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WSG-1068 6.8 LITER - EDI Ford Industrial Engine Documentation

1. Circuit Description Diagnosis and Testing Recommended Accessory Wiring Recommended Generator Wiring Voltage Regulator and Back of Governor Visual Inspection Generator Output Test Generator Voltage Test Battery Drain Test Symptom Chart Pinpoint Test A Generator Output
2. SPECIFICATIONS 34 34 34 35 35 35 36 36 36 36 36 37 37 37 37 38 38 38 38 39 39 40 40 40 42 43 43 3 WSG 1068 GENERAL INFORMATION GENERAL INFORMATION Introduction This section covers various engine tests adjustments service procedures and cleaning inspection procedures Engine assembly and service specifications appear at the end of the Section 02 For engine disassembly assembly installation adjustment procedures and specifications refer to Section 02 This WSG 1068 engine incorporates a closed type crankcase ventilation system To maintain the required performance level the fuel system ignition system and engine must be kept in good operating condition and meet recommended adjustment specifications Before replacing damaged or worn engine components such as the crankshaft cylinder head valve guide valves camshaft or cylinder block make sure part s is not serviceable WARNING TO AVOID THE POSSIBILITY OF PERSONAL INJURY OR DAMAGE DO NOT OPERATE THE ENGINE UNTIL THE FAN BLADE HAS FIRST BEEN EXAMINED FOR POSSIBLE CRACKS OR SEPARATION CAUTION Use of abrasive grinding discs to remove gasket material from the engine sealing surfaces during repair proced
3. Drive Belt Routing Cooling System Flushing Removal and Installation Radiator Hose Removal Radiator Hose Installation Thermostat Removal Thermostat Installation Removal of Heater Water Inlet Tube Installation of Water Heater Return Tube Assembly with by pass Hose Cylinder Head Temperature CHT Sensor Replacement Fan Drive Belt Removal amp Installation Belt T
4. Symptom Charts Engine Control Module GCP Diagnostic Trouble Codes Removal and Installation Camshaft Position CMP Sensor Replacement Crankshaft Position CKP Sensor Removal Crankshaft Position CKP Sensor Installation Cylinder Head Temperature CHT Sensor Replacement Heated Oxygen Sensor HO2S Replacement Knock Sensor KS Replacement Temperature Manifold Absolute Pressure TMAP Sensor Replacement Specifications 267 267 273 274 275 275 275 275 275 276 288 289 289 289 289 289 290 290 291 301 301
5. Oil Level Indicator Tube Removal Oil Level Indicator Tube Installation Oil Pan Removal Oil Pan Installation Oil Pump Removal Oil Pump Installation Flywheel Removal Flywheel Installation Crankshaft Rear Oil Seal Removal Crankshaft Rear Oil Seal Installation Cr
6. Overspeed Protection Engine Protection Starter Lockout Tachometer Output Ignition System Components Location Firing Order Ignition Coil on Plug Removal Ignition Coil on Plug Installation Harness Connector Pinout Description Fuel Select Operation Diagnosis and Testing Service Adjustments and Checks
7. Diagrams and Schematics Engine Component Locator View Diagnosis and Testing Diagnostic Approach GCP Diagnostic Overview On Board Diagnostics GCP Engine Control Module GCP Limp Home Mode Strategy Intermittent MIL Malfunction Indicator Lamp MIL DTC Retrieval Procedure Diagnosis Using a Personal Computer Visual Inspection Intermittent Problems
8. 55 Engine Repair Intake Manifold Variable Resonance Induction System VRIS Removal Intake Manifold Variable Resonance Induction System VRIS Installation Valve Cover Left Removal Valve Cover Left Installation Valve Cover Right Removal Valve Cover Right Installation Crankshaft Pulley Removal Crankshaft Pulley Installation Crankshaft Front Oil Seal Removal Crankshaft Front Oil Seal Installation Front Engine Cover Removal
9. Diagnostic Equipment Preliminary Checks Visual Physical Check Intermittent Problems Electrical Schematics Pinpoint Test A Ignition Check Page 175 175 175 176 176 177 177 178 179 180 180 181 181 181 181 182 182 182 182 183 183 183 183 183 183 184 184 185 185 185 185 185 185 185 186 187 188 188 189 190 191 191 192 192 192 193 197 160 WSG 1068 IGNITION SYSTEM GENERAL INFORMATION NOTE Whenever a wire is labeled with two colors the first color listed is the basic color of the wire and the second color listed is the stripe marking of the wire How to Find Electrical Concerns Troubleshooting Steps These six steps present an orderly method of troubleshooting Step 1 Verify the concern Op
10. Front Engine Cover Installation Timing Drive Components Removal Timing Drive Components Installation Camshaft Removal Camshaft Installation Exhaust Manifold RH Removal Exhaust Manifold RH Installation Exhaust Manifold LH Removal Exhaust Manifold LH Installation Cylinder Head Removal Cylinder Head Installation
11. Engine Identification Parts and Service Diagnosis and Testing Special Tools Inspection and Verification Symptom Chart Engine Oil Leaks Compression Tests Cylinder Leakage Detection Intake Manifold Vacuum Test Excessive Engine Oil Consumption
12. WSG 1068 6 8 LITER INDUSTRIAL ENGINE SERVICE MANUAL EDI March 2009 1 Section Index Reproduction in any manner in whole or in part is prohibited without the express permission in writing from Engine Distributors Inc Engine Distributors Inc policy is one of continuous improvement and while every effort is made to ensure that this publication is up to date and correct in all respects the right to change prices specifications and equipment at any time without notice is reserved Accordingly this publication is not to be regarded as a final description of any individual engine Pages 1 28 Pages 29 158 Pages 159 183 Pages 184 188 Pages 189 219 Pages 220 233 Pages 234 250 Pages 251 298 Pages 299 312 Page 313 HEALTH amp SAFETY WARNING THE FOLLOWING HEALTH AND SAFETY RECOMMENDATIONS SHOULD BE CAREFULLY OBSERVED WARNING CARRYING OUT CERTAIN OPERATIONS AND HANDLING SOME SUBSTANCES CAN BE DANGEROUS OR HARMFUL TO THE OPERATOR IF THE CORRECT SAFETY PRECAUTIONS ARE NOT OBSERVED SOME SUCH PRECAUTIONS ARE RECOMMENDED AT THE APPROPRIATE POINTS IN THIS BOOK WARNING WHILE IT IS IMPORTANT THAT THESE RECOMMENDED SAFETY PRECAUTIONS ARE OBSERVED CARE NEAR MACHINERY IS ALWAYS NECESSARY AND NO LIST CAN BE EXHAUSTIVE ALWAYS BE CAU
13. Oil Pressure Test Valve Train Analysis Static Valve Train Analysis Dynamic Camshaft Lobe Lift Hydraulic Lash Adjuster General Service Procedures Camshaft Journal Diameter Camshaft Journal Clearance Camshaft Lobe Surface Camshaft Lobe Lift Camshaft Runout
14. V Ribbed Serpentine Drive Belt Drive Belt Symptom Chart Drive Tensioner Belt Length Indicator Drive Belt Misalignment Visual Inspection Chart Inspection and Verification Symptom Chart Pinpoint Test A Loss of Coolant Pinpoint Test B The Engine Overheats Pinpoint Test C The Engine Does Not Reach Normal Operating Temperature Page 206 207 207 207 207 208 210 212 212 213 213 213 213 214 214 215 21
15. Component Tests Starter Drive and Flywheel Ring Gear Insection Removal and Installation Starter Motor Battery Cable Routing Starter Motor Removal Starter Motor Installation Specifications Torque Specifications General Specifications Special Tools Electronic Specifications Page 250 251 251 252 252 253 254 254 255 256 258 260 261 262 263 265 265 265 265 235
16. Crankshaft Main Bearing Journal Diameter Crankshaft Main Bearing Journal Taper Crankshaft Main Bearing Journal Clearance Bearing Inspection Crankshaft End Play Crankshaft Runout Cylinder Bore Taper Cylinder Bore Out of Round Piston Inspection Piston Diameter Piston to Cylinder Bor
17. Connecting Rod Twist Connecting Rod Piston Pin Side Clearance Connecting Rod Journal Clearance 5 6 6 7 8 9 10 11 12 13 15 16 17 17 19 20 21 21 22 23 24 24 24 25 25 26 26 27 27 28 28 28 29 29 29 29 30 30 31 31 31 31 32 32 32 32 32 33 33 2 WSG 1068 GENERAL INFORMATION INDEX CONT Subject Page General Service Procedures Bearing Inspection Roller Follower Inspection Hydraulic Lash Adjuster Inspection Valve Stem Diameter Valve Stem to Valve Guide Clearance Valve Ins
18. Hex Nut Strength Identification Other Types of Parts English Metric conversion Decimal and Metric Equivalents Torque Conversion J1930 Terminology List Page 315 315 316 316 317 318 319 319 320 09 300 WSG 1068 METRICS INTRODUCTION Most threaded fasteners are covered by specifications that define required mechanical properties such as tensile strength yield strength proof load and hardness These specifications are carefully considered in initial selection of fasteners for a given application To ensure continued satisfactory vehicle performance replacement fasteners used should be of the correct strength as well as the correct nominal diameter thread pitch length
19. General Specifications 171 171 31 WSG 1068 ENGINE GENERAL INFORMATION Description The 6 8 liter engine consists of four basic modules that can be repaired individually Remove only those components required to repair the module The induction module consists of an upper and lower intake manifold 9424 Each aluminum cylinder head module utilizes a single overhead camshaft 6250 to operate the two valves percylinder design Individual ignition coils 12029 are used for each spark plug 12405 The cylinder block module is a cast iron 90 degree V 10 cylinder block 6010 The basic engine components consist of the following Two overhead camshafts Engine dynamic balance shaft Two valves per cylinder Aluminum cylinder heads 6049 Cast iron 90 degree V 10 cylinder block Two piece aluminum intake manifold system Engine Identification It is important the engine codes and the calibration number be used when ordering parts or making inquiries about the engine Engine Code Information The engine code information label located on the valve cover contains the following Engine build date Engine code 32 WSG 1068 ENGINE Module View 33 WSG 1068 ENGINE Engine Intake Components 34 WSG 1068 ENGINE 35
20. WSG 1068 ENGINE Crankshaft Front Oil Seal Removal Special Tool s Special Service Tools called for by the procedures can be obtained by calling 1 800 ROTUNDA 1 800 768 8632 1 Remove the crankshaft pulley 6312 refer to this section 2 Using the a Front Cover Seal Remover remove the B crankshaft front seal 6700 56 WSG 1068 ENGINE Crankshaft Front Oil Seal Installation 1 Lubricate the A engine front cover 6019 and the B crankshaft front seal inner lip Use Super Premium SAE 5W30 Motor Oil XO 5W30 QSP or equivalent meeting Ford specification WSS M2C153 G 2 Use the A Crankshaft Seal Replacer to install the B crankshaft front seal into the C engine front cover 3 Install crankshaft pulley refer to Crankshaft Pulley in this section 57 WSG 1068 ENGINE Front Engine Cover Removal 1 WARNING DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENTS HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND CAN BE IGNITED RESULTING IN POSSIBLE PERSONAL INJURY Disconnect the battery ground cable 14301 2 Remove the valve covers 6582 refer to Valve Cover in this section 3 Remove the radiator 8005 4 Disconnect the camshaft position sensor CMP sensor 6B288 5 Remove the drive belt 8620 6 Disconnect the crankshaft position CKP sensor electrical connector 7 Remove the drain plug and drain the engin
21. 121 TPS1 lower than TPS2 122 TPS1 low voltage 123 TPS1 high voltage 127 IAT higher than expected 2 129 BP low pressure 134 EGO open lazy pre cat 1 140 EGO open lazy post cat 1 154 EGO open lazy pre cat 2 post cat 1 160 EGO open lazy post cat 2 171 AL high gasoline bank1 172 AL low gasoline bank1 174 AL high gasoline bank2 175 AL low gasoline bank2 182 FT Gasoline Low Voltage 183 FT Gasoline High Voltage 187 FT Gaseaous fuel low voltage 188 FT Gaseaous fuel high voltage 217 ECT higher than expected 2 219 Max govern speed override 221 TPS1 higher than TPS2 222 TPS2 low voltage 223 TPS2 high voltage 236 TIP Active 237 TIP Low Voltage 238 TIP High Voltage 261 Injector Loop Open or Low side short to Ground 262 Injector Coil Shorted 264 Injector Loop Open or Low side short to Ground 265 Injector Coil Shorted 267 Injector Loop Open or Low side short to Ground 268 Injector Coil Shorted 270 Injector Loop Open or Low side short to Ground 271 Injector Coil Shorted 273 Injector Loop Open or Low side short to Ground 274 Injector Coil Shorted 276 Injector Loop Open or
22. 1563 AUX analog PD3 high 1564 AUX analog PD3 low 1611 5VE 1 2 simultaneous out of range 1612 RTI 1 loss 1613 RTI 2 loss 1614 RTI 3 loss 1615 A D loss 1616 Invalid interrupt 293 1621 Rx Inactive 1622 Rx Noise 1623 Invalid Packet Format 1626 CAN Tx failure 1627 CAN Rx failure 1628 CAN addresss conflict failure 1629 J1939 TSC1 message receipt lost 1630 J1939 ETC message receipt lost 1631 PWM1 Gauge1 open ground short 1632 PWM1 Gauge1 short to power 1633 PWM2 Gauge2 open ground short 1634 PWM2 Gauge2 short to power 1635 PWM3 Gauge3 open ground short 1636 PWM3 Gauge3 short to power 1637 PWM4 open ground short 1638 PWM4 short to power 1639 PWM5 open ground short 1640 PWM5 short to power 1641 Buzzer control ground short 1642 Buzzer open 1643 Buzzer control short to power 1644 MIL control ground short 1645 MIL control short to power 1661 PWM6 open ground short 1662 PWM6 short to power 1663 PWM7 open ground short 1664 PWM7 short to power 1665 PWM8 open ground short 1666 PWM8 short to power 1669 PWM9 open ground short 1670 P
23. WSG 1068 STARTER SYSTEM DIAGNOSIS AND TESTING Starter Load Test Conduct this test if the starter cranks slowly and it is desired to compare current to specifications 1 Connect Rotunda Starting and Charging Tester 078 00005 or equivalent Make sure that current is not flowing through ammeter and heavy duty carbon pile rheostat portion of circuit rheostat at maximum counterclockwise position 2 Disconnect load from engine Place transmission 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 on page 07 19 Bench Tests CAUTION Make sure that the starter is securely mounted in bench vise while energizing as starter will move or jump 1 Connect a fully charged battery Rotunda Starting and Charging Tester 078 00005 or equivalent Make sure that the battery and starter motor are grounded 2 Engage the remote starter switch 3 The starter motor should eject the starter drive and run smoothly If the starter motor does not run smoothly
24. 2 If system does not operate properly note condition and continue diagnosis using the symptom chart WARNING WHEN WORKING IN AREA OF THE STARTER BE CAREFUL TO AVOID TOUCHING HOT EXHAUST COMPONENTS SYMPTOM CHART 240 WSG 1068 STARTER SYSTEM Pinpoint Test A Starter Lockout Relay Check Inspection and Verification 1 Visually inspect for obvious signs of mechanical and electrical damage 2 Visually inspect for and note auxiliary system connections not shown on the recommended wiring schematic 3 gt Greater than 4 lt Less than Normal Operation Terminals 30 and 87A of the starter lockout relay are normally closed while the ignition switch is in the start crank position and the engine rpm is less than 600 When the engine has reached 600 rpm or greater the GCP will ground the relay terminal 85 and open terminals 30 amp 87A which will not allow the starter to be engaged while the engine is operating above 600 rpm 241 WSG 1068 STARTER SYSTEM Pinpoint Test B Starter Does Not Crank Inspection and Verification 1 Visually inspect for obvious signs of mechanical and electrical damage 2 Visually inspect for and note auxiliary system connections not shown on the Recommended Customer Connections Wiring Schematic Normal Operation Terminals 30 and 87A of the starter lockout relay are normally closed while the ignition switch is in the start crank position and the engine rpm is less than 600 Battery voltage fl
25. 3 WSG 1068 GENERAL INFORMATION Interpreting Vacuum Gauge Readings A careful study of the vacuum gauge reading while the engine is idling will help pinpoint trouble areas Always conduct other appropriate tests before arriving at a final diagnostic decision Vacuum gauge readings although helpful must be interpreted carefully Most vacuum gauges have a normal band indicated on the gauge face The following are potential gauge readings Some are normal others should be investigated further 1 NORMAL READING Needle between 51 74 kPa 15 22 in Hg and holding steady 2 NORMAL READING DURING RAPID ACCELERATION AND DEACCELERATION When the engine is rapidly accelerated dotted needle the needle will drop to a low reading not to zero When the throttle is suddenly released the needle will snap back up to a higher than normal figure 3 NORMAL FOR HIGH LIFT CAMSHAFT WITH LARGE OVERLAP The needle will register as low as 51 kPa 15 in Hg but will be relatively steady Some oscillation is normal 4 WORN RINGS OR DILUTED OIL When the engine is accelerated dotted needle the needle drops to 0 kPa 0 in Hg Upon deceleration the needle runs slightly above 74 kPa 22 in Hg 5 STICKING VALVES When the needle dotted remains steady at a normal vacuum but occasionally flicks sharp fast movement down and back about 13 kPa 4 in Hg one or more valves may be sticking 6 BURNED OR WARPED VALVES A regular evenlysp
26. CAUTION Do not wipe with anything contaminated with silicone compounds 8 Reinstall the oil level dipstick being sure to seat it firmly in the oil level indicator tube Remove the oil level dipstick and draw a mark on the back unmarked surface at the indicated oil level This level should be about the same as the ADD mark on the face of the oil level dipstick 9 Add one quart of oil Restart the engine and allow to idle for at least two minutes Shut off the engine and allow the oil to drain back for at least five minutes Mark the oil level dipstick using the procedure above This level may range from slightly below the top of the cross hatched area to slightly below the letter F in FULL 10 Record the vehicle mileage or hours 5 WSG 1068 GENERAL INFORMATION 11 Instruct the customer to run engine as usual and perform the following Check the oil level regularly at intervals of 3 to 3 1 2 hours Return to the service point when the oil level drops below the lower ADD mark on the oil level dipstick Add only full quarts of the same oil in an emergency Note the mileage at which the oil is added 12 Check the oil level under the same conditions and at the same location as in Steps 7 9 Measure the distance from the oil level to the UPPER mark on the oil level dipstick and record Measure the distance between the two scribe marks and record Divide the first measurement by the second Divide the hours run during t
27. TP DTC is set the GCP will shut down the engine immediately Specifications Range of Measurement 0 85 angular Measurement Accuracy 2 of VREF Resolution 0 5 max 258 WSG 1068 ENGINE CONTROLS Fuel System Components Gasoline The fuel metering system is made up of the following parts The fuel injectors The fuel rail The fuel filter The GCP The Crankshaft Position CKP Sensor The Camshaft Position CMP Sensor The fuel pump The fuel pump relay Heated Oxygen HO2S Sensor Temp Manifold Absolute Pressure TMAP Sensor The basic function of the air fuel metering system is to control the air fuel delivery to the engine Fuel is delivered to the engine by individual fuel injectors mounted in the intake manifold near each intake valve The fuel metering system starts with the fuel in the fuel tank The fuel is drawn up to the fuel pump through a pre filter The electric fuel pump then delivers the fuel to the fuel rail through an in line fuel filter The pump is designed to provide fuel at a pressure above the pressure needed by the injectors A fuel pressure regulator in the fuel filter assembly keeps fuel available to the fuel injectors at a constant pressure A return line delivers unused fuel back to the tank The main control sensor is the heated oxygen sensor HO2S located in the exhaust system The HO2S tells the GCP how much oxygen is in the e
28. 239 241 242 244 245 246 246 246 247 248 248 248 06 221 WSG 1068 CHARGING SYSTEM GENERAL INFORMATION Generator 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 6007 is started the generator 10346 begins to generate alternating AC current which is converted to direct DC current by the rectifier internal to the generator This current is then supplied to the electrical system through the Battery Positive voltage B terminal located on the rear of the generator Once the generator begins generating current a voltage signal is taken from the stator and fed back to the voltage regulator S circuit turning off the charge indicator lamp With the system functioning normally the generator output current is determined by the voltage at the 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 winter than in the summer allowing for better battery recharge Battery Positive Voltage B Output The generator output circuit 38 BK O is supplied through the battery positive voltage
29. 302 305 309 309 309 310 311 311 312 312 313 252 WSG 1068 ENGINE CONTROLS GENERAL INFORMATION GCP and Sensors Engine Control Module GCP The Engine Control Module GCP has the following features Programmable four speed electronic governing throttle by wire or variable speed control governing Programmable emergency warning shut down feature for high water temperature low oil pressure etc Automatic altitude compensation Sequential port fuel injection gasoline with pressure regulator to precisely control fuel delivery Dry fuel lockout controlled by the GCP produces a reliable transition when switching fuels Certified closed loop dry fuel control Configurable inputs available based on customer requirements Configurable outputs available based on ECT RPM or MAP signals and customer requirements Starter lockout Auto crank Programmable overspeed protection Diagnostic software allows viewing of historical and active faults with on demand diagnostics to assist technicians and reduce equipment downtime The Engine Control Module GCP engine control system is a complete engine control system for Ford industrial engines running on gasoline propane or natural gas Each module can be set up to run an engine on any two of the three fuels in certified closed loop control with virtually transparent on the fly fuel switching Each module can a
30. 617 Start relay coil short to power 627 Fpump relay coil open 628 Fpump relay control ground short 628 FPump motor loop open or high side shorted to ground 629 Fpump relay coil short to power 629 FPump motor high side shorted to power 642 5VE1 low voltage 643 5VE1 high voltage 650 MIL open 652 5VE2 low voltage 653 5VE2 high voltage 685 Relay Coil Open 686 Relay Control ground short 687 Relay coil short to power 1111 Fuel rev limit 1112 Spark rev limit 1121 FPP1 2 simultaneous voltages out of range 1122 FPP1 2 do not match each other or the IVS 1151 CL high LPG 1152 CL low LPG 1153 CL high NG 1154 CL low NG 1155 CL high gasoline bank1 1156 CL low gasoline bank1 1157 CL high gasoline bank2 1158 CL low gasoline bank2 1161 AL high LPG 1162 AL low LPG 1163 AL high NG 1164 AL low NG 1165 LPG cat monitor 1166 NG cat monitor 1171 Megajector delivery pressure higher than expected 1172 Megajector delivery pressure lower than expected 1173 Megajector comm lost 1174 Megajector voltage supply high 1175 Megajector voltage supply low 1176 Megajector internal actuator
31. B output connection to the battery and electrical system The B circuit is hot at all times This circuit is protected by a 12 gage fuse link I Circuit The I circuit or ignition switch 11572 R Tan is used to turn on the voltage regulator This circuit is closed with the ignition switch in the RUN position This circuit is also used to turn the charge indicator lamp on if there is a fault in the charging system operation or associated wiring circuits A Circuit NOTE The A circuit is electrically hot at all times The A circuit or battery sense circuit Red is used to sense the battery voltage This voltage is used by the voltage regulator to determine the output This circuit is also used to supply power to the field coil This circuit is recommended to be protected by a 10 amp fuse or a fuse link S Circuit The S circuit or stator circuit 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 Not used with this system Circuit Description 222 WSG 1068 CHARGING SYSTEM DIAGNOSIS AND TESTING Recommended Accessory Wiring 223 WSG 1068 CHARGING SYSTEM Recommended Generator Wiring Before performing generator tests on the unit note conditions such as slow cranking dead battery charg
32. CAUTION Incorrect drive belt installation will cause excessive drive belt wear and may cause the drive belt to come off the drive pulleys Non standard replacement drive belts may track differently or improperly If a replacement drive belt tracks improperly replace it with an original equipment drive belt to avoid performance failure or loss of belt With the engine running check drive belt tracking If the A edge of the drive belt rides beyond the edge of the pulleys noise and premature wear may occur Make sure the B drive belt rides correctly on the pulley If a drive belt tracking condition exists proceed with the following Visually check the drive belt tensioner for damage especially the mounting pad surface If the drive belt tensioner is not installed correctly the mounting surface pad will be out of position This will result in a chirp or squeal noises With the engine running visually observe the grooves in the pulleys not the pulley flanges or pulley front surfaces for excessive wobble Replace components as required Check all accessories mounting brackets and the drive belt tensioner for any interference that would prevent the component from mounting properly Correct any interference condition and recheck belt tracking Tighten all accessories mounting brackets and drive belt tensioner retaining hardware to specification Recheck the drive belt tracking 212 WSG 1068 COOLING SYSTEM Vi
33. NOTE High tension voltage produced by a distributorless ignition system is higher than for a conventional ignition system It is in excess of 55 000 Volts Description The WSG 1068 engine uses a Coil On Plug Ignition System to ignite the fuel air mixture at the correct time and sequence based upon the input it receives The brain of this system is a Global Control Platform GCP The GCP has the capability at the OEM option to protect the engine from over heating and low oil pressure Inputs are sensors or switches that feed the GCP information Engine Cylinder Head Temperature Sensor CHT Input Camshaft Position Sensor CMP Input Crankshaft Position Sensor CKP Input Fuel Select Switch From these inputs the GCP computes spark strategy spark advance and fuel mixture air fuel to obtain optimum engine performance for correct load conditions Operation The ignition control module needs the following information to calibrate the engine properly Crankshaft position Engine RPM Engine temperature Engine load and altitude Fuel select switch The camshaft position sensor CMP sensor Sends the Ignition Control Module a signal indicating camshaft position used for fuel synchronization The crankshaft position sensor CKP sensor Sends the Ignition Control Module a signal indicating crankshaft position Is essential for calculating spark timing The intake air temperat
34. System Operation LPG System Operation Natural Gas Diagnosis and Testing Pinpoint Test A Fuel Pressure Check Page 200 200 202 NOTE For further information on Servicing the fuel system refer to Manufacturer s Service Information 04 185 WSG 1068 FUEL SYSTEM GENERAL INFORMATION System Operation LPG High pressure liquefied Petroleum Gas passes through a solenoid operated fuel shut off valve into an engine coolant heated vaporizer regulator unit where it is converted into a low pressure gas This gas is then fed into the carburetor body mixer where a vacuum operated gas metering valve ensures that the correct air to fuel ratio is maintained When the engine is switched off the electrical supply to the fuel shut off solenoid is disconnected and the valve closes cutting off the high pressure fuel supply to the vaporizer regulator The electrical supply to fuel shut off valve passes through a vacuum operated safety switch Should the engine stall the vacuum switch opens and cuts off the electrical supply to the fuel shut off valve When starting the engine there is sufficient vacuum present even at cranking
35. WSG 1068 ENGINE Low End Components 36 WSG 1068 ENGINE 37 WSG 1068 ENGINE Upper End Components 38 WSG 1068 ENGINE 39 WSG 1068 ENGINE Major Front End Components 40 WSG 1068 ENGINE DIAGNOSIS AND TESTING Refer to Section 01 for basic mechanical concerns 41 WSG 1068 ENGINE ENGINE REPAIR Intake Manifold Variable Resonance Induction System VRIS Removal 1 Disconnect the battery ground cable 14301 2 Drain the coolant system 3 Loosen and slide the hose clamp and disconnect the water outlet hose 4 Remove the engine vacuum hoses 5 Disconnect the water temperature indicator sender unit electrical connectors 6 Disconnect and remove the ten ignition coils 12029 refer to Section 03 7 Remove the drive belt 8620 refer to Section 05 8 Remove the generator GEN 10300 refer to Section 06 WARNING DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENTS HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND CAN BE IGNITED RESULTING IN POSSIBLE PERSONAL INJURY WARNING FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING 42 WSG 1068 ENGINE 9 Disconnect the hose clamps and remove the heater water hose 18472 10 Remove the water thermostat 8575 11 Remove the two studs retaining the heater water return tube 12
36. fault detection 1177 Megajector internal circuitry fault detection 1178 Megajector internal comm fault detection 1181 Fuel run out longer than expected 1182 Fuel impurity level high 1183 Megajector autozero lockoff failed 1311 Misfire detected 1312 Misfire detected 1313 Misfire detected 1314 Misfire detected 1315 Misfire detected 1316 Misfire detected 1317 Misfire detected 1318 Misfire detected 1511 AUX analog PU1 high 1512 AUX analog PU1 low 1513 AUX analog PU2 high 1514 AUX analog PU2 low 1515 AUX analog PD1 high 1516 AUX analog PD1 low 1517 AUX analog PU3 high 1518 AUX analog PU3 low 1521 CHT higher than expected 1 1522 CHT higher than expected 2 1531 IVS Brake Trans Park interlock failure 1541 AUX analog PUD1 high 1542 AUX analog PUD1 low 1543 AUX analog PUD2 high 1544 AUX analog PUD2 low 1545 AUX analog PUD3 high 1546 AUX analog PUD3 low 1547 AUX analog PUD4 high 1548 AUX analog PUD4 low 1551 AUX DIG1 high 1552 AUX DIG1 low 1553 AUX DIG2 high 1554 AUX DIG2 low 1555 AUX DIG3 high 1556 AUX DIG3 low 1561 AUX analog PD2 high 1562 AUX analog PD2 low
37. to Ground 2319 Primary Coil Shorted 2321 Primary Loop Open or Low side Short to Ground 2322 Primary Coil Shorted 2324 Primary Loop Open or Low side Short to Ground 2325 Primary Coil Shorted 2327 Primary Loop Open or Low side Short to Ground 2328 Primary Coil Shorted 2618 Tach output ground short 2619 Tach output short to power 1624 1625 Shutdown Request 294 WSG 1068 ENGINE CONTROLS REMOVAL AND INSTALLATION Camshaft Position CMP Sensor Replacement 1 Disconnect battery ground cable refer to section 6 2 Remove or disconnect any component to allow access and removal of the CMP Sensor 3 Disconnect CMP electrical connector 4 Remove bolt and CMP Sensor 5 Reverse procedure to install Use a new o ring seal Lubricate o ring with clean engine oil prior to installation Tighten bolt to 7 Nm 62 lb in Crankshaft Position CKP Sensor Removal 1 Disconnect battery ground cable refer to section 6 2 Remove or disconnect any component to allow access and removal of the CKP Sensor 3 Disconnect CKP electrical connector 4 Remove plug 5 Install special tool 303 507 and turn the crankshaft pulley bolt to position the No 1 cylinder at top dead center TDC 6 Remove 2 bolts and CKP sensor 7 Install an M6 bolt in the position shown 295 WSG 1068 ENGINE CONTROL
