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LRG-425 2.5 LITER (153 CID) - Pitt Auto Electric Company

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1. 2 Gleaning Cooling System lee aie eel a A en 2 Diagnosis a te eq ed ft en ctii qo darte e ebd tiens 3 PER 3 Cooling System Pressure 4 Radiator Cap Pressure 5 Thermostat Operation Check re hr it eaten ih e EU E a EUER E Pepe 5 Removal and 8 6 GoolingiE ette c D A 6 Drive Ball er E 6 Hadiator Hose ix cete ettet etat dam at etate i cota ats 7 Drain amp Refill Cooling System riore feti eec eate d c end adinan tidora edoae p adira sad ieee 7 Thermostat Replacemerit 2 2 der tt ia 8 REFER TO SEPARATE PUBLICATION ON ELECTRONIC FUEL INJECTION EFI SYSTEMS FOR INFORMATION ON THAT SYSTEM 08 2 UPPER HOSE LOWER HOSE Description The cooling system is of the full flow type with a centrifugal pump The thermostat located in the cylinder head controls the flow through the system maintaining the proper temperature The coolant flows from the bottom of the radiator to the water pump which delivers it to the cylinder block It then flows through
2. teh ics oes A eA 3 eee ue gh ers M Ue ELE 3 RNC ES 4 PercolatiOn scc eto tete metet m ln te e i eda t t te nee tete e eee tte tee nete 4 gt 52 H 4 5 ag E 4 Sten LLG 4 8101012 8 O 5 SUC OVS SI 5 Poor Accelerator a e 5 Leaking Carburetor 5 Iriconsistent ldle Speed s s e ee ee bee bn e e Den e ER eir er d e N 5 Reduced Power Ot ertet beet petente At ich etal ddd Dr 5 DISASSEMBIIY ARTI 6 Cleanmo and Inspection em RO OE BEER 6 Intake ASSOMDIY ou ccccccccccsssssssessessssessessssessessssecsessssccsssssssesssssssascsusssascessssescensssessesessasssassssssassesssussesseansseessansssesseseseeseesescarseseacareenescereeneseareeeseases 7 bU Bore RR 8 REFER TO SEPARATE PUBLICATION ON
3. E EET 03 01 FUEL BLEU 04 01 GARB RETOR Prata trece rte Eee doe Foe OE aee FR ond e ce hee 05 01 STARTER suce EE BEIC ERE 06 01 GOVERNOR t ii enit teme ead iet etin eret Bede te e Peu eei etude ed debuts 07 01 COOLING SYSTEM emet 08 01 GENERATOR Nive cece Te i Oi ee nen a een Si ee a ee 09 01 SECTION 01 Engine Service General SUBJECT PAGE DESGRIP TION E 2 int tte i tate eate atat Satan hi atit 2 Engine Identification 2 5 3 IMS POCHOM EE 3 SYMPtOM 3 PCV System 5 Engine Olli Leak oes 5 Compression niet PD 7 Cylinder Leakage Test i aei ote ee eid eee hen ti ei 8 Oil Leak and Valve Guide Seal 5 8 IntakeManitfold Vacuum T6st ra iei ai ERA E e ERE 8 Oil Consumption a d
4. 17 Heated Oxygen Sensor 57 Camshaft Timing Belt Outer Cover 17 Flywheel Ring 58 Camshaft Timing Belt Inner Cover 18 DISASSEMBLY AND ASSEMBLY 59 Camshaft Timing Belt 19 Cylinder 59 Camshaft and Oil Pump Sprocket 21 Piston and Piston 64 Crankshaft Sprocket 22 Cylinder Blocks 2 et eee 64 Timing Belt Tensioner 22 Hydraulic Lash 65 Garnshaft etcetera ctt teet 23 Bare Cylinder 65 Camshaft and Oil Pump Oil Seal 25 ADJUSTMENTS e euet ete ieu ean ctn ee eds 66 Cylinder Block Front Cover Seal 26 6 2 67 02 2 Engine Service 2 5L 02 2 Hydraulic lash adjusters are used in the valve train These units are placed at the fulcrum point of the cam followers Their action is similar to the hydraulic tappets used in a push rod engine The cylinder head has drilled oil passages to provide engine oil pressure OS 3A SZ FPP00263 DESCRIPTION Engine The crankshaf
5. uiia 10 Oil Pressure Test eret Pe 11 SERVIGE PROGEDURES 20 td eed eed epee oe nde keene ae evened a eee lee 12 Gamshaft Service x5 acte get dete ct th basta ste dei et 12 Connecting Rod ree Yat e o Tru dee epa etx ade pu dT o ald ele 14 Grankshaft Bearing Service te edt e cete a ete teet etude 15 Service coo ada ela ad arid t pac ode sie nea ed ede EE 18 Gylinder Block Setvic8 itii e dd e C 20 Cylinder Head Service aad x ERR CER deeds 23 Engine nte itte Patito Mes ben t a ii ea Mv i vr n be e a a Een 31 Exhaust Manifold Service 32 Hydraulic Valve Tappet Adjuster 32 Intake Manifold Service iv cise a p e a e Wen enint evadere aet si de dde ee punc Sigue d a dag 34 Oil Ban ServiCe ee D E etat bee E Pe eed 34 PISTONS PEE EE 34 SPECIAL TOOLS iita stem e re 38 01 2 Engine Service General 01 2 DESCRIPTION Introduction This section covers various engine tests a
6. Se eg 42 Center Main Bearing Cap a FISON 43 Rear Intermediate Main Bearing Cap Connecting Rog 76 Connecting Rod Bearings 77 Connecting Rod Cap 78 Nut M9 1 79 Woodruff Key 80 Piston Pin 81 Oil Control Ring Segment DESCRIPTION 02 14 Engine Service 2 5L 02 14 REMOVAL AND INSTALLATION Valve Cover and Gasket Removal 1 2 Remove ignition harness Snap ignition cables out of ignition coil and place to the side Remove bolts and valve cover Remove valve cover gasket from valve cover If necessary remove oil filler cap GASKET 00202 Valve Cover and Gasket Installation 1 Clean valve cover Clean valve cover gasket surface on cylinder head Put valve cover gasket in place on cylinder head Install valve cover Alternately tighten bolts to 9 13 N m 84 120 Ib in 4 Snapignition wiring harness and ignition cables back into place in brackets attached to valve cover If removed install oil filler cap 6 Start engine and check for leaks Camshaft Follower and Hydraulic Lash Adjuster Removal Special Tools Required Valve Spring Compressor T95T 6565 A 1 Remove the valve cover as outlined in this section 2 Rotate the camshaft so the rocker arm to be removed is on the heel of its cam 3 Using Valve Spring Compressor T95T 6565 A compress and hold down the valve and valve spring Slide out the roll
7. 55 80 METRIC THREAD 5 5 ee ee LERRA MI EMI LB FT oe eee acted NEC 6 9 ETT dO iss Donde ipd bris ENS SUA 14 21 NOR P TP IS Hed do aea edet Pesos 28 40 eee 50 71 10857 Sour A Hense oes 80 114 PIPE THREAD SIZES Satin eaten LB FT OT vi 5 8 y 0 DI M 12 18 zr mq RU PI EET M DM DOE 22 33 Uo Er A 25 35 SPECIFICATIONS 02 71 Engine Service 2 5L 02 71 TORQUE SPECIFICATIONS Special Applications ITEM Nm LB FT Air Charge Temperature TEC E ETAT 7 12 Belt tensioner timing pivot 40 55 gei cas rr tae c edu 30 41 Belt tensioner timing adjusting 35 45 26 33 Camshaft gear bolt xu e irt eir cede Camshaft thrust plate Connecting rod oiii na ete dL a Crankcase vent baffle to Crankshaft damper bolt Crank position sensor to front cover Cylinder head
8. 9 0302 3 0556 mm 0 1193 0 1203 PISTON PIN Length 69 2912 70 1040 mm 2 728 2 760 Diameter standard 23 1673 23 1699 mm 0 9121 0 9122 To piston clearance 0 0051 0 0117 mm 0 0002 0 00046 To connecting rod interference fit PISTON RINGS Compression ring width eres top 1 4605 1 4910 mm 0 0575 0 0587 bottom 1 4605 1 4910 mm 0 0575 0 0587 Side clearance compression rings 0 0406 0 0838 mm 0 0016 0 0033 ierat rrr retenti Tit wear limit 0 1524 mm 0 006 max Ring gap compression 0 0 0 4064 0 000 0 016 compression bottom 0 3302 0 4826 mm 0 013 0 019 sweetie ha wie 0 2540 0 7620 mm 0 010 0 030 SPECIFICATIONS 02 69 Engine Service 2 5L 02 69 VALVE TRAIN Rocker arm lift ratio sse 1 86 1 Valve lifter inten diameter 21 3919 21 4046 mm 0 8422 0 8427 clearance to bore 0 0178 0 0686 mm 0 0007 0 0027 ters hydraulic leakdown rate 2 8 seconds Collapsed lifter gap at cam roller ix allowable 0 8890 1 3970 mm 0 035 0 055 1 0
9. 11 Apply a small amount of Ford Multi Purpose Grease DOA2 19584 AA or equivalent meeting Ford specification ESR M1C159 A to valve spring retainer key to hold in place during installation With cylinder pressurized place valve spring and valve spring retainer into position Compress valve spring with Valve Spring Compressor T95T 6565 A and install valve spring retainer keys Release spring to seat valve spring retainer keys in proper cylinder Release air pressure and remove air adapter Install spark plug in proper cylinder Grease contact surfaces of roller finger follower with Ford Multi Purpose Grease DOAZ 19584 AA or equivalent meeting Ford specification ESR 1 159 Using Valve Spring Compressor T95T 6565 A compress and hold down the valve and spring Slide the roller finger follower into place over valve and lash adjuster Release spring Using Valve Spring Compressor T95T 6565 A compress and release lash adjuster Install valve cover as outlined in this section REMOVAL AND INSTALLATION 02 17 Engine Service 2 5L 02 17 Crankshaft Pulley and Damper Removal 1 Loosen crankshaft damper bolt 2 Using flex handle rotate drive belt tensioner and remove drive belt 3 Remove crankshaft damper from crankshaft Crankshaft Pulley and Damper Installation 1 Align keyway with key install crankshaft damper on crankshaft and snug crankshaft damper bolt 2 Position drive belt and rota
10. NIME II RID eM MM MIU MM 0 TEST G Radio Int rterence ete etit meses aM 11 TEST H Indicator Lamp On Key Off seen tte tte tette tette ttt ttt tette ttes 11 i ERG RU GB FO ERG RE ERR RE res RR nc UR ce 12 uiri M 12 Hegulgtold een TA EE ou PU de E M ET 3 09 2 GENE RA TOR 4 Ba 11348 GENERATOR PULLEY GENERATOR REGULATOR 10316 1 DESCRIPTION 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 fuse link The l circuit or ignition switch 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 The A circuit or battery sense circuit circuit 36 Y W 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 The A circuit is hot at all times This circuit is protected by a fuse in the powe
11. Spark plug can be cleaned Oil Fouled Wet black deposits all over Caused by excessive oil entering combustion chamber Correct oil problem and replace the plug Normal Identified by light tan or gray deposits on the firing tip Gap Bridged Deposit build up closing gap Caused by oil or carbon fouling If deposits are not excessive the plug can be cleaned engine overheating wong type of fuel loose spark plugs too hot a plug low fuel pump pressure Caused by incorrect ignition timing Overheating White or light gray insulator with small black or gray brown spots and with bluish burnt appearance of electrodes 2 Replace the spark plug Caused by Pre Ignition Melted electrodes and wrong type of fuel possibly blistered insulator incorrect ignition timing too hot a plug burnt valves engine overheating Replace the plug Metallic deposits on insulator indicate engine damage Fused Spot Deposit Melted or spotty deposits resembling bubbles or blisters Caused by sudden acceleration If not excessive plug can be cleaned Otherwise replace plug DIAGNOSIS 03 9 Ignition System 03 9 REMOVAL AND INSTALLATION Ignition Coil Removal 1 Disconnect battery ground cable 2 Disconnect ignition coil multiplug IGNITION COIL MULTIPLUG 00078 3 Squeeze the locking
12. 3 DUI Se 343 deno 4 Wiring 4 5 1 EU FI ST NN II 5 CHECK So 5 015 ECAA AO 011 CRM 6 Secondary Resistance Checks or t eee OR EOM E C ot ee end 7 Spark PIugilhspectior erret et M a e eme een eee eet eee LO c Le 8 REMOVACAND INSTALLATION reo el a e e C c e URS 9 ONTON EE RE 9 Crankshaft Position Sensor tette tette tette tete tette ttes 0 Seems 11 Fe 12 a 2 ADJUSIMEINT zz ote ta cette e o le HOM 3 ect 59 SBEGIBICATIONS S 4 MIO reseed tesla a E 4 4 RE 4 REFER TO SEPARATE PUBLICATION ON ELECTRONIC FUEL INJECTION SYSTEMS FOR INFORMATION ON THAT SYSTEM 03 2
13. 4 Exhaust Manifold 39 Oil Parii eh ete ne ieee 4 Oll Putrmp s etse miis 40 Oil Pump ite ete 4 Crankshaft Rear Oil Seal 42 Engine Cooling 4 Oil Filter and Adapter 42 Lubrication 5 Oil Pressure 43 Drive Belt 6 Engine Front Cover 44 Ignition 6 Oil 46 System ubere 6 Oil Pump Screen Cover and Tube 47 Engine Governing 7 Crankshaft tei e 47 Wiring 8 Crankshaft Main Bearings 51 Engine 10 Pistons and Connecting Rods 53 REMOVAL AND INSTALLATION 14 Connecting Rod Bearings 55 Valve Cover and 14 Camshaft Position 56 Camshaft Follower Hydraulic Lash Adjuster 14 Engine Coolant Temperature Sensor 56 Valve Spring Retainer Stem Seal 15 Intake Air Temperature Sensor 57 Crankshaft Pulley and Damper
14. ERR a e ade eau nea rea 8 ELECTRONIC GOVERNOR GARB ccs tiet e teenies eire te iet erp tet eim tet dee ea ade edle 9 9 cL i ed 10 aa oce eoe NONI ANN REE 12 REFER SEPARATE PUBLICATION ON ELECTRONIC FUEL INJECTION EFI SYSTEMS FOR INFORMATION ON THAT SYSTEM 07 2 Mechanical Governor 07 2 DESCRIPTION The mechanical flyweight type governors can be used on these engines They are belt driven from the front of the engine A direct mechanical linkage from the governor throttle control lever to the carburetor throttle lever limits carburetor action to the governor setting No Load on Engine As the shaft rotates centrifugal force developed by the flyweights causes them to swing outward The force of the flyweight increases in proportion to engine speed and is always used to close the engine throttle A spring is used to oppose this force and balance it at a predetermined speed The speed at which the flyweight force and the spring force are in balance is the governed speed Engine Load Applied When a load is applied to the engine it tends to slow down and the flyweight force decreases The spring force being now greater than the flyweight force causes the governor throttle lever to move ina direction t
15. Engine Code Information The engine code information label located on the timing belt cover provides the engine build date engine plant code and engine code as well as other data OUTER TIMING BELT COVER 6019 ENGINE CODE DECAL 6E072 FPP00002 Crankshaft The crankshaft Is made from precision cast nodular iron Has five main bearings so each connecting rod is between two main bearings Thrust is taken on the center main bearing to control end play Has a crankshaft damper consisting of a cast iron hub pulley and internal ring with rubber compressed between them to help control torsional vibration The crankshaft damper also has an integral pulse wheel which provides timing information to the crankshaft position sensor mounted in the engine front cover CRANKSHAFT DAMPER PULSE WHEEL FACE DOWN 6312 PART CRANKSHAFT PULLEY GAP IN TEETH PROVIDES POSITION REFERENCE FOR NUMBER ONE PISTON 00003 Camshaft The camshaft operates the engine valves and Is located in the cylinder head Is supported by four bearings which are pressed into the cylinder head Has end play controlled by a combination thrust and retainer plate which bolts to the rear camshaft bearing support Is driven by a cogged timing belt which runs off the crankshaft and also drives the engine oil pump DESCRIPTION 02 4 Engine Service 2 5L 02 4 Valve Train INNER TIMING The valve train consi
16. Cylinder front cover bolt Inner timing belt cover stud bolt nut Outer timing belt cover 42 pin connector to lower Apply Teflon tape or liquid sealer to threads Refer to service manual for proper sequence SPECIFICATIONS 02 72 Sprocket Remover FRPOOOS5S Engine Service 2 5L 02 72 REQUIRED TOOLS T74P 6312 A Crankshaft rre Damper Remover TE Tool Illustration LEE Number Description or T95T 6565 A Valve 2 T59L jud Slide NE Spring Compressor m T58L 101 B Puller 3 Attachment ae T95T 6510 A Valve f FPPODOdS Stem Seal Installer a FPPOOOT2 T73L 6011 A Engine Cylinder Hone Set T74P 6700 B Front au FPPDOD4G Cover Seal Remover an FPPOOOTS Engine ci 7821 6701 Rear Main toy 0057 Seal Replacer FPPOI74 T68P 6135 A Piston Pin Remover Replacer e T95T 6510 B Valve Ut 00 Stem Seal Replacer uM 2 9976 T74P 6150 A Front ff DESIRED TOOLS Seals Replacer Tool Number Description FPPIXXIB3 D81L 6500 A Blind Hole Puller T71P 6250 A Cam WI Bearing Replacer D79L 6731 B Oil Filter Wrench D78P 4201 G Dial Indicator T74P 6254 A Camshaft E Belt Tensioner Tool E Tool 4201 C Dial Indicator with Ed Bracketry FPP DOS3 T74P
17. Inspect connecting rod bearings as outlined in the engine service section Inspect journal and measure for taper and out of round as outlined in the engine service section 12 14 Out of round should be less than 0 01524mm 0 0006 inch Taper should be less than 0 06mm per centimeter of length 0 006 inch per inch of length Inspect connecting rod bearing bore measure for out of round and taper Maximum out of round is 0 0120mm 0 0004 inch Maximum taper is 0 0102mm 0 004 inch Thoroughly clean bearing bore of connecting rod and cap Connecting Rod Bearings Installation 1 Make sure bearing bore of connecting rod and cap and bearing journal are clean Insert upper bearing insert into connecting rod Insert lower bearing insert into connecting rod cap Apply Plastigage to bearing journal Refer to the engine service section NOTE Do not scratch journal with connecting rod bolts 5 10 11 12 13 14 Carefully pull piston and connecting rod assembly into place on crankshaft Install connecting rod cap Hand start each connecting rod nut until flush with end of rod bolt Alternately tighten connecting rod nuts to 34 41 N m 25 30 Ib ft Then continue tightening to a final torque of 41 49 N m 30 36 Ib ft Remove cap and check bearing clearance Lubricate connecting rod bearings with Motorcraft Super Premium Motor Oil XO 5W30 QSP or equivalent 5W30 motor oil meeting F
18. OTHER CIRCUITS DA TO IGNITION eu STARTER SWITCH L ON IGNITION SWITCH BATTERY 120 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 through ammeter and heavy duty carbon pile rheostat portion of circuit rheostat at maximum counterclockwise position 2 Place transmission or transaxle in NEUTRAL Crank engine with ignition off and determine exact 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 S 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 DIAGNOSIS Starter Motor 06 7 06 7 VOLT AMP TESTER POSITIVE LEADS NEGATIVE BATTERY CONVENIENT GROUND ON STARTER SUCH AS MOUNTING EAR ON CASTING FPP00121 Starter No Load Test The starter no load test will uncover such conditions as open or shorted windings or rubbing armature The starter can be tested at no load on the test bench only 1 Make
19. Starter Solenoid Test Make sure that the solenoid is isolated electrically from the motor Using a VOM check for continuity between S terminal and M terminal and between S terminal and ground frame If there is no continuity the wire is broken and the solenoid should be replaced DIAGNOSIS 06 8 Starter Motor 06 8 Jump Starting For cases of a starter that cranks the engine very slowly connect a 12 volt booster battery to the system To avoid damage to the equipment and battery or the possibility of personal harm follow these instructions and precautions 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 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 DO NOT DISCONNECT THE BATTERY OF THE EQUIPMENT TO BE STARTED DISCONNECTING THE BATTE
20. bed 03 01 EUEL PUMP eter iioii NM dete tua fec tende tet at 04 01 GARB URETQOEBS tt reri p Am Dai Des 05 01 STARTER MOTOR LUE 06 01 GOVERNOR cit te note eedem teen aet tecti eee bite itus 07 01 GOOLING SYSTEM eoe teme tbe ede esaet enit seen bete Papa ET RINT 08 01 GENERATOR uem ie il eevee ere dao ee docete aceti We Ide drea 09 01 SUBJECT DESCRIPTION Operation DANON Mni ted 3 Generator Output TEST eee ette taeda a sel ae erbe e d eA DIA D ty 4 GTeTATe1 6 INO aN 4 Symptom Chart PIR DOME e oldie ect ea ll ia lee cullen oiler Ose Mae ls sire TEST A DeadBattery No Generator OUtpUt 6 TEST B slnidicator Lamp Om Engine RUNN Gretes tt tm e e B RR ERRORES 7 TEST C Indicator Lamp 8 TEST s Charging Moltage bligh ete doe there eet e s e dude 9 TEST E Indicator Lamp Off Key On Engine Not R nnlhg t mc t cete e e ent 9
21. e Check for a hole or crack in top of piston caused by pre ignition or foreign object damage e Inspect for excess wear in ring lands indicated by visible steps worn in ring lands e Check for scoring or gouges on piston skirt or crown e Check for looseness between piston and piston pin Fitting Pistons Special Tool Engine Cylinder Hone Set T73L 601 1 A NOTE There may be a piston that can be used when the original standard size bore shows little wear and can be cleaned up This piston must be select fitted to the cylinder bore It will likely be necessary to hone the cylinder bore in order to produce the specified piston to bore clearance To determine if a Service Parts piston can be installed and if so to fit the Service Parts piston proceed as follows 1 Measure the cylinder bore as outlined in this section under Cylinder Bore Measuring If the cylinder bore is not damaged and wear taper and out of round are within specifications listed in Section 02 the cylinder bore may be cleaned up and a new Service Parts piston select fitted to the refurbished bore 2 Hone the cylinder if necessary to restore a proper crosshatch pattern so new rings can seat Remove as little of the cylinder wall as possible SERVICE PROCEDURES 01 35 Engine Service General 01 35 3 After any necessary honing of the cylinder bore check that the piston to bore clearance is to specification If the clearance is too great
22. 2 5L 02 48 13 Install puller part of T74P 6256 B Cam Sprocket Holding Removing Tool Remove oil pump sprocket 14 Slide crankshaft sprocket off crankshaft 15 Remove inner timing belt cover 16 Remove oil pan screws and oil pan 17 Remove oil pan gasket 18 19 Rotate engine on stand so crankshaft is up 20 Remove two bolts and nut and remove oil pump screen cover and tube 21 Using T74P 6700 B Front Cover Seal Remover remove front cover oil seal as outlined in this section 22 Remove bolts and front engine cover 23 Make sure connecting rod caps are marked so each cap can be kept with each rod 24 Remove connecting rod nuts and four caps NOTE Each main bearing cap except rear cap is marked with arrows pointing to the front of the engine The number of arrows corresponds to the number of the main bearing cap For example one arrow for the front cap two arrows for the number two cap SEALER F1AZ 19562 A SPECIFICATION WSE M4G320 A2 2 PLACES CYLINDER BLOCK ASSEMBLY 6010 FRONT OF ENGINE OF BLOCK 25 Remove bolts and main bearing caps 26 Lift out crankshaft Crankshaft rear oil seal 6701 will come out with crankshaft Remove seal from crankshaft 27 Inspect bearings and replace as necessary Inspect crankshaft as outlined in Section 01 and recondition or replace as necessary Crankshaft Installation CAUTION Lubricate parts with Motorcraft Super Premium Motor Oil XO
23. india max allowable loss 0 1270 mm 0 005 Flywheel ring gear lateral runout Theoretical valve lift zero 10 2108 0 402 Jo standard 0 6350 mm 0 025 End 0 0254 0 1778 mm 0 001 0 007 pe automatic trans 1 5240 mm 0 060 wear limit 0 2286 mm 0 009 Journal to bearing clearance 0 0254 0 0762 mm 0 001 0 003 wear limit 0 1524 0 0067 GBANKSHAFEBEARINOS j Journal diameter 44 9910 45 0088 mm 1 7713 1 7720 Connecting rod bearings to crankshaft clearance EE max 0 1270 0 005 0 0203 0 0381 mm 0 0008 0 0015 nie max out of round 0 1270 mm 0 005 vo alowable 0 0203 0 0660 mm 0 0008 0 0026 n a bn 1 5723 1 5850 0 0619 0 0624 Wgeinealan _ ee standard 1 0 0 distance that the rear edge of the bearing installed 0 0508 mm 0 002 thickness add 0 0254 mm 001 towards the front from the rear face of the to standard thickness bearing tower 0 0 0 2540 mm 0 0 0 010 Main bearing to crankshaft clearance rene desired 0 0203 0 0381 mm 0 0008 0 001
24. 3 Then loosen the no load surge adjusting screw locknut and turn the screw inward until the rom increases to the desired control rom E 2 CAUTION Do not turn the screw in all the way It will interfere with proper governor operation and prevent the governor from returning the engine to idle speed 3 Readjust the governor high speed stop screw to maintain the correct high speed under load ADJUSTMENT 07 9 Mechanical Governor 07 9 REMOVAL AND INSTALLATION Mechanical Governor Removal 1 Disconnect hand throttle connection at governor variable speed lever 2 Disconnect governor to carburetor throttle control rod at governor 3 Loosen governor mounting nuts and bolts and move governor toward engine to loosen drive belt 4 Remove drive belt from governor pulley 5 Remove governor to bracket attaching bolts and remove governor Mechanical Governor Installation 1 Position the governor to the mounting bracket and install the attaching bolts snugly 2 Position drive belt to governor pulley and move the governor away from the engine to tighten the belt Tighten the attaching bolts 3 Adjust the belt tension 4 Connect the governor to carburetor throttle control rod Adjust the rod as described previously 5 Connect hand throttle cable to governor variable speed lever Adjust cable as necessary to permit operation from idle to maximum speed REMOVAL AND INSTALLATION 07 10 Electronic G
25. 44 Install and adjust timing belt as outlined in this section Install crankshaft position sensor and tighten bolt to 8 12 72 108 Ib in Install outer timing belt cover Snap tabs into slot Install screw and tighten to 8 12 N m 72 108 Ib in Install crankshaft pulley and washer Tighten bolt to 125 165 N m 72 108 Ib in Connect retaining clip for crankshaft position sensor lead Remove engine from engine stand Install crankshaft rear oil seal using T82L 6701 A Crankshaft Seal Installer Install engine REMOVAL AND INSTALLATION 02 51 Engine Service 2 5L 02 51 Crankshaft Main Bearings Removal NOTE The main bearing inserts are a precision selective fit To check bearing clearances or to select fit a new bearing refer to the engine service section 1 2 Remove oil pan as outlined in this section Remove oil pump screen cover and tube as outlined in this section NOTE Replace one bearing at a time leaving the other bearings securely fastened Remove main bearing cap to which new bearings are to be installed Remove bearing from cap Press on end of upper bearing without tang to start it out Rotate bearing out from between crankshaft and cylinder block MAIN BEARING CAP FRONT OF ENGINE FPP00272 REMOVAL AND INSTALLATION 02 52 Engine Service 2 5L 02 52 Crankshaft Main Bearings Installation 8 Check Plastigage for bearing clearance using
26. A24224 A The procedure involves cutting new threads in the spark plug hole After rethreading operation a tapered sleeve will be installed in the cylinder head The sleeve is threaded on the inside and outside The outside threads into the cylinder head while the inside provides new threads for the spark plug The service is permanent and will have no effect on cylinder head or spark plug life CAUTION The cylinder head must be removed from the engine before installing a taperset The service procedure includes a thread cutting process which produces metal chips Performing this procedure while the cylinder head is on the engine will cause metal chips to fall into the cylinder Once in the cylinder these chips can damage the cylinder wall when the engine is started 1 Thoroughly clean spark plug counter bore seat and threads of all dirt or other foreign material 2 Start tap into spark plug hole being careful to keep it properly aligned As tap begins cutting new threads apply oil to tap Continue cutting threads and applying oil until stop ring bottoms against spark plug seat 3 Remove tap Remove all metal chips using compressed air 4 Coat threads of mandrel with cutting oil Thread taperset onto mandrel until one thread of mandrel TAPERSET A23459 A extends beyond taperset NOTE A properly installed taperset will be flush to one millimeter below spark plug gasket seat 5 Thread tapers
27. D 745 d FASTENER TORQUE SEQUENCE FPP00283 Final pass 26 38 Nem 19 28 lb ft Install engine ground cable and nut at lower intake manifold Tighten to 9 12 Nem 7 9 lb ft Install a new upper intake manifold gasket Position the upper intake manifold to the cylinder head Install retaining bolts finger tight 10 Tighten all bolts to specifications in the tightening sequence shown e First pass 7 10 Nem 5 7 lb ft Final pass 26 38 Nem 19 28 lb ft FASTENER TORQUE SEQUENCE FPP00281 11 Install the engine lifting eye 12 Connect the PCV tube 13 14 Connect the fuel lines to the fuel rail Caution Avoid spilling fuel on hot UN surfaces Use an absorbent rag placed under the fuel line being removed to collect any spilled fuel 15 Install the throttle actuator if removed 16 Connect the electrical connections and vacuum lines as necessary 17 Install the hose clamp on the coolant hose and connect to the fitting on the intake manifold 18 Install the air cleaner assembly 19 Fill the cooling system 20 Install the negative battery cable 21 Start the engine and check for leaks REMOVAL AND INSTALLATION 02 38 Engine Service 2 5L 02 38 Carburetor Removal 1 Disconnect the negative battery cable 2 Remove the air cleaner assembly 3 Disconnect the electrical connections to e the choke thermostat if used e electronic gov
28. ECT sensor to water outlet connector Exhaust man to cyl head bolts stud nut i Flywheel to crankshaft Front lifting eye Generator bracket to head amp block Ignition Coil to bracket cise nitent rendre Intake manifold upper vacuum Intake manifold elbows amp pipe plugs Intake manifold upper to lower 2 2 2 2 2 4 2 2 21 and also manifold to cyl head bolt or nut Main bearing cap bolt Oil pressure sending unit to Oil pump pickup tube to block P Oil pump to blok reete t Oil panto tectae Oilfilterinsertto block rore eor v Oil separator bolt Rear lifting eye nut Rocker arm cover to cylinder Starter solenoid Dolt 2 or tete tee Den Starter amp B terminal Starter through bolt etc RR dpt neto Starter mounting een PUOI Starter brush plate screw Spark plug to cylinder head Temperature sending unit to Water jacket drain plug to Water outlet connection Water pump to block
29. Immerse the radiator cap in water and install on the shallow filler neck of the Rotunda 21 0012 Radiator Cap Pressure Test Adapter or equivalent NOTE The adapter is designed to accept both deep and shallow neck radiator caps 1 Immerse the filler neck seal in water and install in the filler neck adapter NOTE the filler neck seal is reversible so that it may be used on either a deep or shallow radiator filler neck It will also fit either end of the radiator cap pressure test adapter 1 Install the filler neck adapter with filler neck seal on the deep filler neck end to the radiator cap pressure test adapter 2 Connect the female quick disconnect fitting of the pressure test pump to the male quick disconnect fitting of the filler neck adapter 3 SLOWLY depress the plunger of the pressure test pump until the pressure gauge reading stops increasing and note the highest pressure reading obtained NOTE If the plunger of the pump is depressed too fast an erroneous pressure reading will result 1 Release the pressure by turning the pressure relief screw counter clockwise Then tighten the pressure relief screw and pressure test again at least twice to be sure the pressure test reading is repeatable within the acceptable gauge reading limits of the radiator cap and is not erratic 2 If the pressure test gauge readings are not within the acceptable gauge reading limits replace the radiator cap If the pressure test
30. NOTE Check crankshaft journals for out of round before checking An condition on the center journal could be confused as excess runout 1 Set V blocks on surface plate and set crankshaft on V blocks supported on the outer two main bearing journals 2 Set up TOOL 4201 C or equivalent Dial Indicator with Bracketry to measure runout on MAGNETIC BASE DIAL INDICATOR D78P 4201 B CRANKSHAFT V BLOCKS A16693 B center main bearing journal Zero dial indicator 4 Slowly rotate crankshaft one revolution and record highest and lowest readings 5 Crankshaft runout should not exceed 0 050 mm 0 002 in If crankshaft runout is excessive replace crankshaft SERVICE PROCEDURES 01 19 Engine Service General 01 19 Crankshaft Journals Inspect the main journal and crankpin journal diameters Measure the diameter of each journal at two different points in the directions as shown JOURNAL 1 tt A14474 A Refer to Section 02 for crankshaft journal specifications Journal Refinishing NOTE Polish direction is clockwise as viewed from the front of the crankshaft Dress minor imperfections such as scores nicks or burrs with an oil stone If journals are severely marred or exceed service limits for wear taper or out of round they should be refinished to size for the next undersize crankshaft main bearing Follow crankshaft lathe manufacturer s i
31. RING RING GAP A23877 A 5 Make sure that the ring is square in the bore 6 Using a feeler gauge check the piston ring end gap and compare to specification found in Section 02 FEELER GAUGE A14712 B SERVICE PROCEDURES 01 36 Engine Service General 01 36 ese __ 7 f the ring is too small the ring will have to be filled until the end gap is within specifications The use of a ring filing block helps ensure that the ring ends are filed square A23878 A CAUTION Install the piston rings after UN the piston has been installed on the connecting rod Since the piston may be supported by the crown during this operation the rings could be damaged CAUTION Use a piston ring expander to A N install the piston rings Attempting to wind them on by hand may put a deep scratch in the piston or break the ring Using a piston ring expander install the piston rings starting with the oil control rings Make sure rings are installed right side up Refer to instructions with the ring set Rotate the rings so the end gaps are NOT lined up but are spaced properly as shown 25 4 MM 25 4 MM INCH A 7 INCH PIN BORE SERVICE PROCEDURES 01 37 Engine Service General 01 37 10 Using a feeler gauge recheck piston ring side clearance 11 Continue with engine assembly as outlined in Section 02 Piston and Piston Pin Fit NOTE New pistons come with fitted piston pins
32. Service or replace piston or cylinder block Replace valve stem seal Replace valve stem and guide Service oil leak Replace piston rings Service PCV system DIAGNOSIS 01 4 Engine Service General 01 4 CONDITION POSSIBLE SOURCE ACTION e Excessive main bearing oil clearance Adjust clearance or replace crankshaft main bearing e Seized or heat damaged crankshaft main Replace crankshaft main bearing bearing ENGINE NOISE Excessive crankshaft end play Adjust end play or replace crankshaft e Excessive connecting rod bearing oil Adjust clearance or replace clearance connecting rod e Heat damaged connecting rod bearing Replace connecting rod bearing e Damaged connecting rod bushing Replace connecting rod bushing e Worn cylinder Service or replace cylinder block e Worn piston or piston pin Replace piston or piston pin e Damaged piston ring s Replace piston ring s Bent connecting rod Replace connecting rod e Malfunctioning hydraulic valve tappet Replace hydraulic valve tappet e Excessive hydraulic valve tappet clearance Adjust clearance or replace hydraulic valve tappet e Broken valve spring Replace valve spring e Excessive valve guide clearance Service clearance or replace valve guide stem e Malfunctioning or damaged cooling system apr section System 5 Refer to section on fuel system e or damaged fuel system Service exhaust leakage e
33. and should not require refitting unless the connecting rod bore is oversize Some Power Product engines use piston pins which press into the connecting rods The piston pivots on the pin There is no connecting rod bushing but rather an interference fit between the piston and the connecting rod Refer to Section 02 for specifications and assembly instructions 1 Clean and inspect the connecting rod as outlined in this section 2 Clean and inspect the piston and piston pin as outlined in this section 3 Using a suitable micrometer measure the piston pin where the piston pivots and in the center where it is pressed into the connecting rod FEELER PISTON GAUGE 6108 PISTON RING 6148 A23879 A Using a suitable set of plug gauges or bore gauge measure the upper bore of the connecting rod An interference fit is required If the bore is oversize it will be necessary to install an oversize piston pin It is not necessary to reborn or ream the connecting rod If the pin to rod fit is OK measure the piston pin bores in the piston Subtract the piston pin size from the piston pin bore sizes Pin to piston clearance is listed in the specifications section If clearance is excessive it will be necessary to fit an oversize piston pin To fit an oversize piston pin because either the pin to connecting rod or pin to piston clearance was excessive e Obtain an appropriate oversize piston pin e Hone or ream th
34. chart on package Clearance should be 0 010 1 Place lubricated upper bearing on crankshaft and 0 056mm 0 0004 0 0022 inch for front main rotate into place bearing or 0 020 0 066mm 0 0008 0 0026 inch 2 Place lower bearing into cap for bearings 2 5 3 Apply Plastigage across lower bearing 9 If clearance is OK lubricate bearings with Super i Premium Motor X0 5W30 QSP or equivalent 4 Support crankshaft on either side of bearing being meeting Ford specification ESE M2C153 E and installed reinstall cap NOTE Failure to support crankshaft will cause 10 Apply a 7mm 0 27 inch dot of Silicone Gasket incorrect reading of Plastigage while checking and Sealant F1AZ 19562 A or equivalent bearing clearance when installing bearing cap meeting Ford specification WSE M4G320 A2 on 5 Install bearing cap each side of cylinder block as shown in illustration i before installing the No 5 cap 6 Lightly oil main bearing bolt or stud Alternately tighten to an initial torque of 68 81 N m 50 60 Ib 11 Alternately tighten bolts or stud to an initial torque ft Then tighten bolt or stud to a final torque of of 68 81 N m 50 60 lb ft Then tighten the bolts 108 122 N m 79 90 Ib ft or stud to a final torque of 102 115 N m 75 85 Ib ft 12 Check crankshaft end play as outlined in the Section 01 7 Remove main bearing cap 13 Install oil pump screen cover and tube as outlined in this section 14 Install oil pan
35. journal diameters NOTE Make sure to align oil hold in camshaft bearing with the oil hole in the cylinder head before pressing camshaft bearing into place Position new camshaft bearing at the bearing bore and press into place using Camshaft Bearing Set T65L 6250 A and Cam Bearing Replacer T71P 6250 A CAMSHAFT CAM BEARING REPLACER TTTP8250 A BEARING HOLES MUST BE ALIGNED TIME INBTALLATION INSTALLATION FPPO 0062 Make sure the cup plug is in the rear of the camshaft Lubricate the camshaft lobes and journals with Motorcraft Super Premium Motor Oil XO 5W30 ASP or equivalent meeting Ford specification ESE M2C153 E Carefully slide the camshaft into place through the camshaft bearings Be careful not to scratch camshaft bearings Install the camshaft rear retainer Tighten the two screws to 8 12 N m 72 108 Ib in Position camshaft front seal on Front Seals Replacer T74P 6150 A and press into place Remove tool Check camshaft end play as outlined in the engine service section Position camshaft sprocket on camshaft Install Cam Sprocket Holding Removing Tool T74P 6256 B without threaded puller insert on sprocket Install sprocket bolt and washer Tighten to 70 95 52 70 lb ft Remove tool DISASSEMBLY AND ASSEMBLY 02 62 Engine Service 2 5L 02 62 14 Install valve lash adjusters 15 Install one valve and check valve runout looseness in guid
