify repair Go to Step 13 1 Remove spark plugs and check for gas or oil fouling cracks wear improper gap burned electrodes or heavy deposits 2 If spark plugs are fouled the cause of fouling must be determined before replacing the spark plugs Was a problem found Verify repair Go to Step 14 Visually physically check the vacuum hoses for Verify repair Go to Step 15 14 splits kinks and improper connections and routing Was a problem found Check the exhaust system for a possible restriction Pf aaa Verify repair Go to Step 16 Was a problem found Verify repair Go to Step 17 Check the following engine mechanical problems refer to Section 01 of this Manual Low compression Leaking cylinder head gasket Worn camshaft Sticking or leaking valves Valve timing Broken valve springs Camshaft drive belt slipped or stripped Was a problem found Verify repair Go to Step 18 Was a problem found Check for a faulty plugged or incorrectly installed Internal muffler failure 2 If a problem is found repair as necessary Damaged or collapsed pipe 1 Check for faulty motor mounts Verify repair Go to Step 19 Was a problem found 1 Review all diagnostic procedures within this table 2 If all procedures have bee
337. o temperature The element is packaged in a brass bulb housing or molded plastic housing with a protective cap which optimizes response time and a two terminal integral natural colored nylon plastic connector m IAT sensor typical Specifications e Range of Measurement 40 40 F to 125 C 57 F Measurement Accuracy 3 C e Resolution 0 6 C max Output Range 4 8 min to 91 max of VREF e Current Draw lt 5 mA from VREF Load Impedance gt 100 kohms 08 12 Auxiliary Systems EFI amp Ignition Electronics INTAKE AIR TEMPERATURE SENSOR Continued VOLTAGE DIVIDER NETWORK TRANSFER FUNCTION CS 71 FEST 5 906 3 0453 EHAKAL m T EIBHAL 0 247 E RETURN 40 34 11 T amp 2n7 9m d TEMP F TROUBLESHOOTING VOLTAGE SIGNAL amp SIGNAL RETURN ONAL f 242 SHORTED 4 535 OPEN RESISTANCE SIGNAL amp SIGNAL RETURN DISCONNECTED ECM PIN D 1 Q 743 GY 20 PIN B 2 e 359 GY R 359E GY R 18 IAT Detail Sheet 08 13 Auxiliary Systems EFI amp Ignition Electronics MANIFOLD SKIN TEMPERATURE SENSOR MST Part Description NOTE The MST is the same in appearance and specification as the brass IAT The MST sensor is a temperature sensitive resistor thermistor which interfaces with a resistor network m internal to the Engine Cont
338. o Step 7 2 With a DVOM check for ground on circuit 3590 Grey Red cavity 1 Is there a ground Go to Step 4 Go to Step 3 Check for an open on circuit 359D Grey Red and repair as necessary Was a repair necessary Re test Go to Step 4 1 Ignition OFF 2 Disconnect the MST sensor electrical connector 3 Check Ohm value across the two pins of the MST Is it within specs of above chart 1 Reconnect the MST sensor electrical connector Go to Step 7 Go to Step 6 2 With a suitable backprobing technique measure the voltage between cavity 2 circuit 225 BK Y and ground 20802 Is the voltage greater than the specified value Check for a short to voltage on circuit 225 BK Y and repair as necessary Was a repair necessary Remove ECM and install ia ECM Go to Step 9 Replace the MST sensor Is the repair complete Install replacement ECM Is system operation normal with replacement ECM installed reinstalled ECM and reinstall Keep originalECM replacement m installed Re test Go to Step 1 Is the repair complete system operation normal with replacement ECM Leave replacement ECM reinstalled installed Re test Remove original 08 37 Auxiliary Systems EFI amp Ignition Electronics Diagnostic Trouble Code 16 DBW NOTES Connector for PP Sensor Idle Validation Switch Pedal Position PP Sensor Connector Connector for Idle Validation Switch 359A GY R
339. oad program for validation use interface cable Installation of ECM ICM Refer to page 03 55 of this section 03 10 Auxiliary Systems Ignition DESCRIPTION AND OPERATION ECM Continued Camshaft Position Sensor CMP Sensor The CMP sensor detects the position of the camshaft and identifies when piston No 1 is on its compression stroke A signal is then sent to the engine control module ECM and used for synchronizing sequential fuel injection The Input circuit to the ECM is referred to as the CMP input or circuit Typical Hall Effect Sensor Cylinder Head Temperature Sensor CHT Sensor The cylinder head temperature CHT sensor is a thermistor device in which resistance changes with temperature The electrical resistance of a thermistor decreases as temperature increases and increases as temperature decreases The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the ECM corresponding to temperature Thermistor type sensors are considered passive sensors A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the voltage signal at the ECM This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor The CHT sensor is i
340. of Lower Intake Manifold 02 19 trm 02 108 Cylinder Head Removal 02 21 Special Tools METRI 02 108 Cylinder Head Installation 02 26 Assembly of Engine 4 2 02 109 Valve Cover LH Removal 02 32 Valve Cover LH Installation 02 34 steven ences 02 129 Valve Cover RH 02 35 Special TOONS RP 02 129 Valve Cover RH Installation 02 39 Valve Spring and Valve Spring Retainer 02 39 jejej 02 132 Valve Tappet Removal 02 42 Valve Tappet Installation 02 44 Exhaust Manifold LH Removal 02 45 Exhaust Manifold RH Removal 02 47 obecial uis arn densus 02 48 Removal of Crankcase Damper 02 48 Crankcase Front Oil 02 51 Removal of Rear Crankshaft Oil Seal 02 54 Installation of Rear Crankshaft Oil Seal 02 55 vin BOR
341. omplete system operation normal with replacement ECM Leave replacement ECM reinstalled installed Re test 08 53 Auxiliary Systems EFI amp Ignition Electronics Diagnostic Trouble Code 27 NOTES X 359C 1 Electronic Governor HI BE Va Y Throttle M Electronic c Position Governor 2 TP Sensor Connector om Connector Y A 361H R S01 355 GY W 351D BR W 359F GY R 2641 W LB S03 05 361G 359 GY R 351 2 482 A2 Rt K L7 7 Signal By 7777 Power 7 7 Engine Return Sensor Throttie Feed I Contro Signal 5V Reference Control 1 Module ECM DIAGNOSTIC TROUBLE CODE DTC 27 DRIVE BY WIRE IDLE FAILURE Circuit Description The throttle position TP sensor is a potentiometer which is attached to the throttle plate shaft inside the electronic governor The ECM provides a 5V reference voltage to the TP sensor between terminal A Grey Red circuit 359F and terminal C Brown White circuit 351D of the electronic governor A TP signal is returned to the ECM from terminal Grey White circuit 355 of the electronic governor The TP signal varies from about 1 0V at idle to 4 8V at WOT The TP signal is an important input used by the ECM for fuel control and other engine control functions Conditions for Setting the DTC For DBW with IAC only actuators is moving while idle validation switch is off opened
342. onnector 2 With a DVOM measure the voltage from the IAT sensor connector cavity 9 circui ifi Go to Step 4 Go to Step 2 3 Locate and repair the open or short to ground in circuit 743 Grey between the IAT sensor connector and the ECM Is the repair complete Re test Measure the voltage across the IAT sensor connector between cavity 1 and cavity 2 Is the voltage greater than the specified value s Locate and repair the open or short to ground in circuit 359 359E Grey 5 Red between the IAT sensor connector and the ECM Is the repair complete Re test 1 Connect the IAT sensor connector to the sensor 2 With a suitable backprobing technique measure the voltage across the IAT sensor connector between cavity 1 and cavity 2 Is the voltage less than the specified value Go to Step 8 Go to Step 7 7 Replace the IAT sensor Is the repair complete Install replacement ECM Remove replacement Is the system operation normal with replacement ECM installed ECM and install original ECM Go to Step 9 Is the repair complete system operation normal with original ECM Remove original reinstalled ECM and reinstall Keep original ECM replacement ECM installed Re test Go to Step 10 10 Is the repair complete system operation normal with replacement ECM Leave replacement ECM reinstalled installed Re test 08 73 NOTES Auxiliary Systems EFI amp Ignition Electronics Diagnostic Trouble Code 47 359C
343. ont Cover Stud 20 30 15 22 mm Inch Bolt Oil Capacity Engine Front Cover 20 30 15 22 Socket Head Cap Screw With Oil Filter L Qt 6 1 6 6 6 5 7 Engine Lifting Eye Nuts 20 30 15 22 Without Oil Filter L Qt 5 8 6 1 5 Engine Mount 68 92 51 67 Through Bolts Toa Ergin Continued 02 133 ESG 642 SPECIFICATIONS Continued Torque Specifications Torque Specifications Engine to Transmission 40 30 Oil Bypass Filter 10 15 7 5 11 Loe Bolts Oil Filter Adapter Bolts 20 30 15 22 Exhaust Flange Nus 40 30 8mm Exhaust Manifold Bolts 20 30 15 22 Oil Filter Adapter Bolts 8 11 71 97 Lm Exhaust Manifold to 25 18 Oil Galley Pugs 25 0 19 29 Brackett Cil Level Indicator Tube 10 Front Cover to cylinder 25 18 OiPanDran Pug 26 19 Mano Bors Fuel Pressure Dampener 3 4 5 2 5 3 RM Oil Pan to Transmission 38 51 28 38 Fuel Pressure Relief 7 Valve Oil Pickup Tube to Cyl 25 18 Oil Pickup Tube to Oil 48 35 Panbattenut o Fuel Pressure Relief 7 75 Me o ns m oo Fuel Pressure Relief 7 75 ave Oil Pressure Sensor 11 16 9 11 Oil Pump Screen Cover 20 30 15 22 m and Tube Bolts Fuel Pressure Relief Valve Cap Fuel Supply Manifold 10 Bolts 15 22 Oil Pump Screen Cover 40 50 30 37 Power Steering Pressure 40 30 15 22 Generator Positive 10 em
344. ools called for by the procedures can be obtained by calling 1 800 ROTUNDA 1 800 768 8632 07 16 Auxiliary Systems EFI amp Ignition Electronics ELECTRONICS amp DIAGNOSTIC TROUBLE CODES INDEX SUBJECT PAGE SUBJECT PAGE Idle Air Control IAC Valve Detail Sheet 08 3 Diagnostic Trouble Codes Continued Camshaft Position Sensor CMP Hall Effect 08 4 Trouble Code 52 08 78 Detail Sheet 2 nee 08 5 Trouble Code 53 08 80 Manifold Absolute Pressure Sensor MAP 08 6 Trouble Code 08 82 MAP Detail Sheet 2 08 7 Trouble Code 55 08 83 Throttle Position Sensor TP 08 8 Trouble Code 596 nore 08 84 TP Detail Sheet 08 9 Trouble Code 57 08 85 Heated Oxygen Sensor HO2S 08 10 Trouble 08 86 HO2S Detail Sheet 08 11 Trouble Code 02 eoi nante rer 08 87 Intake Air Temperature Sensor IAT 08 12 Trouble Code 65 08 88 IAT Detail Sheet 08 13 Manifold Skin Temperature Sensor 08 14 MST Detail 1 0
345. orm major and minor repairs They are anxious to see that all of your maintenance and service needs are quickly and courteously completed Serial Nutber 01234 1 05 98 Serial Number 37827 1 04 98 Model Number ESG 642 Base Engine Code Base Engine Build Date 6C 276 AA 01 02 2001 E RN FORD POWER PRODUCTS Prior 2001 2001 01 9 ESG 642 DESCRIPTION AND OPERATION Engine System This section covers general procedures and diagnosis and testing of the engine system including exhaust emission control devices which are also covered in the EFI Diagnostic Manual The engines incorporate the following features A closed positive crankcase ventilation PCV system An exhaust emission control system The engine fuel system ignition system 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 Manual 194 308 or call 1 800 833 4773 for the nearest Ford Power Product s Distributor Dealer They are also listed in the back section of this manual Correct engine identification is required to order parts For complete vehicle and engine identification codes refer to this Section Can be purchased as a separate item PFF 194 306 from your nearest Ford Power Products Distributor Dealer listed in back section of this manual 01 10 ESG 642 DIAGNOS