38. valve springs 6513 and remove the roller followers 4 Remove the hydraulic lash adjusters 5 Use the Valve Spring Compressor to compress the valve springs 123 WSG 1068 ENGINE 6 CAUTION Keep the valves and the valve spring retainer keys 6518 in order so they can be installed in the same positions NOTE The 8 cylinder is shown The 10 cylinder is similar NOTE Shown without camshaft for clarity Remove the A valve spring retainer keys the B valve spring retainers 6514 the C valve springs and the valves 7 Remove the valve stem seals 6571 8 CAUTION The caps must be marked for installation in their original location or damage to the engine may occur Remove the bolts the bearing caps and the camshaft 124 WSG 1068 ENGINE Cylinder Head Assembly 1 CAUTION Mating parts must make contact to each other within 4 minutes and connecting bolts must be torqued within 15 minutes after applying sealant Failure to follow this procedure can cause future oil leakage Use silicone gasket and sealant F6AZ 19562 AA or equivalent meeting Ford specification WSEM4G323 A6 NOTE Sealant must be removed and area cleaned with solvent if above instructions are not followed Use metal surface cleaner F4AZ 19A536 RA or equivalent meeting Ford specification WSEM5B292 A 2 Lubricate the camshaft journals Use Super Premium SAE 5W30 Motor Oil D9AZ 19579 A or equivalent meeting Ford sp
39. AT LEAST 110 F 1 Wrap a thick cloth around the pressure relief cap and turn it slowly one half turn counterclockwise Stepping back while the pressure is released from the cooling system 2 When you are sure all the pressure has been released still with a cloth turn counterclockwise and remove the pressure relief cap CAUTION If there is engine coolant in the engine oil the cause must be corrected and the oil changed or engine damage may occur NOTE Check the engine coolant in the degas bottle and radiator 8005 when vehicle has been allowed to reach normal operating temperature This will make sure sufficient engine coolant exchange has occurred 3 Inspect the coolant in both the radiator and the degas bottle for coolant color Clear light green or blue indicates higher water content than required Dark brown indicates unauthorized stop leak may have been used Use cooling system Stop Leak Powder E6AZ 19558 A or equivalent meeting Ford specification ESE M99B170 A only A light or reddish brown color indicates rust in the cooling system Flush the system and refill with the correct mixture of water and Premium Engine Coolant green in color E2FZ 19549 AA or equivalent meeting Ford specification ESEM97B44 A An irridescent sheen on top of the coolant indicates a trace of oil is entering the cooling system A milky brown color indicates that oil is entering the cooling system The causes of
40. Check the valve seat and valve angles Valve Seat Width Measure the valve seat width If necessary grind the valve seat to specification Valve Seat Runout Use the Valve Seat Runout Gauge to check valve seat runout 23 WSG 1068 GENERAL INFORMATION Flywheel Inspection Special Tool s 1 Inspect the flywheel for Cracks A Worn ring gear teeth B Chipped or cracked ring gear teeth C 2 Inspect the flywheel ring gear runout Oil Pump Gear Radial Clearance Measure the clearance between the rotor and the pump housing Oil Pump Rotor Inspection Inspect the oil pump rotor tips for damage or wear Oil Pump Side Clearance Place the Straight Edge across the top of the oil pump and rotors and use the Feeler Gauge to measure the clearance between the rotors and the Straight Edge 24 WSG 1068 GENERAL INFORMATION Cylinder Bore Honing Special Tool s NOTE Before any cylinder bore is honed all main bearing caps must be installed so the crankshaft bearing bores will not become distorted NOTE To correct taper or out of round bore the cylinder block NOTE Honing should be done when fitting new piston rings or to remove minor surface Hone with the Engine Cylinder Hone Set at a speed of 300 500 rpm and a hone grit of 180 220 to provide the desired cylinder bore surface finish Cylinder Bore Cleaning CAUTION If these procedures are not followed rust
41. Connect the water temperature indicator sending unit electrical connector 10 Install the generator 11 Install the drive belt 12 Install the ignition coils 47 WSG 1068 ENGINE 13 Connect the engine vacuum hoses Vacuum source 14 Connect the engine water outlet hose and position the hose clamp 15 Install the air cleaner outlet tube 9B659 16 Fill the cooling system refer to Section 05 17 Install the engine cover 18 Connect the battery ground cable Valve Cover Left Removal 1 NOTE The bolts are a part of the valve cover 6582 and are not to be removed Fully loosen the valve cover Remove the two nuts and the sixteen bolts and remove the valve cover and the valve cover gasket 6584 48 WSG 1068 ENGINE Valve Cover Left Installation 1 CAUTION Mating parts must make contact to each other within 4 minutes and connecting bolts must be torqued within 15 minutes after applying sealant Failure to follow this procedure can cause future oil leakage Use silicone gasket and sealant F6AZ 19562 AA or equivalent meeting Ford specification WSEM4G323 A6 NOTE Sealant must be removed and area cleaned with solvent if above instructions are not followed Use metal surface cleaner F4AZ 19A536 RA or equivalent meeting Ford specification WSEM5B292 A 2 Apply silicone in two places where the engine front cover 6019 meets the cylinder head Use Silicone Gasket and Sealant
42. F6AZ 19562 AA or equivalent meeting Ford specification WSEM4G323 A6 3 Position the valve cover and the valve cover gasket on the cylinder head and loosely install the bolts and nuts 49 WSG 1068 ENGINE 4 Tighten the nuts and bolts in the sequence shown 50 WSG 1068 ENGINE Valve Cover Right Removal 1 WARNING DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENTS HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND CAN BE IGNITED RESULTING IN POSSIBLE PERSONAL INJURY 2 NOTE The bolts are a part of the valve cover and are not to be removed Fully loosen the bolts and remove the valve cover and the valve cover gasket 6584 Valve Cover Right Installation 1 Remove the PCV valve CAUTION Mating parts must make contact to each other within 4 minutes and connecting bolts must be torqued within 15 minutes after applying sealant Failure to follow this procedure can cause future oil leakage Use silicone gasket and sealant F6AZ 19562 AA or equivalent meeting Ford specification WSEM4G323 A6 NOTE Sealant must be removed and area cleaned with solvent if above instructions are not followed 51 WSG 1068 ENGINE Use metal surface cleaner F4AZ 19A536 RA or equivalent meeting Ford specification WSE M5B292 A 2 Apply silicone in two places where the engine front cover 6019 meets the cylinder head 6049 3 Position the
43. Low side short to Ground 277 Injector Coil Shorted 279 Injector Loop Open or Low side short to Ground 280 Injector Coil Shorted 282 Injector Loop Open or Low side short to Ground 283 Injector Coil Shorted 285 Injector Loop Open or Low side short to Ground 286 Injector Coil Shorted 288 Injector Loop Open or Low side short to Ground 289 Injector Coil Shorted 301 Emissions catalyst damaging misfire 302 Emissions catalyst damaging misfire 303 Emissions catalyst damaging misfire 304 Emissions catalyst damaging misfire 305 Emissions catalyst damaging misfire 306 Emissions catalyst damaging misfire 307 Emissions catalyst damaging misfire 308 Emissions catalyst damaging misfire 326 Knock 1 Excessive Signal 327 Knock 1 sensor Open 331 Knock 2 Excessive Signal 332 Knock 2 sensor Open 336 Crank sync noise 337 Crank loss 341 Cam sync noise 342 Cam loss 420 Gasoline cat monitor 430 Gasoline cat monitor 524 Oil pressure low 562 Battery Voltage Low 563 Battery Voltage High 601 Flash checksum invalid 604 RAM failure 606 COP failure 615 Start relay coil open 292 616 Start relay control ground short
44. Remove the bolts the upper intake manifold and the intake manifold gasket 9439 Discard the intake manifold gaskets 13 Pull back and remove the heater water return tube Inspect the O rings and replace if required 43 WSG 1068 ENGINE 14 Separate the upper and lower intake manifolds 9424 Remove the ten bolts Discard the intake manifold gasket 15 Clean all mating surfaces Intake Manifold Variable Resonance Induction System VRIS Installation 1 Position the lower intake manifold gasket 9461 and the upper intake manifold on the intake manifold and loosely install the ten bolts 44 WSG 1068 ENGINE 2 NOTE Tighten the bolts in two stages Tighten the bolts in the sequence shown Stage 1 Tighten to 2 Nm 18 lb in Stage 2 Tighten to 8 12 Nm 71 106 lb in 3 Position the water return tube as shown 4 Install the heater water return tube studs 45 WSG 1068 ENGINE 5 Install the upper intake manifold Position the upper intake manifold gaskets and the intake manifold and loosely install the bolts 6 Install the thermostat gasket and the thermostat housing and loosly install the bolts 7 NOTE Be sure to tighten the bolts in two stages Tighten the bolts in the sequence shown Stage 1 Tighten to 2 Nm 18 lb in Stage 2 Tighten to 20 30 Nm 15 22 lb ft 46 WSG 1068 ENGINE 8 Install the heater water hose and position the clamp 9
45. Remover and the Impact Slide Hammer to remove the crankshaft rear oil seal 6701 17 Remove the bolts and remove the crankshaft rear oil seal retainer plate 18 Mount the engine on an engine stand 19 Remove the Modular Lifting Bar 104 WSG 1068 ENGINE Engine Disassembly 1 With the engine on the engine stand remove the engine wiring harness 105 WSG 1068 ENGINE 2 Remove the bolts the oil pan 6675 and the oil pan gasket 6710 3 Remove the two bolts and nut retaining the oil pump screen cover and tube 6622 and remove the oil pump screen cover and tube 106 WSG 1068 ENGINE 4 NOTE The bolts are a part of the valve cover 6582 and are not to be removed LH is shown RH is similar Fully loosen the sixteen bolts and remove the valve cover gasket 6584 107 WSG 1068 ENGINE 5 Remove the drive belt 6 Remove the water pump pulley 8509 1 Remove the four bolts 2 Remove the water pump pulley 7 Remove the four bolts from the water pump 8 Remove the A water pump 8501 from the B cylinder block 6010 108 WSG 1068 ENGINE 9 Remove the crankshaft pulley bolt 6A340 Use the Crankshaft Damper Remover to remove the crankshaft pulley 6312 10 Use the A Front Cover Seal Remover to remove the B crankshaft front seal 6700 11 Remove the engine front cover fasteners 12 Remove the engine front cover 6019 from the front cover to cylind
46. Use the Valve Spring Compressor to compress the valve springs 6513 and remove the camshaft roller followers CAUTION The caps must be marked for installation in their original location or damage to the engine may occur 7 Remove the bolts the camshaft bearing caps 6B280 and the camshaft 6250 from the cylinder block 6010 Camshaft Installation 1 Lubricate the camshaft journals and bearing caps Use Super Premium SAE 5W30 Motor Oil D9AZ 19579 A or equivalent meeting Ford specification WSS M2C153 G 78 WSG 1068 ENGINE 2 Install the bearing caps in their original locations and the bolts 3 Tighten the bolts in the sequence shown 79 WSG 1068 ENGINE 4 Use the Valve Spring Compressor to compress the valve springs and install the camshaft roller followers 5 Lubricate the balance shaft journals with engine oil Use Super Premium SAE 5W30 Motor Oil D9AZ 19579 A or equivalent meeting Ford specification WSS M2C153 G 6 Using the index mark on the balance shaft mark the corresponding teeth on the gear with chalk 7 Position the balance shaft on the journals 8 Align the balance shaft timing marks as shown Align the chalk mark on the balance shaft with the camshaft timing mark as shown 80 WSG 1068 ENGINE 9 Lubricate the balance shaft journals with engine oil Use Super Premium SAE 5W30 Motor Oil D9AZ 19579 A or equivalent meeting Ford specification WSS M2C153 G 10 Po
47. WSG 1068 STARTER SYSTEM GENERAL INFORMATION The function of the starting system is to crank the engine at a speed fast enough to permit the engine to start Heavy cables connectors and switches are used in the starting system because of the large current required by the starter while it is cranking the engine The amount of resistance in the starting circuit must be kept to an absolute minimum to provide maximum current for starter operation A discharged or damaged battery loose or corroded connections or partially broken cables will result in slower than normal cranking speeds and may even prevent the starter from cranking the engine The starting system includes the permanent magnet gearreduction starter motor with a solenoid actuated drive the battery a remote control starter switch part of the ignition switch the starter relay the heavy circuit wiring and may include starter lock out controlled by the GCP through a starter lockout relay Field Service Sequence Of Operation 1 The ignition switch is turned to the START position 2 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 3 The iron plunger core is drawn into the solenoid coil 4 A lever connected to the drive assembly engages the drive pinion gear to the flywheel ring rear 5 When the iron plunger core is all the way into the coil its conta
48. and finish Most original equipment fasteners English or Metric system are identified with markings or numbers indicating the strength of the fastener These markings are described in the pages that follow Attention to these markings is important to ensure that the proper replacement fasteners are used Further some metric fasteners especially nuts are colored blue This metric blue identification is in most cases a temporary aid for production start up and color will generally revert to normal black or bright after start up English or Metric system fasteners are available through your Ford Parts and Service operation NOMENCLATURE FOR BOLTS The Property class is an Arabic numeral distinguishable from the slash SAE English grade system The length of all bolts is measured from the underside of the head to the end 301 WSG 1068 METRICS BOLT STRENGTH IDENTIFICATION English System English inch bolts Identification marks correspond to bolt strength increasing number of slashes represent increasing strength Metric System Metric mm bolts Identification class numbers correspond to bolt strength increasing numbers represent increasing strength Common metric fastener bolt strength property are 9 8 and 10 9 with the class identification embossed on the bolt head HEX NUT STRENGTH IDENTIFICATION 302 WSG 1068 METRICS OTHER TYPES OF PARTS Metric identification schemes vary by type of part most often a varia
49. assembly turn the crankshaft using a socket or ratchet 6 Zero the dial indicator Continue to rotate the crankshaft slowly until the camshaft lobe is in the fully raised position highest indicator reading NOTE If the lift on any lobe is below specified service limits the camshaft and any component operating on worn lobes must be replaced 7 Compare the total lift recorded on the dial indicator with specifications 8 To check the accuracy of the original dial indicator reading continue to rotate the crankshaft until the indicator reads zero 9 Remove the dial indicator adapter and auxiliary starter switch CAUTION After installing rocker arms do not rotate the crankshaft until lash adjusters have had sufficient time to bleed down To do otherwise may cause serious valve damage Manually bleeding down lash adjusters will reduce waiting time 10 Install the rocker arm seats rocker arms and rocker arm seat bolts 11 Install the valve covers 12 Install the spark plugs 8 WSG 1068 GENERAL INFORMATION Hydraulic Lash Adjuster Hydraulic lash adjuster noise can be caused by any of the following excessive collapsed lash adjuster gap sticking lash adjuster plunger lash adjuster check valve not functioning properly air in lubrication system leakdown rate too rapid excessive valve guide wear Excessive collapsed lash adjuster gap can be caused by loose rocker arm seat bolts nuts incorrec
50. at 12 o clock 2 NOTE Do not turn the crankshaft until otherwise instructed Install the head gasket over the dowel pins 87 WSG 1068 ENGINE 3 NOTE Head bolts are torque to yield and must be replaced whenever cylinder head is removed Install the cylinder head on the head gasket and loosely install new bolts The LH is shown the RH is similar 4 NOTE Be sure to tighten the bolts in three stages Stage 1 Tighten to 37 43 Nm 27 32 lb ft Stage 2 Tighten an additional 85 degrees to 95 degrees Stage 3 Tighten an additional 85 degrees to 95 degrees 5 Install the timing chains refer to Drive Components in this section 6 Install the intake manifold refer to Intake Manifold Variable Resonance Induction System VRIS in this section 88 WSG 1068 ENGINE 1 Remove the bolt and remove the oil level indicator tube 6754 2 Inspect the oil level indicator tube for damage 1 Follow the removal procedure in reverse order 2 Replace and lubricate the O rings with Super Premium SAE 5W30 Motor Oil D9AZ 19579 A or equivalent meeting Ford specification WSS M2C153 G 3 Replace oil level indicator oil dipstick 89 WSG 1068 ENGINE 1 Disconnect the battery ground cable 14301 2 Partially drain the radiator 8005 and disconnect the upper radiator hose 8260 at the radiator 3 Drain the engine oil and remove the oil bypass filter 6714 4 Remove the nuts retaining the
51. causes a low resistance of 70 ohms at 130 C 266 F The GCP supplies a 5 volt signal to the ECT sensor through resistors in the GCP and measures the voltage The signal voltage will be high when the engine is cold and low when the engine is hot By measuring the voltage the GCP calculates the engine coolant temperature Engine coolant temperature affects most of the systems that the GCP controls After engine start up the temperature should rise steadily to about 85 C 185 F It then stabilizes when the thermostat opens If the engine has not been run for several hours overnight the engine coolant temperature and intake air temperature displays should be close to each other A fault in the engine coolant sensor circuit will set a DTC 221 or DTC 222 256 WSG 1068 ENGINE CONTROLS Cylinder Head Temperature CHT Sensor The Cylinder Head Temperature CHT Sensor is a thermistor which changes its resistance based on the temperature of cylinder head Low temperature produces a high resistance of 100 000 ohms at 40 C 40 F High temperature causes a low resistance of 70 ohms at 130 C 266 F The GCP supplies a 5 volt signal to the sensor through a resistor in the GCP and monitors the signal voltage The signal voltage will be high when the cylinder head is cold and low when the cylinder head is hot By measuring the voltage the GCP calculates the cylinder head temperature The CHT sensor signal is used to adjust spark
52. front engine support insulator 6038 to the front engine support bracket 6028 The RH is shown the LH is typical 90 WSG 1068 ENGINE 5 Remove the flywheel inspection plate 6 Remove the bolts and partially lower the oil pan 6675 91 WSG 1068 ENGINE 7 Remove the two bolts and the nut retaining the oil pump screen cover and tube 6622 and let them drop into the oil pan 8 Remove the oil pan and oil pan gasket 6710 from the rear of the engine 9 Clean the mating surfaces and thoroughly clean the oil pan 1 Install the oil pump screen cover and tube 2 CAUTION Mating parts must make contact to each other within 4 minutes and connecting bolts must be torqued within 15 minutes after applying sealant Failure to follow this procedure can cause future oil leakage Use silicone gasket and sealant F6AZ 19562 AA or equivalent meeting Ford specification WSE M4G323 A6 NOTE Sealant must be removed and area cleaned with solvent if above instructions are not followed Use metal surface cleaner F4AZ 19A536 RA or equivalent meeting Ford specification WSE M5B292 A 92 WSG 1068 ENGINE 3 NOTE Be sure to tighten the bolts in three stages Replace oil pan and bolts Tighten the bolts in the sequence shown Stage 1 Tighten to 2 Nm 18 lb in Stage 2 Tighten to 20 Nm 15 lb ft Stage 3 Tighten an additional 60 degrees 4 Install oil drain plug 11 16 Nm 98 143 lb in 5 T
53. ignition must cycle from on to off and to start in order to restart the engine Note this strategy must be compatible with governor controllers 169 WSG 1068 IGNITION SYSTEM Electronic Engine Controls Refer to Section 08 of this manual Cylinder Head Temperature Sensor CHT Sensor The cylinder head temperature CHT sensor is a thermistor device in which resistance changes with temperature The electrical resistance of a thermistor decreases as temperature increases and increases as temperature decreases The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the GCP corresponding to temperature Thermistor type sensors are considered passive sensors A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the voltage signal at the GCP This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor The CHT sensor is installed in the aluminum cylinder head and measures the metal temperature The CHT sensor communicates an overheating condition to the GCP The GCP would then initiate a cooling strategy based on information from the CHT sensor A cooling system failure such as low coolant or coolant loss could cause an overheating condition As a r
54. key will toggle to the last screen you were on 286 WSG 1068 ENGINE CONTROLS Visual Inspection Perform a careful visual and physical engine inspection before performing any diagnostic procedure Perform all necessary repairs before proceeding with additional diagnosis this can often lead to repairing a problem without performing unnecessary steps Use the following guidelines when performing a visual physical inspection check Inspect engine for modifications or aftermarket equipment that can contribute to the symptom verify that all electrical and mechanical loads or accessory equipment is OFF or disconnected before performing diagnosis Inspect engine fluids for correct levels and evidence of leaks Inspect vacuum hoses for damage leaks cracks kinks and improper routing inspect intake manifold sealing surface for a possible vacuum leak Inspect PCV valve for proper installation and operation Inspect all wires and harnesses for proper connections and routing bent or broken connector pins burned chafed or pinched wires and corrosion Verify that harness grounds are clean and tight Inspect GCP sensors and actuators for physical damage Inspect GCP grounds for cleanliness tightness and proper location Inspect fuel system for adequate fuel level and fuel quality concerns such as proper octane contamination winter summer blend Inspect intake air system and a
55. lean condition low sensor signal voltage the GCP responds by increasing the on time of the fuel injectors thus enriching the mixture When the HO2S reports a rich condition high sensor signal voltage the GCP responds by reducing the on time of the fuel injectors thus leaning out the mixture Adaptive Learn Adaptive Learn is a fuel correction coefficient that is derived from the closed loop correction and is stored in the GCP s memory The normal purpose of the Adaptive Learn is to compensate fuel flow for the following Fuel composition variance Engine wear Component variation Component degradation The GCP system will operate in closed loop plus adaptive learn when the ECT reaches 165 F NOTE The adaptive learn coefficient will get erased if battery power falls below 9 5 volts GCP Service Precautions The GCP is designed to withstand normal current draws associated with engine operation When servicing the GCP observe the following guidelines Do not overload any circuit When testing for opens and shorts do not ground or apply voltage to any of the GCP s circuits unless instructed to do so When measuring voltages use only a digital voltmeter with an input impedance of at least 10 megohms Do not employ any non standard practices such as charging the battery with an arc welder Take proper precautions to avoid static damage to the GCP Refer to electrostatic Disc
56. not fully seated in the connector backed out Improperly formed or damaged terminals Improper contact tension All connector terminals in the problem circuit should be carefully checked Poor terminal to wire connections This requires removing the terminal from the connector body to check Improperly installed aftermarket equipment or accessories Operate the engine with accessories OFF and a suitable multimeter connected to the suspected circuit An abnormal voltage when the malfunction occurs is a good indication that there is a fault in the circuit being monitored 178 WSG 1068 IGNITION SYSTEM Engine Controls 179 WSG 1068 IGNITION SYSTEM Engine Sensors part of SK2U1L 12A200 BA 180 WSG 1068 IGNITION SYSTEM 42 Pin Engine Harness Connectors F8JL 14324 AC amp F8JL 14324 BA SH 4 5 06 42 pin engine to frame harness 6 8L GCP Engine to Frame Harness Pinout Harness Part F8JL 14324 AC or BA Pin Wire Color Description 1 Red Light Green 12 V switched 2 Tan Yellow Tachometer output 3 Pink Light Blue RS232 Rx Self Test Input 4 Not populated Brake input 5 Pink Black To fuel pump positive 6 Pink Light Green To MIL 7 Y Bk or BR W Fuel select 8 Yellow Not used 9 Yellow Not used 10 Not populated Aux Analog PUD1 11 Tan Orange RS232 Tx 12 Not populated FPP2 13 Red Light Blue Not used 14 Light Blue Black FPP1 15 Dark Blue To
57. pipe or other concerns will cause the needle to slowly drop to 0 kPa 0 in Hg The needle then may slowly rise Excessive exhaust clogging will cause the needle to drop to a low point even if the engine is only idling When vacuum leaks are indicated search out and correct the cause Excess air leaking into the system will upset the fuel mixture and cause concerns such as rough idle missing on acceleration or burned valves If the leak exists in an accessory unit such as the power brake booster the unit will not function correctly Always fix vacuum leaks 4 WSG 1068 GENERAL INFORMATION Excessive Engine Oil Consumption The amount of oil an engine uses will vary with the way the equipment is driven in addition to normal engine to engine variation This is especially true during the first 340 hours or 16 100 km 10 000 miles when a new engine is being broken in or until certain internal engine components become conditioned Engines used in heavy duty operation may use more oil The following are examples of heavy duty operation severe loading applications sustained high speed operation Engines need oil to lubricate the following internal components cylinder block cylinder walls pistons piston pins and rings intake and exhaust valve stems intake and exhaust valve guides all internal engine components When the pistons move downward a thin film of oil is left on the cylinder walls As the
58. replace it 4 While the starter motor is running check the voltmeter and ammeter 5 If the voltage is lower than the 11 0 volts or the amperage is higher than 70 amps replace the starter motor NOTE Service parts for rebuilding permanent magnet starter are not available from Ford Power Products 1Rotunda 1 800 578 7375 238 WSG 1068 STARTER SYSTEM Starter No Load Test CAUTION Make sure that the starter is securely mounted in bench vise while energizing as starter will move or jump Wire Color Relay Terminal Circuit Description Lt Bl Pink 30 Voltage to Starter Red Lt Gn 86 Relay Coil Power Lt Gn Pr 85 To GCP Lt Bl Pink 87A Ignition Feed W Pink 87 Auxiliary Run Output NOTE All readings are made with connector attached to relay and back probing connector using a paper clip and fully charged battery 239 WSG 1068 STARTER SYSTEM System Inspection and Verification CAUTION When disconnecting the plastic hardshell connector at the solenoid S terminal grasp the plastic connector and pull lead off DO NOT pull separately on lead wire WARNING WHEN SERVICING STARTER OR PERFORMING OTHER WORK IN THE VICINITY OF THE STARTER BE AWARE THAT THE HEAVY GAUGE BATTERY INPUT LEAD AT THE STARTER SOLENOID IS ELECTRICALLY HOT AT ALL TIMES NOTE Be sure to disconnect battery negative cable before servicing starter 1 Inspect starting system for loose connections
59. soldered components on the GCP board Do not open the replacement part package until the part is ready to be installed Before removing the part from the package ground the package to a known good ground on the equipment If the part has been handled while sliding across a seat while sitting down from a standing position or while walking a distance touch a known good ground before installing the part 261 WSG 1068 ENGINE CONTROLS Diagrams and Schematics Symbols 262 WSG 1068 ENGINE CONTROLS GCP Power Distribution Box 263 WSG 1068 ENGINE CONTROLS Wire Colors Revision Level The following wiring schematics are taken from the wiring diagram labeled below 264 WSG 1068 ENGINE CONTROLS Power Distribution 265 WSG 1068 ENGINE CONTROLS Ignition System 266 WSG 1068 ENGINE CONTROLS Starting System 267 WSG 1068 ENGINE CONTROLS Charging System 268 WSG 1068 ENGINE CONTROLS Engine Controls Sensors 1 of 2 269 WSG 1068 ENGINE CONTROLS Engine Controls Sensors 2 of 2 270 WSG 1068 ENGINE CONTROLS Fuel Injectors 271 WSG 1068 ENGINE CONTROLS Engine Controls Actuator Data Link Connector DLC WSG 1068 ENGINE CONTROLS 272 Engine Controls Dry Fuel EPR 273 WSG 1068 ENGINE CONTROLS Engine Component Locator View 274 WSG 1068 ENGINE CONTR
60. speed to close the safety switch FUEL SYSTEMS FIELD CALIBRATIONS GENERAL When performing field calibrations on LPG amp NG systems it should be noted that improper fuel calibrations and or improper hardware installation may result in decreased durability life of the cylinder head valve train Validation testing on the valve train was conducted in a controlled laboratory environment with proper air fuel distribution and proper air fuel ratios which fall within acceptable ranges 186 WSG 1068 FUEL SYSTEM System Operation Natural Gas Natural gas passes through a vacuum operated fuel shutoff valve into a regulator unit where it is converted into a low pressure gas This gas is then fed into the mixer where a vacuum operated gas metering valve ensures that the correct air to fuel ratio is maintained When the engine is switched off vacuum supply to the fuel shut off vacuum is disconnected and the valve closes cutting off the fuel supply to the regulator Should the engine stall the loss of vacuum will close the fuel shut off valve When starting the engine there is sufficient vacuum present even at cranking speed to open the fuel shut off valve The system is similar to the LPG system except a convertor vaporizer is not used and the coolan connections are also not needed A regulator is required and must be supplied by the OEM to suit the mains gas supply pressure 187 WSG 1068 FUEL SYSTEM DIAGNO
61. start switch S terminal 16 Red White Aux PWM 4 17 Not populated Not used 18 White Purple To fuel pump negative 19 Not populated Autocrank start 20 Not populated Not used 21 Not populated Aux PWM 5 22 Purple Not used 23 Not populated GVS 2 24 Tan Light Blue GVS 1 25 Black Yellow IVS 26 Dark Green White Oil pressure 27 Not populated Aux Out 2 28 Not populated CAN 29 Not populated CAN 30 Not populated Not used 31 Brown White 5v ref 32 Not populated Aux Analog PD1 33 Gray Red Analog return 34 Black White Not used 35 Not populated Roadspeed 36 Not populated Roadspeed 37 Dark Green Orange Analog aux PUD2 181 WSG 1068 IGNITION SYSTEM 90 Pin GCP Connector 182 WSG 1068 IGNITION SYSTEM Pinpoint Test A Ignition Check The ignition system check will verify the required inputs and outputs recommended by Engine Distributors Inc Always locate and inspect all power ground and terminal connections prior to the start of this test as failures and corrosion associated with these areas can adversely affect the engine to start properly Inspection and Verification 1 Visually inspect for obvious signs of mechanical and electrical damage 2 Visually inspect for and note auxiliary system connections not shown on the recommended wiring schematic 183 WSG 1068 IGNITION SYSTEM 184 WSG 1068 FUEL SYSTEM INDEX Subject General Information