36. throttle not opening fully a main jet not suited for this application or clogged main jets main fuel passage or air bleeds Clean adjust repair or replace as necessary DIAGNOSIS 05 6 Carburetor 05 6 AIR INTAKE FPP00226 DISASSEMBLY AND ASSEMBLY Disassembly consists of separating the carburetor into two basic groups air intake e fuel bowl throttle body Cleaning and Inspection Thoroughly clean all metal parts in solvent or deepclene Blow out all parts and channels with air pressure Inspect for damage excessive wear burrs or warpage DO NOT CLEAN NON METALLIC PARTS in solvent or Deepclene NOTE The following assembly instructions and the exploded illustration are generalized and include all parts possibly found in the carburetor at this time Therefore all of the parts shown and mentioned may not be included in the particular assembly being worked on DISASSEMBLY AND ASSEMBLY 05 7 Carburetor 05 7 CHOKE LEVER IDLE JET TUBE WASHER ees SCREW amp LOCK WASHER Q PLATE AIR INTAKE BODY CUP PLUG um qi SCREW POWER PISTON WELL FILLER TUBE GASKET FPP00227 Air Intake Assembly 1 Drive channel plug into vacuum channel flush with surface 2 Drive cup plug into end of choke shaft hole 2 opposite choke lever 3 Insert choke shaft with milled flat toward top 4 Install choke plate in air intake and start screws 3 NOTE
37. 1 219 0161 548 148 1 1 0 5 75 5 020 FPP00132 ADJUSTMENTS Calibration Initial speed settings as well as other parameters can be set using a special interface connector and an IBM compatible PC 286 minimum with 640K RAM of which 512K of conventional RAM must be available Also required is a 1 44 Meg High Density floppy drive and a VGA graphic display Programming of the controller is covered in a separate publication ADJUSTMENT 08 1 Cooling System 08 1 SECTION TITLE PAGE ENGINE SERVICE General ie Renee i ee Mi 01 01 ENGINE SERVIGE 2 5I i 2 ht bete dnd v efe e o RE RE dive det Silene ch 02 01 IGNETIONISYSTEM s a r oerte tai bed 03 01 EUEL PUMP eter iioii NM dete tua fec tende tet at 04 01 GARB URETQOEBS tt reri p Am Dai Des 05 01 STARTER MOTOR LUE 06 01 GOVERNOR cit te note eedem teen aet tecti eee bite itus 07 01 GOOLING SYSTEM eoe teme tbe ede esaet enit seen bete Papa ET RINT 08 01 GENERATOR uem ie il eevee ere dao ee docete aceti We Ide drea 09 01 SECTION 08 COOLING SYSTEM SUBJECT PAGE
38. 15 minutes Stop engine and inspect all seal and gasket areas for leaks using Rotunda Oil Leak Detector Y112 R0021 part of 112 0030 kit Lamp or equivalent A clear bright yellow or orange area will identify leak For extremely small leaks several hours may be required for the leak to appear 4 f necessary pressurize main oil gallery system to locate leaks due to improperly sealed loose or cocked plugs flywheel bolts leak oil look for sealer on threads 5 Service all leaks as required DIAGNOSIS 01 6 Engine Service General 01 6 Pressure Method As an alternative testing procedure the crankcase can be pressurized not to exceed 27 kPa 4 psi to locate oil leaks The following materials are required to fabricate the tool to be used e Air supply and air hose e Air pressure gauge that registers pressure in increments of one psi e Airline shutoff valve e Appropriate fittings to attach the above parts to oil fill PCV grommet holes and PCV fresh air hose tube e Appropriate plugs to seal any openings leading to crankcase e A solution of liquid detergent and water to be applied with a suitable type applicator such as a squirt bottle or brush Fabricate the air supply hose to include the air line shutoff valve and the appropriate adapter to permit the air to enter the engine through the rocker arm cover tube Fabricate the air pressure gauge to a suitable adapter for installation on the engine
39. 246 184 248 186 250 187 DIAGNOSIS 01 8 Engine Service General 01 8 2 ROTUNDA PRESSLRIZATION 4 KIT 0714 00705 A23452 A Cylinder Leakage Test When a cylinder produces a low reading the use of Rotunda Pressurization Kit 014 00705 or equivalent will be helpful in pinpointing the exact cause The leakage detector is inserted in the spark plug hole the piston is brought up to top dead center on the compression stroke and compressed air is admitted Once the combustion chamber is pressurized a special gauge will read the percentage of leakage Leakage exceeding 20 percent is considered excessive While the air pressure is retained in the cylinder listen for the hiss of escaping air A leak by the intake valve will be audible in the carburetor A leak by the exhaust valve can be head at the exhaust pipe Leakage past the rings will be audible at the positive crankcase ventilation PCV connection If air is passing through a blown gasket to an adjacent cylinder the noise will be evident at the spark plug hole of the cylinder block or gasket leakage into the cooling system may be detected by a stream of bubbles in the radiator Oil Leak and Valve Guide Seal Test The cylinder leakage detector can be used to test for engine oil leaks and to check the valve seals for leakage 1 Plug all crankcase openings except the one used for connecting the leakage detector 2 Connect the detect
40. 3054 exhaust 7 7114 7 7317 mm 0 3036 0 3044 STARTER Motor diameter 3 2 iere ee 78 mm 3 Current draw under normal load 140 200 amps Normal engine cranking 200 250 rpm Minimum stall torque 9 5 volts 14 7 Nem 11 Ib ft Maximum rrr 800 amps fr 70 10 amps Brush mfg length 16 8 mm 0 66 Spring tension aitaa 18 N 64 oz Maximum commutator 0 12 mm 0 005 Maximum starting circuit voltage drop 0 5 volt battery pos terminal to starter terminal at normal engine temperature SPECIFICATIONS 02 70 Engine Service 2 5L 02 70 NOTE Oil threads with a lightweight engine oil unless the threads require oil or water resistant sealer TORQUE SPECIFICATIONS General Applications U S RTT LB LC ac NEAR Bed RIXA 6 9 tela Iro Mv 12 18 16 DEMO DEEST PRU 14 20 r ast P TT 22 32 Qo MT T ram TOR 27 38 TINS NA toes E 40 55 c Nee m 40 60 ex DE 25 108 tumet uode
41. 64 psi NOTE When pump return line is plugged pressure can go to 100 psi Volume flow 2 18 liters 2 3 quarts per minute IGNITION SYSTEM Spark plug EFI amp AWSF 52 C 1 1176 mm 0 044 MECHANICAL GOVERNOR BELT TENSION ciii nee eres 70 Ibs 311 38 N Used tee een 50 Ibs 222 41 N a used belt is one that has been in operation for 10 minutes or more OIL PUMP Relief valve spring tension 37 37 47 15 N 33 5280 mm ett rti eO n EEG 8 4 10 6 Ibs 1 32 Drive shaft to housing bearing clearance 0 0356 0 0838 mm E 0 0014 0 0033 Relief valve clearance 0 0381 0 0762 mm 0 0015 0 0030 Rotor assembly end clearance pump assembled 0 0254 0 1016 mm 0 0010 0 0040 Outer race to housing radial clearance 0 1397 0 3175 mm 0 0055 0 0125 02 68 5 Diameter eee 95 961 95 974 mm 3 7779 3 7784 measured 90 to pin centerline and at 0 887 from bottom of skirt Piston to cylinder bore clearance 0 0254 0 0508 mm m 0 0010 0 0020 Piston pin bore diameter 23 184 23 1800 mm 0 9127 0 9125 Ring groove width top compression ring 1 536 1 525 mm 0 0604 0 0600 bottom compression ring1 536 1 525 mm 0 0604 0 0600 EE oil ring
42. 7 94mm 5 16 inch steel ball provided with a tester in plunger cap 3 Work tappet plunger up and down until tappet fills with fluid and all traces of air bubbles have disappeared 4 Adjust length of ram so that pointer is 1 59mm 1 16 inch below starting mark when ram contacts tappet plunger to facilitate timing as pointer passes Start Timing mark 5 Use mark on pointer scale as Stop Timing point instead of original Stop Timing mark at top of scale 6 Allow ram and weight to force tappet plunger downward Measure exact time it takes for pointer to travel from Start Timing to Stop Timing marks of tester HYDRAULIC TAPPET LEAKDOWN TESTER TOOL 6500 E A8508 B 7 A valve tappet that is satisfactory must have a leakdown rate time in seconds within minimum and maximum limits specified in Section 02 8 Remove fluid from cup and bleed fluid from tappet by working plunger up and down This step will aid in depressing tappet plungers when checking valve clearance 9 If a valve tappet is not within specifications replace defective valve tappets with new ones It is not necessary to disassemble and clean new valve tappets to test them since they are shipped with testing fluid Camshaft Follower if equipped e Clean all parts thoroughly e Make sure all oil passages are open e Inspect the roller finger follower for indications of scuffing or abnormal wear e the pad is grooved replace the roller finge
43. AND ASSEMBLY 02 63 Engine Service 2 5L 22 Check installed height of valve spring assembly e Measure from cylinder head machined spring pad to top of valve spring Dimension should be 38 278 40 157mm 1 507 1 581 inch STALLED SPRING HERGHT RE 5635 40 846 1 507 1 881 INCH 23 Repeat steps 15 through 22 until all valves are installed 24 Oil contact surfaces of cam followers with clean engine oil 25 With heel of cam facing down use Valve Spring Compressor T95T 6565 A to compress and hold down the valve spring Slide the cam follower into place AN CAUTION Make sure the affected lash adjuster has been collapsed and released before rotating camshaft 26 Using Valve Spring Compressor T95T 6565 A compress and release lash adjuster 27 Repeat the above steps until all cam followers are installed 28 Install cylinder head as outlined in this section 02 63 DISASSEMBLY AND ASSEMBLY 02 64 Piston and Piston Pins Disassembly Piston Pin Removing and Installing Set Special Tools Required T68P 6135 A Remove the connecting rod bearing from the connecting rod and cap Install the cap on the connecting rod from which it was removed Remove the piston rings using a suitable piston ring expander Store the piston pin and connecting rod to ensure assembly with the same rod and installation in the same cylinders from which they were
44. 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 and 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 carburetor flooding Dirt accumulation in the fuel and air passages improper idle adjustments and improper fuel level are the major sources of carburetor troubles Many problems attributed to the carburetor are caused by other systems Proper and careful diagnosis is a must If the problem seems to occur in one engine cylinder the ignition system may be at fault If the problem seems to occur in all engine cylinders then the problem most likely is carburetion When the carburetor is thought to be at fault check the fuel system first Dirt or water in the gas tank leaks in the fuel lines or a defective fuel pump often show the same symptoms as carburetion problems Observation pressure and volume tests on the fuel system show whether the fuel system is the cause of the problem When the carburetor is shown to be at fault a simple cleaning may often solve the problem Spraying a carburetor cleaning solvent into the carburetor s air intake assembly with the engine running may solve th
45. C or equivalent so contact point rests against the end of the crankshaft post and indicator axis is parallel to crankshaft axis 2 Force crankshaft toward rear of engine INDICATOR STYLUS AGAINST AND PARALLEL TO CRANKSHAFT A21123 A 3 Zero dial indicator Push crankshaft forward and note reading on dial 4 If the end play exceeds the wear limit listed in the specification section replace the thrust bearing Inspect the crankshaft for damage to the thrust face before installing the new bearing If the end play is less than the minimum limit inspect the thrust bearing faces for scratches burrs nicks or dirt If the thrust faces are not damaged or dirty the main thrust bearing may not be aligned properly Lubricate and install the thrust bearing and align the faces following Main Bearing Replacement procedure in the appropriate engine section Re check crankshaft end play Cleaning CAUTION Handle the crankshaft with care to avoid possible damage to the finished surfaces Clean the crankshaft with solvent then blow out all oil passages with compresses air Inspection Measure the diameter of each journal in at least four places to determine an out of round taper undersize condition For specifications refer to the specification section Inspect crankshaft sprocket for chipped broken or excessively worn teeth Remove and replace as outlined in Section 02 if necessary Crankshaft Runout
46. CHR RT HR ER el cabe 7 Armat re Opeh Circuit RTT BEEN 7 Grounded Armature he SE emite creen e caeco t c eic e c a ete ee sed aD ecce cre 7 Starter Solenold Testes eet sentite ehe Aste ate oh adele Lc N pale hanks veh att Ades ee 7 Jump Stanine OU 8 REMOVAL AND INSTALLATION nrrainn eae een a el eee 9 irae E E Je 9 DISASSEMBLY AND ASSEMBLY ttt ttt tte ttti ttt ttt tte ttt ttt ttt ttt 0 FEISS SS IIMS c UA 10 Cleaning and Inspection tee ree ete tv reb tinet e teet p t 10 ASSOMDIY ccecsscssssessesssssesesssssssscssessssessessssessassissssssssssssssssssssaussesssusssssssusssssssussssussusssessasssassissussvsssssssuesssisassississnsassisassessssansssessaucstessanseceesaeeeeusaeeeessaeeees 2 Starter DrivexsReplaGe me rte eec ee oe c e ete e i ER I E gS Oct e tete 2 Arrmature heplacermelts s beret ed diede uet tete e He e 12 SPECIFICATIONS RR EROR dtc edt ipt e Lo a debct 14 TORQUES PECITICATI OMS 82222 DEDOS ERE ES UU MUR REN aes 14 GerneralsspecifiCdtOlS cech creen corr e M Us HUN DIM cerea dera gt 4 0019 Rex rere eet EE 14 06 2 Starter Motor 06 2 P N SOLENOID HOLD IN Description The function of the starting sy
47. Connect wiring harness 5 terminal circuit 4 to the positive battery post using a jumper wire Is indicator lamp CHECK FOR s CIRCUIT Yes Repair open or excess resistance in circuit 4 Remove three pin voltage regulator connector No Check for loose or bent pin in voltage regulator or e Measure wiring resistance between the one in S connector connector If OK replace voltage regulator and the S center pin of the voltage regulator connector Is resistance greater than 1 ohm 088 CHECK STATOR OUTPUT VOLTAGE Yes Go to B6 Start engine No Go to Pinpoint Test A to find the cause of low generator Measure voltage at the S terminal on the back of the generator Is voltage at least 1 2 of battery voltage output DIAGNOSIS 09 8 Generator 09 8 B6 CHECK GENERATOR OUTPUT VOLTAGE Yes Go to Pinpoint Test D to find the cause of high output voltage Measure voltage at the B terminal on the back of the No Replace voltage regulator generator with the engine running at 2000 rpm and all accessories turned off Is voltage greater than 15 5 volts TEST C Indicator Lamp Flickers Intermittent TEST STEP RESULT ACTION TO TAKE Check these connections for corrosion loose or bent pins No Clean or repair connections as required or loose eyelets Three pin voltage regulator connector One pin S connector Generator B eyelet Battery cables Are connections
48. ELECTRONIC FUEL INJECTION EFI SYSTEMS FOR INFORMATION ON THAT SYSTEM 05 2 Carburetor 05 2 DESCRIPTION On each carburetor an identification tag is found on the carburetor body Do not remove this tag for any reason The numbers stamped on this tag identify the carburetor for the particular engine usage These numbers are used when finding specifications for carburetor adjustments or in ordering replacement parts The Zenith model 33 carburetor is a single downdraft unit of two piece construction consisting of a cast aluminum air intake and throttle body with a fuel bowl The single venturi is removable for easy adaptability to meet different size engine requirements The mounting flange holes are elongated to allow it to fit either the SAE 1 or 1 1 4 flange A vacuum operated accelerator pump is used Fuel Supply System The fuel supply system consists of the threaded fuel inlet connection and fuel valve seat fuel valve float and fuel chamber The fuel supply line is connected to the threaded inlet Gasoline passes through the connection through the fuel valve seat and past the fuel valve and into the fuel chamber The level of the fuel in the fuel chamber is regulated by the float through its control of the fuel valve The fuel valve does not open and close alternately It assumes a more or less fixed opening position as regulated by the float sufficient to maintain a proper level in the fuel chamber equal to the
49. Edges are beveled to fit against wall when closed On plates including poppet valve the spring should face the top Hold choke plate closed with finger and tighten screws Turn air intake upside down and insert vacuum power piston into cylinder making sure it will move freely Hold in place and stake casting with punch at three points to retain piston assembly Press well filler tube into casting with rolled down orifice into casting until the bottom end is 1 25 inches from the cast surface Do not bend or distort Press idle tube into casting with rolled down orifice into casting until the bottom end is 1 25 inches from the cast surface Do not bend or distort DISASSEMBLY AND ASSEMBLY 05 8 Carburetor 05 8 THROTTLE BODY 2 lt 6 CUP PLUG FUEL VALVE ae By mem VALVE SEAT lt P PLUGS WASHER AA SPRING SPARK X TUBE WASHER THROTTLE gt PLATE 7 IDLE ADJUSTING SCREW amp s LOCK SCREW eS C WASHER FPP00229 Fuel Bowl Assembly T 2 Slide seal over throttle shaft with lip toward lever 1 Install the following parts as needed not normally and install shaft in body removed for service 3 Back out throttle stop screw and place body a Cup plug in shaft hole flush bench with mounting flange up b Fuel channel plug flush 4 With milled flat up install throttle plate with short c Welch plug over idle port side toward idle port and s
50. Generator Voltage Test 1 Connect Rotunda Starting and Charging System 1 Switch the tester to the voltmeter function Or Equant 2 Connect the positive lead to the generator A shown terminal connector and the negative lead to NOTE Refer to the test equipment user s manual for ground 2 dreguons or examining 3 Turn off all electrical accessories 4 With the engine running at 2000 rpm check the generator voltage 2 Connect the positive and negative leads of the 5 Voltage should be between 13 0 15 5 volts tester to the battery 3 Connect current probe to generator B output lead circuit 38 BK O to measure generator output AMPS 95 AMP GENERATOR 100 80 76 AMPS MIN 2000 RPM 60 40 20 0 0 500 1000 1500 2000 2500 ENGINE SPEED 141 4 With engine running at 2000 rpm adjust the VAT 40 or equivalent load bank to determine the maximum output of the generator Generator output should be greater than the values shown in the graph If amperage is NOT within specifications refer to symptom chart If voltage is NOT within specifications refer to symptom chart DIAGNOSIS 09 5 Generator 09 5 Symptom Chart CONDITION POSSIBLE SOURCE ACTION Go to Pinpoint Test A Dead battery Battery will not stay charged Slow crank Low battery voltage No generator output Indicator lamp on with engine running Key off batter
51. Ignition System 03 2 COMPRESSION STROKE DESCRIPTION WARNING HIGH TENSION VOLTAGE PRODUCED BY A DISTRIBUTORLESS IGNITION SYSTEM IS HIGHER THAN FOR A CONVENTIONAL IGNITION SYSTEM WHEN CARRYING OUT SERVICE OPERATIONS ON AN ENGINE EQUIPPED WITH DISTRIBUTORLESS IGNITION IT IS IMPORTANT TO BE AWARE OF THE ABOVE POINT AS WELL AS ALL THE USUAL SAFETY MEASURES TO PREVENT THE POSSIBILITY OF ELECTRIC SHOCKS rf FEE EXHAUST STROKE FPP00075 The Purpose of an engine s ignition system is to ignite the fuel air mixture at the correct time and sequence based upon the input it receives The Distributorless Ignition System DIS is a state of the art system The brain of this system is the Universal Electronic Spark control UESC module This module receives four inputs e Crankshaft position Crankshaft speed e Engine temperature e Engine vacuum load From these inputs the UESC computes spark strategy spark advance to obtain optimum engine performance for correct input conditions DESCRIPTION 03 3 Ignition System 03 3 Operation With this system the electronic control module monitors the engine load speed and operating temperature and decides what degree of spark advance is correct for all of the operating conditions Because timing is set for life inherently in the design of the engine and there are no moving parts in the ignition system itself no maintenance is required except for
52. Maximum voltage drop battery positive to starter 0 5 volts normal operating temperature Special Tools TOOL 4201 C Dial Indicator 078 00005 Starting Charging Tester Starter Motor 06 14 SPECIFICATIONS 07 1 Governor 07 1 SECTION TITLE PAGE ENGINE SERVICE intl ee Mi 01 01 ENGINE SERVICE 3 2 hebetes er etaed 02 01 IGNETIONISYSTEM s a r oerte tai bed 03 01 EUEL PUMP eter iioii NM dete tua fec tende tet at 04 01 GARB URETQOEBS tt reri p Am Dai Des 05 01 STARTER MOTOR LUE 06 01 GOVERNOR cit te note eedem teen aet tecti eee bite itus 07 01 GOOLING SYSTEM eoe teme tbe ede esaet enit seen bete Papa ET RINT 08 01 GENERATOR uem ie il eevee ere dao ee docete aceti We Ide drea 09 01 SUBJECT PAGE MECHANICALE GOVERNOR s o RO ER P RO CS ETUR I a EUG HR e 2 9 5 Sector tueri Lu deut Edo ettet tt 2 ao POSE 3 a eee E 5 Removal and Installati ri p
53. O ring lubricated with silicone grease Install water pump inlet tube in water pump Tighten water inlet tube to generator bracket bolts to 9 12 N m 84 108 Install lower radiator hose to water pump Install heater water hose to the water pump inlet tube Install water pump pulley and fan and tighten bolts finger tight Using half inch drive handle rotate drive belt tensioner and install drive belt Tighten fan and water pump pulley bolts to 20 25 N m 15 19 Ib ft Fill cooling system Start engine and check for leaks REMOVAL AND INSTALLATION 02 33 Engine Service 2 5L 02 33 CYLINDER HEAD WATER OUTLET CONNECTION 000201 Water Thermostat and Outlet Connection Removal 1 Drain the cooling system through the radiator until the coolant level is below the water thermostat and water outlet connection 2 Loosen the hose clamp securing the heater hose to the water outlet and remove the heater hose 3 Loosen the clamp securing the upper radiator hose to the water outlet connection and remove the hose 4 Remove water outlet connection retaining bolts 2 and remove water outlet connection thermostat and gasket Water Thermostat and Outlet Connection Installation 1 Clean the water outlet connection and cylinder head water outlet connection gasket surfaces 2 Apply Pipe Sealant with Teflon D8AZ 19554 A or equivalent meeting Ford specification ESG M4G1
54. and gear assemblies drive end housing pole pieces and planet gears Wash all other parts in solvent and dry 1 Inspect armature windings for broken or burned insulation and unwelded or open connections 2 Check armature for open circuits shorts and grounds Check for pole rub or rub on magnetic shunts DISASSEMBLY AND ASSEMBLY 06 11 Starter Motor 06 11 3 Check commutator for runout Inspect armature shaft and two bearings for scoring and excessive wear with Dial Indicator TOOL 4201 C or equivalent If commutator is rough or more than 0 12mm 005 inch out of round it must be DIAL INDICATOR replaced TOOL 4201 C ROTATE ARMATURE SHAFTS ON BEARING SURFACES Vv BLOCKS FPP00125 4 Examine gears spline on driveshaft and drive pinion for chipped broken or worn conditions Replace if required PINION AND RING GEAR WEAR PATTERNS do NO eL C MILLED CONDITION EXCESSIVE WEAR ON 2 OR 3 TEETH MILLED TOOTH METAL BUILD UP WILL NOT PERMIT ENGAGEMENT lt gt UN DOJ SMALL WEAR PATTERN NORMAL WEAR PATTERN MILLED GEARS FPP00126 DISASSEMBLY AND ASSEMBLY 06 12 Starter Motor 06 12 Assembly 1 Install armature assembly in starter frame Apply a thin coating of ESF M1C218 A grease or equivalent low temperature grease on both ends of armature shaft and spline Install brush assembly ensuring brushes fit over commutator Apply grease to bearing bore in b
55. bore in brush end plate and attach to starter frame TOOL TO ASSEMBLE BRUSH HOLDER TO ARMATURE PRESS FIT BUSHING BRUSH HOLDER ASSEMBLY O MANDREL MAT L MICAATA LL221 TAN TYPE FBL STK 13 8 DIA A LG 1 REQ D BUSHING UNIVERSAL HEADLESS TYPE PRESS FIT BUSHING CAT NO GS 33 471 472 1 0 7518 O D 750 LG 1 REQ D FPP00127 6 Position starter frame to gear assembly and drive end housing and install through bolts Tighten to 5 0 9 5 Nem 45 84 Ib in 7 Attach positive brush connector to solenoid bottom terminal Tighten nut to 9 13 Nem 80 120 Ib in 8 Check that starter no load current draw is within specification Refer to Starter No Load Test DISASSEMBLY AND ASSEMBLY 06 14 SPECIFICATIONS Torque Specifications Description Nem Lb ln Solenoid Bolt 54 96 45 85 M Terminal Nut 9 03 5 80 120 B Terminal Nut 9 03 5 80 120 Through bolt 50 95 45 84 Mounting Bolt 20 3 27 15 20 lb ft Brush Plate Screw 2334 20 30 General Specifications Motor Diameter 78mm 3 Current draw under normal load 140 200 amps Normal cranking speed 200 250 rpm Minimum stall torque 2 5 volts 14 7 Nem 11 0 Ib ft Maximum load 800 amps No load 70 10 Brush length 16 8 mm 0 66 Brush spring tension 18 N 64 oz Maximum commutator runout 0 12 mm 0 005
56. clean and tight C2 CHECK FOR FIELD CIRCUIT DRAIN Yes Go to C3 e key to off position No Go to C5 Measure voltage at test point F on the voltage regulator Is voltage equal to battery voltage C3 CHECK FOR LOOSE A CIRCUIT FUSE Yes Repair loose fuse connection e Start engine No Go to C4 the generator fuse loose connection by wiggling the fuse with the engine running Does indicator lamp flicker C4 CHECK A CIRCUIT CONNECTIONS Yes Replace voltage regulator If problem still exists replace generator e With engine running connect test point A on the voltage No Repair poor connection in circuit 36 regulator to the positive battery post using a jumper wire Does indicator lamp flicker Remove generator from unit No Tighten screws to specification 2 8 4 0 Nem 25 35 Ib Check the brush holder screws located on the voltage in regulator test points F and A e the brush holder screws tight C6 CHECK FOR GROUNDED SLIP RING Yes If grease or dirt has accumulated near the slip rings clean the slip rings and recheck resistance If still less than 200 ohms replace generator Remove voltage regulator No Replace voltage regulator Measure resistance from each generator slip ring to the generator housing Is resistance from either slip ring to housing less than 200 ohms DIAGNOSIS 09 9 Generator 09 9 TEST D Charging Voltage High TES
57. e the choke thermostat if used e Electronic governor actuator if used 6 Disconnect the manual choke cable from the choke lever on the carburetor 7 Remove the support bracket securing the choke cable and set aside 8 Disconnect the governor throttle control rod if used from the throttle lever on the carburetor 9 Remove the vacuum line from the vacuum tee on the intake manifold leading to the ignition control module 10 Disconnect the PCV valve from the oil separator beneath the intake manifold REMOVAL AND INSTALLATION 02 34 Engine Service 2 5L 02 34 CYLINDER HEAD ASSEMBLY EK FRONT OF ENGINE FPP00033 GASKET INTAKE MANIFOLD FPP00267 11 6 Install the PCV valve into the oil separator Install 12 Disconnect the fuel inlet line from the carburetor He vaccum ation Control madula 9510 or fuel filter on the carburetor depending 7 Connect the governor throttle control rod if used on the application to the carburetor throttle lever Caution Avoid spilling fuel on hot surfaces 8 Install the choke cable bracket and the choke Use an absorbent rag placed under the fuel cable to the choke lever on the carburetor line or fuel Mer being removed To collect any 9 Connect the electrical connections at the choke spilled fuel 2 thermostat if used and electronic governor 13 Remove the engine lifting eye actuator if used 14 Remove four bottom bolts from intake manifold 10 I
58. example if the engine is running or the battery is connected to a charger the lamp may fail SERVICE PROCEDURES 01 24 Engine Service General 01 24 6 Using the Rotunda Carbon Blaster and Automotive Borescope 014 00975 or equivalent automotive borescope inspect the backside of the intake valves through the spark plug holes for the presence of carbon deposits Compare the deposits with the deposit rating system chart If any of the intake valves appear to have a carbon deposit level of 7 or less lower number rating intake valve cleaning is required If no carbon deposits are seen or the deposit level is 8 or cleaner the drive concern may be the result of low volatility fuel 7 Remove the intake manifold assembly as outlined in Section 02 8 Remove flex hose and manifold adapter form the hand held vacuum included with the Rotunda 014 00975 Carbon Blaster and Automotive Borescope Insert tapered end of vacuum hose into intake port of cylinder head using a twisting motion to ensure a tight fit NOTE Detailed written instructions and a procedural video tape are included with the Rotunda 014 00975 Carbon Blaster and Automotive Borescope Perform the intake valve carbon cleaning procedure using the Rotunda 014 00975 Carbon Blaster or equivalent The intake valves should be in the closed position Cleaning takes approximately 1 to 1 minutes per valve 9 Confirm the intake valve is clean using Rotunda 014 00975 o
59. free in the body The plunger should drop to the bottom of the body by its own weight when assembled dry and check ball assembly removed e Assemble the hydraulic tappet lash adjuster assembly and check for freeness of operation by pressing down on the plunger e The lash adjusters can also be checked with a hydraulic tester to test the leakdown rate Follow the instructions of the test unit manufacturer or Leakdown Testing in this section SERVICE PROCEDURES 01 33 Engine Service General 01 33 Leakdown Testing Assembled valve tappets can be tested with Hydraulic Tappet Leakdown Tester TOOL 6500 E or equivalent to check the leakdown rate The leakdown rate specification is the time in seconds for the plunger to move a specified distance of its travel while under 22 7 kg 50 load Test the valve tappets as follows NOTE Do not mix parts from different valve tappets Parts are select fitted and interchangeable NOTE Tappets cannot be checked with engine oil in them Only testing fluid can be used Disassemble and clean valve tappet to remove all traces of engine oil HYDRAULIC TAPPET LEAKDOWN TESTER TOOL 6500 E Place valve tappet in tester with plunger facing upward Pour hydraulic tester fluid into cup to a level that will cover tappet assembly The fluid can be purchased from tester manufacturer Using kerosene or any other fluid will not provide an accurate test 2 Place a
60. fuel demand of the engine according to its speed and load Idle System The idle system supplies fuel to run the engine at curb idle and also slow speeds until sufficient velocity is built up in the main venturi to operate the main system This system consists of the idle discharge holes the idle adjusting needle the passage or channel between the idle jet and the discharge holes the idle air bleed and the idle jet and pickup tubes At idling speeds manifold vacuum is transmitted through the primary idle discharge hole to the idle jet through a passage running through the throttle and air intake bodies Fuel from the fuel bowl flows through the main jet into the fuel well where it is picked up by the pickup tube to be metered by the idle jet As the fuel leaves the idle jet it is mixed with air from the idle air bleed which is located just above the jet in the air intake therefore a fuel and air mixture is provided just before the passage to the idle discharge holes This air bleed calibration is to provide better control of the fuel delivery and to prevent the fuel in the bowl from being siphoned into the intake manifold through the idle system when the engine is shut off TT k EFE 1 4 t ji x AN Um gt MR 3 1 f AE rf a ved s E 1 tees 1 TFPI The discharge of the idle
61. gripping the thin edge of the seal tightly before operating the jack screw portion of the tool 7 Install Front Cover Seal Remover T74P 6700 B making sure jaws are gripping the thin edge of the seal 8 Remove seal Clean journal of debris Cylinder Block Front Cover Seal Installation 1 Using Cam Bearing Adapter Tube T72C 6250 and crankshaft pulley hub bolt press engine front cover seal into engine front cover Remove tool Install key Install crankshaft sprocket crankshaft pulley washer and bolt Tighten bolt to 125 165 N m 92 121 Ib ft 5 Install timing belt as outlined in this section Install outer timing belt cover as outlined in this section REMOVAL AND INSTALLATION 02 27 Engine Service 2 5L 02 27 Cylinder Head Removal Camshaft Belt Tensioner Tool 10 11 12 13 Special Tools Required T74P 6254 A Disconnect battery ground cable Drain cooling system Remove intake manifold as outlined in this section Remove ignition harness Remove spark plug wire set from spark plugs and valve cover attachments Disconnect vacuum hose from ignition module Remove valve cover and retaining bolts and remove cover Using flex handle rotate drive belt tensioner counterclockwise and remove drive belt Disconnect generator electrical connections Remove lower radiator hose and heater water hose from water pump inlet tube and thermostat housing Remove bolts s
62. in Specifications in Section 02 PISTON PISTON TO CYLINDER CLEARANCE A14479 B remove too much of the cylinder wall creating excess clearance SERVICE PROCEDURES 01 23 Engine Service General 01 23 Cylinder Head Service On Engine Inspection e Check for loose mounting bolts studs and nuts e Check for a plugged oil feed in the rocker arm or cylinder head e Check for broken or damaged valve springs Check for proper seating of valve spring retainer keys on valve stem and in valve spring retainer e Check for signs of improper head gasket installation such as the shape of the head and block and shape of the gasket not matching Check for signs of cylinder head gasket leakage such as coolant or oil leaking between the cylinder block and cylinder head Check for plugged oil drain back holes e Check for worn or damaged valve tips e Check for missing or damaged intake and exhaust valve stem seals e Check valve clearance e Check installed spring height e Check for missing or worn valve spring seats if equipped On Engine Valve Cleaning The intake valve cleaning procedure is to be used if there is a concern with engine hesitation rough idle long crank times and stall at idle and engine engagement after cold starts Many fluids are available to clean carburetors Some cleaning fluids also claim to remove intake valve deposits IVD Engineering evaluation of these fluids
63. in the actuator moves the throttle shaft to minimum fuel position Velocity Governor The velocity governor is an engine speed limiting type and operates by metering the air fuel mixture flow from the carburetor The governor is installed between the carburetor and the intake manifold It contains a disc valve mounted on a shaft which is similar in appearance to a carburetor butterfly valve However unlike a butterfly valve the governor shaft is mounted off center in the governor bore As engine speed increases the velocity of the air fuel mixture passing across the disc valve increases Since the governor shaft is mounted off center the force of the flowing air fuel mixture attempts to close the disc valve therefore restricting the flow and slowing the engine The force of the flowing air fuel mixture attempting to close the valve is opposed by a spring The force of the spring therefore establishes maximum engine speed DESCRIPTION 02 8A Engine Service 2 5L 02 8A e ee Wiring Diagrams Carbureted DESCRIPTION 02 8B Engine Service 2 5L 02 8B Wiring Diagrams Carbureted 674 BR W 18 72 Y BK 18 CRANKSHAFT 349 DK B 18 POSITION TO SWITCH 350A GY 18 SENSOR GAGE RELAY ree CIRCUIT 16 354 LT G R 18 dE ENGINE COOLANT TEMP SENSOR 16M R G 18 57 BK W UNE 57C BK 18 DIS 16c RG 18 IGNITION 01 COIL UNI
64. new ring gear on a plate approximately 1 8 2 3mm thick and heat up to 260 280 Centigrade from below in area of ring gear itself using a welding torch to give uniform heating E A Note position of gear tooth chamfer Slip ring gear over flywheel with tongs so that ring gear comes to rest on abutment rim Allow to cool in this position Starter ring gear is induction hardened and loses this hardness as soon as it is heated to over 290 To monitor temperature mark ring gear with a thermocromatic colored pencil Faber Castell 2815 before starting heating operation On reaching temperature required color marked on gear changes to color of pencil cover Example If colored pencil is green and cover black indicated temperature of 260 280 C is reached when green colored mark on ring gear changes to black REMOVAL AND INSTALLATION 02 59 Engine Service 2 5L 02 59 RETAINING PLATE FOLLOWEH FRONT E ENGINE CAMSHAFT 0264 DISASSEMBLY AND ASSEMBLY Cylinder Head Disassembly Special Tools Required Valve Spring compressor T95T 6565 A Cam Sprocket Holding Tool T74P 6256 B Front Cover Seal Remover T74P 6700 B Cam Bearing Replacer T71P 6250 A Camshaft Bearing Set T65L 6250 A Front Seals Replacer T74P 6150 A Valve Stem Seal Replacer T95L 6510 A Valve Guide Replacer T95T 6510 B NOTE When disassembling cylinder head mark the cam followers lash ad
65. provide access to the thermostat 5 Remove the thermostat and gasket Thermostat Installation Checkthe thermostat before installing it following the procedures in this section 2 Clean the coolant outlet housing and cylinder head or manifold gasket surfaces 3 Coata new gasket with water resistant sealer 4 Position the gasket on the cylinder head opening 5 The gasket must be positioned on the cylinder head before the thermostat is installed AN Caution To prevent incorrect installation of the thermostat the water outlet casting contains a locking recess into which the thermostat is turned and locked 1 Install the thermostat with the bridge section in the outlet casting 2 Turn the thermostat clockwise to lock it in position on the flats cast into the outlet elbow 3 Position the coolant outlet elbow against the cylinder head 4 Install and torque the retaining bolts to specifications 5 Connect heater return hose to thermostat housing 6 Fill the cooling system with the recommended permanent antifreeze and water mixture 7 Check for leaks and proper coolant level after the engine has reached normal operating temperatures REMOVAL AND INSTALLATION 09 1 Generator 09 1 SECTION TITLE PAGE ENGINE SERVICE intl ee Mi 01 01 ENGINE SERVICE 3 2 hebetes er etaed 02 01 IGNETIONISYSTEM s a r oerte tai