346. ormal 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 Metric System Bolt 1 2 13x1 Bolt M12 1 75x25 G Grade Marking _ P Property Class bolt strength bolt strength L Length inches L Length milirmeters T Thread Pitch T Thread Pitch thread width thread inch crest to crest mm D Nominal Diameter D Nominal Diameter inches millimeters The property class is an Arabic numeral distinguishable from the slash SAE English grade System The length of all bolts is measured from the underside of the head to the end 09 3 Auxiliary Systems Metrics METRICS Continued Bolt Strength Identification English System Grade 1 or 2 English Inch bolts Identification marks correspond to bolt strength increasing number of slashes represent increasing strength Metric System Metric bolts Identification class numbers correspond to bolt strength increasing numbers represent increasing strength Common metric fastener bolt strength property are 9 8 and 10 9 with the class identification embossed on the bolt head Hex Nut Strength Identification ENGLISH SYSTEM METRIC SYSTEM Grade Hex Nut Hex Nut Class Hex Nut Hex Nut Grade 5 Grade 8 Property Property Class 9 Class 10 Identification Identification 3 Dots 6 Dots Arabic 9 Arabic 10 Increas
347. ottle Body Nuts and Bolts p Pressure Norma Maximum Minimum Fuel Pump 441 kPa 451 kPa 431 kPa 64 psi 66 psi 62 psi NOTE Fuel pump has capability to produce 100 PSI 04 29 Auxiliary Systems Cooling COOLING INDEX SUBJECT PAGE Cooling System Description And Operation 05 3 EnG ime COO RENTEN Tm 05 3 The Coolant FaN 05 4 Coolant FIOW Pee Pc 05 4 The TR ACU ALON RTT TU T 05 4 The Radiator Cap 05 4 Recycled Coolant 2 05 4 Unsatisfactory Coolant Materials 05 4 Water Temperature Sending Unit 05 4 Block Heater 05 4 General Procedures 3 13 05 5 Cooling System Draining Filling amp Flushing 05 5 REN 05 7 Flushing Engine amp Radiator 05 8 Flushing Heater Core 05 9 Cooling System Removal And Installation 05 10 Radiator HOSE EN EO OT 05 10 Thermostat TRENT TOS 05 10 With or Without Heater or Dry Fuel Evaporator Plumbing 05 11 Installation of Heater Water Inlet Tube 05 11 Installation of Water Heater Outlet Tube Assembly with by pass Hose
348. ound circuit 359 Gray if other DTCs are also set Inspect the harness connectors for backed out terminals improper mating broken locks improperly formed or damaged terminals and poor terminal to wire connections Inspect the wiring harness for damage If the harness appears to be OK back probe the CHT sensor connector with a digital voltmeter and observe the voltage while moving connectors and wiring harnesses related to the CHT sensor A change in the voltmeter display will indicate the location of the fault NOTE For installation and removal procedures for the CHT refer to page 05 12 of this section 05 32 Auxiliary Systems Cooling MST CHT ECT amp IAT SENSOR DATA Temperature Sensor Characteristics x8 244 m 105 110 221801 23 f 15 199 28 19 257 304 29 98 zs 24 is 289 69 T 302 563 Voltage values calculated for VREF 5 volts may vary 1596 due to sensor and VREF variations 2 135 y TEMPERATURE NOM R NOM E o C F OHMS VOLTS Ls 9 eee E aid 6958 434 2096 o 4 138 415 128485 402 991 888 4 7494 35 _ 58 358 332 68 3734 309 3000 2 24253 22 i oe 1 Le sm 18 9 9
349. overnor This is a pulse width modulated PWM signal which cannot be read with conventional diagnostic tools such as a voltmeter A 12 volt signal which can be read as a steady 12V with a DVOM is pulsed on and off at a high rate of speed by the ECM through circuit 264 W LB pin R 1 The width of the on pulse determines the amount of throttle opening The ECM grounds the VPWR current sent through the governor with the appropriate pulse width base on the position of the accelerator pedal 08 40 Auxiliary Systems EFI amp Ignition Electronics Diagnostic Trouble Code 17 DBW Conditions for Setting DTC e KOER e Two or more opposing differences of normalized TPS signals which exceed 0 98V within 0 5 consecutive seconds Actions Taken When the DTC Sets The ECM will shut down the engine Engine can be restarted after cycling ignition switch off for 20 seconds ECM will light the MIL Trouble Shooting e The actuator may not be operating ECM is programmed incorrectly ECM malfunctions and bad ground DTC 17 Actuator Unstable No O Go to Diagnostic Are you using a personal computer PC to perform this diagnosis system Check before continuing at Step 2 Go to Step 2 2 1 Disconnect electronic governor electrical connector Lewes 98909989 2 KOEO check for voltage at circuit 361H Was voltage within specification VPWR B Go to Step 3 re test sede eA TERT meme Was a problem found Re test
350. own in the illustration DA0663 B 5 Install the main bearing caps 1 Arrows on the bearing caps indicate installation direction and location 2 Tighten the main cap retaining bolts two and stud bolts six in two stages e Stage 1 50 Nm 37 lb ft Stage 2 115 125 degrees NOTE Main cap retaining bolts and stud bolts are torque to yield Discard and replace with new Refer to this Section for installation procedures 02 111 ESG 642 ASSEMBLY Continued 8 14 Nm 71 124 Ib in DA0653 A 02 112 6 A CAUTION Use extreme care installing camshaft to prevent scoring or scuffing cam bearings May cause bearing failure e Lubricate the camshaft Lubricate the camshaft bearings lobes and journals with Engine Assembly Lubricant D9AZ 19579 D or equivalent meeting Ford specification ESR M88C80 A Install the camshaft and tighten 2 bolts to specification 7 CAUTION Use extreme care installing balance shaft to prevent scoring or scuffing balance shaft bearings May cause bearing failure e Lubricate the balance shaft bearings with Engine Assembly Lubricant D9AZ 19579 D or equivalent meeting Ford specification ESR M88C80 A Install the balance shaft and tighten 2 bolts to specification ESG 642 ASSEMBLY Continued 8 Install the timing chain vibration damper 9 Install the balance shaft drive gear Timing marks on the drive and driven gear must
351. per Limit mm Inch 0 050 0 002 Crankshaft Specifications Main Journal Diameter Standard mm Inch 63 983 64 003 2 5182 2 5190 0 25 mm 0 010 Inch Undersize mm Inch Out of Round Limit mm Inch 63 963 63 983 2 5182 2 5190 0 03 0 0012 Taper Limit mm Inch 0 016 0 0006 Runout mm Inch 0 05 0 002 Continued 02 132 ESG 642 SPECIFICATIONS Continued General Specifications Torque Specifications Connecting Rod Journal Diameter A C Compressor Bracket Standard mm Inch 58 682 58 702 to Cylinder Head Bolts 2 3103 2 3111 A C Compressor Bracket to Cylinder Head Nut 0 25 mm 0 010 Inch 58 662 58 682 A C Compressor Bracket Undersize mm Inch 2 3095 2 3103 to Cylinder Stud Bolt Ball 3 3 0 50 mm 0 020 Inch 58 632 58 652 Accelerator Cable Undersize mm Inch 2 3083 2 3091 Bracket Nut and Bolt Accelerator Cable Taper Limit mm Inch 0 016 0 0006 Bracket to Intake 48 48 25 8 11 10 Out of Round Limit 0 030 0 0012 Manifold Bolts mm Inch Accessory Drive Belt 48 64 35 47 Crankshaft Eng Play 0 007 0 20 Tensioner Bolt 9 12 55 55 3 25 45 14 mm Inch 0 00003 0 00787 Accessory Drive Belt 48 64 35 47 Idler Pulley Bolt Connecting Rod Specifications Battery Positive Cable 7 Bend for Each 25 mm 0 04 0 0015 Nut 5 5 8 8 1 1 97 Inches mm Inch Belt Idler Pulley Bots 55 41 Side Clearance 0 11 0 49 0 0047 0 01929 Belt Tensioner Bolt
352. per cables are not in way of moving engine parts Start engine of vehicle with good battery Run engine at a moderate speed Start engine of vehicle with discharged battery Follow starting instructions in the Owner Guide Completely discharged batteries may require an electrical load to initialize charging Remove cables in exact REVERSE sequence Begin by removing negative cable from engine of vehicle 4 that had discharged battery If the starter does not turn the engine over even with the booster battery attached refer to On Vehicle Testing Auxiliary Systems Starter STARTER PERMANENT MAGNET DIAGNOSIS AND TESTING Starter Load Test Conduct this test if the starter cranks slowly and it is desired to compare current to specifications 1 Connect Rotunda Starting and Charging Tester 078 00005 or equivalent Make sure that current is not flowing thorugh ammeter and heavy duty carbon pile rheostat portion of circuit rheostat at maximum counterclockwise position 2 Disconnect load from engine Place transmission or transaxle in NEUTRAL Crank engine with ignition off and determine exact NEGATIVE CARBON PILE RHEOSTAT STARTER SWITCH ON IGNITION SWITCH Bench Tests Make sure that the starter is securely mounted in bench vise while energizing as starter will move or jump 1 Connect a fully charged battery Rotunda Starting and Charging Tester 078 00005 or equivalent Make
353. perform this diagnosis Go to Diagnostic System Check before continuing at Step 2 Go to Step 2 1 KOEO Check the 5V reference signal from the ECM 2 Check the voltage between terminals A and C on the electronic governor 15 the voltage within the specified values 4 9 5 1V Go to Step 3 Go to Step 6 1 KOEO Check the TP signal to the ECM 2 Start the engine 3 Using a DVOM to pins A and B of the three wire pigtail on the electronic governor While observing the voltage reading operate the engine throughout the widest available range of speeds ideally from idle to WOT NOTE If a PC is available you can observe TP voltage on the engine data screen instead of using a DVOM Approx 1V 4 Shut the engine off at idle to 4 8V Does the voltage vary between the specified values Go to Step 4 Go to Step 8 Repair the wiring M 1 Disconnect ECM connector A thru K 2 Disconnect the TP sensor connector 4 3 Check for shorts or opens on circuit 355 between the TP sensor connector and the ECM connector Were any shorts or opens found Re test Go to Step 5 1 Disconnect ECM connector A thru K 2 Check for a short or open on circuits 351B and 359C Were any shorts or opens found Repair the wiring Re test Go to Step 7 7 Check circuits 351D and 359F for poor terminal connections at the ECM Repair the terminal Does either terminal need to be replaced Re test Go to Step 7 Replace the electronic governor Remove amp replace
354. ping tab by bending downward AV0313 A 4 Spread the hairpin clip legs and push the clip into the fitting 04 11 Auxiliary Systems Fuel GENERAL PROCEDURES Continued 5 Separate the fitting from the tube AV0315 B Connect 1 Inspect the fitting and the tube for damage Remove any dirt or obstructions 2 Apply a light coat of clean engine oil meeting Ford specification WSS M2C153 F to the male tube end 3 Insert the hairpin clip into the fitting AVO316 A 4 Align the tube and the fitting AV0317 A 04 12 Auxiliary Systems Fuel GENERAL PROCEDURES Continued 5 Insert the tube in the fitting and push together until a click is heard 18 6 Pull on the connection to make sure it is fully engaged 7 Connect the battery 0318 04 13 Auxiliary Systems Fuel REMOVAL AND INSTALLATION Fuel Injectors Removal ANS 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
355. pipe Internal muffler failure Was a problem found Check for the following engine mechanical problems refer to Section 01 of this Manual Low compression Leaking cylinder head gasket Worn camshaft Camshaft drive chain worn slipped or stripped s speed select switch actualy switching s the preset RPM being obtained 5 actuator responding Was a problem found 1 Review all the diagnostic procedures within this table 2 If all procedures have been completed and no malfunctions have been found review inspect the Go to Step 10 Verify repair Go to Step 11 O 11 following Contact Ford e Visual physical inspection including fuel quality Power Products check Customer All electrical connections within a suspected Service Center circuit and or system Technical Was a problem found Verify repair Support Hotline 1 800 521 0370 03 24 Auxiliary Systems Ignition DETONATION SPARK KNOCK SYMPTOM Value s DEFINITION A mild to severe ping usually worse under acceleration The engine makes sharp metallic knocks that change with throttle opening 10 Was a visual physical check performed Perform MIL DTC retrieval procedure Ignition ON engine not running short STI connector to ground Do any fault codes flash and display 1 If no fault codes display from MIL light and there are no engine mechanical faults fill the fuel tank with a known quality gasolin