62. timing according to the incoming air density Heated Oxygen Sensor HO2S The Heated Oxygen Sensor HO2S is mounted in the exhaust stream where it can monitor the oxygen content of the exhaust gas The oxygen present in the exhaust gas reacts with the sensor to produce a voltage output This voltage should constantly fluctuate from approximately 100mV to 900 mV when the engine is running in closed loop fuel control The Heated Oxygen Sensor HO2S voltage can be monitored on an IBM PC compatible computer with diagnostic software By monitoring the voltage output of the oxygen sensor the GCP calculates the pulse width command for the injectors to produce the proper combustion chamber mixture The 4 wire HO2S indicates whether the air fuel ratio is rich or lean with respect to stoichiometry The signal from this sensor contains valid air fuel ratio information only when the sensor element has reached its normal operating temperature The 4 wire HO2S also has an isolated case ground which goes to Signal Return SIGRTN either in the processor as a dedicated HO2S ground or as a jumper to SIGRTN in the wiring harness Low HO2S voltage indicates a lean mixture which will result in a rich command to compensate High HO2S voltage indicates a rich mixture which will result in a lean command to compensate Specifications Accuracy of measurement 1 5 Operating Temp Range 350 C to 850 C sensor tip Sensor Response Time
63. until the radiator level is OK 197 WSG 1068 COOLING SYSTEM Drive Belt Routing Cooling System Flushing Special Tool s Special Service Tools called for by the procedures can be obtained by calling 1 800 ROTUNDA 1 800 768 8632 198 WSG 1068 COOLING SYSTEM REMOVAL AND INSTALLATION Radiator Hose Removal Radiator hoses should be replaced whenever they become cracked rotted or have a tendency to collapse Drain the radiator into appropriate container then loosen the clamps at each end of the hose to be removed Slide the hose off the radiator connection and the engine water outlet connection upper hose or the water pump connection lower hose Radiator Hose Installation Position the clamps at least 1 8 inch from each end of the hose Coat the connection areas with an approved water resistant sealer and slide the hose on the connection Make sure the clamps are beyond the bead and placed in the center of the clamping surface of the connections Tighten the clamps Fill the radiator with the recommended permanent antifreeze and water 50 50 mixture Operate the engine for several minutes then check the hoses and connections for leaks Thermostat Removal WARNING AVOID INJURY FROM HOT COOLANT WHEN ENGINE IS HOT 1 Partially drain the cooling system For additional information refer to Cooling System Draining Filling and Flushing in this section 2 Disconnect the upper radiator hose 3 Remove the w
64. viewed with the edis_saplot software located in the Windows Start Programs FPP_Dis folder or the data can be viewed in Notepad or Excel Here is a sample of a plot Logging Logging variables means the variables are stored to the PC During logging there is no plot shown on the screen To log variables you must first TAG the variables by right clicking them same as plotting Next click on Plot Log and then Log Tags An Edis Log window will pop up You can type in a custom log File name or select a custom folder to save the log file to The default filename is edis log and the default folder is FPP_Dis The sample interval and time interval can also be changed from the default To start logging click on the START button You will see the progress bar moving from 0 to 100 When the logging is complete you can close the Edis Log box or start another log file If you start another log file you must change the Log File name or the first log file will be overwritten To view the contents of a saved log file you can use Notepad or Excel The following are examples showing the Edis Log box before starting a log file and during a log file 283 WSG 1068 ENGINE CONTROLS Ignition System Test The Spark Kill diagnostic mode allows the technician to disable the ignition on individual cylinders If the Spark Kill diagnostic mode is selected with the engine running below 1000 RPM the minimum throttle command w
65. 300 1500 msec Heater Current Draw 1 A steady state Voltage Output 0 450 mV lean exhaust gas 450 1000 mV rich exhaust gas 257 WSG 1068 ENGINE CONTROLS Temperature Manifold Absolute Pressure TMAP Sensor The Temperature Manifold Absolute Pressure TMAP Sensor responds to changes in intake manifold pressure vacuum The TMAP sensor signal voltage to the GCP varies from below 2 volts at idle high vacuum to above 4 volts with the ignition ON engine not running or at wide open throttle low vacuum The TMAP sensor consists of a pressure sensing element capacitor and signal conditioning electronics The capacitor has a vacuum pressure reference which results in one surface diaphragm of the capacitor being partially deflected Further changes in pressure produce corresponding changes in the deflection of the diaphragm and therefore a change in capacitance This capacitance change is converted to a frequency by the conditioning electronics The TMAP sensor is used to determine the following Engine vacuum level for engine control purposes Barometric pressure BARO Specifications Range of Measurement 1 7 15 2 psi Measurement Accuracy 0 2 psi Sensor Response Time 3 15 msec Resolution 0 02 psi Present design Silicon Capacitive Absolute Pressure SCAP sensor with a maximum operating temperature of 100 C The output is a 50 duty cycle wave form whose frequency
66. 34 WSG 1068 STARTER SYSTEM INDEX Subject General Information Sequence of Operation Jump Starting Negative Grounded Battery Diagnosis and Testing Starter Load Test Bench Tests Starter No Load Test System Inspection and Verification Symptom Chart Pinpoint Test A Starter Lockout Relay Check Pinpoint Test B Starter Does Not Crank
67. 5 216 216 217 217 218 218 220 221 222 223 223 225 225 226 226 227 227 227 228 230 233 190 WSG 1068 COOLING SYSTEM INDEX CONT Subject Specifications General Specifications Torque Specifications Page 234 234 191 WSG 1068 COOLING SYSTEM GENERAL INFORMATION Engine Cooling Walter C Avrea the owner of patents 3 601 181 and RE27 965 has granted Ford Motor Company rights with respect to cooling systems covered by these patents The cooling system components are Cylinder head temperature sensor CHT sensor Water thermostat and gasket assembly Water pump assembly 192 WSG 1068 COOLING SYSTEM Coolant Flow is as follows The water pump 8501 circulates the coolant From the water pump to the engine block and the cylinder heads 6049 to the thermostat Thermostat closed the coolant returns to the water pump through bypass hose Thermostat open the coolant flows back to the radiator To the radiator for heat rejection then back to the lower radiator hose From the lower radiator hose 8286 to the water pump Coolant Use a 50 50 mix of Ethylene Glycol Permanent Antifreeze and water This mixtu
68. 6 Invalid interrupt internal GCP failure DTC 601 Flash checksum invalid internal GCP failure DTC 604 RAM failure internal GCP failure Fault Low Rev Limit The engine RPM will be limited to a maximum of 1600 RPM If the Fault Low Rev Limit is active it will remain active until the active DTC goes away and the ignition input to the GCP usually the ignition switch is cycled DTC 2122 FPP1 high voltage DTC 2123 FPP1 low voltage DTC 2115 FPP1 higher than IVS limit DTC 2139 FPP1 lower than IVS limit DTC 2116 FPP2 higher than IVS limit DTC 2140 FPP2 lower than IVS limit DTC 2126 FPP1 higher than FPP2 DTC 2121 FPP1 lower than FPP2 DTC 1531 IVS Brake interlock failure Force to Idle The engine RPM will be limited to a maximum of 800 RPM If the Force to Idle is active it will remain active until the active DTC goes away DTC 2122 FPP1 high voltage DTC 2123 FPP1 low voltage DTC 2128 FPP2 high voltage DTC 2127 FPP2 low voltage DTC 2115 FPP1 higher than IVS limit DTC 2139 FPP1 lower than IVS limit DTC 2116 FPP2 higher than IVS limit DTC 2140 FPP2 lower than IVS limit DTC 2126 FPP1 higher than FPP2 DTC 2121 FPP1 lower than FPP2 Intermittent MIL Conditions that are only present from time to time are called intermittents To resolve intermittents perform the following steps 1 Evalua
69. AKING THE FINAL CABLE CONNECTION COULD CAUSE AN ELECTRICAL SPARK NEAR THE BATTERY AND COULD CAUSE AN EXPLOSION REFER TO WARNING AT THE BEGINNING OF THE JUMP STARTING PROCEDURE WARNING WHEN SERVICING STARTER OR PERFORMING OTHER UNDERHOOD WORK IN THE VICINITY OF THE STARTER BE AWARE THAT THE HEAVY GAUGE BATTERY INPUT LEAD AT THE STARTER SOLENOID IS ELECTRICALLY HOT AT ALL TIMES NOTE Be sure to disconnect battery negative cable before servicing starter 2 Make jumper cable connections a Connect one end of first jumper cable to positive 1 terminal of discharged battery and other end of positive 2 terminal of booster battery b Connect one end of second jumper cable to negative 3 terminal of booster battery Connect other end to an engine bolthead or good metallic contact spot on engine 4 of equipment to be started NOT TO NEGATIVE BATTERY TERMINAL c Make sure jumper cables are not in way of moving engine parts d Start engine of vehicle with good battery Run engine at a moderate speed e Start engine of vehicle with discharged battery Follow starting instructions in the Owner Guide 3 Completely discharged batteries may require an electrical load to initialize charging 4 Remove cables in exact REVERSE sequence Begin by removing negative cable from engine of vehicle If the starter does not turn the engine over even with the booster battery attached refer to On Vehicle Testing 237
70. AT is greater than 200 F DTC 327 Knock sensor open 1 6L and 4 2L only DTC 326 Excessive knock signal 1 6L and 4 2L only DTC 2122 FPP1 high voltage DTC 2123 FPP1 low voltage DTC 2128 FPP2 high voltage DTC 2127 FPP2 low voltage DTC 1531 IVS Brake interlock failure Power Derate 2 275 WSG 1068 ENGINE CONTROLS The actuator is limited to a maximum opening of 20 If Power Derate 2 is active it will remain active until the active DTC goes away and the igniti n input to the GCP usually the ignition switch is cycled DTC 2115 FPP1 higher than IVS limit DTC 2139 FPP1 lower than IVS limit DTC 2116 FPP2 higher than IVS limit DTC 2140 FPP2 lower than IVS limit DTC 2126 FPP1 higher than FPP2 DTC 2121 FPP1 lower than FPP2 DTC 1171 MegaJector delivery pressure higher than expected DTC 1172 MegaJector delivery pressure lower than expected DTC 1173 MegaJector communication lost DTC 1176 MegaJector internal actuator fault detection DTC 1177 MegaJector internal circuitry fault detection DTC 1178 MegaJector internal communication fault detection DTC 606 COP failure Internal GCP failure DTC 1612 RTI 1 loss internal GCP failure DTC 1613 RTI 2 loss internal GCP failure DTC 1614 RTI 3 loss internal GCP failure DTC 1615 A D loss internal GCP failure DTC 161
71. BE AWARE THAT HEAVY GAUGE LEADS OR CONNECTED DIRECTLY TO THE BATTERY MAKE SURE PROTECTIVE CAPS ARE IN PLACE WHEN MAINTENANCE IS COMPLETE FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY 1 Disconnect the battery ground cable 2 Raise and support the vehicle or equipment 3 Remove the starter motor solenoid terminal cover 11N087 4 Disconnect the starter motor electrical connections 1 Remove the two nuts 2 Remove the battery cable 3 Remove the starter solenoid wire 5 Remove the nut and the starter motor ground cable when equipped 248 WSG 1068 STARTER SYSTEM Starter Motor Installation 6 Remove the bolt and nut 7 Remove the starter motor WARNING WHEN CARRYING OUT MAINTENANCE ON THE STARTER SYSTEM BE AWARE THAT HEAVY GAUGE LEADS ARE CONNECTED DIRECTLY TO THE BATTERY MAKE SURE PROTECTIVE CAPS ARE IN PLACE WHEN MAINTENANCE IS COMPLETE FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY NOTE It is recommended that wiring service kit F2PZ 11K162 A be used which includes a 70 inch long 12 gauge wire a terminal nut a terminal cover four tie wraps and insulation instructions 1 Install the starter motor 1 Position the starter motor 2 Install the bolts 249 WSG 1068 STARTER SYSTEM 2 Connect the starter motor electrical connections 1 Position the starter solenoid wire 2 Position the battery cable 3 Install the nuts 3 Install the s
72. Drain the cooling system For additional information refer to Cooling System Draining Filling and Flushing page 05 05 2 Remove the engine cooling fan 3 Remove the drive belt For additional information refer to Fan Drive Belt page 05 12 4 Remove the water pump pulley 8509 Remove the water pump pulley 5 Remove the water pump bolts 6 Remove the A water pump from the B cylinder block Clean and inspect the mating surfaces Water Pump Installation 1 CAUTION Cooling systems are recommended to be filled with Motorcraft Premium Engine Coolant VC 4 A meeting Ford specification ESE M97B44 A green color Do not mix coolant types Install the water pump 1 Lubricate the new O ring seal using engine coolant and install the O ring seal onto the water pump 2 Position the water pump into the engine block and heater water outlet tube 3 Install the bolts 204 WSG 1068 COOLING SYSTEM 2 Position the pulley onto the water pump 3 Install the fan spacer and fan 4 Install the drive belt 5 Refill the cooling system For additional information refer to Cooling System Draining Filling and Flushing in this section 205 WSG 1068 COOLING SYSTEM DIAGNOSING AND TESTING Refer to the following Diagnosis Chart for cooling system problems their possible cause and recommended correction Refer to the pertinent part for testing and repair The most frequent cooling system complaints ar
73. FF If not the GCP is faulty When this test is completed make sure that you clear the DTC from memory An intermittent MIL with no stored DTC may be caused by the following Ignition coil shorted to ground and arcing at plugs MIL circuit to GCP shorted to ground Poor GCP grounds 287 WSG 1068 ENGINE CONTROLS Symptom Charts NOTE If you have a symptom of the pedal not working and no DTC is set go to the voltage screen and check pedal voltage If pedal voltage is 75 1 25 volts and idle validation switch says you re at idle replace the pedal NOTE Items listed in the possible cause column generally do not set a diagnostic trouble code DTC orilluminate the MIL light NOTE EDI engines are used in many different applications and equipment When performing any system diagnosis be aware of any OEM inputs or equipment monitoring devices that may have an effect on the engine s performance or any of the engine s operating systems Engine Performance No Load 288 WSG 1068 ENGINE CONTROLS Engine Performance While Under Load 289 WSG 1068 ENGINE CONTROLS Engine Concerns 290 WSG 1068 ENGINE CONTROLS Engine Control Module GCP Diagnostic Trouble Codes CAUTION When checking codes with the diagnostic software the DTC terminal can NOT be grounded CAUTION Removing battery power before accessing diagnostic program will erase all codes recorded This section
74. N Do not scratch the cylinder walls or crankshaft journals with the connecting rod 6200 Once the connecting rod is seated on the crankshaft journal remove the connecting rod guide tools 13 CAUTION The rod cap installation must keep the same orientation as marked during disassembly NOTE The connecting rod caps are of the cracked design and must mate with the connecting rod ends Excessive bearing clearance will result if not mated properly Install the connecting rod bearings position the connecting rod cap and loosely install the two new bolts 14 NOTE Be sure to tighten the bolts in two stages Tighten the connecting rod bolts in the sequence shown Stage 1 Tighten to 40 45 Nm 30 33 lb ft Stage 2 Tighten an additional 90 degrees to 120 degrees 15 Rotate the crankshaft and repeat the procedure to position each connecting rod at bottom dead center until all bolts are tightened to specification 133 WSG 1068 ENGINE 16 Install the oil filter adapter 6881 17 Install the front engine support insulators 6038 18 Install the lower crankshaft bearing supports and tighten fasteners in the sequence shown 134 WSG 1068 ENGINE 19 Install the oil level indicator tube 6754 20 Position the oil pump 6600 and install the bolts loosely Tighten the bolts in the sequence shown 21 Rotate the crankshaft to position the keyway at 12 o clock NOTE After crankshaft has been posi
75. N IS IN THE OFF POSITION THEREFORE CARE SHOULD BE TAKEN TO ENSURE THAT THE ELECTRIC COOLING FAN IS COMPLETELY DISCONNECTED WHEN WORKING UNDER THE HOOD 2 WSG 1068 GENERAL INFORMATION Battery Handling and Charging The handling and correct use of lead acid batteries is not as hazardous provided that sensible precautions are observed and that operatives have been trained in their use and are adequately supervised It is important that all labelling on the battery is carefully read understood and complied with The format of the following symbols and labels is common to most brands of lead acid battery NOTE Observe all manufacturers instructions when using charging equipment CAUTION Batteries should not be charged in the vehicle or equipment May damage electrical components 3 WSG 1068 GENERAL INFORMATION Forward This book contains operating and maintenance instructions for the engine s listed on the title page The life of your engine unit and the delivery of the high performance built into it will depend on the care it receives throughout its life It is the operator s responsibility to ensure that the engine is correctly operated and that the maintenance operations outlined in this book are carried out regularly after the specified hours of operation have been reached We consider it to be in your interests to enlist the aid of an authorized EDI Distributor not only when repairs are required but also for regular main
76. NGINE Timing Drive Components Removal Special Tool s Special Service Tools called for by the procedures can be obtained by calling 1 800 ROTUNDA 1 800 768 8632 1 Remove the engine front cover 6019 refer to Engine Front Cover in this section 2 Remove the crankshaft sensor ring from the crankshaft 6303 3 Remove the six bolts and remove the balance shaft bearing caps 63 WSG 1068 ENGINE 4 Remove the balance shaft 5 CAUTION Unless otherwise instructed at no time when the timing chains 6268 are removed and the cylinder heads 6049 are installed may the crankshaft or camshaft 6250 be rotated Severe piston 6108 and valve damage could occur Use the Crankshaft Holding Tool to position the crankshaft as shown 64 WSG 1068 ENGINE 6 Install the Camshaft Holding Tools on the camshafts 7 Remove the bolts and the timing chain tensioners 6L266 Remove the timing chain tensioner arms 6L253 from the dowel pins 65 WSG 1068 ENGINE 8 Remove the LH and RH timing chain and the crankshaft sprockets 6306 1 Remove the RH timing chain from the camshaft sprocket 6256 2 Remove the RH timing chain and outer crankshaft sprocket from the crankshaft 3 Repeat for the LH timing chain and crankshaft sprocket 66 WSG 1068 ENGINE 9 Remove the timing chain guides 6K297 Remove the bolts Remove the timing chain guides Timing Drive Components Installat
77. NY FUEL RELATED COMPONENTS HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND CAN BE IGNITED RESULTING IN POSSIBLE PERSONAL INJURY 2 Remove the intake manifold 9424 refer to Intake Manifold Variable Resonance Induction System VRIS in this section 3 Remove the timing chains 6268 refer to Timing Drive Components in this section 4 Compress and slide the hose clamp back and remove the evaporation water hose 18472 if so equipped 5 Install the Lifting Handles 6 CAUTION These bolts must be replaced with new bolts They are tighten to yield designed and cannot be reused Remove the bolts and the cylinder head 6049 Discard the head gasket 6051 the cylinder head bolts 6049 and clean the engine block surface The LH is shown The RH is similar 86 WSG 1068 ENGINE 7 NOTE Sealant must be removed and area cleaned with solvent CAUTION Mating parts must make contact to each other within 4 minutes and connecting bolts must be torqued within 15 minutes after applying sealant Failure to follow this procedure can cause future oil leakage Use silicone gasket and sealant F6AZ 19562 AA or equivalent meeting Ford specification WSE M4G323 A6 NOTE Sealant must be removed and area cleaned with solvent if above instructions are not followed Use metal surface cleaner F4AZ 19A536 RA or equivalent meeting Ford specification WSE M5B292 A 1 Rotate the crankshaft 6303 to position the keyway
78. OLS DIAGNOSIS AND TESTING Diagnostic Approach Use the following step by step approach when diagnosing an engine performance problem 1 Verify the concern and determine if it is a deviation from normal operation 2 Once the concern has been verified preliminary checks can be done Conduct a thorough visual inspection be alert for unusual sounds or odors and gather diagnostic trouble code DTC information 3 If a diagnostic trouble code DTC is stored follow the designated DTC chart exactly to make an effective repair 4 If no DTC is stored select the symptom from the symptom charts and follow the suggestions to complete the repair 5 If no matching symptom is available analyze the complaint and develop a plan for diagnostics utilizing the wiring diagrams technical assistance and repair history 6 Some diagnostic charts contain diagnostic aids which give additional information about a system Be sure to use all of the information that is available to you GCP Diagnostic Overview FORD Diagnostic Trouble Codes are set when the FORD system GCP runs a diagnostic self test and the test fails When a DTC is set the FORD system GCP will illuminate the Malfunction Indicator Lamp MIL on the instrument panel and save the code in memory The FORD system GCP will continue to run the self test unless the DTC is an oxygen sensor lean oxygen sensor rich or a GCP related DTC If the system continues to fail the test the lamp will stay illu
79. S Crankshaft Position CKP Sensor Installation 1 Position CKP sensor and loosely install the 2 bolts NOTE The CKP sensor alignment tool is supplied with the new sensor and is not available separately 2 Adjust the CKP sensor with the alignment tool and tighten 2 bolts Tighten to 7 Nm 62 lb in 3 Connect CKP sensor electrical connector 4 Remove the M6 bolt 5 Remove special tool 303 507 6 Install the plug Tighten to 10 Nm 89 lb in 7 Reconnect or install any other component that was removed 8 Reconnect battery cable refer to section 6 296 WSG 1068 ENGINE CONTROLS Cylinder Head Temperature CHT Sensor Replacement 1 Disconnect battery ground cable refer to section 6 2 Remove or disconnect any component to allow access and removal of the CHT Sensor 3 Pull back the CHT sensor cover and disconnect electrical connector 4 Remove the CHT Sensor 5 Reverse procedure to install Tighten CHT sensor to 12 Nm 9 lb ft Heated Oxygen Sensor HO2S Replacement 1 Disconnect battery ground cable refer to section 6 2 Remove or disconnect any component to allow access and removal of the HO2S Sensor 3 Disconnect HO2S electrical connector NOTE Use penetrating oil to assist in removal 4 Remove HO2S sensor using special tool 303 476 5 Reverse procedure to install Apply a light coat of anti seize lubricant to the threads of the sensor Tighten sen
80. SIS AND TESTING Pinpoint Test A Fuel Pressure Check Inspection and Verification 1 Visually inspect for obvious signs of mechanical and electrical damage 2 Visually inspect for and note auxiliary system connections not shown on the Recommended Customer Connections Wiring Schematic Normal Operation Fuel pressure is customer supplied The following test is a generalized procedure which should be completed prior to all test 188 WSG 1068 FUEL SYSTEM 189 WSG 1068 COOLING SYSTEM INDEX Subject General Information Engine Cooling Coolant Flow Coolant Recycled Coolant Unsatisfactory Coolant Materials General Service Procedures Cooling System Draining Cooling System Filling
81. TIOUS TO AVIOD POTENTIAL SAFETY RISKS The following recommendations are for general guidance 1 Always wear correctly fitting protective clothing which should be laundered regularly Loose or baggy clothing can be extremely dangerous when working on running engines or machinery Clothing which becomes impregnated with oil or other substances can constitute a health hazard due to prolonged contact with the skin even through underclothing 2 So far as practicable work on or close to engines or machinery only when they are stopped If this is not practicable remember to keep tools test equipment and all parts of the body well away from the moving parts of the engine or equipment fans drive belts and pulleys are particularly dangerous The electric cooling fan used on some installations is actuated automatically when the coolant reaches a specified temperature For this reason care should be taken to ensure that the ignition isolating switch is OFF when working in the vicinity of the fan as an increase in coolant temperature may cause the fan suddenly to operate 3 Avoid contact with exhaust pipes exhaust manifolds and silencers when an engine is or has recently been running these can be very hot and can cause severe burns 4 Many liquids used in engines or vehicles are harmful if taken internally or splashed into the eyes In the event of accidentally swallowing gasoline petrol oil diesel fuel antifreeze battery acid etc do NOT encourage vom
82. TIVE GEAR MAY CAUSE BODILY HARM Remove the thermostat and immerse it in boiling water Replace the thermostat if it does not open at least 0 230 after one minute at 212 F If the problem being investigated is the inability of the cooling system to reach normal operating temperature the thermostat should be checked for leakage This may be done by holding the thermostat up to a lighted background Leakage of light all around the thermostat valve thermostat at room temperature indicates that the thermostat is unacceptable and should be replaced It is possible on some thermostats that a slight leakage of light at one or two locations on the perimeter of the valve may be detected This should be considered normal 208 WSG 1068 COOLING SYSTEM Radiator Leak Test Removed From Vehicle CAUTION Never leak test an aluminum radiator in the same water that copper brass radiators are tested in Flux and caustic cleaners may be present in the cleaning tank and they will damage aluminum radiators 1 Always install plugs in the oil cooler fittings before leak testing or cleaning any radiator 2 Clean the radiator before leak testing to avoid contamination of the tank 3 Leak test the radiator in clean water with 138 kPa 20 psi air pressure Engine Cylinder Head Temp CHT Sensor Circuit Description The engine cylinder head temperature CHT sensor is a thermistor which measures the temperature of the engine cylinder head T
83. TROLS Fuel Filter The fuel filter is an inline filter assembly Refer to Section 4 for information on relieving fuel pressure disconnecting fuel lines and fuel filter replacement Fuel Pump Electrical Circuit When the key is first turned ON the GCP energizes the fuel pump relay for two seconds to build up the fuel pressure quickly If the engine is not started within two seconds the GCP shuts the fuel pump off and waits until the engine is cranked When the engine is cranked and crankshaft position signal has been detected by the GCP the GCP supplies 12 volts to the fuel pump relay to energize the electric fuel pump An inoperative fuel pump will cause a no start condition A fuel pump which does not provide enough pressure will result in poor performance Coil on plug Ignition The coil on plug ignition system controls fuel combustion by providing a spark to ignite the compressed air fuel mixture at the correct time To provide optimum engine performance fuel economy and control of exhaust emissions the GCP controls the spark advance of the ignition system Coil on plug ignition has the following advantages over a mechanical distributor system No moving parts Less maintenance Remote mounting capability No mechanical load on the engine More coil cooldown time between firing events Elimination of mechanical timing adjustments Increased available ignition coil saturation time Elimina
84. Voltage Pinpoint Test B Voltage Output High Pinpoint Test C Indicator Lamp ON Engine Running Removal and Installation Generator Removal Generator Installation R Regulator Removal R Regulator Installation Specifications Torque Specifications Generator Parts Cross Reference Special Tools Page 236 236 237 238 238 239 239 239
85. WM9 short to power 2111 Unable to reach lower TPS 2112 Unable to reach higher TPS 2115 FPP1 higher than IVS limit 2116 FPP2 higher than IVS limit 2120 FPP1 invalid voltage and FPP2 disagrees with IVS 2121 FPP1 lower than FPP2 2122 FPP1 high voltage 2123 FPP1 low voltage 2125 FPP2 invalid voltage and FPP1 disagrees with IVS 2126 FPP1 higher than FPP2 2127 FPP2 low voltage 2128 FPP2 high voltage 2130 IVS stuck at idle FPP1 2 match 2131 IVS stuck off idle FPP1 2 match 2135 TPS1 2 simultaneous voltages out of range 2139 FPP1 lower than IVS limit 2140 FPP2 lower than IVS limit 2229 BP high pressure 2300 Primary Loop Open or Low side Short to Ground 2301 Primary Coil Shorted 2303 Primary Loop Open or Low side Short to Ground 2304 Primary Coil Shorted 2306 Primary Loop Open or Low side Short to Ground 2307 Primary Coil Shorted 2309 Primary Loop Open or Low side Short to Ground 2310 Primary Coil Shorted 2312 Primary Loop Open or Low side Short to Ground 2313 Primary Coil Shorted 2315 Primary Loop Open or Low side Short to Ground 2316 Primary Coil Shorted 2318 Primary Loop Open or Low side Short
86. aced downscale flicking of the needle indicates one or more burned or warped valves Insufficient hydraulic lash adjuster or hydraulic lash adjuster HLA clearance will also cause this reaction 7 POOR VALVE SEATING A small but regular downscale flicking can mean one or more valves are not seating 8 WORN VALVE GUIDES When the needle oscillates over about a 13 kPa 4 in Hg range at idle speed the valve guides could be worn As engine speed increases the needle will become steady if guides are responsible 9 WEAK VALVE SPRINGS When the needle oscillation becomes more violent as engine rpm is increased weak valve springs are indicated The reading at idle could be relatively steady 10 LATE VALVE TIMING A steady but low reading could be caused by late valve timing 11 IGNITION TIMING RETARDING Retarded ignition timing will produce a steady but somewhat low reading 12 INSUFFICIENT SPARK PLUG GAP When spark plugs are gapped too close a regular small pulsation of the needle can occur 13 INTAKE LEAK A low steady reading can be caused by an intake manifold or throttle body gasket leak 14 BLOWN HEAD GASKET A regular drop of fair magnitude can be caused by a blown head gasket or warped cylinder head to cylinder block surface 15 RESTRICTED EXHAUST SYSTEM When the engine is first started and is idled the reading may be normal but as the engine rpm is increased the back pressure caused by a clogged muffler kinked tail
87. ading from the highest dial indicator reading to figure the crankshaft runout If it is out of specification replace as necessary Cylinder Bore Taper Measure the cylinder bore at the top and bottom Verify the cylinder bore is within the wear limit The difference indicates the cylinder bore taper Bore the cylinder to the next oversize 14 WSG 1068 GENERAL INFORMATION Cylinder Bore Out of Round Measure the cylinder bore in two directions The difference is the out of round Verify the out of round is within the wear limit and bore the cylinder to the next oversize limit Piston Inspection Special Tool s CAUTION Do not use a caustic cleaning solution or a wire brush to clean the pistons or possible damage can occur 1 Clean and inspect the ring lands skirts pin bosses and the tops of the pistons If wear marks or polishing is found on the piston skirt check for a bent or twisted connecting rod 2 Use the Piston Ring Groove Cleaner to clean the piston ring grooves Make sure the oil ring holes are clean Piston Diameter Measure the piston skirt diameter Piston to Cylinder Bore Clearance Subtract the piston diameter from the cylinder bore diameter to find the piston to cylinder bore clearance 15 WSG 1068 GENERAL INFORMATION Piston Selection NOTE The cylinder bore must be within the specifications for taper and out of round before fitting a piston 1 Select a piston size based on