66. rag Inspect for scoring and visible wear 4 Inspect bearings for excessive wear f visibly worn or damaged replace bearings If one of the center bearings is worn significantly more than the end bearings check camshaft for excessive runout 5 Using suitable bore gauge or inside micrometer measure each bearing 90 degrees apart to determine bearing size out of round Double check by measuring twice 6 Check results against specifications in the specification section If bearings are out of specifications they will have to be replaced Check camshaft journals before replacing bearings to determine if undersize bearings are required 7 necessary replace the bearings Camshaft Bearing Journals 1 Measure each journal twice 90 degrees apart to determine journal wear size and out of round 2 Check measurements against specifications in the specification section 3 If journals are excessively out of round or worn regrind to a standard undersize Refer to Master Parts Catalogue 4 f journals are too worn to be refinished to an available undersize replace camshaft Camshaft Journals Oil Clearance 1 Measure camshaft bearings and camshaft bearing journals as outlined in this section 2 Subtract size of journal from the size of its bearing 3 Check clearance against specifications in specification section 4 f clearance is excessive but camshaft journals are within specifications
67. same relative position on the new set 4 Route the spark plug wire set toward the spark WIRE REMOVER lugs 74 6666 plug 5 Connect each spark plug wire set on the proper spark plug 273 E Spark Plug Removal NOTE Refer to the Spark Plug Inspection Chart to TWIST AND PULL determine spark plug condition FPP00089 1 Remove ignition wires as outlined 2 Loosen spark plugs and remove any dirt or foreign material from spark plug areas of cylinder 2 Squeeze the locking tabs on the coil retainer and head with compressed air pull upward on the boot with a slight side to side twist to disconnect the spark plug wire set from 3 Remove spark plugs and mark location using a the ignition coil piece of masking tape 4 To install reverse removal procedure Check and CAUTION Do not pull on the spark plug adjust spark plugs Tighten spark plugs to 9 20 UN wire set Nem 7 15 lb ft Ignition Wires Installation 1 Apply an even coating of Silicone Dielectric Compound WA 10 D7AZ 19A331 A or equivalent meeting Ford specification ESE 1 171 to the entire interior surface of the spark plug boot 2 Squeeze locking tabs on coil retainer and push down on boot with a slight side to side twist to connect spark plug wire set on the ignition coil Each of the terminals is identified on the ignition coil The firing order of the coil is 1 3 4 2 Check that each of the spark plug wires is fu
68. screws oil pump screen cover Cam Sprocket Holding Tool T74P 6256 B ana tuper Front Cover Seal Remover T74P 6700 B 3 Remove oil pump inlet tube gasket Cam Bearing Adapter Tube T72C 6250 Clutch Aligner T71P 7137 H SCREEN OIL PUMP amp INLET TUBE FPP00271 Oil Pump Screen Cover and Tube Installation 1 Thoroughly clean oil pump screen cover and tube Clean all mounting surfaces e Install oil pump screen cover and tube and oil pump inlet tube gasket Install two screws and one nut Tighten screws to 20 30 N m 15 22 10 Tighten nut to 40 55 N m 29 40 Ib ft px xm dm Install oil pan as outlined in this section 1 Remove engine and install on suitable engine stand Drain oil from engine Remove engine oil level dipstick Remove crankshaft bolt and washer Remove crankshaft damper JOR mo d Remove outer timing belt cover screw depress tabs and remove outer timing belt cover 7 Remove screw retaining crankshaft position sensor Remove crankshaft position sensor from engine front cover 8 Loosen timing belt pivot bolt one half turn 9 Hold timing belt tensioner with T74P 6254 A Camshaft Belt Tensioner Tool and remove adjusting bolt Relax tensioner spring 10 Remove timing belt 11 Install T74P 6256 B Cam Sprocket Holding Removing Tool on oil pump sprocket 12 Remove oil pump sprocket bolt and washer REMOVAL AND INSTALLATION 02 48 Engine Service
69. simply install new bearings 5 f both bearings and journals are worn turn camshaft journals to a standard undersize and install new undersize bearings SERVICE PROCEDURES 01 13 Engine Service General 01 13 Camshaft Runout NOTE Check camshaft journals for out of round before checking for runout out of round condition on the center journal could be confused for an excess runout condition Set suitable V blocks on surface plate Support outer camshaft journals on V blocks DIAL INDICATOR CAMSHAFT A14453 B 1 Set up TOOL 4201 C or equivalent Dial Indicator with bracketry to check center bearing journal Zero dial indicator Slowly rotate camshaft to determine overall runout If runout exceeds 0 03mm 0 0012 in replace camshaft Cam Lobe Lift Measurement There are two ways of measuring cam lobe lift e micrometer dial indicator more accurate Cam Lobe Lift with micrometer 1 Inspect camshaft bearing as outlined in this section 2 Measure the distance of each cam lobe at the major diameter 3 Measure the distance of each cam lobe at the minor diameter 4 For each cam lobe subtract the minor diameter from the major diameter The result for each lobe is the lobe lift Check the lobe lift for each cam lobe against the Specifications If any cam lobe is worn excessively replace the camshaft and tappets A MINUS B CAM LOBE LIFT 6 35
70. speed settings Engine is hunting Engine is misfiring due to idle mixture mis adjustment This causes engine hunt at no load condition Disconnect the connector from the controller The governor is now disabled and a warm engine should be running at a mechanical idle of approximately 600 rpm If the engine is not running at the mechanical idle and is governed by an integrated carburetor loosen the three actuator fasteners and rotate the actuator to achieve an idle of 600 rpm If the engine is governed by a linear actuator adjust the idle speed screw to achieve 600 rpm Slowly rotate the idle mixture screw clockwise CW until the engine speed begins to decrease Slowly turn the idle mixture screw counterclockwise CCW until the engine speed begins to decrease Now turn the idle mixture screw clockwise CW until maximum idle speed is achieved The idle mixture is now adjusted Engine is misfiring disconnect the connector from the controller and consult the engine repair manual DIAGNOSIS 07 12 Electronic Governor carb 07 12 O au c Basic Wiring Diagram DYN1 10851 Controller FPP00133 DIAGNOSIS 07 13 Electronic Governor carb 07 13 1 509 219 5 012 Nameplate 2 3e2a Si sis ru E o 25 4 000 1127 1 0 4437 2 040 i 556 1 4 ern Le 219 018 419 1 65 Sepia 5 312
71. steps 20 30 N m 15 22 Ib ft then 48 68 N m 35 50 Ib ft REMOVAL AND INSTALLATION 02 30 Engine Service 2 5L 02 30 _ GASKET EXHAUST MANIFOLD LIFTING EYE FPP00214 REMOVAL AND INSTALLATION 02 31 10 11 Install timing belt tensioner and timing belt tensioner spring on cylinder head placing one leg of timing belt tensioner spring under stud on cylinder head and other leg against pin on timing belt tensioner and install spring pivot bolt Install timing belt as outlined in this section Install outer timing belt cover as outlined in this section Install generator mounting bracket with assembled ignition coil and ignition wire and brackets Refer to the following installation drawing for correct torque sequence Tighten in order illustrated MOUNTING BRACKET s ne LM v DRIVE a N BELT TENSIONER N GENERATOR 00265 Engine Service 2 5L 12 13 14 15 16 17 18 19 20 21 22 23 24 25 02 31 Replace O ring lubricated with silicone grease on water pump inlet tube Install water pump inlet tube into water pump Tighten inlet tube to generator bracket bolts to 9 12 N m 84 108 Ib in Install lower radiator hose Install generator Tighten generator to bracket bolts to 40 55 N m 29 40 lb ft Connect upper radiator hose and heater water hose and tighten hose clamps Install water pump pulley and fan Tighte
72. sure service life is extended Valve Guide Reaming If it becomes necessary to ream a valve guide to install a valve with an oversize stem a hand reaming kit is available which contains the following reamer and pilot combinations 0 38mm 0 015 inch OS reamer with 0 076mm 0 003 inch OS pilot 0 76mm 0 030 inch reamer with a 0 38mm 0 015 inch OS pilot HAND REAMER BREAK SHARP CORNER A21329 A NOTE If oversize valve stems and oversize stem seals are not available bore out original valve guide and install service bushing if available Ream inside diameter for specified clearance for standard size valve Reface valve seat as required Install standard size valve stem oil seal When replacing a standard size valve with an oversize valve always use the reamer in sequence smallest oversize first and then the next smallest etc so as not to overload the reamers Always reface the valve seat after the valve guide has been reamed and use a suitable scraper to break the sharp corner inside diameter at the top of the valve guide NOTE The interference angle of the valve and seat should not be lapped out Remove all grooves or score marks from the end of the valve stem and chamfer it as necessary Do not remove more than 0 254mm 0 010 inch from the end of the valve stem If the valve face runout is excessive and or to remove pits and grooves reface the valves to a true 45 degree angle Remove
73. tabs the retainer and pull upward on the boot with a slight side to side twist CAUTION Do not pull on the spark plug wire set DISCONNECT HIGH TENSION LEADS FPP00079 4 Remove four screws 5 Remove the ignition coil assembly FPP00225 Ignition Coil Installation 1 Position coil assembly secure with four screws 2 Tighten screws to 4 5 7 Nem 36 63 Ib in 3 Connect HT leads at coil ensuring that locking tabs snap into position NOTE HT connections at coil are marked 1 to 4 It is important that each HT lead is connected in correct sequence 4 Connect ignition coil multiplug 5 Connect battery ground cable 6 Start engine and check coil operation REMOVAL AND INSTALLATION 03 10 Ignition System 03 10 Crankshaft Position Sensor Removal 1 Disconnect battery ground cable 2 Drain cooling system 3 Using flex handle rotate drive belt tensioner and remove drive belt 4 Disconnect generator connectors Remove three bolts and generator 6 Remove lower radiator hose and heater water hose from water pump inlet tube DRIVE BELT WATER TENSIONER PUMP INLET 0221 7 Remove two bolts and water pump inlet tube 8 Remove o ring from water pump inlet tube 9 Disconnect multiplug from sensor BRACKET CONNECTOR 5 UA j JL SN 12 CRANKSHAFT POSITION SENSOR FPP00222 10 Remove one screw GENERATOR ENGINE FR
74. the cored passages to cool each cylinder wall Upon reaching the rear of the cylinder block the coolant is directed upward in to the cylinder head where it cools the combustion chambers valves and valve seats The coolant from the cylinder head flows past the thermostat if it is open through the coolant outlet housing and into the top of the radiator Another passage in the head routes the warm coolant through the intake manifold to help atomize the fuel mixture and then exits the intake manifold through a hose to the inlet of the water pump Cleaning Cooling System To remove rust sludge and other foreign material from the cooling system use Rotunda Cooling System Cleanser Removal of such material restores cooling efficiency and avoids overheating Always remove the thermostat prior to pressure flushing A pulsating or reversed direction of Cooling System 08 2 FPP00276 flushing water flow will loosen sediment more quickly than a steady flow in the normal direction of coolant flow In severe cases where cleaning solvents will not properly clean the cooling system for efficient operation it will be necessary to use the pressure flushing method Various types of flushing equipment are available MIXTURE by volume PROTECTION Anti freeze Solution Water Above X 20 80 4 C Above X F 35 65 16 C Above X 45 55 26 C Above X 55 45 40 C DIA
75. timing belt tensioner as outlined in this section Remove oil pump sprocket as outlined in this section Remove screw and nut securing inner timing belt cover to cylinder block Loosen stud two or three turns Remove inner timing belt cover Position inner timing belt cover on front of engine and stud Install nut and bolt and tighten to 8 12 72 108 Ib in Tighten stud to 20 30 N m 15 22 Ib ft Install oil pump sprocket as outlined in this section Install timing belt tensioner as outlined in this section Tighten M8 bolt to 22 27 N m 16 20 Ib ft and M10 bolts 3 to 40 55 N m 29 40 lb ft Install timing belt as outlined in this section REMOVAL AND INSTALLATION 02 19 Engine Service 2 5L 02 19 Camshaft Timing Belt Removal Special Tools Required TENSIONER J SPRING Camshaft Belt Tension T74P 6254 A CAMSHAFT Adjusting Tool SPROCKET 1 Remove spark plugs ADJUSTING 2 Align crankshaft so number one piston is at TDC top dead center as indicated by timing marks lt Refer to illustration TENSIONER 3 Remove outer timing belt cover as outlined in this section CAUTION If you attempt to remove timing or adjust tension without loosening both timing belt tensioner adjusting bolt and spring pivot bolt you will break Camshaft Belt Tension Adjusting Tool T74P 6254 A when you attempt to relieve tension on belt SPROCKET 4 Loosen timing belt spring p
76. 11000 ARMATURE ASSEMBLY ARMATURE DRIVE THRUST BALL LEVER 114172 PLANET 11070 GEAR j 11 190 STATIONARY ASSEMBLY DRIVE S 11A165 TRUARC E RING ASSEMBLY ix m N805404 11350 THRU BOLT RETAINER SHAFT N805428 11 167 7 ASSEMBLY G C RMATURE THRUST Lope ARMATU U WASHER 11A075 E M TOP RIN BRUSH POLE SHUNT MAGNET Me RETAINER PLATE 114161 POLE PIECE 11223 SCREW 6 REQ D 41A168 N805406 6 STOP RING BRUSH END 11222 PLATE SPRING MAGNET 11050 BUSHING 11059 elm RETAINER BEARING 4REQ D BRUSH STARTER Nen AQ AA 11135 ASSEMBLY FRAME 6 11434 11076 FPP00124 Disassembly Cleaning and Inspection 1 Remove positive brush connector from solenoid motor M terminal Remove solenoid retaining screws and solenoid Remove through bolts and separate drive end housing from motor frame Remove housing seal assembly from drive Remove drive and gear assembly from drive end housing Remove drive lever from drive assembly Remove stop ring and retainer from driveshaft then remove drive assembly from shaft Push C ring off driveshaft and separate gear assembly from driveshaft Remove brush plate screws and brush end plate from motor frame Remove brush assembly and push armature out of frame CAUTION Do not wash the drive because the solvent will wash out the lubricant causing drive to slip Use a brush or compressed air to clean the drive armature brush
77. 1270 mm 0 005 teste ie Lr 45 1 thrust face 0 0254 mm 0 001 Valve seat runout max 0 0508 0 0020 maximum 0 0127 0 0005 Valve arrangement front to Thrust bearing journal length 30 5054 30 4546 mm Valve tappet bore 20 5359 20 6375 mm 0 8085 0 8125 1 201 1 199 Gasket surface flatness Main rod bearing journal finish RMS 10 inni any 152 4 mm 6 0 0762 mm 0 003 Main bearing thrust face finish RMS 35 front 25 rear max 0 1524 mm 0 006 Connecting rod bearing journal Head gasket surface finish 5 78 157 diameter 51 9786 51 9989 mm 2 0464 2 0472 max out of round 0 0152 0 0006 eis max taper 0 0152 mm 0 0006 per inch CAMSHAFT Crankshaft free end play 0 1016 0 2032 mm 0 004 0 008 an SE AOA Anica d wear 0 3048 mm 0 012 Lobe tts 5 4940 0 2163 faced nott ce a Gace oh 0 1270 mm 0 005
78. 160 1 2700 mm 0 040 0 050 Valve spring pressure intake steeds 253 55 280 24 N 39 6240 mm 57 63 lbs 1 56 Valve spring pressure exhaust 524 89 587 17 N 29 4640 mm 118 132 lbs 1 16 Valve spring wear 10 loss of pressure approx 51 3080 mm 2 02 assembled height pad to retainer 39 1160 40 1320 mm Ea Am a etin MINE 1 54 1 58 out of square 1 27 mm 0 050 Valve stem to guide clearance intake 0 0254 0 0686 mm 0 0010 0 0027 E exhaust 0 08381 0 0813 mm 0 0015 0 0032 UR wear 0 1897 mm 0 0055 Valve head diameter intake 43 9420 44 1960 mm 1 73 1 74 ee exhaust 97 8460 38 3540 mm 1 49 1 51 ce toot iere ette eres 45 Valve face runout max 0 0508 mm 0 002 Valve stem diameter standard nunt intake 6 9748 6 9952 mm 0 2746 0 2754 6 9494 6 9698 mm 0 2736 0 2744 Valve stem diameter 0 015 oversize sexi tes intake 7 3558 7 3761 mm 0 2896 0 2904 exhaust 7 3304 7 3507 mm 0 2886 0 2894 Valve stem diameter 0 030 oversize iuis intake 7 7368 7 7571 mm 0 3046 0
79. 45 Lubricate and install new O ring on water pump inlet tube Install water pump inlet tube into water pump Install water inlet tube to generator bracket bolts and tighten to 9 12 84 108 Install crankshaft sprocket crankshaft damper washer Tighten bolt to 125 165 92 121 Ib ft Install oil pump sprocket and tighten bolt to 40 55 N m 29 40 Ib ft Align sprockets and install timing belt as outlined in this section Install outer timing belt cover as outlined in this section REMOVAL AND INSTALLATION 02 46 Engine Service 2 5L 02 46 Oil Pan Removal 1 Remove the oil pan retaining bolts 2 Remove the oil pan 3 Remove the oil pan gasket 4 Thoroughly clean the engine and oil pan gasket surfaces FPP00203 OIL PAN Oil Pan Installation 1 Apply Silicone Gasket and Sealant F1AZ 19562 A or equivalent meeting Ford specification WSE M4G320 A2 in six places at joints between engine front cover and the cylinder block and rear main bearing cap and engine block as shown Install a new oil pan gasket to the oil pan Position the oil pan to the engine Install and tighten oil pan retaining bolts to 14 16 N m 132 144 Ib in FPP00204 REMOVAL AND INSTALLATION 02 47 Engine Service 2 5L 02 47 Oil Pump Screen Cover and Tube Crankshaft Removal Removal 1 Remove oil pan as outlined in this section preci Tools Reduced 2 Remove nut two
80. 5 allowable 0 0203 0 0660 mm 0 0008 0 0026 Wall thickness standard 2 4155 2 4282 mm 0 0951 0 0956 SPECIFICATIONS 02 68 CONNECTING ROD Engine Service 2 5L cai 23 1242 23 1445 0 9104 0 9112 Connecting rod bearing bore diameter 55 1688 55 1891 mm 2 1720 2 1728 TENE out of round max 0 0102 mm 0 0004 taper 0 0102 mm 0 0004 Connecting rod alignment maximum total diff pin bushing and crankshaft bearing bore must be parallel and in the same vertical plane within the specified total difference at ends of 203 2 mm 8 long bar measured 101 6 mm 4 on each side of rod eat twist 0 0762 mm 0 003 Loses Ses 0 0381 mm 0 0015 Connecting rod assembled to crankshaft Piston pin bore or bushing inside diameter side clearance 0 0889 0 2921 mm 0 0035 0 0115 e limit eoi 0 3810 mm 0 0150 CAPACITIES approximate Crankcase 4 26 L 4 5 quarts includes oil filter FUEL PUMP CARBURETED Static pressure 24 13 34 47 kPa 3 5 5 0 psi Volume 1 9 Liters 2 quarts per minute FUEL PUMP EFI Static pressure esteem 399 90 kPa
81. 5W30 QSP or UN equivalent meeting Ford specification ESE M2C153 E during assembly to prevent a dry start and engine damage 1 If removed install upper crankshaft bearings If reusing bearings reinstall each bearing in the same place from which it was removed Install crankshaft If removed install bearings in main bearing caps If reusing bearings install bearing in same place from which it was removed gt Apply Plastigage to crankshaft bearing journals Install main bearing caps and bolts Alternately tighten bolts to 68 81 N m 50 60 Ib ft Retighten to 108 122 N m 79 90 Ib ft SEALER F1AZ 19562 A SPECIFICATION WSE M4G320 A2 APPROXIMATELY 7MM 0 28 IN DIA DOT ON CYLINDER B OCK 12 MM gt 1 0 48 IN REAR FACE 2 PLACES VIEW B REMOVAL AND INSTALLATION 02 49 Engine Service 2 5L 02 49 18 19 20 21 22 23 Remove caps Check Plastigage for bearing clearance using chart on package If OK go on to next step If not correct clearance Apply 7mm 0 28 inch dot of Silicone Gasket and Sealant F1AZ 19562 A or equivalent meeting Ford specification WSE M4G320 A2 on each side of cylinder block as shown in illustration No sealer allowed on inside diameter of seal lip Lubricate bearings and reinstall main bearing caps and bolts Alternately tighten main bearing bolts to 68 81 N m 50 60 lb ft Retighten 102 115 75 85 lb ft Check cr
82. 6 35 MM 1 4 INCH 1 4 INCH NO PITTING ALLOWED IN THIS AREA A21328 A Cam Lobe Lift with dial indicator 1 Clean and inspect the camshaft as outlined in this section Install the camshaft on a lathe or camshaft grinder centers Position the machine s dial indicator at the heel of the cam lobe you are going to check Zero the dial indicator Slowly turn the camshaft until the point of the dial indicator is on the tip of the cam lobe Read the dial indicator This is your cam lobe lift Check the lobe lift against the specifications in the specifications section If any cam is excessively worn replace the camshaft and tappets SERVICE PROCEDURES 01 14 Engine Service General 01 14 Connecting Rod Service Connecting Rod Side Clearance 1 Install Rotunda Dial Indicator with Bracketry TOOL 4201 C or equivalent so that the contact point rests against the connecting rod cap 2 Pull cap toward front of engine and zero the dial indicator 3 Push cap toward rear of engine and observe amount of side clearance on dial indicator 4 f side clearance exceeds specification replace connecting rod and cap Refer to the specification section If side clearance is less than specification remove rod and cap and inspect for scratches burrs nicks or dirt between crankshaft and connecting rod Cleaning Remove the bearings from the rod and cap Identify each bearing location if they are to be
83. 6256 B Cam ROTUNDA EQUIPMENT Sprocket ue _ Holding Removing Tool Dascrption ooo 021 00045 Belt Tension Gauge T74P 6306 A Crankshaft SPECIFICATIONS 03 1 Ignition System 03 1 SECTION TITLE PAGE ENGINE SERVICE General ainser intel iene cael cite ei a el Mi 01 01 ENGINE SERVICE 1 ett ehe bee ette eer a etos 02 01 IGNETIONISYSTEM 3 oett Por Ee Peters o Se pute a eb 03 01 EUELE eee te bei aet usitate tete dtes das see ndr E ERE 04 01 ttai ee te te este d Tees 05 01 STARTER MOTOR ede cedem ista Be tes idest oed 06 01 GOVERNOR Beate ibt iid 07 01 22 5 inet O E these 08 01 GENERATORS eet ooo ee Wee ae et Oe Be Os 09 01 SECTION 03 IGNITION SYSTEM NOTE This system is used on both carbureted and EFI engines SUBJECT PAGE DESCRIPTION S e e Ee e vacate ded ae ae lel 2 VOTO IA SELL ER oh 3 e ce mete
84. 94 A to water outlet connection bolts prior to installation NOTE To prevent incorrect thermostat installation the water outlet connection contains a locking recess into which the thermostat is turned and locked 3 Install the thermostat with its bridge section in the water outlet connection Twist and lock thermostat into place 4 Position the water outlet connection retaining bolts through the water outlet connection holes and hang gasket on retaining bolts 5 Install water outlet connection thermostat and gasket to cylinder head and hand tighten retaining bolts 6 Tighten retaining bolts to 20 30 15 22 lb ft 7 Position hose clamp on upper radiator hose and install clamp and upper radiator hose to water outlet connection Tighten and secure hose clamp 8 Position hose clamp on heater hose and install heater hose and clamp on water outlet connection Tighten and secure hose clamp 9 Fill cooling system 10 Start engine and check for leaks Intake Manifold Removal carb only NOTE If removing the intake manifold for access to other components only the carburetor may remain attached 1 Disconnect the battery ground cable 2 Remove the air cleaner assembly 3 Drain the coolant from the radiator to a level lower than the intake manifold 4 Loosen the heater hose clamp and remove the heater hose from the coolant fitting on the intake manifold 5 Disconnect the electrical connections to
85. ARNINGS that you should follow when you work on the equipment e Always wear safety glasses for eye protection e 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 itin PARK REVERSE engine off or NEUTRAL engine on unless instructed otherwise for a specific operation Place wood blocks 4 x 4 or larger to the front and rear surfaces of the tires to provide further restraint from inadvertent equipment movement e Operate the engine only in well ventilated area to avoid the danger of carbon monoxide e Keep yourself and your clothing away from moving parts when the engine is running especially the fan and belts e To prevent serious burns avoid contact with hot metal parts such as the radiator exhaust manifold tail pipe catalytic converter and muffler smoke while working on the equipment e To avoid injury 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 through the ignition is in the OFF po
86. Block Distortion Cylinder block distortion is rare because cylinder blocks are normalized after casting and before machining to relieve internal stresses from the casting process The most probable cause of cylinder block distortion would be extreme overheating which would probably be accompanied by other damage such as scored bearings or cylinder walls warped cylinder heads and possible cylinder block cracks Cylinder Head Deck Flatness Place a straightedge across the cylinder head deck in three positions and check for any gaps between the straightedge and the deck with a feeler gauge The deck should be flat within 0 76 mm 0 003 in over 152 mm 6 inches and 0 152mm 0 006 in overall If necessary resurface or replace cylinder block Cylinder Walls Refinishing If the entire engine has NOT been disassembled clean the individual cylinder bore s with a cloth soaked in solvent Dry with a clean lint free cloth If the entire engine HAS been disassembled refer to Cleaning and Inspection in this section After any cylinder bore service operation such as honing or deglazing clean the bore s with soap or detergent and water Then thoroughly rinse the bore s with clean water to remove the soap or detergent and wipe the bore s dry with a clean lint free cloth Finally wipe the bore s with a clean cloth dipped in XO 10W30 QSP or DSP or equivalent motor oil meeting Ford specification ESE M2C153 E Before r
87. DER COOLANT TEMPERATURE SENDER 00269 3 Place aclean drain tray below engine under radiator drain plug and remove drain plug To assist draining remove radiator cap Drain sufficient coolant to lower the level below the temperature sensor 4 Remove temperature sensor multiplug To remove multiplug pull on multiplug do not pull on wiring 5 Unscrew the sensor Engine Coolant Temperature Sensor Installation 1 Install the sensor Do not overtighten Connect multiplug ensuring that locking tabs snap into position 2 Replace radiator drain plug and refill system with correct solution Remove rubber blanking cap on water outlet When coolant is evident refit blanking cap Fill container to maximum mark allowing time for air in system to bubble through Install radiator cap 3 Connect battery and start engine Allow engine to warm to normal operating temperature Check and if necessary add coolant REMOVAL AND INSTALLATION 03 12 Ignition System 03 12 Ignition Wires Removal SQUEEZE LOCKING Special Tools Required s d a Tans TO Spark Plug Wire Remover T74P 6666 A 1 Remove spark plug wires from spark plugs with Spark Plug Wire Remover T74P 6666 A pulling outward on the boot with a slight side to side twist FPP00090 CAUTION Do not pull on the spark plug 3 Remove the ignition wire separator from the spark UN wire set plug wire set and reinstall it in the
88. GNOSIS 08 3 Diagnosis The most frequent cooling system complaints are leakage and overheating Either of these problems will soon render the engine inoperable Most engines use an ethylene glycol base antifreeze solution to which the manufacturers have added a dye color The dye color makes the antifreeze solution an excellent leak detector If this type of solution is not being used in the cooling system a vegetable dye may be added to aid in locating external leakage Cooling System 08 3 Visual Inspection Check for leakage at all hoses and hose connections radiator seams radiator core and radiator drain petcock all block core plugs and drain plugs edges of all cooling system gaskets transmission oil cooler water pump shaft and bushing 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 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 POSSIBLE SOURCE Pressure cap and gasket CONDITION Loss of coolant e e Leakage e External leakage e Internal leakage ACTION Inspect wash 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 gas
89. IRE SIGNAL INPUT 0 5V SIGNAL LB BK 18 14 107 DATA LINK CONNECTOR RS485 GROUND P 18 22 39 WATER TEMPERATURE INDICATOR SENDER TO GAUGE R W 18 16 37B KEEP ALIVE POWER BATTERY Y 18 8 37 VPWR POWER RELAY SWITCHED SIDE 12V BATT Y 12 9 32A TO STARTER SOLENOID 5 TERMINAL DB 16 15 32 FROM IGNITION SWITCH START MODE TERMINAL R LB 16 13 16A SWITCHED IGNITION 12V R LG 16 1 11 TO TACHOMETER T Y 18 2 DESCRIPTION 02 10 Engine Service 2 5L 02 10 Item Description Item Description 1 Bolt M10 1 5 x 55 7 places 35 Camshaft Sprocket 2 Exhaust Manifold 36 Crankshaft Front Seal 3 Engine Lifting Eye rear 37 Camshaft 4 Nut M10 1 5 38 Water Outlet Connection 5 Stud M10 1 5 x M10 1 5 x 84 39 Bolt M8 1 25 x 18 6 Exhaust Manifold Gasket 40 Water Thermostat 7 Valve Cover Gasket 41 Thermostat Gasket 8 Valve Cover 42 Intake Valve 9 Crankcase Ventilation Hose 43 Exhaust Valve 10 Oil Filter Cap 44 Cylinder Head 11 Screw M6 1 x 15 45 Engine Oil Pressure Sender 12 Bolt M8 1 25 x 25 7 places 46 Camshaft Retaining Plate 13 Engine Lifting Eye front 47 Screw M6 1 x 16 14 Nut M8 1 25 48 Spark Plug 15 Bolt M8 1 25 x 33 49 Spark Plug Wire and Bracket Assembly 16 Stud M8 1 25 x 1 25 x 63 7 50 Bolt M12 1 75 x 100 7 10 places 17 Intake Manifold 51 Valve Stem Seal 18 Intake Manifold Gasket 52 Valve Spring 19 Head Gasket 53 Valve Spring Retainer 20 Cylinder Block 54 Valve Spring Retainer Key 21 Inner Tim
90. LRG 425 Power 2 5 LITER The Source for Power 1 53 Cl D Worldwide INDUSTRIAL ENGINE SERVICE MANUAL 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 There are numerous variations in procedures techniques tools and parts for servicing equipment as well as in the skill of the individual doing the work This Manual cannot possibly anticipate all such variations and provide advice or cautions as to each Accordingly anyone who departs from the instructions provided in this Manual must first establish that he compromises neither his personal safety nor the equipment integrity by his 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 give you added information that will help you to complete a particular procedure CAUTIONS are given to prevent you from making an error that could damage the equipment WARNINGS remind you to be especially careful in those areas where carelessness can cause personal injury The following list contains some general W
91. Leaking exhaust system Refer to section on accessory e Improper drive belt tension drivebelts Malfunctioni sid Refer to section on charging system etti as Adjust or replace timing belt x Replace timing belt tensioner e Loose riming belt Refer to section on cooling system e Damaged timing belt tensioner e Malfunctioning water pump bearing e Malfunctioning hydraulic valve tappet Replace hydraulic valve tappet e Damaged hydraulic valve tappet bore Replace cylinder block e Seized valve stem Service or replace valve valve seat and or cylinder head e Weak or broken valve spring Replace valve spring INSUFFICIENT Damaged cylinder head gasket Replace cylinder head gasket POWER e Cracked or distorted cylinder head Replace cylinder head Damaged worn or sticking piston ring s Worn or damaged piston Malfunctioning or damaged fuel system Malfunctioning or damaged ignition system Service or replace piston ring s Replace piston Refer to section on fuel system Refer to section on ignition system DIAGNOSIS 01 5 Engine Service General 01 5 PCV System Malfunction A malfunctioning Positive Crankcase Ventilation System closed type may be indicated by loping or rough engine idle Do not attempt to compensate for this idle condition by disconnecting the crankcase ventilation system and making an air bypass or idle speed adjustment The removal of the crank
92. ONT COVER CRANKSHAFT POSITION SENSOR SCREW FPP00223 11 Carefully pry crankshaft position sensor from engine front cover REMOVAL AND INSTALLATION 03 11 Ignition System 03 11 SCALDING CRANKSHAFT POSITION SENSOR 2 ENGINE FRONT COVER FPP00224 Crankshaft Position Sensor Installation NOTE Engine front cover design precisely locates crankshaft position sensor so no adjustment is required 1 Fit engine speed sensor 2 Install screw and tighten to 8 12 Nem 72 108 Ib in Connect crankshaft position sensor Install new o ring on water pump inlet tube Install water pump inlet tube into water pump E 160 Install water pump inlet tube to generator bracket bolts and tighten to 9 12 Nem 84 108 Ib in 7 Install lower radiator hose and heater water hose on water pump inlet tube 8 Install generator to generator mounting bracket and hand start generator to bracket bolts Alternately tighten bolts to 41 54 Nem 30 40 Ib ft 9 Connect generator electrical connectors 10 Position drive belt Rotate drive belt tensioner position drive belt and rest tensioner pulley on belt 11 Connect battery ground cable 12 Fill cooling system Engine Coolant Temperature Sensor Removal 1 2 Disconnect battery and release cooling system pressure WARNING WHEN RELEASING SYSTEM PRESSURE COVER CAP WITH A THICK CLOTH TO PREVENT COOLANT OIL PRESSURE SEN
93. OR OPEN FIELD CIRCUIT Yes Go to AS Measure voltage at test point F on the voltage regulator No Go to A11 Is voltage equal to battery voltage AS CHECK FOR OPEN I CIRCUIT Yes Go to A6 e key to ON position No Repair open or high resistance in circuit 904 Measure voltage at wiring harness I terminal NOTE Voltage regulator must be connected to wiring harness for this test Is voltage greater than 1 volt A6 CHECK VOLTAGE DROP IN A CIRCUIT Yes Go to A7 Measure voltage drop between test point A on the voltage No Repair excess voltage drop in circuit 36 Check fuses or regulator and the positive battery post fuse link and connectors in circuit 36 and service as Is voltage drop less than 0 25 volts required A7 CHECK FIELD TURN ON Yes Go to A8 Measure voltage at test point F on the voltage regulator No Go to A11 Is voltage less than 2 volts A8 CHECK FOR SHORTED RECTIFIER Yes Replace generator Remove one pin S connector from generator No Go to A9 DIAGNOSIS Generator 09 7 A9 CHECK VOLTAGE DROP IN B CIRCUIT Yes Go to A10 Install 8 connector No Repair excess voltage drop in circuits 38 290 and 37 Start engine Check fuse link in circuits 38 290 and 37 and the Turn on headlights or any accessory connections between the battery and under hood fuse e With engine running at 2000 rpm measure voltage drop b
94. Operation 1 Governor main bearing worn Governor flyweights worn or broken Governor thrust sleeve and bearing worn Je cg Governor main shaft bent Excessive Governor Vibration 1 Governor pulley or main shaft bent or damaged 2 Governor flyweights worn or broken DIAGNOSIS 07 5 Mechanical Governor 07 5 ADJUSTMENT Three preliminary checks must be made on the mechanical governor before attempting any adjustments 1 governor oil level 2 drive belt tension 3 throttle control rod length Cil Level Check Clean the body of the governor in the area of the fill plug Remove the oil level plug If oil drips out the level is full If oil doesn t drip out remove the oil fill plug and add 10W 30 or 10W 40 engine oil into the fill hole until it starts dripping out of the oil level hole Reinstall plugs Belt Tension Adjustment Belt tension should be checked on a cold belt only Belt Tension Tool T63L 8620 A 1 Install the belt tension tool on the drive belt and check the tension Used belt 50 Ib ft 68 Nm used belt in operation 10 minutes or more 2 If adjustments required loosen the governor adjusting bolts and move the governor until the correct tension is obtained 3 Remove the gauge 4 Tighten the governor adjusting bolts 5 Install the tension gauge and recheck the belt tension CONTROL ROD THROTTLE LEVER Throttle Control Rod Length 1 Manually mov
95. RY COULD DAMAGE THE EQUIPMENT S ELECTRONIC SYSTEM TO AVOID POSSIBILITY OF INJURY USE PARTICULAR CARE WHEN CONNECTING A BOOSTER BATTERY TO A DISCHARGED BATTERY 1 Connect one end of first jumper cable to positive terminal of discharged battery and other end to positive terminal of booster battery Dead battery Booster battery 2 Connect one end of second jumper cable to negative terminal of booster battery and other end to an engine bolthead or good metallic contact spot on engine of equipment to be started NOT TO NEGATIVE BATTERY TERMINAL CABLE CONNECTION COULD CAUSE AN ELECTRICAL SPARK NEAR THE BATTERY AND COULD CAUSE AN EXPLOSION REFER TO WARNING AT THE BEGINNING OF THE JUMP STARTING PROCEDURE WARNING MAKING THE FINAL CAUTION 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 Be sure to disconnect battery negative cable before servicing starter 3 Make sure jumper cables are not in way of moving engine parts 4 Start engine of equipment with good battery Run engine at a moderate speed 5 Start engine of equipment with discharged battery Follow starting instructions in the Operator s Manual 6 Completely discharged batteries may require an electrical load to initialize charging 7 Remove cables in exact REVERSE sequ