356. placement Is system operation normal with replacement ECM installed ECM and install original ECM Go to Step 9 V Remove original ECM and reinstall Keep original ECM replacement ECM installed Re test Go to Step 10 s the repair complete system operation normal with replacemen Leave replacement ECM reinstalled installed Re test 08 71 Auxiliary Systems EFI amp Ignition Electronics Diagnostic Trouble Code 45 N O T E S 359E S05 MAP and CHT Sensors Intake Air Temperature IAT Sensor Connector 33 42 Pin Connector B2 da mue T Engine Signal Ground Control Module 1 DIAGNOSTIC TROUBLE CODE DTC 45 INTAKE AIR TEMPERATURE HIGH VOLTAGE Circuit Description The intake air temperature IAT sensor is a thermistor which measures the temperature of the air entering the engine The ECM supplies a ground circuit 359E Grey Red from the sensor When the intake air is cold the sensor resistance is high and the ECM will monitor a high signal voltage at the IAT signal circuit If the intake air is warm the sensor resistance is lower causing the ECM to monitor a lower voltage DTC 45 will set when the ECM detects an excessively low signal voltage on the intake air temperature sensor signal circuit Conditions for Setting the DTC KOEO or sensor signal 1 gt 4 96 e Above conditions are present for at least 3 consecutive seconds Actions
357. ply and cut to proper length NOTE If heater hose is not needed cap outlet G with rubber cap 5 8 in and hose clamp 05 11 Auxiliary Systems Cooling COOLING SYSTEM REMOVAL AND INSTALLATION Continued Cylinder Head Temperature Sensor Cylinder Head Temp Sensor CHT Torque 9 11 Nm Cylinder Head Asy LH Front of Engine Removal Located rear of left cylinder head B 1 Disconnect wire connector 2 Remove sensor A Installation 1 Install sensor dry NOTE Without any sealer on threads N caution Do not over torque May damage sensor 2 Torque to 9 11 Nm 3 Reconnect wire connector 05 12 Auxiliary Systems Cooling COOLING SYSTEM REMOVAL AND INSTALLATION Continued Cooling Fan Removal Installation Hemove fan drive belt Refer to fan drive belt Position the fan and pulley on the water pump hub removal on this page Remove the screws and Install the lock washer and screws and torque the washer assemblies attaching the fan and pulley to capscrews to specifications 55 Nm Install drive the water pump hub Remove the fan and pulley belt Refer to fan drive belt installation on this page Fan Drive Belt Removal 1 With engine off using a 1 2 breaker bar pry against the tension of the tensioner 2 Rotate the tensioner counterclockwise and remove the drive belt PULLEY BELT ROUTING WITH POWER STEERING PULLEY BELT ROUTING NOTE View looking at cranks
358. pump weep hole may be normal 05 19 Auxiliary Systems Cooling COOLING SYSTEM DIAGNOSING AND TESTING Continued Cooling System Visual Test Special Tool s Battery Anti Freeze Tester 014 R1060 or equivalent ST1720 A Special Service Tools called for by the procedures can be obtained by calling 1 800 ROTUNDA 1 800 768 8632 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 AVOID 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 110 F 1 Wrap a thick cloth around the pressure relief cap 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 cap A CAUTION If there is engine coolant in the engine oil the cause must be corrected and the oil changed or engine damage may occur caution If there is coolant in the transmission fluid the cause must be corrected or transmission damage may occur NOTE Check the engine coolant in the degas bottle and radiator 8005 if vehicle has been allowed to reach normal operating temperature This will make sure sufficient engine coolant ex
359. put Switched to open Reaction X is stall engine Aux Aux output 1 open drain Starter lockout X relay control O Aux E Aux output 2 open drain Tach signal or X relay control I O Input Output 03 16 Auxiliary Systems Ignition DESCRIPTION AND OPERATION ICM Continued OCTANE SELECT OPERATION OCT 1 Used to select ignition table for fuel type OCT2 Used to choose constant to add or subtract Input can be V ground or open Fuel choices are from selected timing table LPG Natural Gas The ICM Deluxe is backwards compatible with ICM Basic TABLE 3 Operation of ICM Deluxe Platform OCT1 OCT2 Timing Effect Circuit 674 BR W Circuit 72 Y BK NG To Globally Modify Ignition Timing Table OCT2 Timing Effect Circuit 72 Y BK Oen No Efect on Base Timing 2 Retard 3 Degrees Globally 12V Advance 5 Degrees Globally 03 17 Auxiliary Systems Ignition DISTRIBUTORLESS IGNITION SYSTEM DESCRIPTION AND OPERATION Service Adjustments And Checks 1 Each 400 hours of engine operation remove the spark plugs and clean and adjust the electrode 2 Clean and visually check spark plug high tension leads check for secure fit and replace if necessary Diagnostic Equipment To accurately diagnose DIS certain diagnostic equipment and tools are required In addition the suggested diagnostic equipment may make the job easier and more convenient Prior to diagnosing DIS obtain
360. que converter access cover and the torque converter retaining nuts Rotate the crankshaft to access the retaining nuts Remove if equipped Remove the engine oil pan to transmission retaining bolts on the left side NOTE Remove SAE housing and adaptor plate if equipped Remove the engine oil pan to transmission retaining bolts on the right side e See note in Step 12 above Remove the nuts retaining the exhaust pipe at the exhaust manifolds Remove the shift cable routing bracket retaining bolt if so equipped ESG 642 REMOVAL Continued 16 Remove the engine mount retaining nuts Left side shown 17 Install the engine lifting equipment 18 Remove the transmission dipstick tube for automatic transmissions 1 Position the drain pan 2 Remove the transmission to engine DA0220 A retaining bolt at the dipstick tube bracket 3 Remove the tube 4 Discard the O ring 19 Remove the transmission to engine retaining bolts 20 Remove the engine DA0221 A 02 89 ESG 642 DISASSEMBLY Engine Special Tool s Special Tool s Camshaft Bearing Set Seal Remover T65L 6250 A T92c 6700 CH Connecting Rod Guide Tool Syncro Positioning Tool T93P 6136 A T89P 12200 A Crankshaft Damper Remover Vibration Damper Remover T58P 6316 D Adapter T82L 6316 B Cylinder Ridge Reamer T64L 6011 EA ST1276 A Special Service Tools called for by the procedures can be obtained by calli
361. r 5 if necessary emove origin ECM and reinstall Keep original ECM replacement ECM installed Re test Go to Step 8 Is the repair complete system operation normal with replacement ECM Leave replacement ECM reinstalled installed Re test Is the repair complete system operation normal with original ECM reinstalled Check for fault connections at the ECM harness terminals and repair if necessary Was a repair necessary 1 2 3 4 7 8 08 86 Auxiliary Systems EFI amp Ignition Electronics Diagnostic Trouble Code 62 DIAGNOSTIC TROUBLE CODE DTC 62 SYSTEM VOLTAGE HIGH NOTE This is a software selectable DTC Circuit Description The ECM monitors the system voltage through circuit 361 Red terminal K1 power feed and circuit 37 Yellow terminal F2 battery feed DTC 62 will set whenever the ECM detects a voltage that is above a calibrated value Conditions for Setting the DTC e Engine RPM is greater than 700 e System voltage is more than or equal to 18 0V for at least 2 consecutive seconds Action Taken When the DTC Sets The ECM will illuminate the malfunction indicator lamp MIL ECM will shut down engine Engine can be restarted by recycling ignition switch Diagnostic Aids The DTC sets when an accessory is operated check for a poor connection or excessive current draw Excessive current draw can be a result of a short circuit or partial short circuit due
362. r as necessary Was a repair necessary Re test Go to Step 4 Bm 1 Reconnect the ECM and the CKP sensor 2 Connect a DVOM to measure the voltage on the CKP reference circuit 4 terminal H2 at the ECM connector 3 Observe the voltage while cranking the engine 2 5V Re test Go to Step 5 1 Attemptto start the engine Does the engine start Is the voltage near the specified value Check the connections at the CKP sensor and replace the terminals if necessary Was a repair necessary Replace the CKP sensor Is the repair complete Re test Check the connections at the ECM and replace the terminals if Lm necessary Was a repair necessary Re test Go to Step 8 Is the repair complete system operation normal with original Remove original ECM and reinstall Keep original replacement ECM ECM reinstalled Install replacement ECM Remove replacement Is system operation normal with replacement ECM installed ECM and install original ECM Go to Step 9 installed Re test Go to Step 10 Is the repair complete system operation normal with replacement Leave replacement ECM ECM reinstalled installed Re test 08 79 NOTES Auxiliary Systems EFI amp Ignition Electronics Diagnostic Trouble Code 53 Crankshaft Position CKP Sensor Connector Camshaft Position CMP Sensor Connector a 1 i Ground DGL P
363. r hose to the lower F intake manifold A25880 B 9 Connect the electrical harness 10 Install the upper intake manifold Refer to the procedure in this section 1 Remove the upper and lower intake manifolds Refer to the procedures in this section 2 Remove the valve cover 6582 Remove the ignition coil pack if necessary Refer to procedures in Section 3 1 Remove the three valve cover bolts 2 Remove the two valve cover stud bolts A26874 A 3 Remove the valve cover 3 Remove the exhaust manifold 9430 Refer to the procedure in this section 4 f removing the LH cylinder head 6049 remove and support the power steering pump when applicable 02 21 ESG 642 ENGINE REPAIR Continued 5 Remove the 3 idler pulley bracket bolts 6 If removing the RH cylinder head remove the generator GEN 10346 Refer to Section 06 7 If removing the RH cylinder head remove the idler pulley 1 Remove the bolt 2 Remove the idler pulley 8 If removing the RH cylinder head remove the generator bracket 1 Remove the three bolts 2 Remove the generator bracket A25441 A 02 22 ESG 642 ENGINE REPAIR Continued A CAUTION If components are to be reinstalled they must be installed in the same position Mark the components for location 9 Remove the six rocker arms 6564 1 Remove the six bolts 2 Remove the six rocker arms NOTE Refer to Sectio
364. r to the wire in question and the other lead to a known ground If the bulb glows the circuit ground is OK Figure 6 2 Disconnect other loads powered through the fuse e Motors disconnect motor connector The circuit schematics in this manual make it easy to identify common points in circuits This knowledge can help narrow the concern to a specific area For example if several circuits fail at the same time check for a common power or ground connection If part of a circuit fails check the connections between the part that works and the part that doesn t work e Lights remove bulbs 3 Turnthe Ignition Switch to RUN if necessary to power fuse 4 Connect one Test Lamp lead to the hot end of the blown fuse Connect the other lead to ground The bulb should glow showing power to fuse This step is just a check to be sure you have power to the circuit For example if the low beam headlamps work but the high beams and the indicator lamp don t work then the power and ground paths must be good Since the dimmer switch is the component that switches this power to the high beam lights and the indicator it is most likely the cause of failure 5 Disconnect the test lamp lead that is connected to ground and reconnect it to the load side of the fuse at the connector of the disconnected component In Figure 5 connect the test lamp lead to connector C4 e f the Test Lamp is off the short is in the