88. aft main bearing caps and bearings 2 Lay a piece of Plastigage across the face of each crankshaft main surface NOTE Do not turn the crankshaft while doing this procedure 3 Install and remove the crankshaft main bearing cap 4 Verify the crankshaft journal clearance If it is out of specification replace as necessary Bearing Inspection Inspect bearings for the following defects Possible causes are shown Cratering fatigue failure A Spot polishing improper seating B Scratching dirty C Base exposed poor lubrication D Both edges worn journal damaged E One edge worn journal tapered or bearing not seated F 13 WSG 1068 GENERAL INFORMATION Crankshaft End Play Special Tool s 1 Measure the crankshaft end play Use the Dial Indicator with Bracketry to measure crankshaft end play 2 Position the crankshaft to the rear of the cylinder block 3 Zero the Dial Indicator with Bracketry 4 Move the crankshaft to the front of the cylinder block Note and record the camshaft end play If camshaft end play exceeds specifications replace the crankshaft thrust washers or thrust bearing Crankshaft Runout Special Tool s NOTE Crankshaft main bearing journals must be within specifications before checking runout Use the Dial Indicator with Bracketry to measure the crankshaft runout Rotate the crankshaft and subtract the lowest dial indicator re
89. ak and Valve Stem Seal Test The cylinder leakage detector tests for engine oil leaks and checks the valve stem seals for leakage 1 Plug all crankcase openings except the one used for connecting the leakage detector 2 Connect the Engine Cylinder Leak Detection Air Pressurization Kit to a crankcase opening an oil level indicator tube is convenient Adjust the air pressure to approximately 34 kPa 5 psi 3 Using a solution of liquid soap and water brush the solution along the gasket sealing surfaces and bearing seals Look for bubbles or foam 4 Remove the spark plugs and rotate the crankshaft slowly with a wrench Check for large amounts of air escaping into the cylinders as each intake valve and exhaust valve opens 5 The spark plugs on the leaking cylinders will probably show deposits of burned oil Intake Manifold Vacuum Test Bring the engine to normal operating temperature Connect the Vacuum Pressure Tester to the intake manifold Run the engine at the specified idle speed The vacuum gauge should read between 51 74 kPa 15 22 in Hg depending upon the engine condition and the altitude at which the test is performed Subtract 4 0193 kPa 1 in Hg from the specified reading for every 304 8 m 1 000 feet of elevation above sea level The reading should be steady If necessary adjust the gauge damper control where used if the needle is fluttering rapidly Adjust the damper until the needle moves easily without excessive flutter
90. als 50 Align the balance shaft timing marks as shown 145 WSG 1068 ENGINE 51 Lubricate the balance shaft journals with engine oil Use Super Premium SAE 5W30 Motor Oil XO 5W30 QSP or equivalent meeting Ford specification WSS M2C153 G 52 Install the bearing caps and the bolts Tighten the bolts in the sequence shown 53 Position the crankshaft sensor ring 146 WSG 1068 ENGINE 54 CAUTION Mating parts must make contact to each other within 4 minutes and connecting bolts must be torqued within 15 minutes after applying sealant Failure to follow this procedure can cause future oil leakage Use silicone gasket and sealant F6AZ 19562 AA or equivalent meeting Ford specification WSEM4G323 A6 NOTE Sealant must be removed and area cleaned with solvent if above instructions are not followed Use metal surface cleaner F4AZ 19A536 RA or equivalent meeting Ford specification WSEM5B292 A NOTE The RH timing chain is removed for clarity Apply a bead of silicone along the cylinder headto block surface and the oil pan to cylinder block surface as specified 55 Install a new engine front cover gasket 6020 onto the engine front cover 6019 then position the engine front cover on the front cover to cylinder block dowel 6C002 147 WSG 1068 ENGINE 57 Tighten the fasteners in two stages refer to the preceding illustration Stage 1 Tighten fasteners 1 through 5 to 20 30 N
91. ankshaft Rear Oil Seal with retainer plate Removal Crankshaft Rear Oil Seal with retainer plate Installation Engine Removal Engine Disassembly Cylinder Head Disassembly Cylinder Head Assembly Engine Assembly Engine Installation 56 58 62 63 65 65 68 69 70 71 72 73 77 81 91 92 96 97 98 99 99 101 103 103 104 106 108 108 109 109 110 111 112 113 115 119 136 139 143 168 30 WSG 1068 ENGINE INDEX CONT Subject Page Specifications Torque Specifications
92. ankshaft Seal Replacer and Rear Crankshaft Seal Adapter to install the crankshaft rear oil seal 5 With the Rear Crankshaft Seal Adapter still installed use the Rear Crankshaft Slinger Replacer and Rear Crankshaft Seal Replacer to install the crankshaft oil slinger 6 Install the flywheel refer to Flywheel in this section 7 Connect the battery ground cable 100 WSG 1068 ENGINE 1 Disconnect the battery ground cable 14301 2 Remove the intake manifold 9424 refer to Intake Manifold Variable Resonance Induction System VRIS in this section 3 Remove the radiator upper and lower radiator supports 16138 4 Remove the radiator 8005 fan shroud 8146 and engine cooling fan 5 Remove the drive belt 8620 refer to Section 05 101 WSG 1068 ENGINE 6 At the oil cooler water inlet disconnect and set aside the lower radiator hose 8286 7 Disconnect the engine harness 8 Remove exhaust pipe nuts 9 Drain engine oil and remove the oil bypass filter 6714 10 Remove the starter motor 11002 refer to Section 07 102 WSG 1068 ENGINE 11 Remove the engine support insulator nuts 12 Install the Modular Lifting Bar 13 Remove the engine from the equipment 103 WSG 1068 ENGINE 14 Remove the bolts and remove the flywheel 15 Use the Rear Crankshaft Slinger Remover and the Impact Slide Hammer to remove the crankshaft oil slinger 6310 16 Use the Rear Crankshaft Seal
93. aps are numbered to keep in proper orientation Remove the bolts and the connecting rod caps Rotate the crankshaft so that the connecting rod is at bottom dead center Remove the bolts and discard them 118 WSG 1068 ENGINE 32 CAUTION Do not scratch the cylinder walls or the crankshaft journals with the connecting rod Remove the piston and rod assembly Use the Connecting Rod Guide Tools to guide the piston and rod assembly out of the cylinder 33 Repeat the previous steps until all ten piston and rod assemblies have been removed from the cylinder block 119 WSG 1068 ENGINE 34 Remove and discard the twelve cross mounted bolts 35 Remove the main bearing bolts and discard the bolts 36 Remove the main bearing cap dowel pins 120 WSG 1068 ENGINE 37 Remove the main bearing caps the lower crankshaft main bearings 6333 and the thrust washer 38 Remove the crankshaft and the crankshaft main bearings from the cylinder block 121 WSG 1068 ENGINE 1 Remove the Camshaft Holding Tool from the camshaft 6250 122 WSG 1068 ENGINE 2 CAUTION Do not remove the camshaft before removing the roller followers CAUTION Place the cylinder head on a cardboard or wood surface to prevent damage to the joint face Install the Valve Spring Spacer between the valve spring coils to prevent valve stem seal damage 3 Use the Valve Spring Compressor to compress the
94. ate RPM and crankshaft position Camshaft Position CMP Sensor The Camshaft Position CMP Sensor uses a variable reluctor sensor to detect camshaft position The CMP signal is created as piston 1 is a pre determined number of degrees after top dead center on the power stroke The Camshaft Position CMP Sensor sends a CMP signal to the GCP The GCP uses this signal as a sync pulse to trigger the injectors in the proper sequence The GCP uses the CMP signal to indicate the position of the 1 piston during its power stroke The CMP uses a Hall Effect sensor to measure piston position This allows the GCP to calculate true sequential fuel injection SFI mode of operation If the GCP detects an incorrect CMP signal while the engine is running DTC 245 will set If the CMP signal is lost while the engine is running the fuel injection system will shift to a calculated sequential fuel injection mode based on the last fuel injection pulse and the engine will continue to run As long as the fault DTC 244 is present the engine can be restarted It will run in the previously established injection sequence 255 WSG 1068 ENGINE CONTROLS Engine Coolant Temperature ECT Sensor The Engine Coolant Temperature ECT Sensor is a thermistor a resistor which changes value based on temperature mounted in the engine coolant stream Low coolant temperature produces a high resistance of 100 000 ohms at 40 C 40 F High temperature
95. ater outlet connection Remove the bolts Remove the water outlet connection 4 Remove the B O ring seal and the A water thermostat 8575 Discard the B O ring seal Thermostat Installation NOTE Thermostat must be installed as illustrated 1 Install the B water thermostat and use a new A Oring seal to position the B water thermostat in the C upper intake manifold 9424 2 Install the water outlet connection 1 Position the A water outlet connection on the B upper intake manifold 2 Install the bolts 3 Connect the upper radiator hose 4 Fill the cooling system For additional information refer to Cooling System Draining Filling and Flushing in this section 199 WSG 1068 COOLING SYSTEM With or Without Dry Fuel Evaporator Plumbing Removal of Heater Water Inlet Tube 18663 1 Drain the cooling system 2 Remove the upper and lower intake manifold together Refer to Section 01 for details 3 Remove the two studs securing the tube to the rear of the right side cylinder head and remove the tube 4 Inspect the water pump tube assembly o rings for damage Installation of Water Heater Return Tube Assembly with by pass Hose 1 Lightly lubricate the o rings prior to installing the water outlet tube 2 Install the heater water outlet tube 3 Install the water tube mounting studs 4 Install the lower and upper intake manifold Refer to Section 01 5 Install rubber cap an
96. ation D Both edges worn journal damaged E One edge worn journal tapered or bearing not seated F Roller Follower Inspection Inspect the roller for flat spots or scoring If any damage is found inspect the camshaft lobes and hydraulic lash adjusters for damage Hydraulic Lash Adjuster Inspection Inspect the hydraulic lash adjuster and roller for damage If any damage is found inspect the camshaft lobes and valves for damage 20 WSG 1068 GENERAL INFORMATION Valve Stem Diameter Measure the diameter of each intake and exhaust valve stem at the points shown Verify the diameter is within specification Valve Stem to Valve Guide Clearance Special Tool s NOTE Valve stem diameter must be within specifications before checking valve stem to valve guide clearance NOTE If necessary use a magnetic base 1 Install the Valve Stem Clearance Tool on the valve stem and install the Dial Indicator with Bracketry Lower the valve until the Valve Stem Clearance Tool contacts the upper surface of the valve guide 2 Move the Valve Stem Clearance Tool toward the Dial Indicator and zero the Dial Indicator Move the Valve Stem Clearance Tool away from the Dial Indicator and note the reading The reading will be double the valve stem to valve guide clearance Valves with oversize stems will need to be installed if out of specification Valve Inspection Inspect the following valve areas The end
97. b of the crankshaft sprocket facing inward 12 Position the timing chain on the camshaft sprocket Make sure the two copper colored links align with the camshaft sprocket timing mark 13 Check for proper alignment of all timing marks 71 WSG 1068 ENGINE Camshaft Assembly Timing Mark Alignment 72 WSG 1068 ENGINE Timing Chains Camshaft Gears and Crankshaft Gears Alignment 73 WSG 1068 ENGINE 14 Position the LH and RH timing chain tensioner arms on the dowel pins Position the timing chain tensioners and install the bolts 15 Remove the retaining pins from the RH and LH timing chain tensioners 74 WSG 1068 ENGINE 16 Remove the Camshaft Holding Tools from the camshafts 17 Install the crankshaft sensor ring on the crankshaft 18 Lubricate the balance shaft journals with engine oil Use Super Premium SAE 5W30 Motor Oil XO 5W30 QSP or equivalent meeting Ford specification WSS M2C153 G 19 Position the balance shaft on the journals 20 Align the balance shaft timing marks as shown 75 WSG 1068 ENGINE 21 Lubricate the bearing caps with engine oil Use Super Premium SAE 5W30 Motor Oil XO 5W30 QSP or equivalent meeting Ford specification WSS M2C153 G 22 Install the bearing caps the bolts and tighten the bolts in the sequence shown 23 NOTE The timing chain is removed for clarity CAUTION Mating parts must make contact to each other within 4 minutes and conn
98. be capable of reading milliamps and should have a 10amp capability NOTE If the meter settings need to be switched or the test leads need to be moved to another jack the jumper wire must be reinstalled to avoid breaking continuity 6 Remove the jumper wire NOTE Amperage draw will vary from engine to engine depending on the equipment package Compare to a similar engine for reference NOTE No engine application should have more than a 50 mA 0 050 amp draw 7 If the draw is found to be excessive pull fuses or disconnect suspected draws one at a time and note the current drop Do not reinstall the fuses or connections until you are finished testing 8 Check the wiring for any auxiliary circuits that run from the battery Disconnect these circuits if the draw is still excessive 226 WSG 1068 CHARGING SYSTEM Symptom Chart 227 WSG 1068 CHARGING SYSTEM Pinpoint Test A Generator Output Voltage Inspection and Verification 1 Visually inspect for obvious signs of terminal corrosion and electrical harness damage 2 Inspect fusible links and generator connector for bent or backed out connector pins or damage to wiring 3 Visually inspect for and note auxiliary system connections not shown on the Recommended Customer Connections Wiring Schematic Normal Operation With voltage applied to the generator I circuit the regulator is activated allowing current to flow from the sense A circuit to generator field coil Th
99. be the CHT sensor connector with a digital voltmeter and observe the voltage while moving connectors and wiring harnesses related to the CHT sensor A change in the voltmeter display will indicate the location of the fault 209 WSG 1068 COOLING SYSTEM CHT Sensor Data Temperature Sensor Characteristics 210 WSG 1068 COOLING SYSTEM V Ribbed Serpentine Drive Belt Cracks Across Ribs Normal Drive Belt Symptom Chart Chunks of Rib Missing Replace Belt 211 WSG 1068 COOLING SYSTEM Drive Tensioner Belt Length Indicator Automatic tensioners are calibrated at the factory to provide the correct amount of tension to the belt Unless a spring within the tensioner assembly breaks or some other mechanical part of the tensioner fails there is no need to check tensioners for proper tension The only mechanical check that need be made if you have any doubt about the tensioner function would be to remove the belt in the area of the tensioner to avoid belt contact then using the proper tool rotate the tensioner from its relaxed position through its full stroke and back to the relaxed position to assure that there is no stick grab bind and to assure that there is tension on the spring It is a normal condition for the tensioner to be moving under certain conditions when the engine is running If the tensioner meets this criteria it should be assumed to be a good tensioner Drive Belt Misalignment
100. c Inspection Kit A clear bright yellow or orange area will identify the leak For extremely small leaks several hours may be required for the leak to appear 4 If necessary pressurize the main oil gallery system to locate leaks due to improperly sealed loose or cocked plugs 5 Repair all leaks as required Pressure Method The crankcase can be pressurized to locate oil leaks The following materials are required to fabricate the tool to be used air supply and air hose air pressure gauge that registers pressure in 4 kPa 1 psi increments air line shutoff valve appropriate fittings to attach the above parts to oil fill PCV grommet hole and crankcase ventilation tube appropriate plugs to seal any openings leading to the crankcase a solution of liquid detergent and water to be applied with a suitable applicator such as a squirt bottle or brush Fabricate the air supply hose to include the air line shutoff valve and the appropriate adapter to permit the air to enter the engine through the crankcase ventilation tube Fabricate the air pressure gauge to a suitable adapter for installation on the engine at the oil filler opening Testing Procedure Open the air supply valve until the pressure gauge maintains 34 kPa 5 psi Inspect sealed or gasketed areas for leaks by applying a solution of liquid detergent and water over areas for formation of bubbles which indicates leakage Leakage Points Abov
101. camshaft sprocket slightly to obtain timing mark alignment Position the timing chain on the camshaft sprocket with the two copper chain links and the camshaft sprocket timing mark aligned 142 WSG 1068 ENGINE 42 CAUTION The camshaft sprocket can jump time if the Camshaft Holding Tool is not secured NOTE Be sure the copper chain link and the crankshaft sprocket timing mark are aligned NOTE The lower half of the timing chain must be positioned above the dowel Position the outer camshaft sprocket and the RH timing chain with the long hub of the camshaft sprocket facing inward 43 NOTE If necessary adjust the camshaft sprocket slightly to obtain timing mark alignment Position the RH timing chain on the camshaft sprocket Make sure the two copper colored links align with the camshaft sprocket timing mark 143 WSG 1068 ENGINE 44 As a post check verify timing mark alignment 45 Position the LH and RH timing chain tensioner arm 6L253 on the dowel pins Position the timing chain tensioners 6L266 and install the bolts 46 Remove both the RH and LH retaining pins from the timing chain tensioner assembly 144 WSG 1068 ENGINE 47 Remove the Camshaft Holding Tools from the camshafts 48 Lubricate the balance shaft journals with engine oil Use Super Premium SAE 5W30 Motor Oil XO 5W30 QSP or equivalent meeting Ford specification WSS M2C153 G 49 Position the balance shaft on the journ
102. cation Crankshaft Connecting Rod Journal Taper Measure the crankshaft rod journal diameters in two directions perpendicular to one another at each end of the connecting rod journal The difference in the measurements from one end to the other is the taper Verify measurement is within the wear limit Connecting Rod Cleaning CAUTION Do not use a caustic cleaning solution or damage to connecting rods can occur NOTE The connecting rod large end is mechanically split or cracked to produce a unique parting face This produces a locking joint Parts are not interchangeable Mark and separate the parts and clean with solvent Clean the oil passages 17 WSG 1068 GENERAL INFORMATION Connecting Rod Larger End Bore CAUTION The connecting rod bolts are torque to yield and must be discarded and replaced after this diagnostic test Measure the bore in two directions The difference is the connecting rod bore out of round Verify the outof round is within specification Piston Pin Diameter Measure the piston pin diameter in two directions at the points shown Verify the diameter is within specifications Connecting Rod Bushing Diameter Measure the inner diameter of the connecting rod bushing Verify the diameter is within specification Connecting Rod Bend Measure the connecting rod bend on a suitable alignment fixture Follow the instructions of the fixture manufacturer Verify the bend measuremen
103. ccur Install the water pump 1 Lubricate the new O ring seal using Premium Cooling Fluid E2FZ 19549 AA or equivalent meeting Ford specification ESE M97B44 A and install the O ring seal onto the water pump 2 Position the water pump into the cylinder block 3 Install the water pump retaining bolts 63 Lubricate the A engine front cover and the B front oil seal inner lip Use Super Premium SAE 5W30 Motor Oil XO 5W30 QSP or equivalent meeting Ford specification WSS M2C153 G 64 Use the A Crankshaft Seal Replacer Aligner to install the B crankshaft front seal 6700 into the C engine front cover 150 WSG 1068 ENGINE 65 CAUTION Mating parts must make contact to each other within 4 minutes and connecting bolts must be torqued within 15 minutes after applying sealant Failure to follow this procedure can cause future oil leakage Use silicone gasket and sealant F6AZ 19562 AA or equivalent meeting Ford specification WSEM4G323 A6 NOTE Sealant must be removed and area cleaned with solvent if above instructions are not followed Use metal surface cleaner F4AZ 19A536 RA or equivalent meeting Ford specification WSEM5B292 A Apply silicone to the Woodruff key slot on the crankshaft pulley 6312 Use Silicone Gasket and Sealant F6AZ 19562 A or equivalent meeting Ford specification WSEM4G323 A6 66 Use the Crankshaft Damper Replacer to install the crankshaft pulley 67 Tighten the crankshaft pul
104. contains circuit description information and troubleshooting charts on all the DTC s obtained by diagnostic software or a Malfunction Indicator Lamp MIL When diagnostic trouble codes are obtained by a Malfunction Indicator Lamp MIL the following sequence will be flashed 123 will flash 3 times to indicate the beginning of the flash code display sequence Any active DTC s will flash 3 times each 123 will flash 3 times indicating the end of the code display sequence If code 123 is the only code present the system does not have any active codes all systems are working fine If an active DTC is present refer to the corresponding DTC chart Begin with the lowest number code first NOTE If you have a symptom of the pedal not working and no DTC is set go to the voltage screen and check pedal voltage If pedal voltage is 75 1 25 volts and idle validation switch says you re at idle replace the pedal 291 WSG 1068 ENGINE CONTROLS Diagnostic Trouble Code 11 Intake cam distributor position 16 Never crank synced at start 24 Exhaust cam position 91 FP low voltage 92 FP high voltage 107 MAP Low Voltage 108 MAP High Pressure 111 IAT higher than expected 1 112 IAT low voltage 113 IAT high voltage 116 ECT higher than expected 1 117 ECT CHT Low Voltage 118 ECT CHT High Voltage
105. ct a remote starter switch between the starter motor solenoid S terminal and the battery positive terminal 3 Connect the 73 Digital Multimeter positive lead to the battery positive post Connect negative lead to the starter motor solenoid M terminal 4 E n gage the remote starter switch Read and record the voltage The voltage reading should be 0 5 volts or less 5 If the voltage reading is 0 5 volts or less Refer to Starter Motor Motor Ground Circuit on page 14 6 If the voltage reading is greater than 0 5 volts indicating excessive resistance move the 73 Digital Multimeter negative lead to the starter motor B terminal and repeat the test If the voltage reading at the B terminal is lower than 0 5 volts the concern is either in the connections at the starter motor solenoid or in the starter motor solenoid contacts 7 Remove the cables from the starter motor solenoid B S and M terminals Clean the cables and connections and reinstall the cables to the proper terminals Repeat Steps 3 through 6 If the voltage drop reading is still greater than 0 5 volts when checked at the M terminal or less than 0 5 volts when checked at the B terminal the concern is in the solenoid contacts Replace the starter motor 8 If the voltage reading taken at the starter motor solenoid B terminal is still greater than 0 5 volts after cleaning the cables and connections at the solenoid the concern is either in the positive ba
106. ct disc closes the circuit between the battery and the motor terminals 6 The current flows to the motor and the drive pinion gear drives the flywheel and the engine crankshaft 7 As current flows to the motor the solenoid pull in coil is bypassed 8 The hold in coil keeps the drive pinion gear engaged with the flywheel 9 The gear remains engaged until the ignition switch is released from the START position NOTE The GCP is programmed to lock the starter out when the engine is operating over 600 rpm and the following sequence takes place Starter Lockout Relay See page 07 6 for further details 1 During start up with key in the on position 12V B is applied to relay PIN 72 of the GCP Lt Gn Pr 2 With ignition switch turned to the crank position current flows from ignition switch to relay circuit 87A LB Pink 16G through relay and out circuit 30 LB Pink 16G to starter solenoid 3 The starter than should respond as in steps 2 through 9 The GCP keeps the starter relay closed until it reads 400 engine rpm Over 600 rpm the GCP grounds circuit causing the relay to open This will prevent starter engagement while engine is running NOTE An overrunning clutch in the drive assembly protects the starter from the excessive speeds during the brief period before the driver releases the ignition switch from the START position as the engine starts 236 WSG 1068 STARTER SYSTEM For cases of a starter that cranks the en
107. d battery positive voltage B applied to the coil primary circuit builds a magnetic field around the primary coil When the switch opens the power is interrupted and the primary field collapses inducing the high voltage in the secondary coil windings and the spark plug is fired A kickback voltage spike occurs when the primary field collapses 4 The GCP processes the CKP signal and uses it to drive the tachometer as the Clean Tach Out CTO signal Starting RPM The program strategy requires the engine to obtain a minimum of 100 140 RPM before the GCP will allow ignition spark to be generated Any failure with an auxiliary system can cause excessive engine crank load force which may cause the engine too not reach the required starting RPM Perform a thorough inspection of all auxiliary systems and components inspect for binding hydraulic pumps and misalignment of drive systems Camshaft Position Sensor The Camshaft Position CMP Sensor detects the position of the camshaft The CMP Sensor identifies when piston 1 is on its compression stroke The CMP Sensor is a magnetic transducer mounted on the engine front cover adjacent to the camshaft By monitoring a target on the camshaft sprocket the CMP sensor identifies cylinder one to the GCP The COP EI system uses this information to synchronize the firing of the individual coils 167 WSG 1068 IGNITION SYSTEM The Fuel Select Switch In the event that the engine is operate
108. d clamp on outlet tube if not using LPG or cab heater 6 Refill the cooling system 200 WSG 1068 COOLING SYSTEM Cylinder Head Temperature CHT Sensor Replacement 1 Remove the upper and lower intake manifold together For additional information refer to Section 01 2 Remove the cylinder head temperature CHT sensor 1 Disconnect the electrical connector 2 Remove the CHT sensor 3 To install reverse the removal procedure CAUTION Do not over torque May damage sensor Fan Drive Belt Removal and Installation 1 Rotate the drive belt tensioner counterclockwise and remove the drive belt 2 NOTE Refer to 05 9 for correct drive belt routing To install reverse the removal procedure 201 WSG 1068 COOLING SYSTEM Belt Tensioner Removal 1 Remove the drive belt 8620 For additional information refer to Fan Drive Belt page 05 12 2 Remove the belt tensioner 1 Remove the bolts 2 Remove the belt tensioner Belt Tensioner Installation 1 To install reverse the removal procedure 202 WSG 1068 COOLING SYSTEM Belt Idler Pulley Removal 1 Remove the fan drive belt 8620 off of the belt idler pulley 8678 For additional information refer to Fan Drive Belt page 05 12 2 Remove the bolt and the belt idler pulley Belt Idler Pulley Installation 1 To install reverse the removal procedure 203 WSG 1068 COOLING SYSTEM Water Pump Removal Material 1
109. d on alternate fuels such as natural gas compressed natural gas CNG or liquefied petroleum gas LPG timing can be modified with a Fuel Select Switch NOTE Fuel select switch is supplied by the customer Sends a signal to the GCP to adjust base timing for alternate fuel Is manually controlled With this system the GCP monitors the engine load speed operating temperature air intake temperature and decides what degree of spark advance is correct for all of the operating conditions Because timing is set for life inherently in the design of the engine and there are no moving parts in the ignition system itself no maintenance is required except for periodic spark plug checks The system provides for fixed spark advance at start up for cold weather starting and for average value default settings in case of component failure Particular attention has been given to spark optimization for excellent fuel economy and power in the warm up mode The spark plugs are paired so that one plug fires during the compression stroke and its companion plug fires during the exhaust stroke The next time that coil is fired the plug that was on exhaust will be on compression and the one that was on compression will be on exhaust The spark in the exhaust cylinder is wasted but little of the coil energy is lost Run Mode The GCP interprets engine speed above100 RPM as Run Mode The Base Spark Advance BSA is calculated by the GCP modul
110. diagnose harness faults associated with the Electronic Engine Control EC System The following techniques provide helpful reminders for diagnosing open circuits continuity shorts to ground and shorts to power NOTE The suspect circuit must be isolated before testing When disconnecting any harness connector always inspect for damaged or pushed out pins corrosion and loose wires Repair as necessary The digital multimeter must be set to the correct scale The techniques do not apply in all situations therefore it is necessary to follow each pinpoint test step accurately and completely General resistance and voltage values are specified below Always use the pinpoint test values if they differ Always turn the key to the OFF position unless directed otherwise by the pinpoint test Each of the following procedures will require the Global Control Platform GCP and component to be disconnected to isolate the harness Open Circuit Continuity Disconnect GCP Measure the harness resistance between the suspect circuit at the harness connector and the appropriate GCP harness connector pin The resistance must be less than 5 0 ohms Shorts to Ground Measure the harness resistance between the suspect circuit at the harness connector and a reliable ground B chassis ground or PWR GND The resistance must be greater than 10 000 ohms Shorts to Power Key ON to power up circuit Measure voltage between the
111. e indicator lamp stays on with engine running etc This information will aid in isolating the part of the system causing the symptom Voltage Regulator and Back of Governor 224 WSG 1068 CHARGING SYSTEM Visual Inspection Preliminary checks to the charging system should be made regardless of the fault condition These checks include 1 Check battery posts and cable terminals for clean and tight connections Clean the posts and the cables to ensure good electrical contact 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 Check the fuses fuse links and wiring to the generator to ensure that they are not burned or damaged This condition resulting in an open circuit or high resistance can cause erratic or intermittent charging system concerns 4 Check the battery voltage If the voltage is less than 12 3 volts with the engine and all accessories off charge battery before proceeding In order to check the generator the use of Rotunda Starting and Charging System Tester 078 00005 VAT 40 Rotunda Tools 1 800 578 7375 or equivalent is recommended Generator Output Test NOTE Refer to the test equipment user s manual for complete directions on examining the charging system 1 Switch the tester to ammeter function 2 Connect the positive and negative leads of the tester to the battery 3 Connect curr