96. SIS 03 6 Ignition System 03 6 DIS Harness Checks Check the following circuits with the volt ohmmeter Compare readings with the following chart All sensors connected to harness Checks are made with the UESC disconnected Harness Connector DVOM Set Reading Description of Pin No Selection Ohms VDC Circuit 1 A B Ohm 315 385 Crankshaft Position Sensor CKP 2 B D Ohm 1 95 851 5 Engine Coolant Temp ECT Sensor 3 E F Ohm Continuity Engine Spark Advance 0 resistance Circuit Base Advance Level 0 F H Ohm Continuity Engine Spark Advance Circuit 4 E H Ohm Infinity open Level 1 Advance E H Ohm Continuity Engine Spark Advance Circuit 5 F H Ohm Infinity open Level 2 Advance E H Ohm Continuity Engine Spark Advance Circuit 6 F H Ohm Continuity Level 3 Advance 7 G H 20 VDC 2 12 VDC UESC Power Supply Circuit 8 J K Ohm 0 5 1 3 Coil Primary Circuit 1 ECTS brass only portion in 32 F ice water for the complete range of ECTS values see the chart on the following page 2 Test must be conducted with KEY ON ENGINE OFF KOEO If readings are not to specifications complete the following e Remove the wire harness connector to the UESC e Remove each sensor or component from the harness e Using a high impedance digital volt ohmmeter DVOM check each wire for continuity or resistance for wire numbers and colors for the harness being used e If the wire harness has open circuits or
97. SULT ACTION TO TAKE only Turn key to OFF position Service instrumentation system Indicator lamp circuit is Remove three pin voltage regulator connector finding a path to ground at a point other than the Measure voltage at wiring harness I terminal circuit 904 generator Is voltage greater than 0 volts DIAGNOSIS 09 12 Generator 09 12 A 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 CLOTHING 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 A BEATEN EGG OR VEGETABLE OIL CALL A PHYSICIAN IMMEDIATELY REMOVAL AND INSTALLATION NOTE Only the regulator brush ho
98. Sprocket Holding Removing Tool T74P 6256 B on sprocket Use tool to hold sprocket and remove bolt and washer 4 Install threaded puller insert in Cam Sprocket Holding Removing Tool T74P 6256 B and remove sprocket 5 Remove tool from sprocket REMOVAL AND INSTALLATION 02 22 Engine Service 2 5L 02 22 Camshaft and Oil Pump Sprocket Installation 1 2 Position key and sprocket on shaft Install Cam Sprocket Holding Removing Tool T74P 6256 B without threaded puller insert on sprocket Install sprocket bolt and washer and tighten to 71 95 N m 52 70 lb ft Remove tool Install timing belt as outlined in this section Install outer timing belt cover as outlined in this section Crankshaft Sprocket Removal 1 Remove outer timing belt cover as outlined in this section Remove crankshaft damper and crankshaft pulley retaining washer Remove crankshaft damper Remove timing belt as outlined in this section Remove crankshaft sprocket Crankshaft Sprocket Installation 1 2 3 Install crankshaft sprocket Install timing belt as outlined in this section Install outer timing belt cover as outlined in this section Install crankshaft pulley washer and bolt Tighten bolt to 125 165 N m 92 121 lb ft Belt Tension Adjusting Tool Camshaft Belt Tensioner Tool Timing Belt Tensioner Removal Special Tools Required T74P 6254 A T74P 6256 B Remove outer timing belt cover as
99. T STEP CHECK VOLTAGE DROP IN A CIRCUIT e key to ON position Measure voltage between test point A the voltage regulator and the positive battery post Is voltage drop less than 0 25 volt CHECK VOLTAGE DROP IN I CIRCUIT Measure voltage wiring harness I terminal circuit 904 NOTE Voltage regulator must be connected to wiring harness for this test Is voltage greater than 1 volt CHECK FOR POOR GROUNDS Check for poor ground connections between voltage regulator and generator generator and engine or engine and battery Are all ground connections clean and tight CHECK FOR FIELD CIRCUIT DRAIN e Turn key to OFF position Measure voltage at test point F on the voltage regulator Is voltage equal to battery voltage CHECK FOR GROUNDED SLIP RING Remove generator from vehicle Remove voltage regulator Measure resistance from each generator slip ring to the generator housing Is resistance from either slip ring to housing less than 200 ohms RESULT Yes No Yes No Yes No Yes No Yes No ACTION TO TAKE Go to D2 Repair excess voltage drop in circuit 36 Check fuse or fuse link and connectors in circuit 36 and service as required Repair high resistance in circuit 904 Go to D4 Clean or repair grounds as required Generator is OK Replace voltage regulator If grease or dirt has accumulated near the slip rings Clea
100. TAKE AIR TEMPERATURE SENSOR Intake Air Temperature Sensor Removal 1 Disconnect the negative battery cable 2 Disconnect electrical connector 3 Remove the sensor Intake Air Temperature Sensor Installation Heated Oxygen Sensor Removal 1 2 3 Disconnect the negative battery cable Disconnect electrical connector Remove the sensor using an oxygen sensor wrench e f necessary lubricate sensor using penetrating lubricant such as E8AZ 19A501 B or equivalent HEATED OXYGEN SENSOR FPP00217 Heated Oxygen Sensor Installation 1 Install the sensor Tighten to 13 16 Nem 7 12 lb ft 1 2 Connect electrical connector 3 Connectthe negative battery cable Apply a light coat of Anti seize compound such as F6AZ 9L494 AA or equivalent meeting Ford specification ESE M12A4 A to the threads of the sensor Install the sensor using an oxygen sensor wrench Tighten to 36 46 Nem 27 33 lb ft Connect electrical connector Connect the negative battery cable REMOVAL AND INSTALLATION 02 58 Engine Service 2 5L 02 58 Flywheel Ring Gear Removal 1 Center punch ring gear and drill two holes approximately 5 16 7 to 8mm diameter offset as illustrated Drill must only pass through ring gear and not flywheel Nunc E 2 Remove ring gear by means of a light blow with a hammer noting position of chamfer on ring gear teeth Flywheel Ring Gear Installation Place a
101. TED UNTIL THE ENGINE COOLS ADDING COOLANT TO AN EXTREMELY HOT ENGINE CAN RESULT IN A CRACKED BLOCK OR CYLINDER HEAD FAILURE TO FOLLOW THESE INSTRUCTIONS COULD RESULT IN DAMAGE TO THE COOLING SYSTEM OR ENGINE AND OR PERSONAL INJURY Drain amp Refill Cooling System 1 Remove radiator cap 2 Open drain cock at radiator and drain old coolant from engine 3 rust sludge or other foreign material are present in the old coolant see Cleaning Cooling System at the beginning of this section 4 Fill radiator with a permanent type coolant that meets ford specification ESE M97B44 A such as Ford Cooling System Fluid 5 Operate engine until thermostat opens and the radiator upper hose becomes hot 6 Stop the engine and add coolant to approximately one inch below the filler neck 7 Install radiator cap 8 Operate engine and check all hoses and connections for leaks CAUTION Do not use alcohol methanol antifreeze or mix them with the specified coolant REMOVAL AND INSTALLATION 08 8 Cooling System 08 8 WATER OUTLET CONNECTION 000201 Thermostat Removal 1 Drain the radiator so that the coolant level is below the thermostat 2 Disconnect the heater return hose at the thermostat housing located on the left front lower side of engine 3 Remove the coolant outlet housing retainer bolts 4 Pull the elbow away from the cylinder head or manifold sufficiently to
102. TION TITLE PAGE ENGINE SERVICE intl ee Mi 01 01 ENGINE SERVICE 3 2 hebetes er etaed 02 01 IGNETIONISYSTEM s a r oerte tai bed 03 01 EUEL PUMP eter iioii NM dete tua fec tende tet at 04 01 GARB URETQOEBS tt reri p Am Dai Des 05 01 STARTER MOTOR LUE 06 01 GOVERNOR cit te note eedem teen aet tecti eee bite itus 07 01 GOOLING SYSTEM eoe teme tbe ede esaet enit seen bete Papa ET RINT 08 01 GENERATOR uem ie il eevee ere dao ee docete aceti We Ide drea 09 01 SECTION 06 STARTER MOTOR SUBJECT PAGE DESCRIPTION teen 2 Starter Operation DIAGNOSIS iier ite eite er ette te Ub el o ei tdt te lb cede Prelitimary InspectlOnui i o EE let boe ted e bebe ie e ei eie d S NS 3 Sytmptotrm habt a oto e LA ty 4 TES bles Starter eher terre ears tone tant edn start oo doutes cet 5 TEST B Starter Relay Test Seli oTo bi EET 5 5015 titre am Starter No Loadi Testis ihn t eet e E
103. TRONIC FUEL INJECTION EFI SYSTEMS FOR INFORMATION ON THAT SYSTEM 04 2 Fuel Pump 04 2 a gta pie ge E d wu 5 a TO d 2 EHE d PRESSURE d E i a Tow il a cz LM 524 DUKE FUEL PUMP s ar CDNHECTCHES E P w s 2 ER xd gt e 3 FETU X TO FUEL FILTER 4 nn FROM FUEL DESCRIPTION EFI Depending on engine application either a Zenith Model 33 carburetor or an electronic fuel injection system is used to deliver fuel to the cylinders The illustration above shows the electronic fuel injection fuel delivery system This system operates at a much higher pressure than a carbureted system Refer to the separate publication on electronic fuel injection for information on this system DESCRIPTION 04 3 Fuel Pump 04 3 FPP00489 DESCRIPTION CARB The carbureted fuel system includes a remote mounted electric fuel pump AN CAUTION The electric fuel pump MUST NOT be mounted directly on the engine assembly as engine vibration will shorten the life of the pump The fuel pump regulates and maintains fuel flow which will be used to provide necessary fuel for combustion This Section deals with the carb
104. This quantity is the approximate oil consumption rate in hours per Oil Pressure Test quart Special Tool Required 7 f the calculated oil consumption rate is unacceptable proceed as follows Engine Oil Pressure Gauge T73L 6600 A e Check PCV system Make sure system is not plugged 1 Disconnect and remove the oil pressure sensor e Check for plugged oil drain back holes in from the engine cylinder heads and cylinder block 2 Connect an Engine Oil Pressure Gauge T73L e f condition still exists perform a cylinder 6600 A or equivalent to the oil pressure sensor compression test as described in this section screw port and or perform a cylinder leak detection test with Rotunda Pressurization 014 00705 or 3 Run the engine until normal operating equivalent This can be helpful in determining temperature is reached the source of oil consumption as an example 4 Run the engine at 3 000 rpm and record the valves piston rings etc gauge reading e Check valve guides for excessive clearance e The oil pressure should be 250 490 kPa 36 Replace all valve stem seals after correct 71 psi at 3 000 rpm valve guide clearance has been verified 2 MP 5 f the pressure is not within specification check NOTE After checking for worn parts if it is the following possible sources determined parts should be replaced make sure correct replacement parts are used Worn or e Insufficient oil damaged inte
105. VERSAL ELECTRONIC 12A200 SPARK HARNESS CONTROL 95 T W 18 96 T O 18 687 GY 18 4 ENGINE 57 BK W 1 6 GROUND ale 958 T W 18 18 36B T O 18 289 18 0 GOVERNOR CONTROLLER 128473 GOVERNOR G P 18 HARNESS BAT ACTUATOR IGNITION 591 SWITCH ENGINE SPEED 697 O BK 1 lt 6 SELECT SWITCH FPP00279 DESCRIPTION 02 9A Wiring Diagrams EFI Engine Service 2 5L 02 9A Drive by wire only I FOOT PEDAL SENSOR TOGGLE SWITCH P N F42B 14A464 MA wire only Drive by MIL LAMP 0 Um 18 FUEL SELECT SWITCH IGNITION SWITCH Except Drive by wire L 1 12 VOLT 9 GOVERNOR FUEL SELECT PUMP SWITCH P N F8JL 95704 a 306 T LB 18 39 R W 18 42 PIN CONNECTOR 16A R LG 16 TEMP GAUGE TACHOMETER OIL GAUGE l 11 T Y 18 Ns AMP 787 PK BK16 H 3510 BR W 18 32 RIBUG 658 PK LG 18 674 Y BK 18 DRIVE BY WIRE ONLY 151 LB BK 18 EX 32A D BL 16 Y 18 37 Y 12 CUSTOMER SUPPLIED WIRE E 359M GY R 18 307 BK Y 18 253 DG W 18 00490 DESCRIPTION 02 9B Engine Service 2 5L 02 9B Wir
106. ankshaft end play as outlined in Section 01 OIL PAN SEALANT FPP00204 Attach piston and rod assemblies to crankshaft For each assembly a Puta piece of hose or other protector over connecting rod bolts to protect the crankshaft journal b Place the crankshaft journal for the piston being installed at the bottom of its stroke by rotating the crankshaft c Push piston and rod assembly into place guiding the rod bolts around crankshaft journal d Insert connecting rod bearings in connecting rod end cap 24 25 26 27 e Finish pushing piston and rod assembly in place f Apply Plastigage to bearing journal g Install connecting rod cap and alternately tighten connecting rod nuts to an initial torque of 34 41 N m 25 30 lb ft Then continue tightening to a final torque of 41 49 N m 30 36 Ib ft h Remove cap and check bearing clearance with chart on Plastigage package i If within specification lubricate connecting rod bearings and reinstall cap j Alternately tighten connecting rod nuts to an initial torque of 34 41 N m 25 30 lb ft Then continue tightening to a final torque of 41 49 N m 30 36 lb ft k Repeat for remaining piston and connecting rod assemblies Using Cam Bearing Adapter Tube T72C 6250 and crankshaft damper bolt press crankshaft front seal into place in engine front cover Install oil pump screen cover and tube Tighten bolts to 20 30 Nem 15 22 l
107. as outlined in this section SEALER F1AZ 19562 A SEALER F1AZ 19562 A SPECIFICATION SPECIFICATION WSE M4G320 A2 RT WSE M4G320 A2 2 PLACES APPROXIMATELY 7MM 0 28 IN DIA DOT ON CYLINDER B OGK 12 REAR FACE CYLINDER BLOCK ASSEMBLY 4 OF BLOCK Pole 2 PLACES VIEW B FPPOO050 REMOVAL AND INSTALLATION 02 53 Engine Service 2 5L 02 53 Pistons and Connecting Rods Removal 1 2 Remove oil pan as outlined in this section 3 Remove oil pump screen cover and tube as outlined in this section 4 Remove cylinder head as outlined in this section BEARING INSERTS NOTCH FPP00273 CAUTION Never cut into the ring travel area in excess of 0 8mm 1 32 inch when UN removing ridges 4 Remove any ridges and or deposits from the upper end of the cylinder bores as follows Turn the crankshaft until the piston to be removed is at the bottom of its travel and place a cloth on the piston head to collect the cuttings Remove any ridge and or deposits from the upper end of the cylinder bores Remove the cylinder ridge with a ridge cutter Follow the instructions furnished by the tool manufacturer 5 Make sure all connecting rod caps are marked so that they can be installed in their original positions 6 Turn the crankshaft until the connecting rod being removed is down 7 Remove the connecting rod nuts and caps CAUTION Avoid damage to the UN crankshaft journal or the cylinder
108. at the oil fill opening CAUTION Use extreme caution when pressurizing crankcase Applying air pressure above specified pressure risks damage to seals gaskets and core plugs Under no circumstances should pressure be allowed to exceed 27 kPa 4 psi 1 Open air supply valve until pressure gauge maintains 20 kPa 3 psi 2 Inspect sealed and or gasketed areas for leaks by applying a solution of liquid detergent and water over areas for formation of bubbles which indicates leakage 3 Examine the following areas for oil leakage e Rocker cover sealant or gaskets e Intake manifold gaskets end seals e Cylinder head gaskets Oil bypass filter e Oil level indicator dipstick tube connection e Oil pressure sensor Cup plugs and or pipe plugs at end of oil passages Oil pan gasket e Oil pan front and rear end seals e Oil pan front and rear end seals e Crankshaft front seal Crankshaft rear oil seal Oil pump e Crankshaft rear oil seal Air leakage in area around a crankshaft rear oil seal does not necessarily indicate a rear seal leak However if no other cause can be found for oil leakage it can be assumed that rear seal is the cause of the oil leakage e Rear main bearing cap parting line e Rear main bearing cap and seals e Flywheel mounting bolt holes e Rear cup plugs and or pipe plugs at the end of oil passages Oil leaks at crimped seams in sheet metal parts and cracks in cast or stam
109. ay to prevent the valve from falling in and to allow enough travel to check the valve for binds 9 Inspect the valve stem for damage Rotate the valve and check the stem tip for eccentric movement Move the valve up and down through normal travel in the valve guide and check the stem for any binding If the valve has been damaged it will be necessary to remove the cylinder head as outlined in this section REMOVAL AND INSTALLATION 02 16 Engine Service 2 5L Valve Spring Retainer and Valve Stem Seal Installation plastic installation cap included with valve seal kit over end of valve before installing valve stem seal or valve stem seal will be cut by valve retainer key grooves in valve If valve stem seal is cut it will leak causing oil burning and valve fouling CAUTION Install valve seal protector 1 Put valve seal protector plastic installation cap over end of valve as illustrated VALVE SEAL PROTECTOR PLASTIC INSTALLATION CAP SUPPLIED WITH VALVE SEALS VALVE go 6605 OR 6507 VALVE GUIDE 6510 0010 2 Start valve stem seal carefully over cap Push valve stem seal down until jacket touches top of valve guide 3 Remove seal protector plastic cap Use Valve Stem Seal Replacer T95T 6510 B to install valve stem seal on valve guide 10 11 02 16 VALVE STEM SEAL REPLACER T95T 6510 B VALVE 6505 OR 6507 7 0 SEAL 0 28 0 3 6A517 VALVE GUIDE BUSHING 510
110. b Bolt 125 165 93 121 Crankshaft Position 8 12 71 106 Sensor Special Tools Special Tools Required Spark Plug Wire Remover T74P 6666 A FPP00091 SPECIFICATIONS 04 1 Fuel Pump 04 1 SECTION TITLE PAGE ENGINE SERVICE intl ee Mi 01 01 ENGINE SERVICE 3 2 hebetes er etaed 02 01 IGNETIONISYSTEM s a r oerte tai bed 03 01 EUEL PUMP eter iioii NM dete tua fec tende tet at 04 01 GARB URETQOEBS tt reri p Am Dai Des 05 01 STARTER MOTOR LUE 06 01 GOVERNOR cit te note eedem teen aet tecti eee bite itus 07 01 GOOLING SYSTEM eoe teme tbe ede esaet enit seen bete Papa ET RINT 08 01 GENERATOR uem ie il eevee ere dao ee docete aceti We Ide drea 09 01 SUBJECT PAGE Brei 2 DESCRIPTION CARBY sitit itle cr idle ate e a t la endlich bd at eb tt 3 DIAGNOSIS cR RARI UE RUN VER RUIT DAUERN RR EU R eee 4 mi 4 Euel Supply arndiressuters 4 SPECIFICATIONS titio a n can tu tid ette deir Fe cederet tle lote ec oe ate dt n tte tae 5 REFER TO SEPARATE PUBLICATION ON ELEC
111. b ft Tighten pickup tube to main bearing cap nuts to 40 55 Nem 29 40 lb ft Apply a small amount of Silicone Gasket and Sealant F1AZ 19562 A or equivalent meeting Ford specification WSE M4G320 A2 at joints between front engine cover and cylinder block and rear main cap and cylinder block as shown Press new oil pan gasket into groove in oil pan and install oil pan Tighten screws to 13 16 10 12 Ib ft REMOVAL AND INSTALLATION 02 50 Engine Service 2 5L 02 50 28 Install inner timing belt cover 29 Install inner timing belt cover screw and nut and tighten to 8 11 N m 72 97 Ib in Install stud nut to inner timing belt cover and cylinder head and tighten to 20 30 N m 15 22 Ib ft INNER TIMING BELT COVER OIL PUMP FPP00208 30 Slide crankshaft sprocket onto crankshaft Recess goes toward cylinder block 31 Apply Threadlock 262 E2FZ 19554 B or equivalent meeting Ford specification WSK M2G351 A6 to camshaft bolt threads Install bolt and washer finger tight 32 Install Cam Sprocket Holding Removing Tool T79P 6256 B on sprocket Tighten camshaft bolt to 70 95 52 70 lb ft Remove tool 33 Install oil pump sprocket 34 Install oil pump sprocket bolt and washer finger tight 35 Prime oil pump 36 Install Cam Sprocket Holding Removing Tool T74P 6256 B on sprocket Tighten bolt to 40 55 N m 29 40 Ib ft Remove tool 37 38 39 40 44 42 43
112. below the letter F in FULL 5 Instruct the operator to run the engine as usual and e Check the oil level regularly at intervals of three to five hours e Call for service when the oil level drops below the lower ADD mark previously scribed on the dipstick e In an emergency add only 0 95 liter 1 U S quart of the same oil and note the engine hours at which the oil was added DIAGNOSIS 01 11 Engine Service General 01 11 Eaa 6 Check the oil level under the same conditions as If internal oil consumption still persists proceed as in Steps 3 and 4 reading the back of the dipstick follows where the Senes meae located 1 Remove intake manifold s cylinder heads oil e Measure the distance from the oil level to the pan and oil pump upper scribe mark on the dipstick and record ihe measurement 2 Check piston ring clearance ring gap and ring orientation as outlined in this section Service as e Measure the distance between the two scribe required marks and the measurement 3 Check for excessive bearing clearance as e Divide the first measurement by the second outlined in this section Service as required to 0 95 Mers 1 4 Perform Oil Consumption Test again to verify that U S quart added by the customer as the oil consumption concern has been resolved instructed in Step 5 P e Divide the engine hours operated during the oil test by the result
113. belt cover and timing belt as outlined in this section Remove engine oil pan as outlined in this section Remove crankshaft damper bolt Remove crankshaft damper Remove crankshaft sprocket Remove oil pump sprocket bolt Using Cam Sprocket Holding Removing Tool T74P 6256 B remove oil pump sprocket Remove stud screw nut and timing belt tensioner 12 Using Front Cover Seal Remover T74P 6700 B 13 Remove four bolts engine front cover and gasket REMOVAL AND INSTALLATION 02 45 Engine Service 2 5L 02 45 CRANKSHAFT FRONT SEAL 6700 ENGINE FRONT COVER 6019 X 5 4 22 pe A SEAL REMOVER 7 6700 00043 Engine Front Cover Installation 1 Install a new engine front cover gasket in engine front cover Install front cover assembly onto cylinder block Tighten three bolts and one stud to 13 15 10 12 Ib ft Position a new crankshaft front seal on Front Seals Replacer T74P 6150 A and press into place using vibration damper bolt Remove bolt and tool Install a new oil pan gasket and the oil pan as outlined in this section Install inner timing belt cover Tighten inner timing belt cover bolts to 8 12 N m 72 108 Ib in Install crankshaft position sensor and tighten bolt to 8 12 N m 72 108 Ib in 10 11 12 13 14 15 CRANKSHAFT POSITION SENSOR 6C315 SCREW N605892 S2 8 12 Nem 71 106 LB IN 000
114. case ventilation system from the engine will adversely affect fuel economy and engine crankcase ventilation with resultant shortening of engine life Engine Oil Leak Check When diagnosing engine oil leaks it is important that the source and location of the leak be positively identified prior to service NOTE Due to their remote location rear engine oil leaks may be very difficult to pinpoint This area is also very difficult to clean Make sure to eliminate all other possibilities before removing the engine to repair a suspected leak in this area There are two methods of diagnosing engine oil leaks The following procedure has been found to be very effective and requires only a minimum of equipment Prior to using this procedure it is important to clean the cylinder block cylinder heads valve covers oil pan and flywheel housing areas with a suitable solvent to remove all traces of oil Fluorescent Oil Additive Method To perform oil leak diagnosis using Rotunda Oil Leak Detector Kit 112 R0030 or equivalent perform the following procedure A19016 A 1 Clean engine with a suitable solvent to remove all traces of oil 2 Drain engine oil from crankcase and refill with recommended oil premixed with Rotunda Fluorescent Oil Additive 112 R0015 equivalent Use 29 6ml 1 fluid once of fluorescent additive If oil is not premixed fluorescent additive must be added to crankcase first 3 Run engine for
115. cations found in the specifications section Repeat procedure for remaining bearings that require replacement For This Amount of Use This Bearing Size Lower Bearing inch mm inch 001 Standard Standard 001 025 001 002 025 001 002 050 002 SERVICE PROCEDURES 01 17 Engine Service General 01 17 Crankshaft Bearing Clearance Bore Gauge Method 1 Install bearings in the cylinder block 2 Install bearing caps 3 Install crankshaft and tighten main bearing cap bolts to the specified torque 4 Remove bearing caps and crankshaft Reinstall bearing caps with bearings still installed in cylinder block and caps 6 Tighten bearing cap bolts to torque specified 7 Using micrometer measure main bearing journals as outlined in this section 8 Using bore gauge measure the inside diameter of each bearing assembly It may be necessary to measure the outer bearings first then remove those caps and measure the inner bearings 9 Subtract the maximum measurement for each journal from the minimum measurement of each bearing to determine the minimum oil clearance Compare with specifications SERVICE PROCEDURES 01 18 Engine Service General 01 18 Crankshaft Service Crankshaft End Play Crankshaft must be installed in block with the bearings that will be used but without connecting rods pistons or flywheel installed to check end play 1 Install Dial Indicator with Bracketry TOOL 4201
116. cement 2 5L 153 CID Bore surface finish 5 18 38 BOr o EE 96 01 mm 3 78 Main bearing bore Ne Sa 86 36 mm 340 fo diameter 60 8863 60 9067 mm 2 3971 2 3979 Firing order e Gasket surface IR MA RIRRAHHMM8e8790rpm in any 152 4 mm 6 0 0762 mm 0 003 Rated engine speed 3600rpm overall e 0 1524 mm 0 006 Oil pressure hot 2000 rpm 275 79 413 69 kPa 40 60 psi Head gasket surface finish RMS 60 150 Crankshaft to rear face of block runout ms 0 1270 0 005 CYLINDER HEAD Combustion chamber volume 1409 70 1485 90 mm 55 5 58 5 CRANKSHAFT AND FLYWHEEL Compression pressure Main bearing journal s The lowest cylinder must be at least 75 of the highest cylinder vere diameter 56 0095 56 0299 mm 2 2051 2 2059 Valve guide bore diameter 7 0155 7 0434 mm 0 2762 0 2773 maximum out of round 0 0152 mm 0 0006 Valve seat width intake 1 7200 2 2352 mm 0 068 0 088 1 maximum runout 0 0508 mm 0 0020 Valve seat width exhaust 1 7780 2 2860 mm 0 070 0 090 0
117. ck wire connections between battery and starter solenoid and the ground circuit for open or short Check connections from output of starter relay to S terminal for open or short Defective starter Replace starter Check for voltage at output terminal of remote relay TEST STEP RESULT ACTION TO TAKE B1 CHECK STARTER RELAY Yes Go to B2 START Transmission in NEUTRAL No Repair ground Go to B2 lscase ground OK B2 CHECK VOLTAGE AT STARTER RELAY START Yes Go to B3 TERMINAL Key in START Transmission in NEUTRAL No Open circuit or high resistance exists in external circuit Check for voltage between relay start terminal and case wiring or components Check the following ground circuit connections including plastic hard shell Is voltage 12 12 45 volts connector at solenoid S terminal to make sure it is not broken or distorted Ignition switch e Neutral switch or manual lever position sensor B3 CHECK STARTER RELAY OUTPUT TERMINAL Yes Refer to starter system diagnosis in this section VOLTAGE e START Transmission in NEUTRAL No e Defective starter relay Replace relay Is voltage 12 12 45 volts DIAGNOSIS SWITCH 06 6 Starter Motor 06 6 VOLTMETER ROTUNDA STARTING AND CHARGING EHE CARBON PILE RHEOSTAT TESTER 078 00005 tape AMMETER POSITIVE LEAD POSITIVE LEAD 9
118. continue tightening to achieve a final torque of 41 49 N m 30 36 10 Remove cap and check bearing clearance with chart on Plastigage package Lubricate connecting rod bearings with Super Premium Motor Oil XO 5W30 05P or equivalent meeting Ford specification ESE M2C153 E Reinstall connecting rod cap Alternately tighten connecting rod nuts to 34 41 N m 25 30 lb ft Then continue tightening to achieve a final torque of 41 49 N m 30 36 10 REMOVAL AND INSTALLATION 02 55 Engine Service 2 5L 02 55 FPP00058 Check side clearance Side clearance should be 0 09 0 29mm 0 0035 0 0114 inch Repeat for other piston and rod assemblies as needed Install cylinder head as outlined in this section Install oil pump screen cover and tube as outlined in this section Install oil pan as outlined in this section Connecting Rod Bearings Removal 1 10 11 Remove spark plug of cylinder where bearing is to be replaced Remove oil pan as outlined in this section Rotate engine so it is upside down and remove oil pump screen cover and tube as outlined in this section Rotate crankshaft until connecting rod and bearing being services is placed at the bottom of its stroke Remove two connecting rod nuts Remove connecting rod cap Push piston and connecting rod assembly up into bore Remove bearing insert from connecting rod Remove bearing insert from connecting rod cap
119. cooling DESCRIPTION 02 6 Engine Service 2 5L 02 6 Drive Belt System Engine accessories such as the generator and water pump are driven by a single poly V belt A direct drive fan is attached to the water pump pulley which is driven by the poly V belt when the engine is running Ignition System The ignition used on the 2 5L engine is an Electronic Distributorless Ignition System EDIS A crankshaft position CKP sensor and vacuum port on the intake manifold provide the necessary information to an ignition module The module determines when to fire the ignition coil mounted on the generator bracket based on the two sensors Standard distributorless ignition coil wires and spark plugs are used to ignite the fuel in the cylinders Fuel System The fuel system includes a REMOTE MOUNTED electric fuel pump The pump regulates and maintains fuel flow through an in line fuel filter to the carburetor mounted on the intake manifold Depending on engine application either a Holley or Zenith model carburetor can be used to provide the necessary fuel for combustion DESCRIPTION 02 7 Engine Service 2 5L 02 7 Engine Governing System Mechanical Governor Carb Mechanical belt driven flyweight type governors are used on the 2 5L engine Constant speed and variable speed governors can be used depending on application The governor is attached to the carburetor by a linkage system The governor through the li
120. d hydraulic valve tappet e Damaged hydraulic valve tappet guide POOR IDLING e Improper valve to valve seat contact e Damaged cylinder head gasket Malfunctioning or damaged fuel system e Malfunctioning or damaged ignition system e Damaged hydraulic valve tappet ABNORMAL e Damaged hydraulic valve tappet bore COMBUSTION Burntor sticking valve e Weak or broken valve spring e Malfunctioning or damaged fuel system Malfunctioning or damaged ignition system e Worn piston ring groove e Sticking piston ring s EXCESSIVE OIL Worn piston or cylinder CONSUMPTION e Worn valve stem seal e Worn valve stem or valve guides e Leaking oil e Worn piston rings e Plugged pcv system e Carbon accumulation in combustion chamber ACTION Replace valve Replace piston Replace piston ring s Service or replace cylinder block Replace cylinder head gasket Refer to section on fuel system Refer to section on ignition system Replace hydraulic valve tappet Replace hydraulic valve tappet guide Replace valve and or valve seat Replace cylinder head gasket Refer to section on Fuel system Refer to section on ignition system Replace hydraulic valve tappet Replace cylinder block Service or replace valve Replace valve spring Eliminate carbon buildup Refer to section on fuel system Refer to section on ignition system Replace piston Service or replace piston ring s
121. de detonation protection when the engine load is increased rapidly by fast opening of the throttle plate Rapid increases in engine load are determined by large changes in consecutive Manifold Absolute Pressure MAP values to the UESC module Overspeed Mode If the engine speed exceeds 4000 RPM the dwell will be reduced until the speed drops below 4000 RPM CRANKSHAFT IGNITION POSITION SWITCH SENSOR o DE ENGINE COOLANT TEMP SENSOR 16 R LG 1 16 R G 18 DIS 16 R G 18 IGNITION 96A T O 18 COIL FPP00218 DESCRIPTION 03 5 DIAGNOSIS TIMING LIGHT 00077 Diagnosis 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 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 Spark tester gap type D81P 666 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 e Volt ohmmeter Rotunda 014 00575 A volt ohmmeter is essen
122. djustments service procedures and cleaning inspection procedures Engine assembly and service specifications appear at the end of Section 02 For engine disassembly assembly installation adjustment procedures and specifications refer to Section 02 Most Ford Power Product engines incorporate a closed type crankcase ventilation system Other than the crankcase ventilation system there are no exhaust emission controls or engine emission control systems used with industrial versions of these engines 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 worn engine components such as the crankshaft cylinder head valve guide valves camshaft or cylinder block make sure part s is not serviceable A WARNING TO AVOID THE POSSIBILITY OF PERSONAL INJURY OR DAMAGE DO NOT OPERATE THE ENGINE UNTIL THE FAN BLADE HAS FIRST BEEN EXAMINED FOR POSSIBLE CRACKS OR SEPARATION A CAUTION Use of abrasive grinding discs to remove gasket material from the engine sealing surfaces during repair procedures can contribute to engine damage and wear Airborne debris and abrasive grit from the grinding disc may enter the engine through exposed cavities causing premature wear and eventual engine damage Ford Power Products does not recommend using abrasive grinding discs to remove engine gask
123. e FULL line If a significant overfill is indicated perform Steps 1 through 4 to verify the dipstick calibration If the dipstick calibration checks OK instruct the operator to avoid overfilling the engine and return the engine to service To verify the engine s actual oil consumption perform Steps 5 and 6 only after the dipstick has been calibrated Perform engine oil consumption test as follows 1 Drain engine oil Remove and replace oil filter Using 0 95 liter 1 U S quart less than recommended refill crankcase with recommended quality of oil 2 Run the engine for three minutes 10 minutes if cold then turn engine off Allow oil to drain into the oil pan for an additional five minutes engine should be level 3 Remove oil level dipstick and wipe clean Do not wipe using anything contaminated with silicone compounds Reinstall oil level dipstick being sure to seat the oil level dipstick firmly in the oil level indicator tube Remove the oil level dipstick and scribe a mark on the back unmarked surface at the indicated oil level This should be about the same level as the ADD mark on the face of the oil level dipstick 4 Add 0 95 liter 1 U S quart of oil Restart the engine and allow it to idle for at least two minutes Shut down and allow oil to drain back for at least five minutes Mark the dipstick using the procedure above This level may range from slightly below the top of the cross hatched area to slightly
124. e Installation of the wrong part will result in an inoperative oil pressure indicating system and a damaged sender unit or gauge 1 Make sure the ignition switch is turned off 2 Disconnect the wire at the sender terminal 3 Remove the oil pressure sender from the cylinder head 4 Apply Pipe Sealant with Teflon D8AZ 19554 A or equivalent meeting Ford specification WSK M2G350 A2 to new sender threads 5 For installation follow removal procedures in reverse order Tighten switch to 11 24 N m 8 18 lb ft OIL PRESSURE COOLANT TEMPERATURE SENDER FPPO0269 REMOVAL AND INSTALLATION 02 44 Engine Service 2 5L 02 44 Engine Front Cover Removal DOWEL GASKET ENGINE FRONT COVER FPP00270 8 Remove two screws and water pump inlet tube 9 Remove one screw and crankshaft position Special Tools Required Sensor 10 Remove one bolt and one nut from inner timing Cam Sprocket Holding Tool T74P 6256 B belt cover Front Cover Seal Remover T74P 6700 B 11 Remove inner timing belt cover Front Cover Alignment Tool T74P 6019 B NOTE Remove the crankshaft front seal while Front Seals Replacer 174P 6150 A the front cover is still mounted on the engine NOTE This procedure will require the following replacement parts oil pan gasket crankshaft front remove crankshaft front seal seal engine front cover gasket and a water pump inlet tube O ring 1 Pak wD Remove outer timing
125. e and seating as outlined in the engine service section AN CAUTION Install valve seal protector plastic installation cap included with valve seal kit over end of valve before installing valve stem seal or valve stem seal will be cut by valve keeper grooves in valve If valve stem seal is cut it will leak causing oil burning and valve fouling 16 Put valve seal protector plastic installation cap over end of valve as illustrated VALVE SEAL PLASTIG INSTALLATION CAP SUPPUED WITH VALVE SEALS m VALVE La R VALVE GUIDE 17 Start valve stem seal carefully over cap Push valve stem seal down until jacket touches top of guide 18 Remove seal protector plastic cap Use Valve Stem Seal Replacer T95T 6510 B to seat valve stem seal on valve guide VALVE STEM SEAL 5 T85T G510 B VALVE sme GIDE BUSHING 5519 1 19 Apply small amount of Ford Multi Purpose Grease DOAZ 19584 AA or equivalent to valve spring retainer keys to hold them in place during installation 20 Put valve spring and valve spring retainer into place NOTE Spring must not be compressed beyond a height of 27 5mm 1 08 inch during assembly 21 Compress valve spring with Valve Spring Compressor T95T 6565 A and install valve spring retainer keys Release spring to seat valve spring retainer keys DISASSEMBLY
126. e flaring inward CAUTION It is imperative to push or drive the plug into the machined bore using a properly designed tool Under no circumstances is the plug to be driven using a tool that contacts the crowned portion of the plug This method will expand the plug prior to installation and may damage the plug and or plug bore When installed the trailing maximum diameter must be below the chamfered edge of the bore to effectively seal the plugged bore If the core plug replacing tool has a depth seating surface do not seat the tool against a non machined casting surface Cup Type Cup type core plugs are installed with the flanged edge outward The maximum diameter of this plug is located at the outer edge of the flange The flange on cup type plugs flare outward with the largest diameter of the outer sealing edge CAUTION It is imperative to pull the plug UN into the machined bore by using a properly designed tool Under no circumstances is the plug to be driven into the bore using a tool that contacts the flange This method will damage the sealing edge and will result in leakage and or plug blowout Expansion Type Core Plug A3217 E The flanged trailing edge must be below the chamfered edge of the bore to effectively seal the plugged bore SERVICE PROCEDURES 01 32 Engine Service General 01 32 Exhaust Manifold Service Cleaning Remove all gasket or foreign material from all inl