365. raulic lash adjuster REPLACE hydraulic valve tappet guide or hydraulic lash adjuster e REPAIR or REPLACE valve e REPLACE valve spring e ELIMINATE carbon buildup Refer to EFI Diagnostic Manual or Section 04 of this manual Refer to EFI Diagnostic Manual or Section 03 of this manual Can be purchased as a separate item PFF 194 306 from your nearest Ford Power Products Distributor Dealer listed in back section of this manual 01 12 ESG 642 DIAGNOSIS AND TESTING Continued e Excessive Oil Consumption Engine Noise ENGINE OPERATION e Worn piston ring groove e Sticking piston rings e Worn piston or cylinders e Worn valve stem seal e Worn valve stem or valve guide Leaking oil e Excessive main bearing oil clearance e Seized or heat damaged main bearing e Excessive crankshaft end play Excessive connecting rod bearing oil clearance e Heat damaged connecting rod bearing Damaged connecting rod bushing e Worn cylinder e Worn piston or piston Damaged piston rings Bent connecting rod Malfunctioning hydraulic valve tappet or hydraulic lash adjuster Excessive hydraulic valve tappet or hydraulic lash adjuster clearance Broken valve spring e Excessive valve guide clearance Malfunctioning or damaged cooling system Malfunctioning or damaged fuel System e Leaking exhaust system e Improper drive belt tensio
366. re Indicator Sender Unit EA E intake Manifold Upper NA 718 02 6 ESG 642 DESCRIPTION AND OPERATION Continued Engine Disassembled View Continued DA0615 C ESG 642 DESCRIPTION AND OPERATION Continued 1 10039 Generator Bracket 6758 Crankcase Ventilation Tube Part Number Description A666 Positive Crankcase Ventilation Valve 6 6 12280 in 12280 Ignition Wire and Bracket RH 12280 Ignition Wire and Bracket LH 6 6C324 Crankcase Vent Connector and Hose 6 Valve Cover LH 6049 Cylinder Head LH 448 Valve Cover RH R LH EE 5 EE E EIN Lu KE 7 10 11 12 13 14 15 16 17 8 6754 Oil Level Indicator Tube Number Description _ Number Description 6754 Oil Level Indicator Tube 4 Req d N807699 Rocker Arm Bolt 12 Req d 6518 Valve Spring Retainer Key 24 Req d 6514 Valve Spring Retainer 12 Req d ing d 6513 Valve Spring 12 Req d 6571 Valve Stem Seal 12 Req d Valve Spring Retainer 12 Heq d 2 2 2 2 2 2 19 0 2 3 24 25 26 27 8 9 30 31 32 33 34 02 8 ESG 642 DESCRIPTION AND OPERATION Continued Engine Disassembled View Continued ESG 642 DESCRIPTION AND OPERATION Continued Part Part Number Description Number Description 6255 Distributor Drive Gear 6266 Camshaft Rear Bearing 6288 Chain Belt Cup Plug 3 6A3
367. re connections Inspect the wiring harness for damage If the harness appears to be OK go to diagnostic chart below DTC 53 Camshaft Position Sensor Illegal Pattern Are you using a personal computer PC to perform this diagnosis Go to Diagnostic system Check before continuing at Step 2 Go to Step 2 1 Disconnect the CMP sensor 2 Measure the voltage between the sensor signal circuit 282 Dk Blue Orange and the sensor ground circuit 359C Grey Red at the CMP sensor connector Does the voltage measure near the specified value Go to Step 5 Go to Step 3 Check the sensor signal circuit 282 Dk Blue Orange and the sensor ground circuit 359 Grey Red for an open or short to ground and repair as necessary Was a repair necessary Re test Go to Step 4 ES Check for poor connections at the ECM and repair if necessary ars Was a repair necessary Re test Go to Step 5 1 Connect the CMP sensor 2 With aDVOM backprobe the CMP sensor signal circuit terminal J1 while cranking the engine Does the voltage toggle between the specified value Go to Step 7 Go to Step 6 Replace the camshaft position sensor Is the repair complete Re test Install replacement ECM Remove replacement Is system operation normal with replacement ECM installed ECM and install original ECM Go to Step 8 Is the repair complete system operation normal with original Remove original ECM reinstalled Keep original ECM and reinstall
368. repair complete system operation normal with original ECM reinstalled Remove original ECM and reinstall Keep original ECM replacement ECM installed Re test Go to Step 9 eave replacement ECIV installed Re test Is the repair complete system operation normal with replacement ECM reinstalled Replace the AP assembly 1 Clear code Install original AP 2 Retest Did code reset assembly Re test 08 33 Auxiliary Systems EFI amp Ignition Electronics Diagnostic Trouble Code 14 N OTES Mantfold E Absolute Pressure E E MAP Nr Sensor Connector pod 4 CE CHT IAT Sensors TFP Sensor ee Engine Return Signal Reference Control 1 Module DIAGNOSTIC TROUBLE CODE DTC 14 MANIFOLD ABSOLUTE PRESSURE MAP SENSOR LOW VOLTAGE Circuit Description The manifold absolute pressure MAP sensor responds to changes in intake manifold pressure vacuum The ECM provides a 5V reference voltage to the MAP sensor between terminal A Grey Red Circuit 359K and terminal C Brown White circuit 351C of the MAP sensor A MAP signal is returned to the ECM from terminal B Lt Green Black circuit 358 of the MAP sensor The MAP signal varies from about 1V at idle high vacuum to 4 8V with KOEO or at WOT low vacuum The MAP signal is used by the ECM as an indication of engine load This information is used to
369. ries from about 1V at idle high vacuum to 4 8V with KOEO or at WOT low vacuum The MAP signal is used by the ECM as an indication of engine load This information is used to control spark advance and air fuel ratio The MAP signal is also used at KOEO to indicate barometric pressure This information is used for altitude compensation when establishing spark advance and air fuel ratio DTC 14 will set with a low voltage to ECM and DTC 24 will set with a high voltage to ECM Conditions for Setting the DTC e KOEO MAP signal is significantly lower than estimated by the ECM eAbove conditions are present for at least 2 consecutive seconds Action Taken When the DTC Sets e The ECM illuminates the malfunction indicator lamp MIL The ECM uses an estimated MAP value based on throttle position and engine rpm Conditions for Clearing the DTC Resetting the MIL e The DTC can be cleared from memory by disconnecting the battery for 5 minutes elf a personal computer PC is connected to the engine the DTC can be cleared from memory by hitting the key while in the View Sensor Data screen 03 40 Auxiliary Systems Ignition MST CHT amp IAT SENSOR DATA Temperature Sensor Characteristics x8 244 m 105 110 221801 23 f 15 199 28 19 257 304 29 98 zs 24 is 289 69 T 302
370. rm this diagnosis 1 Ignition OFF 2 Disconnect the IAT sensor electrical connector 3 Check ohm value across the two pins of the IAT Is it within specs of above chart 1 KOEO 2 With a DVOM check for ground on circuit 359E Grey Red cavity 1 Is there a ground Check for an open on circuit 359E Grey Red and repair as necessary Was a repair necessary Ys _ No Go to System Check before continuing at Step 2 Go to Step 2 Go to Step 3 Go to Step 7 Go to Step 5 Go to Step 4 col Sp Check for a short to voltage on circuit 43 Grey and repair as necessary Was a repair necessary Replace the IAT sensor Is the repair complete Keep original replacement ECM Install replacement ECM Is system operation normal with replacement ECM installed V installed Re test Go to Step 10 s the repair complete system operation normal with replacement ECIV Leave replacement ECM reinstalled installed Re test Res cote ss Remove Econ ECM and install original ECM Go to Step 9 Remove original ECM and reinstall 1 Reconnect the IAT sensor electrical connector 2 With a suitable backprobing technique measure the voltage between cavity 2 circuit 743 Grey and ground Is the voltage greater than the specified value Go to Step 6 Go to Step 7 ee 08 63 NOTES Auxiliary Systems EFI amp Ignition Electronics Diagnostic Trouble Code 37 359C Electronic Governor
371. rol Module ECM or amp n Ignition Control Module ICM to provide a ratio metric output voltage inversely proportional to the outside air very close to the lower intake manifold The sensor is screwed into a mounting bracket located at the right rear of the lower intake manifold It provides the strategy with skin temperature of the lower intake manifold monitoring the air right next to the manifold The sensor input is used as a density corrector for air flow calculations and to e Range of Measurement proportion the cold enrichment fuel flow and to 40 40 F to 125 C 57 F modify spark MST sensor typical Specifications Measurement Accuracy 3 C The sensor element is a 0 095 inch diameter disc thermistor with soldered leads and a plastic protective coating The thermistor resistance varies Output Range 4 8 min to 91 max of VREF non linearly and inversely with respect to temperature The element is packaged in a brass bulb housing with protective cap which optimizes Load Impedance gt 100 kohms response time and a two terminal integral natural colored nylon plastic connector e Resolution 0 6 C max 08 14 Auxiliary Systems EFI amp Ignition Electronics MANIFOLD SKIN TEMPERATURE SENSOR MST Continued VOLTAGE DIVIDER NETWORK TRANSFER FUMCTION 55665 E bid 5 9806 5 CONVEHTER O io LET 548 K SENSOR M T S
372. rottle Opener VSV Ignition Control Vacuum Solenoid Valve Throttle Ignition Control Module Relay Idle Air Control VSV Electronic Spark Advance ESA Electronic Spark Timing EST Distributorless Ignition System Module DIS Module Thick Film Ignition Module Module Indirect Fuel Injection Fuel Injection Indirect Fuel Injection IDFI Indirect Diesel Injection IDI Inertia Fuel Shutoff IFS Inertia Fuel Shutoff IFS Inertia Fuel Shutoff Switch IFS Switch Inertia Switch Inertia Fuel Shutoff Switch Intake Air ntake Air m O 09 13 Auxiliary Systems Metrics J1930 TERMINOLOGY LIST New Acronym IA Duct Intake Air System IA System Intake Air Temperature IAT Air Charge Temperature ACT Manifold Air Temperature MAT Throttle Body Temperature TBT Vane Air Temperature VAT Air Temperature Sensor ATS Intake Air Temperature Sensor IATS Manifold Air Temperature Senso MATS Keep Alive Random Access Memory Keep Alive RAM Keep Alive Memory KAM Detonation Sensor DS Long Term Fuel Trim Block Learn Matrix BLM Block Learn Memory BLM Block Learn Multiplier BLM Low Speed Fan Control Switch Low Speed FC Low Speed Fan Control Switch Switch Low Speed FC Switch Malfunction Indicator Lamp MIL Check Engine Service Engine Soon Manifold Abso
373. rter will move or jump Starter Lock out Relay STARTER LOCKOUT 160 R 16 16 3284 R LB 16 m 18 NOTE All readings are made with connector attached to relay and back probing connector using a paper clip and fully charged battery Normal Area to Check Specs Out of Specs Circuit 16 gt Splice 2 gt 42 Pin Connector 01 Check fuse and wiring Check fuse and wiring Ignition switch or wiring Ignition switch amp wiring Ignition switch amp wiring Ignition switch amp wiring Ignition or wiring Ignition or wiring Ignition or wiring KOEO KOER Grd Crank ECM or wiring Relay or ECM ECM or wiring Auxiliary Systems Starter STARTER PERMANENT MAGNET DIAGNOSIS AND TESTING Continued System Inspection A CAUTION When disconnecting the plastic hardshell connector at the solenoid S terminal grasp the plastic connector and pull lead off DO NOT pull separately on lead wire IN WARNING WHEN SERVICING STARTER OR PERFORMING OTHER WORK IN THE VICINITY OF THE STARTER BE AWARE THAT THE HEAVY GAUGE BATTERY INPUT LEAD AT THE STARTER SOLENOID IS ELECTRICALLY HOT AT ALL TIMES NOTE Be sure to disconnect battery negative cable before servicing starter 1 Inspect starting system for loose connections 2 11 system does not operate properly note condition and continue diagnosis using the symptom chart A WARNING WHEN WORKING IN AREA O