112. e keys at the upper left corner or the page command to toggle the three main screens GAUGES FAULTS AND RAW VOLTS NOTE F9 key will toggle to the last screen you were on Data Stream Reading Sensor amp Actuator Values Most applicable sensor and actuator values are displayed on the Gauges Screen The display shows the voltage the FORD system GCP is reading and for sensors the sensor value in engineering units This is one of three main screens GAUGES FAULTS AND RAW VOLTS The GAUGES screen shows the following Manifold Absolute Pressure MAP Engine Coolant Temperature ECT Intake Air Temperature IAT Throttle Position TP Foot Pedal Position FPP Battery Voltage Engine speed RPM Exhaust Gas Oxygen HO2S Hour meter Number of continuous starts Run mode power mode and fuel type Use the keys at the upper left corner or the page command to toggle the three main screens GAUGES FAULTS AND RAW VOLTS NOTE F9 key will toggle to the last screen you were on NOTE If a DTC for a sensor is current the engineering value for that sensor may be a default limp home value and the voltage value will be the actual sensor voltage Use the voltage value when performing diagnostics unless directed to do otherwise by the diagnostic trouble tree 282 WSG 1068 ENGINE CONTROLS Plotting and Data Logging Recording the values and voltages can be a very use
113. e leakage and overheating Either of these problems will soon render the vehicle inoperable Visual Inspection Check for leakage at 1 All hoses and hose connections 2 Radiator seams radiator core and radiator drain petcock 3 All block core plugs and drain plugs 4 Edges of all cooling system gaskets 5 Water pump shaft and bushing NOTE A small amount of antifreeze coming out the water pump weep hole may be normal Most vehicles 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 NOTE A small amount of antifreeze coming out the water pump weep hole may be normal Examine oil dipstick for evidence of coolant contaminated engine oil white milky appearance 206 WSG 1068 COOLING SYSTEM Cooling System Visual Test Special Tool s Special Service Tools called for by the procedures can be obtained by calling 1 800 ROTUNDA 1 800 768 8632 WARNING NEVER REMOVE THE PRESSURE RELIEF CAP WHILE THE ENGINE IS OPERATING OR WHEN THE COOLING SYSTEM IS HOT MAY CAUSE PERSONAL INJURY OR DAMAGE TO COOLING SYSTEM OR ENGINE TO AVOID HAVING SCALDING HOT COOLANT OR STEAM BLOW OUT OF THE DEGAS BOTTLE WHEN REMOVING THE PRESSURE RELIEF CAP WAIT UNTIL THE ENGINE HAS COOLED DOWN TO
114. e Clearance Piston Selection Piston Ring End Gap Piston Ring to Groove Clearance Crankshaft Connecting Rod Journal Diameter Crankshaft Connecting Rod Journal Taper Connecting Rod Cleaning Connecting Rod Larger End Bore Piston Pin Diameter Connecting Rod Bushing Diameter Connecting Rod Bend
115. e Engine Examine the following areas for oil leakage valve cover gaskets intake manifold gaskets cylinder head gaskets oil bypass filter oil level indicator tube connection oil pressure sensor Leakage Points Under Engine oil pan gaskets oil pan sealer oil pan rear seal engine front cover gasket crankshaft front seal crankshaft rear oil seal crankshaft main bearing cap side bolts Leakage Points with Flywheel Removed NOTE Air leakage in the area around a crankshaft rear oil seal does not necessarily indicate a crankshaft rear oil seal leak However if no other cause can be found for oil leakage assume that the crankshaft rear oil seal is the cause of the oil leak NOTE Light foaming equally around valve cover bolts and crankshaft seals is not detrimental no repairs are required crankshaft rear oil seal rear main bearing cap parting line rear main bearing cap and seals flywheel mounting bolt holes with flywheel installed camshaft rear bearing covers or pipe plugs at the end of oil passages Oil leaks at crimped seams in sheet metal parts and cracks in cast or stamped parts can be detected when pressurizing the crankcase 1 WSG 1068 GENERAL INFORMATION Compression Tests Compression Gauge Check 1 Make sure the oil in the crankcase is of the correct viscosity and at the proper level and that the battery is properly charged Op
116. e generator then generates an internal AC current which is converted to a DC output by the rectifier assembly internal to the generator and is supplied to the battery through the B terminal The S stator circuit is used to feed back a voltage signal from the generator to the regulator This voltage typically half battery voltage is used by the regulator to turn off the charge indicator 228 WSG 1068 CHARGING SYSTEM 229 WSG 1068 CHARGING SYSTEM Pinpoint Test B Voltage Output High Inspection and Verification 1 Visually inspect for obvious signs of terminal corrosion and electrical harness damage 2 Inspect for poor ground connections or backed out connector pins or damage to wiring 3 Visually inspect for and note auxiliary system connections not shown on the Recommended Customer Connections Wiring Schematic 230 WSG 1068 CHARGING SYSTEM Pinpoint Test C Indicator Lamp ON Engine Running Inspection and Verification 1 Visually inspect for obvious signs of terminal corrosion and electrical harness damage or a bulb failure 2 Inspect fusible links and generator connector for bent or backed out connector pins or damage to wiring 3 Visually inspect for and note auxiliary system connections not shown on the Recommended Customer Connections Wiring Schematic Normal Operation With voltage applied the high side of a charge warning indicator lamp the generator will momentarily will pull the warning lamp to gr
117. e oil 8 Remove the crankshaft front seal 6700 refer to Crankshaft Front Oil Seal in this section 9 Remove the bolts from the front of the oil pan that hold the front cover 58 WSG 1068 ENGINE 10 Remove the engine front cover fasteners 11 Remove the engine front cover 6019 from the front cover to cylinder block dowels 6C002 1 Install a new engine front cover gasket 6020 on the engine front cover then position the engine front cover on the front cover to cylinder block dowels 59 WSG 1068 ENGINE 60 WSG 1068 ENGINE 2 Tighten the fasteners in two stages following the sequence shown Stage 1 Tighten fasteners 1 through 5 to 20 30 Nm 15 22 lb ft Stage 2 Tighten fasteners 6 through 15 to 40 55 Nm 30 41 lb ft 3 NOTE Be sure to tighten the bolts through the front of the oil pan in two stages Stage 1 Tighten to 20 Nm 15 lb ft Stage 2 Tighten an additional 60 degrees 61 WSG 1068 ENGINE 4 Connect the CKP sensor electrical connector 5 Install the water pump pulley 6 Connect the CMP electrical connector 7 Install a new crankshaft front seal and the crankshaft pulley 6312 refer to Crankshaft Pulley in this section 8 Install the drive belt 8620 9 Install the valve covers refer to Valve Cover in this section 10 Fill the engine 6007 with oil Use engine oil meeting Ford specification D9AZ 19579A 62 WSG 1068 E
118. e processing the engine speed and load plus sensors mentioned in operation of this section and Fuel Select Switch Inputs to the GCP Effecting the Ignition The spark strategy is based on sensors and manifold vacuum input to the GCP module which include the following inputs Crankshaft Position Sensor CKP Sensor The CKP sensor is a magnetic transducer mounted on the engine block adjacent to a pulse wheel located on the crankshaft By monitoring the crankshaft mounted pulse wheel A the CKP is the primary sensor for ignition information to the GCP The pulse wheel located behind the crankshaft pulley B has a total of 39 teeth spaced 9 degrees apart with one empty space C for a missing tooth An A C voltage signal is generated which increases with engine rpm and provides engine speed and crankshaft position information to the GCP By monitoring the pulse wheel the CKP sensor signal indicates crankshaft position and speed information to the GCP The CKP sensor is also able to identify piston travel in order to synchronize the ignition system and provide a way of tracking the angular position of the crankshaft relative to a fixed reference for the CKP sensor configuration GCP also uses the CKP signal to determine if a misfire has occurred by measuring rapid decelerations between teeth 168 WSG 1068 IGNITION SYSTEM Coil On Plug The coil on plug COP ignition operates similar to standard coil pack ignition except each plug has o
119. e selected The injector driver can be re enabled by selecting again If the engine is running below 1000 RPM the injector driver will stay disabled for 15 seconds and then re set If the engine is running above 1000 RPM the injector driver will stay disabled for 5 seconds and then re set Record the change in rpm or closed loop multiplier while each driver is disabled Throttle Test To select this test mode the engine must be off but the key must be in the ON position The DBW Test mode allows the technician to control the throttle directly without the engine running with the foot pedal or entering a number into the TPS Command box It is used during the diagnostic routines specified for FPP and TPS related faults FPP position displays the current position of the foot pedal as a percentage FPP volts display the voltage that the GCP is reading from the FPP sensor TPS Command displays the commanded throttle position expressed as a percentage which is being sent to the throttle TPS Position is the actual percent of throttle opening being sent to the GCP from the throttle TPS volts display the actual TPS signal voltage the GCP is receiving from the throttle 285 WSG 1068 ENGINE CONTROLS RAW VOLTS Screen The RAW VOLTS screen shows actual voltage readings from various circuits Use the keys at the upper left corner or the page command to toggle the three main screens GAUGES FAULTS AND RAW VOLTS NOTE F9
120. e the four screws T20 Torx type head attaching the voltage regulator to the generator housing Remove the voltage regulator with generator brush holder 10351 attached from the generator 232 WSG 1068 CHARGING SYSTEM 2 Hold the voltage regulator in one hand and pry off the cap covering the A screw head with a screwdriver 3 Remove two screws T20 Torx type head attaching the regulator to the generator brush holder Separate the regulator from generator brush holder 06 15 Regulator Installation 1 Replace generator brush holder to voltage regulator and install attaching screws 2 Replace cap on the head of the A terminal screw 3 Depress the generator brushes in the generator brush holder Hold the generator brushes in position by inserting a standard size paper clip or equivalent through both the location hole in the voltage regulator and through the holes in the generator brush holders 4 Install the voltage regulator and generator brush holder to the generator with attaching screws Remove paper clip or equivalent from the regulator 5 Install generator following installation in this section NOTE Only the regulator brush holder and generator pulley are serviceable If the generator needs further service it must be replaced as an assembly 233 WSG 1068 CHARGING SYSTEM SPECIFICATIONS Torque Specifications Generator Parts Cross Reference Special Tools 2
121. e upper and lower radiator supports 16138 16 Install the radiator 8005 17 Install the engine air cleaner ACL 9600 and the air cleaner outlet tube 9B659 18 Fill all fluids to the proper levels 19 Connect the battery ground cable 14301 20 Start the engine and check for leaks Stop the engine and recheck the fluid levels 156 WSG 1068 ENGINE SPECIFICATIONS 157 WSG 1068 ENGINE 158 WSG 1068 ENGINE 159 WSG 1068 IGNITION SYSTEM INDEX Subject General Information Color Abbreviations How to Find Electrical Concerns Troubleshooting Tools Switch Circuit Check and Voltage Check Continuity Check locating open circuits Short Check Ground Check Troubleshooting Wi
122. ecification WSS M2C153 C 3 Install the camshaft and the camshaft bearing caps in their original location and the bolts Lubricate and position the camshaft bearing caps Use Super Premium SAE 5W30 Motor Oil D9AZ 19579 A or equivalent meeting Ford specification WSS M2C153 G 125 WSG 1068 ENGINE 4 Tighten the bolts in the sequence shown 5 Install the valves in the valve guides located in the cylinder block 6010 126 WSG 1068 ENGINE 6 Install the valve spring and the valve spring retainer onto the valve 7 Install the valve spring spacer between the valve spring coils to prevent valve stem seal damage 8 Use the Valve Spring Compressor to compress the valve spring and install the valve spring retainer keys 9 Install the hydraulic lash adjusters 127 WSG 1068 ENGINE 10 Install the roller followers 11 Remove the Valve Spring Spacer 128 WSG 1068 ENGINE 1 NOTE Before assembling the cylinder block 6010 all seating surfaces must be free of chips dirt paint and foreign material Also make sure the coolant and oil passages are clear Lubricate and install the crankshaft upper main bearings into the cylinder block Use Super Premium SAE 5W30 Motor Oil D9AZ 19579 A or equivalent meeting Ford specification WSS M2C153 G 129 WSG 1068 ENGINE 2 Install the crankshaft 6303 into the cylinder block and onto the upper crankshaft main bearings 6333 3 P
123. ecting bolts must be torqued within 15 minutes after applying sealant Failure to follow this procedure can cause future oil leakage Use silicone gasket and sealant F6AZ 19562 AA or equivalent meeting Ford specification WSE M4G323 A6 NOTE Sealant must be removed and area cleaned with solvent if above instructions are not followed Use metal surface cleaner F4AZ 19A536 RA or equivalent meeting Ford specification WSE M5B292 A 24 Install engine front cover refer to Engine Front Cover in this section 76 WSG 1068 ENGINE Camshaft Removal Special Tool s Special Service Tools called for by the procedures can be obtained by calling 1 800 ROTUNDA 1 800 768 8632 WARNING DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENTS HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND CAN BE IGNITED RESULTING IN POSSIBLE PERSONAL INJURY 1 Disconnect the battery ground cable 14301 2 Remove the intake manifold 9424 refer to Intake Manifold Variable Resonance Induction System VRIS in this section 3 Remove the timing chains 6268 refer to Timing Drive Components in this section CAUTION The caps must be marked for installation in their original location or damage to the engine may occur 4 Remove the six bolts retaining the balance shaft bearing caps and remove the bearing caps 5 Remove the balance shaft 77 WSG 1068 ENGINE 6
124. engine is operated some oil is also drawn into the combustion chambers past the intake and exhaust valve stem seals and burned The following is a partial list of conditions that can affect oil consumption rates engine size operator driving habits ambient temperature quality and viscosity of the oil Operating under varying conditions can frequently be misleading An engine that has been run for short hours or in below freezing ambient temperatures may have consumed a normal amount of oil However when checking engine oil level it may measure up to the full mark on the oil level dipstick due to dilution condensation and fuel in the engine crankcase The engine might then be run at high speeds where the condensation and fuel boil off The next time the engine oil is checked it may appear that a liter quart of oil was used in about 3 to 3 1 2 hours This perceived 3 to 3 1 2 hours per liter quart oil consumption rate causes customer concern even though the actual overall oil consumption rate is about 50 hours per liter quart Make sure the selected engine oil meets Ford specification WSS M2C153 F and the recommended API performance category SJ or higher and SAE viscosity grade as shown in the equipment Owner s or Operators Engine handbook It is also important that the engine oil is changed at the intervals specified Refer to the Engine Operator s handbook Oil Consumption Test The following dia
125. ensioner Removal Belt Tensioner Installation Belt Idler Pulley Removal Belt Idler Pulley Installation Water Pump Removal Water Pump Installation Diagnosis and Testing Visual Inspection Cooling System Visual Test Thermostat Test Thermostat Removed Radiator Leak Test Removed from Vehicle Engine Cylinder Head Temperature CHT Sensor
126. ent probe to generator B output lead Circuit 38 BK O to measure generator output 4 With the engine running at 2000 rpm adjust the VAT 40 or equivalent load bank to determine the output of the generator Generator output should be greater than values given in graph below If not refer to symptom chart in this Section Generator Voltage Test 1 Switch the tester to the voltmeter function 2 Connect the positive lead to the generator A terminal connector and the negative lead to ground 3 Turn off all electrical accessories 4 With the engine running at 2000 rpm check the generator voltage 5 Voltage should be between 13 0 15 5 volts NOTE If voltage is not within specifications refer to symptom chart Battery Drain Test WARNING DO NOT ATTEMPT THIS TEST ON A LEAD ACID BATTERY THAT HAS RECENTLY BEEN RECHARGED EXPLOSIVE GASES MAY CAUSE PERSONAL INJURY FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY CAUTION To prevent damage to the meter do not crank the engine or operate accessories that draw more than 10A NOTE No accessory system should have more than a 50 mA 0 050 amp draw NOTE Many modules draw 10 mA 0 010 amp or more continuously NOTE Use an in line ammeter between the battery positive or negative post and its respective cable NOTE Typically a drain of approximately one amp can be attributed to a lamp staying on continually Other component failures or wiring shorts may be loca
127. er block dowels 6C002 109 WSG 1068 ENGINE 13 Remove the crankshaft sensor ring from the crankshaft 6303 14 Remove the balancing shaft bearing caps 15 Remove balancing shaft 110 WSG 1068 ENGINE 16 CAUTION Unless otherwise instructed at no time when the timing chains 6268 are removed and the cylinder heads 6049 are installed is the crankshaft or camshaft 6250 to be rotated Severe piston 6108 and valve damage will occur Position the crankshaft with the Crankshaft Holding Tool as shown 17 Install the Camshaft Holding Tools on the camshafts 2 111 WSG 1068 ENGINE 18 Remove the bolts and the timing chain tensioners 6L266 Remove the timing chain tensioner arms 6L253 from the dowel pins 112 WSG 1068 ENGINE 19 CAUTION Unless otherwise instructed at no time when the timing chain are removed and the cylinder heads are installed is the crankshaft or camshaft to be rotated Severe piston and valve damage will occur Remove the Crankshaft Holding Tool Remove the RH timing chain from the camshaft sprocket 6256 Remove the RH timing chain and outer crankshaft sprocket from the crankshaft Repeat for the LH timing chain and crankshaft sprocket 113 WSG 1068 ENGINE 20 Remove the timing chain guides 6K297 Remove the bolts Remove the timing chain guides 114 WSG 1068 ENGINE 21 Remove the ten nut
128. erate the complete system to check the accuracy and completeness of the customer s complaint Step 2 Narrow the concern Using a DVOM narrow down the possible causes and locations of the concern to pinpoint the exact cause Read the description about the components and study the wiring schematic You should then know enough about the circuit operation to determine where to check for the trouble Step 3 Test the cause Use electrical test procedures to find the specific cause of the symptoms Step 4 Verify the cause Confirm that you have found the correct cause by connecting jumper wires and or temporarily installing a known good component and operating the circuit Step 5 Make the repair Repair or replace the inoperative component Step 6 Verify the repair Operate the system as in Step 1 and check that your repair has removed all symptoms without creating and new symptoms Troubleshooting Tools Jumper Wire This is a test lead used to connect two points of a circuit A Jumper Wire can bypass an open in a wire to complete a circuit WARNING NEVER USE A JUMPER WIRE ACROSS LOADS MOTORS ETC CONNECTED BETWEEN HOT AND GROUND THIS DIRECT BATTERY SHORT MAY CAUSE INJURY OR FIRE Voltmeter A DC Voltmeter measures circuit voltage Connect negative or black lead to ground and positive or red lead to voltage measuring point Ohmmeter Figure 1 Resistance Check An Ohmmeter shows the r
129. erate until the engine is at normal operating temperature Turn the ignition switch to the OFF position then remove all the spark plugs 2 Set the throttle plates in the wide open position 3 Install a Compression Tester in the No 1 cylinder 4 Install an auxiliary starter switch in the starting circuit With the ignition switch in the OFF position and using the auxiliary starter switch crank the engine a minimum of five compression strokes and record the highest reading Note the approximate number of compression strokes required to obtain the highest reading 5 Repeat the test on each cylinder cranking the engine approximately the same number of compression strokes Test Results The indicated compression pressures are considered within specification if the lowest reading cylinder is within 75 percent of the highest reading Refer to the Compression Pressure Limit Chart If one or more cylinders reads low squirt approximately one tablespoon of clean engine oil meeting Ford specification ESE M2C153 E on top of the pistons in the low reading cylinders Repeat the compression pressure check on these cylinders Compression Pressure Limit Chart Interpreting Compression Readings 1 If compression improves considerably with the addition of oil piston rings are faulty 2 If compression does not improve with oil valves are sticking or seating improperly 3 If two adjacent cylinders indicate low compression pressures and squirting o
130. esistance between two connected points Figure 1 161 WSG 1068 IGNITION SYSTEM Figure 2 Test Lamp A Test Light is a 12 volt bulb with two test leads Figure 2 Uses Voltage Check Short Check Self Powered Test Lamp Figure 3 Continuity Check The Self Powered Test Lamp is a bulb battery and set of test leads wired in series Figure 3 When connected to two points of a continuous circuit the bulb glows Uses Continuity Check Ground Check CAUTION When using a self powered test lamp or ohmmeter be sure power is off in circuit during testing Hot circuits can cause equipment damage and false readings Switch Circuit Check amp Voltage Check Figure 4 Switch Circuit Check and Voltage Check In an inoperative circuit with a switch in series with the load jumper the terminals of the switch to power the load If jumpering the terminals powers the circuit the switch is inoperative Figure 4 Continuity Check Locating open circuits Connect one lead of test lamp to a known good ground or the negative battery terminal Test for voltage by touching the other lead to the test point The bulb goes on when the test point has voltage Figure 4 162 WSG 1068 IGNITION SYSTEM Short Check Figure 5 Short Check A fuse that repeatedly blows is usually caused by a short to ground It s important to be able to locate such a short quickly Figure 5 1 Turn off everything powered throug
131. est The MIL bulb test occurs KOEO with the STI connector not grounded The MIL bulb will stay on and remain on if no DTCs are present If DTCs are present except DTC 123 the MIL bulb will blink If the MIL bulb does not illuminate when bulb test is performed access diagnostic software and view the fault indicator on screen If the screen fault indicator is illuminated and the MIL light is not inspect the bulb and replace it if damaged If bulb is OK or does not illuminate after replacement refer to MIL circuit test procedure Once MIL bulb illumination has been verified or established DTCs can be extracted from the MIL as follows DTC Extraction KOEO short the STI circuit to a known good ground There will be a 5 second delay before DTCs begin flashing When extracting DTCs via the MIL the following apply The flashing MIL is on for 0 4 second and off for 0 4 second The MIL is off for 1 2 seconds between digits of three digit DTCs The MIL is off for 2 4 seconds between DTCs Each DTC repeats 3 times before the next stored DTC begins flashing Up to 6 DTCs can be stored Once all stored DTCs are flashed the process repeats with the first stored DTC DTCs are flashed in the order in which they were set Once the DTC s is retrieved refer to the appropriate DTC chart for explanation of what caused the DTC to set Perform component and circuit test as required to conduct repair Diagnosis Usin
132. est to confirm the oil consumption concern has been resolved Oil Pressure Test 1 Disconnect and remove the oil pressure sensor from the engine 2 Connect the Engine Oil Pressure Gauge and Transmission Test Adapter to the oil pressure sender oil gallery port 3 Run the engine until normal operating temperature is reached 4 Run the engine at 3000 rpm and record the gauge reading 5 The oil pressure should be within specifications 6 If the pressure is not within specification check the following possible sources insufficient oil oil leakage worn or damaged oil pump oil pump screen cover and tube excessive main bearing clearance excessive connecting rod bearing clearance 6 WSG 1068 GENERAL INFORMATION Valve Train Analysis Static With engine off and valve cover removed check for damaged or severely worn parts and correct assembly Make sure correct parts are used with the static engine analysis as follows Rocker Arm Check for loose mounting bolts studs and nuts Check for plugged oil feed in the rocker arms or cylinder head Camshaft Roller Followers and Hydraulic Lash Adjusters Check for loose mounting bolts on camshaft carriers Check for plugged oil feed in the camshaft roller followers hydraulic lash adjusters HLA or cylinder heads Camshaft Check for broken or damaged parts Check the bolts on the intake manifold Valve Springs Check for broken or damaged parts Valve Spring Retainer and Valve Spr
133. esult damage to major engine components could occur Using a CHT sensor and cooling strategy would prevent damage by allowing air cooling of the engine and limp home capability 170 WSG 1068 IGNITION SYSTEM Starting Mode Module enters start mode at first application of power No spark is applied for first turn of crankshaft Timing is fixed at 10 degrees BTDC Dwell is fixed at 10 degrees of crankshaft rotation Start mode remains in effect until 10 turns of the crankshaft 500 rpm If drops below 500 rpm at any time turn counter is reset Once 10 turns are made 100 rpm or greater module is set to run mode In transitioning to run mode calculated timing values are ramped into system during approximately 3 5 revolutions to ensure transition Dwell is determined with a base value plus a correction factor based on system voltage CHT Effects Cylinder Head Temperature CHT is monitored and a correction factor is applied to engine timing based on one of three 1 X 8 tables OCT1 selects which timing table will be used for correction IAT Effects Not Used Intake Air Temperature IAT is monitored and a correction factor is applied to engine timing based on one of three 1 X 8 tables OCT1 selects which timing table will be used for correction Overspeed Protection The GCP module contains an RPM limit that is set at 3200 RPM Reaction is the module will be shut off stalling the engine Key must cycle from run to off to start
134. fault was active Snapshot Data explained later Flight Data Recorder explained later The DTC Dialogue Box also allows you to clear a single fault by clicking on the Clear This Fault button and it allows you to clear all faults by clicking on the Click All Faults button NOTE Record faults before clearing them This will aid in diagnosis Hear is an example of a DTC Dialogue Box Snap Shot Data The Snap Shot Data is a listing of specific engine system variables These variables are recorded by the GCP at the instant the DTC sets By clicking on the View Snap Shot Data button a new window will pop up and you will be able to view these variables Here is an example of a Snap Shot Data window 281 WSG 1068 ENGINE CONTROLS Flight Data Recorder The Flight Data Recorder is also a listing of specific engine system variables These variables are recorded by the GCP for an interval of 10 seconds The 10 second interval includes 8 seconds before the DTC sets and 2 seconds after the DTC sets By clicking on the View Flight Data Recorder Data button a new window will pop up and you will be able to view these variables Here is an example of a flight Data Recorder Data window The FAULTS screen shows the following Fault Access System States DBW Variables Closed Loop Control Digital Input Voltages Diagnostic Modes Historic Faults Active Faults Use th
135. ful tool while diagnosing engine problems The FORD diagnostic software includes real time plotting and real time logging capabilities These features enhance the ability to diagnose and repair possible problems with the FORD system Both plotting and logging allows the user to record in real time any variable that can be seen in the FPP_Dis software In order to record variables the FPP_Dis software must be Connected to the GCP Plotting To plot a variable you must first TAG the variable To do this use the mouse to right click on the variable The variable will highlight in green to let you know it is TAGGED Next press the P key or click the Plot Log button and then click the Plot Tags button to invoke the plotting feature This begins the plot function and you can observe the plotted variables The plot sweeps from right to left To stop the plotting feature simply click the STOP button To restart the plotter click on the START button The maximum number of variables that can be plotted at one time is 10 The range of the selected variables will be shown on the Y axis and the time will be shown on the x axis You may change the desired time interval and sample interval for the plot by stopping the plot and typing in a new intervals The plot can be saved to the PC by stopping the plot and clicking the SAVE button When saving a plot you will have to type in a filename Plot files can later be
136. g a Personal Computer Equipment Requirements You will need a laptop computer with a serial port or personal digital assistant PDA and a communications cable interface cable kit Kit for laptop part PN 5080050 The required software is available from your local EDI distributor or you can download it from web fpp ford com Laptop Requirements USB Port 800 x 600 dpi screen Windows 95 or newer operating system No speed minimum 32 MB of RAM 277 WSG 1068 ENGINE CONTROLS Interface Hook up For connection to a laptop use kit PN 5080050 Connect USB port on the back of the laptop computer Connect interface cable to the to the diagnostic connector on the engine harness Laptop Computer USB Connection Diagnostic Connector 278 WSG 1068 ENGINE CONTROLS GCP Software Installation Insert CD into CD ROM drive Double click My Computer Icon Double Click CD ROM drive letter This will display the contents of the CD as shown Double click FPP Display icon You will now see a welcome screen Click next A screen will pop up telling you the name of the destination folder Click next You will now see a screen telling you it is ready to install the software Click next 279 WSG 1068 ENGINE CONTROLS You will see an Installation Success screen when the software is finished installing Click Finish A screen will pop up asking if it is ok to