127. e piston pin bores in the piston to obtain the correct clearance e It is not necessary to hone or ream the connecting rod piston pin bore oversize 8 Once pin connecting rod and piston are correctly sized assemble as outlined in Section 02 SERVICE PROCEDURES 01 38 Engine Service General 01 38 DESIRED TOOLS cont SPECIAL TOOLS Tool Number Description REQUIRED TOOLS Tool Number Description T50T 100 A Impact Slide Hammer T59L 100 B Impact Slide Hammer T73L 6011 A Engine Cylinder Hone Set T73L 6600 A Engine Oil Pressure Gauge Illustration 00145 0 1 0046 FPP00146 TOOL 6513 DD Valve Clutch Spring Tester TOOL 6565 AB TOOL 4201 C Cup Shaped Adapter Dial Indicator with Bracketry ROTUNDA EQUIPMENT DESIRED TOOLS Tool Number Description D81L 6002 D Piston Ring Groove Cleaner D81P 6002 E Valve Seat Runout Gauge D81L 6002 B Plastigage D87C 77000 A Transmission Test Adapter TOOL 6500 E Hydraulic Tappet Leakdown Tester TOOL 6505 E Valve Stem Clearance Tool Model Description 112 R0030 Oil Leak Detector Kit 059 R0009 Compression Tester 014 00705 Pressurization Kit 059 00008 Vacuum Pressure Tester 107 R0901 Taperset Installation Kit 054 00038 Boring Machine 112 r0015 Fluorescent Cil Additive 014 00975 Carbon Blast
128. e problem Percolation Percolation symptoms are a strong smell of fuel vapors and hard starting of a hot engine that has been sitting for 20 minutes Fuel drips from the end of the throttle shaft or from the main discharge nozzle causing a rich mixture in the air intake Opening the choke completely and cranking the engine clears the vapors and eliminates percolation Flooding Flooding occurs from a float level set too high a sticking choke plate float or float valve or a fuel inlet needle held off its seat either by improper seating or dirt particles A punctured or leaking float admitting fuel becomes gas logged causing a heavy float high fuel level and flooding Flooding has decreased due to the use of fuel filters and Vitron fuel inlet needles If flooding does occur disassemble the carburetor observe the operation and condition of components and repair or replace as necessary Hard Starting Hard starting when attributed to the carburetor is caused by a flooded engine due to improper starting procedures An improper idle fuel mixture sometimes due to improper fuel mixture or idle fuel mixture adjusting needles not turned equally in relation to the other adjusting needle causes hard staring A too high or too low float level due to misadjustment or wear also causes hard starting Repair adjust or replace components as necessary Stalling Improper idle air fuel mixture or an idle speed set too low causes an engi
129. e the governor throttle lever to the maximum open throttle with spring tension on the governor 2 Checkthe gap between the carburetor throttle shaft lever and its maximum open position stop It should be 1 32 to 1 16 inch wide 3 f adjustment is necessary loosen the control rod ball joint locknuts remove the rod from the carburetor throttle lever and adjust the length of the rod with the ball joints 3 Install the throttle control rod on the carburetor throttle lever 4 Recheck the gap 6 Tighten the locknuts CAUTION Be sure the throttle control rod is properly installed with the long end at the governor to prevent binding on the ignition wires ADJUSTMENT 07 6 Mechanical Governor 07 6 ADJUSTMENT 07 7 HIGH SPEED STOP ADJUSTMENT SCREW High Speed Adjustment First attach a tachometer to the engine then run the engine until it reaches normal operating temperature 1 Loosen the locknut on the high speed stop screw 2 Disengage engine load 3 Slowly pull the throttle to desired maximum engine speed 4 Adjust the high speed stop screw on the governor to attain the desired maximum engine speed Do not exceed the recommended maximum rpm 5 Tighten the locknut Mechanical Governor 07 7 Sensitivity or Droop Adjustment Proper governor operation requires a difference between full load and no load governed speed Too small an rpm spread between the two speeds will ca
130. ecuring water pump inlet tube to generator mounting bracket and remove water pump inlet tube MOUNTING BRACKET tae 0 _ DRIVE ed TENSIONER GENERATOR 3 00265 Remove three bolts from generator Remove generator Remove 3 bolts from generator mounting bracket Remove bracket with ignition coil and ignition wire and brackets attached Disconnect upper radiator hose at both ends and remove 14 15 18 19 20 Remove fan and water pump pulley Remove timing belt outer cover as outlined in this section Remove timing belt as outlined in this section 17 Remove timing belt tensioner adjuster bolt spring pivot bolt timing belt tensioner spring and tensioner Remove front engine lifting eye Remove retaining bolts and intake manifold Remove rear engine lifting eye REMOVAL AND INSTALLATION 02 28 Engine Service 2 5L 02 28 21 Remove the eight exhaust manifold retaining HERD s 17 lt lt 10 bolts and studs 6 bolts 2 studs 3 6 D P 1 22 Remove cylinder head retaining bolts 10 S 55 s J 23 Remove the cylinder head 9 c Cis 24 Clean cylinder head gasket surface at the block one S ED 06 25 Clean intake manifold gasket surfaces pt 26 Clean exhaust manifold gasket surface E 2 50 GASKET OS 27 Clean exhaust manifold gasket surface at the AQ NO cylinder head 9 28 Clean c
131. emblv 51 Bolt M6 1 x 20 12 Closed Crankcase Vent Hose Gk S Positions 13 Pipe Plua 3 8 18 x 3 8 14 Water Temperature Indicator Sender 53 Stud M6 1 x 1 x 61 9 15 Filter Mountina Insert 54 Oil Pump Sprocket 16 Oil filter 17 Crankshaft Rear Oil Seal 55 Oil Pump Sprocket Washer 18 Crankshaft 56 Bolt 10 1 5 40 19 Crankshaft Main Bearina lower Oil P Seal 20 Stud M10 1 5 x 12 1 75 x 108 5 Front Seal 21 Oil Pump Cover Screen and Tube 58 Bolt M6 1 x 47 5 22 Nut M10 1 5 59 Oil Pump Assembly 23 Bolt M8 1 25 x 20 24 Pump Inlet Tube Gasket 60 O ring Oil Pump Outlet Vent 25 Oil Pan Gasket 61 O ring Oil Pump Inlet Outlet 26 Bolt M6 1 x 57 5 Oil P Cylinder Block Gask 27 Oil Pan Drain Plua Gasket Lae RO 28 Oil Pan Drain Plua 63 Screw M8 1 25 x 25 29 Screw M6 1 x 27 5 64 Water Pump Pulley 30 Oil Pan 31 Bolt M14 1 5 x 55 65 Bolt M8 1 25 x 53 32 Crankshaft Pulley Retainina Washer 66 Water Pump 33 Crankshaft Pullev 7 Water Pump Housing Gask 34 Crankshaft Sprocket 6 sta 35 Crankshaft Front Seal 68 Dowel 36 Bolt M6 1 x 37 5 69 Piston and Connecting Rod 37 Enaine Front Cover 38 Enaine Front Cover Gasket 70 Upper Compression Ring 39 Bolt M12 1 75 x 80 71 Second Compression Ring 40 Front Main Bearina Cap 7277 Oil 41 Front Intermediate Main Bearing
132. emoving the piston 1 Check the amount of ridge at the top of the bore A thick ridge is a sign of considerable wear 2 Look for signs of coolant in the bore especially rust on the bore surface indicating possible leaking head gasket or a crack in the cylinder bore 3 Check the top of the piston for possible oversize If oversize pistons have been installed the oversize will be stamped in the top of the piston After the piston is removed and the bore cleaned 4 Look for scoring These are parallel gouges usually on the piston thrust side that is at right angles to the piston pin If scored the cylinder will have to be refinished 5 Look for cracks If unsure about a crack tiny cracks may be detected by coating the bore with a mixture of 25 percent kerosene and 75 percent light engine oil Wipe the bore dry and immediately apply a coating of zinc oxide dissolved in wood alcohol Do not use rubbing alcohol as a substitute If cracks are present the coating will be become discolored at the damaged area Replace the cylinder block if it is cracked Magnafluxing may also be used SERVICE PROCEDURES 01 21 Engine Service General 01 21 6 Check for cylinder wall glazing When refinished the cylinder bore is given a slightly rough finish with a cylinder hone to help seat the new piston rings This finish is worn away as the rings and cylinder bore mate and the bore becomes glassy smooth If the engine has been
133. ence Begin by removing cable from engine of equipment that had discharged battery If the starter does not turn the engine over even with the booster battery attached refer to Diagnosis DIAGNOSIS 06 9 Starter Motor 06 9 REMOVAL AND INSTALLATION WARNING WHEN SERVICING STARTER OR PERFORMING ANY MAINTENANCE IN THE AREA OF THE STARTER NOTE THAT THE HEAVY GAUGE INPUT LEAD CONNECTED TO THE STARTER SOLENOID IS HOT AT ALL TIMES MAKE SURE THE PROTECTIVE CAP IS INSTALLED OVER THE TERMINAL AND IS REPLACED AFTER SERVICE BATTERY POSITIVE CABLE 12 GAUGE WIRE RED STARTER STARTER CABLE E RELAY TERMINAL STARTER SOLENOID SOLENOID TERMINAL f oS PERMANENT MAGNET TERMINAL STARTER FPP00231 CAUTION A jumper wire must not be UN installed between the large round electrical terminal and the solenoid blade terminal at the starter to avoid use of the 12 wire If done voltage is generated to the solenoid by the spinning starter after release of the start key or button causing the starter to remain engaged resulting in failure Starter Motor Removal 1 Disconnect the negative battery ground cable 2 Disconnect starter cable and push on connector from starter solenoid CAUTION When disconnecting UN hardshell connector at S terminal grasp the plastic shell and pull off Do not pull on wire Be careful to pull straight off to prevent damage to the connector and S t
134. er and Automotive Borescope SPECIAL TOOLS Engine Service 2 5L 02 1 SECTION TITLE PAGE ENGINE SERVICE Genneralll aa sa dei oec dede te 01 01 ENGINE SERVIGE 2 5L m 02 01 5 ENS 03 01 aS zt 04 01 ipee eee eae 05 01 STARTER MOTOR Le von Rae A 06 01 GOVERNOR IEEE 07 01 GOOLING SYSTEM 08 01 GENERATOR Tm 09 01 SECTION 02 Engine Service 2 5L etel PAGE DESGRIPTION O 2 Oylinder Head saric ea 27 Engine 2 Water Pump eines 32 Engine Code Information 3 Water Thermostat Outlet Connection 33 Grankshalt nini nee ree 3 Intake Manifold carb only 33 3 Intake Manifold EFI only 35 dente 4 Carburetor eg 38 Positive Crankcase Ventilation System
135. er finger follower over the lash adjuster 4 Lift out the hydraulic lash adjuster VALVE SPRING COMPRESSOR TOOL 1951 6565 1 2 INCH DRIVE RATCHET OR BREAKER BAR 0 0009 REMOVAL AND INSTALLATION 02 15 Engine Service 2 5L 02 15 Camshaft Follower and Hydraulic Lash Adjuster Installation 1 Rotate camshaft so roller finger follower can be slid under heel of cam 2 Lubricate contact points of roller finger follower with Ford Multi Purpose Grease DOZA 19584 AA or equivalent meeting Ford specification ESR 1 159 3 removed place the lash adjuster in position in the bore 4 Compress the valve spring using Valve Spring Compressor T95T 6565 A Position the roller finger follower over the hydraulic lash adjuster and the valve stem Release valve spring lash adjuster has been collapsed and released before rotating camshaft 5 Using Valve Spring Compressor T88T 6565 BH compress and release hydraulic lash adjuster N CAUTION Make sure the hydraulic 6 Install valve cover as outlined in this section Valve Spring Retainer and Valve Stem Seal Removal Special Tools Required T95T 6565 A Valve Guide Replacer T95T 6510 A Valve Stem Seal Replacer T95T 6510 B Valve Spring Compressor If the valve or valve seat has not been damaged the valve spring valve stem seal valve spring retainer or valve spring retainer keys may be replaced by holding the affected valve against
136. erminal If any part of the connection is damaged replace the damaged components 3 Remove upper bolt with a 3 8 inch drive ratchet Swivel socket and a 22 inch long extension Access is in front of and along side the right hand front engine mount 4 Remove lower bolt Starter Motor Installation 1 Position starter motor to engine and install upper and lower bolt finger tight 2 Tighten the upper bolt to 21 27 Nem 15 20 Ib ft Access to upper bolt is with a 3 8 inch drive ratchet swivel socket and a 22 inch long extension Access is in front of and along side the right hand front engine mount Tighten the lower bolt to 21 27 Nem 15 20 Ib ft 4 Connect starter solenoid connector Be careful to push straight on and make sure connector locks in position with a notable click or detent 5 Install starter cable nut to starter terminal Tighten to 9 13 Nem 80 120 Ib in 6 Replace red solenoid safety cap 7 Connect negative battery ground cable It is recommended that wiring service kit F2PZ 11K162 A be used which includes a 70 inch long 12 gauge wire a terminal nut a terminal cover four tie wraps and insulation instructions REMOVAL AND INSTALLATION 06 10 Starter Motor 06 10 TERMINAL NUT STARTER N805403 SOLENOID END 11390 HOUSING 11130 HOUSING SEAL ASSEMBLY 11 171 SOLENOID SCREW STARTER MOTOR USHING 805405 ASSEMBLY 11135
137. ernor actuator if used ZENITH CARBURETOR GASKET C 4 Disconnect the manual choke cable from the choke lever on the carburetor 0285 5 Disconnect the governor throttle control rod if used from the throttle lever on the carburetor Disconnect the fuel inlet line from the carburetor or fuel filter on the carburetor depending on the application Caution Avoid spilling fuel on hot UN surfaces Use an absorbent rag placed under the fuel line or fuel filter being removed to collect any spilled fuel 8 Remove the retaining nuts from the studs securing the base of the carburetor 9 Remove the carburetor and carburetor base gasket from the intake manifold NOTE If the carburetor is not being serviced and is going to be placed back on the intake manifold do not turn the carburetor upside down This may cause any float bowl sediment to restrict or clog carburetor passages or prevent the inlet needle and seat assembly from closing The carburetor s operation may be affected Carburetor Installation 1 Clean and inspect the mounting surfaces of the intake manifold and the base of the carburetor Both surfaces must be clean and free of any gasket material 2 Install the carburetor base gasket and carburetor on the intake manifold 3 Install the retaining nuts on the studs securing the base of the carburetor 4 Reconnect the fuel inlet line to the carburetor or fuel filter
138. es Inspect the stem for a bend condition and the end of the stem for grooves or scores Check the valve head for signs of burning or erosion warpage and cracking Minor pits grooves etc may be removed Discard severely damaged valves Inspect the valve spring valve spring retainer valve spring retainer keys and discard any visually damaged parts DIAMETER AND VALVE BENT STEM 794 MM 1 32 INCH THIS LINE PARALELL MINIMUM WITH VALVE HEAD A14139 D Valves Refacing NOTE Discard any excessively worn or damaged valve train parts e Minor pits or grooves may be removed e Discard valves that are severely damaged if the face runout cannot be corrected by refinishing or if stem clearance exceeds specification Refer to specifications section for valve specifications e Refer to Engine Service in the Rotunda Tool catalog for a description of the various types of valve resurfacing equipment e The valve refacing operation should be closely coordinated with the seat refacing operations so that the finished angles of the valve face and valve seat will be to specifications and provide a compression tight fit e Make sure refacer grinding wheels are properly dressed SERVICE PROCEDURES 01 30 Engine Service General 01 30 Valve Spring Tension Inspect the valve spring valve spring retainers and keys for wear or damage Discard any damaged parts Check the valve springs for pr
139. estigate other accessory noise contributors Ring gear tooth damage or e Replace flywheel ring gear excessive ring gear runout e Defective starter e Replace starter Starter cranks but engine does not e Problem in fuel system e Refer to fuel system sections SR e Problem in ignition system e Refer to Ignition system section e Refer to section 01 Diagnosis e Engine related problem Starter cranks slowly e Low battery e Charge or replace battery e High resistance or loose Check that all connections are connections in starter solenoid secure battery feed or ground circuit e Ring gear runout excessive e Replace ring gear Defective starter e Replace starter Starter remains engaged and runs e Shorted ignition switch e Replace ignition switch with engine e Battery cable touching solenoid Replace or relocate cable S terminal e Defective starter Replace starter DIAGNOSIS 06 5 Starter Motor 06 5 TEST A Starter Voltage Test TEST STEP CHECK FOR VOLTAGE TO STARTER Key OFF Transmission in Neutral Check for voltage between starter B terminal and starter drive housing Is voltage 12 12 45 volts CHECK STARTER MOTOR Key OFF Transmission in Neutral Connect one end of a jumper wire to the starter B terminal and momentarily touch the other end to solenoid 5 terminal Does starter crank TEST B Starter Relay Test RESULT ACTION TO TAKE Che
140. et and outlet sealing surfaces of the exhaust manifold Inspection e Inspect the cylinder head joining flanges of the exhaust manifold for evidence of exhaust gas leaks e Inspect the exhaust manifold for cracks damaged gasket surfaces or other damage that would make it unfit for further service e A warped or cracked exhaust manifold must be replaced Hydraulic Valve Tappet Adjuster Service The hydraulic lash adjusters used in overhead cam engines are zero lash hydraulic devices similar in construction and operation to the hydraulic valve tappets used on push rod engines They are cleaned inspected and checked in the same manner as hydraulic valve tappets The instructions below apply equally to the lash adjuster and the valve tappet Hydraulic tappet noise may be caused by any of the following Excessive collapsed tappet gap Sticking tappet plunger Tappet check valve not functioning properly Air in lubrication system Leak down rate too rapid Excessive valve guide wear Excessive collapsed tappet gap may be caused by loose valve train parts such as wear of tappet face worn roller finger follower or worn valve tip With valve tappet collapsed check gap between valve tip and roller finger follower to determine if any other valve train parts are damaged or worn Replace any worn or damaged parts A sticking tappet plunger may be caused by dirt chips or varnish inside the tappet The stic
141. et material Use manual gasket scrapers for removing gasket material from the engine sealing surfaces Take added care to prevent scratching or gouging SERIAL NUMBER MODEL NUMBER LAGS SOT MODEL CODE 5 0 0P TIONS aluminum sealing surfaces Engine Identification Nameplate For quick engine identification refer to the Engine Identification Nameplate The nameplate 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 An engine code decal is attached to the engine front cover The symbol code on the decal identifies each engine for determining parts usage ENGINE CODE Aoo ENGINE PLANT FAB m 4 aa MADE IM CH Tias ENGINE BUILD DATE LL LIMA 24340 DESCRIPTION 01 3 Engine Service General DIAGNOSIS Inspection Inspect to determine if any of the following mechanical concerns apply e Engine oil leaks e Damaged and or severely worn parts e Loose mounting bolts studs and nuts CONDITION POSSIBLE SOURCE e Burnt valve DIFFICULT e Worn piston STARTING e Worn piston ring s e Worn cylinder e Damaged cylinder head gasket Malfunctioning or damaged fuel system Malfunctioning or damaged ignition system e Damage
142. et into tapped spark plug hole using a torque wrench Continue tightening mandrel until torque wrench indicates 61 N m 45 10 6 To loosen mandrel for removal hold mandrel stationary and turn mandrel body approximately on half turn Remove mandrel HOLD MANDREL STATIONARY A6658 B SERVICE PROCEDURES 01 26 Engine Service General 01 26 Cylinder Head Flatness NOTE Do not plane or grind off more than 0 254mm 0 010 inch When a cylinder head is removed because of gasket leaks check the flatness of the cylinder head gasket surface for conformance to specification If necessary refinish the cylinder head gasket surface A15267 A Valve Seat Runout Check the valve seat runout with Valve Seat Runout Gauge D81P 6002 E or equivalent 5 illustrated below Follow the instructions of the gauge manufacturer If the runout exceeds the wear limit reface the valve and valve seat For specifications refer to Section RUNOUT GAUGE 02 081 6002 N 9 VALVE SEAT 2553 er Valve Stem to Guide Clearance 1 Check the valve stem to guide clearance of each valve in its respective valve guide with Valve Stem Clearance Tool TOOL 6505 E or equivalent Use a flat end indicator point Install TOOL 6505 E to cylinder head Permit the valve to drop away from its seat 9 55mm 0 375 inch Contact tip of valve stem with dial indicator and tighten c
143. f bore as the lock slot in rod Avoid nicking crank pin journals during rod installation Install piston and connecting rod assembly as outlined in this section Cylinder Block Disassembly 1 2 Mount the engine on a work stand Remove all parts not furnished with the new cylinder block following engine disassembly and assembly in this section Remove the old cylinder block from the work stand Cylinder Block Assembly 1 Clean the gasket and seal surfaces of all serviceable parts and assemblies Position the new cylinder block on a work stand Transfer all serviceable parts removed from the old cylinder block following engine disassembly and assembly as outlined in this section Check all assembly clearances and correct as necessary DISASSEMBLY AND ASSEMBLY 02 65 Engine Service 2 5L 02 65 Hydraulic Lash Adjuster Disassembly NOTE Do not mix parts between different lash adjusters Parts are select fit and not interchangeable 1 2 3 Remove snap ring Remove fulcrum plunger and spring Clean to remove all traces of motor oil and varnish Make sure check ball is free To assemble lubricate parts with clean Super Premium Motor Oil XO 5W30 QSP or equivalent meeting Ford specification ESE M2C153 E and reverse disassembly steps If it is necessary to store lash adjusters for some time before installation protect them from dust and dirt If not kept clean they may stick during o
144. four screws T20 Torx type head attaching the voltage regulator to the generator housing Remove the voltage regulator with generator brush holder attached from the generator Hold the voltage regulator generator regulator in one hand and pry off the cap covering the A screw head with a screwdriver Remove two screws T20 Torx type head attaching the regulator to the generator brush holder Separate the regulator from generator brush holder Regulator Installation 1 Replace generator brush holder to voltage regulator and install attaching screws Replace cap on the head of the A terminal screw Depress the generator brushes into the generator brush holder Hold the generator brushes in position by inserting a standard size paper clip or equivalent through both the location hole in the voltage regulator and through the holes in the generator brush holders Install the voltage regulator and generator brush holder to the generator with attaching screws Remove paper clip or equivalent from the regulator VOLTAGE REGULATOR e GENERATOR BRUSH HOLDER TIGHTEN TO 10347 2 8 4 0 Nem 25 35 IN LBI FPP00144 REMOVAL AND INSTALLATION
145. from the coolant fitting on the intake manifold 5 Mark and disconnect necessary electrical connections 6 Mark and remove vacuum lines from the vacuum tee on the intake manifold 7 Disconnect the PCV tube 8 Remove the throttle actuator if necessary Relieve fuel system pressure 10 11 Disconnect the fuel lines to the fuel rail Caution Avoid spilling fuel on hot 11 placed under the fuel line being removed to collect any spilled fuel Remove the engine lifting eye surfaces Use an absorbent rag LOWER INTAKE MANIFOLD FPPOO280 REMOVAL AND INSTALLATION 02 36 Engine Service 2 5L 02 36 gt gt S MANIFOLD EN FPP00282 14 Remove engine ground cable at lower intake manifold 15 Remove bolts attaching lower intake manifold 16 Remove lower intake manifold and gasket REMOVAL AND INSTALLATION 02 37 Engine Service 2 5L 02 37 Intake Manifold Installation 1 T 8 9 Clean and inspect the mounting surfaces of the intake manifold and the cylinder head Both surfaces must be clean and flat Clean and lightly oil the manifold bolt stud threads Install a new lower intake manifold gasket Position the lower intake manifold to the cylinder head Install retaining bolts studs finger tight Tighten all bolts studs to specifications in the tightening sequence shown e First pass 7 10 Nem 5 7 lb ft 8 4 Ebdon tha ns
146. fuel into the air stream at curb idle is controlled by the idle adjusting needle in the primary idle discharge hole Turning the needle out counterclockwise allows a richer mixture As the throttle plate opens extra fuel is discharged from the secondary idle discharge holes as the throttle plate passes them This hole is precisely located from the closed throttle plate with the size and location depending on fuel requirements As the throttle plate is opened wider the idle system gradually ceases to function The delivery of fuel through the high speed system increases as the throttle plate is advanced Although the delivery of fuel through the idle system diminishes as the throttle plate approaches the wide open position it continues to deliver a small volume of fuel contributing to the fuel delivered by the high speed system It cannot be said that the idle system ceases to deliver fuel entirely at wide open throttle but it must be made clear that the amount of fuel delivered from the idle system at wide open throttle is minute and relatively unimportant DESCRIPTION 05 3 Carburetor 05 3 High Speed System The high speed system consists of a venturi a main jet a well vent and a well tube This system also controls the mixture at part throttle speed the main jet controls fuel delivery from about one quarter to three quarters throttle opening To maintain a proper mixture ratio a small amount of air is admitted thr
147. g Tool T74P 6256 B to hold sprocket Tighten to 71 95 N m 52 70 lb ft 6 Install timing belt as outlined in this section 7 Install outer timing belt cover as outlined in this section 8 Using Valve Spring Compressor T95T 6565 A compress valve spring and install followers 9 Using Valve Spring Compressor T95T 6565 A compress and release valve tappet 10 Install valve cover as outlined in this section 11 Start engine and check for leaks Camshaft and Oil Pump Oil Seal Removal NOTE The camshaft and oil pump shaft seals are each replaced in the same manner with the same tools after the respective sprocket has been removed NOTE Always use a new attaching bolt when replacing the camshaft sprocket or use Teflon or equivalent sealing tape on the threads of the old bolt Special Tools Required Cam Sprocket Holding Tool T74P 6256 B Front Cover Seal Remover T74P 6700 B Front Seals Replacer T74P 6150 A CAM AND AUXILIARY SHAFT SPROCKET TOOL T74P 6256 B CAMSHAFT SPROCKET 6258 FPP00213 1 Remove outer timing belt cover as outlined in this section 2 Remove timing belt as outlined in this section Install Cam Sprocket Holding Removing Tool T74P 6256 B on sprocket and use tool to hold sprocket and remove bolt and washer 4 Install threaded puller insert in Cam Sprocket Holding Removing Tool T74P 6256 B and pull sprocket NOTE When positioning Front Cover Seal Remover T74P 6700 B make s
148. g gear When the iron plunger core is all the way into the coil its contact disc closes the circuit between the battery and the motor terminals The current flows to the motor and the drive pinion gear drives the flywheel and the engine crankshaft As current flows to the motor the solenoid pull in coil is bypassed The hold in coil keeps the drive pinion gear engaged with the flywheel The gear remains engaged until the ignition switch is released from the START position DESCRIPTION 06 3 Starter Motor 06 3 IGNITION SWITCH PM STARTER FPPOO220 DIAGNOSIS A great many problems with the starting system are WARNING WHEN WORKING IN AREA caused by the malfunctioning of other components in OF THE STARTER BE CAREFUL TO the electrical system Therefore it is best to start with AVOID TOUCHING HOT EXHAUST a battery check first when dealing with a starting COMPONENTS problem Make all digital volt ohmmeter connections at the component terminal rather than the cable or wiring terminal Making a connection at the wiring terminal could result in false readings because the meter will not pick up a high resistance between the wiring connector and the component CAUTION Be sure to disconnect battery negative cable before servicing starter CAUTION When disconnecting the Prelimi ti plastic hardshell connector at the solenoid 5 terminal grasp the plastic Inspect the fol
149. gauge readings are within the acceptable gauge reading limits perform the Cooling System Pressure Test Thermostat Visual Inspection 1 2 Hold thermostat up to the light Leakage of light all around the valve room temperature indicates a bad thermostat A slight leakage of light at one or two locations on the perimeter of the valve is normal Thermostat Operation Check 1 2 3 Visually check the valve to be sure it is air tight Place the thermostat and a thermometer in water Gradually increase the water temperature INITIALOPENING 780 82 TEMPERATURE FULL OPEN 204 F TEMPERATURE FULL OPEN LIFT 0 33 0 013 mm Replace thermostat if it does not open at least 0 23 after one minute at 212 F DIAGNOSIS 08 6 Cooling System 08 6 rcm DSSS U EEE SPACER FAN PULLEY FPP00287 REMOVAL AND INSTALLATION TENSIONER Cooling Fan Removal Remove the screws and washer assemblies FPP00288 attaching the fan and pulley to the water pump hub Drive Belt Removal 2 Remove the fan and pulley 1 Using a 3 8 breaker bar pry against the tension Cooling Fan Installation 1 Position the fan and pulley water pump 2 Remove the belt hub Drive Belt Installation 2 Loosen fan belt if necessary 1 Using 3 8 breaker bar pry against the tension 3 Install the lock washer a
150. ge specifications or design without notice and without incurring obligation NOTE The recommendations and suggestions contained in this publication are made to assist the distributor in improving his distributorship parts and or service department operations These recommendations and suggestions do not supersede or override the provisions of the Warranty and Policy Manual and in any cases where there may be a conflict the provisions of the Warranty and Policy Manual shall govern Reroduction in any manner in whole or in part is prohibited without The express permission in writing from Ford Power Products Marketing Department TABLE OF CONTENTS SECTION TITLE PAGE ENGINE SERVICE GENERAL MORE ERES 01 ENGINE SERVICE 2 Bua impete 02 IGNITION SYSTEM twice E E indie ei es 03 ul Bem Renate LU aer 04 CARBURETOR TET 05 STARTEFMOTOE G et ce ee a a a dta tele a ae Ci an 06 GOVERNO eeu enano edu cedi 07 GCGOOLING SYSTEM ved of de en 08 GENERATOR d 09 01 1 Engine Service General 01 1 SECTION TITLE PAGE ENGINE SERVICE 01 01 ENGINE SERVIGE 2 5 i i teer e t ritu ie 02 01
151. governor system is comprised of three major components the carburetor actuator and controller The objective of this document is to help a technician identify which component is creating a problem so it can be fixed or ACTION replaced CONDITION POSSIBLE SOURCE Governor appears dead Battery power is not supplied to controller Remove the connector from the controller and with a voltmeter check for battery power across pins A amp B of the wiring harness connector If battery power is not present check wiring to the controller Controller is not receiving the speed signal NOTE This controller receives its speed signal from the ignition If the controller is connected to an engine with a distributor pins C amp D should both be connected to the negative side of the coil or the tachometer output If the controller is connected to an engine with a DIS ignition pin C should be connected to one of the two tachometer outputs and pin D should be connected to the other tachometer output The DIS ignition utilizes two coils NOTE Do not short the tach leads doing so could damage the spark controller Using an ohmmeter check continuity from pins C amp D to the termination points If continuity is not present repair the wiring Actuator fails to operate NOTE Check wiring before replacing controller Bad wiring might destroy the new Remove the wires connected to the actuator With a DC voltmeter check betwee
152. h triangle on inner timing belt cover 14 Install timing belt over crankshaft sprocket 6306 Then proceeding counterclockwise over oil pump sprocket and camshaft sprocket verify timing marks are aligned 15 Loosen tensioner adjusting bolt allowing tensioner pulley to press against timing belt NOTE When performing the following step do not rotate crankshaft counterclockwise as timing belt may jump a cog putting camshaft out of time 16 Rotate crankshaft two revolutions clockwise 17 Bring crankshaft slowly without stopping to number one cylinder firing position keyway directly up 18 Recheck timing mark alignment Repeat the above steps if timing marks are no longer properly aligned 19 Rotate tensioner assembly against bolt with torque wrench up to 40 45 N m 29 33 Ib ft and tighten adjusting bolt 20 Tighten adjusting bolt to 35 45 N m 26 33 10 2 Tighten spring pivot bolt to 40 55 N m 29 40 Ib ft 22 Install outer timing belt cover as outlined in this section 23 Install spark plugs in proper locations ADJUSTMENTS 02 67 Engine Service 2 5L 02 67 SPECIFICATIONS CYLINDER BLOCK Cylinder bore 95 9993 96 0145 mm 3 7795 3 7801 Bore out or round 0 0381 mm 0 0015 GENERAL wear limit 0 1270 mm 0 005 Bore taper wear limit 0 2540 mm 0 010 Displa
153. haft timing can be checked without 3 If the triangle timing mark cannot be seen through removal of the cover or any other parts the access hole of the outer timing cover rotate NOTE Camshaft and timing belt sprockets turn one crankshaft one revolution TDC will be indicated revolution for every two revolutions of the crankshaft when the timing marks are aligned NOTE If the timing belt has greater than 3 000 hours 4 If the triangle timing mark cannot be properly or five years of use replace it Refer to the service aligned timing must be adjusted Refer to procedures in this section Adjusting Timing Belt in this section 1 Remove the rubber access cap in front of the camshaft sprocket from the outer timing cover 2 Rotate crankshaft so that number one cylinder is at the compression stroke of Top Dead Center TDC TDC will be indicated when the timing marks are aligned e The timing mark on the crankshaft damper assembly will align with TC on outer timing cover ADJUSTMENTS 02 18 Engine Service 2 5L 02 18 Adjusting Timing Belt Special Tools Required Crankshaft Belt Tension Adjuster T74P 6254 A 1 Remove the outer timing belt cover as outlined in this section NOTE Timing belt should be replaced at 3 000 hours or five year intervals If the timing belt has more than 3 000 hours or five years of use replace it Refer to the procedure in this section 2 Inspect belt for cracked or damaged teeth frayi
154. he roller finger follower of the valve to be checked 2 Using Valve Spring Compressor T95T 6565 A slowly apply pressure to the roller finger follower until the lash adjuster is completely collapsed Hold the follower in this position and insert the proper size feeler gauge between the base circle of the cam and the follower VALVE SPRING COMPRESSOR TOOL THST B56S A INCH ORIVE RATCHET DA BREAKER ues SA 3 Remove the roller finger follower and inspect for damage if the clearance is excessive 4 fthe cam follower appears to be intact and not excessively worn measure the valve spring assembled height to make sure the valve is not sticking 5 If the valve spring assembled height is correct check the dimensions of the camshaft Refer to Camshaft Lobe Lift in the engine service section 6 If the camshaft dimensions meet specifications remove clean and test the lash adjuster Refer to Hydraulic Tappets in the engine service section 7 Install the lash adjuster and check the clearance Replace damaged or worn parts as necessary ADJUSTMENTS 02 67 Engine Service 2 5L 02 67 mnm 22 ee TRIANGLE CRANKSHAFT PULLEY MARK 216 e The triangular timing mark on the camshaft sprocket will align with the timing mark on the Camshaft Timing Check An access plug is provided in the cam drive belt cover inner timing cover so that cams
155. ill not compress Plastigage and cause an incorrect reading Place a piece of Plastigage D81L 6002 B or equivalent on bearing surface across full width of bearing cup and about 6 35mm 1 4 inch off center Install cap and tighten bolts to specification Do not turn crankshaft while Plastigage is in place Remove cap Using Plastigage scale check width of Plastigage at widest point to get minimum clearance Check at narrowest point to get maximum clearance Difference between reading is taper of journals Bearing Clearance Excess Upper Bearing mm inch mm 0 013 0 0005 025 013 026 0005 0010 025 026 039 0010 0015 050 039 052 0015 0020 050 7 If bearing clearance exceeds the specified limits Scale part of D81L 6002 B Plastigage A23339 A 10 try using one of the various combinations of undersize bearings as accompanying table Use of any other bearing combination is not recommended Bearing clearance must be within specified limits Refer to specifications in specification section for main and connecting rod bearing clearance limits If use of these bearing combinations does not bring clearance to the desired limits refinish the crank journal to a standard undersize and use the appropriate undersize bearing directed the After bearing has been fitted and cleaned apply a light coat of engine oil to journal and bearings Install bearing cap Tighten cap bolts to specifi
156. inders 1 If compression rings are at fault improves considerably piston 2 f compression does not improve valves are sticking or seating poorly 3 two adjacent cylinders indicate low compression pressures and squirting oil on pistons does not increase compression cause may be a cylinder head gasket leak between cylinders Engine oil and or coolant in cylinders could result from this problem Compression Pressure Limit Chart MAX MIN Example Readings If after checking the compression pressures in all cylinders it was found that the highest reading obtained was 1351 kPa 196 psi and the lowest pressure reading was 1069 kPa 155 psi the engine is within specification and the compression is considered satisfactory 134 101 136 102 138 104 140 105 142 107 144 108 146 110 148 111 150 113 152 114 154 115 156 117 158 118 160 120 162 121 164 123 166 124 168 126 170 127 172 129 174 131 176 132 178 133 180 135 182 136 184 138 186 140 188 141 190 142 192 144 194 145 196 147 198 148 200 150 202 151 204 153 206 154 208 156 210 157 212 158 214 160 216 162 218 163 220 165 222 166 224 168 226 169 228 171 230 172 232 174 234 175 236 177 238 178 240 180 242 181 244 183