374. ry Refer to Section 3 Torque 5 6 Nm 48 Ib in 3 bolts DA0672 A 30 Install the exhaust manifolds Use a new gasket 20 30 Nm 15 22 Ibift DA0674 A 02 122 ESG 642 ASSEMBLY Continued 31 Install the engine oil level indicator tube e Use a new O ring A O Ring Tube Assy C Cylinder Block 1 Lubricate O Ring with WSE M2C908 A oil prior to installation 2 Tube must be seated within 2mm of engine block 3 Install outboard of spark plug wires 32 Install the engine lifting eyes left side shown right side similar 20 30 Nm 15 22 Ibift DA0764 A 02 123 ESG 642 ASSEMBLY Continued 33 Install the crankshaft front seal 6700 A seal installer will be needed DAOS989 A 34 Install the crankshaft damper and the damper retaining bolt An installation tool will be required 35 Install the water pump pulley 22 28 Nm 16 21 Ibift 02 124 ESG 642 ASSEMBLY Continued 36 Install the idler pulley mounting and support brackets 41 55 Nm 30 41 Ib ft DAO767 A 34 Install the generator mounting bracket and belt idler pulley 02 125 ESG 642 ASSEMBLY Continued 38 Align and install the crankshaft pulley DA1013 A 39 Install the oil bypass filter and engine oil cooler if so equipped 0775 02 126 ASSEMBLY Continued 0771 5 642 02 127 40 41 Install the
375. s Ignition IGNITION SYSTEM DIAGNOSING AND TESTING Continued THROTTLE POSITION TP SENSOR DIAGNOSTIC TROUBLE CODE DTC 12 22 Eg CK Sensor Connector Signal Return TP Sensor Signal D MAP TP 5V Reference A Throttle Position TP Electronic Governor Electronic Governor Connector PWM Throttle Control Power Feed J Engine Control Module ECM 42 Pin Connector Pin 31 VREF 5V Circuit 359 Circuit 355 Circuit 351 K Off OV K Off OV K Off OV KOEO Ground KOEO 1 5 KOEO 5V KOER Ground KOER 1 5V to KOER 5V 4 8V Circuit Description The throttle position TP sensor is a potentiometer which is attached to the throttle plate shaft inside the electronic governor or the stock Ford throttle body The ECM provides a 5V reference voltage to the TP sensor between terminal A Grey Red circuit 359F and terminal C Brown White circuit 351D of the electronic governor A TP signal is returned to the ECM from terminal B Grey White circuit 355B of the electronic governor The TP signal varies from about 1 5V at idle to 4 8V at WOT The TP signal is an important input used by the ECM for fuel control and other engine control functions DTC 12 will set when the ECM detects low voltage and DTC 22 for excessively high voltage Conditions for Setting the DTC e KOEO TP signal 1 lt 0 31 12 TP signal is 4 9V or more 22 e A
376. s was not installed correctly when servicing please call FPP Customer Service 800 521 0370 1 Install the ECM or ICM in a vertical position with the electrical connectors facing downward NOTE The mounting location should be away from all heat source in an area that will not exceed 180 F 2 Install the hold down bolts 4 and tighten for ICM 8 10 Nm 71 88 Ib in The ECM bolts 4 tighten to 8 Nm 15 Ib in Insert the two wire connectors using great care not to bend or push out the terminals NOTE The connectors are keyed for correct installation always apply a small amount of dielectric grease to the face of the connectors 4 Tighten the ECM connector bolts 2 to 8 2 5 Nm 15 19 Ib in NOTE When the program has been changed on an ECM please mark on the outside of ECM cover the date program installed and initial 5 Re connect the vacuum hose on the ICM 6 Re connect the negative ground battery cable Engine Control Module ECM Electronic Engine Management System By Ford Power Products 0 Connector Port for A thru K Connector 12034391 Connector Port L thru Y Connector 12034400 Ignition Control Module ICM 5 Pin Auxiliary Connector Round 10 Pin Main Connector Oblong Ignition Control Module Vacuum Port 5 32 1 0 MAP Sensor 03 55 Auxiliary Systems Ignition SPECIFICATIONS Spark Plug Wire Routing Torque Specifica
377. ses being received If the ECM receives an incorrect number of pulses on the reference circuit DTC 52 will set Conditions for Setting the DTC e Extra or missing pulses are checked for after very 35 pulses Actions Taken When the DTC Sets The ECM will illuminate the malfunction indicator lamp MIL ECM will turn off the injectors and ignition for a minimum of one crankshaft rotation and wait for a valid pattern before turning the injectors and ignition back on If a valid pattern is not available the engine will not start The ECM will shutdown engine if the crankshaft pattern is lost 08 78 Auxiliary Systems EFI amp Ignition Electronics Diagnostic Trouble Code 52 Diagnostic Aids Inspect the harness connectors for backed out terminals improper mating broken locks improperly formed or damaged terminals and poor terminal to wire connections Inspect the wiring harness for damage If the harness appears to be OK go to diagnostic chart below DTC 52 Crank Position Extra Missing Pulses No O Are you using a personal computer PC to perform this diagnosis Go to Diagnostic System Check before continuing at Step 2 Go to Step 2 oto Engine Crank mew Go to Step 3 1 KOEO Disconnect the ECM and the CKP sensor 2 Check for an open or a short to ground in the reference circuit 350 Grey between the sensor connector and the ECM harness connector Repai
378. sion Range Selection TRS Transmission Range Sensor TR Sensor Manual Lever Position Sensor MLP Sensor Transmission Range Switch TR Switch Manual Range Position Switch MRPS Transmission Position Switch Transmisison Range Selection Switch TRSS Turbo Distance Sensor 79 UJ Turbocharger Vehicle Speed Sensor Pulse Generator PG Voltage Regulator Voltage Regulator VH Volume Air Flow VAF Air Flow Control AFC Air Flow Meter lt lt a4 Vane Air Flow Volume Air Flow Sensor VAF Sensor Aif Flow Meter Air Flow Sensor AFS Warm Up Oxidation Catalytic Converter WU OC Light Off Catalyst Warm Up Three Way Catalytic Converter WU TWC Light Off Catalyst Wide Open Throttle Full Throttle Wide Open Throttle Switch WOT Switch Wide Open Throttle Switch WOTS 09 17 Auxiliary Systems Metrics 09 18 WE WANT TO HEAR FROM YOU Your suggestions will help us to improve this manual Mail this form or fax your comments to Ford Power Products 28333 Telegraph Rd Suite 300 Southfield Michigan 48034 Or Fax your comments to Ford Power Products Publication 248 945 4431 Manud VWehce YES NO Are you reporting an error in the procedures or illustrations EE If yes _ pleasedescribe in detail YES NO Did the procedures make sense and were they easy to follow
379. sioner for damage especially the mounting pad surface If the drive belt tensioner is not installed correctly the mounting surface pad will be out of position This will result in a chirp or squeal noises e With the engine running visually observe the grooves in the pulleys not the pulley flanges or pulley front surfaces for excessive wobble Replace components as required Check all accessories mounting brackets and the drive belt tensioner for any interference that would prevent the component from mounting properly Correct any interference condition and recheck belt tracking e Tighten all accessories mounting brackets and drive belt tensioner retaining hardware to specification Recheck the drive belt tracking 05 35 Auxiliary Systems Cooling SPECIFICATIONS General Specifications Torque Specifications item Specification Drive Belt Capacity 4 2L L qts 16 4 17 3 Belt Idler Pulley Bolt 4 2L 4 17 Drive Belt Tensioner Bolt 4 2L Pressure Relief Cap Pressure kPa psi 110 16 Water Thermostat Start To Open Temperature C F 86 7 90 6 C 188 195 F 8 Water Thermostat Full Open Temperature C F 97 8 101 7 C 208 215 F Lubrication amp Sealants amp Sealants Pa Ford Premium Cooling System Flush ESR M14P7 A F1AZ 19A503 A 5 Pipe Sealant with Teflon era a D8AZ 19554 A WSK M2G350 A2 Degas Bolts Radiator Draincock 07 1 4 6 12
380. sis Inspect engine fluids for correct levels and evidence of leaks Inspect vacuum hoses for damage leaks cracks kinks and proper routing inspect intake manifold sealing surface for a possible vacuum leak Inspect PCV valve for proper installation and operation Inspect all wires and harnesses for proper connections and routing bent or broken connector pins burned chafed or pinched wires corrosion and verify harness grounds are clean and tight Inspect engine control module ECM sensors and actuators for physical damage e Inspect ECM grounds for cleanliness tightness and proper location Inspect fuel system for adequate fuel level and fuel quality concerns such as proper octane contamination winter summer blend Inspect intake air system and air filter for restrictions Intermittent Problems Important An intermittent problem may or may not turn on the malfunction indicator lamp MIL or store a DTC Do not use the Diagnostic Trouble Code DTC charts for intermittent problems The fault must be present to locate the problem MIL and DTC information is found in Section 08 of this manual Most intermittent problems are caused by faulty electrical connections or wiring Perform a careful visual physical check for the following conditions Poor mating of the connector halves or a terminal not fully seated in the connector backed out Improperly formed or damaged terminals e
381. spection T 01 33 Piston 01 34 Piston to Cylinder Bore Clearance 01 34 Piston Selection m 01 35 Piston Ring End 01 35 Piston Ring to Groove Clearance 01 36 Crankshaft Connecting Rod Journal Diameter 01 37 Crankshaft Connecting Rod Journal Taper 01 37 Connecting Rod Cleaning 01 38 Connecting Rod Larger End Bore 01 38 Piston Pin Diameter icc auis pa ie cusa 01 39 Connecting Rod Bushing Diameter 01 39 Connecting Rod Bend 2 01 40 Connecting Rod 22 01 40 Connecting Rod Piston Pin Side Clearance 01 41 Connecting Rod Journal Clearance 01 41 Bearing Inspection 01 42 Roller Follower Inspection Engines 01 43 Hydraulic Valve Tappet Inspection OHV Engines 01 43 Hydraulic Valve Tappet Leakdown Test Salis i em RH 01 43 ESG 642 SUBJECT PAGE General Service Procedures Continued Hydraulic Lash Adjuster Leakdown Test dt 01 44 Valve Stem Diameter sees 01 45 Valve Stem to Valve Guide Clearance 01 46 Valv
382. ston rings e Worn cylinder Damaged cylinder head gasket Damaged fuel system Damaged ignition system Damaged hydraulic valve tappet or hydraulic lash adjuster Damaged hydraulic valve tappet guide or hydraulic lash adjuster e Improper valve to valve seat contact Damaged cylinder head gasket Malfunctioning or damaged fuel system Malfunctioning or damaged ignition system Malfunctioning or damaged IAC motor or system e Damaged hydraulic valve tappet or hydraulic lash adjuster Damaged hydraulic valve tappet guide or hydraulic lash adjuster Burnt or sticking valve e Weak or broken valve spring Carbon accumulation combustion chamber Malfunctioning or damaged fuel System Malfunctioning or damaged ignition system Action e REFER to Section 07 e REFER to Section 06 e REPLACE valve e REPLACE piston and pin e REPAIR or REPLACE cylinder blocks e REPLACE cylinder head gasket Refer to Section 04 Refer to Section 03 e REPLACE hydraulic valve tappet or hydraulic lash adjuster e REPLACE hydraulic valve tappet guide or hydraulic lash adjuster e REPLACE valve or valve seat e REPLACE cylinder head gasket Refer to EFI Diagnostic Manual or Section 04 of this manual Refer to EFI Diagnostic Manual or Section 03 of this manual e Section 03 of this manual REPLACE hydraulic valve tappet or hyd