137. gine very slowly connect a 12 volt booster battery to the system NOTE Engine may not start if crank sensor reads less than 140 RPM Jump Starting To avoid damage to the vehicle or equipment and battery or the possibility of personal injury 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 WARNING KEEP OUT OF REACH OF CHILDREN BATTERIES CONTAIN SULFURIC ACID AVOID CONTACT WITH SKIN EYES OR CLOTHING ALSO SHIELD YOUR EYES WHEN WORKING NEAR THE BATTERY TO PROTECT AGAINST POSSIBLE SPLASHING OF THE ACID SOLUTION IN CASE OF ACID CONTACT WITH SKIN EYES OR CLOTHING FLUSH IMMEDIATELY WITH WATER FOR A MINIMUM OF 15 MINUTES IF ACID IS SWALLOWED DRINK LARGE QUANTITIES OF MILK OR WATER FOLLOWED BY MILK OF MAGNESIA A BEATEN EGG OR VEGETABLE OIL CALL A PHYSICIAN IMMEDIATELY CAUTION Do not disconnect the battery of the vehicle to be started Disconnecting the battery could damage the vehicle s electronic system Negative Grounded Battery WARNING TO AVOID INJURY USE PARTICULAR CARE WHEN CONNECTING A BOOSTER BATTERY TO A DISCHARGED BATTERY 1 Position vehicles or equipment so jumper cables will reach being careful that vehicles do not touch WARNING M
138. gnostic procedure is used to determine the source of excessive internal oil consumption NOTE Oil use is normally greater during the first 300 hours of service As hours increase oil use generally decreases Engines in normal service should get at least 31 7 hours per quart 900 miles per quart after 300 hours of service High speeds heavy loads high ambient temperature and other factors may result in greater oil use 1 Determine customer s engine load habits such as sustained high speed operation extended idle heavy work loads and other considerations 2 Verify that the engine has no external oil leak as described under Engine Oil Leaks in the Diagnosis and Testing portion of this section 3 Verify that the engine has the correct oil level dipstick 4 Verify that the engine is not being run in an overfilled condition Check the oil level at least five minutes after a hot shutdown with the engine vehicle parked on a level surface In no case should the level be above the top of the cross hatched area and the letter F in FULL If significantly overfilled perform steps 5 through 9 If not proceed to step 10 5 Drain the engine oil remove and replace the oil bypass filter and refill with one quart less than the recommended amount 6 Run the engine for three minutes 10 minutes if cold and allow the oil to drain back for at least five minutes with the engine vehicle on a level surface 7 Remove oil level dipstick and wipe clean
139. h the fuse 2 Disconnect other loads powered through the fuse Motors disconnect motor connector Connector C4 in Figure 5 Lights remove bulbs 3 Turn the Ignition Switch to RUN if necessary to power fuse 4 Connect one Test Lamp lead to the hot end of the blown fuse Connect the other lead to ground The bulb should glow showing power to fuse This step is just a check to be sure you have power to the circuit 5 Disconnect the test lamp lead that is connected to ground and reconnect it to the load side of the fuse at the connector of the disconnected component In Figure 5 connect the test lamp lead to connector C4 If the Test Lamp is off the short is in the disconnected component If the Test Lamp goes on the short is in the wiring You must find the short by disconnecting the circuit connectors one at a time until the Test Lamp goes out For example in Figure 5 with a ground at X the bulb goes out when C1 or C2 is disconnected but not after disconnecting C3 This means the short is between C2 and C3 Figure 6 Ground Check Ground Check Turn on power to the circuit Perform a Voltage Check between the suspected inoperative ground and the frame Any indicated voltage means that the ground is inoperative Figure 6 Turn off power to the circuit Connect one lead of a Self Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground If the bulb glows the ci
140. harge Damage for more information Use of Circuit Testing Tools Do not use a test light to diagnose the engine electrical systems unless specifically instructed by the diagnostic procedures A test light can put an excessive load on a GCP circuit and result in component damage For voltage measurements use only a digital voltmeter with an input impedance of at least 10 megohms Electrostatic Discharge Damage Electronic components used in the GCP are often designed to carry very low voltage Electronic components are susceptible to damage caused by electrostatic discharge Less than 100 volts of static electricity can cause damage to some electronic components By comparison it takes as much as 4000 volts for a person to feel the spark of a static discharge There are several ways for a person to become statically charged The most common methods of charging are by friction and induction An example of charging by friction is a person sliding across a seat Charge by induction occurs when a person with well insulated shoes stands near a highly charged object and momentarily touches ground Charges of the same polarity are drained off leaving the person highly charged with the opposite polarity Static charges can cause damage therefore it is important to use care when handling and testing electronic components CAUTION To prevent possible electrostatic discharge damage follow these guidelines Do not touch the GCP connector pins or
141. he GCP supplies a ground Gray Red from the sensor and monitors voltage signal Lt Green Red to the sensor When the engine coolant is cold the sensor resistance is high and the GCP will monitor a high signal voltage at the CHT signal circuit If the engine cylinder head is warm the sensor resistance is lower causing the GCP to monitor a lower voltage Engine cylinder head temperature CHT sensor is a type of thermistor that converts engine temperature to an electrical voltage signal The electrical resistance of the CHT sensor changes with temperature As engine coolant temperature increases the CHT resistance decreases Output is a variable voltage signal which typically ranges from 0 3 volt to 4 5 volts At 40 F CHT resistance is approximately 925K ohms At 77 F CHT resistance is approximately 30K ohms At 248 F CHT resistance is approximately 1 2K ohms NOTE Complete list of temperature sensor characteristics can be found on page 05 21 of this section Diagnostic Aids The CHT sensor shares the same ground with other sensors Check the ground circuit 359 Gray if other shared components NOTE Refer to Section 08 for further diagnostics Inspect the harness connectors for backed out terminals improper mating broken locks improperly formed or damaged terminals and poor terminal to wire connections Inspect the wiring harness for damage If the harness appears to be OK back pro
142. he crankshaft rear oil seal 6701 4 Remove the oil pan refer to Oil Pan in this section 5 Remove the crankcase bolts and the crankshaft rear oil seal retainer plate 1 CAUTION Mating parts must make contact to each other within 4 minutes and connecting bolts must be torqued within 15 minutes after applying sealant Failure to follow this procedure can cause future oil leakage Use silicone gasket and sealant F6AZ 19562 AA or equivalent meeting Ford specification WSEM4G323 A6 NOTE Sealant must be removed and area cleaned with solvent if above instructions are not followed Use metal surface cleaner F4AZ 19A536 RA or equivalent meeting Ford specification WSEM5B292 A 2 Apply a bead of silicone around the rear oil seal retainer sealing surface Use Silicone Gasket and Sealant F6AZ 19562 A or equivalent meeting Ford specification WSEM4G323 A6 99 WSG 1068 ENGINE 3 NOTE If the rear main oil seal is still in place and being reinstalled be sure the lip is not folded over or wrinkled during the retainer plate installation The seal lip must start squarely on the crankshaft journal Position the crankshaft rear oil seal and retainer 6K301 install the bolts Then install the oil pan and the two bolts Tighten in two stages Stage 1 Tighten retainer plate bolts to 8 12 Nm 71 107 lb in Stage 2 Tighten oil pan bolts to 14 20 Nm 10 15 lb ft then tighten an additional 90 4 Use the Rear Cr
143. he oil test by the result This quantity is the approximate oil consumption rate in hours per quart 13 If the oil consumption rate is unacceptable proceed to next step 14 Check the positive crankcase ventilation PCV system Make sure the system is not plugged 15 Check for plugged oil drain back holes in the cylinder heads and cylinder blocks 16 If the condition still exists after performing the above steps proceed to next step 17 Perform a cylinder compression test or perform a cylinder leak detection test with Engine Cylinder Leak Detection Air Pressurization Kit This can help determine the source of oil consumption such as valves piston rings or other areas NOTE After determining if worn parts should be replaced make sure correct replacement parts are used 18 Check valve guides for excessive guide clearances REPLACE all valve stem seals after verifying valve guide clearance 19 Worn or damaged internal engine components can cause excessive oil consumption Small deposits of oil on the tips of spark plugs can be a clue to internal oil consumption If internal oil consumption still persists proceed as follows Remove the engine from the vehicle and place it on an engine work stand Remove the intake manifolds cylinder heads oil pan and oil pump Check piston ring clearance ring gap and ring orientation Repair as required Check for excessive bearing clearance Repair as required 20 Perform the oil consumption t
144. ification decal mounted on the engine rocker cover That decal provides not only the engine serial number but also the exact model or type options and S O Special Order The combination of that data permits you to isolate the precise engine build level and customer so you can determine the correct replacement parts Engine Identification Decal An identification Decal is affixed to the valve cover of the engine The decal contains the engine serial number which identifies this unit from all others Use all numbers when seeking information or ordering replacement parts for this engine For a handy reference keep this information recorded in a separate location 5 WSG 1068 GENERAL INFORMATION Parts and Service Replacement parts can be obtained through your local EDI Distributors listed in the back portion of this manual They also may be found in the yellow pages under Engines or contact Engine Distributors Engine Distributors Inc are equipped to perform major and minor repairs They are anxious to see that all of your maintenance and service needs are quickly and courteously completed 6 WSG 1068 GENERAL INFORMATION DIAGNOSIS AND TESTING Special Tools 7 WSG 1068 GENERAL INFORMATION Inspection and Verification 1 Verify the customer concern by operating the engine to duplicate the condition 2 Visually inspect for obvious signs of mechanical and electrical damage Engine coolant leaks Engine oil leak
145. ighten the front engine support insulators 6 Connect the battery ground cable 7 Fill the engine with oil Use Motorcraft Engine Oil XO 5W30 QSP or equivalent meeting Ford specification WSSM2C153 G 8 Fill the cooling system 93 WSG 1068 ENGINE 1 Disconnect the battery ground cable 14301 2 Remove the engine front cover 6019 and crankshaft sprockets 6306 refer to Engine Front Cover in this section 3 Remove the oil pan 6675 refer to Oil Pan in this section 4 Remove the oil pump 6600 Remove the bolts Remove the oil pump 1 Clean and inspect the mating surfaces 2 Position the oil pump and loosely install the bolts Tighten the bolts in the sequence shown 3 Install the oil pan refer to Oil Pan in this section 4 Install the timing chain 6268 refer to Timing Drive Components in this section 5 Connect the battery ground cable 94 WSG 1068 ENGINE 1 Disconnect the battery ground cable 14301 2 Remove generator from bell housing 3 Remove bell housing 4 Remove the bolts and the flywheel 6375 1 Follow the removal procedure in reverse order 95 WSG 1068 ENGINE 1 Disconnect the battery ground cable 14301 2 Remove the flywheel 6375 refer to Flywheel in this section 3 Use the Rear Crankshaft Slinger Remover and the Slide Hammer to remove the crankshaft oil slinger 6310 4 Use the Rear Crankshaft Seal Remover and the Impact Slide Hammer to
146. il on each piston does not increase compression the head gasket may be leaking between cylinders Engine oil or coolant in cylinders could result from this condition Use the Compression Pressure Limit Chart when checking cylinder compression so that the lowest reading is within 75 percent of the highest reading 2 WSG 1068 GENERAL INFORMATION Cylinder Leakage Detection When a cylinder produces a low reading use of the Engine Cylinder Leak Detection Air Pressurization Kit will be helpful in pinpointing the exact cause The leakage detector is inserted in the spark plug hole the piston is brought up to dead center on the compression stroke and compressed air is admitted Once the combustion chamber is pressurized a special gauge included in the kit will read the percentage of leakage Leakage exceeding 20 percent is excessive While the air pressure is retained in the cylinder listen for the hiss of escaping air A leak at the intake valve will be heard in the throttle body A leak at the exhaust valve can be heard at the tail pipe Leakage past the piston rings will be audible at the positive crankcase ventilation PCV connection If air is passing through a blown head gasket to an adjacent cylinder the noise will be evident at the spark plug hole of the cylinder into which the air is leaking Cracks in the cylinder blocks or gasket leakage into the cooling system may be detected by a stream of bubbles in the radiator Oil Le
147. ill lock into the position it was in when the test mode was entered If the Spark System Test mode is selected with the engine running above 1000 RPM the throttle will continue to operate normally Disabling Ignition Ouputs To disable the ignition system for an individual cylinder use the mouse to highlight the Spark Kill button and select the desired coil The spark output can be re enabled by using the mouse to highlight the Spark Kill button and selecting Normal If the engine is running below 1000 RPM the spark output will stay disabled for 15 seconds and then re set If the engine is running above 1000 RPM the spark output will stay disabled for 5 seconds and then reset This test mode has a timeout of 10 minutes Record the rpm drop related to each spark output disabled The Spark outputs are arranged in the order which the engine fires not by cylinder number 284 WSG 1068 ENGINE CONTROLS Injector Test The Injector Kill mode is used to disable individual fuel injectors If the Injector Kill mode is selected with the engine running below 1000 RPM the minimum throttle command will lock into the position it was in when the test mode was entered If the Injector Kill mode is selected with the engine running above 1000 RPM the throttle will continue to operate normally Disabling Injectors To disable an injector use the mouse to select the desired injector The word Normal will change to the Injector you hav
148. in order to restart engine Note this strategy must be compatible with governor controllers Engine Protection Reaction for overtemp based on CHT input and low oil pressure based on oil pressure switch input the module will be shut off stalling the engine Key must cycle from run to off to start in order to restart engine Engine protection becomes active after 240 crankshaft revolutions and when 800 rpm is exceeded The purpose of having to meet these conditions provides an opportunity for the engine to restart if the failure still exists which caused the engine to stall Over temperature reaction is experienced when temperature reaches 250 F Low oil pressure reaction is experienced when oil pressure drops below 6 psi 1 5 psi Oil pressure switch position is normally open when engine is off Starter Lockout Starter lockout relay control open drain GCP switch to ground Activated once engine is in the run mode and has reached 600 RPM Will not allow start until ignition voltage to GCP module is switched off and back on Tachometer Output Tachometer output will be from Pin 2 of the 42 pin harness The pulses per revolution will be determined by the number of cylinders the GCP will control The four cylinder GCP will output 2 pulses per revolution the six cylinder GCP output 3 pulses per revolution the eight cylinder output 4 pulses per revolution and the ten cylinder 5 pulses per revolution The intention of this is to allow fo
149. ing Retainer Keys Check for proper seating of the valve spring retainer key on the valve stem and in valve spring retainer Valve Spring Retainer Keys Check for proper seating on the valve stem Valves and Cylinder Head Check the head gasket for proper installation Check for plugged oil drain back holes Check for worn or damaged valve tips Check for missing or damaged guide mounted valve stem seal Check collapsed lash adjuster gap Check installed valve spring height Check for missing or worn valve spring seats Check for plugged oil metering orifice in cylinder head oil reservoir if equipped Static checks engine off are to be made on the engine prior to the dynamic procedure Valve Train Analysis Dynamic Start the engine and while idling check for proper operation of all parts Check the following Rocker Arm Check for plugged oil in the rocker arms or cylinder head Check for proper overhead valve train lubrication If insufficient oiling is suspected accelerate the engine to 1200 rpm 100 rpm with the transmission in NEUTRAL or load removed and the engine at normal operating temperature Oil should spurt from the rocker arm oil holes such that valve tips and rocker arms are well oiled or with the valve covers off oil splash may overshoot the rocker arms If oiling is insufficient for this to occur check oil passages for blockage Positive Rotator and Valve Spring Retainer Keys Check for proper operation of positi
150. ing of the cylinder bores may occur 1 Clean the cylinder bores with soap or detergent and water 2 Thoroughly rinse with clean water and wipe dry with a clean lint free cloth 3 Use a clean lint free cloth and lubricate the cylinder bores Use Engine Oil XO 10W30 QSP or DSP or equivalent meeting Ford specification ESEM2C153 E 25 WSG 1068 GENERAL INFORMATION Cylinder Block Repair Cast Iron Porosity Defects CAUTION Do not attempt to repair cracks areas where temperature will exceed 260 C 500 F or areas exposed to engine coolant or oil These areas will not repair and could cause future failure Repair porosity defects with an epoxy sealer meeting Ford specification M3D35 A E 1 Clean the surface to be repaired to a bright oil free metal surface 2 Chamfer or undercut the repair area to a greater depth than the rest of the cleaned surface Solid metal must surround the area to be repaired 3 Apply the epoxy sealer and heat cure with a 250 watt lamp placed 254 mm 10 inches from the repaired surface or air dry for 10 12 hours at a temperature above 10 C 50 F 4 Sand or grind the repaired area to blend with the general contour of the surface 5 Paint the surface to match the rest of the cylinder block Cylinder Block Core Plug Replacement Special Tool s 1 Use a slide hammer or tools suitable to remove the cylinder block core plug 2 Inspect the cylinder block plug bore for any damage tha
151. ion 1 CAUTION Timing chain procedures must be followed exactly or damage to valves and pistons will result CAUTION Do not compress the ratchet assembly This will damage the ratchet assembly Compress the tensioner plunger using an edge of a vise 67 WSG 1068 ENGINE 2 Using a small screwdriver or pick push back and hold the ratchet mechanism 3 While holding the ratchet mechanism push the ratchet arm back into the tensioner housing 4 Install a paper clip into the hole in the tensioner housing to hold the ratchet assembly and plunger in during installation 68 WSG 1068 ENGINE 5 If copper links are not visible mark two links on one end and one link on the other end and use as timing marks 6 Install the timing chain guides 69 WSG 1068 ENGINE 7 Remove the Crankshaft Holding Tool 8 Install the inner crankshaft sprocket with the long hub facing outward 9 Install the inner timing chain on the crankshaft sprocket with the timing marks aligned 10 NOTE Be sure the upper half of the timing chain is below the tensioner 70 WSG 1068 ENGINE 11 CAUTION The camshaft sprocket can jump time if the Camshaft Holding Tool is not secured NOTE Be sure the chain link and crankshaft sprocket timing marks are aligned NOTE The lower half of the timing chain must be positioned above the dowel Install the outer crankshaft sprocket and timing chain belt with the long hu
152. ir filter for restrictions Inspect battery condition and starter current draw If no evidence of a problem is found after visual inspection has been performed proceed to Diagnostic System Check Intermittent Problems NOTE An intermittent problem may or may not turn on the MIL or store a DTC Do not use the DTC charts for intermittent problems The fault must be present to locate the problem NOTE Most intermittent problems are caused by faulty electrical connections or wiring Perform a careful visual inspection for the following conditions Poor mating of the connector halves or a terminal not fully seated in the connector backed out Improperly formed or damaged terminals Improper contact tension All connector terminals in the problem circuit should be carefully checked Poor terminal to wire connections This requires removing the terminal from the connector body to check Improperly installed aftermarket equipment or accessories Operate the engine with accessories OFF and a suitable multimeter connected to the suspected circuit An abnormal voltage when the malfunction occurs is a good indication that there is a fault in the circuit being monitored To check GCP for loss of diagnostic code memory disconnect the MAP sensor connector and idle the engine until the MIL illuminates Perform MIL DTC retrieval procedure DTC should be stored and kept in memory when the ignition is turned O
153. is proportional to the pressure input Throttle Position TP Sensor Electronic Actuator The Throttle Position TP Sensor is a dual track rotary potentiometer that uses a variable resistive element which is packaged inside a plastic housing The resistive element varies linearly and is directly proportional to the throttle plate angle The GCP applies reference voltage and ground to the sensor and monitors the sensor s ratio metric output voltage to determine precise throttle position The electronic actuator has two TP outputs that the GCP monitors The Electronic Actuator consists of a throttle body an electronically actuated throttle plate and a built in throttle position TP Sensor The Electronic Actuator also acts as an idle air control IAC valve Changes in engine load are detected by the GCP by comparing manifold absolute pressure TMAP with throttle position When the GCP detects a change in engine load it can adjust idle speed by changing the PWM signal to the actuator As the throttle valve opens the output increases so that at wide open throttle WOT the output voltage should be above 4 volts The GCP calculates fuel delivery based on throttle valve angle operator demand A hard failure in the TP sensor 5 volt reference or signal circuits for greater than 2 consecutive seconds will set a DTC 531 or DTC 533 A hard failure with the TP sensor ground circuit for more than two consecutive seconds may set DTC 532 If any
154. iting and OBTAIN QUALIFIED MEDICAL ASSISTANCE IMMEDIATELY Wear protective goggles when handling liquids which are harmful to the eyes these include ammonia and battery acid If any of these substances are splashed in the eyes wash out thoroughly with clean water and OBTAIN QUALIFIED MEDICAL ASSISTANCE IMMEDIATELY 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 1 WSG 1068 GENERAL INFORMATION INDEX Subject Page General Information Introduction Safety Notice Notes Cautions and Warnings Battery Handling and Charging Forward
155. l WARNINGS that you should follow when you work on the equipment GENERAL WARNINGS TO HELP AVOID INJURY ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION USE SAFETY STANDS WHENEVER A PROCEDURE REQUIRES YOU TO BE UNDER THE EQUIPMENT BE SURE THAT THE IGNITION SWITCH IS ALWAYS IN THE OFF POSITION UNLESS OTHERWISE REQUIRED BY THE PROCEDURE SET THE PARKING BRAKE IF EQUIPPED WHEN WORKING ON THE EQUIPMENT IF YOU HAVE AN AUTOMATIC TRANSMISSION SET IT IN PARK ENGINE OFF OR NEUTRAL ENGINE ON UNLESS INSTRUCTED OTHERWISE FOR A SPECIFIC OPERATION PLACE WOOD BLOCKS 4 X 4 OR LARGER TO THE FRONT AND REAR SURFACES OF THE TIRES TO PROVIDE FURTHER RESTRAINT FROM INADVERTENT EQUIPMENT MOVEMENT OPERATE THE ENGINE ONLY IN A WELL VENTILATED AREA TO AVOID THE DANGER OF CARBON MONOXIDE KEEP YOURSELF AND YOUR CLOTHING AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING ESPECIALLY THE FAN BELTS TO PREVENT SERIOUS BURNS AVOID CONTACT WITH HOT METAL PARTS SUCH AS THE RADIATOR EXHAUST MANIFOLD TAIL PIPE CATALYTIC CONVERTER AND MUFFLER DO NOT SMOKE WHILE WORKING ON THE EQUIPMENT ALWAYS REMOVE RINGS WATCHES LOOSE HANGING JEWELRY AND LOOSE CLOTHING BEFORE BEGINNING TO WORK ON THE EQUIPMENT TIE LONG HAIR SECURELY BEHIND THE HEAD KEEP HANDS AND OTHER OBJECTS CLEAR OF THE RADIATOR FAN BLADES ELECTRIC COOLING FANS CAN START TO OPERATE AT ANY TIME BY AN INCREASE IN UNDERHOOD TEMPERATURES EVEN THOUGH THE IGNITIO
156. ley bolt 6A340 in four stages Stage 1 Tighten to 90 Nm 66 lb ft Stage 2 Loosen 360 degrees Stage 3 Tighten to 47 53 Nm 35 39 lb ft Stage 4 Tighten an additional 85 90 degrees 151 WSG 1068 ENGINE 68 Position the water pump pulley 8509 on the water pump and install the bolts 152 WSG 1068 ENGINE 69 CAUTION Mating parts must make contact to each other within 4 minutes and connecting bolts must be torqued within 15 minutes after applying sealant Failure to follow this procedure can cause future oil leakage Use silicone gasket and sealant F6AZ 19562 AA or equivalent meeting Ford specification WSEM4G323 A6 NOTE Sealant must be removed and area cleaned with solvent if above instructions are not followed Use metal surface cleaner F4AZ 19A536 RA or equivalent meeting Ford specification WSEM5B292 A Apply silicone in two places where the engine front cover meets the cylinder head Use Silicone Gasket and Sealant F6AZ 19562 AA or equivalent meeting Ford specification WSEM4G323 A6 70 Position the valve covers 6582 71 Tighten the bolts in the sequence shown 72 Install the engine control wire harness 153 WSG 1068 ENGINE 1 Attach the Modular Lifting Bar 2 Remove the engine from the engine stand 3 CAUTION Mating parts must make contact to each other within 4 minutes and connecting bolts must be torqued within 15 minutes after app
157. lso be set up to run on a variety of electronic governing It can be programmed to provide up to four specific speeds with use of a matching toggle switch It can be programmed to provide an infinite variety of 253 WSG 1068 ENGINE CONTROLS speeds with customer specified minimum and maximum based on a variable signal input It can be an electronic replacement for a throttle cable with maximum speed governing throttle bywire Or it can switch between throttle by wire and a second fixed or variable input based on a neutral parking brake signal With the GCP system a laptop and a communications cable diagnosis becomes simpler The technician can either view engine data with a real time graphing program or store that data into a numeric data file Every time a fault is set the laptop will give you detailed information about the fault including when it happened if the fault still exists a list of essential engine data from the time of the fault It can also display a 10 second graph of critical engine data from 8 seconds before the fault occurred to two seconds after And if you only want to view engine parameters and fault codes all you need is a Personal Digital Assistant PDA and our easy to load software and a communications cable With many OEMs using control modules to control their machinery the GCP has the ability to communicate engine data to and receive commands from other co
158. lying sealant Failure to follow this procedure can cause future oil leakage Use silicone gasket and sealant F6AZ 19562 AA or equivalent meeting Ford specification WSEM4G323 A6 NOTE Sealant must be removed and area cleaned with solvent if above instructions are not followed Use metal surface cleaner F4AZ 19A536 RA or equivalent meeting Ford specification WSEM5B292 A 4 Apply a bead of silicone around the rear oil seal retainer sealing surface 154 WSG 1068 ENGINE 5 Install the retainer plate Tighten the bolts to 8 12 Nm 71 107 lb in 6 Use the Rear Crankshaft Seal Replacer and Rear Crankshaft Seal Adapter to install the crankshaft rear oil seal 6701 7 With the Rear Crankshaft Seal Adapter still installed use the Rear Crankshaft Slinger Replacer to install the crankshaft oil slinger 8 Install the flywheel 6375 9 Install the starter motor 11002 155 WSG 1068 ENGINE 10 Connect the left and right exhaust pipes and install and tighten the nuts NOTE Apply a light coat of anti sieze compound F6AZ 9L494 AA or equivalent meeting Ford specification ESE M12A4 A to the threads of the exhaust manifold studs 11 Connect the LH and RH heated exhaust gas oxygen sensor connector if equipped 12 Install the intake manifold 9424 refer to Intake Manifold Variable Resonance Induction System VRIS in this section 13 Install vacuum hoses 14 Install the drive belt 8620 15 Install th
159. m 15 22 lb ft Stage 2 Tighten fasteners 6 through 15 to 40 55 Nm 30 41 lb ft 148 WSG 1068 ENGINE 58 Position the oil pump screen cover and tube 6622 and install the bolts and nut 59 CAUTION Mating parts must make contact to each other within 4 minutes and connecting bolts must be torqued within 15 minutes after applying sealant Failure to follow this procedure can cause future oil leakage Use silicone gasket and sealant F6AZ 19562 AA or equivalent meeting Ford specification WSEM4G323 A6 NOTE Sealant must be removed and area cleaned with solvent if above instructions are not followed Use metal surface cleaner F4AZ 19A536 RA or equivalent meeting Ford specification WSEM5B292 A Apply a bead of silicone where the rear crankshaft seal retainer plate and the front cover meets the cylinder block Use Silicone Gasket and Sealant F6AZ 19562 AA or equivalent meeting Ford specification WSEM4G323 A6 60 NOTE Be sure to tighten the bolts in three stages Install the oil pan 6675 Tighten the bolts in the sequence shown Stage 1 Tighten to 2 Nm 18 lb in Stage 2 Tighten to 20 Nm 15 lb ft Stage 3 Tighten an additional 60 degrees 61 Install the oil drain plug 11 16 Nm 98 143 lb in 149 WSG 1068 ENGINE 62 CAUTION Do not rotate the water pump housing once the water pump 8501 has been positioned in the cylinder block Damage to the O ring seal will o
160. m the engine before installing a tapersert If this procedure is done with the cylinder head on the engine the cylinder walls can be damaged by metal chips produced by the thread cutting process CAUTION Do not use power or air driven tools for finishing taperserts NOTE This repair is permanent and will have no effect on cylinder head or spark plug life 1 Clean the spark plug seat and threads 2 Start the tap into the spark plug hole being careful to keep it properly aligned As the tap begins to cut new threads apply aluminum cutting oil 3 Continue cutting the threads and applying oil until the stop ring bottoms against the spark plug seat 4 Remove the tap and metal chips 5 Coat the threads of the mandrel with cutting oil Thread the tapersert onto the mandrel until one thread of the mandrel extends beyond the tapersert NOTE A properly installed tapersert will be either flush with or 1 0 mm 0 039 inch below the spark plug gasket seat 28 WSG 1068 GENERAL INFORMATION 6 Tighten the tapersert into the spark plug hole 7 Turn the mandrel body approximately one half turn counterclockwise and remove Exhaust Manifold Straightness Special Tool s Place the Straightedge across the exhaust manifold flanges and check for warping with a feeler gauge NOTE The exhaust manifold shown is a typical exhaust manifold SPECIFICATIONS NOTE Ford Power Products industrial engines are designed to pe