157. indicates no ability to remove the intake valve deposits If engine performance concerns have been affected by cleaning fluids it is most likely due to cleanup of carburetor deposits IVD is more difficult to remove than carburetor deposits IVD must be COMPLETELY removed to restore cold start and normal engine performance CAUTION The overuse of cleaning fluids may cause engine damage not covered under warranty CAUTION Only walnut shell blasting using Rotunda 014 00975 Carbon Blaster and Automotive Borescope or equivalent is recommended for removing carbon from engine valves with the engine assembled Other abrasives may cause engine damage on start up if not completely removed 1 Perform engine inspection of vacuum lines and wiring 2 Perform normal engine diagnostics Check fuel and ignition systems 3 If normal diagnostics have not resolved the engine performance concerns proceed with the following IVD inspection steps 4 Remove any two spark plugs CAUTION Do not bump the engine UN with the remote starter switch or ignition switch with the borescope in the spark plug hole or attempt to view the valve while rotating the engine Damage to the borescope or engine may result 5 Use a remote starter switch to bump the engine over until the intake valve is fully open in the cylinder to be inspected CAUTION Do not power the UN borescope light source from a vehicle battery while it is being charged For
158. ing Belt Cover 55 Roller Finger Follower 22 Screw M6 1 x 22 5 56 Hydraulic Lash Adjuster 23 Nut M6 1 57 Camshaft Oil Flow Control Rod 24 Stud M8 1 25 x 51 58 Expansion Plug 25 Plug Rubber 1 1 4 x 7 16 26 Bolt M6 1 x 17 27 Outer Timing Belt Cover 28 Bolt M8 1 25 x 20 29 Timing Belt Spring Bolt 30 Timing Belt Tension Spring 31 Belt Tensioner Assembly 32 Timing Belt 33 Bolt M12 1 75 x 45 34 Camshaft Sprocket Washer DESCRIPTION 02 11 Engine Service 2 5L 02 11 FPP00205 DESCRIPTION 02 12 Engine Service 2 5L 02 12 00206 DESCRIPTION 02 13 Engine Service 2 5L 02 13 Item Description Item Description 1 Drive Belt Tensioner 44 Rear Main Bearing Cap 2 Water Pump Inlet Tube 3 Screw M6 1 x 22 5 45 Crankshaft Main Bearing Upper blue 4 O ring 46 Crankshaft Main Bearing Upper 3 places 5 Bolt M10 1 5 x 60 Crankshaft Th Main Beari 6 ignition 47 rankshaft Thrust Main Bearing 7 Generator Mounting Bracket 48 Pipe Plug 3 8 18 8 49 Bolt M6 1 x 14 9 Crankcase Vent Oil Separator 10 Screw M6 1 x 15 50 Cylinder Block Ventilation Baffle 11 PCV Valve and Hose Ass
159. ing Bore Alignment Main bearing bore misalignment may be suspected in cases of premature bearing wear if one bearing wears considerably more that the others or bearings wear cone shaped NOTE Bearings are not available with oversize outside diameters to allow line boring If bearing misalignment is suspected 1 Acquire a gauge bar the same diameter as the crankshaft journals and straight within 0 076mm 0 003 in 2 Puta thin coating of Prussian Blue or similar die on gauge bar Insert good bearings in block Insert gauge bar in bearings and rotate one turn Remove gauge bar SOV Inspect bearings Blue die should be deposited evenly on all bearings If die appears on only one side or bottom of bearing or not at all block is distorted and should be replaced Cleaning NOTE Do not scrape gum or varnish deposits from the bearing shells Bearings that are to be reused should be identified so they can be installed in their original locations Clean the bearing inserts and caps thoroughly in solvent and dry them with compressed air Inspection Inspect each bearing carefully Bearings that have a scored chipped or worn surface should be replaced Typical examples of unsatisfactory bearings and their causes are shown in the illustration The copper lead bearing base may be visible through the bearing overlay If the base showing is less than 20 percent of the total area the bearing is not excessively w
160. ing Diagrams 570C 12 107 18 CAUTION EARLY 306 18 PRODUCTION CIRCUITS 674 AND 351D HAVE THE SAME COLOR WIRE CROSSING THESE CIRCUITS WILL CAUSE DAMAGE 39 18 209 18 A0 E 18 11 18 e 915 18 198 18 8 EM 787 16 e 100 E 1500 1 250 351D 18 E e 151097 7 e 32A 16 18 37 12 42 PIN CONNECTOR 307 18 TO 12A581 HARNESS 253 18 359M 18 570E 12 00452 CIRCUIT 2 CIRCUIT DESCRIPTION COLOR GAUGE 42 PIN 915 DATA LINK CONNECTOR RS485 NEGATIVE PK LB 18 3 914 DATA LINK CONNECTOR RS485 POSITIVE T O 18 11 787 TO FUEL PUMP PK BK 16 5 674 FUEL SELECT OPEN CIRCUIT PRIMARY FUEL 12V SECONDARY Y BK 18 7 658 MALFUNCTION INDICATOR LAMP OPEN COLLECTOR OUTPUT 500 mA PK LG 18 6 570E POWER GROUND BATTERY NEGATIVE BK W 12 42 570C POWER GROUND BATTERY NEGATIVE BK W 12 34 359M DRIVE BY WIRE SIGNAL RETURN SIGNAL RETURN FOR DRIVE BY GY R 18 33 351D DRIVE BY WIRE VREF 5V REF VOLT FOR DRIVE BY WIRE POT BR W 18 31 307 GOVERNOR SPEED SELECT 2 GVS2 SEE BELOW DESCRIPTION FOR BK Y 18 25 306 GOVERNOR SPEED SELECT 1 GVS1 0 0 T LB 18 24 258 OIL PRESSURE FOR INDICATOR LIGHT OPEN LOW PRESSURE DG W 18 26 209 SELF TEST INPUT SHORT TO GROUND TO ACCESS TROUBLE CODES W P 18 18 198 AUXILLIARY INPUT DG O 18 37 151 DRIVE BY W
161. ition rear engine lifting eye on studs and install retaining nuts and tighten to 20 30 N m 15 22 Ib ft Install exhaust pipe and bracket REMOVAL AND INSTALLATION 02 40 Engine Service 2 5L Oil Pump Removal 1 02 40 Rotate crankshaft so number one piston is at TDC Top Dead Center of its compression stroke Refer to the camshaft timing procedure in this section CAUTION Do not pry on sealing surfaces 6 Pry between cylinder block and ear on oil pump as show to loosen oil pump OIL PUMP CYLINDER BLOCK EAR ON 66 6 i il CRANKSHAFT PULLEY 5 0 oval gt raa E LONG TIMING SCREWDRIVER 6316 MARK FPP00036 FPP00037 2 Remove outer timing belt cover as outlined in this section 7 Remove oil pump and oil pump to cylinder block gasket Remove timing belt as outlined in this section 4 Remove oil pump timing belt sprocket as outlined in this section 5 Remove four oil pump screws OIL PUMP INLET PASSAGE FPP00286 REMOVAL AND INSTALLATION 02 41 Engine Service 2 5L 02 41 Oil Pump Installation NOTE Inspect and clean oil pump hole in the cylinder block before installing the oil pump 1 If original oil pump is to be reused install new oil pump O rings seals on oil pump 2 Prime back of oil pump and O rings with 236 ml eight ounces of fresh motor oil 3 Add oil to cylinder block hole GASKET FPP00268 4 In
162. its seat using compressed air Use an appropriate air line tool installed in the spark plug hole A minimum of 965 kPa 140 psi line pressure is required If air pressure does not hold the valve shut the valve is damaged or burned and the cylinder head must be removed and serviced Refer to the engine service section 1 Remove the valve cover as outlined in this section 2 Rotate the camshaft so the roller finger follower for the valve to be serviced is on the heel of the cam 3 Using Valve Spring Compressor T95T 6565 A compress and hold down the valve spring Slide out the roller finger follower over the lash adjuster Replace spark plug for cylinder being serviced with an air line adapter Mark location so spark plug is returned to the same cylinder CAUTION The crankshaft may UN rotate when air pressure is applied Remove all objects from fan area lights extension cords etc 6 Turn on air supply and pressurize cylinder Air pressure may rotate the crankshaft until the piston reaches the bottom of the stroke 7 Using Valve Spring Compressor T95T 6565 A compress the valve spring and remove the valve spring retainer keys and valve spring retainer Remove and discard the stem seal 8 If air pressure has forced the piston to the bottom of the cylinder any removal of air pressure will allow the valve s to drop into the cylinder Wrap a rubber band tape or string around the end of the valve stem in such a w
163. ivot bolt Do not remove 5 Hold tensioner with Camshaft Belt Tension FPP00209 Adjusting Tool T74P 6254 A 6 While holding tensioner loosen adjusting bolt and gradually release spring tension 7 Using adjusting tool rotate tensioner against spring pressure as far clockwise as possible While holding tighten adjusting bolt to hold tensioner away from belt 8 Remove timing belt REMOVAL AND INSTALLATION 02 20 Engine Service 2 5L 02 20 SPROCKET RECESS CRANKSHAFT CAMSHAFT SPROCKET TIMING BELT CRANKSHAFT SPROCKET ale SN Qu e FPP00210 REMOVAL AND INSTALLATION 02 21 Engine Service 2 5L 02 21 NOTE Camshaft and oil pump gears are identical and are interchangable Align the triangle mark on the camshaft gear and the diamond mark on the oil pump gear as shown in the above illustration Camshaft Timing Belt Installation NOTE Care must be taken during timing belt installation to prevent damage to the inner timing cover 1 If not done a Loosen tensioner adjusting bolt b Using Camshaft Belt Tension Adjusting Tool T74P 6254 A pry tensioner clockwise against spring tension as far as possible c Tighten adjusting bolt to hold tensioner in released position 2 Align crankshaft so number one piston is at TDC top dead center with crankshaft key pointing straight up and circle on crankshaft sprocket aligned with notch in engine front cover 3 Align triangle on cam
164. justers and valves to that they can be installed in their original positions 1 2 Remove cylinder head as outlined in this section Remove the deposits from the combustion chambers with scraper and wire brush Mount cylinder head on bench fixture Rotate the camshaft so the cam follower to be removed is on the heel of its cam DISASSEMBLY AND ASSEMBLY 02 60 Engine Service 2 5L SPRING FRONT OF ENGINE INSTALLED SPHING INTAKE HEIGHT VALVE EXHAUST VALVE Tri 0 274 Using Valve Spring Compressor 95 6565 14 Remove tool from sprocket compress and hold down the valve spring Slide out the cam follower over the lash adjuster 02 60 NOTE When positioning Front Cover Seal Remover T74P 6700 B make sure the jaws are gripping Repeat steps 4 and 5 until all the cam followers the thin edge of the seal tightly before operating are removed the jack screw portion of the tool Store lash adjusters in order 15 Install Front Cover Seal Remover T74P 6700 B Using Valve Spring Compressor T95T 6565 A pul Wonk seal compress valve spring and remove valve spring 16 Remove two screws and camshaft retaining plate retainer key valve spring retainer and valve spring Remove valve and store in order 17 Remove camshaft Remove valve stem seal Repeat above steps until all the valves are removed NOTE Itis not necessary to remove sprocket from ca
165. kets core plugs and drain plugs transmission oil cooler lines water pump heater system components Repair or replace as required Disassembly engine as necessary check for cracked intake manifold blown head gaskets warped head or block gasket surfaces cracked cylinder head or engine block Engine Overheats e Low coolant level e Loose fan belt e Pressure cap e Radiator obstruction e Closed thermostat e Fan drive clutch e ignition e Temp gauge or cold light e Engine e Coolant mixture Fill as required Check for coolant loss Adjust Test Replace if necessary Remove bugs leaves etc Test Replace if necessary Test replace if necessary Check timing and advance Adjust as required Check electrical circuits and repair as required Check water pump block for blockage 1 2 water and 1 2 permanent anti freeze mixture Engine fails to e Open thermostat e Test replace if necessary reach normal e Temperature gauge or cold e Check electrical circuits and repair as required operating light temperature DIAGNOSIS 08 4 Cooling System 08 4 Cooling System Pressure Test 1 2 Shut the engine off CAUTION prevent loss of coolant and to avoid the danger of being burned let the engine cool before removing the radiator cap 1 When removing the radiator cap place a cloth over the cap and rotate the cap SLOWLY counter clockwise to the safety stop and allow the pre
166. king can be corrected by disassembling the valve tappet and removing the dirt chips or varnish that are causing the condition A tappet check valve that is not functional may be caused by an obstruction such as dirt or chips preventing it from closing when operated or it may be caused by broken check valve spring within the tappet Air bubbles in the lubrication system will prevent the valve tappet from supporting the valve spring load and may be caused by an oil level that is too high or too low 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 may result If no other cause for noisy valve tappets can be found the leakdown rate should be checked and any outside the specification should be replaced Valve tappet assemblies should be kept in proper sequence so that they can be installed in their original position Inspect and test each valve tappet separately Do not intermix tappet positions If any part of the tappet assembly is worn or otherwise damaged replace the entire assembly Cleaning Thoroughly clean all parts in clean solvent and wipe them with a clean lint free cloth Inspection e Inspect the parts and discard the entire tappet lash adjuster assembly if any part shows pitting scoring or excessive wear e Replace the entire assembly if the plunger is not
167. lamping knob DIAL INDICATOR WITH BRACKETRY VALVE STEM CLEARANCE TOOL 6505 F A10707 D Position the dial indicator with its flat tip against the center portion of the tool s spherical section at approximately 90 degrees to the valve stem axis Move the valve stem back and forth in line with the indicator stem Take a reading on the dial indicator without removing the tool from the valve guide upper surface Divide the reading by two the division factor for the tool If valve stem to guide clearance exceeds the wear limit ream the valve guide for the next oversize valve stem as described in this section SERVICE PROCEDURES 01 27 Engine Service General 01 27 Valves Select Fitting If the valve stem to guide clearance exceeds the service clearance ream the valve guide for the next oversize valve stem Valves with oversize stem diameters are available for service Refer to Master Parts Catalogue for available sizes Always reface the valve seat after the valve guide has been reamed Refer to Valve Guide Reaming In the case of valve stem to guide clearance the service clearance is intended as an aid to diagnosing engine noise only and does not constitute a failure or indicate need for service However when overhauling or reconditioning a cylinder head the service clearance should be regarded as a practical working value and used as a determinant for installing the next oversize valve to make
168. lder and generator pulley are serviceable If the generator needs further service it must be replaced as an assembly Generator Removal 1 Disconnect battery ground cable 2 Remove snow ice shield 3 Remove engine air cleaner intake tube 4 Disconnect the generator voltage regulator wiring to the voltage regulator e Remove wiring connector bracket 6 Loosen the drive belt tensioner and remove the drive belt 1 Remove the bolts holding the generator to the generator bracket 2 Remove the generator from the generator bracket 150 Generator Installation 1 Position the generator on the generator bracket 2 Install generator 3 Tighten generator to bracket bolts to 40 55 N m 29 40 Ib ft 4 Position drive belt 5 Using flex handle rotate drive belt tensioner position drive belt and rest tensioner pulley on drive belt 6 Connect generator voltage regulator wiring to the voltage regulator Tighten generator battery positive voltage B wire attaching nut to 9 12 Ne m 6 5 9 Ib ft 7 Install wiring connector bracket 8 Install engine air cleaner intake tube 9 Install snow ice shield 10 Connect battery ground cable REMOVAL AND INSTALLATION 09 13 Generator 09 13 10328 REGULATOR 10316 AND BRUSH HOLDER ASSEMBLY 10347 SCREW 4 REQ D TIGHTEN TO age 2 3 3 4 Nem 20 30 IN LB FPP00143 Regulator Removal 1 Remove the
169. lly seated and both locking tabs are engaged REMOVAL AND INSTALLATION 03 13 Ignition System 03 13 ADJUSTMENT Ignition Timing In the event that the engine is operated on dry fuels the timing can be modified by grounding leaving open or applying 12 volts to circuits 674 and 72 of the module connector The fuel type determines which circuit is altered as shown in the chart below NORMAL OPERATION IF DETONATION OCCURS Circuit 674 Circuit 72 Timing effect Circuit 674 Circuit 72 Timing effect BR W Y BK Gasoline open open base 15 base 12 LPG ground open base 30 base 27 Natural gas ground 12 volts base 35 base 30 674 BR W 18 72 Y BK 18 CRANKSHAFT IGNITION 349 DK B 18 POSITION SWITCH 350A GY 18 SENSOR 359 GY R 18 SWITCH GAGE RELAY 16 RLG 18 ENGINE COOLANT TEMP SENSOR 354 LT G R 18 350 GY 18 16M R G 18 57 BK W 57C BK 18 16 R G 18 DIS 16C R G 18 lt IGNITION 96A T O 1 0 COIL UNIVERSAL ELECTRONIC SPARK CONTROL FPP00218 95 T W 18 96 T O 18 ADJUSTMENT 03 14 Ignition System 03 14 SPECIFICATIONS General Ignition Firing Ignition Plug Type Plug Gap Order Timing 1 3 4 2 10 1 AWSF 52C 1 07 1 17mm 042 046 in Torques Description Nem Ib ft Ib in Spark Plugs 9 20 7 15 Coil Mounting Screws 5 7 44 62 Crankshaft Hu
170. lowing items before performing any connector and pull lead off DO NOT pull starter system diagnosis separately on lead wire A Inspect the condition of the battery using a battery tester A slow or no crank condition is often WARNING WHEN SERVICING STARTER cauged oyan undercharged OR PERFORMING OTHER WORK IN THE e Inspect for frayed or damaged battery and starter VICINITY OF THE STARTER BE AWARE cables and wires THAT THE HEAVY GAUGE BATTERY INPUT LEAD AT THE STARTER SOLENOID IS e Make sure all the terminal connections at the ELECTRICALLY HOT AT ALL TIMES battery starter relay solenoid and starter are clean and tight DIAGNOSIS 06 4 Starter Motor 06 4 Symptom Chart If system does not operate properly note condition inspect starting system for loose connections and continue diagnosis using the following symptom chart CONDITION POSSIBLE SOURCE ACTION Starter solenoid does not pull in and Open fuse Check fuse continuity starter does not crank audible click may or may not be heard Low battery e Test battery Defective remote relay e Perform starter relay test Open circuit or high resistance e Perform starter voltage test in external feed circuit to starter solenoid Defective starter e Replace starter Unusual starter noise during starter e Starter not mounted flush Realign starter on transmission overrun cocked bell housing e Noise from other components e Inv
171. ly enough stock to clean up pits and grooves or to correct the valve seat runout After the seat has been refaced use a seat width scale or a machinist scale to measure the seat width Narrow the seat if necessary to bring it within specification SEAT WIDTH SCALE A6802 B If the valve seat width exceeds the maximum limit remove enough stock from the top edge and or bottom edge of the seat to reduce the width to specification On the intake and exhaust seats use a 60 degree angle grinding wheel to remove stock from the bottom of the seat raise the seats A 30 degree angle wheel is used to remove stock from the top of the seats lower the seats The finished valve seat should contact the approximate center of the valve face It is good practice to determine where the valve seat contacts the face To do this coat the seat with Prussian Blue and set the valve in place Rotate the valve with light pressure If the blue is transferred to the center of the valve face the contact is satisfactory If the blue is transferred to the top edge of the valve face lower the valve seat If the blue is transferred to the bottom edge of the valve face raise the valve seat SERVICE PROCEDURES 01 29 Engine Service General 01 29 Valve Inspection Inspect the valve stem for bends and the end of the stem for grooves or scoring Inspect the valve face and the edge of the valve head for pits grooves or scor
172. m 0 005 inch If out of round exceeds this specification cylinder will have to be refinished SERVICE PROCEDURES 01 22 Engine Service General 01 22 Cylinder Bore Clearance Cylinder Wall Honing 1 Measure the diameter of the piston on the thrust side at right angles to the piston pin 25 4mm 1 00 inch below the oil ring groove OIL RING GROOVE Hone the cylinder bore When reinstalling a piston with new rings To resize a cylinder to accept a service parts piston going into it Measure the diameter of the piston on the thrust side at right angles to the piston pin 25 4mm 1 00 inch below the oil ring groove 2 Measure the cylinder bore diameter at right angles to the piston pin at points A B and C as OUTER i DIAMETER described under cylinder taper 3 Subtract the piston diameter from the maximum A24225 A cylinder bore diameter to determine the maximum amount of material that can be removed 4 Hone the cylinder according to the hone Measure the cylinder bore diameter at right manufacturer s instructions to obtain the proper angles to the piston pin at points A B and C as bore surface finish of 18 38 RMS described under cylinder taper 5 Keep the hone moving up and down to achieve Subtract the piston diameter from the cylinder the proper crosshatch pattern bore diameter The difference should not exceed 6 Measure frequently to make sure that you do not the maximum piston to bore clearance found
173. measure the cylinder bore diameter to determine if it falls within the Service Limits found in the Specifications in Section 02 If the bore diameter falls within the Service Limits it will be possible to select fit a new Service piston If the bore diameter exceeds the Service Limits it will be necessary to replace the cylinder block assembly Oversize pistons are not available for this engine Fitting Piston Rings Do not reinstall used piston rings A special break in finish and sometimes an anti scuff coating is given to new piston rings by the factory The purpose of this special finish is to help the new piston rings and cylinder bore mate properly The special finish like the crosshatching on the cylinder bore wears off during break in The special finish will be already worn off used rings so they probably will not seat properly For this reason attempting to reuse piston rings could lead to excess oil consumption and possible cylinder scoring 1 Insert each piston ring backwards in the piston ring groove into which it will be installed 2 Measure the clearance between the ring and groove side clearance with a feeler gauge and check against the side clearance specifications in Section 02 PISTON 6108 NEW PISTON RING 6149 A14480 B Insert the ring in the cylinder bore Using the piston without rings turned upside down press the ring down to the center of the bore PISTON PISTON
174. mover 1 Remove outer timing belt cover as outlined in this section Remove valve cover as outlined in this section Rotate the camshaft so the rocker arm is on the heel of its cam 4 Using Valve Spring Compressor T95T 6565 A compress valve springs and remove all roller finger followers Remove camshaft sprocket using Cam Sprocket Holding Removing Tool T74P 6256 B Remove camshaft seal using Front Cover Seal Remover T74P 6700 B Remove camshaft retainer plate two screws damaging journal and lobes N CAUTION Be careful to avoid 8 Remove camshaft REMOVAL AND INSTALLATION 02 24 Engine Service 2 5L 02 24 5 i 2 2 42 RETAINING PLATE T74P 6150 A FRONT Re FOLLOWER DS P t 2 2 gt SY 25 2 FRONT OF ENGINE d 55 CAMSHAFT 00264 REMOVAL AND INSTALLATION 02 25 Engine Service 2 5L 02 25 Camshaft Installation 1 Coat the camshaft lobes with Ford Multi Purpose Grease DOAZ 19584 AA or equivalent meeting Ford specification ESR M1C159 A and lubricate the journals with heavy oil before installation Carefully slide the camshaft through the camshaft bearings 2 Install camshaft retaining plate Tighten screws to 8 12 N m 6 9 lb ft 3 Install camshaft front seal using Front Seals Replacer T74P 6150 A 4 Install camshaft sprocket to camshaft Install retaining bolt using Cam Sprocket Holding Removin
175. mshaft unless camshaft or sprocket is to be serviced Install Cam Sprocket Holding Removing Tool T74P 6256 B on sprocket Using tool to hold sprocket remove bold and washer Install threaded puller insert in Cam Sprocket Holding Removing Tool T74P 6256 B and remove sprocket DISASSEMBLY AND ASSEMBLY 02 61 Engine Service 2 5L 02 61 BEARING REPLACER T 1P amp 25D A 18 To remove camshaft bearing a Use tool sets Cam Bearing Replacer T71P 6250 A and Camshaft Bearing Set T65L 6250 A b Select proper size expanding collet and backup nut and assemble on expanding mandrel c With expanding collet collapsed install coiled assembly in the camshaft bearing and tighten backup nut on the expanding mandrel until the collet fits the camshaft bearing d Assemble puller screw cup and nut on expanding mandrel e Tighten the puller nut against the thrust bearing to remove the camshaft bearing Be sure to hold the end of the puller screw to prevent it from turning f Repeat steps to remove the other three bearings Cylinder Head Assembly 1 Clean and inspect cylinder head cam followers valve springs and valves as outlined in the Section 01 AN CAUTION Failure to use the correct expanding collet can cause severe bearing damage NOTE The camshaft bearings are available prefinished to size and require no reaming for standard and 0 08mm 0 003 inch undersize
176. n bolts snug Position drive belt Using flex handle rotate drive belt tensioner position drive belt and rest tensioner pulley on drive belt Tighten four fan and pulley to water pump bolts to 17 23 N m 13 17 lb ft NOTE Spark plug gap is 1 07 1 17mm 0 042 0 046 inch Install spark plugs in proper locations Position and connect ignition harness Install ignition wires Fill cooling system Connect battery ground cable Start engine and check for leaks REMOVAL AND INSTALLATION 02 32 Engine Service 2 5L 02 32 WATER PUMP CYLINDER K BLOCK FPP000215 Water Pump Removal 1 Drain cooling system 2 Using 1 2 inch drive handle rotate drive belt tensioner and remove drive belt Remove fan 4 Remove water pump pulley Remove heater water hose to water pump inlet tube 6 Remove lower radiator hose from the water pump inlet tube 7 Remove water inlet tub to generator bracket bolts and water pump inlet tube 8 Remove water pump retaining bolts and remove water pump 9 Clean water pump gasket surface of cylinder block Water Pump Installation 1 10 11 Apply Pipe Sealant with Teflon D8AZ 19554A or equivalent meeting Ford specification ESG M4G194 A to water pump bolts prior to installation Position gasket and water pump on cylinder block 6010 and install screws Alternately tighten to 20 30 N m 15 22 Ib ft Replace water inlet tube
177. n the actuator wires to battery The voltmeter should read 12 volts 2 volts If the voltage is low disconnect the connector from the controller and check continuity between the wiring harness pins E amp F to their respective actuator terminals If there is no continuity check for openings in the wires Using a voltmeter check for battery voltage from controller terminals E amp F to battery If battery power is not found replace the controller and check the actuator and actuator wiring for grounds and shorts controller Check continuity across actuator wires 2 5 ohm should be measured Check the continuity of actuator wires to the case The ohms measured should be 1M or greater If these values are out of tolerance replace actuator Engine doesn t change speeds Incorrect engine speed With the engine running connect battery power to pin H This will select Run 2 If Run2 is set at a higher speed than Run 1 and the speed does not change replace the controller Contact OEM for speed settings With the engine running connect battery power to pin G This will select Run 3 If Run 3 is set higher than the previous speed and the speed does not change replace the controller Contact OEM for speed settings With the engine running connect battery power to pins G amp H This will select Run 4 If Run 4 is set higher than the previous speed and the speed does not change replace the controller Contact OEM for
178. n the slip rings and recheck resistance If still less than 200 ohms replace generator Replace voltage regulator TEST E Indicator Lamp Off Key On Engine Not Running wire Is indicator lamp circuit 904 TEST STEP RESULT ACTION TO TAKE E1 CHECK FOR OPEN I CIRCUIT Yes Go to E2 Remove three pin voltage regulator connector No Repair open in circuit 904 e Turnkey to ON position Measure voltage at wiring harness I terminal Is voltage greater than 0 volts E2 CHECK FOR BURNED OUT BULB Yes Remove jumper wire Go to E3 Connect wiring harness I terminal to ground with a jumper No Replace bulb or repair high resistance in bulb socket or DIAGNOSIS 09 10 Generator 09 10 E3 CHECK FOR POOR GROUNDS Yes Go to E4 Check for poor ground connections between voltage regulator and generator generator and engine or engine and battery Are all ground connections clean and tight No Clean or repair grounds as required E4 CHECK S CIRCUIT WIRING generator Yes Service circuit 4 Circuit should be hot only when engine is running Check for swapped wires in voltage regulator connector Remove S connector from generator No Go to E5 Measure voltage wiring harness S terminal Is voltage greater than 0 volts E5 CHECK FOR SHORTED RECTIFIER Yes If lamp is on with one pin S con
179. nd screws and torque the of the tensioner capscrews to specifications 2 Install the belt 4 Adjust the fan belt tension to specifications REMOVAL AND INSTALLATION 08 7 Cooling System 08 7 CLAMPS FPP00289 Radiator Hose Removal Radiator hoses should be replaced as directed in the maintenance schedule or whenever they become cracked rotted or have a tendency to collapse 1 Drain the radiator 2 Loosen the clamps at each end of the hose to be removed 3 Slide the hose off the radiator connection and the engine water outlet connection upper hose or the water pump connection lower hose Radiator Hose Installation 1 Position the clamps at least 1 8 from each end of the hose 2 Coat the connection areas with an approved water resistant sealer and slide the hose on the connection 3 Make sure the clamps are beyond the bead and placed in the center of the clamping surface of the connections 4 Tighten the clamps 5 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 WARNING AVOID INJURY WHEN CHECKING A HOT ENGINE COVER THE RADIATOR CAP INA THICK CLOTH AND TURN IT SLOWLY COUNTERCLOCKWISE TO THE FIRST STOP AFTER THE PRESSURE HAS BEEN COMPLETELY RELEASED PRESS DOWNWARD AND FINISH REMOVING THE CAP DO NOT ADD COOLANT TO AN ENGINE THAT HAS BECOME OVERHEA
180. ne speed may run away when the load is removed 1 Tighten the lock nut securely 2 Readjust the governor high speed stop screw to maintain the correct high speed under load Part Load Surge 1 Shorten the throttle rod two or three turns at the rod end ball joint 2 Lookfor worn flyweights in the governor Unresponsive To Changing Loads 1 Incorrectly adjusted throttle linkage Engine parts wires rubbing on throttle linkage Surge screw turned too far into governor body Worn or broken governor flyweights Be es Gy 39 Damaged flyweight carrier Engine Dies Down Under Load 1 Incorrectly adjusted throttle linkage 2 Lengthen throttle rod two three or more turns at the rod end ball joint 3 Check engine timing and distributor advance 4 Look for excessive friction in the throttle link at governor and at carburetor 5 The load may be more than the engine can handle at wide open throttle Overspeeds When Load Is Removed 1 governor drive belt may be slipping Tighten belt 40 to 45 pounds tension 2 Back off surge screw one or two turns Shorten the throttle rod two or three turns at the rod end ball joints DIAGNOSIS 07 4 Mechanical Governor 07 4 Governor Does Not Re Set At Load Or No Load Point 1 Carburetor throttle shaft may be sticking due to carbon or fuel deposits 2 Worn ball joints on the throttle linkage 3 Worn governor flyweights Noisy Governor
181. ne to stall Adjust 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 Clogged idle air bleeds idle air passages or an idle discharge port cause stalling Cleaning eliminates this problem Carburetor icing is also a cause of stalling DIAGNOSIS 05 5 Carburetor 05 5 Rough Idle An improper idle air fuel mixture can cause rough idle This may be due to improper adjustment or damaged worn or grooved idle mixture adjusting screws Rough idle is caused by too high or too low a fuel level due to floats misadjusted or damaged A leak between the carburetor and intake manifold due to a carburetor not tightened down a damaged gasket or a crack in either the carburetor or intake manifold causes rough idle Adjust repair or replace as necessary Clogged idle air bleeds restricted idle air passages or idle discharge ports also cause rough idle Clean or repair as necessary Surging Above Idle Surging above idle is caused by a fuel level too low due to an improperly adjusted float clogged main jets restricted main jet passages or main jet having a size not suited for the application Adjust clean or replace as necessary Poor Acceleration Poor acceleration is caused by a mixture being too rich or too lean If a rich mixture is the cause of poor acceleration the fault may be an improperly adjusted accelerator pump a fuel level to
182. nector removed replace generator Measure voltage at the S terminal on the back of the No Replace voltage regulator Is voltage greater than 1 volt TEST F Generator Noisy TEST STEP CHECK FOR ACCESSORY DRIVE NOISE Check the drive belt to make sure that it is installed properly and is not damaged Check the accessory mounting brackets for loose bolts or out of alignment condition Check for a bent pulley Is accessory drive OK SUBSTITUTE KNOWN GOOD GENERATOR Remove generator and replace with a known good generator Is noise present with known good part RESULT ACTION TO TAKE Service accessory drive as required Generator is OK Install original part Check other accessories to find the cause of the noise Replace generator DIAGNOSIS 09 11 Generator 09 11 TEST G Radio Interference TEST STEP RESULT ACTION TO TAKE VERIFY RADIO INTERFERENCE Generator is OK Interference is occurring elsewhere in the electrical system Start engine Go to G2 Tune radio to a station where interference is present Remove three pin voltage regulator connector Is interference present with connector removed SUBSTITUTE KNOWN GOOD GENERATOR Generator is OK Interference is occurring elsewhere in the electrical system Remove generator and replace with a known good Replace generator generator Is interference present with known good part TEST H Indicator Lamp On Key Off TEST STEP RE
183. ng cracking or oil If the belt is worn or damaged replace it If there is oil on the belt determine the source of the oil leak and repair or replace as necessary CAUTION Attempting to adjust timing belt tension without loosening spring pivot bolt will break Crankshaft Belt Tension Adjusting Tool T74P 6254 A when relieving tension on the belt 3 If belt timing or tension is incorrect loosen timing belt spring pivot bolt 4 Hold tensioner with Camshaft Belt Tension Adjusting Tool T74P 6254 A 5 While holding tensioner loosen adjusting bold and gradually release spring tension 6 Using adjusting tool pry tensioner away from belt While holding tensioner tighten adjusting bolt There should be no tension on belt 7 Remove bolt washer and crankshaft damper 8 Remove the drive belt and inspect it for wear or damage If the belt is damaged replace it 9 Remove the spark plugs Mark locations on a piece of tape for reinstallation 10 If not done e Loosen tensioner adjusting bolt e Using Camshaft Belt Tension Adjusting Tool T74P 6254 A pry tensioner clockwise against spring tension as far as possible e Tighten adjusting bolt to hold tensioner in released position 11 Align crankshaft 6303 so number one piston 6108 is at TDC top dead center as indicated by timing mark 12 Align pointer circle on crankshaft sprocket with line on engine front cover 13 Align triangle on camshaft sprocket wit
184. ngine before the first charge of fuel supplied by the high speed system A lean mixture would result momentarily in this case and to counteract the condition additional fuel must be supplied instantly The supply of that extra fuel is the job of the accelerating pump system PPPOOD The accelerating system consists of the pump diaphragm assembly accelerating jet intake check valve and three parts making up the refill check The pump is vacuum operated In this system the pump diaphragm is pulled against the pump spring by the engine manifold vacuum When the throttle is opened the pull on the diaphragm drops allowing the spring to push the diaphragm against the fuel causing it to discharge through the accelerator jet This amount may be varied by adjusting the travel of the pump spring Such adjustment is made possible by changing the length of the diaphragm protector and the end of the pump spring DESCRIPTION 05 4 Carburetor 05 4 DIAGNOSIS Water and dirt that accumulate in the fuel tank can cause a restricted fuel line or filter and malfunction of the fuel pump or carburetor 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