383. sure This information is used for altitude compensation when establishing spark advance and air fuel ratio Conditions for Setting the DTC KOEO or MAP signal is significantly higher than that estimated by the ECM Above conditions are present for at least 2 consecutive seconds Actions Taken When the DTC Sets ECM illuminates the malfunction indicator lamp MIL e The ECM uses an estimated MAP value based on throttle position and engine rpm 08 48 Auxiliary Systems EFI amp Ignition Electronics Diagnostic Trouble Code 24 Diagnostic Aids The MAP sensor share the same ground with the Engine Coolant Temperature ECT sensor and the Intake Air Temperature IAT sensor Check the ground circuit 359 Gray Red Gray Yellow if these DTC s are also set Inspect the harness connectors for backed out terminals improper mating broken locks improperly formed or damaged terminals and poor terminal to wire connections Inspect the wiring harness for damage DTC 24 Manifold Absolute Pressure MAP Sensor High Voltage Values Yes Are you using a personal computer PC to perform this diagnosis Go to Diagnostic System Check before continuing at Step 2 Go to Step 2 1 Disconnect the MAP sensor electrical connector 2 KOEO 3 Check the voltage between terminals A and C on the MAP sensor electrical connector Is the voltage within the specified values 4 9 5 1V Go to Step 3 1 Reconnect the MAP
384. sure that the battery and starter motor are grounded 2 Engage the remote starter switch The starter motor should eject the starter drive and run smoothly If the starter motor does not run smoothly replace it 4 While the starter motor is running check the voltmeter and ammeter Rotunda 1 800 578 7375 reading on voltmeter This test is accomplished by disconnecting push on connector S at starter relay and by connecting a remote control starter switch from positive battery terminal to 5 terminal starter relay 3 Stop cranking engine and reduce resistance of carbon pile until voltmeter indicates same reading as that obtained while starter cranked the engine The ammeter will indicate starter current draw under load Check this with value listed in Specifications e ROTUNDA STARTING AND CHARGING TO IGNITION SWITCH PPD0039 5 Ifthe voltage is lower than the 11 0 volts or the amperage is higher than 70 amps replace the starter motor NOTE Service parts for rebuilding permanet magnet starter are not available from Ford Power Products 07 5 Auxiliary Systems Starter STARTER PERMANENT MAGNET DIAGNOSIS AND TESTING Continued Starter No Load Test TESTER POSITIVE NEGATIVE BATTERY CONVENIENT GROUND ON STARTER SUCH AS MOUNTING EAR ON CASTING NCAUTION Make sure that the starter is securely mounted in bench vise while energizing as sta
385. t hold down bolt A through flange and into intake manifold Torque hold down bolt to 8 11 5 Nm 2 Install rubber cap and clamp on outlet B tube if not using LPG Fuel or cab heater 3 Whenrunning on LPG fuel or using a cab heater perform the following Install heater hose 19mm 3 4 in customer to supply and cut to proper length from the water inlet tube B to either the cab heater inlet or the LPG evaporator inlet 4 Follow step 5 in the next process installation of water heater outlet tube assembly with bypass hose 5 Fill cooling system with 50 50 mixture of Ethylene Glycol green or green yellow in color not red and water Installation of Water Heater Return Tube Assembly with by pass Hose E Bypass Hole F Hold Down Bolt Heater Tube Heater Water Return Tube A Bypass Tube Inlet Tube Hole Ring 0 Water Pump 1 Install new O ring C on portion of tube going into water pump B and lubricate O ring C with ESE M99B144 B Surfactant or other approved lubricant 2 nserttube into hole in upper portion of water pump B 3 Align hold down flange and insert bolt F Torque bolt to 8 11 5 Nm 4 Attach the by pass hose E along with two hose clamps to bypass tube A and to Heater Water Return Tube that is directed toward Thermostat Water Outlet Connector and connect 5 Attach heater hose 5 8 in to Heater Tube G of Heater Water Return Tube Assembly Customer to sup
386. t runout e Rotate the camshaft and subtract the lowest dial indicator reading from the highest dial indicator reading DA0351 A 1 Measure each of the crankshaft main bearing journal diameters in at least two directions f it is out of specification replace as necessary DA0352 A Crankshaft Main Bearing Journal Taper 1 Measure each of the crankshaft main bearing journal diameters in at least two directions at each end of the main bearing journal f itis out of specifications replace as necessary T DAQ353 A 01 29 ESG 642 GENERAL SERVICE PROCEDURES Continued Crankshaft Main Bearing Journal Clearance Special Tool s CAUTION Before removing main bearing the cylinder heads must be removed Plastigage first on the ESG 642 engine The main bearing D81L 6002 B or Equivalent and head bolts are torque to yield and must be discarded and replaced after this diagnostic test Special Service Tools called for by the procedures Crankshaft main bearing journals must be can be obtained by calling within specifications before checking journal 1 800 ROTUNDA 1 800 768 8632 clearance 1 Remove the crankshaft main bearing caps and bearings 2 Laya piece of Plastigage across the face of each crankshaft main surface A26392 A NOTE Do not turn the crankshaft while doing this procedure Install and remove the crankshaft main bearing 4 Verify the crankshaft journa
387. tall the oil baffle assembly 40 50 Nm 30 37 02 116 ESG 642 ASSEMBLY Continued 17 Install the oil pump screen cover and tube 20 30 Nm 14 22 Ib ft Use a new gasket NN m 3 5 DA0647 A N caution Mating parts must make contact to each other within 4 minutes and connecting bolts must be torqued within 15 minutes after applying sealant Failure to follow this procedure can cause future oil leakage e Use silicone gasket and sealant FGAZ 19562 AA or equivalent meeting Ford specification WSE M4G323 A6 NOTE Sealant must be removed and area cleaned with solvant if above instructions are not followed e Use metal surface cleaner F4AZ 19A536 RA or equivalent meeting Ford specification WSE M5B292 A 18 Clean mating surfaces on oil pan and cylinder block Use Metal Parts Cleaner F4AZ 19A536 RA or equivalent meeting Ford specification WSE M5B292 A e Apply a bead of Silicone Gasket and Sealant at position 1 as shown in the illustration Apply a bead along engine block the entire surface where oil pan mates to block and at 0 0668 each end of crank oil pan seal 02 117 ESG 642 ASSEMBLY Continued 19 Install the rear seal and oil pan 1 Tighten the oil pan retaining bolts in two stages in the sequence shown e Stage 1 4 5 Nm 36 44 Ib in Stage 2 9 12 Nm 80 106 Ib in En M 227 ac dr E CS
388. tart up for cold weather starting and for average value default settings in case of component failure Particular attention has been given to spark optimization for excellent fuel economy and power in the warm up mode The spark plugs are paired so that one plug fires during the compression stroke and its companion plug fires during the exhaust stroke The next time that coil is fired the plug that was on exhaust will be on compression and the one that was on compression will be on exhaust The spark in the exhaust cylinder is wasted but little of the coil energy is lost Run Mode The ECM interprets engine speed above 250 RPM as Run Mode The Base Spark Advance BSA is calculated by the ECM module processing the engine speed and load plus sensors mentioned in operation of this section and Fuel Select Switch Inputs to the ECM Effecting the Ignition The spark strategy is based on sensors and manifold vacuum input to the ECM module which include the following inputs 03 9 Crankshaft Position Sensor CKP Sensor The CKP sensor is a magnetic transducer mounted on the engine block adjacent to a pulse wheel located on the crankshaft By monitoring the crankshaft mounted pulse wheel the CKP is the primary sensor for ignition information to the ECM The pulse wheel located behind the crankshaft pulley has a total of 35 teeth spaced 10 degrees apart with one empty space for a missing tooth An A C voltage
389. ters Overhead Camshaft e Check for loose mounting bolts on camshaft carriers Check for plugged oil feed in the camshaft roller followers hydraulic lash adjusters HLA or cylinder heads Camshaft Overhead Camshaft Engines Check for broken or damaged parts Check the bolts on the intake manifold Push Rods Check for bent push rods 6565 and restricted oil passage Valve Springs Check for broken or damaged parts 01 21 ESG 642 DIAGNOSIS AND TESTING Continued Valve Spring Retainer and Valve Spring Retainer Keys eCheck for proper seating of the valve spring retainer key 6518 on the valve stem and in valve spring retainer 6514 Valve Spring Retainer Keys 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 valve tappet gap Check installed valve spring height Check for missing or worn valve spring seats Check for plugged oil metering orifice in cylinder head oil reservoir if equipped Static checks engine off are to be made on the engine prior to the dynamic procedure Valve Train Analysis Dynamic e Start the engine and while idling check for proper operation of all parts Check the following Rocker Arm
390. th replacement ECM installed ECM and install original ECM Go to Step Is the repair complete system operation normal with original Remove original ECM reinstalled ECM and reinstall Keep original ECM replacement ECM installed Re test Go to Step 7 Is the repair complete system operation normal with replacement Leave replacement ECM ECM reinstalled installed Re test 08 77 NOTES Auxiliary Systems EFI amp Ignition Electronics Diagnostic Trouble Code 52 Crankshaft Position CKP Sensor Connector Camshaft Position CMP Sensor Connector Ground 11077 777 73 Senso Sensor 7 Grund Sensor Sans jEngine Signal Signal Retum p Control gModule DIAGNOSTIC TROUBLE CODE DTC 52 CRANKSHAFT POSITION SENSOR EXTRA MISSING PULSES Circuit Description The reference signal is produced by the crankshaft position CKP sensor During one crankshaft revolution a predetermined number of crankshaft pulses will be produced The ECM uses the reference signal to calculate engine RPM and crankshaft position The ECM constantly monitors the number of pulses on the reference circuit and compares them to the number of camshaft position signal pul
391. the B pointer is just below the C Start Timing mark when the ram contacts the hydraulic valve tappet Start timing as the pointer passes the C Start Timing mark and end timing as the pointer reaches the D center mark DA0374 A Hydraulic Lash Adjuster Leakdown Test OHC Engines 1 NOTE The leakdown test will not be accurate if it is done with engine oil in the hydraulic lash adjuster Use testing fluid New hydraulic lash adjusters are already filled with testing fluid Compress the hydraulic lash adjuster to remove the engine oil if necessary 2 Place A hydraulic lash adjuster B commercially available hydraulic tappet leakdown tester Position the C steel ball provided in the plunger cap Add testing fluid to cover the hydraulic lash adjuster and compress hydraulic tappet leakdown tester until the hydraulic lash adjuster is filled with testing fluid 01 44 ESG 642 GENERAL SERVICE PROCEDURES Continued 3 Adjust the length of the A ram so that the B pointer is just below the C start timing mark when the ram contacts the hydraulic lash adjuster Start timing as the pointer passes the C start timing mark and end timing as the pointer reaches the D center mark DAO374 A Valve Stem Diameter 1 Measure the diameter of each intake and exhaust valve stem at the points shown Verify the diameter is within specification tht DA0375 A 01 45 ESG 642 GENERAL SERVICE PROCEDU