161. minated and the DTC is current ACTIVE All DTC s are stored as historical faults until they are cleared All DTC s except the GCP related DTC s will automatically clear from memory if the DTC does not reset within 50 consecutive engine run cycles While a Diagnostic Trouble Code is current for a sensor the FORD system GCP may assign a default limp home value and use that value in its control algorithms All of the FORD system diagnostic self tests run continuously during normal engine operation The Diagnostic Trouble Codes can be read by using either the Malfunction Indicator Lamp MIL or a Laptop computer Refer to Using a Laptop Computer to Diagnose the FORD System and Using a Diagnostic Jumper to Diagnose the FORD System located in this section Diagnostic Trouble Codes can be cleared from memory with a laptop computer or by turning the ignition key to the OFF position and removing the FORD system main power fuse F3 for 15 seconds If more than one DTC is detected begin with the lowest number DTC and diagnose each problem to correction unless directed to do otherwise by the fault tree The DTC s are numbered in order of importance Having DTC 112 and DTC 122 both concerning the oxygen sensor is possible By repairing DTC 112 first the problem causing the DTC 122 may also be corrected On Board Diagnostics GCP The diagnostic tests and circuit charts are designed to assist the technician to locate a faulty circuit or comp
162. move 194 WSG 1068 COOLING SYSTEM CAUTION The coolant must be recovered in a suitable clean container for reuse If the coolant is contaminated it must be recycled or disposed of properly NOTE About 80 of coolant capacity can be recovered with the engine in the vehicle Dirty rusty or contaminated coolant requires replacement 3 Place a suitable container below the radiator draincock 8115 If equipped disconnect the coolant return hose at the fluid cooler 4 Open the radiator draincock 5 Remove the cylinder drain plug if equipped to drain the coolant from the cylinder block 6010 1 Place a drain pan below the cylinder block 2 Remove the drain plugs 195 WSG 1068 COOLING SYSTEM 6 When the coolant is drained make sure drain plugs are installed and tight 7 Close the radiator draincock when finished Cooling System Filling 1 Add the proper engine coolant mixture to the degas bottle or radiator 2 Move the temperature blend selector to the full warm position when equipped 3 Run the engine until it reaches operating temperature 196 WSG 1068 COOLING SYSTEM 4 Add the proper engine coolant mixture to the degas bottle or radiator until the coolant level is between the COOLANT FILL LEVEL marks NOTE Systems without degas bottle fill radiator up to 1 inch below the filler neck 5 Turn off the engine and allow the cooling system to cool 6 Repeat Steps 1 through 5
163. n ESE M1C171 A To install reverse the removal procedure 174 WSG 1068 IGNITION SYSTEM Harness Connector Pinout Description I O Input Output 175 WSG 1068 IGNITION SYSTEM Fuel Select Operation Fuel Select is Used to select ignition table for fuel type The user has several options for this which is all dependent on whether pin 7 of the 42 pin connector is Open grounded or has 12 volts The configurations are listed below Fuel Select Configuration 1 GND LP Open Gsln V NG 2 Gnd NG Open Gsln V LP 3 Gnd Open Gsln V LP 4 Gnd Open Gsln V NG 5 Gasoline Only 6 LP Only 7 NG Only 8 Gnd Open LP V NG 9 Gnd Open NG V LP 10 Gnd LP Open NG V Gsln 176 WSG 1068 IGNITION SYSTEM DIAGN0SIS AND TESTING Service Adjustments And Checks 1 Each 400 hours of engine operation remove the spark plugs and clean and adjust the electrode 2 Clean and visually check each coil on plug connectors check for secure fit Diagnostic Equipment To accurately diagnose Coil on Plug COP certain diagnostic equipment and tools are required In addition the suggested diagnostic equipment may make the job easier and more convenient Prior to diagnosing COP obtain the following test equipment or equivalent Spark tester neon bulb type Champion CT 436 Spark tester gap type special service tool D81P 6666 A Connect this gap type
164. ne coil per plug COP has three different modes of operation engine crank engine running and CMP Failure Mode Effects Management FMEM Engine Crank Engine Running During engine crank the GCP will fire two spark plugs simultaneously Of the two plugs simultaneously fired one will be under compression the other will be on the exhaust stroke Both plugs will fire until camshaft position is identified by a successful camshaft position sensor signal Once camshaft position is identified only the cylinder under compression will be fired CMP FMEM During CMP FMEM the COP ignition works the same as during engine crank This allows the engine to operate without the GCP knowing if cylinder one is under compression or exhaust Cranking Mode Cranking mode is the area of engine operating speed within which the ignition timing is at a static position The static spark advance is fixed at 10 degrees BTDC up to 250 RPM Transient Mode This function is to provide a limp in mode whenever certain components fail The engine will run but at a set timing and batch fuel delivery This mode will stay in effect until problem is corrected or ignition turned off and back on if an intermittent problem Overspeed Mode Over speed protection is available on certain GCP modules that have set RPM limits Refer to the GCP Replacement chart When the module senses the engine RPM is at the preset limit grounding of the Coil on Plugs is removed stalling the engine The
165. ntrol modules through a Controller Area Network CAN link with messages written in the J1939 protocol This allows large amounts of data to move throughout the machine through only two wires and can be used to run some module based gauge packages The GCP also carries auxiliary features that can be programmed to control OEM devices allowing the OEM to eliminate components from their machinery The GCP is also equipped with multiple safety and protection devices that protect the user and engine from hazards such as over speed over temperature over voltage low oil pressure unauthorized tampering over cranking starter motor The GCP controls the following Fuel metering system Ignition timing On board diagnostics for engine functions The GCP constantly observes the information from various sensors The GCP controls the systems that affect engine performance The GCP performs the diagnostic function of the system It can recognize operational problems alert the operator through the Malfunction Indicator Lamp MIL and store diagnostic trouble codes DTC s DTC s identify the problem areas to aid the technician in making repairs The GCP supplies either 5 or 12 volts to power various sensors or switches The power is supplied through resistances in the GCP which are so high in value that a test light will not light when connected to the circuit In some cases even an ordinary shop voltmete
166. of the stem for grooves or scoring The valve face and the edge for pits grooves or scores The valve head for signs of burning erosion warpage and cracking Minor pits grooves and other abrasions may be removed The valve head thickness for wear 21 WSG 1068 GENERAL INFORMATION Valve Guide Inner Diameter 1 Measure the inner diameter of the valve guides in two directions where indicated 2 If the valve guide is not within specifications ream the valve guide and install a valve with an oversize stem or remove the valve guide and install a new valve guide Valve Guide Reaming 1 Use a hand reaming kit to ream the valve guide 2 Reface the valve seat 3 Clean the sharp edges left by reaming Valve Spring Installed Length Measure the installed length of each valve spring Valve Spring Free Length Measure the free length of each valve spring Valve Spring Out of Square Measure the out of square on each valve spring Turn the valve spring and observe the space between the top of the valve spring and the square Replace the valve spring if out of specification 22 WSG 1068 GENERAL INFORMATION Valve Spring Compression Pressure Special Tool s Use the Valve Clutch Spring Tester to check the valve springs for proper strength at the specified valve spring length Valve and Seat Refacing Measurements NOTE After grinding valves or valve seats check valve clearance
167. on Oil Pump Gear Radial Clearance Oil Pump Rotor Inspection Oil Pump Side Clearance Cylinder Bore Honing Cylinder Bore Cleaning Cylinder Block Repair Cast Iron Porosity Defects Cylinder Block Core Plug Replacement Cylinder Head Distortion Spark Plug Thread Repair Exhaust Manifold Straightness
168. onent through a process of logical decisions The tests and charts are prepared with the requirement that the engine functioned correctly at the time of assembly and that there were not multiple faults present There is a continuous self diagnosis on certain control functions This diagnostic capability is complimented by the diagnostic procedures contained in this section The language for communicating the source of the malfunction is a system of diagnostic trouble codes When a malfunction is detected by the Engine Control Module GCP a Diagnostic Trouble Code DTC is set and the Malfunction Indicator MIL lamp will be illuminated refer to MIL DTC Retrieval Procedure for process description Refer to Diagnosis Using a Personal Computer on page 26 or Palm Pilot Diagnosis for information regarding performing GCP and engine control system diagnosis Engine Control Module GCP Limp Home Mode Strategy The GCP has four settings for limp home mode Depending on what Diagnostic Trouble Code DTC is set one or more of the limp home modes will be in effect The four limp home modes are as follows Power Derate 1 The actuator is limited to a maximum opening of 50 If Power Derate 1 is active it will remain active until the active DTC goes away The following DTC s will cause Power Derate 1 to take affect DTC 1521 CHT ECT higher than expected CHT ECT is greater than 240 F DTC 111 IAT higher than expected 1 I
169. or Coil on Plug Engine Crank Engine Running CMP FMEM Cranking Mode Transient Mode Overspeed Mode Electronic Engine Controls Cylinder Head Temperature CHT Sensor Starting Mode CHT Effects IAT Effects Not Used
170. ound and illuminate the indicator until the regulator is activated The S stator circuit NOT USED is used to feed back a voltage signal from the generator to the regulator This voltage typically half battery voltage is used by the regulator to turn off the charge indicator 231 WSG 1068 CHARGING SYSTEM REMOVAL AND INSTALLATION Generator Removal 1 Disconnect battery ground cable 14301 2 Remove snow ice shield 3 Disconnect the generator voltage regulator wiring 14305 to the voltage regulator 4 Remove wiring connector bracket 5 Relieve the tension of the drive belt tensioner 613209 and remove the drive belt 6 Remove the bolts holding the generator to the generator bracket 10A313 7 Remove the generator from the generator bracket Generator Installation 1 Position the generator on the generator bracket 2 Install the bolts and tighten to 40 55 Nm 30 40 ftlb 3 Install the drive belt over the generator pulley 4 Relieve the tension of the drive belt tensioner and install the drive belt over tensioner 5 Connect generator voltage regulator wiring to the voltage regulator Tighten generator Battery Positive Voltage B wire attaching nut to 9 12 Nm 6 5 9 ftlb 6 Install wiring connector bracket 7 Install snow ice shield 8 Connect battery ground cable Regulator Removal 1 NOTE for ease or removal and installation of regulator remove the generator from engine as described above Remov
171. ows to the starter solenoid engaging the starter When the engine has reached 600 rpm or greater the GCP will ground the relay terminal 85 and open terminals 30 amp 87A which will not allow the starter to be engaged while the engine is operating above 600 rpm Once the relay is energized it will not reset until the GCP is turned off and then back on 242 WSG 1068 STARTER SYSTEM 243 WSG 1068 STARTER SYSTEM Component Tests Starter Motor Voltage Drop Test WARNING WHEN REPAIRING THE STARTER MOTOR OR PERFORMING OTHER UNDERHOOD WORK IN THE VICINITY OF THE STARTER MOTOR BE AWARE THAT THE HEAVY GAUGE BATTERY INPUT LEAD AT THE STARTER SOLENOID IS ELECTRICALLY HOT AT ALL TIMES WHEN SHORTED TO GROUND MAY CAUSE PERSONAL INJURY CAUTION A protective cap or boot is provided over the battery input terminal on all vehicle lines and must be replaced after repairing Failure to replace protective cap could cause electrical short that may damage electrical system Be sure to disconnect the battery ground cable before repiaring the starter motor NOTE Always connect the 73 Digital Multimeter at the component terminal rather than at the wiring end connector Making a connection at the wiring end connector could result in false readings because the meter will not pick up a high resistance between the wiring connector and the component Starter Motor Motor Feed Circuit 1 Make sure the battery is fully charged 2 Conne
172. pection Valve Guide Inner Diameter Valve Guide Reaming Valve Spring Installed Length Valve Spring Free Length Valve Spring Out of Square Valve Spring Compression Pressure Valve and Seat Refacing Measurements Valve Seat Width Valve Seat Runout Flywheel Inspecti
173. r use of a conventional tachometer from this output Global Control Platform GCP 171 WSG 1068 IGNITION SYSTEM Ignition System Components Location The 6 8L engine is equipped with a coil on plug ignition system This system has a separate ignition coil mounted on each spark plug Operation of the coils is controlled by global control platform GCP which computes ignition timing based on inputs from the electronic engine control system sensors For additional information on sensor inputs related to ignition control refer to Section 08 The ignition coils change a supplied low voltage signal into high voltage pulses to the spark plugs The ignition control module controls the low side of each coil The ignition system is set for base timing at 10 degrees before top dead center BTDC and is not adjustable Refer to Specifications for firing order 172 WSG 1068 IGNITION SYSTEM Firing Order 173 WSG 1068 IGNITION SYSTEM Ignition Coil On Plug Removal 1 Disconnect the wiring at the coil 2 Remove the bolt and the coil Ignition Coil On Plug Installation WARNING ALWAYS WEAR SAFETY GLASSES TO PROTECT EYES FROM FLYING FOREIGN MATERIAL 1 NOTE Remove any foreign material from spark plug wells with compressed air 2 Insert a small amount of dielectric grease into each boot using Motorcraft Silicone Brake Caliper Grease and Dielectric Compound XG 3 or equivalent meeting Ford specificatio
174. r will not give an accurate reading because its resistance is too low Therefore a digital voltmeter with at least 10 megohms input impedance is required to ensure accurate voltage readings The GCP controls output circuits such as the fuel injectors electronic governor etc by controlling the ground or the power feed circuit through transistors or other solid state devices The GCP is designed to maintain exhaust emission levels to government mandated standards while providing excellent operation and fuel efficiency The GCP monitors numerous engine functions via electronic sensors such as the throttle position TP sensor and the heated oxygen sensor HO2S GCP Inputs operating conditions read Engine Coolant Temperature Crankshaft Position Exhaust Oxygen Content Manifold Absolute Pressure Battery Voltage Throttle Position Electronic Actuator Fuel Pump Voltage Intake Air Temperature Camshaft Position GCP Outputs systems controlled Fuel control Electronic Throttle Control Electric Fuel Pump Diagnostics Malfunction Indicator Lamp check engine lamp Diagnostics Data Link Connector DLC 254 WSG 1068 ENGINE CONTROLS Crankshaft Position CKP Sensor The Crankshaft Position CKP Sensor provides a signal used by the Engine Control Module GCP to calculate the ignition sequence The sensor initiates the reference pulses which the GCP uses to calcul
175. rcuit ground is OK Figure 6 The circuit schematics in this manual make it easy to identify common points in circuits This knowledge can help narrow the concern to a specific area For example if several circuits fail at the same time check for a common power or ground connection If part of a circuit fails check the connections between the part that works and the part that doesn t work For example if the low beam headlamps work but the high beams and the indicator lamp don t work then the power and ground paths must be good Since the dimmer switch is the component that switches this power to the high beam lights and the indicator it is most likely the cause of failure 163 WSG 1068 IGNITION SYSTEM Troubleshooting Wiring Harness and Connector Hidden Concerns The following illustrations are known examples of wiring harness splices and connectors that will create intermittent electrical concerns The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration NOTE When servicing gold plated terminals in a connector only replace with gold plated terminals designed for that connector 164 WSG 1068 IGNITION SYSTEM 165 WSG 1068 IGNITION SYSTEM WARNING WHEN CARRYING OUT SERVICE OPERATIONS ON AN ENGINE EQUIPPED WITH DISTRIBUTORLESS IGNITION FOLLOW ALL THE USUAL SAFETY MEASURES TO PREVENT THE POSSIBILITY OF ELECTRIC SHOCKS SHOULD BE FOLLOWED
176. re is to be used year round with temperatures above 30 F Recycled Coolant Use recycled engine coolant produced by Ford approved processes Not all coolant recycling processes produce coolant which meets Ford specification ESE M97B44 A or WSS M97B44 D and use of such a coolant may harm engine and cooling system components Unsatisfactory Coolant Material Alcohol type antifreeze does not provide adequate water pump lubrication Has a lower boiling point Provides reduced antifreeze protection CAUTION Alkaline brine solutions will cause serious engine cooling system damage CAUTION Do not use 100 000 mile red in color antifreeze it is not compatible with copper radiators 193 WSG 1068 COOLING SYSTEM GENERAL SERVICE PROCEDURES Cooling System Draining WARNING NEVER REMOVE THE PRESSURE RELIEF CAP WHILE THE ENGINE IS OPERATING OR WHEN THE COOLING SYSTEM IS HOT MAY CAUSE PERSONAL INJURY OR DAMAGE TO COOLING SYSTEM OR ENGINE TO AVOID HAVING SCALDING HOT COOLANT OR STEAM BLOW OUT OF THE DEGAS BOTTLE WHEN REMOVING THE PRESSURE RELIEF CAP WAIT UNTIL THE ENGINE HAS COOLED DOWN TO AT LEAST 110 F 1 Wrap a thick cloth around the pressure relief cap and turn it slowly one half turn counterclockwise Stepping back while the pressure is released from the cooling system 2 When you are sure all the pressure has been released still with a cloth turn the pressure relief cap counterclockwise and re
177. reboot your system Click yes Your system will shut down and reboot The software is now installed on your system in a folder called FPP Display Refer now to Using Technicians GCP Software in this Section Using GCP Software Menu Functions You can begin using the technicians GCP software after installation by clicking Start Programs GCP Display GCP Display as shown Type in the Password which can be found on the label of the CD ROM Place the ignition key in the ON position The GCP system Gauge screen should now appear and a green banner in the upper left hand corner will read Connected 280 WSG 1068 ENGINE CONTROLS Diagnostic Trouble Codes The System Fault screen is used to view and clear DTC s which have been set Checking Diagnostic Trouble Codes The System Fault screen contains a listing of all of the Historic and Active DTC s set within the FORD system If a DTC is stored in memory the screen will display that fault in the Historic Faults column If the fault condition currently exists the DTC will also show up in the Active Faults column Opening Diagnostic Trouble Codes To open a DTC click on the DTC in the Historic Faults column A DTC Dialog Box will pop up on the screen The DTC Dialog Box contains the following useful information If the fault occurred during the current key cycle If the fault caused current engine shutdown How many key cycles since the
178. remove the crankshaft rear oil seal 6701 96 WSG 1068 ENGINE Crankshaft Rear Oil Seal Installation 1 CAUTION Mating parts must make contact to each other within 4 minutes and connecting bolts must be torqued within 15 minutes after applying sealant Failure to follow this procedure can cause future oil leakage Use silicone gasket and sealant F6AZ 19562 AA or equivalent meeting Ford specification WSEM4G323 A6 NOTE Sealant must be removed and area cleaned with solvent if above instructions are not followed Use metal surface cleaner F4AZ 19A536 RA or equivalent meeting Ford specification WSEM5B292 A 2 Using the Rear Crankshaft Seal Replacer and the Rear Crankshaft Seal Adapter install the crankshaft rear oil seal 3 With the Rear Crankshaft Seal Adapter still installed use the Rear Crankshaft Slinger Replacer and the Rear Crankshaft Seal Replacer to install the rear main seal slinger 4 Install the flywheel refer to Flywheel in this section 5 Connect the battery ground cable 97 WSG 1068 ENGINE Crankshaft Rear Oil Seal with retainer plate Removal 1 Disconnect the battery ground cable 14301 Remove the flywheel 6375 refer to Flywheel in this section 2 Use the Rear Crankshaft Slinger Remover and the Impact Slide Hammer to remove the crankshaft oil slinger 6310 98 WSG 1068 ENGINE 3 Use the Rear Crankshaft Seal Remover and the Impact Slide Hammer to remove t
179. rform with engine oils that are licensed by the American Petroleum Institute API and oils carrying the most current API classification should be used 29 WSG 1068 ENGINE INDEX Subject Page General Information Description Engine Identification Engine Code Information Module View Engine Intake Components Low End Components Upper End Components Major Front End Components 46 46 46 47 48 50 52 54 Diagnosis and Testing
180. ring Harness amp Connector Hidden Concerns Electrical Symbols Description Operation Overview Electronic Ignition System Starting RPM Camshaft Position Sensor The Fuel Select Switch Run Mode Inputs to the GCP Effecting the Ignition Crankshaft Position Sensor CKP Sens
181. ring installation 33 If the copper links are not visible mark two links on one end and one link on the other end to use as timing marks 34 Loosen the Camshaft Holding Tools on both camshafts 6250 139 WSG 1068 ENGINE 35 Install the timing chain guides 6K297 140 WSG 1068 ENGINE 36 Rotate the LH camshaft sprocket until the timing mark is approximately at 12 o clock Rotate the RH camshaft until the timing mark is approximately at 11 o clock Tighten the Camshaft Holding Tools to maintain camshaft pre positioning 37 CAUTION Unless otherwise instructed at no time when the timing chains 6268 are removed and the cylinder heads are installed is the crankshaft or camshaft to be rotated Severe piston and valve damage will occur CAUTION Rotate the crankshaft counterclockwise only Do not rotate past the position shown or severe piston or valve damage can occur Position the crankshaft with the Crankshaft Holding Tool 38 Remove the Crankshaft Holding Tool 141 WSG 1068 ENGINE 39 Position the inner crankshaft sprocket 6306 with the long hub facing outward 40 Install the LH timing chain belt onto the crankshaft sprocket aligning the one copper link on the timing chain with the slot on the crankshaft sprocket 41 NOTE Make sure the upper half of the timing chain is below the tensioner guide dowel If necessary use the Camshaft Holding Tool to adjust NOTE If necessary adjust the
182. rs as follows Leakdown Testing NOTE Do not mix parts from different hydraulic valve tappets lash adjusters Parts are select fit and are not interchangeable 1 Clean the lash adjuster to remove all traces of engine oil NOTE lash adjusters lash adjuster cannot be checked with engine oil in them Use only testing fluid New hydraulic lash adjusters lash adjusters are already filled with testing fluid 2 Place the lash adjuster in the tester with the plunger facing upward Position the steel ball provided in the plunger cap Add testing fluid to cover the hydraulic tappet lash adjuster and compress Hydraulic Tappet Leakdown Tester until the hydraulic lash adjuster is filled with testing fluid and all traces of air bubbles have disappeared The fluid can be purchased from the tester s manufacturer Using kerosene or any other fluid will not provide an accurate test 3 Adjust the length of the ram so the pointer is just below the start timing mark when the ram contacts the hydraulic lash adjuster Start Timing as the pointer passes the start timing mark and end timing as the pointer reaches the center mark 4 A satisfactory lash adjuster must have a leakdown rate time in seconds within specified minimum and maximum limits 5 If the lash adjuster is not within specification replace it with a new lash adjuster Do not disassemble and clean new lash adjusters lash adjuster before testing because oil contained in the new lash adju
183. s Fuel leaks Damaged or severely worn pads Loose mounting bolts studs and nuts 3 If the inspection reveals obvious concerns that can be readily identified repair as required 4 If the concerns remain after the inspection determine the symptoms and go to the symptom chart 8 WSG 1068 GENERAL INFORMATION Symptom Chart Condition Possible Source Action 9 WSG 1068 GENERAL INFORMATION WSG 1068 GENERAL INFORMATION Engine Oil Leaks NOTE When diagnosing engine oil leaks the source and location of the leak must be positively identified prior to service Prior to performing this procedure clean the cylinder block cylinder heads valve covers oil pan and flywheel with a suitable solvent to remove all traces of oil Fluorescent Oil Additive Method Use the 12 Volt Master UV Diagnostic Inspection Kit to perform the following procedure for oil leak diagnosis 1 Clean the engine with a suitable solvent to remove all traces of oil 2 Drain engine oil crankcase and refill with recommended oil premixed with Diesel Engine Oil Dye 164 R3705 meeting Ford specification ESEM9C103 B1 or equivalent Use a minimum 14 8 ml 0 5 ounce to a maximum 29 6 ml 1 ounce of fluorescent additive to all engines If the oil is not premixed fluorescent additive must first be added to crankcase 3 Run the engine for 15 minutes Stop the engine and inspect all seal and gasket areas for leaks using the 12 Volt Master UV diagnosti
184. s and the RH exhaust manifold 9430 and exhaust manifold gasket 9448 Discard the exhaust manifold gasket 22 Remove the ten nuts the LH exhaust manifold and the exhaust manifold gaskets Discard the exhaust manifold gasket 115 WSG 1068 ENGINE 23 Remove the oil level dipstick the bolt and the oil level indicator tube 6754 24 Install the Lifting Handles on both ends of the cylinder head 25 CAUTION These bolts must be replaced with new bolts They are tighten to yield designed and cannot be reused Remove the bolts cylinder head and head gasket Discard the head gasket 6051 cylinder head bolts and clean the engine block surface LH is shown RH is similar 116 WSG 1068 ENGINE 26 Use silicone gasket and sealant F6AZ 19562 AA equivalent meeting Ford specification WSE M4G323 A6 NOTE Sealant must be removed and area cleaned with solvent if above instructions are not followed Use metal surface cleaner F4AZ 19A536 RA or equivalent meeting Ford specification WSEM5B292 A 27 Remove the bolts and remove the engine mounts 28 Remove the bolts and nut retaining the oil filter adapter 6881 to the cylinder block Remove the oil filter adapter and clean the gasket surface 29 Remove the bolts and the oil pump 6600 117 WSG 1068 ENGINE 30 Remove the twelve bolts and the two lower crankshaft bearing supports 31 CAUTION Make sure connecting rods 6200 and rod c
185. sition the bearing caps in their original locations and the bolts Tighten the bolts in the sequence shown 11 Install the intake manifold refer to Intake Manifold Variable Resonance Induction System VRIS in this section 12 Install the timing chains refer to Timing Drive Components in this section 81 WSG 1068 ENGINE Exhaust Manifold RH Removal 1 Remove the nuts from exhaust pipe and remove exhaust pipe 2 Remove the ten nuts and the exhaust manifold 9430 and exhaust manifold gasket 9448 Discard the exhaust manifold gasket 3 Clean and inspect the exhaust manifold refer to Section 01 82 WSG 1068 ENGINE Exhaust Manifold RH Installation 1 Follow the removal procedure in reverse order 83 WSG 1068 ENGINE Exhaust Manifold LH Removal 1 Remove the nuts from the exhaust pipe and remove pipe 2 Remove the exhaust manifold nuts and the exhaust manifold 9430 Discard the exhaust manifold gaskets 9448 3 Clean and inspect the exhaust manifold refer to Section 01 84 WSG 1068 ENGINE Exhaust Manifold LH Installation 1 Follow the removal procedure in reverse order Cylinder Head Removal Special Tool s Special Service Tools called for by the procedures can be obtained by calling 1 800 ROTUNDA 1 800 768 8632 85 WSG 1068 ENGINE 1 WARNING DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR A
186. sor to 40 Nm 30 lb ft 297 WSG 1068 ENGINE CONTROLS Knock Sensor KS Replacement 1 Disconnect battery ground cable refer to section 6 2 Remove or disconnect any component to allow access and removal of the knock sensor 3 Disconnect KS sensor electrical connector NOTE The KS sensor is a one time use item and a new KS sensor must be installed 4 Remove bolt and KS sensor and discard sensor 5 Reverse procedure to install Install a new KS sensor Tighten bolt to 20 Nm 15 lb ft Temperature Manifold Absolute Pressure TMAP Sensor Replacement 1 Disconnect battery ground cable refer to section 6 2 Remove or disconnect any component to allow access and removal of the TMAP sensor 3 Disconnect TMAP electrical connector 4 Remove bolt and TMAP Sensor 5 Reverse procedure to install Use a new o ring seal Tighten bolt to Nm lb 298 WSG 1068 ENGINE CONTROLS SPECIFICATIONS 299 WSG 1068 METRICS INDEX Subject Introduction Nomenclature for Bolts Bolt Strength Identification
187. spark tester between any COP and engine ground to instantly determine if spark is being provided to the plug A spark plug with a broken side electrode is not sufficient to check for spark and may lead to incorrect results Volt ohmmeter Rotunda 73111 Automotive Meter 105 R005 7 or equivalent A volt ohmmeter is essential for gathering system operating data during diagnosis testing and engine servicing procedures This digital volt ohmmeter DVOM can also be used for general purpose electrical troubleshooting on conventional starting and charging systems CAUTION There should be no wires spliced to the main wire harness for source of power or RPM signal unless pre approved by Ford Power Products Otherwise any alteration will void the warranty Altering of wire harness may cause lack of power no start or erratic running NOTE When using the spark plug firing indicator place the grooved end as close as possible to the plug boot Very weak or no flashing may be caused by a fouled plug NOTE Do not use an incandescent test lamp to check CKPS or CKPS circuits The lamp will prevent the circuit from operating 177 WSG 1068 IGNITION SYSTEM Preliminary Checks Before using this section verify the customer complaint and refer to the appropriate symptom chart Perform the procedure included in the symptom chart Basic Circuit Checks Basic circuit checks help to minimize pinpoint test steps by providing a procedure to