185. ngine load information is processed into the UESC s electronics by a pressure transducer located within the UESC A vacuum line connects the transducer to the engine intake manifold The engine vacuum is proportional to its load Engine Temperature The Engine Coolant Temperature Sensor ECTS sends engine temperature information to the UESC The ECTS is located above the thermostat at the front of the engine Fuel Octane Level Adjustment In the event that the engine is operated on dry fuels such as natural gas compressed natural gas CNG or liquefied petroleum gas LPG timing can be modified See the Adjustments section for details DESCRIPTION 03 4 Ignition System 03 4 UESC Module Outputs Carb Ignition Coil Driver The UESC switches two ignition coils on and off at the correct times to give the desired spark advance Ignition timing is adjusted constantly by the UESC module Many factors including all the sensor inputs affect the final ignition setting Run Mode The UESC interprets engine speed above 200 RPM as Run Mode The Base Spark advance BSA is calculated by the UESC module processing the engine speed and load Manifold Absolute Pressure inputs Wiring Diagram 674 BR W 18 72 Y BK 18 349 DK B 18 350A GY 18 359 GY R 18 354 LT G R 18 16M R G 18 UNIVERSAL ELECTRONIC SPARK CONTROL 95 T W 18 96 18 Transient Mode This function is to provi
186. nkage limits carburetor throttle plate opening This provides regulation and control of engine rpm during operating engine loads The governor is attached to a bracket bolted to the lower left front of the engine block and is slotted for belt adjustment A single V type belt and pulley are used to operate the governor Electronic Governor Carb The electronic governor consists of three main components e Controller e Actuator Carburetor with special throttle shaft and mounting pad for the actuator The controller is connected to the actuator by a wire harness The controller receives two input signals e Engine speed is sensed from the EDIS Electronic Distributorless Ignition System e Using a remote mounted speed select switch up to four engine operating speeds can be selected There is one output from the controller e The controller sends a modulated signal to the actuator at the carburetor The actuator in turn controls the throttle shaft which determines throttle plate position Signal strength is varied by the controller depending on the input values The electronic governor has an internal FAIL SAFE circuit that instantly reacts to e Interruption of power to the controller which removes power to the actuator A return spring in the actuator moves the throttle shaft to minimum fuel position 1055 of speed signal input which causes the controller to remove power to the actuator A return spring
187. nstall the hose clamp on the heater hose and connect the heater hose to the fitting on the 15 Remove the four upper bolts studs from the intake manifold intake manifold 16 Remove the intake manifold and gasket tie Metal Uie air leang assembly 12 Fill the cooling system Intake Manifold Installation 13 Install the negative battery cable 1 Clean and inspect the mounting surfaces of the 14 intake manifold and the cylinder head Both surfaces must be clean and flat Start the engine and check for leaks 2 Clean and lightly oil the manifold bolt stud threads 3 Install a new intake manifold gasket UN 4 Position the intake manifold to the cylinder head Install four manifold upper retaining bolts studs finger tight 5 Install four remaining manifold bolts studs Tighten all bolts studs to 26 38 N m 919 28 following the tightening sequence Install the engine lifting eye REMOVAL AND INSTALLATION 02 35 THROTTLE ACTUATOR Ve Engine Service 2 5L 02 35 INTAKE MANIFOLD ADAPTER PLATE FPP00233 Intake Manifold EFI only 1 Disconnect the battery ground cable Remove the air cleaner assembly 12 Remove bolts attaching upper intake manifold 13 Remove upper intake manifold and gasket Drain the coolant from the radiator to a level lower than the intake manifold INTAKE MANIFOLD GASKET 4 Loosen the hose clamp and remove the coolant hose
188. nstructions for refinishing crankshaft If the journals will not clean up to less than the maximum undersize bearing available replace the crankshaft Always reproduce the same journal shoulder radius that existed originally Too small a radius will result in fatigue failure of the crankshaft Too large a radius will result in bearing failure due to radius ride of the crankshaft bearing After refinishing the journals chamfer the oil holes Polish the journals with a No 500 grit polishing cloth and engine oil crocus cloth may also be used as a polishing agent to obtain a smooth finish SERVICE PROCEDURES 01 20 Engine Service General 01 20 Cylinder Block Service Cleaning and Inspection If the engine has been removed and disassembled remove all core plugs and pipe plugs Clean the cylinder block using solvent preferably in a hot tank Follow all safety an environmental precautions with regard to the solvent Make sure all oil and dirt is cleaned from the cylinder block Make sure all oil passageways are clean A rifle cleaning brush is useful for this purpose Use a long thin screwdriver to scrape the bottom of the water jackets through the openings in the top deck to make sure all scale and deposits are removed Most engines have a dead spot at the back of the block where the coolant makes a U turn and drops any deposits If the water jackets are not thoroughly cleaned overheating will result Cylinder
189. nto slot provided in body with the float needle sticking into the threaded opening Install the fuel valve seat and washer making sure that the fuel valve enters the seat properly the valve will enter the seat more easily if the float is held in the up position and tighten securely Insert float axle clip in slot to bear against axle ends Holding axle in place raise float by applying light finger pressure to the float bracket Float pontoons should be approximately level when the valve is seated If not bend tab carefully to adjust Install o ring on venturi skirt and place venturi into recess provided in body making sure that the nozzle lines up with the notch in the fuel well Place intake gasket in position on body removable accelerator jet after intake gasket is in place an additional washer will be assembled over the accelerator jet tube and set inside the large hole in the intake gasket and on top of the smaller washer Lower air intake carefully onto bowl and fasten securely and evenly using attaching screws 16 Place accelerator pump diaphragm in place on body with bagged section into cavity Insert diaphragm protector into end of spring and install spring with protector against diaphragm 17 Place cover over spring and compress Insert screws and tighten evenly and securely NOTE Pump spacer will install into cover before assembly if required DISASSEMBLY AND ASSEMBLY 06 1 Starter Motor 06 1 SEC
190. o high due to damaged or misadjusted floats fuel inlet needle not seating due to damage or restriction restricted air bleeds or a worn or damaged main jet Adjust repair or replace as necessary If a lean mixture is the cause of poor acceleration the fault may be an improperly adjusted accelerator pump a damaged accelerator pump piston cap an accelerating pump check valve that is missing damaged or not seating a fuel float level set too low a clogged main metering jet or a restricted main fuel passage Air leaks are also responsible for a lean mixture causing poor acceleration Leaks may occur at the carburetor base to the intake manifold or the intake manifold to the cylinder head Cracks in the assemblies or worn gaskets cause these air leaks Clean adjust repair or replace as necessary Leaking Carburetor The causes of a carburetor leaking fuel are loose fuel connections or a cracked carburetor body Repair or replace as needed Inconsistent Idle Speed Inconsistent idle speed is mostly a throttle related problem An incorrect throttle linkage adjustment a binding throttle linkage a sticking throttle shaft or a loose throttle shaft in the throttle body or bore can cause inconsistent idle speed A sticking fuel inlet needle can also cause this problem Repair replace or adjust as necessary Reduced Power Output Reduced power output is caused by a choke not fully opened an improperly adjusted throttle linkage a
191. o open the carburetor throttle to a point at which the flyweight and spring forces are again in balance DESCRIPTION 07 3 Mechanical Governor 07 3 DIAGNOSIS Full Load Surge 1 Shorten throttle rod two or three turns at the rod end ball joint 2 Check for extra rich or extra lean air fuel mixture at the carburetor 3 Look for air leaks caused by a loose intake manifold 4 Look for loose or worn linkage between the governor and the carburetor 5 Look for engine parts or wires rubbing against the governor linkage No Load Surge The no load surge adjustment is set at the factory and rarely requires adjustment If necessary this adjustment can be used to prevent hunting and surging at no load speeds provided the rpm spread adjustment is set properly Make the adjustment with the tachometer installed Increase the engine speed with the hand throttle or variable speed lever to 75 rpm lower than the maximum no load desired control rpm NOTE At this point if the engine continues to surge light pressure applied to the governor throttle lever will dampen surge e Adjust the surge screw located on back of the governor housing 1 Loosen the no load surge adjusting screw locknut 2 Turn this screw clockwise into the governor until the engine speed stabilizes AN CAUTION Do not turn the surge screw into the housing any further or attempt to adjust this screw when the engine is under a load the engi
192. oil seal scratching or damaging block or crankshaft oil seal surface CAUTION Use caution to avoid Crankshaft Rear Oil Seal Installation 1 Apply clean Motorcraft Super Premium Motor XO 5W30 QSP or equivalent meeting Ford specification ESE M2G153 E to seal lips and inner seal edge 2 Place crankshaft rear oil seal on Rear Main Seal Replacer T82L 6701 A 3 Position tool and crankshaft rear oil seal to rear of engine Alternate bolt tightening to seat the crankshaft rear oil seal properly Oil Filter and Adapter Removal 1 Position oil drain pan under oil filter 2 Using suitable oil filter wrench loosen oil filter 3 Unscrew oil filter by hand and remove Properly recycle or dispose of oil in filter CYLINDER BLOCK 6010 INSERT 6890 TIGHTEN TO 28 35 Nem 21 26 LB FT OIL FILTER ELEMENT 6714 LIGHTLY OIL GASKET AND HAND TIGHTEN FPP00041 Oil Filter and Adapter Installation 1 Apply clean motor oil of the same type as is being used in the engine to the oil filter gasket NOTE Do not tighten filter with oil filter wrench 2 Install oil filter and tighten by hand REMOVAL AND INSTALLATION 02 43 Engine Service 2 5L 02 43 Oil Pressure Sender NOTE The pressure switch type sender used with the indicator lamp system is not interchangeable with the variable resistance type unit which is used with the gauge system Refer to the Master Parts Catalog for proper parts usag
193. on the carburetor depending on the application 5 Reconnect the governor throttle control rod if used to the throttle lever on the carburetor 6 Perform governor adjustment after carburetor installation is complete Refer to Governor Section 7 Reconnect the manual choke cable to the choke lever on the carburetor Adjust cable so that full opening and closing of the choke plate is possible 8 Reconnect the electrical connections to e the choke thermostat if used e electronic governor actuator if used 9 Install air cleaner assembly Start the engine let it warm to operating temperature and perform idle mixture and speed adjustments REMOVAL AND INSTALLATION 02 39 Engine Service 2 5L GASKET 02 39 EXHAUST MANIFOLD LIFTING 0214 Exhaust Manifold Removal Remove exhaust pipe and bracket Remove two nuts and rear engine lifting eye from exhaust manifold studs Remove two studs and six bolts Remove exhaust manifold and gasket from cylinder head Exhaust Manifold Installation i If necessary clean gasket surfaces on exhaust manifold and cylinder head Install exhaust manifold and exhaust manifold gasket Install fasteners NOTE Exhaust manifold fasteners must be tightened in two stages Tighten fasteners to 20 30 Nem 15 22 lb ft during the first stage Retighten fasteners to 60 80 N m N m 44 59 Ib ft during the second stage Pos
194. only enough stock to correct the runout or to clean up the pits and grooves If the edge of the valve head is less than 0 0794mm 1 32 inch thick after grinding replace the valve as the valve will run too hot in the engine If the valve and or valve seat has been refaced it will be necessary to check the clearance between the rocker arm pad and the valve stem with the valve train assembly installed in the engine SERVICE PROCEDURES 01 28 Engine Service General 01 28 A23881 A Item Description 1 Valve A Valve Seat Angle B Seat Width and Proper Location on Valve Bottom Narrowing Angle 75 degrees D Top Narrowing Angle 30 degrees E Valve Face Angle F Valve Margin Valve Seats Refacing Measure the valve seat width Reface the valve seat s if the width is not within specifications Refer to the specifications section Refer to Engine Service in the Rotunda Tool catalog for a description of the various types of valve seat grinders and cutters available Refacing the valve seat should be closely coordinated with the refacing of the valve face so that the finished seat and valve face will be concentric and the specified interference angle will be maintained This is important so that the valve and seat will have a compression tight fit Make sure refacer grinding wheels are properly dressed Grind the valve seats of all engines to a true 45 degree angle Remove on
195. ontainer This is the upper limit of the pressure cap 5 Replace any radiator cap that exceeds the specified UPPER LIMIT pressure without discharging bubbles 6 the radiator cap does not hold pressure remove and wash the cap in clean water to dislodge all foreign particles from the gaskets Check the sealing surface in the radiator filler neck Inspect the cam lock flanges on both sides of the filler neck for maximum cap engagement 7 Pressurize the cooling system using a radiator cap that operates within the original cap upper and lower pressure limits and observe the gauge reading for approximately two minutes Pressure should not drop during this time RESULTS If the pressure drops check for leaks at engine to radiator hoses bypass hose water valve hose if applicable thermostat housing gasket and radiator Also refer to engine system checks if a leak cannot be located in the cooling system Any leaks which are found must be corrected and the system rechecked If the system holds pressure proceed to the next step 12 Release the system pressure by loosening the radiator cap and remove the adapter reinstall the temperature sending unit check coolant level and replenish if necessary with the correct coolant solution 1 2 water and 1 2 permanent anti freeze mixture DIAGNOSIS 08 5 Cooling System 08 5 Radiator Cap Pressure Test 1 Remove the radiator cap from the radiator filler neck 2
196. ontrol rings Make sure rings are installed right side up Refer to instructions with piston ring set Rotate the rings so the end gaps are NOT lined up but are spaced properly as shown 25 4mm 1 INCH A 25 4mm 1 INCH 55 Check the ring side clearance as outlined in the engine service section Side clearance for both compression rings should be 0 041 0 084mm 0 016 0 0033 inch and snug fit for the oil control ring Put a piece of hose or other protector over connecting rod bolt to protect crankshaft journal Rotate crankshaft so journal for piston to be installed is at the bottom of its stroke CAUTION Install the piston pin and ring with the indentation notch in the 10 11 12 13 14 15 16 17 18 NOTCH TO 2 FRONT OF ENGINE piston head toward the front of the engine Apply motor oil to piston and cylinder bore and start piston and rod assembly into cylinder guiding bolts around crankshaft journal Compress piston rings using suitable piston ring compressor Tap piston assembly into place using bottom of hammer handle PISTON RING COMPRESSOR 00057 Insert bearings in connecting rod and Apply Plastigage to bearing journal Refer to the engine service section Install connecting rod cap Hand start each connecting rod nut until flush with end of rod bolt Alternately tighten connecting rod nuts to 34 41 N m 25 30 Ib ft Then
197. oper pressure at the specified spring lengths using Valve Clutch Spring Tester TOOL 6513 DD or equivalent VALVE CLUTCH SPRING TESTER TOOL 6513 DD SET KNOB TO COMPRESSED LENGTH OF SPRING A21330 A Apply torque until click is heard read torque wrench and multiply reading by two Weak valve springs cause poor engine performance Replace any valve spring not within specification Refer to the specification section Manually rotating the valve spring assemblies while installed in the engine will not determine condition of valve springs CAUTION Make sure the valve springs UN are reassembled to their own original dampers by pushing damper on the spring Do not open damper with any kind of tool in order to reassemble Valve Spring Squareness Check each valve spring for squareness using a steel square and a flat surface Stand the valve spring and square on end of the flat surface Slide the valve spring up to the square Revolve the valve spring slowly and observe the space between the top coil of the valve spring and the square CHECK SPECIFICATION CLOSED COIL END DOWNWARD A8517 A Refer to specifications for out of square limits Follow this same procedure for new valve springs before installation Make sure the proper valve spring color coded is installed CAUTION Make sure the valve springs UN are reassembled to their own original dampers by pushing damper on the valve spring Do not open damper
198. or to a crankcase opening The oil level indicator tube is convenient Adjust the air pressure to approximately 34 kPa 5 psi 3 Using a solution of liquid soap and water brush the solution along the gasket sealing surfaces and bearing seals Look for bubbles or foam 4 Remove the spark plugs and rotate the engine slowly with a wrench Check for large amounts of air escaping into the cylinders as each intake and exhaust valve opens 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 Rotunda Vacuum Pressure Tester 059 00008 or equivalent to the intake manifold Run the engine at the specified idle speed VACUUM PRESSURE TESTER 23453 vacuum gauge should read between 51 74 kPa 15 and 22 in Hg depending upon the engine condition and the altitude at which the test is performed Subtract 5 5 kpa from the specified reading for every 500 meters 1 in hg for every 1 000 feet of elevation above sea level DIAGNOSIS 01 9 Engine Service General 01 9 The reading should be quite steady It may be necessary to adjust the gauge damper control where used if the needle is fluttering rapidly Adjust damper until needle moves easily without excessive flutter A careful study of the vacuum gauge reading while the engine is idling will help pinpoint t
199. ord specification ESG M2C153 E Install connecting rod cap Hand start connecting rod nuts until nuts are flush with ends of connecting rod bolts Alternately tighten connecting rod nuts to 34 41 N m 25 30 Ib ft Then alternately tighten again to a final torque of 41 49 N m 30 36 Ib ft Install oil pump screen cover and tube as outlined in this section Install oil pan as outlined in this section Install spark plugs REMOVAL AND INSTALLATION 02 56 Engine Service 2 5L 02 56 Engine Coolant Temperature Sensor Removal Disconnect the negative battery cable 2 Partially drain the cooling system 3 Disconnect the electrical connector 4 Remove the sensor a ENGINE SENSOR COOLANT TEMPERATURE SENSOR FPP00299 Camshaft Position Sensor Removal 1 Disconnect the negative battery cable 2 Disconnect electrical connector Engine Coolant Temperature Sensor 3 Remove screws Installation 4 Remove the sensor 1 Install the sensor Tighten to Camshaft Position Sensor Installation 16 24 Nem 12 17 16 0 1 Install the sensor 2 Connect the electrical connector 2 Install screws Tighten to 3 Connectthe negative battery cable e 5 7 Nem 45 61 Ib in p Fill the cooling system with the proper coolant Connect electrical connector Connect the negative battery cable REMOVAL AND INSTALLATION 02 57 Engine Service 2 5L 02 57 IN
200. orn It is not necessary to replace the bearing if the bearing clearance is within recommended limits Check the clearance of bearings that appear to be satisfactory with Plastigage as described in this section A23338 B ITEM DESCRIPTION 1 Connecting Rod Bearing A Fatigue Failure Craters or Pockets B Improper Seating Bright polished Sections C Dirt Scratching Imbedding D Overlay Wiped Out Lack of Oil or Improper Clearance E Hourglass Overlay Gone from Edges Radius Ride G Overlay Gone from Mating Edge One Side Only Rod Cap Shift SERVICE PROCEDURES 01 16 Engine Service General 01 16 Crankshaft Bearing Clearance Plastigage Method 1 2 3 Clean crankshaft journals Inspect journals and thrust faces for nicks burrs or roughness that would cause premature bearing wear When replacing standard bearings with new bearings it is good practice to fit bearing to minimum specified clearance If desired clearance cannot be obtained with a standard bearing try a 0 050 mm 0 002 inch undersize bearing set to obtain proper clearance CAUTION Do not position jack under crankshaft pulley Crankshaft post damage will result If fitting main bearing in equipment position a jack under counterweight adjoining bearing which is being checked Support crankshaft with jack so its weight w
201. ough the well vent There are also air bleed holes located in the well tube at a point below the level of fuel in the well Introducing air into the well tube below the level of fuel reduces the surface tension of the fuel and helps fuel flow at low suction This bleed also restricts fuel flow through the main jet under high suctions H H i Bn IN When the throttle plate is opened to a point just above the idle position enough air passes through the carburetor to lower the pressure at the discharge tube The float chamber is open to atmospheric pressure consequently the greater pressure in the float chamber will cause the fuel to flow from the fuel bowl through the main jet into the main well and well tube Air admitted through bleed holes in the well tube an amount measured by the well vent is mixed with the fuel This mixture of fuel from the main well tube passes through the discharge tube in the venturi and is added to the air stream in the venturi This mixture then passes into the intake manifold Accelerating Pump System The accelerating pump controls the amount of fuel that is discharged into the air stream on sudden throttle openings When the throttle is opened suddenly air rushes through the carburetor into the intake manifold and to the engine this air is lighter than the liquid fuel and gets into motion more quickly That means that the air reaches the cylinders of the e
202. outlined in this section Remove timing belt as outlined in this section NOTE Belt tensioner assembly is under spring tension Hold tensioner by prying against spring pressure with Belt Tensioner Adjusting Tool T74P 6254 A Remove adjustment bolt which goes through slot in base of tensioner Release pressure Remove spring pivot bolt spring and tensioner assembly TENSIONER SPRING FPP00212 REMOVAL AND INSTALLATION 02 23 Engine Service 2 5L 02 23 Timing Belt Tensioner Installation 1 Install belt tensioner and timing belt tensioner spring on cylinder head placing one leg of spring under stud on cylinder head and other leg against pin on tensioner and install spring pivot bolt loosely 2 Using Camshaft Belt Tensioner Tool T74P 6256 B rotate tensioner clockwise against spring tension as far as possible and install adjustment bolt and tighten to restrain tensioner NOTE Spring pivot bolt is to be tightened after timing belt is installed Adjusting bolt is tightened as part of timing belt installation Install timing belt as outlined in this section After installing timing belt tighten spring pivot bolt to 40 55 N m 29 40 Ib ft 5 Install outer timing belt cover as outlined in this section Camshaft Removal Special Tools Required Valve Spring Compressor T95T 6565 A Cam Sprocket Holding Tool T74P 6256 B Front Seals Replacer T74P 6150 A T74P 6700 B Front Cover Seal Re
203. ove housing seal from drive end housing Remove drive gear assembly from housing and detach drive lever Remove stop ring and retainer from driveshaft and then remove drive assembly 8 Apply a thin coating of ESF M1C218 A grease or equivalent low temperature grease on driveshaft spline Install new drive gear assembly on driveshaft Install new stop ring and retainer Attach drive lever Partially fill drive end housing bearing bore with grease approximately one quarter full Install drive gear assembly in housing making sure to line up bolt holes in gear assembly and housing Install lever support and housing seal in drive end housing Position starter frame to housing and install through bolts Tighten to 5 0 9 5 Nem 45 84 Ib in Install solenoid Refer to Assembly Armature Replacement 1 Remove positive brush connector from solenoid motor M terminal Remove through bolts and separate motor from gear assembly and drive end housing Remove brush end plate screws brush end plate and brush assembly from starter frame Remove armature from frame Install new armature in frame Apply a thin coating of ESF M1C218 A grease or equivalent low temperature grease on both ends of armature shaft and pinion DISASSEMBLY AND ASSEMBLY 06 13 Starter Motor 06 13 EEN E 5 Install brush assembly Using tool make sure that brushes fit over commutator Push black grommet onto frame Apply grease to bearing
204. overnor carb 07 10 SE ee ee ea Controller Model 10851 131 DESCRIPTION The Barber Colman electronic governor consists of three main components controller actuator e carburetor The controller is a Barber Colman model 10851 digital unit This controller allows up to four engine speeds to be used on one application The operator changes the engine speeds via a run speed select switch mounted on the control panel of the machine These governors are isochronous in operation there is no governor droop The governor maintains the same engine speed from no load to full load operation Each controller can be programmed with up to four separate engine speeds The carburetor and actuator are integrated into one unit The carburetor is a Zenith model 33 offered with either a manual or automatic choke It is spring loaded to keep the carburetor at its minimum fuel position when no power is applied This feature causes the carburetor to go fully closed in the event of governor power failure The rotary actuator is mounted directly to the end of the throttle shaft This feature eliminates any need for throttle linkage The actuator is electrically connected to the controller through a two wire Packard connector If the governor is used with any other fuel System such as LPG then a linear actuator is available DESCRIPTION 07 11 Electronic Governor carb 07 11 DIAGNOSIS This
205. ox between the B terminal on the back of the generator and the positive battery post Is voltage drop less than 0 5 volt A10 CHECK FOR OPEN STATOR PHASE Yes Replace voltage regulator Connect test point on the voltage regulator to the No Replace generator negative battery post using a jumper wire Repeat generator output test Is generator output greater than the minimum output specified A11 CHECK FOR OPEN SHORTED FIELD Yes Replace generator Remove generator No Check for worn brushes less than 8mm long or open Remove voltage regulator brush leads and replace if required If OK replace Measure resistance between the generator slip rings voltage regulator Is resistance greater than 10 ohms less than 1 ohm TEST B Indicator Lamp On Engine Running TEST STEP RESULT ACTION TO TAKE Bt CHECK FOR OPEN A CIRCUIT Yes Go to B2 Measure voltage at test point A on the voltage regulator No Check fuse or fuse link in circuit 36 and replace if Is voltage equal to battery voltage required If OK repair open in circuit 36 CHECK FOR SHORTED I CIRCUIT Yes Repair short to ground in circuit 904 Remove three pin voltage regulator connector No Go to B3 e key to ON position Is indicator lamp on CHECK S CIRCUIT FUNCTION Yes Remove jumper wire Go to Install voltage regulator connector No Remove jumper wire Go to 5 Remove one pin S connector
206. ped parts can be detected when pressurizing the crankcase Light foaming equally around rocker arm cover bolts and crankshaft seals is not detrimental and no corrections are required in such cases DIAGNOSIS 01 7 Engine Service General 01 7 Compression Test 1 Make sure oil in crankcase is of the correct viscosity and at proper level and battery is properly charged Operate the engine until it is at normal operating temperature Turn off ignition switch then remove all spark plugs 2 Set throttle plates in wide open position 3 Install a compression gauge such as Rotunda Compression Tester 059 0009 or equivalent in No 1 cylinder 4 Install an auxiliary starter switch in staring circuit With ignition switching the OFF position and using auxiliary starter switch crank engine at least five compression strokes and record highest reading Note the approximate number of compression strokes required to obtain the highest reading 5 Repeat test on each cylinder cranking the engine approximately the same number of compression strokes The indicated compression pressures are considered within specification if the lowest reading cylinder is within 75 percent of the highest refer to chart If one or more cylinders reads low squirt approximately one tablespoon of SAE 50 weight or equivalent engine oil on top of the pistons in the low reading cylinders Repeat compression pressure check on these cyl
207. peration Perform leak down test as outlined in the engine Service section RETAINING RING pre ARM FULCHUM PLUNGER FLUN GER RETURN n SPRING C T ASSEMBLED VALVE TAPPET Bare Cylinder Block Disassembly 1 Before replacing a cylinder block determine if it is repairable If so make the necessary repairs following the procedures given in the engine service section 2 Completely disassemble the old engine following the engine disassembly procedure in this section 3 Remove core plugs as outlined in the engine service section 4 Remove oil gallery pipe plugs NOTE A rifle cleaning brush is helpful for cleaning engine oil galleries 5 Clean cylinder block and inspect as outlined in the engine service section Bare Cylinder Block Assembly 1 If using new or reconditioned cylinder block uncrate and clean preservative materials according to the supplier s instructions 2 Position the new cylinder block in a work stand and install all serviceable parts removed from the old cylinder block following engine assembly procedure in this section 3 Check all assembly clearances and correct as necessary DISASSEMBLY AND ASSEMBLY 02 66 Engine Service 2 5L 02 66 ADJUSTMENTS Valve Clearance Hydraulic Valve Lash Adjuster Special Tools Required Valve Spring compressor T95T 6565 A 1 Position the camshaft so that the base circle of the lobe is facing t
208. periodic spark plug checks The system provides for fixed spark advance at start 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 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 Inputs Affecting Ignition The spark strategy is based on sensors and manifold vacuum input to the UESC module which include the following inputs Engine Speed and Crankshaft Position The crankshaft position and speed information comes to the UESC from the Crankshaft Position Sensor CKP Sensor mounted in the engine front cover The CKP Sensor is triggered by teeth in the pulse wheel The pulse wheel is an integral part of the crankshaft front pulley and damper assembly The 36 teeth minus 1 spaced 10 degrees apart indicate to the UESC the crankshaft speed The missing tooth indicates crankshaft position CRANKSHAFT DAMPER FACE DOWN 6312 PULSE WHEEL PART CRANKSHAFT PULLEY GAP IN TEETH PROVIDES POSITION REFERENCE FOR NUMBER ONE PISTON 00003 Engine Load The e
209. r follower e Do not attempt to true this surface by grinding SERVICE PROCEDURES 01 34 Engine Service General 01 34 Intake Manifold Service Cleaning Remove all gasket material from the machined surfaces of the intake manifold Clean the manifold in a suitable solvent and dry it with compressed air Inspection NOTE Remove all filings and foreign matter that may have entered the manifold as a result of service e Inspect the manifold for cracks damaged gasket surfaces or other problems that would make it unfit for further service e Replace all studs that are stripped or otherwise damaged Oil Pan Service Cleaning Scrape any dirt or metal particles from the inside of the oil pan Scrape all old gasket material from the gasket surface Wash the pan in a solvent and dry it thoroughly Make sure all foreign particles are removed Inspection e Check the oil pan for cracks holes or damaged drain plug threads Check the gasket surface for damage caused overtightened bolts e Replace with a new oil pan if repairs cannot be made Piston Service Cleaning e Clean piston using suitable solvent e Using a putty knife or scraper clean carbon off of the top of the piston e Do not use a power wire brush to clean the piston skirt crown or piston ring grooves as it will remove metal e f using a ring groove scraper be careful not to remove metal from the piston ring lands Inspection
210. r distribution box or a fuse link 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 Generator 09 2 Operation With the key in the RUN position voltage is applied through the charge indicator lamp I circuit to the voltage regulator This turns the voltage regulator on allowing current to flow from the battery sense A circuit to the generator field coil When the engine is started the generator 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 A 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
211. r equivalent automotive borescope 10 Using a remote starter switch bump the engine over until the remaining intake valves to be cleaned are in the closed position and clean them as outlined above 11 Install the intake manifold as outlined in Section 02 Cleaning With the valves installed to protect the valve seats remove deposits from the combustion chambers and valve heads with a scraper and a wire brush Be careful not to damage the cylinder head gasket surface After the valves are removed clean the valve guide bores Use cleaning solvent to remove dirt grease and other deposits from the valves with a fine wire brush or buffing wheel than 0 25mm 0 010 from original cylinder head gasket surface Inspection e Inspect the cylinder head for cracks or excessively burned areas in the exhaust outlet ports Replace the cylinder head if it is cracked N CAUTION Do not plane or grind more e Check the cylinder head gasket surface for burrs and nicks Small imperfections of this type can be dressed down using an oil stone SERVICE PROCEDURES 01 25 Engine Service General 01 25 Spark Plug Thread Service NOTE The use of power or air driven tools is not approved for the installation of tapersets Damaged spark plug threads in the cylinder head can be serviced using Rotunda Taperset Installation Kit 107 R0901 or equivalent MANDREL TAPERSETS ROTUNDA TAPERSET INSTALLATION KIT 107 090
212. raulic lash adjuster clearance will also cause this action POOR VALVE SEATING A small but regular downscale flicking can mean one or more valves are not seating WORN VALVE SPRINGS When the needle oscillates swings back and forth over a 13 kPa 4 in Hg range at idle speed the valve guides could be worn As engine speed is increased the needle will become steady if the 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 Retarded ignition timing will produce a steady but low reading When 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 carburetor mounting flange gasket leak BLOWN HEAD GASKET A regular drop of approximately 33 50 kPa 10 15 in Hg can be caused by a blown head gasket or warped head to block mounting surface DIAGNOSIS 01 10 Engine Service General 01 10 15 RESTRICTED EXHAUST SYSTEM When the engine is first started and idled the reading may be normal But as the engine rpm is increased back pressure caused by a clogged exhaust pipe etc will cause the needle to slowly drop to 0 The needle then may slowly ri
213. removed Using an arbor press and Piston Pin Removing and Installing Set T68P 6135 A press the piston pin from the piston and connecting rod HOTCH POINTING TOWARD FRONT OF ENGIIME HUMBER LEFT SIDE OF 006 Piston and Piston Pins Assembly 1 Apply a light coat of Motorcraft Super Premium Motor Oil XO 5W30 QSP or equivalent to all parts Assemble the piston to the connecting rod with the oil squirt hole on the side of the connecting rod and the notch in the piston positioned as shown Use arbor press and Piston Pin Removing and Installing Set T68P 6135 A Engine Service 2 5L 02 64 Install the piston rings using a suitable piston ring expander Check the end gap of all piston rings They must be within specifications of 0 203 0 406mm 0 008 0 016 inch for top ring 0 33 0 50mm 0 013 0 019 inch for second ring and 0 254 0 762mm 0 010 0 030 inch for oil control ring Check the ring side clearance Refer to Section 01 Side clearance for both compression rings should be 0 041 0 084mm 0 0016 0033 inch and a snug fit for the oil control ring Make sure the connecting rod bearings and the bearing bore in the connecting rod and cap are clean Foreign material under the inserts will distort the bearing and cause a failure Install the connecting rod bearings in the connecting rod and cap with the tangs fitting in the slots provided Make certain lock slots in cap are on the same side o
214. resistance higher than specifications repair or replace the harness e fthe wire harness checks are to specifications reconnect each sensor and component and complete another DIS Harness Check e fthe same sensor or component circuit does not test to specifications replace that sensor coil e engine will not start and or run install a new module and make a normal start DIAGNOSIS 03 7 Ignition System 03 7 Secondary Resistance Checks Test No Test Connections DVOM Set Reading Description of Selection Ohms VDC Circuit Coil Secondary Ohm 14 000 Coil Secondary Towers 1 4 Circuit Ohm 14 000 Coil Secondary Circuit hm 2 Coil Secondary Towers 2 3 3 Ends of Each Spark 9 000 to 16 000 Spark Plug Wire Plug Wire Max 30 000 Resistance Engine Coolant Temperature sensor Characteristics C F Ohms 5 30 22 496 051 20 4 209 816 10 14 160 313 0 32 95 851 10 50 58 987 20 68 37 340 30 86 24 253 40 104 16 113 50 122 10 926 60 140 7 548 70 158 5 335 80 176 3 837 90 194 2 804 100 212 2 080 110 230 1 564 120 248 1 191 130 266 918 140 284 715 150 302 563 DIAGNOSIS 03 8 Ignition System 03 8 Spark Plug Inspection Carbon Fouled Black dry fluffy carbon deposits all over Caused by too cold a plug dirty air cleaner defective fuel pump too rich a fuel mixture faulty heat riser excessive idling