392. the DTC Sets The ECM illuminates the malfunction indicator lamp MIL The ECM will switch to open loop fuel control 08 58 Auxiliary Systems EFI amp Ignition Electronics Diagnostic Trouble Code 32 Diagnostic Aids Even small amounts of water delivered to the fuel injectors can cause a lean condition A misfiring cylinder will result in unburned oxygen in the exhaust which can cause a lean condition A plugged fuel filter can cause a lean condition Inspect the harness connectors for backed out terminals improper mating broken locks improperly formed or damaged terminals and poor terminal to wire connections Inspect the wiring harness for damage If the harness appears to be OK go to diagnostic chart below DTC 32 25 Sensor Low Voltage Stuck Lean Yes No Go to DEus System Check before continuing at Step 2 Go to Step 2 Stp 1 Adin O Are you using a personal computer PC to perform this diagnosis mE 1 Letthe sensor cool 2 KOEO 3 With a DVOM check the voltage between the signal circuit 74 GY LB and the return circuit 89 on the HO2S Sensor NOTE If a PC is available you can observe HO2S voltage on the 0 45V engine data screen instead of using a DVOM Is the sensor voltage approximate to the specified value 1 Disconnect the HO2S sensor electrical connector Go to Diagnostic Aids Go to Step 3 2 Check the sensor signal circuity 74 GY LB for
393. the Piston Ring Groove Cleaner to clean the piston ring grooves e Make sure the oil ring holes are clean Special Service Tools called for by the procedures can be obtained by calling A26388 A 1 800 ROTUNDA 1 800 768 8632 Piston Diameter 1 Measure the piston skirt diameter DA0360 A Piston to Cylinder Bore Clearance 1 Subtract the piston diameter from the cylinder bore diameter to find the piston to cylinder bore clearance 01 34 ESG 642 GENERAL SERVICE PROCEDURES Continued Piston Selection NOTE The cylinder bore must be within the 2 specifications for taper and out of round before fitting a piston 1 Selectapiston size based on the cylinder bore 9 DA0361 A 2 NOTE For precision fit new pistons are divided into three categories within each size range based on their relative position within the range A paint spot on the new pistons indicates the position within the size range Choose the piston with the proper paint color e Red in the lower third of the size range Blue in the middle third of the size range A26397 A Yellow in the upper third of the size range Piston Ring End Gap Special Tool s Special Service Tools called for by the procedures Feeler Gauge can be obtained by calling 1 800 ROTUNDA 1 800 768 8632 CAUTION Use care when fitting piston rings to avoid possible damage to the piston ring or the cylinder bore A CAUT
394. 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 Testing Procedure Open the air supply valve until the pressure gauge maintains 34 kPa 5 psi e Inspect sealed or gasketed areas for leaks by applying a solution of liquid detergent and water over areas for formation of bubbles which indicates leakage Leakage Points Examine the following areas for oil leakage e valve cover gaskets 6584 e intake manifold gaskets 9461 cylinder head gaskets oil bypass filter 6714 e oil pump and filter body 6603 oil level indicator tube connection oil pressure sensor 9278 Under Engine oil pan gaskets 6710 oil pan sealer oil pan rear seal 6723 engine front cover gasket e crankshaft front seal 6700 crankshaft rear oil seal 6701 crankshaft main bearing cap side bolts pump and filter body 4 2L engine With Transmission and 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 cr
395. the following test equipment or equivalent e Spark tester neon bulb type Champion CT 436 There is no need to disconnect a plug wire just place this spark tester on a spark plug wire to determine if spark is being provided to the plug This is especially useful for those hard to reach plug wires NOTE When using the spark plug firing indicator place the grooved end as close as possible to the plug boot Very weak or no flashing may be caused by a fouled plug Spark tester gap type special service tool D81P 6666 A Connect this gap type spark tester between any spark plug wire and engine ground to instantly determine if spark is being provided to the plug A spark plug with a broken side electrode is not sufficient to check for spark and may lead to incorrect results Volt ohmmeter Rotunda 014 00575 A volt ohmmeter is essential for gathering system operating data during diagnosis testing and engine servicing procedures This digital volt ohmmeter DVOM can also be used for general purpose electrical troubleshooting on conventional starting and charging systems 12 volt timing light Rotunda Model Number 164 R0257 This timing light uses an inductive pickup for convenience and safety on 12 volt systems and suitable for DIS ignitions Ignition Timing Check Base timing cannot be checked It is constantly being adjusted electronically To check timing FPP engineers must be contacted for furth
396. thin specifications before checking runout 1 Use the Dial Indicator with Bracketry to measure the crankshaft runout 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 DA0356 A 01 32 ESG 642 GENERAL SERVICE PROCEDURES Continued Cylinder Bore Taper 1 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 A26481 A Cylinder Bore Out of Round 1 Measure the cylinder bore in two directions The difference is the out of round Verify the out of round is within the wear limit and bore the cylinder to the next oversize limit DA0357 A Piston Inspection Special Tool s Piston Ring Groove Cleaner D81L 6002 D or Equivalent Special Service Tools called for by the procedures can be obtained by calling 1 800 ROTUNDA 1 800 768 8632 ST1279 A 01 33 ESG 642 GENERAL SERVICE PROCEDURES Continued CAUTION Do not use a caustic cleaning solution or a wire brush to clean the pistons or possible damage can occur 1 Cleanand inspect the A ring lands B skirts C pin bosses and the D tops of the pistons If wear marks or polishing is found on the piston skirt check for a bent or twisted connecting rod 2 Use
397. tions Lb Ft 20 4 27 5 18 36 810 Camshaft Position Sensor Bolts 2 2 3 3 5 Camshaft Synchronizer Bolt 1 20 30 8 10 Crankshaft Position Sensor 2 4 9 11 Description Air Intake Sensor 15 22 80 95 15 19 5 Foot Pedal Mounting Non Ford Use OEM Bolts Specifications 71 97 Cylinder Head Temperature Sensor Engine Control Module Mounting Bolts Engine Control Module Wire Connector Heated Oxygen Sensor Idle Air Control IAC Valve Ignition Coil Nuts and Stud Bolt 36 46 1 11 Item Base Timing Firing Order opark Plug Gap mm Inch Replacement Spark Plug Either Side Lubricant Silicone Dielectric Compund Motorcraft WA 10 D7AZ 19A331 A Ignition Control Module Mounting Bolts Manifold Skin Temperature Sensor 1 12 44 in Spark Plugs Motorcraft AGSF 42FCM Throttle Position Sensor 42 Pin Connector Bolt ESE M1C171 A 03 56 qo qo 1 25 30 4 5 6 35 50 8 10 10 20 2 8 3 4 Auxiliary Systems Fuel FUEL INDEX SUBJECT PAGE SUBJECT PAGE FUEL SYSTEM DESCRIPTION AND OPERATION FUEL SYSTEM DIAGNOSTIC AND TESTING FUGI TAN RENE EE UU MTM 04 3 e MT TNT TERN uj m 04 3 Fuel Pump Relay toss em gii Maj TOR 04 3 Fuel Supply Pressure gii E PUMI PT o 04 3 Service Check
398. tle positions If it doesn t check for silicone or other contaminants from fuel or use of improper RTV 4 sealant The sensor may have a white powdery coating which is silicone contamination Silicone contamination sends a rich exhaust signal which causes the ECM to command an excessively lean air fuel mixture Replace HO2S Was a problem found Verify repair Go to men 5 Inspect the fuel delivery system to determine if there 5 is a problem with fuel delivery Was a problem found Verify repair Go to neum 6 Inspect the secondary ignition wires Check for the following conditions Verify that the resistance of all ignition wires is less than the specified value Verify that ignition wires are correctly routed to eliminate cross firing Verify that ignition wires are not arcing to ground Spraying the secondary ignition wires with a light mist of water may help locate an intermittent problem key ON engine running Refer to Was a problem found Page 03 35 Verify repair Go to Step 7 Check for proper ignition voltage output with a Was a problem found Verify repair Go to Step 8 1 Check ignition coil secondary resistance 2 Replace the coil if it is not within the specified Did the coil require replacement Page 03 35 Verify repair Go to Step 9 1 Remove the spark plugs and check for gas or oil fouling cracks wear improper gap burned electrodes or heavy deposits 2 If spark plugs are fouled the cause of fou
399. to the CHT sensor 22 4 46 CM 925 021 4 54 A change in the CHT display will indicate the Voltage values calculated for VREF 5 volts may location of the fault vary 1596 due to sensor and VREF variations DTC 43 4 2L Cylinder Head Temperature Low Voltage DVOM Diagnostic Method Potion o X 1 Key off Disconnect the CHT sensor connection vem ewe 2 Check ohm value across the two pins of the CHT Is it within specs of above chart Go to Step 2 Go to Step 7 2 With a DVOM measure the voltage from the CHT sensor connector circuit 1102 Y LG to ground Is the voltage fi ov Co to Step 4 Go to Step 3 Locate and repair the open or short to ground in circuit 1102 Y LG between the CHT sensor connector and the ECM Is the repair complete Re test the voltage across the CHT sensor connector between cavity 1 and cavity 2 Is the voltage greater than the specified value Re test Go to Step 5 Locate and repair the open or short to ground in circuit 359 Grey Red Grey White between the CHT sensor connector and the ECM Is the repair complete Re test 1 Connect the CHT sensor connector to the sensor 2 With a suitable backprobing technique measure the voltage across the CHT sensor connector between cavity 1 and cavity 2 Is the voltage less than the specified value Go to Step 8 Go to Step 7 Replace the CHT sensor Is the repair complete Re test Install replacement Remove re
400. urement Accuracy 3 C Response Time 10 sec max for full range Resolution 0 6 C max Output Range 4 8 min to 91 max of VREF e Current Draw 5 mA from VREF Load Impedance gt 100 ohms 08 16 Auxiliary Systems EFI amp Ignition Electronics ENGINE CYLINDER HEAD TEMPERATURE SENSOR CHT Continued VOLTAGE DMBER NETWORK TRANSFER FUNCTION a SENSOR A 1 180 257 TEMP F TROUBLESHOOTING VOLTAGE SIGNAL SIGNAL 0 242 4 535 OPERATIONAL lt gdz SHORTED ECM ICM ECT SENSOR 1102 SIGNAL LINE RESISTANCE SIGNAL amp SIGNAL RETURN ECM ICM DISCONNECTED ECM ICM B lt lt 359 GY R 20 lt lt 1102 Y LG 20 10 PIN CONNECTOR 08 17 Auxiliary Systems EFI amp Ignition Electronics INJECTOR ASSEMBLY Part Description The fuel injectors are electromechanical devices that meter and atomize the fuel delivered to the engine With Multiport Fuel Injection MFI the injectors are mounted in the lower manifold and are positioned so that their tips are directing fuel just upstream of the intake valves The injector is a solenoid that actuates a normally closed ON OFF needle valve assembly The valve assembly pintle sits above a fixed size orifice seat The fuel pressure regulator maintains a constant pressure on the fuel therefore fuel flow to the engine is regulated only by how long the solenoid is