188. ster is test fluid 6 Remove the fluid from the cup and bleed the fluid from the lash adjuster by working the plunger up and down This step will aid in depressing the lash adjuster plungers when checking valve clearance 9 WSG 1068 GENERAL INFORMATION GENERAL SERVICE PROCEDURES WARNING TO AVOID THE POSSIBILITY OF PERSONAL INJURY OR DAMAGE TO THE EQUIPMENT DO NOT OPERATE THE ENGINE WITH THE HOOD OPEN UNTIL THE FAN BLADE HAS BEEN EXAMINED FOR POSSIBLE CRACKS AND SEPARATION NOTE Specifications show the expected minimum or maximum condition NOTE If a component fails to meet the specifications it is necessary to replace or refinish If the component can be refinished wear limits are provided as an aid to making a decision Any component that fails to meet specifications and cannot be refinished must be replaced Camshaft Journal Diameter Measure each camshaft journal diameter in two directions If it is out of specification replace as necessary Camshaft Journal Clearance NOTE The camshaft journals must meet specifications before checking camshaft journal clearance Measure each camshaft bearing in two directions Subtract the camshaft journal diameter from the camshaft bearing diameter Camshaft Lobe Surface Inspect camshaft lobes for pitting or damage in the active area Minor pitting is acceptable outside the active area 10 WSG 1068 GENERAL INFORMATION Camshaft Lobe Lif
189. sual Inspection Chart Special Tool s Special Service Tools called for by the procedures can be obtained by calling 1 800 ROTUNDA 1 800 768 8632 Inspection and Verification 1 Verify the customer s concern by operating the engine to duplicate the condition 2 Inspect to determine if any of the following mechanical or electrical concerns apply Symptom Chart Inspection and Verification 3 If the inspection reveals an obvious concern that can be readily identified repair as necessary 4 If the concern remains after the inspection determine the symptom s and go to the Symptom Chart 213 WSG 1068 COOLING SYSTEM PINPOINT TEST A LOSS OF COOLANT 214 WSG 1068 COOLING SYSTEM PINPOINT TEST A LOSS OF COOLANT Continued 215 WSG 1068 COOLING SYSTEM PINPOINT TEST A LOSS OF COOLANT Continued PINPOINT TEST B THE ENGINE OVERHEATS 216 WSG 1068 COOLING SYSTEM PINPOINT TEST B THE ENGINE OVERHEATS Continued 217 WSG 1068 COOLING SYSTEM PINPOINT TEST B THE ENGINE OVERHEATS Continued 218 WSG 1068 COOLING SYSTEM PINPOINT TEST C THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURE 219 WSG 1068 COOLING SYSTEM SPECIFICATIONS General Specifications NOTE Bolt information on installation page this section Torque Specifications 220 WSG 1068 CHARGING SYSTEM INDEX Subject General Information Generator
190. suspect circuit at the harness connector and a reliable ground The voltage must be less than 1 0 volt Visual Physical Check Several of the symptom procedures call for a careful visual physical check This can often lead to repairing a problem without performing unnecessary steps Use the following guidelines when performing a visual physical check Inspect unit for modifications or aftermarket equipment that can contribute to symptom verify that all electrical and mechanical loads or accessory equipment is OFF or disconnected before performing diagnosis Inspect engine fluids for correct levels and evidence of leaks Inspect vacuum hoses for damage leaks cracks kinks and improper routing inspect intake manifold sealing surface for a possible vacuum leak Inspect all wires and harnesses for proper connections and routing bent or broken connector pins burned chafed or pinched wires corrosion and verify harness grounds are clean and tight Inspect GCP sensors and actuators for physical damage Inspect fuel system for adequate fuel level and fuel quality concerns such as proper fuel pressure and contamination Inspect intake air system and air filter for restrictions Intermittent Problems Most intermittent problems are caused by faulty electrical connections or wiring Perform a careful visual physical check for the following conditions Poor mating of the connector halves or a terminal
191. t 1 Use the Dial Indicator with Bracketry to measure camshaft intake lobe lift 2 Rotate the camshaft and subtract the lowest dial indicator reading from the highest dial indicator reading to figure the camshaft lobe lift 3 Use the Dial Indicator with Bracketry to measure camshaft exhaust lobe lift 4 Rotate the camshaft and subtract the lowest dial indicator reading from the highest dial indicator reading to figure the camshaft lobe lift Camshaft Runout Special Tool s NOTE Camshaft journals must be within specifications before checking runout Use the Dial Indicator with Bracketry to measure the camshaft runout Rotate the camshaft and subtract the lowest dial indicator reading from the highest dial indicator reading 11 WSG 1068 GENERAL INFORMATION Crankshaft Main Bearing Journal Diameter Measure each of the crankshaft main bearing journal diameters in at least two directions If it is out of specification replace as necessary Crankshaft Main Bearing Journal Taper Measure each of the crankshaft main bearing journal diameters in at least two directions at each end of the main bearing journal If it is out of specifications replace as necessary 12 WSG 1068 GENERAL INFORMATION Crankshaft Main Bearing Journal Clearance Special Tool s NOTE Crankshaft main bearing journals must be within specifications before checking journal clearance 1 Remove the cranksh
192. t initial adjustment or wear of lash adjuster face or worn roller lash adjusters push rod rocker arm rocker arm seat or valve tip With lash adjuster collapsed check gap between the valve tip and the rocker arm to determine if any other valve train parts are damaged worn or out of adjustment A sticking lash adjuster plunger can be caused by dirt chips or varnish inside the lash adjuster A lash adjuster check valve that is not functioning can be caused by an obstruction such as dirt or chips that prevent it from closing when the camshaft lobe is lifting the lash adjuster It may also be caused by a broken check valve spring Air bubbles in the lubrication system will prevent the lash adjuster from supporting the valve spring load This can be caused by too high or too low an oil level in the oil pan or by air being drawn into the system through a hole crack or leaking gasket on the oil pump screen cover and tube If the leakdown time is below the specified time for used lash adjusters noisy operation can result If no other cause for noisy lash adjusters can be found the leakdown rate should be checked and any lash adjusters outside the specification should be replaced Assembled lash adjusters can be tested with Hydraulic lash adjuster Leakdown Tester to check the leakdown rate The leakdown rate specification is the time in seconds for the plunger to move a specified distance while under a 22 7 kg 50 lb load Test the lash adjuste
193. t is within specification Connecting Rod Twist Measure the connecting rod twist on a suitable alignment fixture Follow the instructions of the fixture manufacturer Verify the measurement is within specification 18 WSG 1068 GENERAL INFORMATION Connecting Rod Piston Pin Side Clearance Measure the clearance between the connecting rod and the piston Verify the measurement is within specification Connecting Rod Journal Clearance Special Tool s NOTE The crankshaft connecting rod journals must be within specifications to check the connecting rod bearing journal clearances CAUTION The connecting rod bolts are torque to yield and must be discarded and replaced after this diagnostic test 1 Remove the connecting rod bearing cap 2 Position a piece of Plastigage across the bearing surface NOTE Do not turn the crankshaft during this step 3 Install and torque to specifications then remove the connecting rod bearing cap 4 Measure the Plastigage to get the connecting rod bearing journal clearance The Plastigage should be smooth and flat A change width indicates a tapered or damaged connecting rod bearing or connecting rod 19 WSG 1068 GENERAL INFORMATION Bearing Inspection Inspect bearings for the following defects Possible causes are shown Cratering fatigue failure A Spot polishing improper seating B Scratching dirty C Base exposed poor lubric
194. t would interfered with the proper sealing of the plug If the cylinder block plug bore is damaged bore for the next oversize plug NOTE Oversize plugs are identified by the OS stamped in the flat located on the cup side of the plug 3 Coat the cylinder block core plug and bore lightly with Threadlock 262 E2FZ 19554 B or equivalent meeting Ford specification WSK M2G351 A6 and install the cylinder block core plug Cylinder Head Distortion Special Tool s Use a straight edge and a feeler gauge to inspect the cylinder head for flatness If the cylinder head is distorted install a new cylinder head 26 WSG 1068 GENERAL INFORMATION Cylinder Block Core Plug Cup Type CAUTION Do not contact the flange when installing a cup type cylinder block core plug as this could damage the sealing edge and result in leakage NOTE When installed the flanged edge must be below the chamfered edge of the bore to effectively seal the bore Use a fabricated tool to seat the cup type cylinder block core plug Cylinder Block Core Plug Expansion Type CAUTION Do not contact the crown when installing an expansion type cylinder block core plug This could expand the plug before seating and result in leakage Use a fabricated tool to seat the expansion type cylinder block core plug 27 WSG 1068 GENERAL INFORMATION Spark Plug Thread Repair Special Tool s CAUTION The cylinder head must be removed fro
195. tarter motor solenoid terminal cover 4 Connect the battery ground cable 250 WSG 1068 STARTER SYSTEM SPECIFICATIONS Torque Specifications Electrical Specifications General Specifications Special Tools Special Service Tools called for by the procedures can be obtained by calling 1 800 ROTUNDA 1 800 768 8632 251 WSG 1068 ENGINE CONTROLS Subject Page General Information GCP and Sensors Fuel System Components Gasoline Coil on plug Ignition Open Loop and Closed Loop Operation Adaptive Learn hhhh GCP Service Precautions Use of Circuit Testing Tools Electrostatic Discharge Damage
196. te the history of DTC s observed with this particular engine 2 Evaluate the symptoms and conditions described by the customer 3 Use strategy based diagnosis especially where it relates to the elimination of bad connectors and wiring 4 When using a personal computer with Ford software data capturing capabilities are available that can assist in detecting intermittents Contact an EDI customer service representative at 1 800 220 2700 for more information Malfunction Indicator Lamp MIL DTC Retrieval Procedure NOTE DTC s can be retrieved from the engine control module GCP by using either the MIL or an IBM compatible personal computer or hand held Palm Pilot using the optional serial interface available Refer to Equipment Setup for information about using a personal computer to assist with unit diagnosis DTC s can be retrieved by shorting the Self Test Input STI connector to ground The STI circuit is a white purple wire exiting pin 3 of the 42 pin connector The STI white purple wire branches off to terminal A of the 4 pin diagnostic connector If no DTC is stored with key on engine off KOEO a DTC 123 is flashed indicating that all systems are OK During key on engine running KOER operation with no DTCs stored the MIL is not illuminated If during 276 WSG 1068 ENGINE CONTROLS KOER operation a DTC is stored the MIL will illuminate and remain on steady if the code is active MIL Bulb T
197. ted by selectively pulling fuses to pinpoint the location of the current drain When the current drain is found the meter reading will fall to an acceptable level If the drain is still not located after checking all the fuses it may be due to the generator NOTE To accurately test the drain on a battery an in line digital ammeter must be used Use of a test lamp or voltmeter is not an accurate method 225 WSG 1068 CHARGING SYSTEM Check for current drains on the battery in excess of 50 milliamps 0 050 amp with all the electrical accessories off and the engine off Current drains can be tested with the following procedure 1 Make sure the junction box fuse panels are accessible without turning on auxiliary components 2 Operate the engine at least five minutes and exercise systems 3 Allow the engine to sit with the key OFF for at least 40 minutes to allow modules to time out power down 4 Connect a fused jumper wire between the negative battery cable and the negative battery post to prevent modules from resetting and to catch capacitive drains 5 Disconnect the negative battery cable from the post without breaking the connection of the jumper wire NOTE It is very important that continuity is not broken between the battery and the negative battery cable when connecting the meter If this happens the entire procedure must be repeated Connect the tester between the negative battery cable and the post The meter must
198. tenance Distributors are listed at the back of this manual Regular maintenance will result in minimal operating costs Engines manufactured by Ford Motor Company are available through Engine Distributors Incorporated When in need of parts or service contact your local Authorized Distributor In overseas territories in the event of difficulties communicate directly with the supervising Ford affiliated Company in your area whose address appears at the end of this book Where the terms Right or Left occur in this publication they refer to the respective sides of the engine when viewed from the rear or flywheel end Pistons and valves are numbered from the front or timing cover end of the engine commencing at No 1 You may find that your engine assembly includes optional equipment not specifically covered in the following text Nevertheless the maintenance procedures outlined in this book still apply to your engine 4 WSG 1068 GENERAL INFORMATION Engine Identification Because of such a wide range of industrial engines manufactured both in the U S and overseas it is important that you have as complete identification of the engine as possible in order to provide the correct replacement parts New engines being shipped include a standard parts listing describing the parts which does not tell the owner the part number It remains a distributor function to identify the part number The key to identifying the engine is the ident
199. the cylinder bore NOTE For precision fit new pistons are divided into three categories within each size range based on their relative position within the range A paint spot on the new pistons indicates the position within the size range 2 Choose the piston with the proper paint color Red in the lower third of the size range Blue in the middle third of the size range Yellow in the upper third of the size range Piston Ring End Gap Special Tool s CAUTION Use care when fitting piston rings to avoid possible damage to the piston ring or the cylinder bore CAUTION Piston rings should not be transferred from one piston to another to prevent damage to cylinder worn or piston NOTE Cylinder bore must be within specification for taper and out of round to fit piston rings 1 Use a piston without rings to push a piston ring in a cylinder to the bottom of ring travel 2 Use a feeler gauge to measure the top piston ring end gap and the second piston ring end gap 16 WSG 1068 GENERAL INFORMATION Piston Ring to Groove Clearance Special Tool s 1 Inspect for a stop in the grooves 2 Measure the piston to groove clearance Crankshaft Connecting Rod Journal Diameter Measure the crankshaft connecting rod journal diameters in at least two directions perpendicular to one another The difference between the measurements is the out of round Verify the journal is within the wear limit specifi
200. the leak might be A blown head gasket 6051 A cracked or warped cylinder head 6049 A crack in the engine oil gallery and the cooling passageways If engine coolant is present in the engine oil the cause of the leak might be A blown head gasket A cracked or warped cylinder head A crack in the engine oil gallery and cooling passageways 207 WSG 1068 COOLING SYSTEM 4 If the engine coolant appearance is good test the engine coolant range with the battery and antifreeze tester Maximum ratio is 60 40 Minimum ratio is 45 55 5 Check the engine coolant system conditions If the engine cooling fluid is low add specified coolant mixture only If the engine coolant fluid tests weak add straight engine coolant until the readings are within acceptable levels If the engine coolant tests strong remove some of the engine coolant and add water until readings are within acceptable levels 6 Check for electrical charge in coolant Using a DVOM insert the probe into coolant without touching radiator Hold the probe to radiator shell or a good ground and read the volts Less then 1 5 volts is good If voltage is above 1 5 volts drain flush and replace coolant with a 50 50 mixture NOTE Above 3 volts may indicate a bad head gasket Thermostat Test Thermostat Removed WARNING USE CAUTION WORKING WITH HOT BOILING WATER AND WEAR APPROPRIATE PROTEC
201. tion of high tension wires The coil on plug design has individual coils mounted directly over each spark plug Each cylinder is paired with its opposing cylinder in the firing order so that one cylinder on compression fires simultaneously with the opposing cylinder on exhaust The spark that occurs in the cylinder on the exhaust stroke is referred to as a waste spark The primary coils in the coil pack are triggered by the ignition coil feed 1 and ignition coil feed 2 signals from the GCP 260 WSG 1068 ENGINE CONTROLS Open Loop and Closed Loop Operation NOTE No DTC will be set unless engine has operated in closed loop status for more than 6 seconds The GCP will operate in the following two modes Open loop Closed loop When the engine is first started the system is in open loop operation In open loop the GCP ignores the signal from the Heated Oxygen Sensor HO2S It uses a pre programmed routine to calculate the air fuel ratio based on inputs from the TP ECT TMAP amp CKP sensors The system remains in open loop until the following conditions are met The ECT has reached 95 F 35 C 15 seconds has elapsed since starting the engine After these conditions are met the engine is said to be operating in closed loop In closed loop the GCP continuously adjusts the air fuel ratio by responding to signals from the HO2S except at wide open throttle When the HO2S reports a
202. tion of that used of bolts and nuts Note that many types of English and Metric fasteners carry no special identification if they are otherwise unique 303 WSG 1068 METRICS ENGLISH METRIC CONVERSION 304 WSG 1068 METRICS DECIMAL AND METRIC EQUIVALENTS TORQUE CONVERSION 305 WSG 1068 METRICS J1930 TERMINOLOGY LIST Certain Ford Component names have been changed in this Service Manual to conform to Society of Automotive Engineers SAE directive J1930 SAE J1930 standardizes automotive component names for all vehicle manufacturers 306 WSG 1068 METRICS 307 WSG 1068 METRICS 308 WSG 1068 METRICS 309 WSG 1068 METRICS 310 WSG 1068 METRICS 311 WSG 1068 METRICS 312 WSG 1068 METRICS 313 314 EDI Worldwide Service Engine Distributors Inc 400 University Court Blackwood NJ 08012 Service Warranty 1 800 220 2700 1 856 228 7298 1 856 228 5657 fax parts amp service 1 856 228 5531 fax sales
203. tioned do not turn the crankshaft until instructed to do so 135 WSG 1068 ENGINE 22 Install the head gasket 6051 over the dowel pins 23 Install the Camshaft Holding Tools 24 Install the Lifting Handles 25 Install the cylinder head 6049 on the head gasket and loosely install new bolts The LH is shown the RH is similar 26 NOTE Be sure to tighten the new bolts in three stages Stage 1 Tighten to 37 43 Nm 27 32 lb ft Stage 2 Tighten an additional 85 degrees to 95 degrees Stage 3 Tighten an additional 85 degrees to 95 degrees 136 WSG 1068 ENGINE 27 Install the left and right exhaust manifold gaskets 9448 and exhaust manifolds 9430 Loosely install the nuts Tighten the nuts in the sequence shown 137 WSG 1068 ENGINE 28 CAUTION Timing chain procedures must be followed exactly or damage to valves and pistons 6108 will result If removed install the left and right camshaft sprockets 6256 29 CAUTION Do not compress the ratchet assembly This will damage the ratchet assembly Compress the tensioner plunger using an edge of a vise 30 Using a small screwdriver or pick push back and hold the ratchet mechanism 31 While holding the ratchet mechanism push the ratchet arm back into the tensioner housing 138 WSG 1068 ENGINE 32 Install a paper clip into the hole in the tensioner housing to hold the ratchet assembly and plunger in du
204. ttery positive 7 Connect the multimeter negative lead to the terminal at the other end of the cable 8 Crank the engine and observe the voltage reading The voltage reading should be 0 5 volts or lower If the voltage drop is too high clean the terminal ends Retest and if still high replace the cable If the voltage reading is less than 0 5 volts and the engine still cranks slowly replace the starter motor 245 WSG 1068 STARTER SYSTEM Starter Drive and Flywheel Ring Gear Inspection 1 Check the wear patterns on the A starter drive 11350 and the B flywheel ring gear If the wear pattern is normal install the starter motor refer to Starter Motor Installation on page 07 18 2 If the A starter drive gear and the flywheel ring gear are not fully meshing or the gears are B milled or damaged replace the starter motor refer to Starter Motor Installation on page 07 18 Replace the flywheel ring gear 246 WSG 1068 STARTER SYSTEM REMOVAL AND INSTALLATION CAUTION A jumper wire must not be installed between the large round electrical terminal and the solenoid blade terminal at the starter If done voltage is generated to the solenoid by the spinning starter after release of the start key or button causing the starter to remain engaged resulting in failure 247 WSG 1068 STARTER SYSTEM Starter Motor Removal WARNING WHEN CARRYING OUT MAINTENANCE ON THE STARTER SYSTEM
205. ttery cable connection or in the positive battery cable itself 9 By moving the 73 Digital Multimeter negative lead toward the battery and checking each mechanical connection point the excessive voltage drop can be located When the high reading disappears the last mechanical point that was checked is the concern Repair or replace this connection as required 244 WSG 1068 STARTER SYSTEM Starter Motor Motor Ground Circuit A slow cranking condition can be caused by resistance in the ground or return portion of the cranking circuit Check the voltage drop in the ground circuit as follows 1 Disconnect the inertia fuel shutoff switch on road vehicle only 2 Connect a remote starter switch between the starter motor solenoid S terminal and the battery positive terminal 3 Connect the 73 Digital Multimeter positive lead to the starter motor housing the connection must be clean and free of rust or grease Connect the negative lead to the negative battery terminal 4 Engage the remote starter switch and crank the engine Read and record the voltage reading The reading should be 0 5 volts or less 5 If the voltage drop is more than 0 5 volts clean the negative cable connections at the battery and body connections and retest 6 If the voltage drop is greater than 0 5 volts determine which way the current is flowing in the cable Connect the 73 Digital Multimeter positive lead to the end of the cable nearest ba
206. ure sensor IAT sensor Sends the ignition control module a signal indicating the temperature of the air entering the engine but is not used on this engine Resistance decreases as temperature increases The cylinder heat temperature CHT sensor Sends a signal to the Ignition Control Module indicating the cylinder head temperature 166 WSG 1068 IGNITION SYSTEM Overview The Ignition System is designed to ignite the compressed air fuel mixture in an internal combustion engine by a high voltage spark from an ignition coil The ignition system also provides engine timing information to the GCP for proper engine operation and misfire detection Electronic Ignition System The Coil On Plug COP EI System uses a separate coil per spark plug and each coil is mounted directly onto the plug The COP EI System eliminates the need for spark plug wires but does require input from the camshaft position CMP sensor Operation of the components are as follows 1 Note Electronic Ignition engine timing is entirely controlled by the GCP Electronic Ignition engine timing is NOT adjustable Do not attempt to check base timing You will receive false readings 2 The GCP uses the CMP sensor not shown on COP EI Systems to identify top dead center of compression of cylinder 1 to synchronize the firing of the individual coils 3 The GCP acts as an electronic switch to ground in the coil primary circuit When the switch is close
207. ures can contribute to engine damage and wear Airborne debris and abrasive grit from the grinding disc may enter the engine through exposed cavities causing premature wear and eventual engine damage Engine Distributors Inc does not recommend using abrasive grinding discs to remove engine gasket material Use manual gasket scrapers for removing gasket material from the engine sealing surfaces Take added care to prevent scratching or gouging aluminum sealing surfaces 1 WSG 1068 GENERAL INFORMATION Safety Notice There are numerous variations in procedures techniques tools and parts for servicing equipment as well as in the skill of the individual doing the work This manual cannot possibly anticipate all such variations and provide advice or cautions as to each Accordingly anyone who departs from the instructions provided in this Manual must first establish that neither personal safety nor equipment integrity are compromised by the choice of methods tools or parts Notes Cautions and Warnings As you read through the procedures you will come across NOTES CAUTIONS and WARNINGS Each one is there for a specific purpose NOTES gives you added information that will help you to complete a particular procedure CAUTIONS are given to prevent you from making an error that could damage the equipment WARNINGS remind you to be especially careful in those areas where carelessness can cause personal injury The following list contains some genera
208. ush the crankshaft rearward and install the rear lower crankshaft thrust washer 6334 at the back of the No 6 main boss 4 Push the crankshaft forward and install the front lower crankshaft thrust washer at the front of the No 6 main boss 5 NOTE To aid in assembly apply petroleum jelly to the back of the crankshaft thrust washer Install the upper crankshaft thrust washer to the back side of the No 6 main bearing cap with oil grooves facing the crankshaft surface and install the No 6 rear main bearing cap 130 WSG 1068 ENGINE 6 Install the No 1 through No 5 crankshaft lower main bearings into the main bearing caps Locate the main bearing caps on the cylinder block and tap into place using a plastic or dead blow hammer 7 Install new main cap bearing bolts 8 Install the ten dowel pins so that the flat sides face the crankshaft Install the cross mounted bolts 131 WSG 1068 ENGINE 9 Tighten fasteners 1 through 12 in two stages in the sequence shown Stage 1 Tighten to 37 43 Nm 22 32 lb ft Stage 2 Tighten an additional 85 degrees to 95 degrees 10 Tighten fasteners 13 through 24 in two stages in the sequence shown Stage 1 Tighten to 27 33 Nm 20 26 lb ft Stage 2 Tighten an additional 85 degrees to 95 degrees 132 WSG 1068 ENGINE 11 Use the Connecting Rod Guide Tool and Piston Ring Compressor to install the piston and connecting rod assembly 12 CAUTIO
209. valve cover on the cylinder head and loosely install the bolts 52 WSG 1068 ENGINE 4 Tighten the bolts in the sequence shown 5 Reinstall the PCV valve 53 WSG 1068 ENGINE Crankshaft Pulley Removal Special Tool s Special Service Tools called for by the procedures can be obtained by calling 1 800 ROTUNDA 1 800 768 8632 1 Remove the engine cooling fan and fan shroud 8146 2 Remove the drive belt 8620 3 Remove the crankshaft pulley bolt 6A340 4 Using the Crankshaft Damper Remover remove the crankshaft pulley 6312 54 WSG 1068 ENGINE Crankshaft Pulley Installation CAUTION Mating parts must make contact to each other within 4 minutes and connecting bolts must be torqued within 15 minutes after applying sealant Failure to follow this procedure can cause future oil leakage Use silicone gasket and sealant F6AZ 19562 AA or equivalent meeting Ford specification WSE M4G323 A6 NOTE Sealant must be removed and area cleaned with solvent if above instructions are not followed Use metal surface cleaner F4AZ 19A536 RA or equivalent meeting Ford specification WSE M5B292 A 1 Use the Crankshaft Damper Replacer to install the crankshaft pulley 2 Tighten the crankshaft pulley bolt in four stages Stage 1 Tighten to 90 Nm 66 lb ft Stage 2 Loosen 360 degrees Stage 3 Tighten to 47 53 Nm 35 39 lb ft Stage 4 Tighten an additional 85 95 degrees 55
210. ve rotator Valves and Cylinder Head Check for plugged oil drain back holes Check for missing or damaged valve stem seals or guide mounted valve stem seals If insufficient oiling is suspected check oil passages for blockage then accelerate the engine to 1200 rpm with the transmission in NEUTRAL or load removed and the engine at normal operating temperature Oil should spurt from the rocker arm oil holes such that valve tips and camshaft roller followers are well oiled With the valve covers off some oil splash may overshoot camshaft roller followers 7 WSG 1068 GENERAL INFORMATION Camshaft Lobe Lift Check the lift of each lobe in consecutive order and make a note of the readings 1 Remove the valve covers 2 Remove the rocker arm seat bolts rocker arm seat and rocker arms 3 Make sure the lash adjuster is seated against camshaft Install the dial Indicator with Bracketry so the ball socket adapter of the indicator is on top of the hydraulic lash adjuster or the Cup Shaped Adapter is on top of the push rod and in the same plane as the lash adjuster push rod movement 4 Remove the spark plugs 5 Connect an auxiliary starter switch in the starting circuit Crank the engine with the ignition switch in the OFF position Bump the crankshaft over until the hydraulic lash adjuster is on the base circle of the camshaft lobe At this point the hydraulic lash adjuster will be in its lowest position If checking during engine
211. xhaust gas The GCP changes the air fuel ratio to the engine by controlling the amount of time that the fuel injector is ON The best mixture to minimize exhaust emissions is 14 7 parts of air to 1 part of gasoline by weight which provides the most efficient combustion Because of the constant measuring and adjusting of the air fuel ratio the fuel injection system is called a closed loop system The GCP monitors signals from several sensors in order to determine the fuel needs of the engine Fuel is delivered under one of several conditions called modes All modes are controlled by the GCP Refer to Open Loop and Closed Loop Operation for more information Fuel Injector The Electronic Fuel Injection EFI fuel injector is a solenoid operated device controlled by the GCP The GCP energizes the solenoid which opens a valve to allow fuel delivery The fuel is injected under pressure in a conical spray pattern at the opening of the intake valve Excess fuel not used by the injectors passes through the fuel pressure regulator before being returned to the fuel tank A fuel injector which is stuck partly open will cause a loss of fuel pressure after the engine is shut down causing long crank times Fuel Rail The fuel rail is mounted to the top of the engine and distributes fuel to the individual injectors Fuel is delivered to the fuel inlet tube of the fuel rail by the fuel lines 259 WSG 1068 ENGINE CON

WSG-1068 6.8 LITER - EDI Ford Industrial Engine Documentation

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