215. ressure pump for low pressure application Change to a low pressure pump e Air leak on inlet side of pump due to holes in Replace fuel line and tighten fittings apply a fuel line or loose fittings sealer if necessary Fuel pump leaks Fuel line fitting connections at pump are loose e Tighten and clean all connections at pump or dirty DIAGNOSIS 04 5 Fuel Pump 04 5 SPECIFICATIONS SPECIFICATION Shutoff pressure Maximum current draw Minimum flow 3 psi 12 volt input SPECIFICATIONS 05 1 Carburetor 05 1 SECTION TITLE PAGE ENGINE SERVICE General ainser 1 EO ee edades eite ted eA 01 01 ENGINE SERVIGE 2 5I eet ta 02 01 IGNETIONISYSTENM 3 03 01 EUELE PUMP eee te bd eet ur E 04 01 tt oae ine aote eo ee Ete di 05 01 STARTER MOTOR IER 06 01 cett i o ae eed 07 01 GOOLING SYSTEM RT ee diee A 08 01 GENERATOR Cx EE 09 01 SUBJECT PAGE DESCRIRHON G erena 2 Fuel SyS EA a e bee e ER et eia dM cd 2 Idle System UR 2
216. rnal engine components can cause Oil leakage excessive oil consumption Small deposits of oil on tip of spark plugs can a clue to internal oil e Worn or damaged oil pump consumption e Clogged oil pump screen cover and tube e Excessive main bearing clearance e Excessive connecting rod bearing clearance DIAGNOSIS 01 12 Engine Service General 01 12 SERVICE PROCEDURES Camshaft Service Camshaft End Play CAUTION Prying against the camshaft sprocket with valve train load camshaft can break or damage the camshaft sprocket Remove load on camshaft prior to checking end play Cleaning 1 Remove camshaft from engine Remove sprocket 2 3 Clean the camshaft in an appropriate solvent 4 Wipe it dry with a clean lint free cloth 5 Remove light scuffs scores or nicks from the camshaft machined surfaces with an oil stone Inspection e Inspect the camshaft journals and lobes for scoring and signs of abnormal wear e Lobe pitting except in the general area of the lobe toe is not detrimental to the operation of the camshaft The camshaft should not be replaced unless lobe lift loss has exceeded the specifications or pitting has occurred in the lobe lift area Refer to Cam Lobes in this section e Inspect camshaft sprocket for worn or broken teeth If necessary remove and replace Camshaft Bearings 1 Wipe bearing bore clean with a clean rag and solvent 2 Dry with a clean
217. rouble areas Always conduct other appropriate tests before arriving at a final diagnostic decision Remember that vacuum gauge readings although helpful must be interpreted with care Most vacuum gauges have a normal band indicated on the gauge face The following are potential gauge readings compare with the corresponding text 10428 1 NORMAL READING Needle between 51 and 75 kPa 15 and 20 in Hg and holding steady 2 NORMAL READING DURING RAPID ACCELERATION AND DECELERATION When engine is rapidly accelerated dotted needle needle will drop to a low not to 0 reading When throttle is suddenly released the needle will snap back up to a higher than normal figure IGNITION TIMING RETARDING INSUFFICIENT SPARK PLUG GAP NORMAL FOR HIGH LIFT CAM WITH LARGE OVERLAP Needle will register as low as 50 kPa 15 in Hg but will be relatively steady Some oscillation is normal WORN RINGS OR DILUTED OIL When engine is accelerated dotted needle needle drops to 0 kPa 0 in Hg Upon deceleration needle runs slightly above 74 kPa 22 in Hg STICKING VALVE S When the needle dotted remains steady at a normal vacuum but occasionally flicks sharp fast movement down and back about 13 kPa 4 in Hg one or more valves may be sticking BURNED OR WARPED VALVES A regular evenly spaced downscale flicking of the needle indicates one or more burned or warped valves Insufficient hyd
218. run enough for this to have happened the cylinder will at least have to be honed to seat the new rings on the piston 7 New rings should be installed when the piston is removed and reinstalled because piston rings are given a special finish by the factory to help them wear in and seat In seating the special finish is worn off Reusing piston rings will result in high oil consumption Cylinder Bore Diameter Make sure cylinder bore is clean and dry before measuring Using a suitable cylinder bore micrometer or gauge measure the cylinder bore s in the X and Y directions 90 degrees apart at points A B and C The X direction is parallel to the piston pin The Y direction is perpendicular to the piston pin and is the direction of piston thrust CYLINDER BORE CYLINDER WALLS A14470 B CYLINDER BORE TAPER CYLINDER WALLS A14471 A Cylinder Bore Taper Subtract the micrometer or gauge reading from point C direction Y from point A direction Y Also from point C direction X from point A direction X Each difference should be less than 0 127mm 0 005 inch If taper exceeds this specification cylinder will have to be refinished FRONT OF ENGINE 2 Z CYLINDER BORE EIE Qu M MN A23876 A Cylinder Out of Round Subtract the reading in direction X non thrust from direction Y thrust side at all points A B and C All readings should be less than 0 127m
219. rush end plate Push back grommet onto frame and attach brush end with brush plate screws Tighten to 2 3 3 4 Nem 20 30 Ib in Apply grease to driveshaft spline and place stationary gear assembly over driveshaft Install armature thrust washer and push C ring onto driveshaft Place drive assembly onto shaft and install stop ring and retainer Attach drive lever to drive assembly Grease and install planet gears Apply grease into drive end housing bearing bore approximately one quarter full Install drive gear assembly into housing making sure to line up bolt holes in gear assembly and housing Place gear retainer over gear assembly Install housing seal assembly into drive end housing Position starter frame to housing and install through bolts Tighten to 5 0 9 5 Nem 45 84 Ib in Correctly position solenoid to housing ensuring that solenoid plunger is attached through drive lever bottom solenoid terminal M should have a metal strip attached to it Tighten solenoid bolts to 5 1 9 6 Nem 45 85 Ib in Attach positive brush connector to solenoid bottom terminal Tighten nut to 9 13 Nem 80 120 Ib in Check that starter no load current draw is within specification Refer to Bench Tests Starter Drive Replacement 1 Remove positive brush connector from solenoid motor M terminal Remove solenoid retaining screws and remove solenoid Remove through bolts and separate motor assembly drive end housing Rem
220. se Excessive exhaust clogging will cause the needle to drop to a low point even if the engine is only idled When vacuum leaks are indicated search out and correct the condition Excess air leaking into the system will upset the fuel mixture and cause conditions such as rough idle missing or burned valves ALWAYS SERVICE VACUUM LEAKS Oil Consumption Test The following diagnostic procedure is intended to be used to determine the source of excessive internal oil consumption Determine what is considered to be excessive oil consumption Note hours of engine service and the following observations e How many hours of engine use per 0 95 liter 1 U S quart of oil used e How is the engine being used e g sustained high speed operation heavy loads high ambient temperature etc e What is the expected normal oil consumption Verify that the engine has no external oil leak as described under Engine Oil Leaks in this section Verify that the oil level dipstick and oil level indicator tube are unmodified and in good condition Verify that the oil level indicator tube is properly seated in the block and the dipstick seats properly in the oil level indicator tube KEEP THE OIL IM THIS RANGE 17629 Verify that the engine is not being run in an overfilled condition Check the oil level at least five minutes after a hot shutdown engine must be level Under no circumstances should the oil level be above th
221. shaft sprocket with triangle on inner timing belt cover 4 Install timing belt over crankshaft sprocket Then proceeding counterclockwise install timing belt over oil pump sprocket and camshaft sprocket 5 Loosen tensioner adjusting bolt allowing tensioner pulley to press against timing belt NOTE When performing the following step do not rotate crankshaft counterclockwise as timing belt may jump a cog putting camshaft out of time Rotate crankshaft two revolutions clockwise Bring crankshaft slowly without stopping to number one cylinder firing position keyway directly up 8 Recheck timing mark alignment Repeat the above Steps if timing marks are not properly aligned 9 Rotate tensioner assembly against belt with torque wrench up 40 45 N m 29 33 lb ft and tighten adjusting bolt 10 Tighten adjusting bolt to 35 45 N m 26 33 lb ft 11 Tighten spring pivot bolt to 40 55 N m 29 40 Ib ft 12 Install outer timing belt covers as outlined in this section CAM AND AUXILIARY SHAFT SPROCKET TOOL T74P 6256 B CAMSHAFT SPROCKET 6256 FPP00213 Camshaft and Oil Pump Sprocket Removal NOTE Removal and installation steps are the same for both camshaft and oil pump 6600 sprockets Special Tools Required Cam Sprocket Holding Tool T74P 6256 B 1 Remove outer timing belt cover as outlined in this section 2 Remove timing belt as outlined in this section 3 Install Cam
222. sition Therefore care should be taken to ensure that the electric cooling fan is completely disconnected when working under the hood A WARNING A The Engine Exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm Introduction In general this manual covers the servicing of the engine and associated standard equipment In many cases engines are supplied with accessories and equipment that are unique to the application If service information is ever required on such unique accessories or equipment it is suggested that Ford Power Products be contacted The proper information will either be forwarded or the Service Technician will be advised where it can be obtained The information in this manual is grouped in sections according to the type of work being performed The various sections are indicated in the index In addition each section is subdivided include topics such as diagnosis and testing cleaning and inspection overhaul removal and installation procedures disassembly and assembly procedures and service specifications Special service tools called for by the procedures can be obtained by calling 1 800 ROTUNDA 1 800 768 8632 The descriptions and specifications contained in this manual were in effect at the time the book was released for printing Ford Power Products reserves the right to discontinue models at any time or chan
223. ssure to escape completely Then turn the cap again SLOWLY counter clockwise past the safety stop to remove 2 Adjust the radiator coolant fill or drain to one inch below the filler neck opening before testing Wet the rubber sealing surface of the cap before installing the cap tightly on the radiator 3 Disconnect the electrical connector from the engine temperature sending unit and remove the temperature sending unit from the manifold NOTE With the radiator cap installed and the cooling system pressure relieved only a small amount of coolant will be lost when the sending unit is removed 1 Install the adapter fitting from the Rotunda Pressure Tester 21 0012 or equivalent male thread on one end and a hose connector on the other end to accommodate the tester hose tightly into the cylinder block in place of the sending unit 2 Remove the radiator overflow hose from the retainer clips Make sure the hose is firmly installed on the radiator overflow nipple and is in good condition Insert the free end of the overflow hose into a container of water 3 Attach the pressure pump and gauge to the adapter fitting and pressurize the cooling system to the cap LOWER LIMIT 4 No bubbles should appear in the water container when the system is pressurized to the cap s LOWER LIMIT If the system is satisfactory at the lower limit gradually increase the system pressure until a slight stream of bubbles appears in the water c
224. stall oil pump and oil pump to cylinder block gasket being careful to retain the priming oil in the back of the pump 5 Install four oil pump screws and tighten to 10 14 N m 89 124 Ib in 6 Install oil pump sprocket as outlined in this section 7 Checkto make sure crankcase is filled to proper level with motor oil 8 Prime oil pump with a drill motor by rotating oil pump sprocket approximately 10 revolutions or until resistance is felt 9 Align timing marks and install timing belt as outlined in this section 10 Install outer timing belt cover as outlined in this section 11 Install oil filler cap and tighten until it ratchets REMOVAL AND INSTALLATION 02 42 Engine Service 2 5L 02 42 LUBRICATE SEAL AND SEAL MATING SURFACE WITH OIL ESE M2C39 F CYLINDER CRANKSHAFT SEAL INSTALLER 821 6701 SEAL 6701 INSTALL WITH SPRING SIDE TOWARD ENGINE NOTE REAR FACE OF SEAL MUST BE WITHIN 0 508 MM 0 019 INCH OF THE REAR FACE OF THE BLOCK 00040 Crankshaft Rear Oil Seal Removal Special Tools Required Jet Plug Remover T77L 9533 B Rear Main Seal Replacer T82L 6701 A NOTE Clean exterior surface of crankshaft rear oil seal and cylinder block before removing crankshaft rear oil seal 1 Using a sharp awl punch one hole into the seal metal surface between the seal lip and the cylinder block 2 Screw in the end of Jet Plug Remover T77L 9533 B 3 Remove crankshaft rear
225. stem 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 devices An overrunning clutch in the drive assembly protects the starter from excessive speeds during the brief period as the engine starts START SWITCH 0 NEUTRAL START SWITCH OR LOCK OUT SWITCH FPP00118 Starter 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 coil A lever connected to the drive assembly engages the drive pinion gear to the flywheel rin
226. sts of BELT COVER CYLINDER BLOCK 6019 6010 e Roller finger follower arms e Hydraulic lash adjusters Camshaft motion is transmitted through the rollers in the finger follower arms to the engine valves The lash adjusters provide the finger follower fulcrum point and automatically adjust valve lash for silent operation Positive Crankcase Ventilation System This engine is equipped with a positive closed type crankcase ventilation system which recycles crankcase vapors to the intake manifold Oil Pan The oil pump is a rotor type with an inner rotor which turns inside of an off center outer ring The oil pump is located in the front of the cylinder block and is driven by the timing belt through a sprocket identical to the camshaft sprocket Oil Pump The oil pump contains a pressure relief valve To deliver sufficient pressure and volume at low rpm the pump is designed to provide high pressure and volume at high rom To prevent damage or excess oil consumption the pressure relieve valve exhausts excess pressure and volume at high rpm The oil pump is not serviced except to replace he front seal and the two O rings that seal it to the cylinder block OIL PUMP 6621 0004 Engine Cooling System The 2 5L Engine is liquid cooled using an engine mounted water pump and external radiator This is a full flow system regulated by a water thermostat located behind the water outlet connection The thermos
227. t is supported by five main bearings and the camshaft by four Main connecting rod and camshaft shaft bearings are replaceable to the lash adjusters NOTE A set of metric wrenches is required to service the 2 5L engine WARNING TO AVOID T HE POSSIBILITY OF PERSONAL INJURY OR DAMAGE DO NOT OPERATE THE ENGINE UNTIL THE FAN BLADE HAS BEEN FIRST EXAMINED FOR POSSIBLE CRACKS OR SEPARATION Engine Identification For quick engine identification refer to the identification nameplate The nameplate is mounted on the applicable equipment panels A build code and information label is also attached to the engine The symbol code on the build code and information label identifies each engine for determining parts usage for instance engine cubic inch displacement CID and model year The camshaft is driven by the crankshaft with a cogged timing belt The timing belt also operates the oil pump Tension on the timing belt is maintained by a timing belt tensioner which bears on the outside of the belt The water pump and the fan are driven from the crankshaft by a six ribbed poly V belt which also drives the generator SERIAL NUMBER MODEL NUMBER S 0JOPTIONS MODEL CODE Power Products 0060 DESCRIPTION Engine Service 2 5L 02 3 02 3 ENGINE CODE ENGINE PLANT CODE SG612AB L MADE IN LIMA OHIO 11 07 85 ENGINE BUILD DATE L LIMA A24340 A
228. tart screws Make sure beveled sides of plate are next to throttle body d channel plug flush bore Tap the plate lightly plate held closed to e Welch plug over spark vacuum port center it and tighten screws f Spark vacuum tube to approximately 9 16 5 While holding throttle closed screw idle stop from casting screw in until it touches the casting then screw in an additional 3 4 turn g Throttle body plug flush 6 Install idle needle washer and spring and screw h Pump Check Valve flush using tool C151 53 to gently touch the seat Back screw out i Well tube making sure that end openings align with notch in casting at top and fuel channel at bottom approximately one turn DISASSEMBLY AND ASSEMBLY 05 9 Carburetor 05 9 O RING DISCHARGE TUBE VENTURI 22 ETAINER LOAT ACCELERATOR JET i ony AXLE SPRING WEIGHT lt f CHECK ai POWER VALVE eS D gt JET bn cud VALVE SPRING COVER PROTECTOR GASKET PLUG FPP00228 7 Install power jet valve using C161 9 wrench No NOTE If you have an older model unit with 10 11 12 13 14 15 gasket required Install main jet and seat firmly with screwdriver No gasket required Install main jet plug and washer and tighten securely If main jet adjustment or solenoid shutoff are used install in place of plug Turn body right side up Insert float axle into holes in float Lower float axle and float i
229. tat controls and maintains engine temperature Typical coolant flow produced by the centrifugal water pump is through the engine block and then into the cylinder head From the cylinder head it flows through the thermostat and water outlet connection into the upper radiator hose and down through the radiator for cooling A passage from the water outlet connection through a heater by pass hose allows coolant to flow to the intake manifold which provides heat for fuel atomization It then flows through another heater by pass hose assembly to the inlet side of the water pump DESCRIPTION 02 5 Engine Service 2 5L 02 5 TAPPET HYDRAULIC LOCK RELIEF PASSAGE CAMSHAFT SUPPLY PASSAGE OIL PRESSURE SENDING UNIT PASSAGE BLOCK TO HEAD TRANSFER CAMSHAFT BEARINGS SIDE REAR DRAIN BACK REAR DRAIN BACK HEAD MAIN GALLERY 4 E A OIL FILTER SIDE FRONT DRAIN BACK FRONT DRAIN BACK BLOCK MAIN GALLERY OIL PUMP PICK UP TUBE CRANKSHAFT MAIN BEARINGS FILTER SUPPLY GALLERY OIL PUMP FPP00284 Lubrication System The engine lubrication system consists of e Oil pan e Oil pump screen cover and tube e Oil pump e Oil filter the cylinder block crankshaft camshaft and cylinder head The oil pan is pressure cast aluminum and serves as both an oil reservoir and engine bottom cover The oil pan has reinforcing ribs which strengthen the pan reduce engine noise transmission and aid in oil
230. te drive belt tensioner away from drive belt 3 Position drive belt under drive belt tensioner and release drive belt tensioner tensioning drive belt 4 Tighten crankshaft damper retaining bolt to 127 165 N m 93 121 Ib ft Camshaft Timing Belt Outer Cover Removal 1 Loosen four fan and water pump pulley to water pump bolts 2 Rotate drive belt tensioner and remove drive belt OUTER COVER CRANKSHAFT WHEEL PULLEY FPP00207 3 Remove four bolts fan and water pump pulley 4 5 Remove timing belt outer cover retaining screw Release seven cover interlocking tabs and remove outer timing belt cover Camshaft Timing Belt Outer Cover Installation 1 Position outer timing belt cover and secure by snapping the seven interlocking tabs into place Install timing belt cover retaining screw and tighten to 8 12 N m 70 106 Ib in Install water pump pulley and fan snug bolts but do not tighten Install drive belt Using flex handle rotate drive belt tensioner position drive belt and rest tensioner pulley on belt Tighten four clutch and pulley to water pump bolts to 18 22 N m 13 16 lb ft REMOVAL AND INSTALLATION 02 18 1 2 INNER TIMING BELT COVER 5 6 Engine Service 2 5L 02 18 Camshaft Timing Belt Inner Cover Installation OIL PUMP FPP00208 Camshaft Timing Belt Inner Cover Removal 1 2 Remove timing belt as outlined in this section Remove
231. test connections with Rotunda Starting and Charging Tester 078 00005 or equivalent cables connected to starter large enough to carry high current the same as in the vehicle The starter will run at no load Be sure that no current is flowing through ammeter rheostat at maximum counterclockwise position determine exact reading on voltmeter is securely mounted in bench vise while energizing as starter will move or jump N CAUTION Make sure that the starter 2 Disconnect starter from battery Then reduce resistance of rheostat until voltmeter indicates same reading as that obtained while starter was running The ammeter will indicate starter no load current draw Refer to Specifications for a comparative value 3 If current exceeds specification check for rubbing armature bent shaft binding bearings or shorts in armature or brush assembly Armature Open Circuit Test An open circuit armature may sometimes be detected by examining the commutator for evidence of burning A burn spot on the commutator is caused by an arc formed every time the commutator segment connected to the open circuit winding passes under a brush FPP00122 Grounded Armature Test This test will determine if the winding insulation has been damaged permitting a conductor to touch the frame or armature core To determine if the armature windings are grounded check with a VOM as shown Infinite resistance indicates a normal condition
232. the voltage regulator or fuses fuse links All key ON measurements are made with the engine not running unless directed to start engine TEST A Dead Battery No Generator Output Measure voltage between the S terminal on the back of the generator and ground Measure voltage between the positive battery terminal and the S terminal on the back of the generator Is either voltage reading greater than 1 volt TEST STEP RESULT ACTION TO TAKE A1 CHECK FOR KEY OFF DRAIN Yes Go to A2 e Turn key to OFF position No Check to ensure that the key switch is functioning e Turn off all accessories properly and that all lights and accessories are off Connect an ammeter or test lamp between the negative with the key switch in the off position battery cable and the negative battery post Is current drain less than 100 mA or test lamp off A2 CHECK FOR OPEN B CIRCUIT Yes Go to A3 Measure voltage at B terminal on the back of the No Check fuse link in circuit 38 290 and 37 and replace if generator required If OK repair open in circuits 38 290 and 37 Is voltage equal to battery voltage A3 CHECK FOR OPEN A CIRCUIT Yes Go to A4 Measure voltage at test point A on the voltage regulator No Check fuse or fuse link in circuit 36 and replace if Is voltage equal to battery voltage required If OK repair open in circuit 36 A4 CHECK F
233. tial 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 Ignition System 03 5 12volt timing light Rotunda 059 00006 This timing light uses an inductive pickup for convenience and safety on 12 volt systems This timing light includes a tachometer which reads from zero to 3000 RPM Service Checks e Each 400 hours of engine operation remove the spark plugs and clean and adjust the electrode e Clean and visually check spark plug high tension leads check for secure fit and replace if necessary Clean spark plugs as necessary using a wire brush or professional spark plug cleaner follow manufacturer s instructions Inspect the firing tip Refer to Spark Plug Inspection Chart Replace spark plugs if they are worn or damaged e Wipe the coil towers with a clean cloth dampened with soap and water Remove any soap film and dry with compressed air Inspect for cracks carbon tracking and dirt e Wipe the spark plug wire set with a clean damp cloth before inspecting it Without removing the spark plug wire set from the spark plugs or ignition coil inspect the wire set for visible damage such as cuts pinches or cracked or torn boots Refer to Ignition Wires Removal and Installation in this section and replace as necessary DIAGNO
234. und 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 1 Start the engine and allow it to come up to operating temperature 2 Setthe throttle control to high idle Place as full a load onto the engine as possible 3 Fuel pressure should be maintained at a minimum of 3 5 psi 4 If fuel pressure cannot be maintained verify that all of the above checks have been carried out IF ALL OF THE ABOVE CHECKS HAVE BEEN CARRIED OUT AND FUEL PRESSURE CANNOT BE MAINTAINED REPLACE THE FUEL PUMP ASSEMBLY WARNING ONCE ALL OF THE ABOVE TESTS ARE COMPLETED REMOVE THE JUMPER WIRE FROM THE OIL PRESSURE SWITCH For additional diagnostic information see the Service Check Chart below CONDITION POSSIBLE SOURCE ACTION Insufficient fuel delivery Clogged pump filter screen or fuel filter Clean or replace filter A break or restriction in fuel lines Repair fuel line or remove restriction e Anincorrect float level malfunctioning inlet Repair or replace as needed needle valve or clogged inlet screen in the carburetor Pump not operating Damaged loose ground or improper wiring Inspect mounting or wiring Carburetor flooding e Worn needle and seat assembly in carburetor Replace worn needle and seat assembly e Wrong pump application that is standard carburetor p
235. ure the jaws are gripping the thin edge of the seal very tightly before operating the jack screw portion of the tool 5 Install Front Cover Seal Remover T74P 6700 B making sure jaws are tightly gripping the thin edge of the seal Clean journal of debris 6 Remove seal REMOVAL AND INSTALLATION 02 26 Engine Service 2 5L 02 26 FRONT COVER SEAL REMOVER T74P 6700 8 0021 Camshaft and Pump Seal Installation 1 Position camshaft or oil pump shaft seal on Front Seals Replacer T74P 6850 A and press into place 22 Remove tool Position sprocket on shaft Install Cam Sprocket Holding Removing Tool T74P 6256 B without threaded puller insert on sprocket 5 Install sprocket bolt and washer and tighten to 71 95 N m 52 70 Ib ft Remove tool 7 Install timing belt as outlined in this section 8 Install outer timing belt cover as outlined in this section Cylinder Block Front Cover Seal Removal Special Tools Required T74P 6700 B T72C 6250 Front Cover Seal Remover Cam Bearing Adapter Tube 1 Remove outer timing belt cover as outlined in this section Remove timing belt as outlined in this section Remove crankshaft pulley hub bolt Slide crankshaft pulley 63120 off crankshaft 63030 5 Slide crankshaft sprocket off of crankshaft 6 Remove key from crankshaft NOTE When positioning Front Cover Seal Remover T74P 6700 B make sure jaws are
236. ureted system only Refer to the separate publication on electronic fuel injection for information on this system DESCRIPTION 04 4 Fuel Pump 04 4 DIAGNOSIS NOTE For the following tests TEMPORARILY place a jumper wire across the terminals of the oil pressure switch Electrical 1 Connect the positive lead of a voltmeter to the pump power wire and the negative lead to the pump housing 2 Turn on ignition switch 3 The voltmeter should read 12 volts If not check the power supply to the pump and the ground wire between pump housing and engine cylinder block 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 Then proceed as follows 1 Tee a pressure gauge into the fuel line at the carburetor inlet 2 Turn on the ignition switch but do not start the engine 3 The pump should click rapidly for a short time and pressure should build to and level off at 3 5 to 5 psi 4 If pressure fails to come up check for obstruction in the supply line from the tank to the pump and between the pump and carburetor m Ensure that the fuel cap vent is operating properly The vent should allow air to enter the tank as fuel is removed Correct any obstruction or restriction fo
237. use governor hunting and surging Too large a spread will cause low response For this governor normal rpm spread or droop is approximately 250 rpm with the full load speed range of 2000 2800 DROOP ADJUSTMENT SCREW Decrease Spread Increase Spread 1 With the engine running under no load at maximum governed speed loosen the locknuts Increase Droop adjust the screw to move the spring away from the lever hub Decrease Droop adjust the screw to move the spring closer to the lever hub 2 Tighten the locknuts 3 Recheck governor operation under full load and no load conditions to determine if operation is stabilized and sensitivity is satisfactory 4 Readjust the governor high speed stop screw to maintain the correct high speed under load ADJUSTMENT 07 8 Mechanical Governor 07 8 NO LOAD SURGE ADJUSTMENT SCREW No Load Surge Adjustment The no load surge adjustment is set at the factory and rarely requires adjustment If necessary this adjustment can be used to prevent hunting and surging at no load speeds provided the rom spread adjustment is set properly 1 Make the adjustment with the tachometer installed Increase the engine speed with the hand throttle or variable speed lever to 75 rom lower than the maximum no load desired control rpm NOTE At this point if the engine continues to surge light pressure applied to the governor throttle lever will dampen surge 2
238. used again Clean the connecting rod in solvent including the rod bore and the back of the inserts Do not use a caustic cleaning solution Blow out all passages with compressed air Inspection The connecting rods and related parts should be carefully inspected and checked for conformance to specifications Refer to the specifications section Various forms of engine wear caused by these parts can be readily identified A shiny surface on either pin boss inside of the piston usually indicates that a connecting rod is bent Abnormal connecting rod bearing wear can be caused by either a bent connecting rod worn or damaged piston pin or a tapered connecting rod crankshaft pin Twisted connecting rods can create an identifiable piston skirt wear pattern but badly twisted rods will disturb the action of the entire piston rings and connecting rod assembly and may be the cause of excessive oil consumption Check the connecting rods for bend or twist on a suitable alignment fixture Follow the instructions of the fixture manufacturer If the bend and or twist exceeds specification the connecting rod must be replaced Inspect the connecting rods for signs of fractures and the rod bearing bores for out of round and taper If the bore exceeds the recommended limits and or if the connecting rod is fractured it should be replaced SERVICE PROCEDURES 01 15 Engine Service General 01 15 Crankshaft Bearing Service Main Bear
239. wall when removing the piston and rod 8 Push the connecting rod and piston assembly out the top of the cylinder with the handle end of a hammer 9 Remove the bearing inserts from the connecting rod and cap 10 Select the proper bore gauge and micrometer Measure the cylinder bore for out of round and taper as outlined in the engine service section Deglaze cylinder bore as outlined in the engine service section 11 Remove rings and clean ring grooves Clean carbon from piston pin and ring 12 Check ring gaps using the procedure given in the engine service section NOTE Never install compression rings on pistons by hand Always use ring expander tool 13 Install rings using a ring expander tool Check ring side clearance 14 Clean crankshaft journals 15 If necessary disassemble piston and rod assemblies as outlined in this section 16 Clean gasket surfaces and fasteners REMOVAL AND INSTALLATION 02 54 Engine Service 2 5L 02 54 Pistons and Connecting Rods Installation 1 If disassembled assemble piston and connecting rod assembly as outlined in this section Refer to Pistons Piston Pins and Piston Rings in the engine service section for Cleaning Inspection Pistons Fitting and Piston Rings Fitting If necessary install piston and pin on connecting rod as outlined in this section Using a piston ring expander install the piston rings starting with the oil c
240. winter than in the summer allowing for better battery recharge BD GENERATOR REGULATOR TEST POINT FPPO0138 DESCRIPTION 09 3 09 3 DIAGNOSIS Before performing generator tests on the unit note conditions such as e slow cranking e dead battery e charge indicator lamp stays on with engine running This information will aid in isolating the problem Visual Inspection Preliminary checks to the charging system should be made regardless of the fault condition 1 Check battery posts and cable terminals for clean and tight connections Clean the posts and the cables to ensure good electrical contact 2 Check for secure connections at the generator output regulator and engine ground Also check the connection at the load distribution point starter relay 3 Checkthe 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 4 Check the battery voltage If less than 12 3 volts with the engine and all accessories off charge battery before proceeding 5 Check belt condition and tension In order to check the generator the use of Rotunda Starting and Charging System Tester 078 00005 VAT 40 or equivalent is recommended MOUNTING ECREWE FPPOUS3U DIAGNOSIS 09 4 Generator 09 4 Generator Output Test
241. with any kind of tool in order to reassemble SERVICE PROCEDURES 01 31 Engine Service General 01 31 Engine Block Plug Service Special Tools Impact Slide Hammer T59L 100 B Impact Slide Hammer T50T 100 A Removal and Installation To remove a large core plug drill a 12 70mm 1 2 inch hole in the center of the plug and remove with an Impact Slide Hammer T59L 100 B or T50T 100 A or pry it out with a large drift punch On a small core plug drill a 6 35mm 1 4 inch hole in the center of the plug and pry it out with a small pin punch Clean and inspect the plug bore Prior to installing a core plug the plug bore should be inspected for any damage that would interfere with the proper sealing of the plug If the bore is damaged it will be necessary to true the surface by boring for the next specified oversize plug Oversize plugs are identified by the OS stamped in the flat located on the cup side of the plug Coat the plug and or bore lightly with an oil resistant oil galley Stud and Bearing Mount EOAZ 19554 BA or equivalent meeting Ford specification WSK M2G349 A1 or Threadlock 262 E2FZ 19554 B or equivalent meeting Ford specification WSK M2G351 A6 and install it following the procedure for cup type or expansion type below Expansion Type Expansion type core plugs are installed with the flange edge inward The maximum diameter of this plug is located at the base of the flange with the flang
242. y drain Open voltage drop in B circuit Open voltage drop in A circuit Open high resistance in circuit Voltage regulator Generator Open A circuit Shorted I circuit Open high resistance in S circuit Voltage regulator Generator Go to Pinpoint Test B Indicator lamp flickers or intermittent Loose connection to generator voltage regulator or battery Loose fuse or poor connection in A circuit Loose brush holder screw Voltage regulator Generator Go to Pinpoint Test C Battery over charging battery voltage greater than 15 5 volts Voltage drop in A circuit Voltage drop in I circuit Poor ground Voltage regulator Generator Go to Pinpoint Test D Indicator lamp off key on engine not running Open high resistance in I circuit Burned out bulb Poor ground S circuit shorted to B Voltage regulator Generator Go to Pinpoint Test E Generator noisy Indicator lamp on key off Accessory drive belt Accessory brackets Bent generator pulley Generator Other components Lamp circuit shorted to B Go to Pinpoint Test F Go to Pinpoint Test H Improper lamp circuit wiring DIAGNOSIS 09 6 Generator 09 6 Pinpoint Tests All voltage measurements are referenced to the negative battery post unless otherwise specified Do not make jumper connections except as directed Improper connections may damage
243. ylinder head gasket surface at the cylinder head CYLINDER 29 30 31 32 Clean intake manifold gasket surface at the cylinder head Blow oil out of the cylinder block bolt holes Clean valve cover gasket surface on the cylinder head Check cylinder head for flatness as outlined in the engine service section Cylinder head and cylinder block head gasket surface should be flat to 0 08mm 0 003 inch over any 152mm 6 inches and flat within 0 15mm 0 006 inch overall FPP00024 Cylinder Head Installation 1 2 3 Position head gasket on the block Position cylinder head to cylinder block Install 10 cylinder head bolts in numerical sequence Tighten to 70 52 Ib ft in illustrated sequence Retighten to 70 N m 52 Ib ft in sequence Then turn all head bolts an additional 90 100 degrees in sequence REMOVAL AND INSTALLATION 02 29 Engine Service 2 5L 02 29 CYLINDER HEAD ASSEMBLY 6049 FPP00202 EK FRONT OF ENGINE 4 Install valve cover and valve cover gasket FPP00026 Tighten retaining bolts to 9 13 80 115 Ib in 5 Install intake manifold and gasket Tighten retaining bolts in sequence refer to illustration to 6 38 N m 19 28 lb ft 6 Install front lifting eye and tighten nut and bolt to 20 30 N m 15 22 Ib ft 7 Install exhaust manifold gasket and eight exhaust manifold retaining bolts and or stud bolts Tighten the bolts in sequence in two

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