401. ust gas 600 to 1100 mV rich exhaust gas 08 10 Auxiliary Systems EFI amp Ignition Electronics HEATED OXYGEN SENSOR 25 Continued TRANSFER FUNCTION 3 0 TOO 2 BO 5 5 w 0 ji 13 14 15 18 16 5 RATIO TROUBLESHOOTING HO2SGND ECM 4 WIRE VOLTAGE HOT EGO ECM POWER GROUND PIN B 2 359 GY R 89 18 PIN K 1 361 G R 34 LB O 18 SIGNAL RETURN VPWR BATT 570 BK W 570 G BK 18 74 GY LB 74 GY LB 20 08 11 Auxiliary Systems EFI amp Ignition Electronics INTAKE AIR TEMPERATURE SENSOR Part Description The IAT sensor is a temperature sensitive resistor thermistor which interfaces with a resistor network internal to the Engine Control Module ECM ICM to provide a ratio metric output voltage inversely proportional to intake air or air charge mixture temperature The sensor is mounted in the air intake assembly or threaded into a cylinder runner of the intake manifold It provides the strategy with intake air temperature information The sensor input is used as a density corrector for air flow calculations to proportion the cold enrichment fuel flow and to modify spark advance The sensor element is 0 095 inch diameter disc thermistor with soldered leads and a plastic protective coating The thermistor resistance varies non linearly and inversely with respect t
402. ved prior to removal of the oil baffle assembly Failure to observe this caution can result in severe engine damage Remove the cylinder heads Refer to the procedure in this Section 2 Remove the oil pan Refer to the procedure in this Section 3 Remove the oil pump screen cover and tube Refer to the procedure in this Section 02 63 ESG 642 ENGINE REPAIR Continued 4 Remove the oil baffle assembly 5 Remove the main bearing cap or piston rod cap Rotate the crankshaft as required to access the rod caps To check main or rod bearing clearances refer to Section 01 CAUTION Discard all main and rod bolts and replace Bolts are torque to yield The use of used bolts may result in improper torque setting and could cause engine failure DA0883 A 02 64 ENGINE REPAIR Continued ESG 642 Installation of Crankshaft Main Piston Rod Bearings DAO886 A 02 65 2 On a main bearing cap locate the arrows that indicate the cap location and direction of installation On a rod cap locate the bearing insert notches which must align when the cap is installed Install the main bearing cap or rod cap as required 1 Tighten the main bearing cap retaining bolts in two stages 50 Nm 37 Ib ft 115 125 degrees 2 Tighten the rod cap bolts retaining bolts in three stages 20 25 Nm 15 18 lb ft 40 45 Nm 29 33 lb ft 90 120 degrees CAUTION main and ro
403. wire a terminal nut a terminal cover four tie wraps and insulation instructions 1 Install the starter motor 1 Position the starter motor 2 Install the bolts 07 14 Auxiliary Systems Starter REMOVAL AND INSTALLATION Continued 2 Connect the starter motor electrical connections ON Nm 88 133 Ib in 1 Position the starter solenoid wire 2 Position the battery cable 22 3 Install the nuts Nm a _ 45 82 Ibjin 3 Install the starter motor solenoid termial cover 4 Connect the battery ground cable 07 15 Auxiliary Systems Starter STARTER PERMANENT MAGNET SPECIFICATIONS TORQUE SPECIFICATIONS Description Nm 15 20 Lb Ft Starting Circuit Max Voltage Drop Engine Temp Normal Volts 0 5 Terminal Nut M 10 14 84 120 Terminal Nut 10 14 84 120 Through Bolt 5 0 9 5 45 84 Starter Motor Starter Brushes Brushes Current Normal Draw Under Engine Min Stall Motor Normal Cranking Torque Max No Diameter Load Speed 5 Volts Load Load Mfg Length Spring Tension om fret Maximum commutator runout is 0 12mm 0 005 inch Maximum starting circuit voltage drop battery positive terminal to starter terminal at normal engine temperature is 0 5 volt STARTING SYSTEM SPECIAL SERVICE TOOLS EQUIPMENT ROTUNDA EQUIPMENT 078 00005 VAT 40 Starting charging Tester Special Service T
404. without creating any new symptoms Some engine circuits may need special test equipment and special procedures See the Service Manual and other service books for details You will find the circuits in this manual to be helpful with those special test procedures Troubleshooting Tools Jumper Wire This is a test lead used to connect two points of a circuit A Jumper Wire can bypass an open in a wire to complete a circuit A warnina NEVER USE A JUMPER WIRE ACROSS LOADS MOTORS CONNECTED BETWEEN HOT AND GROUND THIS DIRECT BATTERY SHORT MAY CAUSE INJURY OR FIRE Voltmeter A DC Voltmeter measures circuit voltage Connect negative or black lead to ground and positive or red lead to voltage measuring point Ohmmeter Figure 1 Resistance Check An Ohmmeter shows the resistance between two connected points Figure 1 Auxiliary Systems Ignition INTRODUCTION Continued Test Lamp TEST LAMP o Figure 2 Test Lamp A Test Light is a 12 volt bulb with two test leads Figure 2 Uses Voltage Check Short Check Self Powered Test Lamp Figure 3 Continuity Check The Self Powered Test Lamp is a bulb battery and set of test leads wired in series Figure 3 When connected to two points of a continuous circuit the bulb glows Uses Continuity Check Ground Check AN caution When using a self powered test lamp or ohmmeter be sure power is off in circuit during testing
405. y Systems Ignition DIESELING RUN ON SYMPTOM Yes DEFINITION Engine continues to run after key is turned OFF but runs very rough If engine runs smoothly check the ignition switch and adjustment Was a visual physical check performed Go to 1 Visual Physical Go to Step 2 Check Perform MIL DTC retrieval procedure Refer to DTC Ignition ON engine not running short STI connec chart perform tor to ground component and Do any fault codes flash and display circuit test as required Go to Step 3 Check for a short between and the ignition feed circuit Was a problem found Verify repair Go to Step 4 1 Review all diagnostic procedures within this table 2 f all procedures have been completed and no malfunctions have been found review inspect the following Contact Ford Visual physical inspection including fuel quality Power Products check Customer All electrical connections within a suspected Service Center circuit and or system Technical Was a problem found Verify repair Support Hotline 1 800 521 0370 03 29 Auxiliary Systems Ignition BACKFIRE SYMPTOM Value s Yes efron Fuel ignites in the intake manifold or in the exhaust system making a loud popping Was p check performed Lusso Go to Visual Go to Step Physical Check Perform MIL DTC retrieval procedure Refer to DTC Ignition ON engine not running short STI chart perform connector to ground Do
406. y Systems Ignition INTRODUCTION COLOR ABBREVIATIONS BL Blue N Natural BK Black O Orange BR Brown PK Pink DB Dark Blue P Purple DG Dark Green R Red GN Green T Tan GY Gray White LB Light Blue Y Yellow LG Light Green NOTE Whenever a wire is labeled with two colors the first color listed is the basic color of the wire and the second color listed is the stripe marking of the wire How to Find Electrical Concerns Troubleshooting Steps These six steps present an orderly method of troubleshooting Step 1 Verify the concern Operate the complete system to check the accuracy and completeness of the customer s complaint Step 2 Narrow the concern e Using a DVOM narrow down the possible causes and locations of the concern to pinpoint the exact cause Read the description about the components and study the wiring schematic You should then know enough about the circuit operation to determine where to check for the trouble Step 3 Test the cause Use electrical test procedures to find the specific cause of the symptoms Step 4 Verify the cause Confirm that you have found the correct cause by connecting jumper wires and or temporarily installing a known good component and operating the circuit Step 5 Make the repair Repair or replace the inoperative component 03 3 Step 6 Verify the repair Operate the system as in Step 1 and check that your repair has removed all symptoms
407. y other fluid will not provide an accurate test Adjust the length of the ram so the pointer is 1 59 mm 0 062 inch below the starting mark when the ram contracts the tappet plunger to facilitate timing as the pointer passes Start Timing mark Use the center mark on the pointer scale as the Stop Timing point instead of the original Stop Timing mark at the top of the scale Work the valve tappet plunger up and down until the valve tappet fills with fluid and all traces of air bubbles have disappeared Allow the ram and weight to force the valve tappet plunger downward Measure the exact time it takes for the pointer to travel from the Start Timing to Stop Timing marks of the tester A satisfactory valve tappet must have a leakdown rate time in seconds within specified minimum and maximum limits If the valve tappet is not within specification replace it with a new valve tappet Do not disassemble and clean new valve tappets before testing because oil contained in the new valve tappets is test fluid Remove the fluid from the cup and bleed the fluid form the valve tappet by working the plunger up and down This step will aid in depressing the valve tappet plungers when checking valve clearance Timing Chain Refer to Section 02 for the removal and installation of timing chain belts sprockets and tensioners Make sure the timing marks on the A crankshaft sprocket 6306 and B camshaft sprocket 6256 are positioned
408. y the procedures can be obtained by calling 1 800 ROTUNDA 1 800 768 8632 NOTE If components are to be installed they must be installed in the same positions Mark components removed for correct location Disassembly of Cylinder Head 1 Remove the spark plugs 12405 2 UseValve Spring Compressor to compress the valve springs A26648 A 02 107 ESG 642 DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES Continued 3 Remove the following 1 Remove the valve spring retainer key 2 Remove the valve spring retainer 3 Remove the valve spring 4 Remove and discard the valve stem seal 5 Remove the valve spring seat 6 Remove the valve 1 NOTE Lubricate parts with engine oil before Assembly of Cylinder Head installing Follow the disassembly procedure in reverse order ASSEMBLY Engine Special Tool s Special Tool s Camshaft Bearing Set Front Crankshaft Seal Replacer T65L 6250 A T94P 6701 AH c ST1379 A Connecting Rod Guide Piston Ring Compressor T93P 6136 A D81L 6002 C or Equivalent gt Front Crankshaft Seal Continued Installer Aligner T88T 6701 A Special Service Tools called for by the procedures can be obtained by calling 1 800 ROTUNDA 1 800 768 8632 02 108 ESG 642 DISASSEMBLY Continued Special Tool s C Special Service Tools called for by the procedures can be obtained by calling Vibration Damper Remover 1 800 ROTUNDA 1 800 7
409. zed Ford Dealer Europe or Ford Power Products Distributor USA not only when repairs are required but also for regular maintenance Distributors are listed at the back of this manual Regular maintenance will result in minimal operating costs Engines manufactured by Ford Motor Company are available through Ford Power Products Dealers or Distributors When in need of parts or service contact your local Authorized Dealer or Distributor In overseas territories in the event of difficulties communicate directly with the supervising Ford affiliated Company in your area whose address appears at the end of this book Where the terms Right or Left occur in this publication they refer to the respective sides of the engine when viewed from the rear or flywheel end Pistons and valves are numbered from the front or timing cover end of the engine commencing at No 1 You may find that your engine assembly includes optional equipment not specifically covered in the following text Nevertheless the maintenance procedures outlined in this book still apply to your engine ENGINE IDENTIFICATION Because Ford Power Products markets such a wide range of industrial 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 New engines being shipped include a standard parts listing describing the parts which does not tell th

ESG-642 4.2 LITER - Pitt Auto Electric Company

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